AU2005202709B2 - A Container Including Side Wall Retaining Means - Google Patents

Description

1 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name of Applicant Amcor Limited Actual Inventors Gordon Mellis George Ganzenmuller Address for Service: CULLEN & CO . Patent & Trade Mark Attorneys, 239 George Street Brisbane Qld 4000 Australia Invention Title: A Container Including Side Wall Retaining Means Details of Associated Provisional Applications No. 2004904164 - filed 27 July 2004 The following statement is a full description of this invention, including the best method of performing it, known to us: 2 Field of the Invention The present invention relates generally to containers of the type that are erected from a blank of a foldable material and, in particular, to containers of the aforementioned type which include side walls having outer and inner side wall panels. 5 Although the invention will be described with particular reference to manually-erectable stackable containers it will be appreciated that the invention may be incorporated into other types of containers. Brief Discussion of the Prior Art 10 Manually-erectable stackable containers of the type that are erected from a blank of a foldable material and that include a pair of opposing end walls extending upwardly from a base, often also include double thickness side walls extending upwardly from the base. Each side wall usually includes an outer side wall panel and an inner side wall panel overlying the outer side wall panel. The outer side wall panel 15 is usually hinged to the base by a fold line and the inner side wall panel is usually hinged to the outer side wall by a fold line which is laterally offset from the fold line hinging the outer side wall panel to the base. A plurality of locking tab receiving apertures which extend through the base are located adjacent to the outer side wall panels. A plurality of locking tabs extend from a free edge of each inner side wall 20 panel. The arrangement is such that the locking tabs of the inner side wall panels are received by the locking tab receiving apertures in the base such that the inner side wall panels are secured relative to the outer side wall panel. Summary of the Invention 25 It is an object of the present invention to provide a container which has outer and inner side wall panels and which is provided with an alternative means to that described above in relation to the prior art of securing the inner side wall panels relative to the outer side wall panels, or to provide the consumer with a useful or commercial choice. 30 Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying illustrations, wherein, by way of illustration and example, a preferred embodiment of 3 the present invention is disclosed. According to the present invention there is provided a container erected from a blank of foldable material, the container comprising a base, a pair of opposing outer side wall panels substantially upstanding from the base and hinged relative thereto by 5 fold lines, a respective inner side wall panel overlying an interior surface of each outer side wall panel and being hinged relative to the outer side wall panel by a fold line, and a plurality of capturing tabs hinged relative to the base by respective fold lines, wherein each inner side wall panel is captured between a respective outer side wall panel and at least one respective capturing tab such that the inner side wall panel 10 is thereby substantially secured relative to the outer side wall panel. The container may be a manually-erectable container or a machine-erectable container. It is preferred that the container is a stackable container. The blank is preferably a unitary blank which is fabricated from a single sheet of foldable material. 15 The blank may be fabricated from any suitable foldable material. Preferably, the blank is fabricated from a paper-based foldable material. In a particular preferred form, the blank is fabricated from a paper-based foldable material such as corrugated fibreboard or cardboard. The container may be of any size. Preferably, the container is 200 mm to 20 1000 mm long, 100 mm to 600 mm wide, and 50 mm to 500 mm high. In one particular preferred form, the container is 380 mm long, 290 mm wide, and 120 mm high. In another particular preferred form, the container is 580 mm long, 380 mm wide, and 220 mm high. The container may be any suitable shape. In a preferred form, the container 25 is generally rectangular in shape. The base may be any size. Preferably, the base is 200 mm to 1000 mm long, and 100 mm to 600 mm wide. In one particular preferred form, the base is 380 mm long and 290 mm wide. In another particular preferred form, the container is 580 mm long and 380 mm wide. 30 The base may be any suitable shape. In a preferred form, the base is generally rectangular in shape. It is preferred that the base is provided by a single base panel.

4 Preferably, the base includes a plurality of stacking apertures extending therethrough. The stacking apertures may be of any suitable size and shape. In one particular preferred form, a respective stacking aperture is located adjacent each end of the base. In another preferred form, a respective pair of stacking apertures is 5 located adjacent each side of the base. Preferably, a respective enlargement flap is located adjacent to each stacking aperture and is hinged relative to the base by a fold line so that the stacking aperture is able to be enlarged by folding the enlargement flap relative to the base along the fold line. 10 The outer side wall panels may be any size. Preferably, the outer side wall panels are 200 mm to 1000 mm long, and 50 mm to 500 mm high. In one particular preferred form, the outer side wall panels are 380 mm long and 120 mm high. In another particular preferred form, the outer side wall panels are 580 mm long and 220 mm high. 15 The outer side wall panels may be of any suitable shape. In a preferred form, the outer side wall panels are generally rectangular in shape. Preferably, each outer side wall panel has at least one ventilation aperture extending therethrough. In a preferred form, each outer side wall panel has a respective pair of 20 opposing outer flaps hinged relative thereto by respective fold lines. The outer flaps may be any suitable size and shape. Preferably, each outer flap has a respective stacking tab extending from an upper free edge thereof. In one preferred form, a respective ventilation aperture extends through each outer flap. In another preferred form, each outer flap includes a respective recess in a free edge thereof. 25 The inner side wall panels may be any size. Preferably, the inner side wall panels are 200 mm to 1000 mm long, and 50 mm to 500 mm high. In one particular preferred form, the inner side wall panels are 380 mm long and 120 mm high. In another particular preferred form, the inner side wall panels are 580 mm long and 220 mm high. 30 The inner side wall panels may be of any suitable shape. In a preferred form, the inner side wall panels are generally rectangular in shape. The fold lines hinging the outer side wall panels to the inner side wall panels 5 are preferably double fold lines. It is also preferred that the fold lines hinging the outer side wall panels relative to the inner side wall panels are parallel with respect to the fold lines hinging the outer side wall panels relative to the base. Preferably, at least one ventilation aperture extends through and between 5 each pair of hinged outer side wall panels and inner side wall panels. Preferably, each inner side wall panel has a respective pair of locking apertures extending therethrough such that the locking apertures are located adjacent opposite ends of the inner side wall panel. Preferably, each inner side wall panel has at least one ventilation aperture 10 extending therethrough. In one preferred form, each inner side wall panel includes a plurality of stacking tab receiving recesses in a free edge thereof Preferably, each inner side wall panel includes a plurality of stacking tabs extending therefrom. 15 Preferably, each inner side wall panel has a respective pair of opposing corner gusset panels hinged relative thereto by fold lines. The corner gusset panels may be any suitable size and shape. Each corner gusset panel may have a respective inner flap hinged relative thereto by a fold line. The inner flaps may be any suitable size and shape. Preferably, 20 each inner flap has a respective stacking tab extending from an upper free edge thereof. In one preferred form, a respective ventilation aperture extends through each inner flap. In another preferred form, each inner flap includes a respective recess in a free edge thereof The capturing tabs may be any suitable size. Preferably, the capturing tabs 25 are 20 mm to 80 mm long, and 5 mm to 50 mm wide. In one preferred form, the capturing tabs are 50 mm long and 10 mm wide. In another preferred form, the capturing tabs are 60 mm long and 10 mm wide. The capturing tabs may be any suitable shape. Preferably, the capturing tabs are generally rectangular in shape. 30 Preferably, each inner side wall panel is captured between a respective outer side wall panel and a single respective capturing tab. Preferably, a respective capturing tab is located midway along each inner 6 side wall panel. It is preferred that a respective capturing tab is cut out from each outer side wall panel and the base. The fold lines hinging the capturing tabs relative to the base are preferably 5 parallel with respect to the fold lines hinging the outer side wall panels relative to the base. Preferably, the capturing tabs are substantially perpendicular with respect to the base. Preferably, a pair of opposing and substantially upstanding end wall panels is 10 hinged relative to the base by fold lines. The end wall panels may be any suitable size and shape. Preferably, the end wall panels are 100 mm to 600 mm wide, and 50 mm to 500 mm high. In one particular preferred form, the end wall panels are 290 mm wide and 120 mm high. In another preferred form, the end wall panels are 380 mm wide and 220 mm high. The end wall panels are preferably generally rectangular in 15 shape. Preferably, each end wall panel has a respective ventilation aperture extending therethrough. In a particular preferred form, each end wall panel has a respective pair of ventilation apertures extending therethrough. A respective extension panel is preferably hinged relative to each end wall 20 panel by a respective fold line. The extension panels may be any suitable size and shape. Preferably, the extension panels are generally rectangular in shape. A respective pair of opposing end flaps may be hinged relative to each extension panel by fold lines. A respective locking tab is preferably hinged relative to each end flap by a 25 fold line. Each locking tab is preferably received by a respective locking aperture such that the end wall panels are thereby secured relative to the inner side wall panels. Preferably, each end flap overlies a respective corner gusset panel. The fold lines hinging the extension panels relative to the end wall panels are preferably double fold lines. A respective aperture preferably extends between each 30 of the double fold lines. Preferably, each of the outer flaps hinged relative to either outer side wall panel overlie an interior surface of a respective end wall panel. It is also preferred 7 that each inner flap overlies an interior surface of a respective outer flap. The stacking tabs of the overlying outer and inner flaps preferably form a composite flap. Each composite flap is preferably captured by a respective one of the apertures extending between the double fold lines hinging the extension panels relative to the 5 end wall panels. Preferably, the stacking tabs of the inner and outer flaps are locking tabs instead. Brief Description of the Illustrations 10 In order that the invention may be more fully understood and put into practice, preferred embodiments thereof will now be described with reference to the accompanying illustrations, in which: Figure 1 illustrates a blank from which a container according to a first embodiment of the present invention is able to be erected; 15 Figure 2 depicts an initial stage in the erection of a container from the blank illustrated in figure 1; Figure 3 depicts another stage in the erection of the container from the blank illustrated in figure 1; Figure 4 depicts a further stage in the erection of the container from the 20 blank illustrated in figure 1; Figure 5 depicts another stage in the erection of the container from the blank illustrated in figure 1; Figure 6 is a perspective of the container erected from the blank illustrated in figure 1; and 25 Figure 7 illustrates a blank from which a container according to a second embodiment of the present invention is able to be erected. Detailed Description of the Illustrations Referring to figure 1, there is illustrated a blank 10 from which a container 30 according to a first embodiment of the invention is able to be erected. Blank 10 is fabricated from a suitable foldable material such as corrugated fibreboard or cardboard.

8 Blank 10 has a generally rectangular base panel 11 that has respective stacking apertures 12 located adjacent to the ends of the base panel 11. A respective enlargement flap 13 is located adjacent to each stacking aperture 12 and is hinged relative to the base panel 11 by a fold line 14 so that each stacking aperture 12 is able 5 to be enlarged by suitably folding the adjacent flap 13 relative to the base panel 11. Respective generally rectangular outer side wall panels 15 are hinged to opposite sides of the base panel 11 by fold lines 16. Each outer side wall panel 15 has a respective pair of opposing outer flaps 17 hinged thereto by fold lines 18. Each outer flap 17 has a stacking tab 19 extending therefrom, and a ventilation aperture 20 10 extending therethrough. Each outer side wall panel 15 is hinged to a respective inner side wall panel 21 by a double fold line 22. Each inner side wall panel 21 is generally rectangular in shape and includes a respective locking aperture 23 located adjacent each end thereof Each inner side wall panel 21 has a respective rectangular corner gusset 15 panel 24 hinged to each end thereof by a fold line 25. Each corner gusset panel 24 is hinged to a respective inner flap 26 by a fold line 27. Each inner flap 26 has a respective stacking tab 28 extending therefrom, and a respective ventilation aperture 29 extending therethrough. The stacking tab 28 of each inner flap 26 is offset from the stacking tab 19 of an adjacent outer flap 17. 20 Respective generally rectangular end wall panels 30 are hinged to opposite sides of the base panel 11 by fold lines 31. Each end wall panel 30 includes a respective pair of ventilation apertures 32. A respective extension panel 33 is hinged to each end wall panel 30 by a double fold line 34. Respective apertures 35 are provided partway along the double 25 fold lines 34 and extend partially into the extension panels 33. Each extension panel 33 has a pair of opposing end flaps 36 that are hinged to opposite ends of the extension panel 33 by fold lines 37. Each end flap 36 has a respective locking tab 38 hinged thereto by a fold line 39. The locking tabs 38 are complementary in shape to the locking apertures 23 in 30 the inner side wall panels 21. A respective side wall capturing tab 40 is cut into each outer side wall panel 15 and the base panel I1 such that each capturing tab 40 is located midway along a 9 respective fold line 16 and forms a discontinuity therein. Each capturing tab 40 is hinged to the base panel II by a respective fold line 41 which is parallel to the fold lines 16. A plurality of parallel cuts 42 extend through each outer side wall panel 15 and intersect the cuts in the base panel 11 and outer side walls panels 15 which define 5 the capturing tabs 40. A container is erected from the blank 10 by initially folding the inner side wall panels 21 relative to the outer side wall panels 15 along the fold lines 22 so that the inner side wall panels 21, corner gusset panels 24, and inner flaps 26 overlie the outer side wall panels 15 and outer flaps 17. The outer side wall panels 15 are then 10 folded along the fold lines 16 and away from an interior surface of the base panel 11 as shown in figure 2 until the free edges of the inner side wall panels 21 are located on the side of the capturing tabs 40 which includes the exterior surface of the base panel 11. Referring to figures 3 and 4, the outer side wall panels 15 are then folded 15 relative to the base panel 11 along the fold lines 16 in the opposite direction until the outer side wall panels 15 are upstanding from the interior surface of the base panel 11. As a consequence of folding the outer side wall panels 15 in this manner, the capturing tabs 40 are folded with respect to the base panel 11 along the fold lines 41 so as to be upstanding from the base panel 11. Also, the inner side wall panels 21 are 20 retained between the outer side wall panels 15 and the capturing tabs 40. The resultant upstanding and overlying outer and inner side wall panels 15, 21 form the side walls of the container. Each pair of overlying outer and inner flaps 17, 26 and their associated corner gusset panels 24 are then folded along the fold lines 18, 25, and 27 relative to 25 the outer and inner side wall panels 15, 21 so that the outer and inner flaps 17, 26 extend at right angles to the side wall panels 15, 21, and the gusset panels 24 extend diagonally across the corners formed by the outer flaps 17 and the outer side wall panels 15. The angle at which the corner gusset panels 24 extend across the aforementioned corners is such that the stacking tabs 19, 28 and ventilation apertures 30 20, 29 of the overlying flaps 17, 26 coincide. The ends of adjacent pairs of overlying outer and inner flaps 17, 26 meet midway along the ends of the base panel I1 so that the stacking tabs 19, 28 of each of those adjacent pairs of flaps 17, 26 form respective to single composite stacking tabs 43 of double thickness at each end of the partially erected container 50 as illustrated in figure 5. The double thickness of the composite stacking tabs 43 increases their strength relative to that of the individual stacking tabs 19, 28. 5 The end wall panels 30 are then folded relative to the base panel I1 along the fold lines 31 until they extend upwardly from the base panel 11 at right angles thereto and overlie the outer flaps 17. The extension panels 33 are then folded relative to the end wall panels 30 along the fold lines 34 so that the composite stacking tabs 43 extend through the 10 apertures 35, and the extension panels 33 overlie the inner flaps 26. Each end flap 36 overlies a respective corner gusset panel 24, and each locking tab 38 is received by a respective locking aperture 23 and forms an interference fit therewith so as to thereby lock the extension panels 33 in position and complete the erection of the manually erectable and stackable container 50 illustrated in figure 6. 15 The container 50 includes a pair of opposing side walls and a pair of opposing end walls extending upwardly from the base panel I1. The side walls are formed by the outer and inner side wall panels 15, 21, while the end walls are formed by the outer flaps 17, inner flaps 26, and end wall panels 30. Referring to figure 7, there is illustrated a blank 60 from which a container 20 according to a second embodiment of the invention is able to be erected. The blank 60 is formed from a suitable foldable material such as corrugated fibreboard. For convenience, features of the blank 60 which correspond to features of the blank 10 have been referenced with the same reference numbers. Blank 60 differs from the blank 10 in that blank 60 includes a respective pair 25 of stacking apertures 12 in the base panel I 1 adjacent to each fold line 16. Also, the outer side wall panels 15 and inner side wall panels 21 include a plurality of ventilation apertures 61 extending therethrough. Moreover, a respective pair of stacking tabs 62 extends from each inner side wall panel 21 into the outer side wall panels 15, and each inner side wall panel 21 has a pair of stacking tab receiving 30 recesses 63 formed in a free edge thereof opposite the stacking tabs 62. Furthermore, each outer flap 17 has a recess 64 in an edge thereof which forms part of a ventilation aperture, and the tabs 19 are locking tabs rather than stacking tabs. Similarly, each 11 inner flap 26 has a recess 65 in an edge thereof which forms part of a ventilation aperture, and the tabs 28 are locking tabs rather than stacking tabs. Each end wall panel 30 includes a single ventilation aperture 32 rather than a pair of ventilation apertures. 5 Throughout the specification and the claims, unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers. Throughout the specification and claims, unless the context requires 10 otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be 15 apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.

Claims (9)

1. A container erected from a blank of foldable material, the container comprising a base, a pair of opposing outer side wall panels substantially upstanding from the base and hinged relative thereto by fold lines, a respective inner side wall panel overlying an interior surface of each outer side wall panel and being hinged relative to the outer side wall panel by a fold line, and a plurality of capturing tabs hinged relative to the base by respective fold lines, wherein each inner side wall panel is captured between a respective outer side wall panel and at least one respective capturing tab such that the inner side wall panel is thereby substantially secured relative to the outer side wall panel.

2. The container of claim 1, wherein the capturing tabs are generally rectangular in shape.

3. The container of any one of the preceding claims, wherein each inner side wall panel is captured between a respective outer side wall panel and a single respective capturing tab.

4. The container of any one of the preceding claims, wherein a respective capturing tab is located midway along each inner side wall panel.

5. The container of any one of the preceding claims, wherein a respective capturing tab is cut out from each outer side wall panel and the base.

6. The container of any one of the preceding claims, wherein the fold lines hinging the capturing tabs relative to the base are parallel with respect to the fold lines hinging the outer side wall panels relative to the base.

7. The container of any one of the preceding claims, wherein the capturing tabs are substantially perpendicular with respect to the base.

8. The container of any one of the preceding claims, wherein the fold lines hinging the outer side wall panels relative to the inner side wall panels are parallel with respect to the fold lines hinging the outer side wall panels relative to the base.

9. A container erected from a blank of foldable material, the container being substantially as herein described with reference to figures 1 to 6, or figure 7 of the illustrations. 13 DATED this 2 2 "d day of June 2005 AMCOR LIMITED By its Patent Attorneys CULLEN & CO.