GB2485904A

GB2485904A - Blank for Hexagonal Tubular Container

Info

Publication number: GB2485904A
Application number: GB201120324A
Authority: GB
Inventors: Nigel Hardiman
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-11-24
Filing date: 2011-11-24
Publication date: 2012-05-30
Also published as: GB201120324D0

Abstract

A container erectable from a plurality of first elements 4a initially in a flat configuration e.g. a blank, the container being elongate and having at least one open end which is closed by one or more second elements (24, Figure 3a). The container may be prismatic e.g. hexagonal, one or both ends being open and closed by a cap or lid formed from the second elements. The container may be held in the erect configuration by tabs or inserts 10a, b engaging slots 18a, b and/or by means of double sided tape 4g. The blank may be erected by rolling or wrapping the first elements about an axis B, and may be rolled twice round the axis forming double thickness walls. The second elements may separate from the first elements or may be integrally connected to one of the first elements in the flat configuration (Figures 5c, 5d). Where integral, the caps may be removed from the blank by frangible lines of weakness

Description

Improved Containers and Assembly Thereof The present invention relates to improvements in containers and assembly thereof. In particular the invention relates to improvements for elongate containers suitable for use as items of packaging.

Although the following description refers to elongate containers where the length of the container is larger than the diameter of the same, it will be appreciated by those skilled in the art that the container and method of assembly disclosed herein could also be used for containers wherein the diameter of the same is substantially equal to or larger than the length.

Cylindrical containers or tubes, often made of cardboard, are well known. Typically, such tubes are manufactured by wrapping at least one strip of cardboard helically or spirally around a central cylinder to form the wall of the container. The strips of cardboard are then usually fixed in position with glue and the resulting tube cut to the required length. Containers formed in this way are used in a wide range of applications including toilet roll cores, containers and packaging, and particularly packaging for sending items through the post.

One problem of such types of containers is that they are expensive to transport, because they are relatively bulky and take up a large volume relative to their weight after they are assembled. This is a particular problem for individuals and companies who use the conventional tubular containers as containers or packaging, because the containers are generally not assembled on the site at which they are filled and thus the expense of transporting the tubes before use is incurred. The cost of transporting the bulky containers ultimately increases the costs of the goods which are packaged therein. There is also a relatively high cost associated with storing bulky container tubes before use as they take up a large amount of space.

It is therefore an aim of the present invention to provide a container which is inexpensive to transport and/or store.

It is a further aim of the present invention to provide an improved method of assembling elongate hollow containers.

In a first aspect of the invention there is provided a container, said container including a plurality of first elements movable between a first substantially planar or collapsed configuration and at least a second substantially erect configuration to form a substantially elongate container with at least one open end, one or more of said first elements forming at least one planar wall of said substantially elongate container in said second configuration, wherein said container further includes one or more second elements for selectively closing said at least one open end.

In one embodiment the elongate container formed in said second configuration is substantially hollow. Typically the elongate container has two openings formed at either end of the container in the second configuration.

In one embodiment the open ends of the container are selectively closed and/or sealed using one or more second elements when the container is in use. Typically the second elements are different in shape and/or size to the first elements.

In one embodiment the second elements are one or more caps.

Typically the caps are shaped such that one cap can be inserted inside another cap or otherwise stacked, thereby reducing their volume for shipping or transporting with the container. Further typically the caps are formed from such material to allow them to be reused a number of times if required.

In one embodiment the first and second elements are integrally formed.

In one embodiment the first elements are all substantially planar in form. Typically all the first elements are substantially the same size and/or shape. Further typically the first elements form the walls of a substantially prismatic container and/or non-cylindrical tube in the second configuration.

Preferably the walls of the container form a hexagonal prism in the at least second configuration.

In one embodiment the container includes a plurality of walls which are angularly displaced in respect to the other walls, said walls defining a container or housing within which one or more items can be packaged.

In one embodiment the first configuration is a transport and/or storage configuration and the second configuration is an in-use configuration.

Typically the container formed in at least the second configuration can function as packaging for the same items, and be used in the same way, as traditional cylindrical packaging containers or tubes. However, the present invention has the advantage that the transportation and/or storage costs of the container are greatly reduced due to the reduced volume of the container when in the first substantially planar transport configuration. Furthermore, the substantially planar/ flat or collapsed configuration of the container facilitates printing on one or more of the container surfaces using conventional printing techniques. Printing onto cylindrical tubes requires specialist printing techniques and printing onto the card before assembly has considerable problems with the alignment of images, or other information printed on the surfaces of the same.

In one embodiment the container is formed from a plurality of square and/or rectangular first elements.

Typically the first and/or second elements include a number of edges, at least one of which is attached or otherwise joined to an adjacent element. For example, two or mote of the first elements can be joined by fold lines located between said elements.

In a preferred embodiment the first elements are rectangular in shape and at least one lateral edge of an element is attached to the lateral edge of an adjacent element.

In a second aspect of the invention there is provided a blank for assembly into an elongate container, said blank including a plurality of first elements joined together by fold lines, said blank movable from a first substantially planar or collapsed condition to a second substantially erect condition to form an elongate container with at least one open end, said first elements forming at least one planar wall of the elongate container, wherein said at least one open end is selectively closed and/or sealed with one or more second elements.

In one embodiment the first elements are preformed into the blank or integrally formed as a blank. Typically all the first elements are substantially planar and are of the same size and/or shape. Further typically the first elements form the walls of a substantially non-cylindrical prismatic tube when moved into the second erect configuration.

In one embodiment the second elements are preformed or are integral with the blank.

In construction of the container, the blank is folded along one or more of the fold lines to convert or move the same from the first substantially planar transport configuration to the second substantially in-use configuration.

In one embodiment the container is formed by rolling, wrapping, and/or coiling the blank about an axis. Typically the axis will be the longitudinal axis of the container when formed.

Typically the container is formed by manipulating the planar first elements substantially about an axis to form at least the planar walls of a non-cylindrical prismatic container.

In one embodiment each element forms an individual wall and/or face of the container.

In one embodiment the planar elements are wrapped, coiled and/or rolled at least once around the longitudinal axis of the elongate container.

In one embodiment the planar elements are wrapped at least twice around the axis, thereby increasing the wall thickness and/or rigidity of the container.

In one embodiment the planar elements are rolled, wrapped and/or coiled at least twice around an axis. Typically a double layer of elements and/or a double wall thickness of the container is achieved by rolling, wrapping and/or coiling the elements twice around the axis.

In one embodiment the first and/or second elements are substantially the same size and/or shape.

In one embodiment the blank is substantially square or rectangular in shape. Typically the blank is formed from a number of planar elements wherein each element is joined to an adjacent planar element.

In one embodiment the blank is divided into a plurality of first elements situated substantially parallel with respect to adjacent elements.

Typically the container includes at least one securing means.

Further typically the securing means includes any or any combination of adhesives, staples, hook and loop type fastenings, pins and/or the like.

In one embodiment the securing means includes one or more adhesive areas and/or surfaces. Typically at least one of the elements includes an adhesive area which can be attached and/or adhered to a further element, thereby holding the container in shape or position. Preferably the adhesive area is a sticky strip with a protective peel back layer. In use, the peel back layer is removed to expose the adhesive surface.

In one embodiment the securing means includes one or more slot members and/or insert members. Typically the slot members are shaped to receive at least one insert member.

Further typically engagement of the insert members with the slot members substantially holds the blank in an elongate container form.

In one embodiment the slot members form one or more recesses and/or apertures in the elements, and/or between adjacent elements.

In one embodiment the insert members are formed substantially at the edge of, and/or integrally with, the edge of an element.

In one embodiment the second elements include a number of fold lines. Typically the second elements are divided into a plurality of substantially planar sections.

In one embodiment the substantially planar sections can be folded to form a cap. Typically the second element can be manipulated to substantially close the open ends of the container when in the second substantially erect configuration.

Further typically the second element forms a cap to seal at least one end of the tube in use.

In a third aspect of the invention there is provided a method of forming a container, said container including a plurality of elements and movable between a first substantially planar configuration and a second substantially elongate or erect configuration, said method including the step of; -rolling and/or coiling the first elements about an axis to form an elongate container with at least one open end, said elements forming at least one planar wall of the elongate container, and wherein the at least one open end of said container can be closed using one or more second elements.

Typically the first elements are substantially planar, thereby forming a substantially elongate non-cylindrical prismatic container.

Typically at least part of one element overlaps with at least part of another element in the at least second configuration. Further typically the overlapping elements, or parts thereof, are attached together.

In one embodiment the at least one element which overlaps with another includes securing means.

In one embodiment the elements are situated substantially in-register and/or one on top of another when the same overlap.

Typically at least the faces of the planar first elements are substantially in-register.

In one embodiment the container includes at least seven first elements. Typically the container formed from seven first elements is substantially a hexagonal prism in form. Further typically the hexagonal container has at least one face or wall formed from substantially two elements overlapping.

In one embodiment the container includes thirteen first elements and is rolled and/or coiled twice around an axis to form a substantially hexagonal prism. Typically three elements overlap to form one face in this configuration.

The person skilled in the art will appreciate that the shape of the container and the number of faces or walls thereof can be determined by the number of first elements formed in the blank.

For example:

(No. of first elements) -I No. of faces of prismatic container for substantially single thickness walled container and; 2(No. of first elements) -1 No. of faces of prismatic container for substantially double thickness containers.

In a further aspect of the invention there is provided a container, said container including a plurality of substantially planar elements and movable between a first substantially planar configuration and at least a second substantially erect configuration, wherein the elements form at least the walls of a prismatic tube in the second configuration.

Typically prismatic tube in this context means a non-cylindrical or non-circular tube.

Further typically the container is suitable for packaging one or more items to be sent through the postal system and/or mailed.

Embodiments of the invention are now described with reference to the following figures, wherein: Figures Ia and lb show a plan view of a blank in accordance with one embodiment of the invention; Figures 2a-2c show isometric views of the assembly of the container in accordance with one aspect of the invention; Figures 3a-3c show top and side views of the end caps of the container in accordance with one embodiment of the invention; Figures 4a and 4b show plan views of blanks for the first and second elements in accordance with one embodiment of the invention; and Figures 5a-Sd show plan views of blanks in accordance with various embodiments of the invention.

The following description teaches a new type of non-cylindrical tubular packaging that is easier and less expensive to produce than conventional cylindrical tubes, with the additional advantage of being flat in at least one condition, thereby reducing shipping, transport and/or storage costs. The reduced volume also allows users of the non-cylindrical tubes to hold a larger stock in less space than with conventional tubes.

Turning to figure Ia, there is shown a plan view of a blank 2 which forms the non cylindrical tubular container shown in figure 2. The blank is divided into thirteen substantially planar elements 4a-f, 4a'-g', which are pre-formed in the blank and aligned in parallel across the width of the same. At least one longitudinal or lateral edge of an element is attached to an adjacent element. It is the joints between adjacent elements which form the fold lines 6 along which the blank is manipulated to form the container.

In this example the final element in the series 4g' includes a double sided adhesive/sticky strip 8 with a peel back layer which can secure the container in position during and/or after assembly. The person skilled in the art will appreciate that this element does not have to be an element which is the same shape and/or size as the others, but merely provide a surface by which to secure the elements and thereby the container in its non-cylindrical tubular form.

The blank 2 in this example is intended to form a hexagonal container wherein the elements are rolled up in direction A. The blank folds at fold lines 6 and forms a container which is prismatic with six side faces or walls and is open at either end.

The person skilled in the art will appreciate that the number of sides or faces the container has, is determined by the number of elements 4 and fold lines 6 the blank includes. The fact that the elements are planar allows the blank to be substantially planar in shape whereby reducing the shipping or transport volume of the same.

The blank in this example is also formed with two tabs lOa, lOb on one side of the endmost element 4a. During assembly of the container the two tabs are received in the slots l2a, 12b formed between elements 4f and 4a'. This tab and slot arrangement provides additional stability to the container during and/or after assembly. The other endmost slot 4g' also includes recesses 14a, 14b which accommodate the tabs when the container is assembled.

Figure lb shows a blank 16 of similar design to that in figure la.

However, the blank in this example is smaller, and thus the container formed therefrom will be smaller. As such, the tab and slot stability features are not required and the container is assembled and held in position only with the adhesive strips 18 and 20. The blank is marked with a designated area 22 to which the adhesive strip is attached when forming the container. As in figure la the blank 16 is formed into a container by rolling the same in direction A, and about axis B which is the longitudinal axis of the container, once it is formed.

Turning now to Figures 2a-2c, wherein the process of forming the container from the blank 2 is shown. The first step is moving the elements to form the container. The elements are moved by rolling and/or coiling the blank about the axis B in direction A, until the tabs lOa, lOb are received in the slots 12a, 12b. The protective film is typically then removed from the adhesive layer 8 located on element 4g'. The blank is then further rolled in direction A until the sticky surface of the adhesive layer is in contact and thereby attached to a surface of element 4a'. The hexagonal elongate container is thereby formed.

In this example the container formed has a number of angular faces or planar side walls angularly displaced from each other.

The container is also formed with the walls forming a double layer, thereby giving additional stability and strength to the container. Each of the elements lies in-register with another (i.e. directly on top of another element not directly joined to the same, when viewed in plan). For example, one face of element 4a lies in contact with the opposite face of element 4a', one face of 4b with the opposite face of 4b', this is repeated to elements 4f and 4f'. In this arrangement one face includes three elements (4a, 4a' and 4g') attached together.

The final step is to seal one or both ends of the tube with caps 24 in this example. The person skilled in the art will appreciate that the ends could be sealed with flaps or further elements judiciously positioned on, or attached to, the blank.

Figures 3a-3c show hexagonal caps 24 which fit into the open ends of the container 26 when it is formed. Figure 3a shows a plan view of one cap. The side view, figure 3b, shows how the walls 28 of the cap taper to the base 30. This slight tapering allow the caps to be stacked, one inside another as shown in figure 3c, to reduce their overall aggregate volume when shipping. The caps in this example are formed from injection moulded plastic but could equally be formed from vacuum moulded plastics, compressed paper, card and/or the like. The tapering walls 28 of the caps in this embodiment also enable an interface fit with the walls of the container. Securing means, such as adhesives, adhesive strips, fastenings, tags and/or the like, can also be used to hold the end caps 24 in position.

Figure 4a shows an embodiment of the invention wherein the caps 34 are formed from a number of planar elements jointed together by fold lines, which when assembled form caps to close the end of the container 26. The caps 34 in this example include a planar element which forms a hexagonal face 36 sufficiently sized to seal the ends of an assembled hexagonal container 26.

The edges of the hexagonal face are joined to peripheral planar elements 38', 38". The peripheral planar elements are alternately arranged such that every other element includes one or more tabs 40. The tabs can be used to engage with and/or extend into slots 42 formed in the cap 34 and/or slots 44 formed in the container blank as shown in figure 4b. Engaging the tabs in this way reinforces the edges of the cap and can also secure the same in the open end of the container. It is intended on assembly of the container that the slots 42 formed in the second element align with the slots 44 on the container body.

The tabs can thus extend through, or otherwise engage with the aligned slots when the second element is inserted as a cap into the open end of the container.

In this particular embodiment the elements 38' which include tabs 40 are first folded to lie substantially flat against the face 36 of the cap. The elements 38" which do not include tabs can be folded to be substantially perpendicular to the face 36, thereby engaging the tabs4O with slots 42. If the elements 38' are not folded to lie perpendicular to the to the face, this arrangement will nevertheless result when the caps are inserted into the ends of the formed hexagonal tube.

The caps can also be formed integrally with the container blank 16 as shown in figures 5a to 3d. Turning to figure 5a there is shown two second elements 46a, 46b which form hexagonal end caps to the hexagonal tube when formed. The peripheral planar elements 48a, 48b join the face 30 of the second elements to the body of the container, at the short edges of the rectangular element 4f. Assembly of this container is achieved by firstly forming the hexagonal tube in the same manner as shown in figures 2a-2c, however without inserting the independent caps.

Once the body of the tube is assembled the second elements 46a, 46b are inserted into the open ends of the tubes such that the face 50 of the second elements is substantially perpendicular to the wall elements of the tube. In this example, two of the peripheral elements have rounded edges 52 in order that the tabs 54 can engage with the apertures 58 formed between the elements and the face 50 and/or the apertures 60 formed in the inside walls 4a-f of the blank, without interference. This additional engagement provides additional strength and security to the formed container by preventing the caps being forced inward during transport, or outward from contact with the container contents. The engagement of the tabs 54 with the apertures 58, 60 is typically performed once the elements 46a, 46b are inserted into the ends of the tubes, by folding peripheral elements to lie substantially adjacent to the face 50.

The blank 16 also includes notches 56 cut into the side of the same. These notches enable the blank to be rolled more easily to form the body of the tube.

The tabs 54, notches 56 and the apertures 58, 60 are concealed when the tube is assembled by the outermost walls 4a'-g' substantially surrounding the same. This is a particular advantage as the outer surface of the tube can be pre-printed before assembly of the tube. For example, packages or containers can be personalised and printed before assembly, something which is virtually impossible with conventional cylindrical tubes as aligning a covering layer or the spirals of card forming the tube is very difficult. It is envisaged that, for example in mail order companies or the like, when an order is received the container can be printed with information and/or images relevant to the contents of the container, by conventional printing methods, before packaging the contents and/or assembling the container.

In comparison to figure Sa, figure Sb shows a similar embodiment, however the edges of the peripheral elements of the second elements or caps 46a, 46b are not rounded. It is intended that the tabs 54 will engage with the apertures 58, 60 in the same manner, however the peripheral elements without tabs 62 will have to be folded into position first so as not to overlap the tabs when in position. The face SO of the cap will be positioned in the same arrangement as that in figure Sa, by being recessed into the end of the formed tube.

Figure Sc shows an embodiment very similar to that shown in figure Sb, however the edge of the blank is joined to an end cover elements 64a, 64b. The tube in this embodiment is assembled in the same manner as that in Sb including the cap or second elements 46a, 46b being recessed into the ends of the formed tube. In figure Sc the cover elements are folded along fold lines to cover the ends of the container. Tab 66 engages with aperture 68 to secure the cover in position over the recessed face SO.

Figure Sd shows a yet further embodiment of the invention where the second elements or caps 46a, 46b are attached to the blank or body of the container 16 by arms 70. In this embodiment, once the body of the container is assembled by rolling the blank 16, the second elements can be manipulated into position to seal the open ends of the tube. It will be appreciated by those skilled in the art that in the aforementioned embodiments the caps could be removable from the blank 16, typically by one or more frangible portions or lines of weakening.

Claims

Claims 1. A container including a plurality of first elements movable between a first substantially planar or collapsed configuration and at least a second substantially erect configuration to form a substantially elongate container with at least one open end, one or more of said first elements forming at least one planar wall of said substantially elongate container in said second configuration, wherein said container further includes one or more second elements for selectively closing said at least one open end.
2. A container according to claim I wherein the container has two openings formed at either end of the container in the second configuration.
3. A container according to claims 1 or 2 wherein the open ends of the container are selectively closed and/or sealed using one or more second elements when the container is in use.
4. A container according to claim 3 wherein the second elements include a number of fold lines along which the element can be folded.
5. A container according to any preceding claim wherein the second elements are one or more caps.
6. A container according to any preceding claim wherein the first elements are substantially planar in form.
7. A container according to any preceding claim wherein the first elements are substantially the same size and shape thereby forming the walls of a substantially prismatic container in the second configuration.
8. A container according to claim 7 wherein the walls of the container form a hexagonal prism in the at least second configuration.
9. A container according to any preceding claim wherein the first configuration is a transport and/or storage configuration and the second configuration is an in-use configuration.
10. A container according to any preceding claim wherein the container includes at least one securing means.
11 A container according to any preceding claim wherein the container includes one or more slot and/or inset members.
12. A blank for assembly into an elongate container, said blank including a plurality of first elements joined together by fold lines, said blank movable from a first substantially planar or collapsed condition to a second substantially erect condition to form an elongate container with at least one open end, said first elements forming at least one planar wall of the elongate container, wherein said at least one open end is selectively closed and/or sealed with one or more second elements.
13. A blank according to claim 12 wherein the blank is folded along one or more of the fold lines to convert or move the same from the first substantially planar transport configuration to the second sub stantially in-use configuration.
14. A blank according to claim 12 or 13 wherein the container is formed by rolling, wrapping, and/or coiling the blank about an axis.
15. A blank according to claim 14 wherein the first elements are wrapped at least twice around the axis, thereby increasing the wall thickness and/or rigidity of the container.
16. A method of forming a container said container including a plurality of elements and movable between a first substantially planar configuration and a second substantially elongate or erect configuration, said method including the step of; -rolling and/or coiling the first elements about an axis to form an elongate container with at least one open end, said elements forming at least one planar wall of the elongate container, and wherein the at least one open end of said container can be closed using one or more second elements.
17. A container including a plurality of substantially planar elements and movable between a first substantially planar configuration and at least a second substantially erect configuration, wherein the elements form at least the walls of a hexagonal prismatic tube in the second configuration.