AU645269B2

AU645269B2 - Container and methods of making same

Info

Publication number: AU645269B2
Application number: AU64954/90A
Authority: AU
Inventors: Barry Mulder
Original assignee: TRI ENGLE SYST
Current assignee: TRI-ENGLE SYSTEMS Ltd
Priority date: 1989-10-24
Filing date: 1990-10-24
Publication date: 1994-01-13
Anticipated expiration: 2010-10-24
Also published as: NZ231103A; EP0425279A1; CA2028405A1; JPH03275439A; AU6495490A

Description

S4 5 2 6 OMMONWEALTH OF AUSTRALIA Patents Act 1952 COMPLETE SPECIFICATION (Original) FOR OFFICE USE Application Number: Lodged: Class Int. Class 6YOS

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0* sofot 0 0000 a 06 IS Complete Specification Lodged: Accepted: Published: Priority: Related Art: TO BE COMPLETED BY APPLICANT .05 ac Name of Applicant: Address of Applicant: Actual Inventor: Address for Service:- TRI-ENGLE SYSTEMS LIMITED Corner Clarence Pembroke Streets, Hamilton, New Zealand BARRY MULDER Wray Associates Primary Industry House 239 Adelaide Terrace Perth Western Australia 6000.

Complete Specification for the invention entitled: "CONTAINER AND METHODS OF MAKING SAME" The following statement is a full description of this invention, including the best method of performing it known to me:- 1 A container made from a laminate of plastics sheet and stif material which is self-erecting on filling.

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000005 p S OS 0 550 p. 0 9 0 0 0 55 This invention relates to containers and methods of making same.

)3ACKGRf2IflMfl2DTE E TIO Our New Zealand patent application No.s 200565, 202266, 203278, 204265, 205072, 222443 and 206030, and overseas equivalents, describe containers formed from a larainate of a stiff material and a flexible material(s) which 000* are erectable into containers with the free edges of flexible material being 0:0 used for securing the container in an erected condition and for closure.

The containers' can be made of a laminate of plastics sheet material and cardboard with the cardboard completely encapsulated within two sheets of plastic.

*woe US Patent No. 4,082,216 by Eli Lilly and Company describes a carton and se* bag container. The product described is manufactured from a lam~inate of plastics sheet and cardboard. The manufacturing method involves producing a two ply laminate of plastics sheet material and cardboard overlaying the laminate and forming slide s~eams by joining the plastics sheet material at the edges of the laminate to form an open ended container. The Lily manufacturing method makes good economic use of materials. The Lily blank incorporates the use of' gusset panels designed to secure the container in 6n erected condition. However the gussets which are external are taped into position and may become loose as a result of subsequent handling of the container. In addition the Lily container requires the use of the hand or mechanical means to spread the container prior to filling.

I. C* -3- An object of the present invention is to provide a container, and a method of forming a container of the kind described which further enhances the range of potential uses of same and which tends itself to automated manufacture and filling.

Further objects and advantages of the present invention will become apparent from the ensuing description which is given by way of example.

SUMMARY OF INVENTION A container formed from a laminate of stiff material and a larger piece of flexible material, said stiff material including a bottom panel having a bisecting crosswise fold-line, side panels fixed to and extending from opposite edges of the bottom panel, said side panels each comprising a first panel substantially equivalent in width to the bottom panel and flanking second panels which extend to either side of the first panel, folding seams between the bottom and side panels and folding seams between the first and second side panels, said flexible material providing a peripheral border about the sides of the stiff material and 0000 the laminate being formable into a container by folding so that the side and bottom panels overlap one another and the bisecting fold line and bottom panels are inset and lie between lower portions of flanking panels.

00 00@ S A method of forming the container of claim 1 comprising the stepin of: *00• 0 of bonding the stiff material with the flexible material, folding the bonded materials so that the side panels 0. overlie uni another and the fold line of the bottom panel is inset and lies between lower portions of the Sflanking panels, and 3a fixing together overlaid portions of the flexible material together adjacent said side panels.

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o a The end user can open the container to remove the contents simply by slitting the seams.

If a triple ply laminate of plastics sheet/cardboard/plastics sheet is used plastics material forms an inner liner for the container which hygienically seals the contents.

The specification for the laminate can be dependent upon the customer requirements and it will be apparent that the structure can be made to be very strong.

The container is seen as an alternative to cardboard boxes with plastic bag liners and would clearly minimise the problem of the liner being embedded ir frozen or setting food, e.g. processed cheese.

The container manufactured from a triple ply laminate as described can be made waterproof inside and out and high fluid content products can effedively be sealed in the container and packed in a wet environment, Heat can be used for the lamination process including forming side seams and the sealing of the opening; and no adhesives are used.

Where increased container stackability is required non-slip films which can be used for the outer film. Alternatively where high slip is required this feature could be designed into the outer film.

We believe that the container system will reduce overall production, packaging and associated costs plus increace management control all being major cost reduction benefits.

Internally the container has minimal material overlaps to form air pockets which would fill with ice if it is used for frozen foods. Heat transfer to and from the container is improved through the economical use of materials. If it is desirad to insulate the container, the stiff material can be made from a recognised insulation material such as o9o* polystyrene.

1 o The clear flm lid allows product to be seen without opening the container.

?P'oducts within the container can be made readily visible by the provision of viewing ports (not shown) in the blank of stiff material and/or by shortening the depth of the side or end panels.

The laminate. provides potential for the use films of gas barrier or permeation properties in accordance with customer requirements.

Barrier films which may be used include linear low-density EVOH/EVA films with the EVA surface being used as the internal surfaces of the laminate.

Where appropriate films that actively modify the container's internal 2oenvironment can be used as part of the structure.

The container can incorporate tamper evident sealing.

BRIE DESQRIQION OF DRAWINGS Aspects of the present invention will now be described by way of example only with reference to the accompanying cdrawings in which: AEiurel: is a cro8spection of a container laminate in accordance with the present invention, and Sews C S 0* 0 eWg *a S 0* S EimZ EiCgur 2: ieureo 2A: is a plan view of a lamination process in accordance with one possible embodiment of the present invention, and shows how the laminate is folded prior to the adjacent edges of the flexible material thereof being joined, and is a perspective view of the formed container, in a semi-flat condition, is a perspective view of the closed end of thi container of Figure 3 in an erected condition, and 10 i 8: Pigures 4 to 4B and 5 to SB: are long-sectional and cross-sectional drawings of the container in various stages of expansion.

DESCRIPTION OF PREERED EMBODTMENT With respect to the drawings a. container laminate in accordance with the present invention'.comprise a stiff material 1 and one or two layers of flexible material 2 laminated with the stiff material 1. The flexible material is larger than the stiff material and provides a peripheral border.

The stiff material 1 can be cardboard although other materials can be used. The flexible material 2 may be plastics sheet, but again other materials may be used.

00 The laminate of Figures 1 and 2 can be formed afPtr a blank generally indidated by arrow 3 is laid onto a sheet of plastics material 2 with a larger sized sheet of plastics material 2 being overlaid on the blank 3 once it has been correctly centred. The overlaid sheets of plastics material 2 and lo blaik 3 are laminated together using a heated roller method as described in our earlier patents (not shown) so that there is adherence of the plastics material to the blank and also adherence of overlaid surfaces of the plastics material 2.

Having completed the lamination the laminate, is overlaid so that one major portion thereof ovorli the other and the plastics edges of the overlaid portions of the laminate are joined to form the opened ended container as illustrated by Figures 3 to It will be apparent that the process described lends itself to automation with the steps of lamination, folding, and joining of the edges being completed as subsequent in-line production steps, It is envisaged that the open-en'ad container could be filled with goods at the end of the lamination, joining and erection processes dependant upon customer requirements and abilities. No angular gusseting or other erection or process steps are required, and all steps required to fill and close off the container can be affected externally, In the example illustrated the stiff material 8 is a blank comprising two large sections 4, four flanking sections 5 and end flap sectns 6 all joined about fold lines 7. The blank can be cut using a simple clicking knife or die with simultaneous or later formation of the folding seams 7.

So The bla4t 3 includes a bi-secting fold line 7A which divides what is to become the bottom panel of the container.

The blank is folded about fold line 7A which is inset from the end of the 10 folded blank and side edges are joined using lengthwise seams 8. The completed container is laid flat and can be stored for transportation to a packaging factory or alternatively packaging cen be completed after lamination. The container is self-erecting as the interiors of the openended container are filled with material or by applying external pressure to the seams 8, Folding seams 7 and 7A and the joined edges 8 act as hinges so that the container is erected into a rectangular box formation as is illustrated by Figures 8 and 3A. An internal gusset 9 (see Figures 4A and 6A) is formed to each side of the erected container at the base and is a very minor intrusion over otherwise smooth internal surfaces. The container has the ability to be "self-erecting" on filling because the bottom panels 6 are inset and material entering the container impacts on the bottom panel straightening it and simultaneously pulling the side panels via the gussets 9 inwards until they straighten. This is a significant advantage as the erection of the container can be readily automated.

It will be apparent from those familiar with the art that the simple lamination and erection steps described provide major advantages to the user and or manufacturer especially if the container is used for packaging bulk materials such as cheeses or powders.

The container can be readily adapted for use as a waterproof sports or utility bag by the provision of cut-outs (not shown) for the hands in panels and/or plastics at the open end thereof.

If the inner layer of the laminate is substantially corrosion resistant or rupture-proof the container may be used to facilitate the disposal of So dangerous objects or materials.

eg*e 06e o Use of the container for drinks and other liquids is also a possibility. Use of the container for packaging drinks or other liquids may involve slightly different assembly steps to those described. One possible variation may involve sealing off the open end of the container prior to forming side seams. A filling and outlet spout (not shown) may be incorporated into the walls of the container prior to formation of the side seals.

As far as other similarly constructed containers the shape of the container panels determines the shape of the container. One possible shape of th* container described would be to omit two of the panels 5 on one side of the carton blank to use triangular panels 6. Similar assembly steps to those described for the rectangular container would result in the formation of a triangular section container.

Claims

1. A container formed from a lalwi. ate of stiff material and a larger piece of flexible material, said stiff material including a bottom panel. having a bisecting crosswise fold-line, side panels fixed to and extending from opposite edges of the bottom panel, said side panels each comprising a first panel substantially equivalent in width to the bottom panel and flanking second panels which extend to either side of the first panel, folding seams between the bottom and side panels and folding seams between the first and second side panels, said flexible material providing a peripheral border about the sides of thE stiff material and the laminate being formable into a container by folding so that the side and bottom panels overlap one another and the bisecting fold line and bottom panels are inset and lie between lower portions of flanking panels.

2. A container as claimed in claim I wherein the stiff material is cardboard. *o 0*

3. A container as claimed in claim 1 or claim 2 wherein 6:06 the flexible material is a film of plastics sheet. oC

4. A container as claimed in any one of claims 1 to 3 wherein the lamination is of plastics sheet, cardboard and plastics sheet. *e @5 p. *o o C ego

5. A container as claimed in any one of claims 1 to 4 Swherein the stiff material includes closure panels extending from opposite side panels.

S6. A method of forming the container of claim 1 comprising the steps of: S(a) bonding the stiff material with the flexible material, 11 folding the bonded materials so that the side panels, overlie one another and the fold line of the bottom panel is inset and lies between lower portions of the flanking panels, and fixing together overlaid portions of the flexible material together adjacent said side panels.

7. A container substantially as herein described with reference to the accompanying drawings.

8. A method of forming a container substantially as herein described with reference to the accompanying drawings. DATED this TWENTY SIXTH day of MAY 1993 TRI-ENGLE SYSTEMS LIMITED Applicant. WRAY ASSOCIATES, Perth, Western Australia, Patent Attorneys for the Applicant. ?o•o 6 S SS C 555°* oo* e f S CS S S S oS..