GB2463881A

GB2463881A - Fold-flat paper-based container

Info

Publication number: GB2463881A
Application number: GB0817577A
Authority: GB
Inventors: Colin Jones; John Kirkby; Natalie Turner; Steve Battle
Original assignee: BILLERUD SALES Ltd; Billeruds AB; Billerud AB
Current assignee: BILLERUD SALES Ltd; Billeruds AB; Billerud AB
Priority date: 2008-09-25
Filing date: 2008-09-25
Publication date: 2010-03-31
Also published as: EP2326563B1; WO2010034772A1; GB2463881A8; EP2326563A1; GB0817577D0

Abstract

The container (300) comprises a rectangular base portion 310; and first and second pairs of opposing side walls 320a, 320b and 330a, 330b, respectively, extending from the perimeter of the base portion and defining an enclosed volume therebetween. The upper portion 305 of the first and second pair of opposing side walls are foldable to form the container into a substantially cuboid shaped enclosure when in the closed configuration, via a gusset end arrangement where the upper portions of the first pair of side walls 320a, 320b each comprise a square section 365 having fold lines 350a, 350b (150a, 150b, Fig. 1) extending between a centre point 366 (166, Fig. 1) and opposing lower corners 367a, 367b (167a, 167b, Fig.1) of the square section. Integral handles (210, Fig.2) may be formed on the second pair of side walls (220a, 220b, Fig.2), or alternatively a handle 370 may extend from one of the second pair of side walls 330b and, in use, be threaded through a slot (380, Fig.4) on the other of the second pair of side walls 330a. The upper portion 305 may be reinforcing layer.

Description

CON TAI NER

The invention relates to fold-fiat packaging, and n particular to containers n the form of closable bags.

Types of packaging in the form of foldable paper and cartonboard containers may range from simple paper bags for low value items and carry-out items to complex machine-folded cartonboard containers for higher value items and enhanced point of sale display.

Current non-plastics based packaging solutions for products such as take-away food items include cartonboard packaging in the form of a rectangular box having foldable side walls, typically with a handle incorporated into a lid portion. The lid portion is typically formed by folding side wall portions of the box inwards towards each other, with an arrangement to engage the portions with each other when closed. Such solutions can be suitable for both on-shelf display purposes and for a customer to carry away.

One particular problem with cartonboard packaging solutions relates to the weight and cost of the packaging itself, which is typically substantially greater than equivalent paper or plastics packaging. Lighter and cheaper paper-based packaging solutions are however not generally acceptable, due to the requirements for an attractive shelf appearance and for sufficient strength to withstand the weight of the items contained. A typical paper bag solution would comprise a flat folded and glued base and either an open top with attached handles or a folded over top, possibly secured with glue or an adhesive strip. Although such paper bag solutions would serve the purpose of containing items, these would generally not be ideally suited for on-shelf display purposes, where a uniform appearance and form is required.

It would consequently be advantageous to be able to combine some of the advantages of a lightweight paper-based product while retaining at least some of the aesthetic appearances of cartonboard packaging.

It is an object of the invention to provide a paper-based packaging solution that avoids the problems of cartonboard packaging while retaining strength and an aesthetic appearance suitable for point of sale applications.

According to the invention there is provided a fold-flat paper-based container comprising: a rectangular base portion; and first and second pairs of opposing side walls extending from the perimeter of the base portion and defining an enclosed volume therebetween, an upper portion of the first and second pair of opposing side walls being foldable to form the container into a substantially cuboid shaped enclosure in a closed configuration, wherein the upper portions of the first pair of side walls each comprise a square section having fold lines extending between a centre point and opposing lower corners of the square section.

Because the container comprises a foldable upper portion in the form of square sections that are foldable along diagonal fold lines, the article can be easily and simply transformed from an open configuration, in which articles to be contained can be loaded and removed, and a closed configuration suitable for both on-shelf display and for being carried away by a customer.

The upper edges of each of the container side walls in the open configuration are preferably contiguous with each other, i.e. are not split into separate foldable sections as in prior cartonboard solutions. Transition from the open configuration to the closed configuration is achieved by collapsing the first pair of side walls inwards towards each other, which causes the second pair of side walls to fold together as they are brought inwards towards each other when folded into the closed configuration.

The fold lines on the upper portions of the first pair of side walls can extend between the lower corners and opposing upper corners of the square section through the centre point, thereby forming diagonal cross-shaped fold lines across the upper sections of the first pair of side walls. The side walls can thereby fold inwards from the open configuration to the closed configuration to form a substantially cuboid-shaped package.

The second pair of side walls may comprise a handle for carrying the article when in the closed configuration. The handle may be of various types, one type being formed from matching cut-out handles in each of the second pair of side walls. Alternatively, a handle may be provided on a first one of the side walls and a slot on a second one of the side walls, the slot being configured to receive the handle such that the handle extends through the slot in the closed configuration. This alternative configuration provides for additional security and strength in the packaging, because the box is prevented from being inadvertently opened when being carried.

For further security, the upper portion of one or both of the second pair of side walls may comprise a reinforcing layer extending across the upper portion. This reinforcing ayer adds strength and stiffness to the square section of the upper portion of one or both of the second pair of side walls, which a'so provides for an improved shelf appearance. The reinforcing layer is preferably composed of cartonboard.

The side walls of the container are preferably composed of paper, having a weight of preferably between 60 and 200 g!m2. For improved strength and aesthetic appearance, the paper is preferably composed of primary, or virgin, fibre, also known as kraft' paper.

The invention will now be described by way of example, and with reference to the enclosed drawings in which: figure 1 shows a perspective view of a bag according to a first embodiment in an open configuration; figure 2 shows a perspective view of the bag of figure 1 in a closed configuration; figure 3 shows a perspective view of a bag according to a second embodiment in an open configuration; figure 4 shows a perspective view of the bag of figure 3 in a partially closed configuration; figure 5 shows a perspective view of the bag of figures 3 and 4 in a further partially closed configuration; and figure 6 shows a perspective view of the bag of figures 3 to 5 in a closed configuration.

A first exemplary embodiment of a fold-fiat paper-based container according to the invention is shown in figure 1. The container 100 comprises a base portion 110, a first pair of opposing side walls 120a, 120b and a second pair of opposing side walls 130a, 130b extending from the base portion 110 and joined along edges 170a-d. Diagonal and vertical fold lines 140a, 140b are provided on a lower portion and along a central line of the first pair of side walls 120a, 120b to allow the container 100 to be stored in a folded flat configuration before use, as for a conventional paper bag. The container 100 is shown in an open configuration in figure 1, in which it can be filled or emptied of its contents.

A square section 165 (shown in perspective in figure 1) on an upper portion of each of the first pair 120a, 12Db of side walls is defined by a horizontal fold me 160, upper portions of edges 170a-d joining the first and second pairs of side walls 120a, 120b, 130a, 130b above the horizontal fold line 160 and an upper edge 180a-d of each side wall. The diagonal fold lines 140a extend between a centre point 166 of the square section 165 towards opposing lower corners 167a, 167b.

Collapsing the square section 165 of each of the first pair 120a, 120b of side walls by folding the section inwards along the diagonal fold lines 150a, 150b and the horizontal fold line 160 allows the container to transform into a substantially cubod shaped enclosure shown in figure 2. In this embodiment, handles 210 are provided as matching cut-outs in upper portions of each of the second pair 130a, 130b of side walls, the handles 210 meeting when the container 100 is in the closed configuration shown in figure 2. The upper portions of the side walls are shown in figure 2 in a slightly opened configuration, although the container can be held firmly closed by use of glue points or adhesive strips for security when on a shelf. Advantageously, the upper portions 220a, 220b of the second pair of side walls 130a, 130b can be folded along a horizontal fold line 230 to allow the container 100 to be reduced in height, for example when placed in a restricted height shelf location.

A second embodiment of a container 300 according to the invention is illustrated in figure 3. The lower portion of the container 300 is constructed similarly to that shown in figures 1 and 2, i.e. with a base portion 110 and first and second pairs of opposing side walls 320a, 320b, 330a, 330b. Similarly, diagonal and vertical fold lines 340a, 340b are provided on the first pair of side walls 320a, 320b to allow the container to be stored in a folded flat configuration.

As for the container 100 of figures 1 and 2, diagonal fold lines 350a, 350b are provided in the first pair of side walls 320a, 320b extending from a centre point 366 of an upper square section 365 of the side walls 320a, 320b. In this embodiment, the diagonal fold lines 350a, 350b extend across the square section 365 between opposing lower corners 367a, 367b and corresponding opposing upper corners 368a, 368b of the square section 365. This configuration allow the upper portion 305 of the container 300 to collapse in a different way to that of the embodiment of figures 1 and 2, as described below with reference to figures 4, 5 and 6.

A handle 370 may be provided on one of the second pair of side walls 330b, with a corresponding slot 380 (shown in figure 4) provided in the other of the second pair of side walls 330a, through which the handle can be extended in the closed configuration, as described below. The handle 370 may be provided as a folded part of a cartonboard reinforcing element attached to the upper portion of the sde wall 330b.

The handle 370 and corresponding slot 380 are shown in figures 3-5 oriented vertically relative to the second pair of side walls 330a, 330b. Other orientations for the handle are also possible, such as the handle being horizontally oriented relative to the side walls. A handle may alternatively be provided in a different form, such as a rope or ribbon handle attached to the side wall 330b.

In a first step, shown in figure 4, the upper portion 420b of one of the second pair of side walls 330b folds inwards along a horizontal fold line 430, and the upper portion of the first pair of side walls 320a, 320b folds along diagonal fold line 350b. This first step is readily achieved by first flexing the upper portion of the first pair of side walls outwards and folding the upper portion of side walls 330b inwards, causing the first pair of side walls 320a, 320b to naturally fold along the diagonal fold line 350b. The upper portion 420b of side wall 330b then forms the upper internal surface of the container 300 when in the closed configuration.

In a second step, shown in figure 5, the upper portion 520a of the other of the second pair of side walls 320a is folded inwards. This is achieved by flexing the upper portion of the first pair of side walls 320a, 320b inwards, causing the diagonal fold line 350a to fold and bring the upper portion 520 of one of the second pair of side walls 330a inwards to meet and engage with the upper portion 420 of the other of the second pair of side walls 330b.

The handle 370 then engages with and extends through the slot 380.

In a third step, shown in figure 6, the handle 370 is extended through the slot 380 and the container is in the closed configuration, forming a substantially cuboid shaped enclosure.

The container 300 can be secured in this configuration by glue or by an adhesive strip, for example a security strip across the gap between the upper edge 610 of the upper portion 520 of one of the second pair of side walls 330a and the horizontal fold line 430 on the other of the second pair of side walls 330b. In the closed configuration, the container 300 is prevented from being inadvertently opened while carried because the handle 370 extends through the slot 380.

To provide for a sturdier construction and a more uniform top surface, a reinforcing ayer may be applied to the upper portion 420 of one or both of the second pair of side walls 330a, 330b. Preferably such a reinforcing layer is applied to at least the portion to which the handle 370 is attached, since the weight of the container and its contents are transmitted through the handle 370. The reinforcing layer may be made of cartonboard, for example in the form of a section fitting within the upper portion 420 of the second pair of side walls 330a, 330b. The handle 370 is preferably formed from a folded cut-out portion of the reinforcing layer. The reinforcing layer may be attached to either face of the upper portion 420.

Overall dimensions of the container 100, 300 in the closed configuration as shown in figures 2 and 6 may typically be in the range of 10 to 30 cm to each side. Exemplary forms of the container may for example be configured to carry a wine bottle or a takeaway meal. The relative sizes of the side walls and base portion may therefore vary according to the required application. For certain applications, such as when using the container to carry hot food, an internal liner may be additionally used, to provide a 2-ply construction for added strength and resistance to leakage. Such an inner liner may be provided in the form of a conventional open bag structure having dimensions fitting within the internal volume of the container in the closed configuration.

Other embodiments are intentionally within the scope of the invention as defined by the appended claims.

Claims

CLAIMS1. A fold-flat paper-based container comprising: a rectangular base portion; and first and second pairs of opposing side wal's extending from the perimeter of the base portion and defining an enclosed volume therebetween, an upper portion of the first and second pair of opposing side walls being foldable to form the container into a substantially cuboid shaped enclosure in a closed configuration, wherein the upper portions of the first pair of side walls each comprise a square section having fold lines extending between a centre point and opposing lower corners of the square section.
2. The container of claim 1 wherein the fold lines extend between the lower corners and opposing upper corners of the square section through the centre point.
3. The container of claim I or claim 2 wherein the second pair of side walls comprises a handle for carrying the article in the closed configuration.
4. The container of claim 3 wherein the second pair of side walls comprise matching cut-out handles.
5. The container of claim 3 wherein the second pair of side walls comprises a handle on a first one of the side walls and a slot on a second one of the side walls, the slot being configured to receive the handle such that the handle extends through the slot in the closed configuration.
6. The container of claim 5 wherein the upper portion of one or both of the second pair of side walls comprises a reinforcing layer extending across the upper portion.
7. The container of claim 6 wherein the reinforcing layer is composed of cartonboard.
8. The container of claim 1 wherein the side walls are composed of paper having a weight of between 60 and 200 g/m2.
9. The container of claim 8 wherein the paper is composed of primary fibre.
10. A fold-flat paper-based container substantially as descrthed herein, with reference to the accompanying drawings.