GB2584429A

GB2584429A - Partially-assembled container

Info

Publication number: GB2584429A
Application number: GB1907594.4A
Authority: GB
Inventors: Neale Steven
Original assignee: Coveris Flexibles UK Ltd
Current assignee: Coveris Flexibles UK Ltd
Priority date: 2019-05-29
Filing date: 2019-05-29
Publication date: 2020-12-09
Anticipated expiration: 2039-05-29
Also published as: GB2584429B; GB201907594D0

Abstract

A container (48, figure 7) made from a blank 10, suitable for forming a sandwich container or salad box. The container can move between a semi-erect flat position (44, figure 2) to a fully erect position for ease of transport. The blank comprises a base panel 12, with front 14, rear 16 and side panels 18,20 connected thereto via hinges. The side panels comprise a fold line 19, 21 that divide it into first and second portions 18a-b and 20a-b. Preferably, the front and side panels are secured together via tab portions 22, 24 located on the front panel. Ideally the fold lines on the side panels are diagonal. Preferably, there is a barrier of film material 28, 32 that forms a webbing between the side and rear panels. Ideally, the front and/or side panels comprise a flange 34, 36, 38. There is also a method claim for forming the container.

Description

Partially-Assembled Container

FIELD

The present teachings relate to a partially-assembled container, a method of erecting a container from the partially-assembled container and an erected container formed from the partially-assembled container.

BACKGROUND

For paper and cardboard packaging that is intended to be in direct contact with food, blanks are produced that are typically formed from a paperboard material that is laminated with a plastics barrier layer. The blank is assembled into a container such as a sandwich skillet or salad box, with a cavity that contents can be loaded into at a packing station.

Normally the blank is formed on a press, such as a Gallus EM 510 press manufactured by Gallus Ferdinand Ruesch AG of St. Gallen, Switzerland. When complete, blanks are loaded into a folder/gluer machine, to be assembled into the final container. The final containers are then transported to the packing location. At the packing location, the contents can be quickly inserted into the container.

However, transporting the containers takes up a lot of space, and it can be difficult to efficiently separate the containers at the packing location so the contents can be inserted.

The present teachings seek to overcome or at least mitigate this and other problems

associated with the prior art.

SUMMARY OF INVENTION

A first aspect provides a partially-assembled container comprising a blank. The blank comprises a base panel; a front panel hingedly connected to the base panel; a rear panel hingedly connected to the base panel; and a side panel hingedly connected to the base panel. The base panel, front panel and rear panel are all substantially rectangular. The blank has been formed into a substantially flat semi-erect condition. The side panel comprises a fold line that divides the side panel into a first side panel portion and a second side panel portion.

Advantageously, as the partially-assembled container is in a flat condition, it can be stacked with other partially-assembled containers and stored in a magazine. This magazine requires a relatively small amount of space for transportation to another stage of the process or a different location. Final assembly of the container is simple as part of the assembly has already been completed. This fold line helps the blank to be more easily formed into the semi-erect condition.

An internal face of the front panel may oppose an internal face of the base panel such that the front panel and the base panel are substantially parallel.

This helps to reduce the space taken up by the blank and helps to enable the partially-assembled containers to be stacked in a magazine.

The front panel may be secured to the side panel.

If a force is applied to the front panel to move it in a direction away from the base panel, this will erect the container, as the side panel moves with the front panel.

The first side panel portion may be secured to the front panel. The first side panel portion may oppose the second side panel portion.

The fold line may extend diagonally across the side panel from an intersection between the base panel, the front panel and the side panel. The fold line may extend at an angle of approximately 45°.

The blank may further comprise a tab portion. The front panel may be secured to the side panel via the tab portion.

The tab portion may extend from the front panel.

The tab portion may secure the front panel to the side panel by adhesive. The adhesive may be located on an external face of the tab portion. The adhesive may be located on an internal face of the side panel. The adhesive may be located on both the external face of the tab portion and the internal face of the side panel.

The blank may further comprise a sealing panel extending between the side panel and the rear panel.

The blank may further comprise a barrier material webbing. The barrier material may extend between the sealing panel and the rear panel.

The barrier material webbing helps to seal an internal cavity if the partially-assembled container is erected into a container.

The blank may further comprise a hinge line between the barrier material webbing and the sealing panel. The hinge line may be at an angle of approximately 45° from an intersection between the base panel, the rear panel and the side panel.

The barrier material helps to reduce the risk that the sealing panel obstructs an internal cavity if the partially-assembled container is erected into a container.

The blank may further comprise a front flange hingedly connected to the front panel. The blank may further comprise a side flange connected to the side panel.

The blank may further comprise a lid hingedly connected to the rear panel. The lid may be arranged to be engageable with the front flange. The lid may be arranged to be engageable with the side flange.

The lid protects the contents of the assembled container.

The side panel may taper outwardly from the base panel. The front panel may taper outwardly from the base panel. The rear panel may taper outwardly from the base panel.

The tapering helps any erected containers formed from each partially-assembled container to be more easily removed from a further erected container, if a plurality of erected containers are stacked.

A second aspect provides a method of erecting a container. The method comprises providing a magazine comprising a plurality of stacked partially-assembled containers in line with any of those set out in the first aspect; removing one of the partially-assembled containers from the magazine; and applying a force to the front panel to move it in a direction relatively away from the base panel to erect the container.

This is a simple process of erecting the container that can be easily repeated and automated to simplify the assembly process.

The force may be applied to the front panel by applying suction to an external face of the front panel. The force may be applied to the front panel by a hook engaging an internal face of the front panel.

This automation further increases the efficiency of the assembly process.

The partially-assembled container may be removed and located in a recess. An internal surface of the recess may provide a reaction force to the partially-assembled container as the force is applied to the front panel to erect the container.

The reaction force helps to ensure a consistent erected container as it limits the possible extent of the movement of the front and side panel as the partially-assembled container is erected.

A third aspect provides an erected container formed from a partially-assembled container in line with any of those set out in the first aspect.

The blank may have a front flange hingedly connected to the front panel. The blank may have a side flange hingedly connected to the side panel. The blank may further comprise a lid that is secured to the front flange. The blank may further comprise a lid that is secured to the side flange.

BRIEF DESCRIPTIONS OF DRAWINGS

Figure 1 shows a blank for assembly into a container; Figure 2 shows the blank of Figure, partially-assembled into a semi-erect condition; Figures 3 to 8 show the steps of forming the partially-assembled container into an assembled container, as shown in Figures 7 and 8; Figure 9 shows an alternative blank for assembly into a container, and Figure 10 shows a further alternative blank for assembly into a container.

DETAILED DESCRIPTION

A blank 10 for assembly into a container 48 will now be described. As will be described, the blank 10 can be partially-assembled into a semi-erect condition before then being erected into the final container 48. In this description, the words external and internal refer to surfaces that will be internal or external in the final container 48. Likewise, the terms left, right, front, and rear relate to the final container 48.

Looking firstly at Figure 1, the blank 10 is shown. The blank 10 is typically formed from a printable substrate. The paperboard could have a specific weight of between 215 and 415 gsm. The paperboard could have a thickness of between 310 and 690 pm. In this example, the printable substrate could be a paperboard having a specific weight of around 220gsm and a nominal thickness of 325 pm. The paperboard could have a plastics barrier layer on at least part of its internal face. In this example, the paperboard is that sold under the trade name Performa WhiteTM manufactured by Storaenso of Helsinki, Finland. However, any suitable material could be used. Typically, the blank 10 is formed on a flexographic press apparatus such as a Gallus EM 510 press by a known process that will not be described in any more detail.

The blank 10 has a rectangular base panel 12. In this example, the base panel 12 has short sides with a length of 60mm and long sides with a length of 120mm.

Hingedly connected to the base panel 12 is a front panel 14, a rear panel 16, a left side panel 18, and right side panel 20. The front panel 14 extends from a long side of the base panel 12 and is substantially rectangular. The front panel 14 is tapered outwardly in a direction from the base panel 12, i.e. in this example, a long side of the front panel 14 adjacent the base panel 12 is 120mm, but a long side opposite the base panel 12 is 130mm. The rear panel 16 also extends from a long side of the base panel 12 and is substantially rectangular but is tapered outwardly from the base panel 12. The left and right side panels 18, 20 each extend from a short side of the base panel 12 and are substantially square in shape. The left and right side panels 18, 20 are each tapered outwardly from the base panel 12, i.e. the sides of the left and right side panels 18, 20 adjacent the base panel 12 are 60mm, but the sides opposite the base panel 12 are 70mm.

The left side panel 18 is divided into a first portion 18a and a second portion 18b by a fold line 19. The fold line 19 extends in a diagonal direction from an intersection between the front panel 14, the base panel 12, and the left side panel 18. As can be seen in Figure 1, the fold line 19 has an angle a to the short side of the base panel 12. The angle a is preferably between 30° and 60°. The angle a is even more preferably between 40° and 50°. In this example, the angle a is approximately 45°. The right side panel 20 is identical to the left side panel 18. The right side panel 20 has a first portion 20a and a second portion 20b. The first and second portions 20a, 20b, are divided by a fold line 21. In this example, the fold line 21 extends at an angle an angle a to the short side of the base panel 12 identical to the angle a. The fold line 21 extends from an intersection between the front panel 14, the base panel 12 and the right side panel 20.

The base panel 12, front panel 14, rear panel 16 and left and right side panels 18, 20 together define a body 11 of the blank 10. The body 11 also includes a left tab portion 22 and a right tab portion 24. The left tab portion 22 is hingedly connected to the front panel 14. The left tab portion 22 is substantially rectangular, but with cut off portions intended to line up with other features after the container is assembled so that the left and right tab portions 22, 24 are hidden (described in more detail below). The right tab portion 24 also extends from the front panel 14 and is identical to the left tab portion 22. The left and right tab portions 22, 24 each extend from a short side of the front panel 14.

At a free side of the front panel 14, opposite the long side connected to the base panel 12, a front flange 38 is hingedly connected to the front panel 14. The front flange 38 is substantially rectangular.

The body 11 also comprises a left side flange 34 and a right side flange 36. The left side flange 34 is hingedly connected to the left side panel 18, extending from a side of the left side panel 18 opposite the base panel 12. The right side flange 36 is hingedly connected to the right side panel 20, extending from a side of the right side panel 20 opposite the base panel 12. The fold line 19 of the left side panel 18 continues into the left side flange 34 such that the left side flange 34 can be easily folded at this point. The fold line 21 of the right side panel 20 also continues into the right side flange 36 such that the right side flange 36 can be easily folded at this point. The left and right side flanges 34, 36 are both substantially rectangular. However, they each have a portion that has been cut off such that a side of a sealing panel (described below) is continued into the right and left side flanges 34, 36.

Hingedly connected to the left side panel 18 is a left sealing panel 26. Hingedly connected to the right side panel 20 is a right sealing panel 30. The left and right sealing panels 26, 30 are both substantially triangular.

Between the rear panel 16 and the left sealing panel 26 is a left barrier material webbing 28. Between the rear panel 16 and the right sealing panel 30 is a right barrier material webbing 32. The left and right barrier material webbing 28, 32 are both substantially triangular. In this example, the barrier material is a plastics film material. For example, the barrier material could be polyethylene (PE), polyethylene terephthalate (PET), cellulose, polylactic acid (PLA), or polypropylene (PP). In this example, the entire internal face of the blank 10 is covered by barrier material, and the areas of barrier material webbing 28, 32 are defined by the paperboard being cut away in these areas, e.g. by a die cutter. Alternatively, the barrier material webbing 28, 32 could be discreet separate triangular portions that are adhered to the blank 10 in the defined locations.

Between the left sealing panel 26 and the left barrier material webbing 28 is a diagonal left fold line 27. Between the right sealing panel 30 and the right barrier material webbing 32 is a diagonal right fold line 31. The angle of the left fold line 27 to the short side of the rear panel 16 is equal to the angle of the right fold line 31 to the short side of the rear panel 16. Both angles are shown in Figure 1 as angle B. Angle B is preferably between 30° and 60°, even more preferably between 40° and 50°. In this example, angle 13 is 45°.

Hingedly connected to a long free side of the rear panel 16 is a lid 40. The lid 40 is substantially rectangular. The lid 40 has a rectangular window 42. The window 42 is a cut out from the lid 40. The window 42 is covered in barrier material. In this example, the barrier material is transparent. The same barrier material can be used for the window 42 as the barrier material webbing 28, 32. Again, the barrier material could cover the entire internal face of the blank 10, with the area of the window having the paperboard cut away, e.g. by a die cutter. The window 42 enables the contents of the final container 48 to be seen, but, at the same time, protected.

The interaction of these features will now be described in more detail. Particularly, it will be described how this blank 10 is formed into the semi-erect condition to define a partially-assembled container 44, as shown in Figure 2.

With reference to Figures 1 and 2, the assembly steps will be described. It will be appreciated that this is an example, and the exact order of the steps can be varied as desired. Firstly, the front panel 14 is folded towards the base panel 12 until an internal face of the left tab portion 22 comes into contact with an internal face of the second portion 18b of the left side panel 18 and an internal face of the right tab portion 24 comes into contact with an internal face of the first portion 20a of the right side panel 20. An adhesive is then applied to the external faces of the left and right tab portions 22, 24.

Next, the left and right side panels 18, 20 are folded. Specifically, the first portion 18a of the left side panel 18 is folded towards the second portion 18b of the left side panel 18 about the fold line 19, such that the internal face of the first portion 18a is adjacent to and opposes the internal face of the second portion 18b. Located between the first portion 18a and the second portion 18b is the left tab portion 22. Due to the adhesive on the external face of the left tab portion 22, the left tab portion adheres to the internal face of the first portion 18a of the left side panel 18.

The first portion 20a of the right side panel 20 is folded towards the second portion 20b of the right side panel 20 about the fold line 21, such that the internal face of the first portion 20a is adjacent to and opposes the internal face of the second portion 20b. Located between the first portion 20a and the second portion 20b is the right tab portion 24. Due to the adhesive on the external face of the right tab portion 24, the right tab portion adheres to the internal surface of the first portion 20a of the right side panel 20.

This secures the front panel 14 to the left and right side panels 18, 20. In this embodiment, the adhesive is a low migration hot melt adhesive that is suitable for use in food packaging.

As can be seen from Figure 2, the blank 10 has been folded at fold lines 19, 21, forming the blank 10 into a flat semi-erect condition. This semi-erect condition is defined as the partially-assembled container 44. As can been seen, in this condition, an internal face of the front panel 14 opposes an internal face of the base panel 12, such that the front panel 14 and the base panel 12 are substantially parallel. Accordingly, in this semi-erect condition, the partially-assembled container is substantially flat, taking up a minimum of space. In the semi-erect condition, a plurality of partially-assembled containers can be stacked together in a magazine to be efficiently transported to another stage of the process or a new location.

By reference to Figures 2 to 8, the erection of this partially-assembled container 44 into the final container 48 will be described. In general, a force is applied to the front panel 14 to move it in a direction away from the base panel 12. As the left and right side panels 18, 20 are secured to the front panel, they also move simultaneously with the front panel 14.

This causes the folded left and right side panels 18, 20 to each unfold and define substantially planar side walls. The rear panel 16 is then folded in a direction towards the base panel 12. As can be seen in Figure 4, as the rear panel 16 contacts the left and right side panels 18, 20, the front panel 14, rear panel 16, left side panel 18 and right side panel 20 each define a wall perpendicular to the base panel 12. These walls define a cavity 46. The cavity 46 is suitable for storing contents of the container 48. For example, the contents could be food, such as rectangular sandwiches, fruits or salads. Alternatively, the contents could be non-food items.

As the rear panel 16 is folded, the left and right sealing panels 26, 30 and left and right barrier material webbing 28, 32 are brought together because of the left and right fold lines 27, 31. In the condition shown in Figure 6, an external surface of the left sealing panel 26 opposes an external surface of the left barrier material webbing 28. An external surface of the right sealing panel 30 opposes an external surface of the right barrier material webbing 32. This helps to seal the separation between the rear panel 16 and the left and right side panels 18, 20 to block air ingress and help prevent other fluid movement into or out of the final container 48. This can help keep the contents fresher and increase life span. Further, as the webbing is barrier material, the thickness is lower than the paperboard of the sealing panel. This helps to reduce the risk that the sealing panel is pushed into the cavity 46, obstructing the products from being inserted.

As shown in Figure 5, the front flange 38, the left side flange 34 and the right side flange 36 are each folded outwardly, perpendicular relative to the left side panel 18, right side panel 20, and front panel 14. As shown in Figure 6, in the next step the lid 40 is moved towards the left side flange, right side flange and front flange 34, 36, 38. As shown in Figures 7 and 8, the lid 40 comes into contact with the left side flange, right side flange and front flange 34, 36, 38 to seal the container. The lid 40 can be secured to left side flange, right side flange and front flange 34, 36, 38 in any suitable way. In this example, the lid 40 is heat sealed to the left side flange, right side flange and front flange 34, 36, 38. However, in alternative arrangements, an adhesive could be used, such as glue suitable for food contact. Any other appropriate sealing technology could also be used, for example, ultrasonic sealing.

In this example, the lid 40 is also paperboard. Also, in this example, the lid 40 is part of the blank 10. However, in alternative arrangements, the lid 40 could be a separate component. If it is a separate component, the lid could be a formed plastic lid, or a flexible film lid, or any other suitable design.

The general steps of assembling the container 48 are described above. An example manufacturing process for performing these steps will now be described, to illustrate the advantages of providing the blank 10 in the form of a partially-assembled container 44.

As described above, once the partially-assembled containers 44 have been formed, by securing the left and right side panels 18, 20 to the front panel 14, a magazine of stacked partially-assembled containers can be produced. As each partially-assembled container is substantially flat, many can fit into each magazine, enabling space efficient transportation, and reducing storage costs.

At the location where the partially-assembled containers 44 are to be assembled into the final containers, the magazine can simply be fitted into the assembly line. The form of the partially-assembled containers 44 means that the remainder of the assembly process can be automated.

For example, a first step of the process will remove a partially-assembled container 44 from the magazine. The partially assembled container 44 could be removed with a roller. The partially-assembled container 44 can be placed into a rectangular shaped recess on the assembly line, which can provide a reaction force as the container is assembled. For example, as the front panel 14 and the left and right side panels 18, 20 are unfolded, the inner surfaces of the recess apply an opposite force.

The next step applies a force to the front panel 14 to move it away from the base panel 12. As the left and right side panels 18, 20 are connected to the front panel 14, they are also pulled up simultaneously. It will be appreciated that simply by applying a force to the front panel 14, the entire container 'pops-up' and is erected into the shape of the final container 48, with a cavity 46 defined by side walls of the container, the side walls being made up of the left and right side panels 18, 20, the rear panel 16 and the front panel 14. Advantageously, this enables the final assembly of the container to be automated. No manual intervention is required to remove the partially-assembled container 44 from the magazine, or erect the container. The design of the partially-assembled container therefore enables a large increase in the efficiency of assembly of the container 48.

There are a range of different ways that the force can be applied to the front panel to move it away from the base panel 12. For example, suction could be applied to the external face of the front panel 14 to move the front panel 14 away from the base panel 12. Alternatively, a hook could engage an internal surface of the front panel 14 to assemble the container 48.

In some arrangements, the force applied to remove a partially-assembled container 44 from the magazine and locate it in the recess could be the same force that pulls the front panel 14 away from the base panel 12. It will be appreciated that in these alternative arrangements, a force may need to be applied, at least temporarily, to the lid 40, rear panel 16 or base panel 12 while the front panel 14 is being pulled away, to enable nearly simultaneous removing and erecting of the final container 48.

The blank of Figure 1 is suitable for producing a container with a depth of about 60mm, and is particularly suitable for use as a sandwich skillet. It will be appreciated, however that is equally applicable to the containers with different dimensions An alternative blank 110 is shown in Figure U. This blank is intended to form a large salad tray, which is shallower than the sandwich skillet, with a depth of about 44mm, but longer and wider, with the base panel 112 having a length of 155mm and a width of 105mm.

A further alternative blank 210 is shown in Figure 12. This is also intended to be a salad tray, but is smaller, with a depth of 45mm, but a base panel 212 with a length of 82mm and a width of 72mm.

It will be appreciated that other dimensions are possible: e.g. a medium salad tray with a depth of 45mm, but a base panel with a length of 130mm and a width of 90mm.

As can be seen, the blanks 110 and 210 are substantially identical to the blank 10, so will not be described in detail.

However, it will be noted that the blanks 110 and 210 each have additional barrier material webbing between the tab portions 122, 124, 222, 224 and the left and right side panels 118, 120, 218, 220. This webbing furthers seals the final container and helps to prevent food egress, which is more likely if the product is a salad. The webbing also helps to reduce the risk of the tab portions 122, 124, 222, 224 protruding into the cavity 146, 246 when the respective containers 148, 248 are assembled, which can obstruct insertion of the contents at the packing station.

It will be appreciated that numerous changes may be made within the scope of the present teachings. For example, it will be appreciated that the dimensions of the blanks 10, 110 and 210 are given as examples only, and can be varied as required. Further, the angles of the fold lines are given as examples and can also be varied as required. The blanks 10, 110, 210 may be manufactured from plastics material only rather than paperboard. The blanks 10, 110, 210 may be manufactured with or without a plastics layer laminated or co-extruded. In alternative arrangements, rather than being hingedly connected to the rear panel 16, the lid 40 could be hingedly connected to the front panel 14, or the left side panel 18, or the right side panel 20.

Claims

CLAIMS1. A partially-assembled container comprising a blank, the blank comprising: a base panel; a front panel hingedly connected to the base panel; a rear panel hingedly connected to the base panel; and a side panel hingedly connected to the base panel, wherein the base panel, front panel and rear panel are all substantially rectangular, wherein the blank has been formed into a substantially flat semi-erect condition, wherein the side panel comprises a fold line that divides the side panel into a first side panel portion and a second side panel portion.
2. The partially-assembled container of claim 1, wherein an internal face of the front panel opposes an internal face of the base panel such that the front panel and the base panel are substantially parallel.
3. The partially assembled container of claim 2, wherein the front panel is secured to the side panel.
4. The partially-assembled container of any previous claim, wherein the first side panel portion is secured to the front panel and the first side panel portion opposes the second side panel portion.
5. The partially-assembled container of any previous claim, wherein the fold line extends diagonally across the side panel from an intersection between the base panel, the front panel and the side panel, preferably wherein the fold line extends at an angle of approximately 45°.
6. The partially-assembled container of claim 3, wherein the blank further comprises a tab portion and the front panel is secured to the side panel via the tab portion.
7. The partially-assembled container of claim 6, wherein the tab portion extends from the front panel.
8. The partially-assembled container of claim 7, wherein the tab portion secures the front panel to the side panel by adhesive, wherein the adhesive is located on an external face of the tab portion or an internal face of the side panel.
9. The partially-assembled container of any previous claim, wherein the blank further comprises a sealing panel extending between the side panel and the rear panel.
10. The partially-assembled container of claim 9, wherein the blank further comprises a barrier material webbing, preferably wherein the barrier material extends between the sealing panel and the rear panel.
11. The partially-assembled container of claim 10, wherein the blank further comprises a hinge line between the barrier material webbing and the sealing panel, preferably at an angle of approximately 45° from an intersection between the base panel, the rear panel and the side panel.
12. The partially-assembled container of any previous claim, wherein the blank further comprises a front flange hingedly connected to the front panel and/or a side flange connected to the side panel.
13. The partially-assembled container of claim 12, wherein the blank further comprises a lid hingedly connected to the rear panel, the lid arranged to be engageable with the front flange and/or the side flange.
14. The partially-assembled container of any previous claim, wherein the side panel, the front panel, and/or the rear panel each taper outwardly from the base panel.
15. A method of erecting a container, the method comprising: providing a magazine comprising a plurality of stacked partially-assembled containers in line with any of those set out in claims 1 to 14; removing one of the partially-assembled containers from the magazine; and applying a force to the front panel to move it in a direction relatively away from the base panel to erect the container.
16. The method of erecting a container of claim 15, wherein the force is applied to the front panel by applying suction to an external face of the front panel or by a hook engaging an internal face of the front panel.
17. The method of erecting a container of claim 15 or claim 16, wherein the partially-assembled container is removed and located in a recess, wherein an internal surface of the recess provides a reaction force to the partially-assembled container as the force is applied to the front panel to erect the container.
18. An erected container formed from a partially-assembled container in line with any of claims 1 to 14.
19. The erected container of claim 18, wherein the blank has a front flange hingedly connected to the front panel and a side flange hingedly connected to the side panel, and the blank further comprises a lid that is secured to the front and side flanges.