Recyclable Container Blank and Method of Forming a Shipping Pack Having Articles Secured Therein

Abstract

A container blank ( 1 ) of the RSC type having a material web ( 2 ) attached thereto to retain an article within a container formed from the blank ( 1 ). The web material ( 2 ) is selected from one or more materials having substantially identical recycling characteristics to the material from which the blank ( 1 ) is formed. The web material is coated in a cohesive film and can be stacked and handled without tack.

We claim: 
     
         1 . A container blank which comprises:
 a series of four segments, each having a side wall portion to which there is attached, along respective fold lines, a base element and a lid element, the segments being joined to at least one other segment by a side wall fold line; and   a web of material adapted to line the blank and, in an erected configuration, is tensioned to retain an article within the container,   wherein the material web is secured to each of the segments so that, in the erected configuration, adhesive carrying portions of the material web overlie one another and are tensioned intimately against one or more articles to secure said articles therewithin, the web being selected from one or more materials having substantially identical recycling characteristics to the material from which the blank is formed,   and wherein the blank has a substantially regular elongate rectangular profile which is configurable as a flat stackable lined blank.   
     
     
         2 . A container blank according to  claim 1 , in which the web material is sized and shaped so as not to extend beyond the periphery of the profile of the blank, thereby minimising snagging and facilitating increased throughput. 
     
     
         3 . A container blank according to  claim 1 , in which the container blank is configured as a regular slotted container (RSC) type container blank in which the web of material is secured thereto over at least part of the side wall forming portions and is folded such that extending over at least a major part of the lid forming elements of each segment. 
     
     
         4 . A container blank according to  claim 3 , wherein the material web is detachably secured to each of the lid forming elements of each segment. 
     
     
         5 . A container blank according to  claim 1 , in which the material adapted to retain an article within the container formed from the blank is a card or paper web. 
     
     
         6 . A container blank according to  claim 1 , in which the material web forms an article retaining profile, around the article, the material web then being closed and tensioned to secure the article against the base of the container. 
     
     
         7 . A container blank according to  claim 1 , in which the material web has cohesive portions thereon, the portions being brought together so that the cohesive regions bond across their entire free area until the bonded section abuts the upper surface of the or each article held therein, thereby creating the constraining tension to the article(s). 
     
     
         8 . A container blank according to  claim 7 , in which the cohesive portion includes an adhesive adapted to adhere only to surfaces having like adhesive thereon. 
     
     
         9 . A container blank according to  claim 7 , in which the cohesive portions are spray coated with a cold-seal adhesive. 
     
     
         10 . A container blank according to  claim 1 , in which an adhesive strip is applied to the blank and the material web is adhered to the blank by the strip. 
     
     
         11 . A container blank according to  claim 1 , in which an adhesive strip is formed on the material web. 
     
     
         12 . A method of forming a shipping pack from a container blank of the type claimed in  claim 1  having attached thereto a material web adapted to retain an article within a container formed from the blank, the material web being selected from one or more materials having substantially identical recycling characteristics to the material from which the blank is formed, the method comprising:
 assembling an open-mouthed container from a container blank by folding two opposed base forming regions inwardly and subsequently folding the remaining two opposed base forming regions inwardly and securing said remaining regions in position to form a base portion; 
 placing one or more articles onto the base portion of the open-mouthed container; 
 bringing together the free ends of the material web so that cohesive regions of the web are brought together across their free surfaces and sufficient force is applied thereto to activate the adhesive and secure the or each article within the article retaining web; 
 closing the lid portions in an overlying relationship and sealing the lid. 
 
     
     
         13 . A method of forming a shipping pack as claimed in  claim 12 , in which pre-applied pressure-sensitive adhesive is used to bond the base forming regions and the lid forming regions respectively together. 
     
     
         14 . A method of forming a shipping pack according to  claim 12 , the material web having cohesive regions and being cut along its fold lines, the free ends of two opposed web segments are brought together to overlie the or each article before the remaining cohesive regions are brought together and tension applied. 
     
     
         15 . An apparatus for forming a shipping pack from a container blank of the type claimed in  claim 1  having attached thereto a material web adapted to retain an article within a container formed from the blank, the material web being selected from one or more materials having substantially identical recycling characteristics to the material from which the blank is formed, the apparatus comprising:
 a magazine from which unlined container material is fed; 
 an adhesive application station; 
 a material web feeding mechanism; 
 an application station where the web material is adhered to the container material to form a container blank; 
 a conveyor means; and 
 a folding station where free end segments of the blank are folded along their respective fold lines and are secured together by a fixing tab. 
 
     
     
         16 . An apparatus for forming a shipping pack according to  claim 15 , in which means are provided to fold the end segments inwardly over their respective fold lines to overlie inner segments of the blank, the end segments being secured together in a flattened configuration by adhesive present on said fixing tab. 
     
     
         17 . An apparatus for forming a shipping pack according to  claim 15 , in which there is provided means for forming an open-mouthed container from a lined container blank including means for bringing together opposed base forming regions and subsequently folding the two remaining opposed base forming regions inwardly and securing said remaining regions in position to form a base. 
     
     
         18 . An apparatus for forming a shipping pack according to  claim 17 , in which there is provided means for closing and sealing the lid forming portions subsequent to the placement of one or more articles onto the base portion of the open-mouthed container and to the bringing together of the free ends of the material web so that cohesive regions of the web are brought together across their free surfaces and sufficient force is applied thereto to activate the adhesive and secure the or each article within the article retaining web. 
     
     
         19 . A container blank according to  claim 1 , wherein the material web is secured to the base element of each segment and is detachably secured to the lid element of each segment. 
     
     
         20 . A method of forming a shipping pack as claimed in  claim 12 , further comprising the step of folding the container blank so that the material web is not exposed prior to assembling the open-mouthed container. 
     
     
         21 . A method of forming a shipping pack according to  claim 12 , wherein free end segments of the container blank are folded inwardly to overlie corresponding inner segments, thereby presenting a substantially flat stackable blank, for storage or subsequent container assembly. 
     
     
         22 . A method of forming a shipping pack according to  claim 12 , wherein free end segments are secured together to present a rectangular tube having the material web lining the inner surface thereof, the tube being then flattened to provide a stackable lined blank for handling or conveying.