A CONTAINER

Abstract: A container is formed from a blank (10) comprising a first layer (11) and a second layer (12). The layers (11, 12) are adhesively attached to one another such that a first end (13) of layer (11) is spaced apart from a first end (14) of layer (12), and a second end (15) of layer (11) is spaced apart from the second end (16) of layer (12). The two layers (11, 12) are thus stepped relative to one another and two steps (17, 18) are formed. A container is formed by rolling the blank (10) such that ends (13, 14) are brought into abutment with ends (15, 16) respectively. The surfaces of steps (17, 18) will come into contact with each other thus resulting in no overlap at the ends of the layers.

Description: A CONTAINER This invention relates to a container, and particularly, but not exclusively to a container made from card or cardboard. It is known to form containers from any suitable material. Containers are required to package a wide range of products such as food, toiletries, books, bottled drinks etc. It is necessary to be able to form containers in any desired shape or size appropriate to the product or products to be packaged within the container. One type of container which is often required is a substantially cylindrically shaped box which has a substantially circular cross section. Known such boxes may be formed from an elongate rectangular piece of material such as card. In one method of forming the box, the elongate piece of material is wound spirally around a cylindrical former to form a substantially cylindrical shaped box. A spiral join will exist running spirally down the length of the so formed cylindrical box which join must be adhesively held together to form the cylindrical box. A disadvantage in spirally wound cylindrical boxes is that it is necessary to wrap the cylindrical box thus formed with an outside wrapper on which is printed any desirable design or lettering. This is because it is not possible to print onto the blank which will form the cylindrical box prior to forming the box by spiralling the blank. Another way of forming a cylindrically shaped box from an elongate rectangular piece of material is to roll the piece of material transversely such that opposite ends of the piece of material meet. In order to form the finished box opposite ends may be brought into abutment and then adhesively attached to one another. A problem with boxes so formed is that a joint is weak. Alternatively, opposite ends may be brought into overlapping contact with one another before being adhesively attached to one another. A disadvantage with boxes so formed is that due to the overlap, there will be an edge formed on both the outside and the inside of the container. This edge is unattractive to the eye. In addition, products to be packaged within the box may rub against particularly the internal edge so formed, and may damage the strength of the joint. It is known to form boxes which are substantially cube or cuboidal in shape or have other shapes, for example, tetrahedrons or pyramids similarly from a single piece of appropriately shaped card. According to a first aspect of the present invention, there is provided a container formed from a piece of material, the material being formed from a first layer having a first end and an opposite end, and a second layer having a first end and an opposite end, the first layer being fixedly attached to the second layer such that the respective first ends of each of the first and second layers are spaced apart from one another to form a first step, and the respective second ends of each of the first and second layers are spaced apart from each other to form a first step. According to a second aspect of the invention there is provided a blank of material for forming a container, the blank of material comprising a first layer having a first end and a second end, and a second layer having a first end and a second end, the two layers being fixedly attached to one another such that the respective first ends of the first and second layers are spaced apart from one another to form a first step, and the respective second ends of each of the first and second layers are spaced apart from each other to form a second step. According to a third aspect of the invention there is provided a method of forming a container, the method comprising: forming a laminate from a first layer and a second layer, each layer having a first end and a second end, the laminate being such that the respective first ends of the first and second layers are spaced apart from one another and the respective second ends are spaced apart from one another to form a step; forming the laminate into a desired shape; applying adhesive to form the finished container. By means of the present invention, it is possible to form a container which is very strong being formed from a laminate of two layers. In addition, the container so formed is easy to assemble, and thus may be provided to customers in flat pack form. A container according to the present invention is formed with a flat joint formed from the edges of the two steps which abut. There is thus no overlap forming an edge on either the inside or the outside of the container. The edges of the steps formed from the respective first ends and respective second ends of the two layers may be substantially straight, or may be any other shape. The join formed from the abutment of the two edges may thus be any shape, for example, straight, curved, helical, sinusoidal or any other regular or irregular shape. If the joint is substantially straight it may lie at any desired angle to the base of the carton. Preferably the blank is formed into the desired shape by means of an anvil. Alternatively pressurised air could be used or a former could be used. Each of the first and second layers may each comprise a single sheet of material. Alternatively one or both of the first and second layers may comprise a laminate formed from a plurality of sheets. By forming one or both of the first and second layers from a laminate formed from a plurality of sheets, further strength is added to the resulting container. Each sheet may be formed from a similar material to each other sheet, or two or more different materials may be used to form the sheets. The grain in the material used to form each of the sheets may be arranged to be falling in substantially the same direction as that of each other sheet, or alternatively, the grain in one or more sheets may be different to that in other sheets. This is known as cross graining and further adds to the strength of the resultant container. The first and second layers may be attached to one another by any suitable means, but preferably they are adhesively attached to one another by means of a heat curable adhesive. The first and second layers may be of different lengths to one another, but preferably they are of substantially the same length at least along the edges of each layer. The first and second layers may have substantially the same shape as one another. Alternatively, the first layer may be shaped differently to the second layer. Opposite ends of the first layer may be complementarily shaped such that an abutting joint is formed on completion of the container. The abutting join may comprise substantially two straight edges, or alternatively may be any other shape, for example, a curve, a zigzag line etc. It may be advantageous to have differently shaped joints, for example, in the case of a cylindrical container it may be advantageous to have a curved abutting joint. The advantage of having, for example, a sinusoidal abutting joint is that particularly with a substantially cylindrical container, the forces existing around the joint are spread, thus minimising any visible distortion of the container. The dimension of each layer in a transverse direction may be substantially the same. Alternatively the longitudinal dimension of one layer may be substantially longer than that of the other layer. This results in a step being created running transversely across the laminate. The longer layer may then be folded over in line with the shorter layer and attached to the inside of the shorter layer. This results in a neat edge, and also provides a step within the container where the folded over layer is attached to the other layer. The step may be used to locate, for example, a base of the container. Each of the two layers may be formed from separate sheets or laminates. Alternatively, the two layers may be formed from a single sheet or laminate which single sheet or laminate may be folded transversely to form the first and second layers. An advantage in forming the two layers from a single sheet or laminate is that when the single sheet or laminate is folded over a neat edge is formed. Conveniently, each layer may be scored or creased with any desired shape whilst in a flat form. This produces a container having, for example, indentations of any desired shape which adds to the aesthetic appeal of the container. Advantageously, one of the layers may be formed with partial cut-outs defined on the layer which a partial cut out is adhesively attached to the second layer, and wherein the surrounding portion of the first layer is detached from the second layer. The cut out formed on the first layer will thus adhesively attach to the second layer, and the surrounding area of the first layer around which the cut out is formed will remain detached from the second layer due to the fact that no adhesive is applied to the portion of the second layer over which the portion of the first layer surrounding the cut-outs will be positioned. There may be more than one cut-out. A container may thus be formed in which a lid may be formed integrally with the container which lid will be held in a closed position by means of the cut out which is adhesively attached to the first layer. The present invention is applicable to containers such as boxes which are generally pre-formed before being delivered to a customer. The invention is equally applicable to containers such as cartons which are generally delivered to customers in flat pack form for the customer to assemble on their own premises. Embodiments of the invention will now be further described by way of example only with reference to the accompanying drawings in which: Figures la, lb and lc are schematic representations of a first embodiment of the invention; Figure 2 is a schematic representation of a second embodiment of the invention; Figures 3a and 3b are schematic representations of a third embodiment of the invention; Figures 4a and 4b are schematic representations of a fourth embodiment of the invention; Figure 5 is a schematic representation of a part of an apparatus used to form a container according to the first aspect of the present invention using a blank according to the second aspect of the present invention; Figures 6a to 6e are schematic representations of a container in which indentations are being formed by means of scores or creases formed in the layers; Figures 7a to 7g illustrate a blank which may be used to form a container having an integrally formed and lockable lid; Figures 8a to 8c illustrate a container formed from the blank illustration in Figures 7a to 7g; Figures 9a and 9b illustrate the different cross sectional shapes which may be achieved for a container of the type illustrated in Figures 8a to 8c; Figures 10a, 10b, 10c and lOd illustrate a tamper-proof container and a blank for forming such a container; Figures 11a, lib, lie and lid illustrate a container incorporating an indented display panel, and a blank for forming such a container; and Figure 12 illustrates a substantially cylindrical container having a sinusoidal joint. Referring to Figures la, lb and lc a blank and a container formed from the blank according to the invention are illustrated schematically. The blank shown in Figure la and is designated generally by the reference numeral 10. The blank comprises a first layer 11 and a second layer 12. The layers 11, 12 may each comprise a single sheet of a material such as card or cardboard. Alternatively, each layer 11, 12 comprises a laminate formed from a plurality of sheets of card or cardboard or any other suitable material. The layers 11, 12 are adhesively attached to one another by any suitable adhesive, for example, a heat curing adhesive. Layers 11, 12 are attached together such that a first end 13 of layer 11 is spaced apart from a first end 14 of layer 12, and a second end 15 of layer 11 is spaced apart from a second end 16 of layer 12. The two layers 11, 12 are thus stepped relative to one another and two steps 17, 18 are formed. In the example illustrated in Figures la, lb and lc, the two layers 11, 12 are substantially the same shape as one another and in particular are of substantially the same length. This means that the step 17, 18 produced by the stepped attachment of the layers 11, 12 are of substantially the same shape and similarly dimensions. The blank 10 illustrated in Figures la, b and c is suitable for use in forming a substantially cylindrical container. In order to form the container, the blank is formed into a cylinder by rolling blank 10 such that ends 13, 14 are brought into abutment with ends 15 and 16 respectively. Because of the presence- of the steps 17, 18, when forming the blank 10 into a cylindrical shape, the ends of the respective layers will come into abutment and there will be no overlap of the ends of a particular layer in order to form the container. The overlapping surfaces of the steps 17, 18 are adhesively attached to one another. When the blank 10 is rolled to form the container, the surfaces of steps, 17, 18 will come into contact with each other. The resultant container benefits from a strong joint formed on the overlap between the two steps 17, 18. In addition, opposite ends of each layer will come into abutment with one another resulting in a neat joint having no overlap of the ends of a particular layer. In the examples shown in Figures la, b and c, ends 19 and 20 of layer 11 will abut with one another in the completed container as will ends 21 and 22 of layer 12. Referring to Figure 2, a second embodiment of the invention is illustrated. In Figure 2, the blank used to form a container is designated generally by the reference numeral 25. The blank 25 is formed from two layers 26, 27 which are similar to layers 11, 12 illustrated and described with reference to Figures la to c. In the example illustrated in Figure 2, layer 27 is longer than layer 26 in a longitudinal direction. The container is formed in a similar way to that described with reference to Figures la to lc in that the blank will be rolled such that layer 26 will form an inner layer and layer 27 forms an outer layer. When the blank 25 has been rolled, ends 28 and 29 of layer 26 abut with one another, ends 30 and 31 of layer 27 abut with one another, and steps 32 and 33 are adhesively attached to one another. Edges 34, 35 of layer 27 will extend beyond the edges 36, 37 of layer 28. The portions 34, 35 may be folded along creased lines 36, 37 such that the portions 34, 35 are folded inwardly and rest on an inner surface of inner layer 26 or inner surface of outer layer 27. The portions 34, 35 may be adhesively attached to the inner surface of inner layer 26. This results in a step being formed at either end of the container which step may be used to locate further portions which are to form, for example a base or a lid of the container. In addition, the fact that the portions 34, 35 are folded over means that neat edges are formed. Whilst the embodiment illustrated in Figure 2 shows that layer 27 has portions 34, 35 on either side of layer 26 which extend beyond layer 26, it is also envisaged that the two layers 26, 27 may be positioned relative to one another and dimensioned relative to one another such that edge 38 of layer 27 is substantially flush with edge 36 of layer 26, the layer 27 extending beyond the layer 26 only on one side of layer 26. Referring to Figures 3a and 3b a third embodiment of the invention is illustrated. A blank 40 is used to form a box having a substantially square cross section. Portions 41, 42, 43 and 44 form sides of the box whilst portion 45 forms the base. The blank is formed from a laminate of two layers 46, 47 which are positioned relative to one another in a similar manner to that described in respect of the two layers shown in Figures 1 and 2. Laminate 47 is longer than laminate 46 and therefore portions of layer 47 extend beyond the lower edge of layer 46. In addition, layer 47 has further portions 48, 49, 50, 51 which are shaped such that when the box is formed from the blank 40 the portions 48, 49, 50, 51 may be adhesively attached to the portion 45 forming the base in order to strengthen the box. Figure 3b is a cross sectional representation of a completed box formed from the blank shown in Figure 3a. Referring to Figure 4a a further embodiment of the invention is illustrated. Figure 4a illustrates a blank 60 formed from a single layer or single laminate. The two layers which will ultimately form the blank to form a box in accordance with the present invention are formed by folding the single layer or laminate along fold line 62. Portion 63 of the blank 60 which will form the inner layer has been shaped to form two stripped out areas 64 which are cut out at the initial cutting edge. The join which will be formed when a container is formed from the blank 60 is in this example substantially V-shaped. A disc 65 may be inserted into the completed container to form a base. The disc is shaped such that it will be locatable in strip 64. Referring to Figure 5 a portion of a machine suitable for assembling a container according to the present invention is illustrated. The two layers or laminates of the type described hereinabove which will be used to form a blank are first of all assembled and adhesively attached to one another in a way described hereinabove with reference to Figures 1 to 4 such that steps of the type described hereinabove are formed. A substrate so formed may be stored in a magazine and may be automatically unloaded from the magazine and fed onto a mandrel. The substrate will be wrapped around a spinning mandrel until the steps of the substrate come into contact with one another to form the join. The mandrel will stop its revolution at which point a heating element will press firmly against the substrate thus causing the heat curing adhesive to react to fix the join. The mandrel forms the blank into an appropriate shape before a heating element comes into contact with the join area of the blank to adhesively seal the blank. Referring to Figures 6a to 6e a container 100 having indentations 110 in its surfaces shown. The container is formed from a blank similar to that illustrates in Figures la to lc, for example. However, before the container is formed from the blank, the laminate will be scored or creased to form appropriate shapes in the surface of the container. Figure 6a is a section through container 100 and Figure 6b illustrates the base of container 100. Referring to Figures 7a to 7g, a blank for forming a container having an integral lid is shown and designated generally by the reference numeral 70. In the examples shown particularly with reference to Figure 7g, a blank designated generally by the reference numeral 70 is formed from a single laminate folded along line 71. A first portion 72 which will form a first layer 72 is formed with a slit 73 which in this example is substantially V-shaped. A second portion 74 which will form a second layer 74 is formed with creases 75 which correspond to the shape of the slit 73. In addition, the layer 74 is formed with cut-outs 76. In this example there are three cut-outs, although there could be any number of cut-outs, for example, one or more. The cut-outs are formed by perforating the layer 74 in order that the cut out is held in place, but may be easily removed. To form the laminate, an underside of layer 74 is coated with an adhesive. However, an area 77 is left without adhesive applied to it. Adhesive is applied to the underside of the cut-outs 76. To form the laminate which will eventually form the container, layer 72 is brought into contact with layer 74 by folding along fold lines 71 such that slit 73 corresponds with crease line 75. The two portions 72, 74 will be adhesively attached to one another apart from the area 77 where no adhesive is applied. Portion 74 will be formed with a slit 78. The area of the laminate falling between the fold line 71 and the slit 78 will form the lid of the finished container. Referring to Figures 8a to 8c a container formed from the blank of 7g is shown in more detail. Corresponding parts have been given corresponding reference numerals. The area 77 of layer 74 will be detachable from the corresponding area of layer 72. This allows the container to have an openable lid which is kept locked due to the fact that adhesive is applied under the cut out 76. However, on application of pressure to open the lid towards the position shown in Figure 8c, the cut-outs will tear away from layer 74 allowing the lid 80 to open. The container shown in Figures 8a to 8c has a substantially triangular cross section which could have either sharp corners or more curved corners. The container could however have any other desirable cross section or shape. Referring now to Figures 10a, 10b, 10c and lOd a tamper proof container and a blank for forming the container are illustrated. The container 100 is similar to the type illustrated in Figures 8a, b and c in that it has a hinged lid 110 which is openable to allow access to the product contained within the container 100. The container 100 is formed from a blank 120 formed from two layers and of the type described hereinabove. Both the top layer 130 and the bottom layer 140 have a cut line 150 and 160 respectively formed therein. The cut lines 150, 160 may be formed from a broken cut line rather than a continuous cut line. The area designated by the reference numeral 170 and shown in more detail in Figure 10b shows that a discontinuous cut line results in a series of shorter cut lines with untouched boards spaced between the shorter cut lines. After erection of the container 100, the lid 110 remains joined to the body of the container 180 due to the fact that the cut lines are not continuous. In order to open the container the lid may be pulled away from the body in order to cause tears to the uncut portions of the board between the shorter cut lines. The advantage of such a container is that if the product has been tampered with, this is clearly visible because the seal between the lid 110 and the body 180 formed by the discontinuous cut lines has been broken. Referring to Figures 11a, lib, lie and lid a container 200 is shown. The container 200 is formed with an indented panel 210 positioned adjacent a step 220 which step 220 extends into the interior of the container 200 as shown in Figure lib. The container 200 is formed from two layers 230 and 240 in accordance with the present invention and as already described hereinabove. The panel 210 is formed in layer 230 by means of appropriately positioned cut lines 250 and score lines 260. Step 220 is formed in layer 240 by means of appropriately positioned cut lines and score lines. When blanks 230, 240 are attached to one another, relative positions of panel 210 and step 220 are such that the panel 210 is positioned over the step 220. After erecting the container 200, a product such as a bottle may be inserted into the container. Step 220 may then be folded down along score line 270 to rest around the neck of the bottle in a substantially horizontal position. The neck of the bottle will extend through aperture 280. Panel 210 may be pushed inwardly to rest on the step 220. An advantage of such a carton is that a product such as a bottle may be held in place more securely. In addition, motifs, labels etc may be printed onto the indented panel 210 adding aesthetic appeal to the carton. A container according to the present invention may incorporate one or more windows by forming apertures in both of the two layers forming the laminate from which the container is to be formed. The apertures may be covered with a layer of, for example, clear acetate, PVC or similar material. Referring now to Figure 12, a preferred shape of the abutting joint is shown and designated generally by the reference numeral 300. The joint shown therein is substantially sinusoidal. It has been found that a joint of this shape spreads the load produced by the joint and minimises any distortion of the container.

Claims: CLAIMS 1. A container formed from a piece of material, the material being formed from a first layer having a first end and an opposite end, and a second layer having a first end and an opposite end, the first layer being fixedly attached to the second layer such that the respective first ends of each of the first and second layers are spaced apart from one another to form a step, and the respective second ends of each of the first and second layers are spaced apart from each other to form the step. 2. A blank material for forming a container, the blank of the material comprising a first layer having a first end and a second end, and a second layer having a first end and a second end, the two layers being fixedly attached to one another such that the respective first ends of the first and second layers are spaced apart from one another to form a step, and the respective second ends of each of the first and second layers are spaced apart from each other together to form a step. 3. A container according to claim 1 or claim 2 in which an edge of each of the first and second steps abuts the other edge to form a flat joint. 4. A container according to claim 3 wherein the joint is sinusoidal in shape. 5. A container according to any of the preceding claims wherein the blank is formed into the desired shape by means of an anvil. 6. A container according to any one of the preceding claims wherein the first and second layers each comprise a single sheet of the material. 7. A container according to claim 5 wherein one or both of the first and second layers comprises a laminate formed from a plurality of sheets. 8. A container according to any one of the preceding claims wherein the first and second layers are attached to one another by means of a heat curable adhesive. 9. A container according to any one of the preceding claims wherein the first and second layers are substantially the same length at least along the edges of each layer. 10. A container according to any one of the preceding claims wherein opposite ends of the first layer are complementarily shaped such that an abutting joint is formed on completion of the container. 11. A container according to any one of the preceding claims wherein the longitudinal dimension of one layer is substantially longer than that of the other layer. 12. A method of forming a container, the method comprising: forming a laminate from a first layer and a second layer, each layer having a first end and a second end, the laminate being such that the respective first ends of the first and second layers are spaced apart from one another and the respective second ends are spaced apart from one another to form a step; forming the laminate into a desired shape; applying adhesive to form the finished container.

Inventors: CLARK JAMES THOMAS, CLARK, JAMES, THOMAS
Applicants: CLARK JAMES THOMAS, RENAISSANCE PACKAGING DESIGN U, CLARK, JAMES, THOMAS, RENAISSANCE PACKAGING DESIGN (UK) LTD.
Application year: 1996
Main classification: B65D5
IPC codes: B65D3, B65D5