COMPLETE ICATION
CONTAINERS AND APPARATUS
FIELD OF THE INVENTION
The present invention s to containers. More particularly, but not solely, the
present invention relates to containers erectable from a planar blank. Still more
particularly, the present invention relates to stack ble containers constructed from
a laminate blank that includes at least one corrugated core layer.
BACKGROUND TO THE INVENTION
Containers in the form of erectable trays, cases or the like from blanks are known
for use in the packaging of goods. Frequently such containers are formed from a single
blank cut from a sheet of a te material which includes at least one corrugated core
layer defining a flute run direction. An example of such a material is a paperboard
laminate which includes outer (usually kraft) paper liners having interposed adhesively
therebetween a corrugated medium also of paper. Such corrugated medium can be of
one or more contiguous layers.
Other forms of such materials may include two separated corrugated layers (each
of one or more sheets of paper). For example a double cushion corrugated board is one
having three substantially planar paper sheets, each adjacent pair of sheets having
interposed therebetween a corrugated medium of one or more sheets of paper.
Preferably such double cushion material has the flute run direction of each ated
layer running parallel.
Such corrugated board materials with a flute run direction have a stacking
strength lity greater where the flutes run vertically as d to horizontally.
Various forms of container have been d to take advantage of such ionality of
the al. Some make good use of the material in this respect such as our M
product range (see New Zealand Patent Specification No. 270912) or the P84TM product
form of IberoAmericana. Others may make less effective use of such directionality.
The present invention relates to an improved container of a kind where a blank of
such a material is to be erected to a container form which is to have stack indexing
capability. The present invention recognises an advantage to be derived from indexing
one on top of another reliant on an underlying cut edge transverse to the flute run
direction.
In our New Zealand Patent Specification No. 270912 we se a tray like
product range erectable from a single piece blank which has given rise to the DEFORTM
t range. The full content of that specification is here included by way of reference.
The present invention in one aspect is directed to tray or container forms that are
a t of the aforementioned DEFORTM product range or which are capable of being
offered as a potential replacement therefor.
It is therefore an object of the present invention in respect of some aspects of the
invention to provide blanks and containers erectable from such blanks having novel
aspects over aforementioned tray or container forms.
The present invention has as an object therefore the provision of such containers
or to at least provide the public with a useful choice.
In one aspect the invention broadly consists in a container formed from a blank
comprising:
a base,
a flap ce of two indexing wall flaps extending from each of two opposed
sides of said base, the first indexing wall flap of each flap sequence being connected to
the base at a first fold line, the second indexing wall of each flap sequence being
ted to its ated first indexing wall flap by a second fold line parallel to its said
first fold line, wherein said container has said second indexing wall flap of each flap
sequence inwardly of its associated first indexing wall flap,
a non indexing wall flap ing from each of the other two sides of said base,
each said non indexing wall flap including a pair of locking res,
each indexing wall flap sequence having at each end thereof:
i) a first extension flap beyond a third fold line extending substantially
normal to said second fold line,
ii) a second extension flap extending from said first extension flap beyond a
fourth fold line extending normal to said second and third fold lines,
wherein one of the first extension flap or the second extension flap includes a
locking tab,
wherein at least a portion of said non indexing wall flap is sandwiched n
said first and second ion flaps, and said locking tab passing through said locking
aperture,
and wherein, above a tion between each associated first and second
indexing wall flap of an indexing wall flap sequence there is defined at least one indexing
projection, indexable by an identical container having a cut or aperture in its base for
that e, and
each said fourth fold line includes at least one cut portion defining a locating
aperture, and
said non indexing wall includes on an upper edge, upwardly ting locating
projections extending into or through a respective said locating aperture.
According to another aspect, the other of said first or second extension flap includes a
cut-out section that, when the container is erected, is nt to the locking aperture, to
allow the locking tab to pass through the locking aperture.
According to another aspect, the first extension flap es a locking tab.
According to r aspect said locking tabs include at least one barb configured to
inhibit l of said locking tab once said tab has passed through said locking
According to another aspect said locking tab includes two barbs on opposing sides of said
locking tab.
According to another aspect each said flap extension s from said first indexing wall
flap of said flap sequence.
According to another aspect a further extension flap of each second indexing wall flap at
least in part triangulates (in a straight, curved and/or other manner) a corner to the non
indexing wall flap.
According to another aspect said further extension flap defines in conjunction with part of
said first indexing wall flap, at the corner and with part of the adjacent non-indexing wall,
a column like vertical load ting structure.
According to another aspect each indexing projection is flanked on either side, in its
indexing wall, by a hinging transition between a said first indexing wall flap and a second
indexing wall flap.
According to another aspect said further extension flap tucks in between a respective
said non indexing wall and said second extension flap.
According to another aspect said further extension flap is onally adhesively secured
to said non indexing wall.
According to r aspect the blank is a laminate ing at least one corrugated
core layer defining a flute run direction, and at least at about the level of said g
transition, further from each hinging region and the indexing projection, there is
upwardly exposed by both indexing wall flaps of each indexing wall, load supporting cut
edges of the laminate, such cut edges being transverse to the flute run direction.
According to another aspect the blank is a laminate including at least one corrugated
core layer defining a flute run direction, and
above the level of said hinging transition, further from each hinging region and the
ng projection, there is upwardly exposed by both indexing wall flaps of each flap
sequence, load supporting cut edges of the laminate, such cut edges being transverse to
the flute run ion.
According to another aspect each said fourth fold line comprises two substantially parallel
fold lines of approximately ninety degrees and spaced by substantially at least one
laminate thickness.
According to another aspect said substantially parallel fold lines define a hinge support
ledge.
ing to another aspect said base is rectangular having opposing long sides and
opposing short sides, and said non indexing walls depend from said short sides.
According to another aspect said base includes a plurality of indexing apertures
configured to receive a respective indexing projection from an identical container
beneath.
According to another aspect each said flap sequence and each said indexing wall is
angled slightly s of normal with respect to said base.
According to another aspect said indexing projections are contiguous with said first
indexing wall flap and said second indexing wall flap and comprise a fold line at the
uppermost extent.
According to another aspect said indexing projections comprise a fold line at the
uppermost , and only one end is contiguous with one of said first indexing wall flap
and said second indexing wall flap, and
the other end of said indexing projection es at least one retaining projection
tucked between said first indexing wall flap and said second indexing wall flap to retain
said ng projection.
According to another aspect said indexing projections are also adhesively secured to said
flap ce.
According to r aspect there is more than one indexing wall projection per indexing
wall.
According to another aspect a cut edge is defined between each projection and a corner.
According to another aspect each second indexing wall flap sits on a ushed region
of the base.
ing to another aspect a scallop is interposed between each said indexing
projection.
According to another aspect the invention consists in blank substantially as herein
described with reference to Figure 2 of the anying drawings.
According to another aspect the invention consists in blank substantially as herein
described with reference to Figure 5 of the accompanying gs.
According to r aspect the invention consists in blank substantially as herein
described with reference to Figure 7 of the accompanying drawings.
According to another aspect the invention consists in stack of stack indexed containers in
accordance with in any one of the previous clauses.
According to another aspect the invention consists in a substantially planar flat blank as
herein described where each said second indexing wall is preglued to said first indexing
wall.
In some forms of the present invention the non cutting fully of the blank al is a
e of full cutting along certain parts of the transition to leave some linking or
bridging regions uncut.
This invention may also be said broadly to consist in the parts, elements and
features referred to or indicated in the specification of the application, individually or
collectively, and any or all combinations of any two or more of said parts, elements or
es, and where specific integers are mentioned herein which have known
lents in the art to which this invention relates, such known equivalents are deemed
to be incorporated herein as if individually set forth.
DEFINITIONS
As used herein the term “and/or” means “and” or “or”, or both.
As used herein the term “(s)” following a noun includes, as might be appropriate,
the singular or plural forms of that noun.
As used herein the term “stack indexable” in respect of containers, preferably
but not necessarily, refers to containers of a kind having projections able to be inserted
into openings or scallops of a pack above. Nevertheless other stack indexing forms are
plated as being within the scope of the present invention. Thus the term “stack
indexable” is to be interpreted broadly in respect of any form of ner able to be
stacked one above another in an d stack and where plural stacks on a pallet (with a
slip sheet supported or not) are to be used in close proximity.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred form of the present invention will now be described with reference to
the accompany drawings in which:
Figure 1 is a perspective view of a container according to one embodiment.
Figure 2 is a plan view of a blank from which the container of Figure 1 is
constructed.
s 3a-f are illustrations of the steps for forming the ner of Figure 1
from the blank of Figure 2.
Figure 4 is perspective view of a container according to another embodiment.
Figure 5 is a plan view of a blank from which the container of Figure 4 is
constructed.
Figure 6 is a perspective view of a container according to yet another
embodiment.
Figure 7 is a plan view of a blank from which the container of Figure 6 is
constructed.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The containers may utilise suitable corrugated paper board and adhesive such as
that used in our DEFOR™ range. The blank diagrams show the preferred flute run
ion in order to se al stacking strength of the indexing walls. Preferred
forms of the present invention will now be described with reference to the accompanying
drawings. It will be appreciated from the drawings that the container has symmetry.
Therefore, parts of the description and/or drawings may refer specifically to only one wall
or flap for example. r, it is to be understood that this is for illustrative es
and a similar (symmetric) part may exist at another part of the container.
With reference to Figure 1, a container 1 ing to one embodiment of the
invention is illustrated. Container 1 includes a base 2 that is ably rectangular but
may alternatively be square. The container 1 includes a flap sequence 3, of two indexing
wall flaps 4,5 ing from each of two opposed sides of base 2 at fold line 6. The
second indexing wall flap 5 is connected to its associated first indexing wall flap 4, via a
second fold line 7. The specific folding sequence to form container 1 from a blank will be
described in more detail later.
On the other two opposing sides of base 2, are non indexing wall flaps 8. Non
indexing wall flaps 8 are also connected to base 2 along a fold line. Non indexing wall flap
8 es a pair of g res 9. Preferably these locking apertures are d at
the fold line connecting the flap with the base so that the aperture is adjacent the fold
line. Alternatively, locking apertures 9 may be located nearer the fold line or alternatively
still, locking apertures 9 may be located elsewhere on non indexing wall flaps 8. In the
most red embodiments, non indexing wall flaps 8 each include at least a pair of
locking apertures 9 (i.e. one for each associated corner of the ner). Alternatively,
non indexing wall flaps 8 may include more than one locking aperture 9 for each corner
of the container 1.
Each indexing wall flap sequence 3 includes a first extension flap 10 beyond a
third fold line 11. Third fold line 11 when erected, extending ntially normal to the
second fold line 7. Each first extension flap 10 includes a locking tab 14, having one or
more barbs 16 configured to t removal of g tab 14 once it has passed through
a respective locking aperture 9 in non indexing wall flap 8. In most preferred
embodiments, locking tabs 14 include two barbs 16 on opposing sides of the locking tab
14. It will be appreciated that the main body of locking tab 14 is sized to substantially
correspond with locking apertures 9. Once through a respective locking aperture 9, and
with ) 16 deployed (ie in plane with locking tab 14), the locking tab 14 is
prevented from passing back through locking aperture 9 thereby fixing the indexing wall
to the non indexing wall. The second extension flap 12 includes a cut-out section 35
which is adjacent to the locking aperture 9 when the container is erected, in order to
allow the locking tab 14 to pass through the locking aperture 9.
Each indexing wall flap also includes a second extension flap 12 extending from
the first extension flap 10, beyond a fourth fold line 13. When erected into container 1,
fold line 13 is substantially normal to the second and third fold lines 7 and 11
respectively, such that at least a portion of non indexing wall flap 8 is sandwiched
between the first and second extension flaps 10 and 12 respectively. Preferably, fold line
13 comprises two substantially parallel fold lines folding h approximately 90
degrees each and spaced by approximately the thickness of non indexing wall 8 (i.e.
substantially one laminate thickness). The spaced folds of fold line 13 define a hinge
support ledge 20. Hinge support ledge 20 preferably includes one or more ng
apertures 21, adapted to receive and locate a ponding tab projection 22 extending
from an upper edge of non indexing walls 8. Hinge support ledges, are one structure that
can be used to support another container, indexed with, and on top of container 1.
When erected, first and second extension flaps 10,12 ch a respective
corner of the non indexing wall flap 8, while the tab projections 22 locate within or
h locating apertures 21. Locking tabs 14 pass through locking apertures 9 to
secure the container together. The resulting container, can be hand erected and forms a
sufficiently rigid form without any additional fixation. In the most preferred
embodiments, there is a space 31 between the respective first extension flaps 10 of a
side of the container in order to provide improved air flow of two stacks of containers
whose ends walls (8) are adjacent each other.
Each indexing wall sequence 3 es at least one indexing projection 15 above
the tion between each associated first and second indexing wall flap 4, 5. The
indexing projection 15 is indexable by an identical container stacked on top by one or
more indexing projection apertures 19 located in base 2. In most preferred
ments, container 1 includes four ng projections 15 (two per ng wall
sequence 3) and corresponding indexing projection apertures 19. It is also most
preferred that the indexing projections 15 are provided on the long side of container 1
(when base 2 is rectangular). Alternatively, indexing projections may be provided on the
short side or alternatively still, on both sides.
Alternatively, it may be preferred that onal glue fixation is employed to
further enhance rigidity of the container 1. In particular, in one embodiment it is
advantageous to pre glue the first and second indexing walls 4,5 together (with indexing
projections) and ship the substantially flat blanks in that form. These pre glued (but
substantially flat) blanks can then be hand d onsite into a container with improved
Preferably each indexing projection 15 is flanked on either side by a hinging
transition 23 between the first and second indexing walls 4,5. In the most preferred
embodiments, hinging transitions 23 immediately flank indexing projections 15 on each
side. That is, the hinging transition is adjacent the ng projection. In addition, it is
preferred that the region of fold line 7 also includes one or more load supporting cut
edges 24, upwardly exposed by both indexing wall flaps of each indexing wall, and
defining a supporting surface erse to the flute run direction at about or slightly
above the level of hinging transitions 23. For example, the cut edges 24 shown in Figure
1 may be approximately 1-2mm above the upper extent of hinging transitions 23.
It is anticipated that indexing projection 15, may take a number of different
forms. For example in Figures 1 to 3, indexing projection 15 is a pop-up type. The pop
up ng projection 15, is formed from a cut out 25 in second indexing wall 5, and is
contiguous with the first indexing wall flap 4. Projection 15, is pulled up from the cut out
and comprises a fold line 26 at the uppermost extent. Cutout 25 is preferably shaped
to define retaining projections 27 which are tucked between the first indexing wall flap 4
and the second indexing wall flap 5 to retain the indexing projection when popped up. In
one alternative embodiment, pop up indexing projections may be additionally adhesively
fixed and ably shipped pre-glued with the first and second indexing wall flaps 4,5
as described earlier. This ment has an advantage of reduced material for forming
the blank.
In another alternative form of the invention as illustrated in Figures 4 and 5, the
indexing projections are contiguous with the first indexing wall flap and the second
indexing wall flap and comprise a fold line 26 at the uppermost extent. It will be
appreciated that this embodiment orates the hinge between the indexing wall flaps
4 and 5, into the indexing projection. Accordingly, the load support cut edges 24 extend
right up to the indexing projections 33.
This embodiment has advantages in automated processing e the indexing
projection structure 33 is less prone to damage as the blanks are passed along an
automated cutting and/or pre gluing and/or folding line. Any features that stick out of the
blank can cause the machinery to jam, for example during blank ng and/or during
pre gluing and/or folding.
In yet another alternative form of the invention as illustrated in Figures 6 and 7,
the indexing projections are of a single thickness. The indexing tion 34 are cut out
of the first indexing wall flap 4 and extend substantially in plane (and are integral with)
with the second indexing wall flap 5. The indexing projection 34 projects above the
tion between indexing walls 4 and 5 and is of a single laminate thickness.
In a similar manner to the embodiment of Figure 1, each indexing projection 34 is
preferably flanked on either side by a g transition 23 between the first and second
indexing walls 4, 5. In the most preferred embodiment, hinging transitions 23
ately flank indexing projection 34 on each side. The upper surface of indexing
walls 4,5 provides load supporting cut edges for a like box stacked on top.
With this single thickness style indexing projection 34, it is not necessary for the
indexing walls to be inclined or angled inwardly in order to line up with corresponding
indexing projection apertures 9 and 10. Preferably, the indexing walls are substantially
vertical.
In an alternative form of the invention, the second extension flap 12 includes a
locking tab 14, having one or more barbs 16 configured to inhibit removal of locking tab
14 once it has passed through a respective locking aperture 9 in non indexing wall flap 8.
The first extension flap 10 ably es a cut-out section 35 which is adjacent to
the locking aperture 9 when the container is erected, in order to allow the locking tab 14
to pass through the locking aperture 9.
In the most preferred embodiments a further extension flap 17 is also provided
depending from each second indexing wall flap 5. When the container 1 is erected,
further ion flap 17 triangulates each corner of the container (from the indexing
wall to the non indexing wall). While it is preferred that the further extension flap 17
triangulates the corner in a straight line, it is anticipated that it may be curved or
otherwise shaped. In order to secure the triangulated extension flap 17, a portion 18 is
tucked between the second extension flap 12 and a respective non indexing wall 8. In
other embodiments, the triangulating corner features may be absent.
While in some preferred embodiments, container 1 is able to be d by hand
(and including no additional ve), it may be preferred to optionally provide
mental fixing of ion flaps 10 and/or 12 to respective non indexing wall flaps
8. In other ments, further extension flap 17, 18 may be optionally adhesively
fixed to non indexing wall flap 8.
It is also noted that further locating projections 29 may be provided on one or
more of the second extension flaps 12 and the second ng wall flap 5. Where
provided, these locating projections 29 fit into correspondingly sized and shaped
apertures 30 in base 2. It will be appreciated that these features help retain the flap
elements in position when container 1 is fully assembled.
Of particular importance to the present ion is the efficient use of material in
forming the blank. For example, the ion of first and second extension flaps 10, 12
respectively from the first indexing wall flap reduces the amount of board ed
compared to many other designs. In particular, the blank may be narrower with this
present design because the fold over panels come from the longitudinal direction of the
material (28).
It will be appreciated that this type of indexing ner 1 is primarily (but not
exclusively) intended for use in packing produce that is typically stored and transported
in a refrigerated environment. As a result, it is extremely important to optimise cool air
flow around a stack of ners 1 (in order to cool produce as quickly as possible
initially etc). To this end, it is preferred that indexing walls 8 and/or non indexing flap
sequences 3, include one or more cut outs or scallops 32, in order to improve air flow in
and out of the interior space of container 1.
A further advantage of the present container 1 is that the non indexing wall 8
provides a venting aperture in a stack of ners via gap 31 (shown in figure 1),
formed between first extension flaps 10. In many known containers, the non indexing
wall is ntially planar (at least dly) and therefore there is no provision for a
venting ‘chimney’ to be formed between two adjacent stacks of containers ed endto-end
), as there is with container 1.
It will be appreciated that container walls including indexing projections 15, 33
may be slightly inwardly angled to ensure that the indexing tions 15, 33 align and
properly index with corresponding indexing apertures 19 of an cal container stacked
above. In other embodiments, the indexing walls may be ntially vertical rather
than slightly inwardly angled. It will be appreciated that the desirability of each
alternative will in part depend on the style of indexing projection. For example, it is most
preferred that the containers of Figures 1 and 4 have ly ed ng walls,
while the container of Figure 6 (with indexing projections 34) most preferably has
substantially vertical indexing walls.
In another alternative embodiment, the first and second extension flaps may
depend from the second indexing wall flaps. Alternatively still, the container may have
the second indexing wall flap of each flap sequence located (after folding) outwardly of
its associated first indexing wall flap.
However, it is most preferred that the container 1 has the second indexing wall
flap 5 of each flap sequence 3 inwardly of its associated first indexing wall flap 4. This
results in a container where the outer perimeter of the container is mostly contiguous
with the base (except for the ion flaps). Particularly when indexing wall flaps 4,5
are pre glued, this results in a container with very good rigidity.
Assembly
With reference to Figure 3 a preferred folding sequence for the container 1 of
Figure 1 will be described in more detail. It will be readily understood from the
illustrations when the bed operations are completed for each corner of container 1.
Figure 3A shows the flat blank of Figure 1 and illustrates the preferred core flute
run ion 28.
With reference to Figure 3B, r extension flap 17(and tuck 18) are folded
downwards along parallel fold lines (each by approximately 45 degrees). At the same
time, pop up indexing projections 15 are removed from cut outs 25 and folded along line
26. The ng projections may be optionally adhesively fixed in the position shown.
In the next step illustrated by Figure 3C, the second indexing wall flap 5 is folded
over onto first indexing wall flap 4 along fold line 7. It will be appreciated that indexing
wall flap 4 is connected to indexing wall flap 5 via a plurality of hinging portions 23 as
previously described.
In the next step illustrated in Figure 3D, non indexing wall flaps 8 are folded
upwards with t to the base along fold lines.
In the next step illustrated in Figure 3E, the ng wall flap sequence 3 is
folded upwards along fold line 6, so that first and second indexing wall flaps 4 and 5 are
substantially vertical. Further extension flaps 17 are located in the interior of the
container and triangulate each corner. In this position, first and second extension flaps
,12 respectively, t outwards beyond the perimeter of the container 1 as shown.
In the next step illustrated in Figure 3F, each first extension flap 10 is folded
about fold line 11 to form a corner of container 1. This brings locking tabs 14 into
ent with locking apertures 9 on each corner. To secure the walls together, each
locking tab 14 is pushed through a respective locking aperture 9 so that barbs 14 inhibit
removal.
In the final step (shown by the ted container of Figure 1), each second
extension flap 12 is folded over the non indexing wall 8 so that it is positioned inwards of
the container 1. The second extension flap 12 is folded about fold line 13. As shown in
the figures, the fold line 13 of the most preferred embodiment comprises two parallel fold
lines spaced by approximately the width of non ng wall 8. Once folded over, second
extension flaps 12 capture portion 18 of the r extension flap and secures it.
It will be appreciated that the assembly sequence for the embodiment illustrated
in Figure 4 is substantially the same as that described above. In this embodiment,
indexing projections 15 are formed as second indexing flap 5 is folded onto first indexing
flap 4 at hinging top fold 26. Similarly, the container of Figure 6 is also assembled
substantially the same way, save for the formation of the indexing projections 34.