U.S. patent application number 11/792838 was filed with the patent office on 2009-03-19 for blanks for containers.
Invention is credited to Bruce Michael Drew, David Brian Edwards, William John McCarthy, Michael Edward Parkes.
Application Number | 20090072015 11/792838 |
Document ID | / |
Family ID | 35985289 |
Filed Date | 2009-03-19 |
United States Patent
Application |
20090072015 |
Kind Code |
A1 |
Drew; Bruce Michael ; et
al. |
March 19, 2009 |
Blanks for Containers
Abstract
A blank from which may be erected a protective enclosed tamper
evident container for the packaging of articles during
transportation and storage has five aligned panels that form
opposed roof and floor walls having a dome shape connected at
opposite ends of the container by side walls having a concave
shape. The centre panel forming the floor wall has opposed closure
panels that fold over the roof wall to close the open sides of the
container and are provided with locking tongues that engage slots
in the roof wall to secure the container. The tongues and slots
provide a tamper evident mechanism for securing the container such
that no adhesive is required during the erection process in order
to hold the container in its closed position.
Inventors: |
Drew; Bruce Michael; (Essex,
GB) ; Parkes; Michael Edward; (Cambridgeshire,
GB) ; Edwards; David Brian; (Hertfordshire, GB)
; McCarthy; William John; (Dorset, GB) |
Correspondence
Address: |
GREER, BURNS & CRAIN
300 S WACKER DR, 25TH FLOOR
CHICAGO
IL
60606
US
|
Family ID: |
35985289 |
Appl. No.: |
11/792838 |
Filed: |
December 9, 2005 |
PCT Filed: |
December 9, 2005 |
PCT NO: |
PCT/GB05/04732 |
371 Date: |
May 29, 2008 |
Current U.S.
Class: |
229/102 |
Current CPC
Class: |
B65D 5/2057 20130101;
B65D 5/0209 20130101; B65D 5/2023 20130101 |
Class at
Publication: |
229/102 |
International
Class: |
B65D 5/42 20060101
B65D005/42 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 10, 2004 |
GB |
0427153.2 |
Jun 22, 2005 |
GB |
0512644.6 |
Claims
1. A blank from which may be formed a protective enclosed tamper
evident container, the blank being made of shape-retaining material
and comprising a main section which has five aligned panels, a
first of these panels defining a first main wall of the container,
second and third of these panels, each defining a side wall of the
container, are connected to opposite ends of said first panel,
fourth and fifth of these panels, each defining a portion of a
second main wall of the container, are connected to said second and
third panels at an end that opposes the end connected to said first
panel, wherein the second main wall is, when erected, opposed to
the first main wall, with said fourth and fifth panels being
dimensioned to overlap free end of one panel over free end of the
other panel, the side wall panels are defined between first and
second arcuate crease lines curved towards each other such that
each side wall panel is almost elliptical, and the blank includes a
closure panel on each side of the main section, wherein each
closure panel is provided with a tongue that is, when the container
is erected, received in a respective matching slot provided in one
of the main walls of the container in order to hold the container
in a closed position, and each slot being so shaped and dimensioned
that, once entered, neither tongue can be removed without leaving
evidence of tampering, and in which no adhesive is required during
the erection of the blank in order to hold the container in its
closed position.
2. A blank as claimed in claim 1, wherein the closure panels are
provided at opposing sides of the first main wall that are not
connected to the second and third panels, and the slots are
provided in the outermost panel of the second main wall.
3. A blank as claimed in claim 1, wherein the closure panels are
provided at opposing sides of the outermost panel of the second
main wall and the slots are provided in the first main wall.
4. A blank as claim in claim 1, wherein a first closure panel is
provided at one side of the first main wall that is not connected
to the second and third panels, and the slot engaged by the tongue
of the first closure panel is provided in the outermost panel of
the second main wall, and a second closure panel is provided at one
side of the outermost panel of the second main wall on the opposite
side of the main section to the first closure panel, and the slot
engaged by the tongue of the second closure panel is provided in
the first main wall.
5. A blank as claimed in claim 1, wherein the material used for the
blank is fluted board, the fluting being aligned generally from end
to end of the aligned panels of the blank, and thus generally
normal to the arcuate crease lines.
6. A blank as claimed in claim 1, wherein the material used for the
blank comprises a second layer attached to the inside surface of
the blank in order to provide the erected closed container with
desired properties.
7. A blank as claimed in claim 6, wherein the second layer is an
insulating material and/or a protective material.
8. A blank as claimed in claim 7 wherein the second layer is
selected from the group comprising bubble wrap, cradle wrap or
other filmic materials incorporating sealed bags or bubbles
containing air or other gases.
9. A blank as claimed in claim 1, wherein the degree of curvature
of the arcuate crease lines is generally in a ratio of centre point
height to outer limit height of from 4:1 down to 1.5:1.
10. A blank as claimed in claim 1, wherein, to improve the ease
with which the blank can be folded, the crease lines have been
perforated.
11. A blank as claimed in claim 10, wherein the perforation has
been carried out using lasers.
12. A blank as claimed in claim 1, wherein the closure panels are
connected to the main section of the blank at an edge defined by
first and second straight crease lines.
13. A blank as claimed in claim 1, wherein the closure panels are
connected to the main section of the blank via side wall panels
defined by first and second arcuate crease lines.
14. A protective enclosed tamper evident container made by erecting
a blank as claimed in claim 1.
Description
[0001] This invention relates to blanks for containers, and in
particular, but not exclusively, a blank for a protective enclosed
tamper evident container and such a container made therefrom.
[0002] Many designs of blank made from sheet materials and then
formed or folded into an assembled container, have been proposed to
protect the contents from damage during storage, handling and
transport. Some designs have used the architecture of the container
to provide increased strength over that of the material from which
they are made.
[0003] In British Patent Specifications Nos: 2,315,060 and
2,342,343, there are described two different types of container
blank which are especially suitable for the packaging of fluids
contained within a plastic bag. These blanks have arcuate crease
lines, and when erected, form pillow shaped containers, with
arcuate panels providing strength and durability to the assembled
container.
[0004] The sleeve-like containers disclosed in these British Patent
Specifications have open ends and must be transported in a
"sleeping" position in order to prevent the contents from falling
out of one or other end of the sleeve. In turn, this means that
either of these sleeve-like containers require to be transported in
a shipping container such as a carton box, typically made from
heavier duty corrugated fibreboard.
[0005] Two different changes in the market place have made it
necessary to consider improvements to these blanks and the
containers made therefrom described in the earlier British Patent
Specifications listed above. Firstly, new legislation and
increasing environmental pressure is resulting, amongst other
things, in a need to eliminate unnecessary layers of packaging.
Secondly, there is an increasing requirement for tamper evident
packaging to highlight interference with goods during storage and
carriage.
[0006] The present invention seeks to provide an improved form of
blank for forming a container and a container assembled from such
blank.
[0007] In a first aspect, the present invention provides a blank
from which may be formed a protective enclosed tamper evident
container, the blank being made of shape-retaining material and
comprising a main section which has five aligned panels, a first of
these panels defining a first main wall of the container, second
and third of these panels, each defining a side wall of the
container, are connected to opposite ends of said first panel,
fourth and fifth of these panels, each defining a portion of a
second main wall of the container, are connected to said second and
third panels at an end that opposes the end connected to said first
panel, wherein the second main wall is, when erected, opposed to
the first main wall, with said fourth and fifth panels being
dimensioned to overlap free end of one panel over free end of the
other panel, the side wall panels are defined between first and
second arcuate crease lines curved towards each other such that
each side wall panel is almost elliptical, and the blank includes a
closure panel on each side of the main section, wherein each
closure panel is provided with a tongue that is, when the container
is erected, received in a respective matching slot provided in one
of the main walls of the container in order to hold the container
in a closed position, and each slot being so shaped and dimensioned
that, once entered, neither tongue can be removed without leaving
evidence of tampering, and in which no adhesive is required during
the erection of the blank in order to hold the container in its
closed position.
[0008] This aspect of the invention provides an alternative form of
blank with arcuate crease lines that may easily be erected into a
protective enclosed tamper evident container without the use of any
adhesive being required to hold the resulting container together in
its erected form. The arcuate crease lines form side walls of
concave shape that provide the container with inherent impact
resistance and mechanical strength.
[0009] In one arrangement, this aspect of the invention provides a
blank in which the crease lines on both aligned edges of a first
panel defining a first main wall are made in a curvilinear shape so
that the erected container assumes a pillow shape, while the other
two edges of this first panel bear closure panels each of which
carries at its free end a tongue in the shape of an arrow head that
in use co-operates with a matching slot/slit combination in a panel
of a second main wall of the blank opposed to the first main
wall.
[0010] In another arrangement, this aspect of the invention
provides a blank in which the crease lines on both aligned edges of
a first panel defining a first main wall are made in a curvilinear
shape so that the erected container assumes a pillow shape, while
the two opposed edges of the outermost panel of the second main
wall bear closure panels each of which carries at its free end a
tongue in the shape of an arrow head that in use co-operates with a
matching slot/slit combination in the panel defining the first main
wall of the blank opposed to the second main wall.
[0011] Preferably, the blank is made of shape-retaining material
and is generally a paper product, preferably corrugated fibre
board. However, other materials, may be used, including all types
of corrugated board, single or double face, solid paperboard such
as folding boxboard, extruded plastic sheets such as those made
from polyethylene, extruded plastic cellular sheets such as those
known by the trade name "CORREX".TM., laminated materials of all
kinds including those containing aluminium foil, and composite
materials.
[0012] A preferred material, though, is a single-wall "B" flute
corrugated fibre board material made from recycled materials,
although it will be understood that the fluting media used may vary
depending on the nature of the product to be packaged and the
strength required in the container. Indeed, whilst numerous other
materials and combinations of fluting medium could be utilised, the
material known by the trade name "TEST" is particularly preferable
since it is made from recycled material and is therefore inherently
weaker than a pure kraft (virgin) construction. This is a desirable
feature, as a container made therefrom, when erected and subjected
to mechanical shocks, affords much greater resilience (cushion
factor) and energy-absorbing characteristics.
[0013] Where the material used for the blank of the invention is
fluted board, the fluting is preferably aligned generally from end
to end of the blank (and thus generally normal to the arcuate
crease lines). This gives increased shock-absorbing and inherent
strength properties to the container made therefrom.
[0014] The blank has aligned panels defining first and second
opposed main walls of the container, between which, and defined by
first and second crease lines at opposed ends of the container, are
two opposed side walls of the container. Each of these crease lines
is arcuate, the sense of the arc--bowed in or bowed out--being such
that the side walls are generally correspondingly almost
elliptical. It is this which causes the container erected from the
blank to take on the desired pillow shape.
[0015] It may be convenient, depending on the material from which
the blank is made, to perforate the crease lines by the use of
lasers or otherwise, firstly to render easier the folding of the
blank (especially as the degree of curvature of the arcuate crease
lines increases), and secondly to make the resulting container
crumple and so absorb shock more readily.
[0016] Thus, the arcuate nature of the crease lines defining the
elliptical side walls is preferably such that the heights between
the arcuate crease lines at their centres--the centre point
heights--and between the same arcuate crease lines at their outer
limits--the outer limit heights--are generally in a ratio of centre
point height:to outer limit height of 100:1 or less. A preferred
range is from 4:1 down to 1.5:1, and in one example the ratio is
2:1. It might also be worth observing that the greater the degree
of curvature, the more the erected container will be "waisted" as
well as "rounded".
[0017] The slots are shaped and dimensioned to retain the tongues
in place, and to stop them being subsequently removed without
leaving evidence of tampering. This can be achieved by arranging
that each slot is partly die cut and partly slit such that the
width of the arrow head tongue is approximately the same as the
overall length of the slit. In this way, a degree of force is
required to press the arrow head tongue through the slot, and once
inserted, the die cut slot is not sufficiently wide to allow the
arrow head tongue to be withdrawn without obvious damage to the
tongue or to the area of the container surrounding the slots.
[0018] If the blank has been appropriately dimensioned, the arcuate
nature of the erected container allows the contents of the
container to become clamped as the arrow shaped tongues are pushed
through the slots into their locked position, thereby preventing
the contents from movement during storage or transport.
[0019] In another embodiment, the blank is made from one of the
materials described above, to the inside surface of which has been
attached by whatever means is considered most appropriate, an
insulating or further protecting layer such as a foamed material,
bubble wrap, cradle wrap or other filmic materials incorporating
sealed bags or bubbles containing air or other gases. In this
context, it will be understood that the inside surface of the blank
means that surface which will become the inside surface of the
container after erection.
[0020] In this way, and again if the blank has been appropriately
dimensioned, as the arrow shaped tongues are pushed through the
slots into their locked position, the contents of the container
will become even more tightly clamped due to the elasticity of the
insulating or further protecting layer.
[0021] In a second aspect, the present invention provides a blank
designed to be assembled into a container having opposing roof and
floor faces and a plurality of between three and eight side wall
faces of which the wall faces are two dimensionally concave
intersecting in plan view to form acute angled corners and in side
elevation to form substantially elliptical shapes, and the two
opposing roof and floor faces have a three dimensionally convex
domed shape, such that all faces of the assembled container are
curved in at least two dimensions.
[0022] This aspect of the invention provides a blank which, once
assembled into a container, may provide greater strength and
resistance to damage of the contents of the container, in all three
dimensions and may provide equally high strength around the entire
periphery. This may be achieved without sacrificing simplicity of
manufacture of the blank, or ease of assembly and closure of the
container.
[0023] The blank is produced by cutting and creasing a sheet
material that is rigid enough to maintain its shape after assembly
but flexible enough to be readily creased and folded. The blank is
preferably made from corrugated material although any foldable
material may be used. If the material is difficult to fold, it can
be assisted by perforating along the fold lines by blade point, by
laser, or by any other method known to persons skilled in the art.
Preferably, corrugated fibreboard is used, having a weight of
100-300 grams per square metre (gsm), typically 125-190 gsm.
[0024] The corrugated fibreboard may be of any fluting format,
single wall (including microflutes), double, or triple wall, which
lends itself easily to cutting and creasing. It must be noted
however that other flat sheet materials can be used to manufacture
the blank according to this invention, such as extruded plastic
corrugated sheet, (for example, that known as "CORREX".TM.), paper
carton board, paper folding box board, lightweight metals and
various mono or multi-laminated polymeric sheets.
[0025] It may be convenient, depending on the material from which
the blank is made, to perforate the crease lines by the use of
lasers or otherwise, firstly to render easier the folding of the
blank (especially as the degree of curvature of the arcuate crease
lines increases), and secondly to make the resulting container
crumple and so absorb shock more readily.
[0026] The inside surface of the blank may be provided with a layer
of an insulating material and/or a further protecting material such
as a foamed material, bubble wrap, cradle wrap or other filmic
materials incorporating sealed bags or bubbles containing air or
other gases.
[0027] When assembled from the blank according to this aspect of
the invention, a typical container has opposing roof and floor
faces and a plurality of wall faces extending therebetween, of
which the wall faces take a two dimensional concave form and the
opposing roof and floor faces take a three dimensional convex domed
shape offering particular strength to the container. Thus, a
particular feature of the invention is that all faces of the
assembled container are curved in at least two dimensions.
[0028] In one preferred embodiment, the container has four concave
wall faces but this is not essential and the container may have
fewer wall faces, for example three, or more wall faces, for
example from five to eight. In this preferred embodiment having
four concave wall faces, the blank may be assembled into a
container that is square in outline or into a container that is
rectangular in outline.
[0029] Preferably, the blank is configured so that, after assembly,
the radius of each of the concave wall faces is such that the
assembled containers can fit together to form a stable stack. The
blank may be configured so that, after assembly, the concave wall
faces extend between the opposing convex floor and roof faces
around the entire periphery of the assembled container. The
curvature of both arcuate crease lines of any panel is preferably
identical.
[0030] In at least one embodiment, the blank is configured so that,
after assembly, container can provide maximal protection and shock
resistance of the contained volume per unit area of sheet material
from which the blank is made due to the plurality of concave
vertical wall faces and opposing convex domed roof and floor faces.
For example, the contents of the assembled container can be
protected from external impact or pressure in a horizontal
direction by means of the container's acute angled corners, and
similarly protected in a vertical direction by means of the
opposing convex domed roof and floor faces.
[0031] In a preferred embodiment, the dimensions of the blank are
chosen so that the contents of the assembled container are in
contact with the centre of each concave wall face and the corners
are preferably free to deform or collapse thereby sacrificially
absorbing or dissipating impacts and protecting the product.
[0032] Preferably, the blank is configured so that the acute angled
corners of the assembled container define a progressively narrowing
space in a direction away from the container's geometric centre
such that any movement of the contents causes the contents to make
contact with an internal surface of the container which is at an
incline to the direction of motion causing gradual deceleration of
the contents, reducing shock and therefore damage to the
contents.
[0033] In at least one embodiment, the blank may be configured so
that the fluting of the corrugated material is disposed at 45
degrees to the longitudinal direction of the blank in each concave
vertical wall face such that the strength in a vertical direction
of all wall faces is equal.
[0034] Preferably, the blank is configured in such a way that, for
corrugated material, the fluting direction of all the concave wall
faces is in a vertical direction. In one embodiment, the blank may
comprise two or more parts in which successive parts are placed
upon the first part at angles not greater than 90 degrees to each
other so that, for corrugated material, the fluting direction of
all the concave wall faces is in a vertical direction thereby
providing maximum vertical strength.
[0035] The blank may include flaps provided as extensions to any or
all of the panels of the blank that can be folded to provide the
assembled container with internal supports to restrain the movement
of the contents within the closed container or to provide internal
structural support to the faces of the container.
[0036] In a third aspect, the present invention provides a blank
having a plurality of panels for erecting an enclosed container
having opposed main walls and a plurality of side walls, and tamper
evident means for securing the container in an assembled condition
enclosed on all sides.
[0037] Preferably the tamper-evident means comprise at least one
locking tongue that is inserted in a locking slot wherein the
tongue and slot are configured so that once inserted, the tongue
cannot be removed without leaving evidence of tampering. The tongue
may be of arrow shape and the slot may be part die cut and part
slit to allow insertion of the tongue and resist removal.
[0038] The main walls preferably provide the container with opposed
roof and floor walls of curved shape, preferably convex, and side
walls of arcuate shape, preferably concave. The container may be
pillow shaped or dome shaped.
[0039] Preferably, the blank has a first section comprising five
aligned panels that form the main walls of the container and a pair
of side walls at opposite ends of the container, and a second
section with panels that close open sides of the container between
the side walls of the first section.
[0040] The first and second sections may be formed integrally in
one piece or as two separate parts that are laid one on top of the
other during assembly of the container.
[0041] In a fourth aspect, the invention provides a blank for
erection of a container, the blank having five aligned panels of
which the first, third and fifth panels form opposed main walls of
the container and the second and fourth panels form opposed side
walls at opposite ends of the container, and at least two panels
arranged to close the container between the ends.
[0042] Preferably, the second and fourth panels are defined by
arcuate crease lines at the edges adjoining the first, third and
fifth panels such that the side walls are of arcuate concave shape
in plan view in the assembled container.
[0043] In one arrangement, the at least two panels that close the
container between the ends are connected to opposite sides of the
third panel along straight crease lines such that, during assembly,
these panels fold over the first and fifth panels and are secured
in a tamper-evident manner.
[0044] In a fifth aspect, the invention provides a protective
enclosed tamper evident container made by erecting a blank
according to any of the preceding aspects of the invention.
[0045] This aspect of the invention provides a protective enclosed
tamper evident container capable of being stored and transported
without a further layer of packaging such as a shipping container
around it, using arcuate crease lines to provide the container with
impact resistance in all dimensions, and capable of being erected
without the use of any adhesive.
[0046] Moreover, whilst this invention was conceived with the
transport of fragile articles in mind, any articles susceptible to
shock, or any application requiring ease of erection without the
need for adhesive, could equally benefit from its principles.
[0047] What the invention proposes is a containerisation system
which offers protection of a packaged article against mechanical
shock, ease of erection, and detection of tampering during storage
and transport.
[0048] To achieve these aims, the invention suggests the use of a
novel construction of arcuate blank that may be folded and then
erected into a protective tamper evident arcuate folded container
enclosed on all sides so that the contents cannot fall out as they
were able to do from the open ends of the sleeve-like containers
described in the earlier inventions and yet offer a similar ability
to withstand and cushion the contents of the container against
physical shocks associated with normal conditions of transport,
storage and use.
[0049] The corrugated material forming the blank may be arranged so
that, in the assembled container, the fluting in the side wall
panels extends between the main panels to resist crushing of the
container.
[0050] The closure panels may be connected to the first main panel
by side wall panels of arcuate shape so that the assembled
container has four concave side walls extending between opposed
convex dome-shaped main panels. The main panels may form the roof
and floor of the container.
[0051] The invention is now described, by way of illustration only,
with reference to the accompanying drawings in which like reference
numerals are used throughout to indicate corresponding parts and
wherein:
[0052] FIG. 1 shows a blank according to a first embodiment of the
present invention for assembly of a tamper evident container;
[0053] FIG. 2 shows the blank of FIG. 1 partially assembled;
[0054] FIG. 3 shows a plan view of the erected container
illustrating the tongues in their locked position;
[0055] FIG. 4 shows a modification to the blank of FIG. 1;
[0056] FIG. 5 shows a blank according to a second embodiment of the
present invention for assembly of a tamper evident container;
[0057] FIG. 6 shows the blank of FIG. 5 partially assembled;
[0058] FIG. 7 shows a plan view of the erected container
illustrating the tongue in its locked position;
[0059] FIG. 8 shows a perspective view of the erected container of
FIG. 7;
[0060] FIG. 9 shows a two-part blank according to a third
embodiment of the present invention for assembly of a tamper
evident container;
[0061] FIG. 10 shows a modification to the two-part blank of FIG.
9; and
[0062] FIG. 11 shows a blank according to a fifth embodiment of the
present invention for assembly of a tamper evident container.
[0063] Referring first to FIGS. 1 to 3 of the accompanying
drawings, a blank 1 according to a first embodiment of the
invention is shown in FIG. 1 having five aligned panels (A, B, C,
D, E) for assembly of a tamper evident container 2 shown in FIG.
3.
[0064] The container 2 has a first side wall formed by the panel B
that is defined on either side by arcuate crease lines 3,4.
Similarly, the container 2 has a second side wall formed by the
panel D that is defined on either side by arcuate crease lines 5,6.
In the case of both side walls B and D, the arcuate crease lines
3,4 and 5,6 respectively are curved towards each other such that
the side walls are almost elliptical.
[0065] The container 2 has a bottom or main wall formed by the
centre panel C and an opposed top or main wall formed by the panels
A and E. The bottom wall panel C extends between and has opposed
edges defined by the arcuate crease lines 4,5 connected to the side
wall panels B,D respectively. The top wall panels A,E have one edge
defined by the arcuate crease lines 3,6 connected to the side wall
panel B,D respectively and opposed free edges that overlap one
another.
[0066] The other edges of the centre panel C are defined by two
straight crease lines 7,8 which are parallel to each other. The
crease lines 7,8 define one edge of two wing or closure panels F,G.
The other three edges of the wing panels F,G are defined by lines
9, 10 and 11.
[0067] Attached to both wing panels F,G are locking tongues H.
These locking tongues H are arrow shaped to facilitate erection of
the container and have square die cut heads defined by lines 12, 13
and angled side edges defined by lines 14,15. The top wall panel E
is provided with two parallel slots 16 to receive the tongues H.
The tongues H and slots 16 provide tamper-evident formations that
provide a visual indication if the container 2 has been opened.
[0068] Assembly of the container 2 from the blank 1 will now be
described.
[0069] In a first operation, side wall panel B is folded around
line 4 and top wall panel A is folded around line 3 such that top
wall panel A extends partially across bottom wall panel C as shown
in FIG. 2.
[0070] In a second operation, side wall panel D is folded around
line 5 and top wall panel E is folded around line 6 and then laid
over top wall panel A creating a pillow shape container 2 with
opposed concave side walls B and D, and opposed convex bottom and
top walls C and A,E. As shown the free end of the panel E is of
arcuate shape to match the curved shape of the side wall B.
[0071] In a third and fourth operation, each wing panel F,G is
folded at crease lines 7,8 and laid over top wall panel E to close
the open sides of the container 2 so that any article packed within
the container 2 is already prevented from falling out.
[0072] In a fifth and sixth operation, the wing panels F,G are
locked in place by inserting the arrow shaped locking tongues H
through the slots 16 in the top wall panel E. The slots 16 are in
part die cut 17 and in part slit 18 so that, when the arrow shaped
locking tongues H are pushed through the slots 16, the tongues H
are secured by the square cut outs defined by lines 12 and 13 which
hold against the slots 16 (FIG. 3).
[0073] In this embodiment, the blank 1 is made of shape retaining
material such as corrugated cardboard in which the fluting (not
shown) extends parallel to the length of the blank, i.e.
longitudinally from one end to the other, and is generally
perpendicular to the crease lines 3,4,5,6. In this way, the fluting
extends between the bottom and top walls of the assembled container
2 and provides increased shock-absorbing and inherent strength
properties to the container. This is not essential however, and the
fluting may extend at an angle to the longitudinal direction of the
blank 1 to vary the shock-absorbing and strength properties of the
container 2 as desired.
[0074] In a modification (not shown), the wing panels F,G are
connected to opposed edges of the top wall panel E and the slots 16
are provided in the bottom wall panel C to receive the locking
tongues H when the wing panels F,G are folded over to close the
open sides of the container 2. Alternatively, the bottom wall panel
C may have wing panel F and the top wall panel E may have wing
panel G with locking tongue H of wing panel F received in the slot
16 in top wall panel E and locking tongue H of the wing panel G
received in the slot 16 in the bottom wall panel C.
[0075] Referring now to FIG. 4, there is shown another modification
to the design of the blank 1 shown in FIG. 1. In this modification,
the parallel crease lines 7,8 at either edge of the centre panel C
are replaced by arcuate crease lines 19,20 that define side wall
panels J and K between the bottom wall panel C and the wing panels
F,G.
[0076] In this modification, when the blank 1 is erected to form a
container, the side wall panels B,D,J,K form concave side walls
around the entire perimeter of the container and the bottom wall
panel C and top wall panels A,E form domed convex top and bottom
walls. As shown, the free edges of the top wall panel E are curved
to match the curved shape of the side walls formed by the side wall
panels B,J,K.
[0077] The wing panels F,G are locked in place by inserting the
arrow shaped locking tongues H in the slots 16 in the top wall
panel E as described previously. In a modification (not shown), the
side wall panels J,K and wing panels F,G may be provided on opposed
edges of the top wall panel E with the slots 16 provide din the
bottom wall panel C to receive the locking tongues H.
Alternatively, the bottom wall panel C and top wall panel E may
each have one side wall panel and wing panel and one slot/
[0078] In this embodiment, the blank 1 is made of shape retaining
material such as corrugated cardboard in which the fluting (not
shown) extends parallel to the length of the blank, i.e.
longitudinally from one end to the other, and is generally
perpendicular to the crease lines 3,4,5,6.
[0079] In this way, the fluting of the side panels B,D extends
between the bottom and top walls of the assembled container 2 and
the fluting of the side wall panels J,K extends generally parallel
to the bottom and top walls. As a result, the shock-absorbing and
inherent strength properties of the side wall panels B,D are
different to those of the side wall panels J,K.
[0080] In a modification, the fluting extends at 45.degree. to the
longitudinal direction of the blank 1 so that the shock-absorbing
and strength properties of the side walls B,D,J,K are the same. The
direction of the fluting may be altered as desired to provide the
container with any required shock-absorbing and strength
properties.
[0081] Referring now to FIGS. 5 to 8 of the drawings, a blank 1
according to a second embodiment of the invention is shown in which
the locking mechanism for securing the container 2 erected from the
blank 1 in the assembled condition is altered.
[0082] In this embodiment, the two arrow shaped locking tongues H
on the wing panels F,G are replaced with a single arrow shaped
locking tongue H on the free edge of the top wall panel E remote
from the side wall panel D and the slots 16 in the top wall panel E
are replaced by a single slot 16 formed at the junction of top wall
panel A and side wall panel B.
[0083] Assembly of the container 2 from the blank 1 shown in FIG. 5
will now be described.
[0084] The contents to be packed within the container are first
placed upon bottom wall panel C. Opposed side wall panels J,K and
wing panels F,G are folded along their respective arcuate crease
lines 19,20 to form opposed side walls of concave shape with wing
panels F,G folded over to form a partial roof over the
contents.
[0085] Side wall panels B,D are then folded along the respective
arcuate crease lines 4,5 to form opposed side walls of concave
shape as shown in FIG. 6. Top wall panel A is then folded along
crease line 3 to extend over the wing panels F,G at one end of the
container 2 and reveal the locking slot 16 into which the arrow
shaped locking tongue H on the top wall panel E is to be
inserted.
[0086] The slot 16 is only revealed at this stage when the top wall
panel A is folded about crease line 3 due to its presence in the
blank 1 as a slit which opens to create the locking slot 16 when
the crease line 3 on which the locking slot is located is bent
through 90 degrees.
[0087] Finally, top wall panel E is folded along crease line 6 to
insert the arrow shaped locking tongue H at the free end of the top
wall panel E into the slot 16 to secure the container 2 in the
assembled condition as shown in FIGS. 7 and 8. In this way, the top
wall panel E is also the closure panel that secures the container 2
in the erected condition.
[0088] As best shown in FIG. 8, the assembled container 2 has
opposing top and bottom walls of convex dome shape and four
vertical side walls of concave shape extending between the top and
bottom walls around the entire periphery of the container 2. The
terms "top", "bottom", "side" refer to the orientation of the
container 2 shown in FIG. 8 and the term "vertical" is used to
describe the direction parallel to the line between the centre
point of the top wall and the centre point of the bottom wall in
this orientation.
[0089] In this embodiment, the container 2 is assembled from a
blank 1 of corrugated material with the fluting arranged to extend
longitudinally of the blank where the term longitudinal is defined
as that direction perpendicular to the centre point of the arcuate
crease lines 3,4,5,6 of each blank 1.
[0090] In this way, when the container 2 is assembled, the opposing
vertical concave side walls B,D present the fluting in a vertical
direction where the term vertical direction is as defined above
and, where provided, the opposing concave side walls J,K present
the fluting normal to the vertical direction.
[0091] As a result, the side walls B,D present a higher resistance
to loads in the vertical direction than the side walls J, K. In a
modification, the fluting may extend at 45.degree. to the
longitudinal direction so that all four side walls B,D,J,K have the
same strength and shock-absorbing properties.
[0092] Referring now to FIG. 9, a third embodiment of the invention
is shown in which the design is modified in such a way that after
assembly, the fluting of all four vertical concave side walls is in
a vertical direction, thus offering even greater strength to the
container.
[0093] In this embodiment, the blank 1 comprises first and second
blank parts 1',1'' each with fluting arranged to extend
longitudinally of the blank parts 1',1'' where the term
longitudinal is defined as that direction perpendicular to the
centre point of the arcuate crease lines of the blank part.
[0094] The first blank part 1' comprises five aligned panels
A,B,C,D,E similar to the panels A,BC,D,E of the blank 1 shown in
FIG. 5 with an arrow shaped locking tongue H on top wall panel
E.
[0095] The remaining side wall panels J,K and wing panels F,G of
the blank 1 shown in FIG. 5 are now provided by the second blank
part 1'' which also comprises five aligned panels with the side
wall panels J,K at opposite ends of a centre panel L and wing
panels F,G at the free ends of the side wall panels J,K.
[0096] The blank 1 may be formed in one piece with edge 21 of panel
A of blank part 1' joined to edge 22 of panel G (or panel F) of
blank part 1'' along a perforated line such that the blank parts
1',1'' can be formed with the fluting extending longitudinally of
both blank parts 1',1'' and the blank parts 1',1'' separated along
the perforated line for assembly of the container as now
described.
[0097] The centre panel L of the second blank 1'' is placed upon
the centre panel C of the first blank part 1' such that the parts
1',1'' extend at right angles to each other. In this condition, the
blank parts 1',1'' resemble the blank 1 of FIG. 5 when viewed in
plan. At this point, the contents to be packed in the container are
placed upon the upper surface of panel L. The second blank part 1''
is then folded about its arcuate crease lines 19,20 until side wall
panels J,K form opposed sidewalls and wing panels F,G form a
partial roof over the panel L
[0098] Panel B of the first blank part 1' is then folded about
arcuate crease line 3 to form a side wall and panel A is folded
about crease line 4 to extend over parts of panels F,G and open
locking slot 16. Panel D is then folded about crease line 5 to
forms a sidewall opposite panel B and panel E is folded about
crease line 6 to form the roof wall of the container and insert
locking tongue H in locking slot 16 to secure the container in the
assembled condition.
[0099] The assembled container 2 has a shape similar to that of
FIG. 8 but now all the side walls B,D,J,K have the fluting
extending in a vertical direction which increases the strength of
the container 2.
[0100] Referring now to FIG. 10, there is shown a modification to
the embodiment of FIG. 9 in which the blank 1 is formed in one
piece with two blank parts 1',1'' connected by a panel M for
assembly of a container of similar shape to that shown in FIG. 8
with the fluting extending in a vertical direction on all four side
walls B,D,J,K similar to that produced by the blank parts 1',1'' of
FIG. 9 without having to separate the blank parts 1',1'' for
assembly.
[0101] In this modification, the fluting direction in each blank
part 1',1'' is again arranged longitudinally as this term has been
defined above. Here, panel M is used as a hinge allowing the centre
panel L of blank part 1'' to be rotated through 90 degrees and
swung over centre panel C of blank part 1', thereby trapping panel
M between panel C and panel L. The remaining assembly procedure
follows exactly in accordance with that described above for FIG.
9.
[0102] Referring now to FIG. 11, a blank 1 according to a fourth
embodiment of the invention is shown for assembly of a container
having six side walls of concave shape and opposing roof and floor
walls of convex dome shape.
[0103] The blank 1 has five aligned panels A,B,C,D,E with a locking
tongue H provided at the free end of panel E for insertion in a
locking slot 16 formed at the junction of panels A and B.
[0104] In addition, panel B has four additional side wall panels
N,P,R,S--two on each side--each having a respective wing panel
T,U,V,W. The panel E also has four additional locking tongues
H--two on each side--for insertion in respective locking slots 16
formed at the junction of each side wall panel N,P,R,S and its
associated wing panel T,U,V,W respectively.
[0105] The blank 1 is assembled in a similar way to that described
above and the top wall panel E is held in position by inserting
each of the five locking tongues H into the locking slots 16.
[0106] It will be understood that the principle of this embodiment
can be applied to containers having any number of side walls. In
particular, containers having side walls equal to, or greater than,
three are possible although in practice, as the number of concave
vertical side walls increases, the number of overlapping roof
panels also increases and the point is quickly reached where the
contribution of each roof panel to the strength of the container
has decreased to the point where the cost of so many overlapping
roof panels can no longer be justified in protecting the contents
from external shock.
[0107] The above-described embodiments show blanks for assembly of
containers having a plurality of side walls when viewed from a
vertical direction having the appearance of a multi-pointed star
with acute angled corners which provide an important feature for
protecting the contents of the container.
[0108] When the corners of the assembled container are left empty
as will typically be the case, the walls of the corner sections
become the first points of contact in any lateral movement of the
contents of the container resulting from any applied external force
that has a horizontal component. In this way, the contents of the
container are protected from direct contact with the external
force.
[0109] The opposing roof and floor walls of convex dome shape
provide a similar function against any applied external force that
has a vertical component. Furthermore, it will be noticed that
where the external force is sufficiently large, the acute angled
corners of the side walls or convex domed shape of the opposing
roof and floor walls of the container will be crushed before the
contents of the container are damaged.
[0110] The act of crushing the corners or convex domed faces of the
container will absorb and dissipate the external force either fully
or partially. It is a feature of this invention that the acute
angled corners and the convex domed faces of the assembled
container are sacrificed in this way in order to offer maximum
protection to the contents of the container.
[0111] It has been found that containers assembled from blanks
according to this invention offer greater resistance to impact and
crushing due to the plurality of vertical concave side walls around
the entire periphery and the two convex domed roof and floor walls
at the base and top of the container respectively.
[0112] It will be seen that when a relatively flat product is
packed within a container made from a blank according to the
invention, especially if the product is round or oval, it can be
held in position within the container without the need for
additional internal packaging. By selecting the dimensions of the
blank with this in mind, the periphery of the product will make
contact with the assembled container at the internal centre points
of each concave face. It will thus be held firmly against internal
movement within the container at those points least exposed to
external forces, due to the concave shape of the vertical wall
faces of the container.
[0113] A further important protective feature of containers made
from blanks according to the invention is the deceleration provided
to the contents after the container has been subjected to shock in
which acceleration is imparted to the contents due to gravity or
other applied force. Any movement of the contents of the container
away from the centre of the container will be resisted due to
contact of the contents with an internal face of the container.
[0114] Due to the inherent design of blanks according to this
invention, all internal faces of the container will always present
an acute angle to the direction of motion of the contents following
a shock to the container. Consequently, resistance to the movement
will increase more gradually than would be the case if the
resisting internal face or faces were perpendicular to the
direction of motion. This more gradual increase of forces resisting
the movement of the contents allows containers made from blanks
according to the invention to offer improved protection from shock
to the contents.
[0115] If the radii of the concave vertical wall faces are chosen
with such an objective in mind, the assembled containers will fit
together when stacked alternately in horizontal and vertical
layers. Such a design provides considerable strength and rigidity
to the stack which, once stacked upon a pallet, may be wrapped with
film by any means without the need for outer shippers made from
corrugated board, typically known as cartons. Eliminating the need
for cartons as part of the transit packaging system saves
considerable cost.
[0116] Containers assembled from blanks according to the invention
may be of any size provided that the thickness of the sheet
material from which the blanks are made has been appropriately
chosen. The contents packed in such containers can be of any size
or shape and comprise one or more items of similar or different
size and shape. It has been found, however, that although the
dimensions of the arcuate panels of the blank may differ according
to the size of the blank, the curvature of the arcuate crease lines
in each arcuate panel are preferably identical in order that the
blank can be properly assembled.
[0117] If it is wished to pack products that, for any reason,
require fittings to be present within the container, for example,
to provide additional internal support to the contents, this can be
done either by means of separate fittings or by means of additional
panels at the extremities of the blank which be folded and formed
into fittings as the container is assembled.
[0118] The above-described embodiments disclose blanks for assembly
of containers secured by one or more locking tongues giving
security and tamper evident features. These features are beneficial
when the container is to be shipped for example by mail, as many
postal services require all packs either to have secure,
non-accidentally opening closures or to be secured by means of
adhesive or adhesive tape.
[0119] It will be understood that the number of locking tongues can
be varied according to the size and shape of the container and/or
the length of the edge to be closed. Locking tongues of any
suitable form can be used that provide evidence of opening or
tampering of the container. Such locking tongues are preferably of
arrow head shape which allows the tongue to be pushed through a
corresponding locking slot.
[0120] For some applications, however tamper-evident locking
tongues may not be required such as where the container is secured
with adhesive or adhesive tape and in this case quick locating
tongues (non arrow head type) can be used to hold the container
closed whilst it is taped or glued with adhesive.
[0121] Finally, it will be understood that features of each
embodiment described herein may be used separately or in
combination with any feature of the other embodiments to provide
blanks and containers erected from such blanks having the
advantages and benefits described herein. For example, in FIGS. 1
to 4, the roof panel E may be provided with one or more locking
tongues to be inserted in locking slots similar to FIGS. 5 to
11.
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