AU2018204778B2

AU2018204778B2 - A container and process

Info

Publication number: AU2018204778B2
Application number: AU2018204778A
Authority: AU
Inventors: Frank Farchione; Fab Macali; Mark Moore
Original assignee: Opal Packaging Australia Pty Ltd
Current assignee: Opal Packaging Australia Pty Ltd
Priority date: 2017-06-29
Filing date: 2018-06-29
Publication date: 2024-02-01
Anticipated expiration: 2038-06-29
Also published as: NZ743978A; AU2018204778A1; AU2021106621A4

Abstract

A plant pot, blank for making a plant pot and a process for making a plant pot is provided. The blank and plant pot includes a board having an inner paper layer and polymeric layers on opposite sides of the paper layer. The polymeric layers inhibiting ingress of water to the paper layer so as to retain structural rigid 10397782_1 (GHMatters) P106134.AU.1 10397782_1 (GHMatters) P106134.AU.1 Figure 1 Figure 2 10 313 q' T 161 13

Description

10397782_1 (GHMatters) P106134.AU.1

Figure 1

Figure 2 10

313

q' 161 T

A CONTAINER AND PROCESS FIELD OF THE INVENTION

The present invention relates to a plant container for plants and a

blank for making a plant container. The present invention also

relates to a process of making the plant container.

BACKGROUND OF THE INVENTION

There is a range of different plant pots presently available,

including ceramic pots, plastic materials, timber barrels and wire

baskets. Plastic pots are at present the most popular, which may

be the result of a range of factors including plants being able to

be propagated and sold in plastic pots, and plastic pots being

relatively low cost, light weight and durable. However, once the

plant in the plastic pot has been removed from the pot and planted

in the ground, disposal of a plastic pot or finding a suitable

recycling chain can be difficult for the end consumer. This can

have an impact on the environment as most plastic pots are not

readily recyclable.

SUMMARY OF THE INVENTION

An embodiment of the present invention relates to a plant container

constructed from a foldable board and configured to be nested inside

an alike container, the plant container including:

a bottom wall on which the container can be seated,

a plurality of side walls that are joined to the bottom wall

by a plurality of first fold lines and extend from the bottom

wall to form a receptacle configured to receive a plant, the

bottom wall and the side walls being formed from the board,

a stop formation that prevents an alike container from being

completely received within the container when nested, the stop

formation having a first limb extending inwardly from one of

20359698_2 (GHMatters) P106134.AU.1 the plurality of side walls of the container and a second limb extending from the bottom wall of the container, wherein the second limb is joined to the first limb and supports the first limb in an operative position in the container, wherein the board comprises a paper layer and water resistant layers on opposite sides of the paper layer that inhibit ingress of water into the paper layer, the container can thereby retain structural rigidity while a plant is located in the container.

Ideally, the container can retain structural rigidity for a period

of at least 3 months with the plant in the container. Even more

ideally, the container can retain structural rigidity for a period

of at least 6 months with the plant in the container. Having the

plant in the container means that the container will be exposed to

water and in contact with soil.

Without a plant in the container, the container may be able to last

for at least 2 years and suitably up to 3 years.

The term "plant" embraces any living plant material that requires

water and a soil material in which to bed its roots.

Ideally, if the plant is removed from the plant container the

container can be folded flat and disposed in a normal refuse bin, so

that it degrades with the other standard waste.

Ideally, the plant container can be recycled with other paper

recyclable material using conventional recycling equipment, such as

a hydro-pulper.

The paper layer of the board ranges from 80 to 97 wt.% of the board.

Even more ideally, the paper layer ranges from the 85 to 95wt.% of

the board, and even more suitably the paper layer is 90wt.% of the

board. The remainder of the board may comprise the water resistant

layers. In one example, the paper layer constitutes 90wt.% of the

board, and the water resistant layers constitutes lwt.%.

The paper layer and the water resistant layers may comprise any

number of sub-layers. Moreover the board may also contain one or

20359698_2 (GHMatters) P106134.AU.1 more other additional layers, such as, natural fibre, or even metallised foil. Ideally the board consists of the inner paper layer and the water resistant layers are bonded directly to opposite sides of the paper layer.

Ideally, the board is in the form of an integrally formed blank.

The integrally formed blank is cut from a single sheet. The

container will have an outer face, which will be provided

predominantly by an outer face of the blank. Similarly, the inner

face of the container will be provided predominantly by the inner

face of the blank. References to the inner face of the blank may

therefore also refer to the inner face of the container, and vice

versa. Similarly, references to the outer face of the blank may

therefore also refer to the inner face of the container, and vice

versa.

The plant container can be printed with ink by any suitable means,

to provide information about the plant and how it can be planted.

The water resistant layer forming an outside face of the container

or blank may be treated to increase the surface tension of the layer

to facilitate adhesion of ink, glue or other substances thereto.

The treatment may, for example, be a corona treatment. Other

examples include a flame treatment.

In another embodiment, characteristics of the water resistant layer

on the inner face of the plant container or blank may differ from

characteristics of the water resistant layer on the outer face of

the container or blank. For example, the water resistant layer on

the inner face of the container may have a higher weight (for

instance grammage per area) than on an outer face of the container.

In another example, the thickness of the water resistant layer of

the outer face may be greater than the thickness of the water

resistant layer of the outer face.

The water resistant layer on an inside of the paper layer may have a

thickness in the range of 10 to 25pm. This may equate to a weight

in the range of 9 to 20gsm.

20359698_2 (GHMatters) P106134.AU.1

The water resistant layer on an outside of the paper layer may have

a thickness in the range of 15 to 35pm. This may equate to a weight

in the range of 13 to 30gsm.

The water resistant layer on an outer face of the container may have

the same characteristics as the inner face of the container.

The water resistant layers may be a polymeric film, for example a

polyolefin. The water resistant layers may be a film such as a

polypropylene film (PP) including BOPP film, polyethylene film (PE),

polyester film, nylon film, a film comprising polymers derived from

plant materials such as corn, sugar cane, and so forth. Plant

material can be used as a source of ethanol, which is a precursor to

an ethylene monomer in the manufacture of polythylene. The water

resistant layer may be applied to the paper layer using any suitable

technique including printing, extrusion coating, or adhesion

coating, for example, using a suitable adhesive between the paper

layer and the water resistant layers.

Ideally, the water resistant layers are low density polyethylene

(LDPE) films and/or high density polyethylene (HDPE) films. In one

example, at least one of the water resistant layers is 100% LDPE.

In another example, at least one of the water resistant layers is

100% HDPE. In another example, at least one, and suitably both of

the water resistant layers is a LDPE/HDPE blend range from 25/27 to

72/25 wt.%.

Typically, the water resistant layer has a 50/50 blend of HDPE/LDPE.

The side wall may be tapered outwardly moving in a direction away

from the bottom wall.

The container has a stop formation that prevents one of the

containers from being completely received within the other

containers when nested. Therefore, when the containers are nested

together, an upper portion of the container received within another

container will protrude above the other container, which enables the

containers to be more easily de-nested.

20359698_2 (GHMatters) P106134.AU.1

The first limb can contact an outside face of a bottom wall of

another container received inside the container. The first limb may

be joined to the side wall by a second fold line. The second fold

line may be spaced from the bottom wall by a spacing of 5 to 15mm,

and ideally 10mm from the bottom wall.

The first limb may be tongue cut from the side wall of the

container.

The second limb may be a tongue cut from the bottom wall of the

container.

The first limb may be wider than the second limb. When the

containers are located in a nesting position, the first limb being

wider than the second limb, may contact the bottom wall of an alike

container, also having the stop formation, so that the stack of the

containers can be formed in which the containers are not completely

received, one inside the other.

The stop formation may collapse into a non-operative position when

soil is placed in the container.

The container may include drainage holes for draining water from the

container. Water drainage is important to prevent the roots of the

plant from drowning or rotting. The draining holes may be located

in either one or both of the side wall or the bottom wall. Ideally,

the side wall has four side panels which define four corners, and a

drainage hole is provided in each corner.

The drainage holes may be formed as a cutout in the board, and the

paper layer will be directly exposed to moisture ingress at the

cutout, for example, over the thickness of the board.

Ideally, one of the water resistant layers forms an outer face of

the container, and the water resistant layer includes pigmentation

to obscure from view the paper layer about the drainage hole. For

example, the water resistant layer may be pigmented white which

obscures from view water staining of the paper layer about the

drainage hole.

20359698_2 (GHMatters) P106134.AU.1

The side wall of the container may include an attachment flap that

is glued to an overlapping side wall panel to retain the container

in the erected position. A user can detach the attachment flap from

the side wall panel to open the side wall of the container.

The side wall of the container may include a line of weakness that

can be torn to open the side wall of the container. The line of

weakness may extend from an outer end of the side wall toward the

bottom wall. In one embodiment, the line of weakness may extend the

length of the side wall.

By opening the side wall panel, a user can remove the plant from the

container with no or minimal root disruption.

The side wall of the container may also include side wall panels, of

which there are suitably four side wall panels, and a detachable

panel that forms part of the side wall of the container. The

detachable panel may be defined by a line of weakness that connects

the detachable panel to the side wall panel. The line of weakness

may be cut or torn. The detachable panel may also have information

or directions that are printed with an ink relating to use of the

container or the type of plant being planted.

The side wall panels may include a taller side wall panel that

extends above the other side wall panels when the container is in an

upright orientation. The taller side wall panel may include an

opening configured for carrying the container. The opening may be

sized as a finger opening or a hand opening.

In one example, the opening for carrying the container may be

provided in the detachable panel.

Ideally, the base wall of the container includes a set of

overlapping flaps. In particular, the base wall includes base flaps

extending from each side wall panel, and when erected, the base

flaps are oriented in an overlapping manner whereby each flap

extends from inside to outside the container, a part of the flap

located inside, is at least partially overlapped by part of an

adjacent flap located outside the flap container.

20359698_2 (GHMatters) P106134.AU.1

Moreover, either one or both of the side wall and the detachable

panel may have the following types of information or directions:

i) labelling information such as the type or variety of the

plant of the container;

ii) care instructions for the type of plant of the container;

iii) images or photographs of the plant of the container;

iv) directions on how to use the container; and

v) directions on how deep to bury the container in the ground,

and the amount of sunlight and watering required by the

plant.

The container may also have a lip formation extending about the side

wall of the container. For example, the lip formation may extend

outwardly from the side wall.

Another embodiment of the present invention relates to a blank for

making a plant container that is configured to be nested one inside

another, the blank including:

a first panel that forms at least part of a bottom wall of the

container on which the container can be seated when erected

into the container,

a set of second panels that are joined to the first panel by a

first fold line, and when assembled, the second panels and the

first panel form a receptacle for receiving potting mix and a

plant, the blank further comprising a stop formation that

prevents an alike container from being completely received

within the container when nested, the stop formation having a

first limb that extends inwardly from a second panel when

erected into the container and a second limb that extends from

the first panel when erected into the container, wherein the

second limb is joined to the first limb and supports the first

limb in an operative position in the erected container,

the first and second panels being formed from a foldable

board,

20359698_2 (GHMatters) P106134.AU.1 wherein the board comprises a paper layer and water resistant layers on opposite sides of the paper layer that inhibits ingress of water into the paper layer, the container can thereby retain structural rigidity while a plant is located in the container.

The blank may have three or more second panels that are each joined

to a side of the first panel by the first fold line.

Two embodiments of the blank will now be described. In one

embodiment, the first panel may have four sides, and the blank

includes four second panels that are each joined to the sides of the

first panel by the first fold lines. In other words, the first

panel may be centrally located and the second panels may be arranged

about the first panel.

The second panels may be interconnected by gusset panels, in which a

pair of gusset panels are arranged to interconnect each adjacent

second panel.

The gusset panels may be equally sized and joined to the second

panels by second fold lines, and the gusset panels interconnected by

a third fold line.

The two gusset panels may also concertina relative to each other

when the blank is erected.

The first limb may be formed by a cutout in the first panel, and a

second limb formed may be formed by a cutout in the second panel.

The first limb and the second limb being joined by a fourth fold

line. The second limb may be wider than the first limb.

The blank may also include lip flaps extending outwardly from the

second panels, the lip flaps forming a lip formation that extends

about the side wall of the container erected from the blank.

The blank may also include drainage openings for draining water

poured into the container. The drainage openings may be located at

corners of the first panel. Suitably, the drainage openings are

located at an intersection of: i) a corner of the first panel that

20359698_2 (GHMatters) P106134.AU.1 is adjacent second panels and iii) the gusset panels interconnecting adjacent second panels.

The second panels may have a width in a direction transverse to the

length of the second panels.

In a second embodiment, the blank includes a line of the second

panels arranged side-by-side in which adjacent second panels are

joined by second fold lines, and the first panel is joined by the

first fold line to one of the second panels.

The blank may have four second panels. Ideally the blank has six

second panels.

An attachment flap may extend from one end of the line of the second

panels, and the attachment flap is attached to the second panel at

an opposite end of the line of the second panels to form a closed

side wall during assembly of the blank. The closed side wall can

then be moved between a flat collapsed position and an erected

operative position. When the second panels are located in an

erected position, the side wall can form a receptacle with the

bottom wall.

The first panel may have a number of sides that equals the number of

the second panels.

The first panel may include a set of bottom flaps that extend from

the second panels. The bottom flaps may be configured so that at

least one of the bottom flaps extends from the bottom of the second

panels and can be arranged in a partially overlapping configuration

that moves into an operative position to form the bottom wall as the

closed side wall of the container is moved from the collapsed

position to an operative position.

In an embodiment, the side wall of the container may include four

side wall panels, an attachment flap extending from one of the side

wall panels that is attached to another side wall panel to form a

closed side wall that can be moved between a collapsed flattened

position, with the attachment flap connected, and an erected

operative position, and the base wall includes a set of overlapping

20359698_2 (GHMatters) P106134.AU.1 flaps in which one of the flaps extends from each side wall panel, and the overlapping flaps also move into an operative position when the closed side wall moves from the collapsed position to the erected position.

The side wall may be opened by a user by either detaching the

attachment flap or breaking a line of weakness that extends

longitudinally of the side wall that can be broken to open the side

wall into an opened flat orientation.

At least one of the second panels may also include a detachable

panel that forms part of the side wall of the container made from

the blank. The detachable panel may be defined by a line of

weakness that connects the detachable panel to one of the second

panels. The line of weakness may be cut or torn. The detachable

panel may also have information or directions that are printed with

an ink relating to use of the container or the type of plant being

planted.

Another embodiment also relates to a process of making a plant

container that is configured to be nested one inside another, the

process including:

applying water resistant layers to opposite sides of a paper

layer to form a board;

cutting a blank from the board having i) a first panel that

forms at least part of a bottom wall of the container on which

the container can be seated when erected into a container, and

ii) a set of second panels that are joined to the first panel

by a first fold line; and

folding the second panels relative to the first panel into an

operative position to form a receptacle for receiving potting

mix and a plant, and having a stop formation that prevents an

alike container from being completely received within the

container when nested, a first limb extending inwardly from a

second panel when erected into the container and a second limb

extending from the first panel when erected into the

container, wherein the second limb is joined to the first limb

20359698_2 (GHMatters) P106134.AU.1 and supports the first limb in an operative position in the erected container; wherein the water resistant layers inhibit the ingress of water into the paper layer, so that the paper layer can retain structural rigidity while a plant is located in the container.

The water resistant layer may be applied using any suitable

technique including spraying, printing, or bonding a preformed film

to opposite sides of the board. Suitably, the step of applying the

water resistant layer to the paper layer includes extruding the film

onto the paper layer.

Bonding the preformed film may include applying an adhesive and

using the adhesive to fix the film to the board. Bonding may also

include physical bonding using pressure and heat to fix the film to

the board.

The step of applying the water resistant layer to the board may

include controlling the weight (or grammage) of the water resistant

layers applied to the paper layer.

The step of applying the water resistant layer to the board may

include adding a pigment to the water resistant layer that forms an

outer face of the board.

The process may include a surface treatment step that increases the

surface energy of an outer face of the board, for example by a

corona treatment. The surface treatment increases the wettability

of the board.

The process may also include printing information, such as

directions of use and plant information onto the board. Ideally,

the printing step is carried out after the surface treatment step.

The step of cutting the blank may include forming the first fold

line.

The step of cutting the blank may include forming second fold lines

that join the second panels in a line.

20359698_2 (GHMatters) P106134.AU.1

The step of cutting the blank may include forming a line of weakness

that defines a detachable panel in the second panels.

The step of cutting the blank may include forming drainage openings.

The drainage openings may be located at the junction between the

side wall and the base wall. Ideally four drainage openings are

formed.

The process may also include a step of selecting the thickness of

the paper layer depending on the size of the container to be formed.

For example, a container having a cross-section or diameter ranging

from 2 to 6 inch may have a thickness in the range of 350pm to

750pm.

The process described herein may include any one or a combination of

the features of the blank, and/or the plant container described

herein. Similarly, the blank may include any one or a combination

of the features of the process and/or the container, and the

container may include any one or a combination of the features of

the blank and/or the process described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described with

reference to the accompanying figures, of which:

figure 1 is perspective view of a plant container according to an

embodiment;

figure 2 is blank that can erected to form the container shown in

figure 1;

figure 3 is perspective view of a plant container according to

another embodiment;

figure 4 is blank that can erected to form the container shown in

figure 3;

figure 5 is perspective view of a plant container according to yet

another embodiment;

20359698_2 (GHMatters) P106134.AU.1 figure 6 is blank that can erected to form the container shown in figure 5; figure 7 is a photograph of the of the plant container shown in figure 5 that is in the process of the collapsed into a flattened formation; figure 8 is perspective view of a plant container according to a preferred embodiment; figure 9 is blank that can be erected to form the container shown in figure 8; and figure 10 is a block diagram illustrating process steps according to one embodiment for making the container shown in any one of the figures 1 to 9.

DETAILED DESCRIPTION

A preferred embodiment of the present invention will now be

described in the following text with reference to the accompanying

figures. The text also includes reference numerals to help identify

corresponding features in the figures. However, to maintain clarity

of the figures, not all reference numerals are included in each

figure.

The preferred embodiment of the present invention relates to a blank

, plant container 20, and a process for making the plant container

that, amongst other things, comprises a board having a paper

layer and water resistant layers on opposite faces. The water

resistant layers may be made of any suitable polymeric material. The

water resistant layers enable a plant to be propagated and watered

in the container 20 and the container 20 retains an acceptable

rigidity for a period, such as at least 3 months, and ideally at

least 6 months with the plant in the pot. Prior to a plant being

planted in the pot, the container 20 may have self-life of 2 to 3

years.

The paper layer of the board ideally has limited water wicking

properties. Ideally, the paper layer is a paper board material

having a thickness in the range of 350 to 750pm. An example of a

20359698_2 (GHMatters) P106134.AU.1 suitable paper layer includes high strength unbleached uncoated virgin kraft paper. The paper layer is "uncoated" in the sense that it does not include a clay coating or a finishing surface containing clay because clay wicks water extremely well. Another example of a suitable paper layer, is bleached long fibre board.

The thickness of the board may be selected based on the size of the

container. For example, a container of notional diameters may have

a board, which is principally determined by the thickness of the

paper layer in accordance with the following table:

Table 1.

Notional container cross-section Thickness of the paper layer

or diameter

2 to 3 inch container 350pm to 400pm

3 to 4 inch container 450pm to 550pm

4 to 6 inch container 550pm to 750pm

The water resistant layers that line the opposite faces of the paper

layer may be made of any polymeric films such as polypropylene

films, BOPP films, polyethylene films, polyester films, nylon films,

films derived from plant material such as corn, and other synthetic

polymers. Suitably, the water resistant layer is a polyolefin

material that is a neat resin without any additives, however

additives may be added to increase shelf-life. The outer face of

board may also be subjected to a surface altering treatment, such as

a corona treatment, to increase surface tension and to improve

adhesion of inks and other coatings.

The polymer layers may have any suitable thickness but typically

each polymer layer may have a thickness in the range of 10pm to

pm. Ideally, the polymer layer on an inside of the board, and

therefore forms in the inside the container, is ideally a clear

/50 blend of HDPE/LDPE at a thickness in the range of 10 to 25pm,

which equates to a weight in the range of 9 to 20gsm.

20359698_2 (GHMatters) P106134.AU.1

The polymer layer on the outside of the board, and therefore forms

the outside of the container, is ideally a 50/50 blend of HDPE/LDPE

having a thickness in the range of 15 to 35pm, which equates to a

weight in the range of 13 to 30gsm. Ideally, the outer polymeric

layer also contains a white pigment, such as 8 to 15 wt.% titanium

dioxide. The pigment has the benefit of obscuring from view

staining of the paper layer, for example, at the edges of the paper

layer about the drainage holes, or at the top and bottom edges of

the board.

The board as described above has a paper content of about 90wt% and

a polymeric content of about 10%, which enables the containers to be

recycled with other conventional boards.

Figure 1 is a perspective view of a plant container 20 and Figure 2

illustrates the blank 10 that is folded to make the plant container

20. The blank 10 and container 20 are made from the board including

a core paper layer and water resistant layers as described herein.

The blank 10 and container 20 have a first panel 11 for forming the

bottom wall 11a of the container 20 and a set of second panels 12

for forming the side wall 12a of the container 20. The bottom wall

11a is square with a first fold line 13 at each side of the bottom

wall 11a joining to one of the second panels 12 of the side wall

12a.

A pair of triangular gusset panels 14 are located between and joined

to adjacent side wall panels 12a by second fold lines 15. In one

embodiment, the pair of gusset panels 14 may be interconnected by a

third fold line 16 that enables the gusset panels 14 to concertina

relative to each other when the blank is folded into an erected

position in which the second panels 12 extend upwardly from the base

panel 11 as shown in figure 1. An adhesive can be used to fix the

gusset panels 16 against an inside face of the side walls 12a of the

container 20. In an alternative embodiment the third fold line 16

may be a cut formed in the blank 10 which may enable the gusset

panels 14 to extend from one of the second panels to be folded over

and adjacent second panel 12 and an adhesive used to fix the gusset

panel 14 in position.

20359698_2 (GHMatters) P106134.AU.1

Four drainage holes 17 are located so as to overlie a junction of

the corner of the first panel 11, corners of adjacent second panels

12, and corners of the gusset panels 14.

The container 20 also includes two stop formations 18 that are

arranged on opposite sides of the container 20 and the blank 10. The

stop formations 18 are arranged to prevent nesting containers 20

from being completely nested one inside the other. Specifically, the

base wall 11 of a container 20 being received within another

container 20 is intended to hit the stop formation 18 of the outer

container 20, and thereby cause a top section of the side wall 12a

of the container 20 being received to protrude above the side wall

12a of the outer container.

The stop formation 18 has first and second limbs 19, 19a that are

cut as tongues from the first panel 11 of the bottom wall and the

second panel 12 of the side wall 12a, respectively. The second limb

19a has a width greater than first limb 19a such that when alike

containers 20 are stacked one inside the other, the second limb 19a

of the container 20 receiving another container 20 is inhibited from

passing through the cutout formed in the bottom wall 11. The first

limb 19 is joined to the first panel of the bottom wall via fold

line 22, the second limb 19 is joined to the second panel of the

side wall via fold line 23, and the first and second limbs are

joined via a fold line 21. Ideally, the second limb 19a of the stop

formation 18 may be arranged at a spacing of approximately 5 to 15

mm above the base wall, and ideally approximately 10 mm.

As can be seen, the width of the second panels 12 increases in a

direction away from the base wall 11 so that the side wall of the

container 20 tapers outwardly.

Although not shown in figures 1 and 2, the side wall 12a of the

container 20 may also include a line of weakness that can be torn by

hand or cut to enable the side wall 12 to be opened. This can

facilitate easier removal of the plant from the container 20 for

planting. The line of weakness may also define a removable panel

which can be retained by the consumer. The removable panel may

20359698_2 (GHMatters) P106134.AU.1 include information such as information about the plant and directions or use.

In addition, the side wall 12a of the container 20 may include

printed information, including directions of use and horticultural

information on the plant.

Figures 3 and 4 illustrate a container 20 and blank 10 that is

essentially the same as the container 20 and blank 10 shown in

figures 1 and 2 respectively. The main difference of the container

and blank 10 of figures 3 and 4 is that they include flaps 25

extending from an outer edge of each of the second panels 12 of the

side wall 12a. The flaps 25 are joined by fold lines 26 to the

second panels 12 and extend along the width of the second panels 12

and include extensions portions that protrude beyond to form the

container 20 width of each of the second panels. When the blank 10

is erected as shown in figure 3, the flaps 25 can be folded

laterally to the side wall panel 12 to form a lip formation 25a

about the opening of the container 20. The extension portions of

adjacent flaps may overlap and an adhesive can be used to fix

adjacent flaps together.

The lip formation 25a can reduce spillage of the potting mix being

loaded onto the container, particularly when automated machinery is

being used to fill the containers.

Figure 5 illustrates an embodiment of a hexagonal container 20 and

figure 6 illustrates a blank 10 for making the hexagonal container

20. The container 20 and blank 10 for making the container 20 shown

in figures 5 and 6 may be made from the board having a core paper

layer and water resistant layers on opposite faces described herein.

The blank 10 has a first panel 11 for forming the bottom wall 11a of

the container 20 and a line of second panels that when erected, form

the side wall of the container 20. The first panel 11 is joined to

the lower edge of one of the second panels 12 by first fold line 13.

The second panels 12 are interconnected in the line by the second

fold line 15. A first attachment flap 28 extends from the second

panel 12 at one end of the line of panels 12 which can be attached

20359698_2 (GHMatters) P106134.AU.1 to the second panel at the opposite end of the line of second panels

12 when the blank 10 is erected.

A second attachment flap 29 also extends from the lower edge of the

opposite second panel 12 of the container which provides support for

the first panel 11. The second attachment flap may be connected to

the first panel 11 using an adhesive or, alternatively, provide

support without being fixed to the base wall of the container.

The container 20 also includes a stop formation 18 comprising pairs

of supplementary flaps 19, 19a that are also joined to the second

panels 12 via fold lines 31 intermediate of the first panel 11 and

the second flap 29. One of the supplementary flaps 19. 19a on each

pair includes a base panel 19a and a support panel 30. The support

panel 30 can be folded relative to the base wall 11 to provide the

stop formation 18 that can be engaged when alike containers are

stacked one inside the other.

Drainage holes 17 are also provided part way along the first fold

line 13 of the fold line 31 of each of the second panels which is

best seen in figure 6.

One of the features of the embodiment shown in figures 5 and 6 is

that the base wall 11a of the container is not necessarily connected

to each of the second panels of the side wall 12a of the container

20. As a result, the side wall 12a of the container 20 can be moved

into a flattened configuration. Figure 7 is a photograph in which

the side walls of the container 20 are located in a partially

flattened condition.

Figure 8 is perspective view of a container 20 according to a

preferred embodiment and figure 9 is a blank 10 for making the

container 20. The container 20 and blank 10 have an attachment flap

28 at one end of the line of side wall panels 12 that is attached,

using a suitable adhesive, to a side wall panel 12 at the opposite

end of the line of panels to form a closed side wall that can be

moved between a collapsed position and an erected position. Figure

8 illustrates the situation in which the side wall panels 12 are in

a fully erected position.

20359698_2 (GHMatters) P106134.AU.1

The base wall 11 comprises a first panel that includes a set of the

bottom wall flaps 19, 19a and 30. The flaps 19a and the flaps 19

extend from every second side wall panel 12 and are joined to the

side wall panel by fold lines 13. The flaps 19a include tongue

extensions 30. Adjacent extensions 30 and flaps 19 are glued

together to form a connection in a preliminary assembly step. One

of the advantages of the preliminary assembly step is that the side

wall of the container can move between collapsed and erected

positions while the extensions 30 and flaps 19 are glued together by

folding along fold line 29. When in the collapsed position, the

container can be stored and transported flat in small shippers, and

the container is erected by a user, by moving the side wall from the

collapsed position to an assembled position.

Specifically, the base wall 11 is a crush style bottom in which

panels 19 and 30 are glued together and move into an operative

position when the side wall moves from a collapsed position to an

operative position. When in the operative position, the cutouts 31

interfit, securing the bottom wall 11 in the operative position.

When a plant is located in the container 20, weight on the inside of

the bottom wall 11 causes the flaps 19a to fractionally engage

against each other, and as a load on the inside of the bottom wall

11 increases, the frictional engagement also increases.

To remove the plant from the container 20, a user can release the

attachment flap 28 from the side wall panel 12 to which it is glued

and the side wall opened, suitably into a flat formation. Although

not shown in the figures, the side wall panels 12 may also have a

line of weakness to facilitate opening of the container 20. The

line of weakness may be provided, for example, at one of the fold

lines 15.

The side wall 12 also includes a detachable panel 25 that is

connected to one of the side wall panels by a line of weakness 24.

The detachable panel 25 may be of any shape, in the case of figures

8 and 9 the detachable panel 25 is a scalloped shaped panel. The

detachable panel 29 has a finger opening 20 for removing the

detachable panel 25. Although not shown in the figures, the

20359698_2 (GHMatters) P106134.AU.1 detachable panel 25 may have information, such as the species of the plant and care instructions including the amount of sunlight and watering recommended. It is intended that a user may remove the detachable panel from the container when the plant has been removed from the container and planted in the ground. The remainder of the container can be disposed via the usual paper recycle methods.

The blank 10 and container 20 also have drainage holes 17 that are

punched into the blank 10 and the container 20 at the corners of the

container 20. The drainage holes allow excess water to drain from

the inside of the container.

The containers 20 and blanks 10 shown in figures 1 to 9 may include

the inner paper layer and water resistant outer layers as described

herein.

Figure 10 is a block diagram illustrating possible process steps for

making a blank and container as shown in figures 1 to 7. The process

steps may be described as follows.

i) Selecting the type of paper layer, and the thickness of the

paper layer based on a notional size of the container.

ii) Selecting the water resistant layers, and optionally adding

a pigment if required, for example to an outer polymeric

layer.

iii) Applying the water resistant layer to opposite sides of the

paper layer to form a board. The water resistant layer may

be any suitable polymeric material including polypropylene

or polyethylene. Applying the water resistant layer to the

board may also include controlling the weight or grammage at

which the water resistant layer is applied to the paper

layer.

iv) Treating an outer surface of the board that forms an outside

face of the container. The treatment increasing the surface

energy to allow printing ink to adhere to the surface.

20359698_2 (GHMatters) P106134.AU.1 v) Printing information on the board. The information printed may relate to how the container is formed from the blank, how the container is intended to be used, horticultural information relating to a plant, barcodes, prices and promotional details.

vi) Cutting the board to form the blank. Cutting the board may

include forming pre-creased fold lines which define a first

panel for forming the base of the container and second

panels for forming the side wall of the container. Cutting

the board may also include forming lines of weakness which

may enable the side wall of the container to be opened, or

enable a detachable panel to be removed from the side wall.

vii) Assembling the container. In one example, assembling the

container may include the blank being partially erected by

securing an attachment flap of the side wall to form a

closed side wall, and securing two pairs of flaps of the

wall bottom wall to each other to form panels. While

partially erected, the closed side wall may be moved between

collapsed and erected positions, and when in the erected

position, the bottom flaps can engage.

In another example, assembling the container may include

folding the first and second panels into an operative

position to form a receptacle of the container. An adhesive

may then be used to secure the first and second panels to an

inside face of the side wall to retain the first and second

panels in an operative position. Optionally, flaps extending

from the second panels may be oriented to form a lip

formation about an up on opening of the container.

viii) Stop formations may then be located in an operative position

to prevent complete nesting of stacked containers.

20359698_2 (GHMatters) P106134.AU.1 ix) The fully erected containers can then be stacked one inside the other.

x) Automated machinery may then separate a stack of the containers and load potting mix and plant material into the container.

It will be understood by persons skilled in the art of the invention that many modifications may be made to the embodiment described herein without departing from the spirit and scope of the invention.

Although not shown in the figures, the container and blank for making the container may have a number of different tear away or pop out panels or holes on one or more sides of the container. The tear away or pop out panels can be removed to allow, promote and accommodate sideways root growth.

20359698_2 (GHMatters) P106134.AU.1

Claims

CLAIMS:

1. A plant container constructed from a foldable board and configured to be nested inside an alike container, the plant container including:

a bottom wall on which the container can be seated,

a plurality of side walls that are joined to the bottom wall by a plurality of first fold lines and extend from the bottom wall to form a receptacle configured to receive a plant, the bottom wall and the side walls being formed from the board,

a stop formation that prevents an alike container from being completely received within the container when nested, the stop formation having a first limb extending inwardly from one of the plurality of side walls of the container and a second limb extending from the bottom wall of the container, wherein the second limb is joined to the first limb and supports the first limb in an operative position in the container,

wherein the board comprises a paper layer and water-resistant layers on opposite sides of the paper layer that inhibit ingress of water into the paper layer, the container can thereby retain structural rigidity while a plant is located in the container.

2. The container according to claim 1, wherein the stop formation collapses into a non-operative position when soil is placed in the container.

3. The container according to claim 1 or 2, wherein the paper layer ranges from 80 to 97 wt.% of the board, and the remainder comprise the water resistant layers.

4. The container according to any one of the preceding claims, wherein the paper layer has a thickness in the range of 350 to 750pm.

20359698_2 (GHMatters) P106134.AU.1

5. The container according to any one of the preceding claims, wherein the water resistant layers include either one or a combination of low density polyethylene (LDPE) or high density polyethylene (HDPE).

6. The container according to any one of the preceding claims, wherein the water resistant layer on an inside face of the paper layer, and located on an inside of the container, has a thickness in the range of 10 to 25pm.

7. The container according to any one of the preceding claims, wherein the water resistant layer on an outside face of the paper layer, and located on an outside of the container, has a thickness in the range of 15 to 35pm.

8. The container according to any one of the preceding claims, wherein the side wall of the container is tapered outwardly moving in a direction away from the bottom wall.

9. The container according to any one of the preceding claims, wherein the side wall of the container includes four side wall panels, an attachment flap extending from one of the side wall panels that is connected to another side wall panel to form a closed side wall that can be moved between a collapsed flattened position and an erected operative position, and the bottom wall includes a set of overlapping flaps in which one of the flaps extends from each side wall panel, and the overlapping flaps also move into an erected operative position when the closed side wall moves from the collapsed flattened position to the erected operative position.

10. A blank for making a plant container that is configured to be nested one inside another, the blank including:

a first panel that forms at least part of a bottom wall of the container on which the container can be seated when erected into the container,

20359698_2 (GHMatters) P106134.AU.1 a set of second panels that are joined to the first panel by a first fold line, and when assembled, the second panels and the first panel form a receptacle for receiving potting mix and a plant, the blank further comprising a stop formation that prevents an alike container from being completely received within the container when nested, the stop formation having a first limb that extends inwardly from a second panel when erected into the container and a second limb that extends from the first panel when erected into the container, wherein the second limb is joined to the first limb and supports the first limb in an operative position in the erected container, the first and second panels being formed from a foldable board, wherein the board comprises a paper layer and water resistant layers on opposite sides of the paper layer that inhibit ingress of water into the paper layer, the container can thereby retain structural rigidity while a plant is located in the container.

11. The blank according to claim 10, wherein the stop formation collapses into a non-operative position when soil is placed in the container.

12. The blank according to either claim 10 or 11, wherein the paper layer has a thickness in the range of 350 to 750pm.

13. The blank according to any one of claims 10 to 12, wherein the water resistant layers include either one or a combination of low density polyethylene (LDPE) or high density polyethylene (HDPE).

14. The blank according to any one of claims 10 to 13, wherein the water resistant layer on an inside face of the paper layer that is located on an inside of the container has a thickness in the range of 10 to 25pm.

15. The blank according to any one of claims 10 to 14, wherein the water resistant layer on an outside face of the paper layer that is located on an outside of the container has a thickness in the range of 15 to 35pm.

20359698_2 (GHMatters) P106134.AU.1

16. The blank according to any one of claims 10 to 15, wherein the blank includes a line of the second panels arranged side-by-side in which adjacent second panels are joined by second fold lines, and the first panel includes a set of bottom flaps that extend from the second panels, an attachment flap extending from one end of the line of the second panels, and the attachment flap is attached to the second panel at an opposite end of the line of the second panels to form a closed side wall during assembly of the blank, and the closed side wall can then be moved between a flat collapsed position and an erected operative position, the bottom flaps are configured so that the bottom flaps are arranged in a partially overlapping configuration and moves into the erected operative position to form the bottom wall when the side wall moves from the flat collapsed flattened position to the erected operative position.

17. A process of making a plant container that is configured to be nested one inside another, the process including:

applying water resistant layers to opposite sides of a paper layer to form a board;

cutting a blank from the board having i) a first panel that forms at least part of a bottom wall of the container on which the container can be seated when erected into a container, and ii) a set of second panels that are joined to the first panel by a first fold line; and

folding the second panels relative to the first panel into an operative position to form a receptacle for receiving potting mix and a plant, and a stop formation that prevents an alike container from being completely received within the container when nested, the stop formation having a first limb extending inwardly from a second panel when erected into the container and a second limb extending from the first panel when erected into the container, wherein the second limb is joined to the first limb and supports the first limb in an operative position in the erected container;

20359698_2 (GHMatters) P106134.AU.1 wherein the water resistant layers inhibit the ingress of water into the paper layer, so that the paper layer can retain structural rigidity while a plant is located in the container.

18. The process according to claim 17, wherein the step of applying the water-resistant layer to the paper layer includes extruding a film onto the paper layer.

19. The process according to either claim 17 or claim 18, wherein the step of applying the water-resistant layer to the paper layer includes controlling the weight (or grammage) of the water-resistant layers applied to the paper layer.

20. The process according to any one of claims 17 to 19, wherein the step of cutting the blank includes forming the first fold lines, forming second fold lines that join the second panels in a line, forming a line of weakness that defines a detachable panel, and forming drainage openings at the junction between the side wall and the bottom wall.

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