Note: Descriptions are shown in the official language in which they were submitted.
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Container
Background to the Invention
This invention relates to a container comprising a base and lid, each
made of stiff yet foldable sheet material, e.g. corrugated material. The
container is particularly, but not exclusively, suitable for containing food
produce such as, for example, fresh fish. The invention also relates to a
blank
of stiff yet foldable sheet material, e.g. corrugated material, which is
erectable
into a base of a container and to a packaging method.
Conventionally fish boxes, i.e. boxes used for the packing, storage
and dispatch of fish, have been made from wood or plastics material. Such
boxes are often filled on board deep-sea ~ trawlers and take up valuable deck
and storage space when not in use. These known fish boxes are relatively
expensive and, as such, are re-used after being cleaned. However, it is
difficult
effectively to clean such fish boxes to the requixed hygienic standards.
It is desirable for fish boxes to have good thermally insulating
properties so that fresh fish stored within the boxes ~do not become too hob
It is
difficult to provide relatively cheap,, thermally insulating fish boxes made
of
wood or plastics material.
It has been proposed in US-A-3,937,390 to manufacture a fish box
from corrugated board provided 'with a water-repellent impregnation. ~ In
particular, blanks of such impregnated corrugated board can be ~ stored on
board a crawler and' erected ' when required into fish boxes having single
thickness walls of the corrugated board. However although such a known fish
box overcomes many of the disadvantages °of fish boxes made of wood or
plastics mafierial, the thermally insulating properties of a fish box having
walls
of single thickness corrugated board could be improved.
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Summary of the Invention
It is an aim of the present invention to provide an easily erectable
container comprising a base and a top or lid having walls made of stiff yet
foldable sheet material and possessing improved thermally insulating
properties. It is also an aim of the invention to provide a container base
erectable from a blank of stiff yet foldable sheet material.
According to one aspect of the present invention there is provided a
blank made of stiff yet foldable sheet material erectable into a container
base,
comprising:
a rectangular bottom panel;
a pair of side wall panel means each comprising a first side wall panel
foldably connected to an associated side of the bottom wall panel so as to be
foldable upwardly therefrom to provide one layer of a side wall, a second
side wall panel foldably connected, to the first side wall panel so as to be
foldable over against 'the latter to provide a second layer of the side wall,
and end flaps foldably connected to opposite ends of the second side wall
panel;
a pair of end wall panel means each comprising a first end wall panel
foldably conrtected~ to an associated end of the bottom wall panel so as to be
foldable upwardly therefrom to provide one layer of an end wall, and a
second end wall panel foldably connected to the first end wall panel; and
foldable gusset means at each corner of the bottom panel connecting
opposite ends of each side wall panel means to opposite ones of said end
wall panel means;
whereby in the erected container base the two end flaps associated with each
end of the blank are folded against the associated first end wall panel to
provide a second layer of the end wall and the second' end wall panel of each
end wall panel means is folded over; for . connection to, the underlying end
flaps.
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A blank according to the invention enables a container base to be
erected having double thickness side and end walls thereby enhancing the
thermally insulating properties of the container base.
Conveniently, the second side wall panels are folded downwardly
outside the first side wall panels in the erected container in which case the
second end wall panels are also folded outside the first end wall panels.
However it is also possible for the second side wall panels to be folded
downwardly inside the first side wall panels and in this case the second end
wall panels would be folded downwardly inside the corresponding first end
wall panels.
In an embodiment of the invention more suitable for erection by a
machine, each end flap is shaped so as to overlap the other end flap of the
pair
when the blank is erected into as container base.
Suitably the' blank has means, such as adhesive means, for connecting
the second end wall panels to thewnderlying end flaps: Typically the adhesive
means comprises double-sided adhesive strip or tape one side of which is
adhered to the blank and the other side of which has a removable non adhesive
covering thereon: Suitably'the adhesive strip or tape is provided on the
second
end wall panels although; alternatively, it could be provided on the end
flaps.
In an alternative embodiment the means for connecting the second end wall
panels to the end flaps comprise a tab on the second end wall panel arranged
to
be tucked between the end flaps and the first end wall panel after the second
side wall panels are folded 'downwardly.
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Conveniently there is provided a further blank of stiff yet foldable
sheet material for a top of the container, the further blank having a
rectangular
top panel and, foldable downwardly therefrom, side wall panels and end wall
panels foldably connected to sides and ends, respectively, of the top wall
panel,
the side wall panels and end wall panels of the further blank being
connectible,
e.g, adhesively, to walls of the erected container base. By suitable
dimensioning of the side wall panels and the end wall panels of the further
blank, the folded down panels provide an additional layer of thickness for the
side and end walls of the container erected from the two blanks. Rectangular
blanks of any suitable material, e.g. the same material as the blanks or a
material having good thermally insulating properties, may be positioned on the
bottom panel of the erected container base and/or beneath the top panel when
the erected container is being closed by the container top.
Suitably the~sheet material of the~or each blank comprises corrugated
material, e.g. corrugated fibreboard or cardboard. ' Corrugated material, with
its cavities, has good thermally insulating properties and these thermally
insulating properties are considerably enhanced in an erected container having
walls of more than a single thickness ~ In the case of a fish box the
provision of
good thermal insulation is important since any ice added to the contents in
use,
e.g. whilst fish is ~being~ peeked on a trawler, will thaw less quickly the
better
the thermally insulating 'properties of the walls of the fish box. Typically,
the
sheet material will be' provided on both sides with a water resistant coating,
such as a plastics material and/or wax, or a laminated finish or may be
impregnated with water-repellent material. By way of example only, water-
repellent corrugated sheet material is described in US-A-5,626,945. The sheet
material, at least for the blank of . the container top, may have, on its side
destined to form the outside of the container, a reflective foil covering for
reflecting external heat and light radiation.
, , ,
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By using strips of adhesive material on the blanks to retain the
erected containers in their erected condition, the containers can be erected
on-
site without the use of container erecting machinery.
5 At least one hole may be arranged in the blank to provide drainage in
the erected base. For example, a hole in the stiff yet foldable sheet material
may
have at least one fluid resistant film applied over its periphery such as to
allow
fluid to flow through the hole without exposing the periphery to the fluid. In
particular, a first layer of fluid resistant film may be applied to a first
side of the
blank and a second layer of fluid resistant film may be applied to a second
side
of the blank, the first and second layers of film having mutually coincident
apertures which allow fluid to flow through the hole.
According to another ° aspect °of the present invention
there is
provided a container base erected from a blank according to said one aspect of
the present invention.
A set of blanks' 'according to a further aspect of the invention
comprises a base blank as described above and a lid blank erectable to into a
lid
sized to fit the container base, the' second end wall panel of each end wall
panel
means being arranged to be spaced from the first end wall panel in the erected
base so as to engage .an end panel of the ~ lid when the latter is fitted to
the
erected base to keep the lid so fitted.
The second end wall panel of the base blank, and said end panel of
the lid blank, may in particular be sized to pass fully~past one another on
fitting
the erected lid to the erected ba'se~ said end panel of the lid blank then
engaging
below a bottom edge of said second end wall panel.
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The container may be provided with an absorbent pad or member
positioned inside the base on top of the bottom panel. The purpose of such an
absorbent pad is to absorb liquid material, such as melted ice and blood from
the stored contents, e.g. fish, inside the container base when the latter is
in use.
This is intended to prevent the stored contents from "floating" in the liquid
material. Ideally, the absorbent member is intended to fit closely inside the
container base, i.e. it will have substantially the same dimensions as the
bottom
panel so that there are gap or only small gaps between the positioned
absorbent pad and the side walls of the container base. Typically, the
absorbent pad comprises a liquid-impervious top layer and an absorbent
bottom layer, which may itself be several layers thick. In particular the
absorbent bottom layer may comprise corrugated cardboard material, layers,
e.g. from 3 to 5, of paper. The pad may incorporate a bactericide or other
substance for controlling~possibly harmful bacteria, such as salmonella,
listeria
and leionella.
According ;to a still further aspect of the present inventioii~ there is
provided a method of packaging products; such as food produce; comprising
erecting .a container base from a blarik~ according to said' one aspect of the
present invention, loading the container base with the products to be
packaged,
and closing the container base with a top formed from the said further blank.
An absorbent member may be positioned in the container base after erection of
the base and before loading the container base with products.
Brief Description of the Drawings
Embodiments of ~ the' invention ' will now be' described, by way of
example only, with particular reference to the accompanying drawings, in
which:
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Figure 1 is a plan of a first blank of stiff yet foldable sheet material
which can be erected to form a base of a container according to the
present invention;
Figure 2 is a plan of a second blank of stiff yet foldable sheet material
for a top of a container according to the present invention;
Figures 3 to 7 are schematic views not drawn to scale showing
various stages in the erection of the blanks shown in Figures 1 and 2
into a container;
Figure 8 is a plan of an alternative first blank of stiff yet foldable sheet
material which'can be erected'to form a base of a container according
to the.present invention;
Figure 9 is a plan of an alternative second blank of stiff yet foldable
sheet material for a top ~of 'a container according to the present
invention;
Figure 10 is a schematic view showing the use ~ of an absorbent
member in the container base;
Figure 11 is a plan of a further alternative first blank;
Figure 12 is a plan of a further alternative second blank for use with
the blank of Figure 11;
Figure 13 is a plan of yet a further alternative first blank;
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Figure 14 is a plan of yet a further alternative second blank for use
with the blank of Figure 13;
Figure 15 is a partially cut away view of a container according to the
invention having drainage holes; and
Figure 16 is a schematic sectional view of a drainage hole.
Detailed Description of Particular Embodiments
Figures 1 and 2 show container blanks, generally designated by the
reference numerals 1 and 2, made of stiff yet foldable sheet material. Blank 1
is
intended to be erected into a container base 3 and blank 2 is intended to form
a
container top 4 of a container 5for example a fish box, shown in Figupes 6 and
A particularly suitable material for the blanks 1 and 2 which has good
thermally insulating properties ~ is corrugated material, e.g. corrugated
fibreboard or corrugated cardboard, having a pair of spaced apart flat
parallel
outer liner sheets and one or more fluted or corrugated sheets between these
outer liner sheets. If more than one, e.g. two, fluted/corrugated sheets are
provided they are separated by one or more intermediate flat sheets. In
Figures
1 and 2 the blank is made from corrugated fibreboard comprising spaced apart
outer liner sheets which are hprovided with a water-resistant or water-
repellent
coating or lamination sandwiching ~ a single corrugated sheet, the flutes or
corrugations of the corrugated sheets extending in the directions of double-
headed arrow A. The blank 2 may be provided with a light and heat reflective
layer on its lower face, i.e. the face destined to form the outside of the
erected
container. In the blanks 1 and 2 fold lines are represented by dashed and
chain
lines, the dashed lines representing folds upwardly out of the plane of the
paper and the chain lines representing fold lines downwardly out of the plane
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of the paper. The fold lines are typically crease lines but may, for example,
be
full or partially perforated lines. Dotted portions of the blanks represent
parts
of the blank which are provided with adhesive means.
The blank 1 comprises a rectangular bottom panel 10 with a pair of
side wall panel means and a pair of end wall panel means joined thereto. Each
side wall panel means comprises a first side wall panel 11 (12) foldably
connected to a side 13 (14) of the bottom panel 10 and a second side wall
panel
(16) foldably connected to its associated first side wall panel 11 (12) along
10 fold line 17 (18). Each second side wall panel 15 (16) has end flaps or
panels 19
and 20 (21 and 22) foldably connected thereto about fold lines 23 and 24 (25
and
26), respectively.
Each end wall panel mean's comprises a first end wall panel 27 (28)
15 foldably connected to an end~29 (30) of the bottom panel, and a second end
wall
panel 31 (32) foldably connected to the first end wall panel 27 (28) about a
pair
of closely spaced apart fold lines 33,34 (35,36). As can be seen in Figure 1,
the
second end wall ~ panels 31 and 32 are ~ divided along fold lines 39 and 40,
respectively, into i_n_n_er and outer portions 37a, 37b and 38a, 38b. The
upper
face (as vie~red iri Figure 1) of the blank 1 has double-sided self adhesive
strips
41 and 42 provided on the portions 37b and 38b, respectively. These self
adhesive strips 41 and 42 are covered by removable non-adhesive release
covering strips. ~ Alternatively (not shown) it is possible not to divide the
second panels 31 and 32 by the fold lines 39 and 40 but instead to provide the
self adhesive strips 41 and 42 on the underside of the blank 1 (as viewed in
Figure 1).
At each of the four corners of the bottom panel there is a gusset
means generally designated 43-46, respectively, only one (gusset means 43) of
which will be described in detail hereinafter. The gusset means 43 comprises a
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pair of gusset panels 43a and 43b separated by a diagonal fold line 43c.
Gusset
panel 43a is foldably joined to the first end wall panel 27 about fold line
43d
and gusset panel 43b is foldably connected to the first side wall panel 11 and
the end panel 19 along fold lines 43e and 43f, respectively.
5
Figures 3 to 6 show various stages in the erection of an open-topped
container from the blank 1. Figure 3 shows initial stages of the folding of
one of
the side wall panel means and one of the end wall panel means relative to the
bottom panel 10. In Figure 4 it can be seen how the second side wall panels 15
10 and 16 are folded outwardly back against first side wall panels 11 and 12,
respectively to form double thickness side walls. From Figures 4 to 6 it can
be
seen how the end flaps or panels 19-22 and gusset means 43-46 are folded flat
against the outside of the respective first end wall panels 27 and 28 to form
at
least double thickness end Walls for' the open-topped container. In the final
stage of the erection of the open-topped' container; the release covering
strips
are removed from the self adhesive strips 41 and 42; the outer portions 37b
and
38b of the end wall panels 31 and 32 are folded back against the inner
portions
37a and 38a, respectively, of the end wall. panels'31 and 32 and the folded ~
over
panels 31, 37 and 32, 38 are pressed 'against the underlying end panels 19, 21
and 20, 22 to be adhered thereto by the self adhesive strips 41 and 42 (see
Figure 6).
The blank 2 comprises a rectangular top panel 50 having side panels
51 and 52 foldably joined to the top panel along sides 53 and 54,
respectively,
and end panels 55 and 56 foldably joined to the top panel along ends 57 and
58,
respectively. End flaps '59, 60 and 61, ~2 are foldably joined to opposite
ends of
the end panels 55 and 56, respectively. Double-sided adhesive tape is adhered
to opposite side regions ~of the blank 2'to provide parallel adhesive strips
63
and 64 on side panels 51 and 52, respectively, and parallel adhesive strips 65-
68
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on end flaps 59-62, respectively. As with blank 1, the outer adhesive layer is
covered by a suitable removable covering strip.
In order to close the open-topped container 3, the top 4 is erected
from the blank 2. Suitably the top is not pre-erected but instead is
positioned
with the top panel 50 over the top of the open topped container. The end
panels are then folded downwardly against the end walls of the container, the
covering scrip is removed from the adhesive strips 65-67 and the flaps 59-62
are
folded against, and adhered to, the side walls of the container. Finally, the
removable covering strips are removed from the adhesive strips 63 and 64 and
the side panels 51 and 52 are folded downwardly against, and adhered to, the
side walls of the container (see Figure ~.
Figures 8 and 9 show alternative first and second blanks respectively.
Reference numerals in Figures 8 and 9 correspond to those in Figures 1 to 7
but
with the addition of 100:
Figure 8 shows an alternative fist blank 101, which is largely similar
to the first blank 1 of Figure 1. The main difference is that the end flaps
119 to
122 of the alternative first blank 101 are elongated in the longitudinal
direction
of the blank. This means' that when the blank is erected into awcontainer, end
flaps 119 and 121 overlap and end flap's 120 and 122 overlap: This provides
additional strength ao the ends of the container and helps ~in preventing
buckling of the ends when the full container is pulled in a longitudinal
direction.
Figure 9 shows an alternative second blank 102 which comprises a
rectangular top panel 150 having side panels 151 and 152 foldably joined to
the
top panel along sides 153 and 154, respectively, and end panels 155 and 156
foldably joined to the top panelvalong ends 157~and 158, respectively. End
flaps
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159,160 and 161,162 are foldably joined to opposite ends of the side panels
151
and 152 respectively. Double-sided adhesive tape is adhered to opposite side
regions of the blank 102 to provide an adhesive strip 163 running along side
panel 151 and end flaps 159, 161, and a parallel adhesive strip 164 r~ynning
along side panel 152 and end flaps 160, 162. As with blank 101, the outer
adhesive layer is covered by a suitable removable covering strip.
In order to close an open-topped container erected from the blank
102, a top is erected from the blank 102. Either the top may be pre-erected or
the blank 102 may be positioned with the top panel 150 over the top of the
open
topped container. The end panels 155,156 are then folded downwardly against
the end walls of the container. The covering scrip is removed from the
adhesive strips 163, 164 and the side panels 151, 152 are folded' downwardly
against, and adhered to, the side walls of the container. The end flaps 159-
162
are then folded against; and adhered to, the end panels 155,156.
In the closed container according to the invention the side and end
walls provided by'the open topped container and 'the lid or top each have at
least three thicknesses of blank material to provide good thermal insulation
to
any contents of the °container. 'Typically, in use, the open topped
container
would be packed with suitable products, such as fresh fish and optionally also
ice, and would be closed by the'top erected from the blank 2 or 102. ~If used
on
site on a trawler or the like; the blanks 1 and 2 or 101 and 102 can be kept
in
their unerected flat storage condition until a container is required to be
used.
Storage space is therefore not taken up by erected, non filled containers.
One particular advantage of the erected open-topped container is that
the construction is intended to protect any open ended flutes of the
corrugated
sheet material from contact/exposure to ice or water when it is being packed.
Normally during packing ice is thrown 'in ~ on top of the packed contents in a
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haphazard manner. However, as can be seen in the drawings, there is a
minimum of exposure of the edge fluting with inner and outer protective layers
throughout the design. In particular, none of the upper edges of the
upstanding walls has exposed edge fluting.
Conveniently, an absorbent member 70 (see Figure 10) may be
positioned in the bottom of the erected open-topped container before the
container is filled with products. The absorbent member 70 has a liquid-
impervious, e.g. plastics, top layer 71 and an absorbent bottom layer 72
typically comprising a number, e.g. from 3 to 5, layers of paper, one or more
layers of corrugated cardboard or other absorbent material. The purpose of the
absorbent member ~0 is to provide an absorbent pad at the bottom of the
container for absorbing liquids; e.g. melted ice and blood from stored produce
such as fish, to prevent the stored product fram ~"swimming" in fluid.
Ideally,
the absorbent member 70 is sized to be similar to the bottom of the container
so
that there are no gaps, or only ~ small gaps, between the edge of the
absorbent
pad and the walls of the container. The liquid-impervious top layer 71
provides a virtually dry surface or barrier on which the product to be
packaged
is supported. The absorbent member or "pad" may incorporate a bactericide
for controlling possible ~ harmful bacteria, such as salmonella, listeria .
and
leionella. The bactericide or~ other substance may be impregnated in the paper
or incorporated in glue or other material of the absorbent pad.
Figure 11 shows a further alternative first blank 201, which is largely
similar to the blank 101 of Figure 8. However second end wall panels 231, 232
of the blank of Figure 11 ~ are wider than'the corresponding second end wall
panels of Figure 8. Additionally tabsw280, 281 are provided at the centre of
the
free edges of the second end wall panels 231, 232 respectively. When the
container base is . erected tab 280 is tucked underneath the overlapping
bottom
edges of end flaps 220 and 222 and tab 281 is tucked underneath the
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overlapping bottom edges of end flaps 219 and 221 to secure the second end
wall panels in place.
Figure 12 shows a further alternative lid blank 202. This has panels
which correspond to those of the lid blank 102 of Figure 9 (and designated by
reference numerals with the addition of 100). However in the lid blank of
Figure 12, triangular corner pieces 285 connect end panels 255, 256 to end
flaps
259-262. Also, the end flaps 259-262 are elongated. End tabs 290, 291 are
provided on second end wall panels 292, 293 of the lid blank which are
connected by crease lines to the first end wall panels 255, 256 respectively.
In erecting a lid from the lid blank 202, the side wall panels 251, 252
and the end wall panels 255, 256 are folded downwardly from the top panel
250. The end flaps 259-262 and triangular pieces 285 are folded to create
gusseted corners thus preventing leakage even when the closed container is
inverted. Tn contrast to the end flaps 219 222 of the base which are folded
outside the first end wall panels thereof, the end flaps 259-262 of the lid
blank
are folded inside the first end wall panels 255; 256: Second end wall panels
292,
293 are then folded inwardly and upwardly over the end flaps 259-262 and tabs
290, 291 are tucked over and behind the end flaps.
On fitting a lid erected from the blank 202 to a base erected from the
blank, the second end wall panels 231, 232 of the base press against the
second
end wall panels 292; 293 of the lid and provide a tight fit.
Figures 13 and 1:4 show base 'and lid blanks respectively having an
enhanced engagement' between the ° lid and base when erected. Tn this
embodiment of the invention the second end wall panels 331, 332 of the base
and the second end wall. panels 392, '393 of the lid are narrower than the
corresponding panels shown in Figures 11 and 12. Also the base end flaps 319-
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322, and the outermost parts of the lid end flaps 359-362 are narrower so that
tabs 380, 381, 390, 391, can still be tucked therebehind respectively.
A lid erected from the blank of Figure 14 has its second end wall
5 panels 392, 393 extending upwardly inside the first end panels 355, 356 over
only a part, for example about half, of the height thereof. Similarly a base
erected from the blank of Figure 13 has its second end wall panels 331, 332
extending upwardly inside the first end panels 355, 356 over only a part, of
the
height thereof, preferably about the same extent as the part of lid first end
10 panels 355, 356 which are not covered by lid second end wall panels 331,
332.
Thus, when the lid is fitted to the blank, there is a positive latching
between the
second end wall panels 331, 332 of the base, and the second end wall panels
392, 393 of the hd as the former move into° the space above the latter
and vice
versa.
In machine-erecta~ble versions (not shown) of the blanks 201, 202, 301
and 302 the end tabs ~ 280, 281, 290, 291, 380, 381, 390, 391 are omitted and
securing of the second end wall 'panels could be achieved solely by adhesive
means.
It is often desirable to allow drainage of fluid, such as melt water
resulting from ice packed around produce in the container. To this end
drainage holes may be provided. For example, as shown in Figure 15, drainage
holes 95 can be provided at the crease between the bottom panel and the walls
(here the end walls) 'of the container base. Simply providing a hole in the
corrugated sheet material may be unacceptable because of the possible ingress
of fluid into the flutes of the material. Thus, water resistant films,
preferably in
the form of adhesive patches 96~ having drainage apertures 97, are applied to
the holes. As shown in Figure 16, the patches 96 are applied~to both sides of
the
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blank and prevent fluid reaching the edges of the holes 95 that would
otherwise be exposed.
If desired additional flat, rectangular thermally insulating blanks (not
shown) may be positioned in the bottom of the erected open topped container
before the latter is filled with products and on top of the filled container
just
before the lid is fitted over the container. In this way, additional thermally
insulating layers can be provided on the bottom and top of the container.
The provision of a light and heat reflective layer, at least on the
surface of the blank 2, 102, 202 or 302 destined to form the outside of the
lid or
top, improves the thermal insulating properties of the top.
Although corrugated fibreboard/cardboard is the presently preferred
material for the enclosure it may be made, for example, of double skinned
fluted polypropylene copolymer or of other stiff yet foldable sheet material
which may or may not be' corrugated or 'fluted and which may comprise
plastics materials; e.g. EVA (ethylene vinyl acetate), EPS (polyform) or PVC.
According to a further aspect of the invention there is provided an
absorbent pad for inclusion in a fish box or other food product box and
incorporating a bactericide.
