EP1992564A1

EP1992564A1 - Container having reinforced corners

Info

Publication number: EP1992564A1
Application number: EP07252022A
Authority: EP
Inventors: Catherine c/o SCA Packaging Jeff
Original assignee: SCA Packaging Ltd
Current assignee: SCA Packaging Ltd
Priority date: 2007-05-17
Filing date: 2007-05-17
Publication date: 2008-11-19
Anticipated expiration: 2027-05-17
Also published as: EP1992564B1

Abstract

A container is disclosed having corner supports 30 at each inside corner for increasing the strength and weight bearing capacity of the corners. The container is formed from a blank comprising flaps 18 which are configured to automatically form the corner supports 30 when they are folded in to make the corners of the container. The flaps 18 comprise a first portion 18a hingedly connected to a second portion 18b such that the second portion 18b extends across the corner to form the corner support 30 when the flap 18 is folded in.

Description

The present invention relates to a container, such as a box or tray, which is structurally reinforced at its corners.
A container is generally formed from interconnecting side walls and at least a base wall. In order to strengthen the container, particularly for stacking purposes, it is known to reinforce each of the corners, typically by forming triangular posts at the corners. These triangular posts make the corners of the box more rigid and resistant to collapse under compression.
However, conventional methods of forming triangular posts at the inside corners of a container complicate the manufacturing and construction processes.
Therefore it is desired to provide an improved container, an improved blank for forming a container and an improved method of constructing a container.
From a first aspect the present invention provides a container comprising a flap having a first flap portion having a first end hingedly connected to an end of a first wall of the container about a first fold line, and a second flap portion hingedly connected to said first flap portion about a second fold line so as to extend beyond said first fold line, such that when said first flap portion is folded inwardly with respect to said first wall, said second flap portion rotates about said second hinge line to form a corner support across the corner of the container.
Thus the second flap portion is configured such that it automatically forms a corner support when the first flap portion is folded to form a part of the main body of the container. This avoids the need for a separate corner support forming operation, thereby greatly simplifying the manufacturing and construction of the container.
According to a preferred embodiment, the second flap portion is hingedly connected to the first flap portion about the second fold line such that when the first flap portion is arranged coplanar with the first wall (i.e. before the first flap portion is folded inwardly) the second flap portion extends beyond the first fold line.
According to the preferred embodiment, the first flap portion is configured to be folded to form at least part of a second wall of the container. The second flap portion then automatically forms a corner support on the inside corner between the first and second walls of the container.
According to the preferred embodiment the second hinge line, which connects the first and second flap portions, is outwardly displaced (i.e. in a direction away from the first wall) from the first fold line connecting the first flap portion and the first wall.
According to the preferred embodiment, the second flap portion has an inner free end that remains unattached such that as the first flap portion is folded inward, the inner free end of the second flap portion rides along the inner side of the first wall until the first flap portion has been folded to its desired position.
According to the preferred embodiment, the first and second flap portions are formed integrally, i.e. from the same continuous piece of material. Preferably, therefore, the first and second portions of the flap are formed from a single panel of material, suitably folded. The first and second portions of the flap may be formed by folding the flap panel in on itself about a third fold line, which may form a distal end of the first flap portion, to form inwardly and outwardly extending portions of the flap. The inwardly extending portion is longer than the outwardly extending portion such that the second flap portion extends beyond the first fold line connecting the first flap portion and the first wall.
The inwardly extending portion of the flap panel is formed with the aforementioned second fold line so as to form the second portion of the flap between the second fold line and the inner free end of the inwardly extending portion.
The above mentioned second and/or third fold lines are preferably provided by intermittently cutting the flap panel.
The inwardly extending and outwardly extending portions of the flap panel are preferably fixedly connected to each other between the second and third fold lines, preferably by an adhesive.
In an alternative, less preferred embodiment, instead of the flap being formed from a single panel the second portion of the flap may be a separate piece of material suitably secured to the first portion of the flap.
In the preferred embodiment, the container is configured to have at least one removable and/or incomplete, partial wall. For example, the container may have a removable lid formed from a removable portion of the top wall. In a preferred embodiment the removable lid is also formed from a removable portion in at least one of the side walls. Corner supports according to the present invention are particularly advantageous in these embodiments because if any of the walls are only partial walls, or once the removable portions of the wall(s) have been removed, a larger proportion of any forces exerted on the box must be supported at the corners.
Although only a single corner of the container has been described above, corner supports may be provided in more than one or in all of the corners of the container according to the present invention. Further, corner supports may be provided in corners between internal and/or external walls of the container. Corner supports may also be provided in the corners between side walls and the top and/or base walls.
From another aspect the present invention provides a blank for erection into a container, said blank comprising a flap having a first flap portion having a first end hingedly connected to an end of a first wall panel about a first fold line, and a second flap portion hingedly connected to said first flap portion about a second fold line so as to extend beyond said first fold line, such that when said first flap portion is folded inwardly with respect to said first wall panel, said second flap portion rotates about said second hinge line to form a corner support across the corner of the container.
The blank of the present invention is preferably a one-piece blank formed from a single sheet of material.
The container and blank of the present invention are preferably formed from cardboard, paperboard, plastic or any other foldable sheet material.
From another aspect the present invention provides a method of forming a container from a blank, said blank comprising a flap having a first flap portion having a first end hingedly connected to an end of a first wall panel about a first fold line, and a second flap portion hingedly connected to said first flap portion about a second fold line so as to extend beyond said first fold line, said method comprising folding said first flap portion inwardly with respect to said first wall panel so that said second flap portion rotates about said second hinge line to form a corner support across the corner of the container.
A preferred embodiment of the present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

Fig. 1 shows a prior art tray having reinforced corners;
Fig. 2A shows a box according to a preferred embodiment of the present invention, Figs. 2B and 2C show the box of Fig. 2A when partially constructed;
Figs. 3A-3C show views of an inside corner region of the box at different stages during construction of the box;
Figs. 4A-4E show a preferred embodiment of the blank for forming the box at different stages during the construction of the box; and
Figs. 5A-5E show a preferred embodiment of the box at different stages as the lid is being removed.

Although the preferred embodiment is described herein in relation to a box it will be appreciated that the present invention is equally applicable to other types of containers, such as trays. The differences between a container according to the preferred embodiment and conventional containers will now be illustrated by referring to the conventional tray shown in Fig. 1.
Fig. 1 shows a prior art tray having reinforced corners 2. The tray has four side walls 3 and a base wall 4. In order to strengthen the corners 2 of the tray additional support panels 5 have been adhered to the pairs of interconnecting side walls 3 forming the corners 2 of the tray. It will be appreciated that the subsequent addition of support panels 5 to the main body of the tray complicates the construction process.
Figs. 2A-2C show a box according to a preferred embodiment of the present invention at various stages during construction. Fig. 2A shows the box when fully constructed. The box comprises a front wall 6, a back wall 7, left 8 and right 9 end walls, a base wall 4 and a top wall 10. The front wall 6 is provided with a cut out portion 12 and the front 6 and top 10 walls are provided with lines of weakness 14 forming a removable lid 15, as will be described in more detail below.
Fig. 2B shows a view of the box of Fig. 2A at the stage of construction before the end wall flaps 18 and end wall panels 8a,8b,9a,9b have been folded in to form the left 8 and right 9 end walls of the box.
Fig. 2C shows a view of the box of Fig. 2B at the stage where the left end wall flaps 18 and end wall panels 8a,8b have been folded in to form the left end wall 8 and the right end wall flaps 18 are being folded in. As will be described below with reference to Figs. 3A-3C the step of folding in the end wall flaps 18 automatically creates corner supports inside the corners between the end walls 8,9 and the front and back walls 6,7.
Figs. 3A-3C show views of the inside of the back, bottom left hand corner region of the box at three different stages during folding in of the left end wall flaps 18 and end wall panels 8a,8b to form the left end wall 8.
Fig. 3A shows a view of the box at the stage where the back, left end wall flap 18 is just being folded in. It can be seen from this view that the end wall flap 18 is hingedly connected to the back wall 7 along a first fold line 22. The end wall flap 18 comprises a first portion 18a extending outwardly away from the fold line 22 between the end wall flap 18 and the back wall 7 and a second portion 18b which is hingedly connected to the first portion 18a along a second fold line 28. The second fold line 28 is provided parallel to and outwardly displaced from the first fold line 22, i.e. displaced in a direction away from the end of the back wall 7 and towards the free end of the end wall flap 18. The second flap portion 18b extends inwardly beyond the first fold line 22 and terminates at a free, unattached end 23.
Fig. 3B shows a view of the box corresponding to that of Fig. 3A except wherein the end wall flap 18 has been partially folded inwards during construction of the left end wall 8 of the box. As the second flap portion 18b extends inwardly beyond the first fold line 22 (connecting the end wall flap 18 and the back wall 7), when the end wall flap 18 is folded in the free end 23 of the second flap portion 18b rides along the inside surface of the back wall 7. Also, because the second flap portion 18b is hingedly connected to the first flap portion 18a along the second fold line 28 (that is outwardly displaced from the first fold line 22) the attached end of the second flap portion 18b is pulled away from the back wall 7 in a direction perpendicular to the back wall 7 as the flap 18 is folded in. In other words, due to the configuration of the end wall flap 18, as the flap 18 is folded in the second flap portion 18b is drawn at an angle to the back wall 7 and the first flap portion 18a.
As shown in Fig. 3C, when the end wall flap 18 is folded in to form part of the left end wall 8 the second flap portion 18b extends across the inside corner of the box to form a corner support 30. This corner support 30 increases the weight bearing capacity of the corners of the box. All four end wall flaps 18 are folded in to form corner supports 30 at each corner. Fig. 3C also shows the box at the stage where the left end wall inner panel 8a has been folded upwards to form part of the left end wall 8.
Figs. 4A-4C show an embodiment of a blank used to construct the box at three different stages during formation of the end wall flaps 18. The blank comprises a front outer wall panel 6a, a top wall panel 10a, a back wall panel 7a, a base wall panel 4a and a front inner wall panel 6b. The blank also comprises left and right outer wall panels 8b,9b, left and right inner wall panels 8a,9a and flap panels 18c for forming the left and right end wall flaps 18. Fold lines are provided between each of the above-mentioned panels so as to enable the blank to be folded into a box. The top wall panel 10a, front outer wall panel 6a and front inner wall panel 6b comprise intermittently cut lines 14 for forming removable portions 16a,16b,16c which will be described in more detail below. The front outer 6a and inner 6b wall panels also comprise cut out portions 12 for assisting the removal of the removable portions 16a,16b,16c.
Fig. 4A shows the blank prior to the formation of the end wall flaps 18. The panels 18c for forming the end wall flaps 18 are connected to the back wall panel 7a and the front inner wall panel 6b along first fold lines 22. Each flap panel 18c is provided with a second fold line 28 and a third fold line 38, which are parallel to the first fold line 22. The second 28 and third 38 fold lines may be weakened by intermittently cutting the flap panel 18c so as to make it easier to fold. The third fold line 38 is provided closer to the back wall panel 7a (or front inner wall panel 6b) than the free end of the flap panel 18c.
As shown in Figs. 4B and 4C the flap panel 18c is folded about the third fold line 38 so as to provide an outwardly extending portion between the first 22 and third 38 fold lines and an inwardly extending portion between the third fold line 38 and the free end of the flap panel 18c. The outwardly and inwardly extending portions are arranged to be on the outside and inside of the box respectively. The inwardly extending portion is longer than the outwardly extending portion and includes the second fold line 28. The second fold line 28 hingedly connects the second flap portion 18b to the first flap portion 18a and allows the free end of the second flap portion 18b to pivot relative to the rest of the flap 18. The second flap portion 18b extends inwardly beyond the first fold line 22 connecting the flap panel 18c and the back wall panel 7a (or the front inner wall panel 6b). The second fold line 28 is arranged such that when the blank is laid flat, as in Fig. 4C, it is parallel to and outwardly displaced from the first fold line 22. The inwardly extending portion of the flap panel 18c is adhered to the outwardly extending portion of the flap panel 18c between the first 22 and third 38 fold lines.
Fig. 4D shows the blank of Fig. 4C at the next stage of construction of the box. At this stage the front inner wall panel 6b is folded onto the base panel wall 4a and then the top wall panel 10a and front outer wall panel 6a are folded in over the front inner wall panel 6b, base wall panel 4a and back wall panel 7a to the position shown in Fig. 4E. The removable portions 16a,16b,16c and the cut out portions 12 in the front inner wall panel 6b and the front outer wall panel 6a are arranged to coincide with each other. However, the removable portion 16b in the front outer wall panel 6a is arranged to extend to a lower point in the front wall 6 than the removable portion 16c in the front inner wall panel 6b for reasons which will be discussed further below. The front inner wall panel 6b is adhered to the front outer wall panel 6a at least in regions outside of the removable portions 16b,16c.
The folded blank is then erected into the partially enclosed box as shown in Fig. 2B. The end wall flaps 18 are then folded in so as to automatically form the corner supports 30 as has been described above with reference to Figs. 3A-3C.
The end wall inner panels 8a,9a are then folded in. The end wall inner panels 8a,9a are connected to the base wall panel 4a by a fold line. The sides of the end wall inner panels 8a,9a taper inwardly towards a rectangular portion arranged at their free ends. The rectangular portions are sized and shaped so as to fit in between the top wall panel 10a of the box and the end wall flaps 18 once they have been folded in. The rectangular portion may be provided with a fold line 40 parallel to the free end of the panel 8a,9a. This enables the free end of the end wall inner panel 8a,9a to fold in between and be flush with the end wall flaps 18. This configuration enables the end wall outer panels 8b,9b to be folded in over the end wall inner panels 8a,9a more easily. The end wall outer panels 8b,9b are then adhered to the end wall inner panels 8a,9a so as to complete the end walls 8,9 of the box.
Figs. 5A-5E show the box at various stages during the removable and storage of its lid 15. As described above, the removable lid 15 is formed by the removable portions 16a,16b,16c in the top wall panel 10a and the front inner 6b and outer 6a wall panels. The user may firstly put their finger through the cut out portions 12 in the front inner 6a and outer 6b wall panels. The user is then able to pull the removable portions 16b, 16c of the front inner 6b and outer 6a wall panels outwards breaking those panels along the lines of weakness 14. As seen in Figs. 5A-5E the removable portion 16c in the front inner wall panel 6b does not extend as far down the front wall 6 as the removable portion 16b in the front outer wall panel 6a. This is advantageous in that if the front wall 6 is subjected to external forces, e.g. during transport, then the front inner wall panel 6b prevents the removable portion 16b of the front outer wall panel 6a from being pushed inwards and accidentally opening the box.
Once the front wall portion of the lid 15 has been removed this portion can then be used as a tab to pull up and remove the removable portion 16a in the top wall 10 of the box as shown in Figs. 5B-5D. The removable portion 16a in the top wall 10 may be configured so that regions of the top wall 10 remain at the corners of the box above the corner supports 30.
As shown in Figs. 5D and 5E the removable portion 16a of the top wall 10 remains attached to the box along a portion of the back wall 7. The removable portion 16a may have a fold line 44 arranged parallel to and between the front wall 6 and back 7 wall (i.e. before the lid 15 has been removed) so as to allow the lid 15 to fold as shown in Fig. 5E to form a header 48 for the box. The removable portion 16a is configured such that recesses 46 are provided in the remaining portions of the top wall 10 adjacent to the hinge which connects the removable portion 16a and the back wall 7. These recesses 46 are configured to receive a portion of the lid 15 so as to maintain the box in an open position as shown in Fig. 5E.

Claims

A container comprising a flap having a first flap portion having a first end hingedly connected to an end of a first wall of the container about a first fold line, and a second flap portion hingedly connected to said first flap portion about a second fold line so as to extend beyond said first fold line, such that when said first flap portion is folded inwardly with respect to said first wall, said second flap portion rotates about said second hinge line to form a corner support across the corner of the container.
A container as claimed in claim 1, wherein the first flap portion is configured to be folded to form at least part of a second wall of the container.
A container as claimed in claim 2, wherein the second flap portion automatically forms a corner support on the inside corner between the first and second walls of the container when said first flap portion is folded inwardly.
A container as claimed in claim 1, 2 or 3, wherein the second hinge line is outwardly displaced from the first fold line.
A container as claimed in any preceding claim, wherein the second flap portion has an inner free end that remains unattached such that as the first flap portion is folded inward, the inner free end of the second flap portion rides along the inner side of the first wall.
A container as claimed in any preceding claim, wherein the first and second flap portions are formed integrally.
A container as claimed in claim 6, wherein the first and second portions of the flap are formed by folding a flap panel in on itself about a third fold line to form inwardly and outwardly extending portions of the flap.
A container as claimed in claim 7, wherein the inwardly extending portion of the flap panel includes said second fold line so as to form the second portion of the flap between the second fold line and an inner free end of the inwardly extending portion.
A container as claimed in claim 8, wherein the inwardly extending portion is longer than the outwardly extending portion such that the second flap portion extends beyond the first fold line.
A container as claimed in claim 8 or 9, wherein the inwardly extending and outwardly extending portions of the flap panel are fixedly connected to each other between the second and third fold lines.
A container as claimed in any preceding claim, comprising at least one removable and/or incomplete wall portion.
A blank for erection into a container, said blank comprising a flap having a first flap portion having a first end hingedly connected to an end of a first wall panel about a first fold line, and a second flap portion hingedly connected to said first flap portion about a second fold line so as to extend beyond said first fold line, such that when said first flap portion is folded inwardly with respect to said first wall panel, said second flap portion rotates about said second hinge line to form a corner support across the corner of the container.
A method of forming a container from a blank, said blank comprising a flap having a first flap portion having a first end hingedly connected to an end of a first wall panel about a first fold line, and a second flap portion hingedly connected to said first flap portion about a second fold line so as to extend beyond said first fold line, said method comprising folding said first flap portion inwardly with respect to said first wall panel so that said second flap portion rotates about said second hinge line to form a corner support across the corner of the container.