Field of the invention

The present invention relates to a container and a blank therefor. In particular, although not exclusively, the present invention relates to a container for storage of items such as fresh produce requiring temperature control.

Background of the invention

Polystyrene containers are ubiquitous in the use for storage of items requiring refrigeration such as fresh produce. Polystyrene is a plastic material and therefore is not environmentally friendly in its use of a limited resource and is also difficult to dispose of.

It is therefore an object of the present invention to provide a container and/or a blank therefor which overcomes or ameliorates the above disadvantage. It is another object of the present invention to provide a container and/or a blank therefor which provides the public with a useful choice.

Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and/or combined with other pieces of prior art by a skilled person in the art.

Summary of the invention

In accordance with a first aspect of the present invention, there is provided a container including a base wall and surrounding walls, wherein at least some of the base wall and surrounding walls are each double-walled, the base wall comprising an inner base panel and an outer base panel such that the inner base panel is supported in spaced disposition above the outer base panel; and wherein one or more of the surrounding walls create a substructure to at least partly support the inner base panel in spaced disposition above the outer base panel. In a preferred form of the invention, all walls including the base wall and surrounding walls are double-walled.

By "double-walled", we mean that the walls are formed of spaced panels. For example, the base wall may be formed by an outer base panel and an inner base panel the outer base panel and the inner base panel being spaced. Likewise, each surrounding wall may be formed by an inner panel and an outer panel.

In a preferred form of the invention, the container may include a container base and a container lid having a top wall. The top wall may also be double-walled. The doublewalled surrounding walls may be provided in the container base and/or the container lid. In a most preferred form of the invention, the container having a container base and a container lid is provided with double-walled base wall, a double-walled top wall, with surrounding walls on each side being double-walled. In other words, the container with base and lid may be enveloped with double walls. The double walls need not be provided on both the surrounding walls of the container lid and the surrounding walls of the container base. Preferably, the double walls are formed in the surrounding walls of the container base. Alternatively, the double walls could be formed in the surrounding walls of the container lid with single walls provided in the surrounding walls of the container base.

The container may be formed from a single blank. In a preferred form of the invention, the container base is formed from a single blank and the container lid is formed from a single blank.

The container may be parallelepiped. Traditional container forms are envisaged such as a container base having a base wall and four upright side surrounding walls, the container having a container lid having a top wall and four side depending surrounding walls. In such a form, the container lid is placed over the container base to encompass at least part, if not all of the container base. However other forms are envisaged. For example, the container could be a carton which is end or side opening, with no lid.

Each of the surrounding walls may be formed by an inner panel and an outer panel such that in each surrounding wall, the inner panel and the outer panel are spaced to define the double wall. The spacing between the inner panels and the outer panels may be such that they are spaced apart and do not contact. Alternatively, there may be contact between the inner and outer panels. Similar comments apply for the inner base panel and the outer base panel.

The inner base panel may be integral with one or more of the surrounding walls. The outer base panel may be integral with one or more of the surrounding walls. The container may be constructed from a single sheet of cardboard i.e. in the form of a blank. The blank may be punched to define the external boundary of the blank. The blank may also be scored, perforated and/or creased in the manner known in the art to define fold lines and individual panels, wherein the panels fold to facilitate construction of the assembled container.

Preferably, an air gap is provided between the inner base panel and the outer base panel. Likewise, an air gap is preferably provided between the inner panel and the outer panel of each of the surrounding walls. Alternatively, suitable insulative material may be provided between the inner base panel and the outer base panel and/or between the inner panel and the outer panel of each of the surrounding walls.

For all or some of the surrounding walls, the outer panel may be of the same length to the corresponding inner panel. However, in a more preferred form of the invention, the outer panel is of greater length than the inner panel, such that the outer panel extends beyond the inner panel at each end.

Each surrounding wall may be further defined by a top panel disposed between the inner panel and the outer panel. The top panel is preferably commensurate in length with the corresponding inner panel and outer panel. Where the outer panel extends beyond the inner panel at each end, the top panel is shaped to bridge from the outer panel to the inner panel. Accordingly, the top panel may be shaped as a trapezium. Preferably, the angle of the nonparallel edges of the trapezium extend at 45° to the parallel edges of the trapezium. As will be appreciated, where all surrounding walls have a top panel of trapezium shape then adjacent top panels will abut each other in mitred fashion.

The width of the top panel may determine the spacing between the inner panel and the outer panel and in preferred forms of the invention, the width of the air gap between the inner and outer panels. Preferably, the spacing between the panels, defining the air gap is in the range of 18 to 30 mm. Likewise, the width of the spacing between the inner base panel and the outer base panel may lie within the range of 18 to 30 mm.

For one or more of the surrounding walls, the inner and outer panels may be provided with a gusset panel. However, preferably there are first and second opposite surrounding walls, each of which have inner and outer panels and each of the inner and outer panels have a wing gusset panel at each end edge thereof. Preferably, there are also third and fourth opposite surrounding walls, each of which have inner and outer panels. The wing gusset panels may lie within the inner and outer panels of the third and fourth surrounding walls. In other words, the wing gusset panels at one end of the first and second surrounding walls lie within the inner and outer panels of the third surrounding wall, while the wing gusset panels at the other end of the first and second surrounding walls lie within the inner and outer panels of the fourth surrounding wall.

The third and fourth surrounding walls may also have gusset panels. Preferably, only the ot/terwalls of the third and fourth surrounding walls have auxiliary gusset panels at each end edge thereof. Preferably, each auxiliary gusset panel is integral with the wing gusset panel of the outer panel from the adjacent first or second surrounding wall.

Furthermore, one or more surrounding walls may create the substructure to support the inner base panel in spaced disposition above the outer base panel. For example, one or more surrounding walls may be connected to a supporting internal flap which supports the inner base panel in spaced disposition above the outer base panel. The supporting internal flap may be integrally connected to the inner panel of a supporting surrounding wall. The supporting internal flap may be inclined from the inner panel of the supporting surrounding wall to the outer base panel. The inner base panel may be integrally connected to the inner panel of any of the other surrounding walls. Preferably, the inner base panel is integrally connected to the inner panel of a surrounding wall opposite the supporting surrounding wall and supported at its other end by the supporting internal flap. Preferably, the inner base panel is supported at the top of the incline of the supporting internal flap.

Thus, in the supporting surrounding wall, the outer panel will be of greater height than the inner panel to provide the incline of the supporting internal flap. Similarly, in the opposite surrounding wall, the outer panel will be of greater height than the inner panel such that the integrally connected inner base panel will be spaced above the outer base panel.

In an alternative configuration, two or more such supporting internal flaps, extending from respective adjacent surrounding walls, could be provided to support the inner base wall. For instance, two supporting internal flaps could extend from respective surrounding walls at opposite sides of the container. The inner base panel could extend from surrounding walls at one or both ends of the container. In another configuration, two supporting internal flaps could extend from respective surrounding walls at opposite ends of the container. The inner base panel could extend from surrounding walls at one or both sides of the container. Alternatively, the inner base panel could be a separate piece to the remainder of the container.

Other internal flaps may be provided which do not serve as supporting internal flaps to support the inner base wall. The other internal flaps may be integral with an adjacent inner panel. The other internal flap may lie flush with the outer base panel.

The internal flaps may be commensurate in length with the inner panel with which they are integrally connected.

A lid may also be provided having a top wall and dependent surrounding lid walls. The top wall may be defined by spaced upper and lower panels. Preferably, the surrounding walls of the lid are not defined by spaced panels.

In accordance with a second aspect of the invention, there is provided, a container including a base wall and surrounding walls, wherein at least some of the base wall and surrounding walls are each double-walled, the base wall comprising an inner base panel and an outer base panel such that the inner base panel is supported in spaced disposition above the outer base panel; and wherein the container further includes an internal flap which is inclined and the inner base panel is at least partly supported in spaced disposition by the inclined internal flap. Any of the features described above in connection with the first aspect may have application to this aspect.

In accordance with a third aspect of the present invention, there is provided A container including a base wall and surrounding walls, wherein at least some of the base wall and surrounding walls are each double-walled, the base wall comprising an inner base panel and an outer base panel such that the inner base panel is supported in spaced disposition above the outer base panel, wherein the inner base panel includes one or more flaps extending lengthwise along respective edges thereof, the width of the flaps corresponding to the spaced disposition.

Any of the features described above in connection with the first aspect may have application to this aspect.

In accordance with a fourth aspect of the invention, there is provided, a blank to form the container set out in the first or second aspects of the present invention.

In accordance with a fifth aspect of the present invention, there is provided a blank for a container including a base wall and surrounding walls, the blank including: an inner base panel and an outer base panel to form the base wall in the assembled container; one or more panels arranged to form the surrounding walls in the assembled container; and one or more further panels connected to at least one of the panels of the surrounding walls to create a substructure to at least partly support the inner base panel in spaced disposition above the outer base panel.

In accordance with a sixth aspect of the present invention, there is provided a blank for a container including a base wall and surrounding walls, the blank including: an inner base panel and an outer base panel to form the base wall in the assembled container; one or more panels arranged to form the surrounding walls in the assembled container; and a supporting flap arranged to be inclined in the assembled container, to at least partly support the inner base panel in spaced disposition above the outer base panel.

In accordance with a seventh aspect of the present invention, there is provided, a blank for a container including a base wall and surrounding walls, the blank including: an inner base panel and an outer base panel to form the base wall in the assembled container; one or more panels arranged to form the surrounding walls in the assembled container; wherein the inner base panel includes one or more flaps extending lengthwise along respective edges thereof, to at least partly support the inner base panel in spaced disposition above the outer base panel in the assembled container, wherein the width of the flaps corresponds to the spaced disposition.

The blank may have any of the features set out above. The blank may be provided or sold to the customer in partially assembled configuration.

The container/blank may be constructed of cellulose-based material. A suitable material is cardboard, such as corrugated board, with or without coating. A range of fluted cardboard is possible from e to c and twin cushion. The container/blank may be constructed of foil-laminated cardboard. Preferably, the foil is disposed to face outwardly on the outside of the container and inwardly on the inside of the container. The optimum cardboard thickness lies within the range of 2.5 mm to 6 mm. The lid may have a similar construction to the container. Alternatively, the cardboard may be laminated with foil on both sides.

As used herein, except where the context requires otherwise, the term "comprise" and variations of the term, such as "comprising", "comprises" and "comprised", are not intended to exclude further additives, components, integers or steps. Further aspects of the present invention and further embodiments of the aspects described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings.

Brief description of the drawings

In order that the invention may be more fully understood, one embodiment will now be described, by way of example, with reference to the figures in which:

Figure 1 is a plan view of a blank used to construct a container in accordance with a preferred embodiment of the present invention;

Figures 2- 9 are perspective views showing the process of assembling the container; and

Figure 10 is a perspective view showing the assembled container;

Figure 11 is a plan view of a blank for a lid for the container of Figure 10;

Figures 12 and 13 are perspective views showing the process of assembling the lid; and

Figure 14 is a perspective view of the assembled lid;

Figure 15 is a plot of the temperature inside a polystyrene container over time in August 2020 (indoors environment); and

Figure 16 is a plot of the temperature inside the container according to the present invention, over time in August 2020 (indoors environment)

Figure 17 is a plot of the temperature inside the container according to the present invention, over time in November 2020 (indoors environment);

Figure 18 is a plot of the temperature inside a polystyrene container over time in November 2020 (indoors environment);

Figure 19 is a plot of the temperature inside a polystyrene container over time in January 2021 (outdoors environment); Figure 20 is a plot of the temperature inside the container according to the present invention, over time in January 2021 (outdoors environment);

Figure 21 is a is a plan view of a blank used to construct a container in accordance with a preferred embodiment of the present invention.

Detailed description of the embodiments

Figure 1 illustrates the blank 10 to assemble the container base shown in Figure 10. The blank is constructed from a single sheet of foil-laminated cardboard and is formed by punching to define the outer boundary with score lines or fold lines or perforations defining individual panels in the blank as will be explained.

As shown in Figure 1 , the blank 10 for the container base 11 includes a central outer base panel 12 surrounded by outer panels including first outer panel 14, a second outer panel 16, a third outer panel 18 and a fourth outer panel 20. To each outer panel is connected a respective top panel, including first top panel 22 second top panel 24 third top panel 26 and fourth top panel 28. To each top panel is connected a respective inner panel including first inner panel 30, second inner panel 32, third inner panel 34 and fourth inner panel 36.

As will be appreciated in connection with subsequent figures, the first outer panel 14, the first top panel 22 and the first inner panel 30 assemble to form a first surrounding wall 40 (see figure 3). Likewise, the second outer panel 16, the second top panel 24 and the second inner panel 32 assemble to form a second surrounding wall 42 (see Figure 3).

Furthermore, the third outer panel 18, the third top panel 26 and the third inner panel 34 assemble to form a third surrounding wall 44 (see Figure 6). Lastly, the fourth outer panel 20, the fourth top panel 28 and the fourth inner panel 36 assemble to form a fourth surrounding wall 46 (see Figures 9 and 10).

The outer panels 14, 16, 18, 20 are interconnected by gusset panels including wing gusset panels 48 integrally connected to and arranged at each end of the first and second outer panels 14, 16. First and second inner panels 30, 32 also have wing gussets 50 arranged at each end thereof. When the first and second surrounding walls are assembled, the wing gussets 48, 50 will lie adjacent to each other but spaced apart as will be appreciated from consideration of Figure 3 and Figure 5.

As mentioned, the outer panels 14, 16, 18, 20 are interconnected by gusset panels which further include auxiliary gusset panels 52. The third and fourth outer panels 18, 20 in each case have an associated auxiliary gusset 52 at each end. The third and fourth inner panels 34, 36 do not have associated gussets.

The first inner wall 30 and the second inner wall 32 have respective internal flaps 54, 56, the purpose of which will become evident from the subsequent explanation.

The third inner wall 34 is integrally connected to inner base panel 57. The fourth inner wall 36 also has an integrally connected support flap 58 which supports the inner base panel 57 as will be explained.

Figure 2 illustrates a partially assembled container 11 in which the first and second surrounding walls 40, 42 have been folded flat onto the outer base panel 12. It will be appreciated that the inner panels 30, 32 have been folded underneath the outer panels 14, 16. The container 11 could be provided in this partially assembled form to the customer.

Figure 3 illustrates the container 11 where the surrounding walls 40, 42 have been moved to the upright configuration as shown. Furthermore, the arrangement of the wing gussets 48, 50 can be seen extending from each end of the inner and outer panels 30, 32, 14, 16. The wing gussets 48, 50 are folded to lie at approximately 90° to the associated inner and outer panel to which they are attached. The auxiliary gussets 52 are also visible in this view, being folded inwardly relative to the third outer panel 18 and the fourth outer panel 20. In the assembled container, the auxiliary gussets 52 will lie flat against the associated outer panel 18, 20 and will thus be sandwiched between the associated wing gusset 48 and the outer panel 18.

As will be appreciated from a comparison of Figure 3 and Figure 7, the wing gussets 48, 50 and the auxiliary gussets 52 at the proximal end of the container become captured between the third outer panel 18 and the third inner panel 34 in the assembled container. Likewise, gussets 48, 50, 52 at the other end of the container become captured between the fourth outer panel 20 and the fourth inner panel 36 in the assembled container.

As will be apparent from Figure 1 , the outer walls 14, 16, 18, 20 are of greater length than their respective inner walls 30, 32, 34, 36. Accordingly, each of the top panels 22, 24, 26, 28 are of a trapezium shape. As shown in Figure 10, this enables the top panels 22, 24, 26, 28 to meet each other at the corners in mitred fashion.

As shown more clearly in Figure 4, the first and second internal flaps 54, 56 can be seen. In the assembled container, these are folded at 90° to the associated inner walls, 30, 32. The first and second internal flaps 54, 56 contact the outer base panel 12 (and may be glued thereto) and lie substantially flat on top of the outer base panel 12. The first and second internal flaps 54, 56 are commensurate in length with the inner walls 30, 32.

Figure 5 illustrates the assembly of the fourth surrounding wall 44. The outer panel 20 (not shown) is moved to an upright orientation relative to the outer base panel 12 and the inner panel 36 is folded over the top until it comes to an upright configuration spaced from the outer panel 20 as will be appreciated from Figure 6. From consideration of the blank shown in Figure 1 , it will be understood that the inner panel 36 is shorter in height than the outer panel 20. Thus, in the assembled configuration illustrated in Figure 6, the lower extent of the inner panel 36 will be spaced from the outer base panel 12. Thus, the upper extent of the supporting flap 58 will be spaced above the outer base panel 12, while the lower extent of the supporting flap 58 will lie adjacent to the outer base panel 12. Accordingly, the supporting flap 58 will lie on an incline extending between the upper extent and the lower extent. The lower extent of the supporting flap 58 rests against the internal flaps 54, 56. A crease or fold line 60 lies between the inner panel 36 and the supporting flap 58.

Figures 7 - 9 illustrate the assembly of the third surrounding wall 46. Initially, as shown in Figure 7, the outer panel 18 is moved to an upright configuration and then the inner panel 34 is lifted over the top of the outer panel 18, together with the inner base panel 57. The inner panel 34 is pushed to lie in an upright configuration, spaced inwardly from the outer panel 18. Similarly as for the fourth surrounding wall 44, the inner panel 34 of the third surrounding wall 46 is shorter in height than the outer panel 18. Thus, once the inner panel 34 is in position, the lower extent of the inner panel 34 will be spaced above the outer base panel 12. Since the inner base panel 57 is connected to the lower extent of the inner panel 34, the corresponding (first) end of the inner base panel 57 will be spaced above the outer base panel 12. The other end of the inner base panel 57 rests upon the supporting flap 58, typically in the location of the crease or fold line 60. As discussed above, the crease or fold line 60 lies spaced above the outer base panel 12, preferably by the same amount as the first end of the inner base panel 57. Thus, the inner base panel 57 will be supported in spaced disposition above the outer base panel 12. The preferred spacing of the inner base panel 57 above the outer base panel 12 is in the range of 18 to 30 mm.

As will be appreciated from the foregoing discussion, the outer panels 14, 16, 18, 20 are in spaced disposition from the inner panels 30, 32, 34, 36. The preferred spacing is in the range of 18 to 30 mm.

Figure 11 is a plan view of a blank 70 to form a container lid 71 for use with the container base 11 illustrated in Figures 1 - 10. From comparison with Figure 1 , it can be seen that there are many features in common with the blank 10 for the container 11. Accordingly, like numerals will be used to indicate like features, except with the addition of a prime (‘) symbol to indicate the application of the feature in the lid 71.

The main distinguishing feature of the blank 70 for the lid 71 compared to the blank 10 for the container 11 is the omission of the first and second inner panels. This is because the first and second surrounding walls in the lid are not double walls. Accordingly, the first and second surrounding walls comprise only outer panels 14’, 16’.

Figures 12 and 13 illustrate the assembly of the lid 71 , the process of which is very similar to assembly of the container 11. In similar fashion to the container 11 , the lid 71 has a double-walled top. The outer lid panel 12’ is spaced from the inner lid panel 57 ’ by resting on the crease 60’ between the inner panel 36’ and the support flap 58’.

The assembled lid is illustrated in Figure 14. Figures 15 to 20 illustrate the relative performance of the container according to the present invention compared to a conventional polystyrene container. The results are not necessarily the same container.

Figure 21 is a is a plan view of a blank 100 used to construct a container in accordance with a preferred embodiment of the present invention. The blank is similar in many respects to the blank illustrated in Figure 1 , except that the inner base panel 57 is provided with one or more edge flaps 102 (2 are shown here) extending in a lengthwise direction along opposite edges of the inner base panel 57. The flaps are folded to extend towards the outer base panel 12 and the width of the flaps 102 is such that they support the edges of the inner base panel 57 in spaced disposition above the outer base panel 57. The edge flaps 102 thus work together with the supporting flap 58 to support the inner base panel 57 around 3 sides.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.