GB2316393A - Collapsible Receptacle - Google Patents

Abstract

A collapsible receptacle made from a blank of sheet material has fold lines 17 (along its base panel 1) and 7 (along its end portions 4) to allow it to be folded flat by extending the base away from the receptacle and folding the end panels inwardly. The side portions 2 are hingeably connected to the base portion 1 and the ends of the receptacle are formed by joining panels 4 and 5 which are extensions of side panels 2. Panels 4 and 5 can be stitched, glued, stapled 6 or heat sealed. The tops of the side panels 2 fold back to form reinforcement 10 held in place by staple 11, and the end panels 4,5 fold forward to form a flange 12,13 for stacking. Panel 8 extending from base 1 folds inside the end panel 4,5 where it is held in place by the contents of the receptacle. Panel 8 has a flange 9 which can be folded under flange 13 to provide additional support. Alternatively the flange 9 can be replaced with a wedge arrangement (30-33, Figure 3) to give extra support.

Description

Collapsible Receptacle Field of the Invention This invention relates to collapsible receptacles, and in particular to a collapsible receptacle which is formed from a blank.

Background to the Invention Many different products are packaged in boxes. The requirements of any particular box depend, amongst other criteria, on the products which are to be packed therein.

Fruit and vegetables, such as lettuce, cucumbers, tomatoes, cabbages, cauliflowers, calabrese etc. are generally packed into boxes. Any box used must therefore be sufficiently strong to enable the box to be moved when it is full. However, there are other criteria which must be taken into account when designing a box suitable for packaging fruit and vegetables. The space occupied by the box prior to it being used is significant, as is the strength of the box when it is assembled.

In order to reduce the space occupied by a box prior to its use, it is known to use boxes which are supplied as flat blanks, and which are assembled (usually by folding and stapling) as and when they are needed.

However, this requires additional labour during the harvest period, when labour is often scarce, and as such boxes of this type are disadvantageous.

Collapsible boxes, which overcome this problem, are known. Such boxes are generally formed from a flat blank and are assembled by folding and stapling. However, additional fold line are provided so that the box can be collapsed. By collapsing the box, the space occupied by the box prior to its use is reduced, but when the box is required for use it can be erected quite simply at the point of use by a harvester. This means that the requirement for extra labour is removed, whilst the advantage of reduced storage space is retained.

Known collapsible boxes suffer from a number of disadvantages.

Generally, a flange is provided on each side of the box, running along the length thereof, and at each end of the box a portion of the box equal to the width of the flange is folded back on to the box so that there is a double thickness of material (usually cardboard or similar). The flange which runs along the length of the side of the box enables one box to be stacked on top of the other, and provides a certain degree of stiffness. When this type of box is filled with product, there is a tendency for the sides of the box to bow outwards. This is because the stiffness provided by the flanges is not great. As the number of boxes stacked on top of each other is increased, there is a greater tendency for the sides of the boxes at the bottom of the pile to bow outwards. This results in the flanges not properly serving their function of enabling one box to be stacked on top of another, and results in the contents of the box being damaged.

Boxes of the type described cannot generally be re-used. This is because they are insufficiently stiff and strong, and are therefore damaged when used in normal fashion.

Another type of self-stacking box has posts at each corner of the box. The posts provide a much stiffer and stronger box, and allow one box to be stacked on top of another without the danger of the sides of the box collapsing. However, such boxes cost more to manufacture, and require additional labour for assembly thereof at the point of use.

It would therefore be desirable to provide a collapsible box which is stronger and stiffer than existing collapsible boxes, and which can be collapsed and erected numerous times.

Summary of the Invention The invention provides a collapsible receptacle made from a sheet material, comprising two side members each provided with a stiffening member, two end members each provided with a flange, and a base member, the said end and base members being provided with fold lines which permit the receptacle to be folded flat.

Preferably, the flange is twice the thickness of the sheet material.

Preferably, each end member comprises two flaps which are joined by suitable fastening means, such as staples, adhesive, stitching, heat sealing, etc. The flange may be formed integrally with each flap. More preferably, the two flaps overlap. Advantageously, the flanges formed integrally with the flaps overlap to provide a flange which is twice the thickness of the sheet material across a substantial part of the width of the receptacle.

In order to provide an even stronger structure, a flange which is three times the thickness of the sheet material may be provided. A flap suitably extends from the base member, the said flap being provided with a flange and being so dimensioned to co-operate with the end member and the flange thereof, thereby forming a flange three times the thickness of the sheet material. Preferably, the flap which extends from the base member engages with the inside of the end member, and may be held in position by the products placed in to the receptacle.

The base member and end members and/or side members suitably comprise fold lines which enable the receptacle to be folded along the said lines and thereby collapsed. A fold line preferably runs along the length of the base member, including the flaps extending therefrom where provided, and from the bottom of the end member to the top thereof.

The stiffening member provided on each side member is preferably integral therewith, and may be formed by folding the sheet material along a fold line back onto the side member. Advantageously, the stiffening member is attached to the side member by suitable means, such as a staple, stitching, an adhesive, or heat treatment.

According to another aspect of the invention, there is provided a blank for a receptacle, comprising a sheet of material having a plurality of fold and cut lines arranged so that the blank can be formed into a collapsible receptacle, comprising two side members each provided with a stiffening member, two end members each provided with a flange, and a base member, the said end and base members being provided with fold lines which permit the receptacle to be folded flat.

Preferably, the fold and cut lines are arranged so that the flange is twice the thickness of the sheet material.

Preferably, the fold and cut lines are arranged so that each end member comprises two flaps, and more preferably, so that the two flaps overlap. Advantageously, the flanges formed integrally with the flaps overlap to provide a flange which is twice the thickness of the sheet material across a substantial part of the width of the receptacle.

In order to provide an even stronger structure the fold and cut lines may be arranged so that a flange which is three times the thickness of the sheet material is provided. The fold and cut lines are suitably arranged so that a flap extends from the base member, the said flap being provided with a flange.

The blank suitably comprises fold lines in the base member and end members and/or side members which enable the receptacle to be folded along the said lines and thereby collapsed. A fold line preferably runs along the length of the base member, including the flaps extending therefrom where provided, and from the bottom of the end member to the top thereof. Advantageously, two slightly spaced apart fold lines run along the length of the base member, including the flaps extending therefrom.

The receptacle may be made from any suitable material such as fibre based products, e.g. cardboard or a plastics material, e.g. polypropylene. The material used may be corrugated. Where the receptacle is to hold wet products, or to be used in a chilling process, it is desirable to use a plastics material.

The collapsible receptacle of the invention is considerably stronger that conventional collapsible receptacles. This is because flanges are provided at the ends of the receptacle, rather than the sides. This allows a flange which is two or three times the thickness of the sheet material to be made. Stiffening members reduce the tendency of the side members to bow outwards due to the weight of the content of the receptacle, and the weight of other receptacles and their contents which may be stacked on top of the receptacle. The increased strength of the receptacle enables it to be re-used many more times than is the case for known receptacles. Also, the increased strength of the receptacle of the invention allows it to be used where formally collapsible boxes would not have been used because they are too weak. Therefore, the receptacle of the invention brings the advantages of a collapsible container (in terms of manpower, logistics, etc.) to areas where they have not been used before. The receptacle of the invention is particularly suitable for use as a container for heavy vegetables such as cabbage, calabrese, broccoli, and cauliflower, but is equally suitable for use with lighter crops, such as lettuce.

Brief Description of the Drawings In the drawings, which illustrate preferred embodiments of the invention: Figure 1 is a schematic representation of one end of a collapsible box in erected form; Figure 2 is a plan view of one end of a blank cut and scored to enable it to be made into the box shown in Figure 1; Figure 3 is a plan view of an alternative blank cut and scored; and Figure 4 is a perspective view of the collapsible box formed from the blank shown in Figure 3.

Detailed Description of the Preferred Embodiments In Figure 1, there is shown a collapsible box comprising a base 1, side members 2, and an end member 3. It will be appreciated that the box comprises two end members 3, although only one is shown in the Figures.

The box may be made from any suitable material such as fibre based products, e.g. cardboard or a plastics material, e.g. polypropylene.

The material used may be corrugated.

From Figure 1, it can be seen that end member 3 comprises two flaps 4 and 5, flap 4 overlapping flap 5, and that the two flaps are fastened together with staples 6 (although other fastening means such as adhesives, heat treatment or sewing could be used).

Referring to Figure 2, the blank is foldable along a part of its length at 16 to provide base 1 and side members 2. Further longitudinal score lines are provided at 14 to provide reinforcement members 10 and flanges 12, 13. At 19, the blank is cut so that flap 8 becomes an extension of base member 1, whilst flaps 4 and 5 can co-operate to form end member 3.

In Figure 1, it can be seen that reinforcement members 10 are folded back on side members 2, and attached thereto by staples 11. The fold lines 15 and 18 enable the folding back of reinforcement members 10 to cause flanges 12 and 13 to take up the position shown in Figure 1, i.e.

at right angles to flaps 4 and 5 from which they extend.

Flap 8, which extends from base 1, has a fold line at 20 to provide a flange 9. Flap 8 and flange 9 are shown in Figure 1 in dashed lines, and it can be seen that flap 8 essentially corresponds in height to the height of flaps 4 and 5, so that when the box is assembled the flap co-operates with the inside of end member 3. As the box is filled with product, the flaps 8 are pushed outwards. The provision at each end of the box of flaps 8 with flanges 9 results in flanges which are 3 layers thick where the flaps 4 and 5 overlap. Also, where a corrugated material is used, the corrugations in the flaps 4 and 5 and flanges 12 and 13, run at right angles to those in flap 8 and flange 9. This is particularly advantageous, since it increases the rigidity of the box.

A double fold line 17 runs the length of the blank. Flange 13 is also provided with a fold line 7. These fold lines allow the box shown in Figure 1 to be collapsed, so as to occupy less space, which is a requirement for storage of the boxes prior to there use.

To collapse the box, flaps 8 are pulled inwardly so as to lie essentially flat on the base member 1. The base member 1 is then pushed downwardly and folds about fold lines 17. This has the tendency to pull end members 3 inwards, causing flap 4 to fold about fold line 7. This also has the tendency to lift flaps 12 and 13 into the same vertical plane as flaps 4 and 5. However, it may be necessary to lift flanges 12 and 13 manually.

The box tends to erect itself, although as one skilled it the art will understand, the degree of this tendency depends very much on the material from which the box is made.

Referring to Figures 3 and 4, the alternative configuration of box, suitably for larger sizes of box containing a greater load than that shown in the other embodiment, is essentially the same as that shown in Figures 1 and 2, except that the flap 8 and flange 9 are replaced with a flap 30 divided into two approximately equal sections with a narrow strip 31, defined by two creases 32 and 33, between them. This permits the end of the box to be strengthened by the two sections of the flap 30 being folded over on themselves, the narrow strip causing the two sections to adopt a wedge shape which is then pushed up under the flanges 12 and 13 to add support to the flanges and rigidity to the end of the box. The flap 8 is simply opened out along the base member 1 to permit the box to be folded flat, as hereinbefore described with reference to Figures 1 and 2. In Figure 3, fold lines or creases are shown as broken lines, while cut lines are shown as solid.

Claims (29)

Claims

1. A collapsible receptacle made from a sheet material, comprising two side members each provided with a stiffening member, two end members each provided with a flange, and a base member, the said end and base members being provided with fold lines which permit the receptacle to be folded flat.

2. A receptacle according to Claim 1, wherein the flange is twice the thickness of the sheet material.

3. A receptacle according to Claim 1 or 2, wherein each end member comprises two flaps which are joined by suitable fastening means, such as staples, adhesive, stitching, heat sealing.

4. A receptacle according to Claim 3, wherein the flange is formed integrally with each flap.

5. A receptacle according to Claim 3 or 4, wherein the two flaps overlap.

6. A receptacle according to Claim 5, wherein the flanges formed integrally with the flaps overlap to provide a flange which is twice the thickness of the sheet material across a substantial part of the width of the receptacle.

7. A receptacle according to any preceding claim, wherein a flange which is three times the thickness of the sheet material is provided.

8. A receptacle according to Claim 7 when dependent on Claim 6, wherein a flap extends from the base member, the said flap being provided with a flange and being so dimensioned to co operate with the end member and the flange thereof, thereby forming a flange three times the thickness of the sheet material.

9. A receptacle according to any preceding claim, wherein the flap which extends from the base member engages with the inside of the end member, and may be held in position by the products placed in to the receptacle.

10.A receptacle according to any preceding claim, wherein the base member and end members and/or side members suitably comprise fold lines which enable the receptacle to be folded along the said lines and thereby collapsed.

11.A receptacle according to Claim 10, wherein a fold line preferably runs along the length of the base member, including the flaps extending therefrom where provided, and from the bottom of the end member to the top thereof.

12.A receptacle according to any preceding claim, wherein the stiffening member provided on each side member is integral therewith.

13. A receptacle according to Claim 12, wherein the stiffening member is formed by folding the sheet material along a fold line back onto the side member.

14. A receptacle according to any preceding claim, wherein the stiffening member is attached to the side member by suitable means, such as a staple, stitching, an adhesive, or heat treatment.

15.A blank for a receptacle, comprising a sheet of material having a plurality of fold and cut lines arranged so that the blank can be formed into a collapsible receptacle, comprising two side members each provided with a stiffening member, two end members each provided with a flange, and a base member, the said end and base members being provided with fold lines which permit the receptacle to be folded flat.

16.A blank according to Claim 15, wherein the fold and cut lines are arranged so that when assembled into a receptacle, and the receptacle is erect, the flange is twice the thickness of the sheet material.

17. A blank according to Claim 15 or 16, wherein the fold and cut lines are arranged so that each end member comprises two flaps.

18.A blank according to Claim 17, wherein so that when assembled assembled into a receptacle, and the receptacle is erect, the two flaps overlap.

19.A blank according to any of Claims 15 to 18, wherein the flanges formed integrally with the flaps overlap to provide a flange which is twice the thickness of the sheet material across a substantial part of the width of the receptacle.

20.A blank according to any of Claims 15 to 20, wherein the fold and cut lines are arranged so that a flange which is three times the thickness of the sheet material is provided.

21.A blank according to Claim 20, wherein the fold and cut lines are arranged so that a flap extends from the base member, the said flap being provided with a flange.

22.A blank according to any of Claims 15 to 21, wherein the blank comprises fold lines in the base member and end members and/or side members which enable the receptacle to be folded along the said lines and thereby collapsed.

23.A blank according to any of Claims 15 to 22, wherein a fold line runs along the length of the base member, including the flaps extending therefrom where provided, and from the bottom of the end member to the top thereof.

24. A blank according to Claim 23, wherein two slightly spaced apart fold lines run along the length of the base member.

25. A blank according to Claim 24, wherein the two slightly spaced apart fold lines run along the length of each flap.

26. A receptacle according to any of claims 1 to 14 or a blank according to any of Claims 15 to 25, wherein the receptacle or blank is made from any suitable material such as fibre based products, such as cardboard or a plastics material, such as polypropylene.

27. A receptacle according to Claim 26, wherein the material used is corrugated.

28. A receptacle substantially as described with reference to, or as shown in, Figures 1 and 4.

29. A blank substantially as described with reference to, or as shown in, Figures 2 and 3.