NZ577407A - A lie flat pop-up container with unitary gusseted side flaps each interconnecting base and front wall panels, and connected to front wall panel and inturned rear wall extension flaps - Google Patents

Abstract

A lie flat pop-up container is disclosed with unitary gusseted side flaps each interconnecting base and front wall panels, and connected to front wall panel and inturned rear wall extension flaps. The container is formed from a blank and typically has an integral lid.

Description

Received by IPONZ 27 Apr 2012 NB:W ZEALAND PATENTS ACT, 1953 COMPLETE SPECIFICATION A LIE FLAT POP-UP CONTAINER We, CARTER HOLT HARVEY LIMITED, a company duly incorporated under the laws of New Zealand of 173 Captain Springs Road, Onehunga, Auckland, New Zealand, do hereby declare this invention to be described in the following statement: Received by IPONZ 27 Apr 2012 The present invention relates to containers formed from a blank sheet material.

More particularly the present invention relates to, and has an object the provision of, a container assembled from a blank of first and second surfaces to have a substantially lie flat form from which it can be popped up and, with a minimal of activity, albeit preferably some over folding, be held to a ready to use form.

The present invention envisages, and has as a further or alternative object, the provision a single blank container assembly able to be supplied in substantially a lie flat form but which can be easily erected from that lie flat form in a pop-up type manner to provide an effective liddable base region.

It is a further or alternative object of the invention to provide a container having a combination of adhesive, glue or other joints or connections substantially as hereafter described (whether two or three pairs of joints or connections) and/or the use of in-folds and out-folds substantially as hereinafter described.

The present invention has as a further or alternative object a lie flat pop up form container able simply to be pulled open ready for filling.

It is a further or alternative object to provide a full bottom type container (ie. not one reliant on flaps) able to be uplifted or popped up from lie flat form.

It is a further or alternative object to have a pop up/lie flat form container where all necessary pre-filling gluing and/or taping has occurred prior to customer usage.

It is also an object to provide any of the features herein discussed or shown, or at least to provide the public with a choice.

The present invention comprises any novel blank or container able to satisfy any one or more of such objects.

In another aspect the invention is a pop-up container formed from a blank of sheet material of first and second surfaces, wherein the blank defines: a rectangular or square base panel, a front wall panel as a flap from the base panel, a unitary flap at each end of the pairing of the base panel and front wall panel, a panel ("fold over panel") as a flap from the front wall panel, the fold over panel optionally having end extension flaps, a rear wall panel as a flap from the base panel, the rear wall panel having end extension flaps, and optionally a lid panel as a flap from the rear wall panel, the lid panel optionally having end extension flaps, Received by IPONZ 27 Apr 2012 an optionally a panel ("lid skirt panel") as a flap from the optional lid panel, the lid skirt panel optionally having end extension flaps; and wherein the first surface is the inside of the base panel of the container; and wherein, in the assembled lie flat container, (A) the unitary flap overlies in part both the base panel and front wall panel and is connected, first surface to first surface, to the front wall panel and (B) each unitary flap is overlayed at least m part by an in folded end extension flap of the also at least in part overlying rear wall panel, each such unitary flap and rear wall extension flap being connected first surface to second surface respectively; and wherein the assembled lie flat container can be popped up from its lie flat form owing to both sets of said connections each involving a gusset forming region of said unitary flap.

Preferably there is a said lid panel.

Preferably said lid panel has said end extension flaps.

Preferably there is a said lid skirt panel.

Preferably the lid skirt panel has said end extension flaps.

Optionally the second surface of each end extension flap of the lid skirt panel is connected to the first surface of its proximate lid panel end extension flap, or vice versa.

Preferably the lid skirt panel includes gusset regions at each end to facilitate connection of the proximate extension flap.

Preferably said fold over panel has end extension flaps.

The invention in another aspect consists in a pop-up container formed from a blank of sheet material having first and second surfaces, wherein, in it's at least substantially lie flat form, a front wall flap lies at least substantially in the plane of a base panel; wherein a rear wall panel overlies at least in part the base panel and has end extensions thereof affixed by the second surface to the first surface of infolded flanking wall flaps; and wherein a first surface of each flanking wall flap in connecting to the first surface of front wall flap.

In another aspect the invention is a pop-up container formed from a sheet material blank wherein front and rear panel flaps upfoldable from a base panel are also linked respectively (i) by adhesion of a first and internal surface of the front panel to the first surface of a gusset of each flanking panel flap upfoldable from the base panel; and (ii) by adhesion of a gusseted part of each flanking panel flap by its first surface to the second and other surface of end extension flaps of the rear panel flap.

Received by IPONZ 27 Apr 2012 In another aspect the invention is a pop-up container of a kind structured from a blank of sheet material and having a front wall flap, a rear wall flap and flanking wall flaps from a base panel having (A) a gusset outside of the base panel from each flanking wall flaps into each end of the front wall flap, affixed adhesively to the same surface of the front wall flap in part by adhesive, and (B) a gusseted part of each flanking wall flap connected by the same first surface of the blank to the other and second surface of an end extension of the rear wall flap.

In still another aspect the invention is a pop-up container formed from a blank of sheet material, the blank in the lie-flat form of the container defining: (A) in a plane, a square or rectangular base panel, and a front wall panel, from the base panel, (and optionally a front wall reinforcement panel (optionally with end extensions in the same plane or another plane) connected via a transition or hinge(s) from the front wall panel); (B) infolded flanking wall panels from the base panel and from the front wall panel, overlying the base panel and front wall panel and each affixed by the same first surface of the blank to the inside and same first surface of the front wall panel, and (C) a rear wall panel with in and under folded end extensions each affixed by the other and second surface of the blank to the upper and first surface of each underlying flanking wall panel flaps.

In a further aspect the invention consists in a pop-up container as previously described where any one or more of the aforementioned features is substantially as hereinafter described with reference to any one or more of the accompanying drawings.

In yet a further aspect the invention consists in a method of forming a lie flat pop-up container of any of the previously defined forms when performed substantially as hereinafter described with or without reference to any one or more of the accompanying drawings.

In still a further aspect the invention consists in a blank of any of the forms hereinafter described with reference to any one or more of the accompanying drawings.

In yet a further aspect the invention consists in a blank for a lie flat pop-up container wherein it is erectable in a manner substantially akin to that described by reference to the assembly drawings of any one of the embodiments shown in the accompanying drawings.

In still a further aspect the invention is a lie flat pop-up container substantially as hereinafter described with reference to any one or more of the accompanying drawings.

The invention also consists in the use of containers herein exemplified for produce containment.

As used herein the term "and/or" means "and" or "or", or both.

Received by IPONZ 27 Apr 2012 As used herein "(s)" following a noun means the plural and/or singular forms of the noun.

As used herein "connected" or "connect" or other variations thereof preferably refers to gluing or adhesive fixing. It may involve the addition of a material to the material of a blank but may not, ie, a characteristic of the material from which the blank is formed may allow the use of ultrasound or heat to provide an appropriate connection.

Preferably however the material of the blank is a paperboard having some wet strength, for example, a corrugated paperboard manufactured using any flute specification A, B, C, D or E flute and lined both sides with kraft paper and/or recycled paper and/or whiteline paper. An example is a frozen meat case using 175gsm liners and 150gsm fluted medium. Preferably kraft/kraft/recycled if that form. Any board form is usable. Even non corrugated paperboard. Even film or metallised film paperboard etc.

Preferably a hot melt adhesive and/or other cold glue types (eg PVA, EVA, ) is preferably used for the assembly.

The term "comprising" as used in this specification means "consisting at least in part of. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.

Preferred forms of the present invention will now be described with reference to the accompanying drawings in which Figure 1 shows a blank from the first surface side of a first embodiment of the present invention, Figure 2A shows the blank of Figure 1 from the same and first surface side as an unglued case with the asterisks denoting gluing points involving that first surface of the unitary flaps and the extension flaps of the lid skirt panel extension flaps, Figure 2B shows a first stage of assembly with the unitary flaps of the pairing of the base panel and front wall panel being infolded so that there is adhesion by the asterisked gusset forming region shown in Figure 2A, Figure 2B showing on the second surface with the asterisks regions to which there is to be a connection to the second surface of each end extension flap of said rear wall panel, Figure 2C shows the arrangement of Figure 2B after infolding of the end extension flaps of the rear wall and the overlaying of the rear wall and its infolded flaps as well as the lid panel over much of the remainder, Figure 2D shows the assembled container of Figure 2C partially opened from the front, Received by IPONZ 27 Apr 2012 Figure 2E shows the same arrangement as in Figure 2D but from an end view, Figure 2F shows the fully opened container of Figures 2D and 2E ready for product, the fold over panel having been folded over the gusset connected unitary flap regions more proximally associated and connected with the front panel, Figure 3 shows a first surface side of different variant blank to that of Figure 1, Figure 4A shows the blank of Figure 3 from the same and first surface side as an unglued case with the asterisks denoting gluing points involving that first surface of the unitary flaps and the extension flaps of the lid skirt panel extension flaps and the extension flaps of the lid skirt panel extension flaps, Figure 4B shows a first stage of assembly with the unitary flaps of the pairing of the base panel and front wall panel being infolded so that there is adhesion by the asterisked gusset forming region shown in Figure 4A, Figure 4B showing on the second surface with the asterisks regions to which there is to be a connection to the second surface of each end extension flap of said rear wall panel, Figure 4C shows the arrangement of Figure 4B after infolding of the end extension flaps of the rear wall and the overlaying of the rear wall and its infolded flaps as well as the lid panel over much of the remainder, the assembly being complete in so far as the base assembly region is concerned, Figure 4D shows the assembled container of Figure 4C partially opened from the front, Figure 4E shows the same arrangement as in Figure 4D but from an end view, Figure 4F shows the fully opened container of Figures 4D and 4E ready for product, the fold over panel having been folded over the gusset connected unitary flap regions more proximally associated and connected with the front panel, Figure 5 shows a first surface side of different variant blank to that of Figure 1 and 2, Figure 6A shows the blank of Figure 5 from the same surface side as an unglued case with the asterisks denoting gluing points involving that first surface of the unitary flaps, Figure 6B shows a first stage of assembly with the unitary flaps of the pairing of the base panel and front wall panel being infolded so that there is adhesion by the asterisked gusset forming region shown in Figure 6A, Figure 6B showing on the second surface with the asterisks regions to which there is to be a connection to the second surface of each end extension flap of said rear wall panel, Figure 6C shows the arrangement of Figure 6B after infolding of the end extension flaps of the rear wall and the overlaying of the rear wall and its infolded flaps as well as the lid panel over much of the remainder, Figure 6D shows the assembled container of Figure 6C partially opened from the front, Received by IPONZ 27 Apr 2012 Figure 6E shows the same arrangement as in Figure 6D but from an end view, and Figure 6F shows the fully opened container of Figures 61) and 6E ready for product, the fold over panel having been folded over the gusset connected unitary flap regions more proximally associated and connected with the front panel.

The blank 4 a container as hereinafter described is preferably of a paper board. Such a paper board can be a corrugated paper board for not. It can be a laminated paper board or not. Indeed one or more layers of any such material can be other than paper eg, a plastics material, metalised plastics material, metal foil, or other.

Three embodiments but each having similar features (but primarily with some of the same blank regional shapes) are described in the accompanying drawings. Each is able to be assembled with adhesive from the blank form. An assembled but lie flat form is respectively is shown in Figures 2C, 4C and 6C from whence it can be uplifted (ie, the so called "pop-up") to a form as shown respectively in Figures 2F, 4F and 6F. Thereafter the lid panel with its end flaps and separate or adhesively related skirt panel and end extensions of the lid panel can then overly the base region for strapping, adhesive fixing, adhesive taping, etc.

A person skilled in the art would appreciate the various ways it could be used.

A. particularly preferred material for each blank is for example L60BW paper board although any other appropriate kind can be used. It can be waxed or unwaxed, film or foil laminated, or otherwise.

Other examples of sheet materials include...

With reference to the terminology used to define the invention the different embodiments of Figures 1, 3 and 5 describe respectively a rectangular or square base panel, 1, 1', 1" a front wall panel 2, 2' and 2" as a hinged flap from the respective base panel, a unitary flap 5, 5 and 5" each hinged at each end of the pairing of the base panel and front wall panel, a panel ("fold over panel") 3, 3' and 3" as a hinged flap from the front wall panel, fold over panel end extension flaps 4, 4' and 4", a rear wall panel 6, 6' and 6" as a hinged flap from the base panel, the rear wall panel end extension flaps 7, 7' and 7", a lid panel 8, 8' and 8" as a hinged flap from the rear wall panel, lid panel hinged end extension flaps 9, 9' and 9", a panel ("lid skirt panel") 10, 10' and 10" as a hinged flap from the optional lid panel, lid skirt end extension flapsll and 11'; Received by IPONZ 27 Apr 2012 As can be seen from the drawings the first surface is the inside of the base panel of the container, and in the assembled lie flat container; (A) the unitary flap overlies in part both the base panel and front wall panel and is connected, first surface to first surface, to the front wall panel, and (B) each unitary flap is overlayed (at least in part) by the in folded end extension flaps of the (also at least in part overlying) rear wall panel, each such unitary flap and rear wall extension flap being connected second surface to second surface.

From that lie flat form [See Figures 2C, 4C and 6C) the assembled lie flat container can be popped up from its lie flat form to its ready to fill condition shown respectively as Figures 2F, 4F and 6F owing to both sets of said connections each involving a gusset forming region of said unitary flap.

The four connections of the non-lid regions are of the gusset forming region 12 (ie, a gusset owing to 45° hinge line 13) to the front wall panel 2, all with adhesive between regions of the inside or first surface. of the gusset forming region 14 (ie, a gusset owing to 45° hinge line 15) to the outside or second surface presented during assembly by an in turned rear wall extension flap 7.

Likewise for the corresponding Figure 3 and Figure 5 variants.

This all enables the lie flat forms shown.

Individual embodiment differences as depicted include between Figures 1 and 3, the different extent of the fold over panel extensions 4 and 4'. The Figure 1 embodiment includes a recess 16 to accommodate 4 [see Figure 2F].

P^ach of the Figure 1 and 3 embodiments includes an integral gusset region 17 and 17' to better facilitate deployment from the lie flat form after adhesive connection of the first surface of 11 or 11' to the second surface of infolded lid panel extension flaps 9 and 9' respectively or, alternatively, the second surface of 11 or 11' to the first surface of 9 and 9' respectively.

A suitable use of any of the lie flat embodiments described include the package, storage and/or transportation of produce (eg. meat or fish) packs [chilled or frozen]. For this purpose a lidded closed container may have a rectanguloid form of any size but heavier and/or stronger sheet material is preferably used for larger sizes. A corrugated paperboard of a paper makeup of say, 205gsm white top liner 150gsm fluted medium 145gsm kraft top liner can be used for a container of size L:W:B approximately 545:210:185mm.

Received by IPONZ 27 Apr 2012

Claims (16)

WHAT WE CLAIM IS:

1. A pop-up container of a kind structured from a blank of sheet material, said container being able to be converted between a lie-flat and a ready-to-fill form; wherein said blank has first and second surfaces, and defines, in a singular plane: i) a square or rectangular base panel; ii) a front panel flap upfoldable from said base panel; iii) flanking panel flaps infoldable from each end of said base panel and said front panel flap; and iv) a rear panel flap, upfoldable from said base panel, and having extension flaps infoldable from each end; and wherein in the lie-flat condition said base panel and said front and rear panel flaps are also linked respectively by: i) adhesion of a first and internal surface of the front panel flap to the first surface of a gusset of each flanking panel flap; and ii) adhesion of a gusseted part of each flanking panel flap by its first surface to the second and other surface of end extension flaps of the rear panel flap.

2. A container of claim 1 wherein said blank also defines a lid panel as a flap from the rear panel flap.

3. A container of claim 2 wherein said blank also defines end extension flaps infoldable from said lid panel.

4. A container of claim 2 or 3 wherein said blank also defines a lid skirt panel as a flap from the lid panel.

5. A container of claim 4 wherein said blank also defines end extension flaps infoldable from said lid skirt panel.

6. A container of claim 5 wherein the second surface of each end extension flap of the lid skirt panel is connected to the first surface of its proximate lid panel end extension flap, or vice versa.

7. A container of claim 4, 5 or 6 wherein the lid skirt panel includes gusset regions at each end to facilitate connection of the proximate extension flap.

8. A container of any one of the preceding claims wherein said blank also defines a fold over panel as a flap from the front wall panel.

9. A container of claim 8 wherein said blank also defines end extension flaps depending from said fold over panel. Received by IPONZ 27 Apr 2012

10. A container of claim 9 wherein each of said end extension flaps of the rear panel flap has a recess able to accommodate said fold over panel end extension flaps when the container is in its ready-to-fill condition.

11. A pop-up container as claimed in any one of claims 1 to 10 and substantially as hereinbefore described with reference to any one or more of the accompanying drawings.

12. A method of forming a lie flat pop-up container of any one of the preceding claims when performed substantially as herein described with or without reference to any one or more of the accompanying drawings.

13. A blank of any of the forms herein described with reference to any one or more of the accompanying drawings.

14. A blank for a lie flat pop-up container wherein it is erectable in a manner substantially as described by reference to the assembly drawings of any one of the embodiments shown in the accompanying drawings.

15. A lie flat pop-up container substantially as herein described with reference to any one or more of the accompanying drawings.

16. The use for produce packing of a container of any one of the embodiments herein described by reference to any one or more of the accompanying drawings. DATED THIS ) }K SHY OF ! V' » I '/ „ 7 T"" in, y AGENTS FOR THE AlWcANT