NZ506739A - Container collapsible to lay flat condition, with extension of wall being connected to adjacent wall by section having vertical and diagonal fold lines - Google Patents

Abstract

The container is shown in a partially folded state. Adhesive is applied at 19,20,21. After folding about transverse fold lines a "lie flat" collapsible container is obtained. This is erected by lifting out side walls of base and lid. The diagonal fold lines shown extend from a base corner, only partially to the edge of the flaps shown.

Description

NEW ZEALAND PATENTS ACT, 1953 No: 506739 Date: 04 September 2000 IfitC Jjly OiViC'* Qf fsijj c:P 2ZZ\ RE CEi VE COMPLETE SPECIFICATION "A Container" We, CARTER HOLT HARVEY LIMITED, a company duly incorporated under the laws of New Zealand of 640 Great South Road, Manukau City, Auckland, New Zealand, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention relates xo containers ana particularly, or though not solely, containers erectable from an assembly made from a blank therefor. The present invention also extends to the lay flat assembled forms of such containers and to the use and related methods thereto.

There is frequently a need to provide a container formed from a sheet material such as a solid card or a laminate (eg, which may include a corrugated or a flute providing medium, eg, a kraft paper lined corrugated board).

Frequently it is desirable for a manufacturer to both die cut a single piece blank for a container and to provide the container (or container components) in an assembled yet lay flat form to an ultimate end user who hopefully will only be required to make simple manipulations of the lay flat form to make it usable as a container to receive goods and thereafter, where (as is usually preferred) there is a lidding feature integral therewith, to close the container.

It is to such lay flat form type pre-assembled containers that the present invention is directed and to blanks suitable therefor as well as the related uses and methods.

In one aspect the present invention consists in a container assembled from a sheet material to define (at least when erect) a rectangular or square base, four walls and a hinged lid (optionally with peripheral flanges), wherein said lid hinges from the top of one of the walls (hereafter defined as "the lid hinging wall") and which lid hanging wall is connected to each adjacent wall (hereafter the adjacent walls) by at least part of an extension at each end of the hinging wall to the extent said extension in each case in the assembled container is defined by (i) a part (hereafter part (i)) hinged on a hinge axis with said hinging wall substantially normal to the hinge axis of that hinging wall with said lid, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate base corner of the hinging wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base, said connection fold between said part (i) and part (ii) on said fold-line not extending to the top of its proximate adjacent and wherein the assembled construction at each said hinging wall corner allows one or both of (a) an erection by simple pop-up of the hinging wall and its adjacent walls of the assembled container from the base thereof, the popping up being from a lay flat condition of each said adjacent wall on said base under a lay flat overlay of part thereof by said hinging wall, and (b) a location of (optional) peripheral flanges of said hinged lid proximate to each end of the lid hinge in the erect both assembled and erect container outside of each said adjacent wall so as to be each sandwiched between a said part (i) and a part (ii) at least in part.

In the preferred form, preferably said sheet material is a single form blank.

Preferably said lid hinging wall is a longer side wall of a rectangular base.

Preferably the base corner construction is substantially hereinafter described with reference to the accompanying drawings.

In a further aspect the present invention consists in an erect form of a container as previously defined.

Preferably the assembled construction at each said hinging wall corner allows both (a) and (b).

Preferably a complementary corner assembly to that of each hinging wall base corner and its adjacent wall is involved at each base, distal wall and adjacent wall corner In another aspect the present invention consists in a container or container component assembled from a sheet material to define (at least when erect) a rectangular or square base or top (if a lid) and four walls or flanges. wherein at least one of an opposed pair of walls or flanges ("primary wall" or "primary walls") is connected to each adjacent wall or flange (hereafter "the adjacent walls") by at least part of an extension at each end of the or a primary wall flap, said extension in each case in the assembled container or container component defining (i) a part (hereafter part (i)) hinged on a hinge axis with the or a said primary wall substantially normal to the hinge axis of that wall with said base or top, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate corner of the primary wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base or top, said connection fold between said part (i) and part (ii) on said fold line not extending to the distal edge of its proximate adjacent wall, wherein the assembled construction of said container at the or each said primary wall corner allows an erection of the container from a lay flat form by a simple pop up of the primary wall (or walls) and its adjacent walls of the assembled container from the base (or top) thereof, the popping up being from a lay flat condition of each said adjacent wall on said base (or top) under a lay flat overlay of part thereof by said primary wall.

In another aspect the present invention consists in a container assembled from a sheet material to define (at least when erect) a rectangular or square base, four walls and a hinged lid, wherein said lid hinges from the top of a wall flap (hereafter that flap to define "the lid hinging wall") and which lid hanging wall is connected to each adjacent wall (hereafter the adjacent walls) by at least part of an extension at each end of the hinging wall flap, said extension in each case in the assembled container defining (1) a part (hereafter part (i)) hinged on a hinge axis with said hinging wall substantially normal to the hinge axis of that hinging wall with said lid, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate base corner of the hinging wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base, said connection fold between said part (i) and part (ii) on said fold-line not extending to the top of its proximate adjacent wall, wherein the assembled construction of said container at each said hinging wall corner allows an erection of the container from a lay flat form by a simple pop up of the hinging wall and its adjacent walls of the assembled container from the base thereof, the popping up being from a lay flat condition of each said adjacent wall on said base under a lay flat overlay of part thereof by said hinging wall.

In yet another aspect the present invention consists in a container assembled from a blank of sheet material to define (at least when erect) a rectangular or square base, four walls and a hinged lid with a peripheral flanges, wherein said lid hinges from the top of a wall flap (hereafter that flap to define "the lid hinging wall") and which lid hanging wall is connected to each adjacent wall (hereafter the adjacent walls) by at least part of an extension at each end of the hinging wall flap to extent said extension in each case in the assembled container defining (i) a part (hereafter part (i)) hinged on a hinge axis with said hinging wall substantially normal to the hinge axis of that hinging wall with said lid, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate base corner of the hinging wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base, said connection fold between said part (i) and part (ii) on said fold-line not extending to the top of its proximate adjacent wall, wherein the assembled construction of said container at each said hinging wall corner allows the location of the peripheral flanges of said hinged lid proximate to each end of the lid hinge in the both assembled and erect container outside of each said adjacent wall so as to have the proximal flange region of each sandwiched between a said part (i) and a part (ii) at least in part.

In yet another aspect the invention is a container assembled from a blank or blanks and capable of being erected from an assembled lay flat form, said container being characterised in that it includes between at least a pair of wall flaps from the base a connecting feature substantially hereinbefore described.

In still a further aspect the present invention consists in a lidded container formable from a blank and having a lay flat assembled form and an erected assembled form, said erected assembled form allowing the opening and closing (and vice versa) of a hinged lid with peripheral flanges, the interconnection between that wall from which the lid is hinged and each adjacent wall being with an extension of the hinging wall.

In another aspect the invention is a pop-up corner assembly of a container or container part, said assembly being substantially as defined or described.

In a further aspect the present invention consists in a blank suitable for forming a container of any of the kinds herein defined.

In still a further aspect of the present invention consists in a blank suitable for being assembled into a lay flat and/or erect container, said blank being of a form substantially as herein described with reference to Figure 1A of the accompanying drawings.

In still a further aspect the present invention consists in a blank for a container to have one of or both (a) lid engagement feature substantially as herein described adjacent to the lid hinging axis or (b) a pop up characteristic substantially as herein described, said blank having a base with a hinging wall flap with extensions at each end thereof having the capability of providing the part (i) and part (ii) characteristics herein described and/or to provide the features during erection or upon erection.

In still a further aspect of the present invention consists in the use of a container of any of the kinds hereinbefore described with reference with to any one or more of the accompanying drawings.

The present invention also consists in methods of forming a lay flat yet assembled container capable of being readily manipulated into an erect form, said method being performed substantially herein described preferably with reference to any one or more of Figures 1A to 1G.

In yet a further aspect the present invention consists in a transport pack of goods which comprises a container of any of the kinds previously defined in its erect enclosed form, the goods being held within the container.

The present invention also extends to the use of such a pack in the course of commerce.

One preferred form of the present invention will now be described with reference to the accompanying drawings in which; Preferred forms of the present invention will now be described with reference to the accompanying drawings in which Figure 1A to 1G show a preferred lidded form of the container in accordance with the present invention which has the capability of being glued or otherwise attachment assembled (eg,, using staples, etc.) from a single piece blank as depicted in Figure 1A into the lay flat form shown in Figure 1G, the container in such preferred form having several preferred aspects of the present invention embodied therein, Figure 2 shows the reverse view of the lay flat form shown in Figure 1G, and Figures 3A-3F shows the lay flat form of Figures 1G and Figure 2 being manipulated by a customer or user to a useable form whereby goods can be placed within the container, ie, on the preferably rectangular base within the four upright or substantially upright walls thereafter to be enclosed therein by use of the peripheral flanges lid which locates the proximate ends of its flange pair for the adjacent walls (ie, not that flange which is the distal lidding flange) externally of the walls but none the less confined by a sandwich type arrangement by the connected extension between the hinging wall and the adjacent walls.

In the preferred form of the present invention the container is formed from a paper board blank (preferably a shade fluted corrugated board with its flute run direction preferably being such that it is upright in the hinging wall and the distal wall). Other flute run directions however fall within the scope of the present invention as do all non corrugated variants In the preferred form of the present invention the hinged lid is provided from a long wall and the lid is provided with peripheral flanges to position about adjacent walls and the distal wall (a distal in respect to the hinging wall) of the goods receiving part of the container. The lid is lockable close preferably using any appropriate die cut lid flange to wall engagement system.

In the preferred form of the present invention the arrangement of the interconnection engenders sufficient interconnection strength between each end of the hinging wall and the adjacent walls so as to allow, despite its preassembly, its manual uplifting in a pop up manner from its lay flat condition to its erect condition and thereafter the container to be used as a reasonably water tight container with preferably the proximal to the hinge wall hinge line regions of the lid flanges being located externally of the adjacent walls but held in such a way as to enhance the strength of the container.

In its preferred form the present invention provides significant savings in material since a container in accordance with the present invention provides a lay flat preassembled container with sufficient strength without reliance upon a full depth peripheral flange feature for the lid. Such full depth peripheral flange features have hitherto been thought necessary where there has been a different mode of interconnection between the hinging wall and the adjacent walls owing to the greater weakness thereof in its assembled form with respect to that of the present invention.

In Figure 1A there is seen a preferred single piece blank defining a rectangular base 1, a hinging wall flap 2 to adjacent wall flaps 3 and a distal wall flap 4.

Connected to the hinging wall by a hinging axis is the lid flap 5 with its distal flange flap 6 and the pair of flange flaps 7.

The hinging wall flap 2 includes extensions 8 which in the manner to be described in more detail with respect to other drawings provides a said part (i) indicated by reference numeral 9 at a part (ii) (to be glued on its reverse surface) designated by reference numeral 10 During the course of manufacture a blank as depicted would be provided with die cuts at 11 separating parts 9 and 10 in the region 8.

Similar arrangements if desired can be provided for the corner regions 12 and therefore a detailed description in that respect shall not be provided even though such corner regions 12 during assembly allow a similar pop up arrangement and similar containment features for the corners of the base 1 away from the hinging wall base corners. It is preferable however that the hinging wall corners only and the parts of the extensions 8 that lie outside of the adjacent wall flaps 3 are to confine the proximal regions 13 of each lid flange 7.

As can be seen in Figure 1A it is possible by simple die cutting to present the form as depicted in Figure 1A with the distal wall flap 4 including features 14 of any suitable know kind that will coact with locking features 15 of a complementary form in the distal flap 6 of the lip which is to provide the aforementioned said distal flange.

The assembly sequence precedes as shown from Figures 1A to 1G with initially the extensions 8,12 and 16 being folded inwardly together with the lid flange flaps 7 and the adjacent wall flaps 3. This happens on both sides.

As shown in Figure IB the regions 17 of the flange flaps 7 are then folded about a fold axis 18 to present a region 19 capable of being affixed to the region 16.

As shown in Figure ID it is then possible for the arrangement as shown in Figure 1C to then have adhesive (preferably a solvent or hot malt adhesive) applied on surfaces 19, 20 (being the reverse side of the part 10 shown in Figure 1A) and the region 21 of the infolds 12 of Figure IB the region 21 being a corresponding region to that of reference numeral 20 itself separated by a die cut 22 in a similar manner to the die cut 11 previously referred to.

In the form as depicted in Figure ID it is then possible to sequence other folds to provide the lie flat container. Initially the end wall flap 6 is folded over so as to make the regions 16 and 19 together.

Subsequent to the arrangement shown in Figure IE it is then possible for the region 21 to be adhesively mated with the infolded adjacent walls 3 so that region 21 adheres to the outside thereof much the same as region 20 will likewise be adhered thereto.

Finally, about a fold axis AA of Figure IF the top region would be down folded over the region below the line AA such that the regions 20 adhere to the region 24 of the adjacent wall flaps 3.

Figure 1G therefore shows the lay flat hinging wall 2 as well as the lid 5.

Figure 2 shows the arrangement from the other side In its lie flat assembled form as depicted in Figures 1G and Figure 2 the lay flat arrangement can be opened out in the fold out or pop up sequence shown by 3A through 3F. It is to be noted in this sequence the role that the various extensions 8 and 12 play. It is to be seen that region 10 which is affixed to the side wall or adjacent wall 3 is connected by a hinge line 23 (or at least a curvable region that upon erection takes a fold line 23) to the part 9.

In the final assembled form as shown in Figure 3F it can be seen that the proximal regions 13 of the lid flaps 7 are sandwiched into a relationship between part of the member 10 and the outer part of the extension 8 designated as 9 thereby to be confined in the manner as shown in Figure 3F. This greatly enhances the strength of the corner 24.

Options include lidless components of a container eg, a base or lid each with at least two and preferably four corner assemblies of the present invention. -'0- - ^

Claims (21)

WHAT WE CLAIM IS: ~ 506735

1. A container assembled from a sheet material to define (at least when erect) a rectangular or square base, four walls and a hinged lid (optionally with peripheral flanges), wherein said lid hinges from the top of one of the walls (hereafter defined as "the lid hinging wall") and which lid hanging wall is connected to each adjacent wall (hereafter the adjacent walls) by at least part of an extension at each end of the hinging wall to the extent said extension in each case in the assembled container is defined by (i) a part (hereafter part (i)) hinged on a hinge axis with said hinging wall substantially normal to the hinge axis of that hinging wall with said lid, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate base corner of the hinging wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base, said connection fold between said part (i) and part (ii) on said fold-line not extending to the top of its proximate adjacent wall, and wherein the assembled construction at each said hinging wall corner allows one or both of (a) an erection by simple pop-up of the hinging wall and its adjacent walls of the assembled container from the base thereof, the popping up being from a lay flat condition of each said adjacent wall on said base under a lay flat overlay of part thereof by said hinging wall, and (b) a location of (optional) peripheral flanges of said hinged lid proximate to each end of the lid hinge in the erect both assembled and erect container outside of each said adjacent wall so as to be each sandwiched between a said part (i) and a part (ii) at least in part.

2. A container of claim 1 wherein said optional flanges are locatable as in (b).

3. A container of claim 1 wherein both (a) and (b) are allowed.

4. A container of any one of the preceding claims wherein said sheet material is a single form blank.

5. A container of any one of the preceding claims wherein said lid hinging wall is a longer side wall of a rectangular base.

6. A container of any one of the preceding claims wherein the base corner construction is substantially hereinafter described with reference to the accompanying drawings.

7. A container of any one of the preceding claims wherein a complementary corner assembly to that of each hinging wall base corner and its adjacent wall is involved at each base, distal wall and adjacent wall corner.

8. An erect form of a container as defined in any one of the preceding claims.

9. A container or container component assembled from a sheet material to define (at least when erect) a rectangular or square base or top (if a lid) and four walls or flanges. wherein at least one of an opposed pair of walls or flanges ("primary wall" or "primary walls") is connected to each adjacent wall or flange (hereafter "the adjacent walls") by at least part of an extension at each end of the or a primary wall flap, said extension in each case in the assembled container or container component defining (i) a part (hereafter part (i)) hinged on a hinge axis with the or a said primary wall substantially normal to the hinge axis of that wall with said base or top, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate corner of the primary wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base or top, said connection fold between said part (i) and part (ii) on said fold line not extending to the distal edge of its proximate adjacent wall, wherein the assembled construction of said container at the or each said primary wall corner allows an erection of the container from a lay flat form by a simple pop up of the primary wall (or walls) and its adjacent walls of the assembled container from the base (or top) thereof, the popping up being from a lay flat condition of each said adjacent wall on said base (or top) under a lay flat overlay of part thereof by said primary wall.

10. A container assembled from a sheet material to define (at least when erect) a rectangular or square base, four walls and a hinged lid, wherein said lid hinges from the top of a wall flap (hereafter that flap to define "the lid hinging wall") and which lid hanging wall is connected to each adjacent wall (hereafter the adjacent walls) by at least part of an extension at each end of the hinging wall flap, said extension in each case in the assembled container defining (i) a part (hereafter part (i)) hinged on a hinge axis with said hinging wall substantially normal to the hinge axis of that hinging wall with said lid, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate base corner of the hinging wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base, said connection fold between said part (i) and part (ii) on said fold-line not extending to the top of its proximate adjacent wall, wherein the assembled construction of said container at each said hinging wall corner allows an erection of the container from a lay flat form by a simple pop up of the hinging wall and its adjacent walls of the assembled container from the base thereof, the popping up being from a lay flat condition of each said adjacent wall on said base under a lay flat overlay of part thereof by said hinging wall.

11. A container assembled from a blank of sheet material to define (at least when erect) a rectangular or square base, four walls and a hinged lid with a peripheral flanges, wherein said lid hinges from the top of a wall flap (hereafter that flap to define "the lid hinging wall") and which lid hanging wall is connected to each adjacent wall (hereafter the adjacent walls) by at least part of an extension at each end of the hinging wall flap to extent said extension in each case in the assembled container defining (i) a part (hereafter part (i)) hinged on a hinge axis with said hinging wall substantially normal to the hinge axis of that hinging wall with said lid, and (ii) a part (hereafter part (ii)) fold connected to part (i) yet lying against and fixed to said adjacent wall, a fold line between said part (i) and said part (ii) of each extension in the erect container angling away from the proximate base corner of the hinging wall on the outside of said adjacent wall to extend, in the erect container between the plane of the hinging wall and the plane of the base, said connection fold between said -13- part (i) and part (ii) on said fold-line not extending to the top of its proximate adjacent wall, wherein the assembled construction of said container at each said hinging wall corner allows the location of the peripheral flanges of said hinged lid proximate to each end of the lid hinge in the both assembled and erect container outside of each said adjacent wall so as to have the proximal flange region of each sandwiched between a said part (i) and a part (ii) at least in part.

12. A container assembled from a blank or blanks and capable of being erected from an assembled lay flat form, said container being characterised in that it includes between at least a pair of wall flaps from the base a connecting feature substantially hereinbefore described with reference to the accompanying drawings.

13. A lidded container formable from a blank and having a lay flat assembled form and an erected assembled form, said erected assembled form allowing the opening and closing (and vice versa) of a hinged lid with peripheral flanges, the interconnection between that wall from which the lid is hinged and each adjacent wall being with an extension of the hinging wall.

14. A pop-up corner assembly of a container or container part, said assembly being substantially as described herein with reference to the accompanying drawings.

15. A blank suitable for forming a container of any of the kinds herein defined in any one of the preceding claims.

16. A blank suitable for being assembled into a lay flat and/or erect container, said blank being of a form substantially as herein described with reference to Figure 1A of the accompanying drawings.

17. A blank for a container to have one of or both (a) lid engagement feature substantially as herein described adjacent to the lid hinging axis or (b) a pop up characteristic substantially as herein described, said blank having a base with a hinging wall flap with extensions at each end thereof having the capability of providing the part (i) and part (ii) characteristics herein described and/or to provide the features during erection or upon erection.

18. The use of a container of any of the kinds hereinbefore described with reference with to any one or more of the accompanying drawings. -14-

19. A method of forming a lay flat yet assembled container capable of being readily manipulated into an erect form, said method being performed substantially herein described preferably with reference to any one or more of Figures 1A to 1G.

20. A transport pack of goods which comprises a container of any of the kinds defined in any one of claims 1 to 13 in its erect enclosed form, the goods being held within the container.

21. The use of such a pack of claim 20 in the course of commerce. DATED THIS 10^ DAY OF mksZCOf A] - PER \GEVJTS TOR THE APPLICANT h \library\patents\djj\specs\428536 wpd