Container, container blank, and method of manufacture

Abstract

This invention provides a self-supporting container ( 10; 110; 210; 310 ) having at least one wall ( 36; 336 ), a base ( 52; 152; 252; 352 ) and a top ( 50; 350 ). The top has a closable spout ( 54 ) whereby the container is suitable for storing and transporting materials such as a drinks and other liquids. The wall is made of plastics material and includes at least one wall air chamber ( 26; 226; 326 ). The base has at least one base air chamber ( 84, 86 ), the at least one base air chamber having a dimension (2d) which is greater than a dimension (w) of the base whereby the base of the container is concave. The concave shape of the base makes the container more stable in use. There is also provided a blank for making the container, and a method of manufacturing the container blank.

1 . A self-supporting container having at least one wall, base and a top, the top having a closable spout, the wall being made of plastics material and including at least one wall air chamber, the base having at least one base air chamber, said at least one base air chamber having a dimension which is greater than a dimension of the base whereby the base of the container is concave. 
     
     
         2 . A self-supporting container according to  claim 1  in which the base has a bottom chamber the bottom chamber being connected to the at least one wall air chamber and to the at least one base air chamber, the bottom chamber surrounding the at least one base air chamber. 
     
     
         3 . A self-supporting container according to  claim 1  in which the container is substantially rectangular in plan view, with four walls. 
     
     
         4 . A self-supporting container according to  claim 3  in which there is one wall air chamber defining each of the four corners of the container. 
     
     
         5 . A self-supporting container according to  claim 1  in which the spout is part of a spout assembly with a first passageway adapted to permit material to be introduced into and removed from the container and a valve for inflating the at least one air chamber. 
     
     
         6 . A self-supporting container according to  claim 1  in which the is made of a two-layer material, the spout having a passageway to permit material to be introduced into and removed from the container and a base plate surrounding the passageway, the base plate being located between parts of each layer of material in the top of the container. 
     
     
         7 . A self-supporting container according to  claim 1  in which the wall, the base, the top and the spout are made from the same plastics material. 
     
     
         8 . A self-supporting container according to  claim 1  having deflating means. 
     
     
         9 . A self-supporting container according to  claim 1  having four walls, the base and the top being substantially rectangular, the container having fold lines whereby to define the form of the container when collapsed, there being at least one fold line an opposing pair of walls whereby the opposing walls are folded inwardly in the collapsed container. 
     
     
         10 . A self-supporting container according to  claim 1  in which all of the air chambers are connected together in a single air network. 
     
     
         11 . A self-supporting container according to  claim 1  in which the at least one wall air chamber and the base air chamber define a first network comprising interconnected air chambers, the walls of the container comprising a separate second air network. 
     
     
         12 . A self-supporting container according to  claim 11  in which the pressure within the first air network is greater than the pressure within the second air network. 
     
     
         13 . A blank for making a container according to  claim 1 , the blank comprising two layers of plastics material formed with seams joining the layers together, the seams defining the air chambers and also defining regions between the air chambers, all of the air chambers being interconnected. 
     
     
         14 . A blank for making a container according to  claim 11 , the blank comprising two layers of plastics material formed with seams joining the layers together, the seams defining the air chambers and also defining regions between the air chambers, the air chambers forming two separate air networks. 
     
     
         15 . (canceled) 
     
     
         16 . A method of manufacturing a container comprising the steps of:
 providing a first layer of wall material;   forming an opening through the layer to define a fill opening;   fixing a base plate of a substantially rigid spout to the first layer, the spout having a passageway, the passageway being substantially aligned with the opening;   providing a second layer of wall material;   laying the second layer of wall material over the first layer of wall material, the second layer of wall material having an opening to surround the passageway;   fixing the second layer of material to the base plate of the spout whereby the spout is secured between the two layers; and   fixing the first layer and the second layer together.   
     
     
         17 . The method according to  claim 16  in which the first layer and the second layer are fixed together by way of a number of seams, the seams also defining air chambers within between the layers. 
     
     
         18 . The method according to  claim 16  in which the spout also includes a valve, the spout defining a passageway for air to pass through the valve and between the layers. 
     
     
         19 . A method according to  claim 17  in which the seams are formed by a welding operation 
     
     
         20 . A self-supporting container substantially rectangular in plan view having four walls, a base and a top, the top having a closable spout, the wall being made of plastics material wall air chambers defining each of the four corners of the container, the base having at least one base air chamber, said at least one base air chamber having a dimension which is greater than a dimension of the base whereby the base of the container is concave, in which the base has a bottom chamber, the bottom chamber being connected to the at least one wall air chamber and to the at least one base air chamber, the bottom chamber surrounding the at least one base air chamber, the spout having a passageway adapted to permit material to be introduced into and removed from the container and a valve inflating the at least one air chamber, the top being made of a two-layer material, a base plate surrounding the passageway, the base plate being located between parts of each layer of material in the top of the container. 
     
     
         21 . A self-supporting container according to  claim 20  additionally having deflating means.