A method for forming a container

Abstract

A method of forming a container from a blank, the method comprising the steps of: heat inducing one or more fold lines on at least one surface of a container blank made from a thermally insulating sheet material, folding a first panel portion of the container blank along a first fold line; folding a third panel portion of the container blank along a second fold line, wherein when folded, the third panel portion is substantially perpendicular to the second panel portion and substantially parallel to the first panel portion; sealing a portion of the first panel portion to a portion of the third panel portion to form a side seam; and sealing a portion of the panel portion adjacent the side seam to an edge of the second panel portion to form a base seam.

Description

Technical Field

[0001] The present invention relates to a method for forming a container from a blank, and the container formed therefrom. Background Technology

[0002] Known packaging for storing and transporting temperature-sensitive items (such as seafood) includes expanded polystyrene (polystyrene foam) boxes and corrugated cardboard boxes coated or wax-impregnated with polyethylene. These are packaged with refrigeration materials (such as ice) to keep the items refrigerated outside of cold chain storage and to ensure transport within the recommended temperature range (which is typically 2°C to 8°C for seafood).

[0003] The disadvantages of using expanded polystyrene (EPS) boxes are their limited lifespan due to their decomposition during use. Furthermore, EPS poses an environmental hazard because it breaks down into non-biodegradable flakes. Additionally, this type of packaging material often has poor barrier properties, making it susceptible to contamination from its contents. The reusability of other insulated containers is also limited due to the use of single-use plastic liners in shipping boxes. Moreover, while some insulated containers may be leak-proof, these often include single-use plastic liners or liner-like structures, which are limited in that they cannot fill the available space inside the box and are difficult to clean for reuse. Although some liners do conform to a box shape, these are often foldable or multi-piece structures, thus not providing a complete seal along all edges and failing to prevent leaks. Furthermore, these liners typically contain creases, wrinkles, or other excess material that can trap contaminants or be difficult to clean.

[0004] Furthermore, their efficiency is limited because existing insulation containers have fixed dimensions and are bulky to transport and store when not in use, as they are not foldable.

[0005] Therefore, it would be advantageous if it were possible to provide an improved container or at least a container that improves upon the aforementioned problems.

[0006] It should be clearly understood that if prior art publications are cited herein, such citation does not constitute an acknowledgment that such publications constitute common general knowledge in the field in Australia or any other country. Summary of the Invention

[0007] The present invention relates to a method for forming a container from a blank and the container formed by the method, which can at least partially overcome one of the above-mentioned disadvantages or provide consumers with a useful or commercial option.

[0008] In view of the above, one aspect of the present invention mainly relates to a method for forming a container from a blank, the method comprising the following steps:

[0009] One or more fold lines are thermally induced on at least one surface of a container blank made of insulating sheet, wherein the blank comprises:

[0010] First panel section;

[0011] The second panel portion is located near the first panel portion and shares a first common edge with it; and

[0012] The third panel portion is located near the second panel portion and shares a second common edge with it. The second common edge is substantially parallel to the first common edge.

[0013] Each of the first and third panel portions is associated with a pair of baffle members adapted for folding movement relative to the respective first and third panel portions, such that, upon assembly, each baffle member covers an edge of the second panel portion that is substantially perpendicular to the first and second common edges.

[0014] Fold the first panel portion of the container blank along the first fold line, wherein when folded, the first panel portion is substantially perpendicular to the second panel portion of the container blank;

[0015] Fold the third panel portion of the container blank along the second fold line, wherein when folded, the third panel portion is substantially perpendicular to the second panel portion and substantially parallel to the first panel portion;

[0016] A portion of each of the pair of baffle members in the first panel portion is sealed to a portion of each of the pair of baffle members in the third panel portion to form a side seam; and

[0017] A portion of the first panel portion adjacent to the side seam and a portion of the third panel portion adjacent to the side seam are sealed to the edge of the second panel portion to form the bottom seam.

[0018] Throughout the specification and claims, the terms "container blank" and "blank for forming a container" are used interchangeably.

[0019] Container preforms can be formed in any suitable manner. However, it should be understood that the method of forming a container preform can vary depending on many factors, such as the type of material used to manufacture the container preform and the complexity of the container preform. These methods are known to those skilled in the art. For example, a container preform can be formed by applying a template to an insulation sheet and cutting or stamping the preform from the insulation sheet. In one embodiment of the invention, the container preform can be formed by a die-cutting process. Any suitable die-cutting process can be used. For example, the die-cutting process can be flatbed die-cutting, laser cutting, waterjet cutting, pressure die-cutting, rotary die-cutting, or any suitable combination thereof.

[0020] In one embodiment of the invention, the container blank can be formed by rotary die cutting. Any suitable rotary die cutting process can be used. In some embodiments of the invention, the rotary die cutting process can use a flexible cylindrical rotary die or a solid cylindrical rotary die. In a preferred embodiment of the invention, the container blank can be formed using a flexible cylindrical rotary die process. In this case, it should be understood that the template (die) can be a sheet of flexible material. In some embodiments of the invention, the rotary die cutter can be designed to cut substantially through or at least partially through the insulation sheet. In this case, it should be understood that the rotary die cutter can cut through one or more layers of insulation sheet.

[0021] The first panel portion, the second panel portion, and the third panel portion can have any suitable dimensions relative to each other. For example, in some embodiments of the invention, each of the first panel portion, the second panel portion, and the third panel portion can be substantially the same size as each other. Alternatively, at least one of the first panel portion, the second panel portion, and the third panel portion can have different dimensions from each other. The first panel portion, the second panel portion, and the third panel portion can differ from each other in any suitable dimensions, particularly in their length and width. It is conceivable that the thickness of the blank can be substantially constant.

[0022] In embodiments of the invention, the third panel portion may be larger than the first panel portion and the second panel portion. Specifically, it is contemplated that the length of the third panel portion may be greater than the lengths of the first and second panel portions. In one specific embodiment, the length of the third panel portion may be approximately similar to the combined length of the first and second panel portions. In this case, it is contemplated that, upon assembly, a portion of the third panel portion may cover at least a portion of the second and first panel portions to form a lid portion of the container. In one embodiment of the invention, upon assembly, a portion of the third panel portion may cover at least a portion of the first panel portion to form the outer surface of the container. Optionally, upon assembly, a portion of the third panel portion may cover at least a portion of the first panel portion and may be configured to fold into the container such that it contacts the inner surface of the first panel portion and substantially closes the container.

[0023] The first and third panel portions may include one or more sub-panel portions. The sub-panel portions can be of any suitable size, shape, or configuration. For example, the third panel portion may include a sub-panel portion that, when assembled, forms the lid portion of the container. In this case, it is envisioned that the sub-panel portion forming the lid portion can be at least the width of the second panel portion (which, when assembled, forms the bottom of the container) and at least the length of the sub-panel portion of the third panel portion (which, when assembled, forms the sidewall of the container). For example, the first and third panel portions may each include a sub-panel portion that can be folded to provide an edge seal. In this case, it is envisioned that the sub-panel portion is substantially continuous along the length of the respective first and third panel portions, but relatively narrow in width. For example, the first and third panel portions may each include a sub-panel portion that, when assembled, facilitates the reusable closure of the container. In this case, it is envisioned that the sub-panel portion can be at least the length of the respective first and third panel portions.

[0024] The first panel portion and the third panel portion may be associated with a pair of baffle members. The baffle members may be associated with the first panel portion and the third panel portion in any suitable manner. For example, the baffle members may be integrally formed with the container preform, or they may be formed separately and attached to the container preform. In one embodiment of the invention, the baffle members may be integrally formed with the container preform.

[0025] In one embodiment of the invention, at least one of the first panel portion and the third panel portion may be provided with two or more pairs of baffle members. For example, the third panel portion may be provided with a first pair of baffle members associated with a portion of the third panel portion, which, when assembled, can form the wall (and preferably the rear wall) of the container, and a second pair of baffle members associated with the sub-panel portion, which, when assembled, can form the lid portion of the container. In this case, it is conceivable that the two or more pairs of baffle members can be folded independently of each other.

[0026] In one embodiment of the invention, each of the pair of baffle members may be located near and share a common edge with the respective first and third panel portions. The pair of baffle members may be associated with any suitable edge of the respective first and third panel portions. However, preferably, the pair of baffle members may be associated with opposite edges of the respective first and third panel portions. In one embodiment, when assembled, each of the pair of baffle members may be positioned substantially parallel to each other.

[0027] These baffle members can be of any suitable size, shape, and construction. For example, in some embodiments of the invention, each baffle member in the pair can have substantially the same size, shape, and construction as the others. Optionally, the first baffle member of the pair can have different dimensions from the second baffle member of the pair. The first and second baffle members in the pair can differ from each other in any suitable dimensions, particularly their length and width. It is envisioned that the thickness of the container blank can be substantially constant.

[0028] For example, in some embodiments of the invention, each pair of baffle members of the respective first and third panel portions may be substantially the same size, shape, and construction as each other. Optionally, the size of a pair of baffle members associated with the first panel portion may differ from the size of a pair of baffle members associated with the third panel portion. The pairs of baffle members of the respective first and third panel portions may differ from each other in any suitable dimensions, particularly in their length and width. Preferably, the length of the pair of baffle members of the third panel portion may be greater than the length of the pair of baffle members of the first panel portion. In one embodiment of the invention, the length of the pair of baffle members of the third panel portion may be substantially similar to the length of the third panel portion. In an alternative embodiment of the invention, the length of the pair of baffle members of the third panel portion may be less than the length of the third panel portion. In one embodiment of the invention, one or more fold lines may be located in a portion of the pair of baffle members such that the one or more fold lines are substantially aligned with one or more fold lines located in adjacent panel portions. In this case, it is conceivable that the fold lines can help the baffle members fold into the same construction as the adjacent panel portions.

[0029] However, preferably, when assembled, the baffle members can be sized such that each baffle member of the respective first panel portion and third panel portion covers the edge of the second panel portion, which is substantially perpendicular to the first common edge and the second common edge.

[0030] Preferably, the baffle member is adapted to fold relative to the respective first and third panel portions. In use, it is conceivable that one or more fold lines can be provided along a portion of a common edge shared by the baffle member and the respective panel portions.

[0031] In one embodiment of the invention, at least one baffle member of the pair of baffle members and the sub-panel portions of the corresponding first panel portion and third panel portion may share a common edge. In a preferred embodiment of the invention, each baffle member of the pair of baffle members and the sub-panel portions of the corresponding first panel portion and third panel portion may share a common edge. In this case, it is conceivable that one or more fold lines may be positioned along a portion of the common edge to facilitate folding of the baffle member and the sub-panel portion relative to each other. Alternatively, at least a portion of the baffle member and / or the sub-panel portion may be cut off, such that the baffle member and the sub-panel portion can be folded relative to each other with minimal amount of stacked material. In an alternative embodiment of the invention, each baffle member of the pair of baffle members and the sub-panel portions of the corresponding first panel portion and third panel portion may not share a common edge. In this case, each baffle member and sub-panel portion of each of the first panel portion and third panel portion may be folded independently of each other.

[0032] During assembly, it is conceivable that the second panel portion can form the bottom plate of the container, the first panel portion can form the wall of the container (especially the front wall of the container), the third panel portion can form the wall of the container (especially the rear wall) and the lid portion, and the baffle member can form the side wall of the container.

[0033] During assembly, the first panel portion can be positioned relative to the second panel portion in any suitable location. For example, the first panel portion can be at an angle between 40° and 140° relative to the second panel portion. More preferably, the first panel portion can be positioned at an angle between 60° and 120° relative to the second panel portion. Even more preferably, the first panel portion can be positioned at an angle between 80° and 100° relative to the second panel portion. Most preferably, the first panel portion can be positioned at an angle between 85° and 95° relative to the second panel portion.

[0034] During assembly, the third panel portion can be positioned relative to the second panel portion in any suitable location. For example, the third panel portion can be at an angle between 40° and 140° to the second panel portion. More preferably, the third panel portion can be at an angle between 60° and 120° to the second panel portion. Even more preferably, the third panel portion can be at an angle between 80° and 100° to the second panel portion. Most preferably, the third panel portion can be at an angle between 85° and 95° to the second panel portion.

[0035] In a preferred embodiment, when assembling the container, both the first panel portion and the third panel portion can be positioned substantially perpendicular to the second panel portion. Preferably, the first panel portion and the third panel portion can be positioned substantially parallel to each other. In a preferred embodiment of the invention, the baffle member can be positioned substantially perpendicular to the first panel portion, the second panel portion, and the third panel portion.

[0036] The preform used to form the container can be made of any suitable material. Preferably, the container preform can be made of any suitable type of material with insulating properties. In one embodiment of the invention, the container preform can be made of a sheet. In a preferred embodiment of the invention, the container preform can be made of a flexible sheet. Preferably, the flexible sheet can be in roll form. In one embodiment of the invention, the container preform can be made of an insulating sheet. Any suitable insulating sheet can be used. However, it is conceivable that in use, the insulating sheet can reflect radiant heat, thereby reducing or minimizing the temperature rise of the object at least partially surrounded by the insulating sheet.

[0037] The insulation sheet may include at least one layer. In one embodiment of the invention, the insulation sheet may be a multi-layer structure. In one embodiment of the invention, the insulation sheet includes an insulation layer located between at least one upper layer and at least one lower layer. In a preferred embodiment of the invention, the insulation layer may include a foam layer, wherein the foam layer may be made of extruded polymer, foamed polymer, foam polymer, or any suitable combination thereof. In some embodiments of the invention, the insulation layer may be made of closed-cell foam material or open-cell foam material. In a preferred embodiment of the invention, the insulation layer may be made of closed-cell foam material. Preferably, the insulation layer may be made of cross-linked closed-cell foam material. Any suitable cross-linked closed-cell foam layer may be used. For example, the cross-linked closed-cell foam layer may be a chemically cross-linked closed-cell foam layer, a physically cross-linked closed-cell foam layer, or any suitable combination thereof. Preferably, the insulation layer may be made of cross-linked closed-cell polyethylene foam layer.

[0038] In a preferred embodiment of the invention, at least one upper layer and at least one lower layer may be formed of a polymer sheet, wherein the polymer sheet may be made of polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, polycarbonate, acrylonitrile butadiene styrene, or any suitable combination thereof. In some embodiments of the invention, at least one upper layer and at least one lower layer may be made of the same type of material or different types of materials. Preferably, at least one upper layer and at least one lower layer may be made of polyethylene.

[0039] In one embodiment of the invention, the insulation sheet comprises at least one polymer sheet laminated onto the insulation layer. In use, it is envisioned that the laminated insulation sheet does not include any cavities behind the polymer sheet that prevent contamination of the insulation layer. In one embodiment of the invention, the insulation sheet may be laminated prior to its use in the method of the invention. In a preferred embodiment of the invention, the insulation sheet may be laminated as a step in the method of the invention. Preferably, the insulation sheet may be laminated prior to introducing one or more fold lines on at least one surface of a container blank formed from the insulation sheet. Advantageously, residual heat from the lamination process can promote thermal induction of the fold lines in the insulation sheet.

[0040] In one embodiment of the invention, the thermal insulation sheet includes a foam layer encapsulated between one or more layers of reflective material and one or more layers of antibacterial material. Preferably, the thermal insulation sheet may include a cross-linked closed-cell foam layer encapsulated between an outer layer of metallized polyethylene film and an inner layer of antibacterial film.

[0041] Preferably, the preform used to form the container can be made of flexible insulating sheet. Preferably, the preform used to form the container can be made of waterproof and insulating sheet. Preferably, the preform used to form the container can be assembled from food-grade approved insulating sheets. For the purposes of this specification, the term "food-grade" means that the preform used to form the container is permitted to come into contact with food intended for human or animal consumption.

[0042] In a preferred embodiment, the container preform may have resistance to one or more environmental factors. For example, the container preform may be waterproof, impermeable, UV resistant, chemical resistant, impact resistant, fire resistant, or a combination thereof. In a preferred embodiment of the invention, the container preform may be at least waterproof. Preferably, the container preform may be substantially waterproof such that if cooling material or frozen items stored in a container formed from the container preform thaw, the resulting water will not contaminate the inner layer of the container preform.

[0043] Any suitable method can be used to provide waterproofing to the container blank. For example, the container blank can be formed from a substantially waterproof insulating sheet, can be provided with a waterproof coating, can be provided with a lining having a high moisture barrier, or a combination thereof. Preferably, the insulating sheet can have sealed edges. This improves the insulation capacity of the material, and the sheet can have improved water resistance. Any suitable technique can be used to seal the edges of the sheet. However, it should be understood that the sealing technique can vary depending on many factors, such as the type of sheet to be sealed, the thickness of the sheet, and the required degree of seal. For example, the edges of the sheet can be sealed by using adhesives or tapes, pulse heat treatment, heat treatment, chemical treatment, mechanical treatment (e.g., ultrasonic welding, compression, etc.), or a combination thereof.

[0044] Preferably, during assembly, the reflective layer of the insulation sheet forms the outer surface of the container, and the antibacterial layer of the insulation sheet forms the inner surface of the container.

[0045] A method of forming a container from a preform includes forming one or more fold lines on at least one surface of a container preform made of insulating sheet. The one or more fold lines can be located on any suitable surface of the container preform. For example, the fold lines can be located on the inner surface of the container preform, the outer surface of the container preform, or both the inner and outer surfaces of the container preform. In a preferred embodiment of the invention, the one or more fold lines can be located on the inner surface of the container preform. The fold lines can be located on any suitable portion of the container preform. For example, the fold lines can be located near the edge of the container preform, within the area defined by the panel portions of the container preform, between two adjacent panel portions, or any suitable combination thereof. However, preferably, the fold lines can be located within a portion of the container preform, which facilitates folding the panel portions and / or folding at least a portion of the periphery of the container preform to form an edge seal.

[0046] Fold lines can be any suitable size, shape, and structure. However, it should be understood that the size, shape, and construction of fold lines can vary depending on many factors, such as the type and thickness of the material used to manufacture the container blank, the construction of the container blank, and the desired end construction of the panel portion to be folded.

[0047] The fold line can have any suitable depth. However, it is conceivable that the fold line can have sufficient depth to facilitate folding of the panel portion. For example, the fold line can extend at least partially from the inner surface of the container blank into the insulation layer of the container blank, at least partially from the outer surface of the container blank into the insulation layer of the container blank, or at least partially from both the inner and outer surfaces of the container blank into the insulation layer of the container blank.

[0048] One or more fold lines may be oriented relative to one or more other fold lines. For example, a container blank may have a fold line perpendicular to the second fold line forming an L-shape, a fold line perpendicular to the second fold line forming a T-shape, a fold line perpendicular to the second fold line forming an X-shape, a fold line at a 45° angle relative to the second fold line, a pair of fold lines, each at a 45° angle relative to a third fold line, at a 90° angle relative to each other, and so on.

[0049] The container blank may be provided with one or more pairs of parallel fold lines. Each of these pairs of parallel fold lines may be spaced apart at any suitable thickness. In one embodiment, the first thickness is approximately the thickness of the container blank. In use, it is envisioned that providing one or more pairs of parallel fold lines to the container blank can facilitate the folding of panel portions. For example, the pair of parallel fold lines can reduce stress on the material, help ensure predictable angles between adjacent panel portions, allow panel portions to be nested within folds formed between two adjacent panel portions, allow folds formed between two adjacent panel portions to be nested within folds formed between two different adjacent panel portions, and so on.

[0050] A method for forming a container from a preform includes the following steps: forming one or more fold lines on at least one surface of a container preform made of insulating sheet. The one or more fold lines can be formed at any suitable stage of forming the container preform. For example, the one or more fold lines can be formed before the container preform is cut or stamped, during the cutting or stamping of the container preform, after the cutting or stamping of the container preform, or any suitable combination thereof. In one embodiment of the invention, the template for the container preform may include one or more fold line positioning portions. In this case, it is envisioned that the fold line positioning portions allow the positions of the fold lines to be marked on the surface of the container preform. The positions of the fold lines can be marked on the surface of the container preform using any suitable method. In one embodiment of the invention, the fold lines can be formed using one or more fold line positioning portions.

[0051] Fold lines can be formed by any suitable method. For example, fold lines can be formed by cutting or perforating, by heating, by laser, by extruding the material between the forming die portion and the anvil portion, by extruding the material between complementary forming die portions, by using a heat-sensitive adhesive, etc. In a preferred embodiment of the invention, one or more fold lines can be thermally induced on at least one surface of a container preform made of insulating sheet. Preferably, fold lines can be formed by pulse heating, heating, compression, or any suitable combination thereof. However, preferably, the method of forming fold lines does not puncture or damage the container material or affect its resistance to environmental factors, such as water resistance. In a preferred embodiment of the invention, one or more fold lines can be formed during rotary die cutting. In this case, it is conceivable that one or more forming die portions can press the insulating sheet against the anvil portion until the fold line is formed. Preferably, one or more forming die portions can be heated.

[0052] In one embodiment of the invention, the container preform includes one or more monitoring devices embedded in at least one surface of the container preform. The monitoring devices can be of any suitable type and can monitor any suitable parameters related to the container preform and / or the container formed from the container preform. However, preferably, the one or more monitoring devices provide information about the condition of the container preform and / or the container formed from the container preform. For example, a suitable monitoring device can be an electronic monitoring device. Electronic monitoring devices may include electronic chips, Internet of Things (IoT) modules, data loggers, radio frequency identification (RFID) chips, near field communication (NFC) tags, smart tags, etc. It is conceivable that, in use, the monitoring devices can be used to track and / or trace the container preform and / or the container formed from the container preform, identify worn or damaged parts, monitor temperature or humidity, or a combination thereof, at one or more locations within the container formed from the container preform.

[0053] One or more monitoring devices may be located at any suitable portion of the container preform. However, it should be understood that the location of the monitoring device can vary depending on many factors, such as the function of the monitoring device and the transmission frequency (the time frequency and / or the radio frequency at which the monitoring device transmits). In one embodiment of the invention, the monitoring device may be located on the surface of the container preform. In this case, it is conceivable that the monitoring device may be at least partially covered by a polymer film to provide a protective barrier for the monitoring device and to secure the monitoring device to the container preform. In one embodiment of the invention, the monitoring device may be located within the container formed from the container preform.

[0054] In one embodiment of the invention, a method of forming a container from a preform includes the step of embedding one or more monitoring devices in at least one surface of a container preform made of insulating sheet. The monitoring devices can be of any suitable type and can monitor any suitable parameters related to the container preform and / or the container formed from the container preform. However, preferably, the one or more monitoring devices provide information about the condition of the container preform and / or the container formed from the container preform. For example, a suitable monitoring device can be an electronic monitoring device. Electronic monitoring devices may include electronic chips, Internet of Things (IoT) modules, data loggers, radio frequency identification (RFID) chips, near field communication (NFC) tags, smart tags, etc. It is conceivable that, in use, the monitoring devices can be used to track and / or trace the container preform and / or the container formed from the container preform, identify worn or damaged parts, monitor temperature or humidity, or a combination thereof, at one or more locations within the container formed from the container preform.

[0055] One or more monitoring devices may be located at any suitable part of the container formed from the container preform. However, it should be understood that the location of the monitoring device can vary depending on many factors, such as the function of the monitoring device and the transmission frequency (the time frequency and / or the radio frequency at which the monitoring device transmits). In embodiments of the invention, the monitoring device may be located on the surface of the container formed from the container preform. In this case, it is conceivable that the monitoring device may be at least partially covered by a polymer film to provide a protective barrier for the monitoring device and to secure the monitoring device to the container formed from the container preform. In one embodiment of the invention, the monitoring device may be located inside the container formed from the container preform.

[0056] One or more monitoring devices can be embedded at any suitable stage of forming the container preform. For example, one or more monitoring devices can be embedded before the container preform is cut or stamped, during the cutting or stamping of the container preform, after the container preform has been cut or stamped, or any suitable combination thereof. In a preferred embodiment of the invention, one or more monitoring devices can be embedded in the container preform during the cutting or stamping process.

[0057] One or more monitoring devices can be embedded using any suitable method. For example, one or more monitoring devices can be adhered to the container preform using adhesives or tapes, pulse heat treatment, heat treatment, chemical treatment, mechanical treatment (e.g., ultrasonic welding, compression, etc.), or combinations thereof. In this case, it is conceivable that the monitoring device may include a substrate (e.g., a thermoplastic material, etc.) configured to adhere to the container preform. For example, during the manufacturing process of insulation sheets, the monitoring device can be embedded in one or more layers of insulation sheets. For example, one or more monitoring devices can be printed or embossed onto the container preform.

[0058] In some embodiments of the invention, hot gas welding and / or contour heat stamping can be used to embed one or more monitoring devices into at least one surface of a container preform. In a preferred embodiment of the invention, one or more monitoring devices can be embedded during rotary die-cutting. In this case, it is envisioned that one or more formed die portions can press a portion of the monitoring device against an insulating sheet. Preferably, one or more formed die portions can be heated.

[0059] In one embodiment of the invention, a method of forming a container from a preform includes the step of sealing one or more edges of the container preform. Any suitable edge of the container preform may be sealed. Preferably, one or more edges of the container preform may be sealed, and these edges may not engage with adjacent edges of the container preform. In one embodiment of the invention, a portion of an edge on one side of the container preform may be sealed, while a portion of the same edge may not be sealed. In this case, it is conceivable that the unsealed portion of the edge may connect to an adjacent unsealed portion of the edge of the container preform. In one embodiment of the invention, at least a portion of the periphery of the container preform may be sealed. In an alternative embodiment of the invention, substantially all of the periphery of the container preform may be sealed. In this way, the thermal insulation of the container preform is improved, and the container preform has improved water resistance. In one embodiment of the invention, at least a portion of the periphery of the container preform may be sealed before the container preform is assembled into a container. Optionally, at least a portion of the periphery of the container preform may be sealed during the assembly of the container from the container preform into a container.

[0060] Any suitable sealing device can be used to seal the edges of a container blank. However, it should be understood that the method of forming an edge seal can vary depending on many factors, such as the type of insulation sheet to be sealed, the thickness of the insulation sheet, and the required degree of sealing. For example, the edges of a container blank can be sealed by using adhesives or tapes, pulse heat treatment, heat treatment, chemical treatment, mechanical treatment (e.g., ultrasonic welding, compression, etc.), or a combination thereof.

[0061] In one embodiment of the invention, a portion of the insulation sheet may be pre-compressed to reduce the thickness of the inner insulation layer prior to forming the edge seal. In this case, it is contemplated that this portion of the insulation sheet may include one or more edges of the insulation sheet. In one embodiment of the invention, a portion of the insulation sheet may be pre-treated to facilitate edge sealing. Any suitable pre-treatment may be used. For example, one or more edges may be provided with an adhesive, may be chemically treated, may be heat-treated (e.g., but not limited to, hot air treatment, etc.), may be subjected to a discharge treatment (e.g., but not limited to, corona discharge treatment, plasma treatment, etc.), or any suitable combination thereof. In use, the pre-treatment step is expected to contribute to forming an edge seal with improved water and heat resistance.

[0062] In one embodiment of the invention, one or more edges of a container preform may be sealed using heat treatment. In this case, it is conceivable that one or more layers of insulating sheet may be heat-sealed onto adjacent layers of insulating sheet to substantially enclose the insulating layer therein and form an edge seal. In a preferred embodiment of the invention, one or more edges of the container preform may be sealed using heat treatment under pressure. In this case, it is conceivable that the compressive force may reduce the thickness of the inner insulating layer in the area surrounding the edge seal. In one embodiment of the invention, one or more edges of the container preform may be sealed using pulse welding. In this case, it is understood that the sealed edge portion remains under pressure during heating. Preferably, the sealing process includes a cooling phase, wherein the sealed edge portion remains under pressure during heating and cooling cycles. In one embodiment of the invention, one or more edges of the container preform may be sealed during rotary die cutting. In this case, it is conceivable that one or more forming die portions may press the insulating sheet against the anvil portion until an edge seal is formed. Preferably, one or more forming die portions may be heated.

[0063] In one embodiment of the invention, excess material can be trimmed after the edge seal is formed. In this case, it is conceivable that a cutting bar associated with the sealing device can be used to trim the excess material. In one embodiment of the invention, a rotary die-cutting process can form the edge seal by compression while simultaneously trimming excess material. Optionally, at least a portion of the periphery of the container preform can be folded before forming the edge seal. In this case, it is conceivable that the folded portion of the container preform can be heat-sealed onto the container preform to form the edge seal.

[0064] A method for forming a container from a blank includes the following steps: folding a first panel portion of the container blank along a first fold line, wherein when folded, the first panel portion is substantially perpendicular to a second panel portion of the container blank.

[0065] The first fold line can be located at any suitable position within the container blank. However, preferably, the position of the first fold line facilitates the folding of the first panel portion relative to the second panel portion. In a preferred embodiment of the invention, the first fold line can be positioned along a portion of a common edge shared by the first and second panel portions, wherein this common edge is the first common edge. The first fold line along the portion of the first common edge can be continuous or discontinuous. However, it should be understood that the configuration of the first fold line can vary depending on many factors, such as the type of material to be folded, the shape and size of the container blank to be folded, and the length of the first common edge.

[0066] The first panel portion can be folded along the first fold line in any suitable direction. However, preferably, the inner surface of the first panel portion is folded towards the inner surface of the second panel portion. The first panel portion can be folded along the first fold line at any suitable angle. However, preferably, when folded, the first panel portion is substantially perpendicular to the second panel portion. It should be understood that the first panel portion does not need to be positioned to extend at a precise 90° angle relative to the second panel portion, and relatively small vertical deviations are acceptable and will not affect the performance of the invention.

[0067] A method for forming a container from a blank includes the following steps: folding a third panel portion of the container blank along a second fold line, wherein when folded, the third panel portion is substantially perpendicular to the second panel portion and substantially parallel to the first panel portion.

[0068] The second fold line can be located at any suitable position within the container blank. However, preferably, the position of the second fold line facilitates the folding of the third panel portion relative to the second panel portion. In a preferred embodiment of the invention, the second fold line can be positioned along a portion of a common edge shared by the third panel portion and the second panel portion, wherein this common edge is the second common edge. The second fold line along this portion of the second common edge can be continuous or discontinuous. However, it should be understood that the construction of the second fold line can vary depending on many factors, such as the type of material to be folded, the shape and size of the container blank to be folded, and the length of the second common edge.

[0069] The third panel portion can be folded along the second fold line in any suitable direction. However, preferably, the inner surface of the third panel portion is folded towards the inner surface of the second panel portion. The third panel portion can be folded along the second fold line at any suitable angle. However, preferably, when folded, the third panel portion is substantially perpendicular to the second panel portion. It should be understood that the third panel portion does not need to be positioned to extend at a precise 90° angle relative to the second panel portion, and relatively small vertical deviations are acceptable and will not affect the performance of the invention.

[0070] Preferably, the second common edge can be substantially parallel to the first common edge. In this case, it is understood that when the first panel portion is folded along the first fold line and the third panel portion is folded along the second fold line, such that the first panel portion and the third panel are substantially perpendicular to the second panel portion, the first panel portion and the third panel portion can be substantially parallel to each other. It should be understood that the first panel portion does not need to be positioned to extend at a precise 180° angle relative to the third panel portion, and relatively small parallel deviations are acceptable and will not affect the performance of the invention.

[0071] A method for forming a container from a blank includes the following steps: sealing a portion of each of a pair of baffle members of a first panel portion to a portion of each of a pair of baffle members of a third panel portion to form a side seam. Any suitable portion of the baffle members and / or the first panel portion may be sealed to any suitable portion of the baffle members and / or the third panel portion to form a side seam. For example, inner surfaces may be sealed together, outer surfaces may be sealed together, inner insulation layers may be sealed together, or any suitable combination thereof. Preferably, both the inner and outer surfaces of the baffle members and / or the first panel portion may be sealed to the corresponding inner and outer surfaces of the baffle members and / or the third panel portion. In this case, it should be understood that the process of sealing the corresponding inner and / or outer surfaces together fuses or welds the materials together such that the resulting layers are substantially resistant to separation. In use, it is contemplated that the side seams and / or bottom seams formed by the method of the present invention may comprise a laminated material, wherein the insulating sheets of each corresponding baffle member and / or panel portion may be substantially fused together.

[0072] In one embodiment of the invention, the inner and outer surfaces of the baffle member and / or the first panel portion can be sealed substantially simultaneously to the corresponding inner and outer surfaces of the baffle member and / or the third panel portion. Preferably, the corresponding inner surfaces can be sealed together before the corresponding outer surfaces are sealed together. However, it should be understood that the order in which the respective inner and outer layers can be sealed together can vary depending on the type and combination of sealing devices used, the type and composition of the insulation sheet, and the desired characteristics of the side seams and / or bottom seams.

[0073] Preferably, the laminated material formed at the side seams and / or bottom seams by this process can be substantially waterproof and leak-proof. Preferably, the laminated material formed at the side seams and / or bottom seams by this process can substantially resist delamination. In this case, it should be understood that under tensile stress, the bonded polymer sheets of the laminate resist separation. In use, it is envisioned that fusing the inner surfaces of the insulating sheets together at the side seams and / or bottom seams forms a leak-proof container and reduces the risk of contaminant ingress during container reuse, and fusing the outer surfaces of the insulating sheets together at the side seams and / or bottom seams can prevent contaminant ingress and can prevent delamination of the outer surfaces around the side seams and / or bottom seams under pressure, especially when the container can be a flat package. In one embodiment of the invention, fusing the inner layers together and fusing the outer layers together can form a laminated material at the seams that can resist delamination under stress better than seams formed solely by laminating the inner film.

[0074] Any suitable portion of each pair of baffle members in the first panel portion can be sealed to a portion of each pair of baffle members in the third panel portion to form a side seam. In a preferred embodiment of the invention, a portion of each of the pairs of baffle members in the first panel portion and / or the third panel portion includes the edge of the respective baffle member. Preferably, this portion of the first panel portion can be a first baffle member located near and sharing a common edge with the first panel portion, and preferably, this portion of the third panel portion can be a third baffle member located near and sharing a common edge with the third panel portion. In this case, it is contemplated that the first baffle member can be sealed to the third baffle member to form a side seam. In use, it is contemplated that the common edge between the panel portion and the baffle member can be provided with one or more fold lines to facilitate folding of the baffle member relative to the panel portion.

[0075] In one embodiment of the invention, the side seam extends at least a portion of the length of each of a pair of baffle members of the first panel portion and / or the third panel portion. The side seam may extend any suitable length of each of the pair of baffle members of the first panel portion and / or the third panel portion. For example, the side seam may extend substantially the entire length of each pair of baffle members of the first panel portion, substantially the entire length of each pair of baffle members of the third panel portion, at least partially extend the length of each pair of baffle members of the first panel portion, at least partially extend the length of each pair of baffle members of the third panel portion, or any suitable combination thereof. The side seam may extend the same length of each of the first and third panel portions, or may extend different lengths of each of the first and third panel portions. In use, where the third panel portion is longer than the first panel portion, it is conceivable that the side seam may extend substantially the entire length of the first panel portion and at least partially extend the length of the third panel portion.

[0076] In one embodiment of the invention, a method of forming a container from a blank includes the steps of: sealing a portion of each of a pair of baffle members of a first panel portion to a portion of each of a pair of baffle members of a third panel portion to form a side seam, and sealing the edge of the third panel portion in a single operation. In this case, it is envisioned that the side seam and the edge seal are continuous along the length of the third panel portion.

[0077] Any suitable technique can be used to seal a portion of each of the pair of baffle members of the first panel portion to a portion of each of the pair of baffle members of the third panel portion to form a side seam. However, it should be understood that the method of forming the side seam can vary depending on many factors, such as the type of insulation sheet to be sealed, the thickness of the insulation sheet, and the required degree of sealing. For example, the side seam of a container blank can be formed by using adhesives or tapes, pulse heat treatment, heat treatment, chemical treatment, mechanical treatment (e.g., ultrasonic welding, compression, etc.), or a combination thereof. In one embodiment of the invention, heat treatment can be used to seal a portion of the first panel portion to a portion of the third panel portion. In this case, it is conceivable that one or more layers of insulation sheet associated with the first panel portion can be heat-sealed to one or more adjacent layers of insulation sheet associated with the third panel portion to form a side seam. In one embodiment of the invention, at least a portion of the periphery of the first panel portion and / or the third panel portion can be folded before forming the side seam.

[0078] In use, it is envisioned that the first panel portion and the third panel portion can be stacked on top of each other, such that the inner surface of the first panel portion can abut the inner surface of the third panel portion, and at least a portion of the stacked panel portions is placed in the sealing device. Preferably, each of the paired baffle members of the first panel portion and the third panel portion can be stacked on top of each other, such that the inner surface of each of the paired baffle members of the first panel portion can abut the inner surface of each of the paired baffle members of the third panel portion, and at least a portion of the stacked panel portions is placed in the sealing device. In one embodiment of the invention, a portion of the stacked panel portions placed in the sealing device can extend outward from the sealing device. Preferably, a portion of the baffle member of the stacked panel portions placed in the sealing device can extend outward from the sealing device. In this case, it is envisioned that the portion of the stacked first panel portion and the third panel portion extending outward from the sealing device can form part of a side seam.

[0079] In a preferred embodiment of the invention, the stacked first and third panel portions can be pre-treated before forming the side seam. Preferably, the stacked baffle members of the first and third panel portions can be pre-treated before forming the side seam. In use, it is conceivable that the pre-treatment step can occur before or after the stacked panel portions are placed into the sealing device. In this case, it is conceivable that the sealing device can hold the stacked panel portions in place while the pre-treatment operation is being performed, that the pre-treatment of the stacked panel portions can be achieved before sealing the stacked panel portions to each other, or any suitable combination thereof. Advantageously, the pre-treatment step can help form a side seam with improved water and heat resistance.

[0080] Any suitable type of pretreatment can be used. For example, the stacked baffle members of the first and third panel portions can be pre-compressed to reduce the thickness of the insulation layer before forming the side seams and / or bottom seams. In this case, it is conceivable that at least a portion of the baffle members of the first and third panel portions can be permanently pre-compressed. In this case, it is conceivable that the rotary die-cutting and / or sealing process can help form the side seams and / or bottom seams by pre-compressing the insulation layer. For example, the inner surfaces of the stacked panel portions can be provided with adhesives, can be chemically treated, can be heat-treated (e.g., but not limited to hot air treatment), can be discharge-treated (e.g., but not limited to corona discharge treatment, plasma treatment, etc.), or any suitable combination thereof. In this case, it is conceivable that after the inner surface pretreatment of the stacked panel portions, the sealing device can provide a heat source and / or pressure source that affects the sealing process. For example, the outer surfaces of the stacked panel portions can be directly heated by contact with the surface of the sealing device, or indirectly heated by contact with the semi-molten insulation layer.

[0081] In one embodiment of the invention, the stacked baffle members of the first panel portion and the third panel portion can be pre-treated to facilitate sealing between the stacked baffle members. In another embodiment of the invention, a portion of the stacked baffle members of the first panel portion and the third panel portion can be unfolded, such that the stacked baffle members of the first panel portion and the third panel portion form an opening. Any suitable opening can be formed. However, preferably, the angle formed when the stacked panel portions are unfolded can be substantially symmetrical. In this case, it should be understood that the opening can be narrowest near the sealing device, such that the opening forms a generally V-shaped structure. The V-shaped opening between the baffle members of the first panel portion and the third panel portion can be at any suitable angle. In one embodiment of the invention, the V-shaped opening can form an angle of up to 180°, preferably up to 170°, preferably up to 160°, preferably up to 150°, preferably up to 140°, preferably up to 130°, preferably up to 120°, preferably up to 110°, preferably up to 100°, preferably up to 90°, preferably up to 80°, preferably up to 70°, preferably up to 60°, preferably up to 50°, preferably up to 40°, preferably up to 30°, preferably up to 20°, or preferably up to 10°. Preferably, the V-shaped opening between the baffle members of the first panel portion and the third panel portion can form an angle of approximately 5° to 90°, preferably approximately 10° to 80°, preferably approximately 15° to 70°, preferably approximately 15° to 60°, preferably approximately 15° to 50°, or preferably approximately 15° to 45°.

[0082] In a preferred embodiment of the invention, a hot air source and / or discharge treatment may be applied to the V-shaped opening to soften the inner surfaces of the baffle members of the first panel portion and the third panel portion and fuse them together.

[0083] Any suitable sealing device can be used to form the side seam and / or bottom seam. For example, the sealing device can be a rotary welder, a hot plate welding process, etc. For example, the sealing device can be directly heated (e.g., hot air welding, hot wedge welding, etc.) or indirectly heated (e.g., ultrasonic welding, electromagnetic welding, radio frequency welding, etc.). However, preferably, the sealing device can provide sufficient heat and pressure to seal a portion of each baffle member of the first panel portion to a portion of each baffle member of the third panel portion. In one embodiment of the invention, the sealing device for forming a side seam between a portion of each baffle member of the first panel portion and a portion of each baffle member of the third panel portion is the same sealing device used to form an edge seal around at least a portion of the periphery of the container blank. Alternatively, different sealing devices can be used. In some embodiments of the invention, two or more sealing devices can be used. For example, pulse welding and rotary die devices can be used. In use, it is contemplated that two or more sealing devices can be used to achieve sealing of different components of the insulation sheet.

[0084] In one embodiment of the invention, the sealing device includes at least one upper heating rod, which may be associated with a press frame. In a preferred embodiment of the invention, the sealing device includes an upper heating rod and a lower heating rod, wherein the upper heating rod may be associated with a press frame. In one embodiment of the invention, the upper heating rod and / or the lower heating rod may be provided with a forming surface to facilitate heating and / or cooling of the working surfaces of the upper heating rod and / or the lower heating rod. In a preferred embodiment of the invention, the forming surface includes one or more channels that at least partially extend through the working surfaces of the upper heating rod and / or the lower heating rod. In this case, it is envisioned that pre-treating the insulation sheet by applying hot air to the container blank during the sealing process softens the inner insulation layer of the insulation sheet, reduces the thickness of the side seams, and improves the container's ability to be flattened. In another embodiment of the invention, the upper heating rod and / or the lower heating rod may be associated with a cooling manifold to facilitate cooling of the working surfaces of the upper heating rod and / or the lower heating rod. In use, it is envisioned that the seams cooled and compressed under pressure allow the molten or semi-molten polymer in the insulation sheet to solidify upon contact, thereby improving the water and heat resistance of the side seams.

[0085] The upper heating rod of the sealing device can be associated with the press body. In this case, it is conceivable that the press body can provide compression support for the upper heating rod, which helps to compress the insulation layer of the insulation sheet and significantly reduce the thickness of the joint. The press body can provide compression support for the upper heating rod in any suitable manner. Preferably, the laminated panel portion is formed at the side seams and / or bottom seams using heat treatment compression fusion under combined forces.

[0086] In one embodiment of the invention, a portion of each baffle member of the first panel portion may be pulse-welded to a portion of each baffle member of the third panel portion of the container blank. In this case, it is understood that the sealed portion of the container blank remains under pressure during heating. Preferably, the sealing process includes a cooling phase, wherein the sealed edge portion remains under pressure during heating and cooling cycles.

[0087] In one embodiment of the invention, the sealing device includes one or more rotating rollers (e.g., rollers, cylinders, drums, etc.), each of which is configured for a specific operating temperature, and the gap is available for forming a side seam. In this case, the sealing device is envisioned to include an upper rotating roller and a lower rotating roller, between which a thermoplastic insulating sheet can pass to form a weld. In use, the rotating rollers are envisioned to include opposing profiled surfaces, wherein, in use, as the thermoplastic insulating sheet passes between the rollers, it is compressed or clamped between the profiled surfaces forming the seal. In use, the rotating rollers are envisioned to be directly and / or indirectly heated to seal the thermoplastic sheet under heat and pressure.

[0088] In one embodiment of the invention, after the side seam is formed, excess material can be trimmed. In this case, it is conceivable that a cutting rod associated with the sealing device can be used to trim the excess material. In one embodiment of the invention, a rotary die-cutting process can form the side seam by hot pressing and simultaneously trim excess material.

[0089] A method for forming a container from a blank includes the step of sealing a portion of a first panel portion adjacent to a side seam and a portion of a third panel portion adjacent to a side seam to an edge of a second panel portion to form a bottom seam. Preferably, the method for forming a container from a blank includes the step of sealing a first baffle member of the first panel portion adjacent to the side seam and a third baffle member of the third panel portion adjacent to the side seam to an edge of the second panel portion such that, when assembled, each baffle member covers an edge of the second panel portion substantially perpendicular to the first common edge and the second common edge.

[0090] Any suitable technique can be used to seal portions of the first panel portion adjacent to the side seam and portions of the third panel portion adjacent to the side seam to the edge of the second panel portion to form a bottom seam. However, it should be understood that the method of forming the bottom seam can vary depending on many factors, such as the type of insulation sheet to be sealed, the thickness of the insulation sheet, and the desired degree of sealing. For example, the bottom seam of a container blank can be formed using adhesives or tapes, pulse heat treatment, heat treatment, chemical treatment, mechanical treatment (e.g., ultrasonic welding, compression, etc.), or a combination thereof. In one embodiment of the invention, a portion of the first panel portion adjacent to the side seam and a portion of the third panel portion adjacent to the side seam can be heat-sealed to the edge of the second panel portion. In this case, it is contemplated that one or more layers of insulation sheet associated with each of the first, second, and third panel portions can be heat-sealed to form the bottom seam. In one embodiment of the invention, at least a portion of the periphery of the second panel portion can be folded before forming the bottom seam. Preferably, the inner layers of the insulation sheet are laminated together and the outer layers of the insulation sheet are laminated together substantially simultaneously to form the side seam and / or the bottom seam.

[0091] In use, it is envisioned that a portion of the first panel portion adjacent to the side seam and a portion of the third panel portion adjacent to the side seam can be stacked on a portion of the second panel portion, such that the inner surfaces of the portion of the first panel portion adjacent to the side seam and the portion of the third panel portion adjacent to the side seam can abut the inner surface of the third panel portion, and at least a portion of the stacked panel portions are placed in a sealing device.

[0092] In one embodiment of the invention, the sealing device and sealing technology for forming the bottom seam can be the same as those for forming the side seam. Alternatively, the sealing device and sealing technology for forming the bottom seam can be different from those for forming the side seam. In one embodiment of the invention, the method of pre-processing the stacked panel portions to form the bottom seam can be the same as the method of pre-processing the stacked panel portions to form the side seam. Alternatively, the method of pre-processing the stacked panel portions to form the bottom seam can be different from the method of pre-processing the stacked panel portions to form the side seam.

[0093] In one embodiment of the invention, after the bottom seam is formed, excess material can be trimmed. In this case, it is conceivable that a cutting rod associated with the sealing device could be used to trim the excess material. In another embodiment of the invention, a rotary die-cutting process can form the bottom seam by hot pressing and simultaneously trim excess material.

[0094] In one embodiment of the invention, a method of forming a container from a blank includes the step of welding at least a portion of a seam and / or edge seal. Any suitable seam and / or edge seal can be welded. For example, the seam and / or edge seal can be a side seam, a bottom seam, an edge seal, or any suitable combination thereof. In one embodiment of the invention, a method of forming a container from a blank includes the step of welding at least a portion of a panel portion adjacent to a seam to a portion of an adjacent panel portion sharing the same seam. In one embodiment of the invention, a method of forming a container from a blank includes the step of welding at least a portion of a side seam to a bottom seam. In one embodiment of the invention, a method of forming a container from a blank includes the step of welding at least a portion of a side seam to an edge seal. It is contemplated that welding at least a portion of the seam can reinforce the seam and / or edge seal.

[0095] Any suitable portion of the joint and / or edge seal may be welded. For example, the joint and / or edge seal may be spot-welded at one or more locations along its length, may at least partially weld its length, may substantially weld its length, or any suitable combination thereof. In use, welding is envisioned for reinforcing high-load points.

[0096] In one embodiment of the invention, a plastic filler rod may be used during the welding process to provide material for the joint and / or edge seal. Optionally, the welding process softens the material near the joint and / or edge seal, allowing the softened material to join the joint and / or edge seal. In this case, it is envisioned that a portion of the outer polymer layer of the container blank may be melted to form a weld. In a preferred embodiment of the invention, one or more reinforcing tabs may be welded to the joint and / or the intersection of two joints. Any suitable reinforcing tab may be used. For example, the reinforcing tab may be part of a plastic filler rod, or it may be a plastic disc, plastic sheet, etc. The reinforcing tab may be made of any suitable material. In some embodiments of the invention, the reinforcing tab may be the same type of material as the outer layer of the insulation sheet, or it may be a different type of material. Preferably, the reinforcing tab may be the same type of material as the outer layer of the insulation sheet.

[0097] The reinforcing sheet can be any suitable size, shape, or structure. However, preferably, the reinforcing sheet can be large enough to cover the seam and extend beyond the edge of the seam. The reinforcing sheet can have any suitable thickness. For example, the reinforcing sheet can be thinner than, substantially similar to, or thicker than the outer layer of the insulation sheet. Preferably, the reinforcing sheet can be thicker than the outer layer of the insulation sheet. In use, the reinforcing sheet can be envisioned for reinforcing high-load points and / or helping to reduce stress along the seam.

[0098] Any suitable type of welding technique can be used. For example, welding techniques can include hot gas welding, rapid tip welding, extrusion welding, contact welding, hot plate welding, non-contact / IR welding, high-frequency welding, pulse welding, induction welding, injection welding, ultrasonic welding, friction welding, rotary welding, laser welding, solvent welding, etc. However, it should be understood that welding techniques can vary depending on many factors, such as the type of material to be welded, the size of the seam and / or edge seal, and the type and purpose of the container. In a preferred embodiment of the invention, the method of forming a container from a blank includes the step of hot gas welding at least a portion of the seam and / or edge seal. Preferably, the method of forming a container from a blank includes the step of welding one or more reinforcing pieces along at least a portion of the seam and / or edge seal. In one embodiment of the invention, one or more reinforcing pieces can be heat-stamped onto the seam and / or edge seal using molding.

[0099] In one embodiment of the invention, after welding, a compressive force may be applied to the joint and / or edge seal, such that the joint remains in contact until the weld cools and re-cures to produce a permanent bond.

[0100] It is conceivable that, during assembly, a portion of the first panel portion can fold into a void formed within the container, such that it contacts a portion of the third panel portion extending through the void within the container. In use, a portion of the third panel portion can extend through the void formed within the container, such that it extends onto the outer surface of the first panel portion. In this way, the first and third panel portions enclose the container, forming a substantially waterproof container without permanently sealing it.

[0101] In a second aspect, the invention primarily relates to a container formed from a blank according to the method of the first aspect of the invention. Preferably, the invention primarily relates to a container formed from a blank according to the method of the first aspect of the invention, wherein the insulating sheet comprises two or more layers, and wherein one or more layers are cross-linked closed-cell foam layers.

[0102] In a third aspect of the invention, the invention is mainly about a container formed from a blank by the method of the first aspect of the invention, wherein a first panel portion forms the front wall of the container, a third panel portion forms the rear wall of the container, a second panel portion forms the bottom wall of the container, and wherein a portion of the third panel portion forms the lid portion of the container, and wherein a portion of the third panel portion and a portion of the first panel portion interact to close the container.

[0103] This invention offers numerous advantages over existing technologies. For example, it increases flexibility of use by allowing the container to be folded (flattened) when not in use for convenient cost-effective transport and storage without excessive pressure on the packaging material or seams. Furthermore, the container-forming process creates a laminate at the seams, where the respective inner and outer surfaces of the joined panels are laminated together, which is substantially waterproof and leak-proof, and substantially resistant to delamination. For example, this invention is environmentally friendly because it eliminates the need for disposable plastic liners to ensure leak-proof transport boxes. Moreover, the box-like construction of this invention substantially conforms to the available space within the packaging box, minimizing wasted space and preventing damage to the transported goods, and substantially eliminating folds and creases, making reuse easier. Particularly advantageous is the fully laminated insulating sheet with no cavities behind the surface barrier film, which prevents contaminants from entering if the surface film is punctured by sharp or pointed contents.

[0104] Within the scope of this invention, any feature described herein may be combined with any one or more other features described herein in any way.

[0105] Any reference to prior art in this specification is not, and should not be construed as, an acknowledgment or any form of implication that the prior art is part of common general knowledge. Attached Figure Description

[0106] Preferred features, embodiments, and variations of the present invention will become apparent from the following detailed description, which provides sufficient information for those skilled in the art to practice the invention. This detailed description should not be construed as limiting the scope of the foregoing overview of the invention in any way. The detailed description will be referenced to the following figures:

[0107] Figure 1 A template for preparing a container blank according to an embodiment of the present invention is shown;

[0108] Figure 2 A partially assembled container blank of a flat packaging structure according to an embodiment of the present invention is shown;

[0109] Figure 3 A first panel portion and a third panel portion stacked in a sealing device according to an embodiment of the present invention are shown;

[0110] Figure 4 A partial side seam formed according to an embodiment of the present invention is shown;

[0111] Figure 5 The image shows a partially assembled container blank prior to the formation of the bottom seam;

[0112] Figure 6A reinforcing sheet embedded in a complete side seam according to an embodiment of the present invention is shown;

[0113] Figure 7 The complete side seam and the reinforcing sheet welded to the side seam are shown according to an embodiment of the present invention;

[0114] Figure 8 A monitoring device embedded in a container blank according to an embodiment of the present invention is shown;

[0115] Figure 9 A monitoring device embedded in a container blank according to an embodiment of the present invention is shown; and

[0116] Figure 10 An assembly container formed according to the method of the present invention is shown. Detailed Implementation

[0117] exist Figure 1 The image shows a template for forming a blank of a container 10 according to an embodiment of the present invention. The container blank 10 includes a first panel portion 12, a second panel portion 14 adjacent to the first panel portion 12 and sharing a first common edge 16 therewith, and a third panel portion 18 adjacent to the second panel portion 14 and sharing a second common edge 20 therewith, the second common edge 20 being substantially parallel to the first common edge 16. Each of the first panel portion 12 and the third panel portion 18 is associated with a pair of baffle members 22, 24 adapted to folding movement relative to the respective first and third panel portions 12, 18, such that when assembled, each baffle member 22, 24 covers an edge 26 of the second panel portion 14, the edge 26 being substantially perpendicular to the first common edge 16 and the second common edge 20.

[0118] One or more fold lines 34 located in the container blank 10 facilitate folding a portion of the container blank relative to adjacent portions of the container blank. For example, a fold line 34 positioned along the first common edge 16 facilitates folding the first panel portion 12 relative to the second panel portion 14.

[0119] Additional material 36 located around a portion of the container blank may be used to form edge seals, side joints, and / or bottom joints.

[0120] When assembled, the sub-panel 28 of the third panel portion 18 forms the lid portion of the container, and the sub-panel portion 30 of the first panel portion 12 and the sub-panel portion 32 of the third panel portion help to reusably close the container.

[0121] exist Figure 2The image shows a partially assembled container blank 40 of a flat packaging structure. During assembly (and in the flat packaging configuration), a second panel portion 14 can be folded along a fold line 34, which is positioned such that a first panel portion 12 and a third panel portion 18 can overlap each other, such that the inner surface of the first panel portion 12 can abut the inner surface of the third panel portion 18. A portion of the first panel portion 12 can be sealed to a portion of the third panel portion 18 to form a side seam 42.

[0122] exist Figure 3 The image shows a first panel portion 12 and a third panel portion 18 stacked in a sealing device 44. The sealing device 44 is capable of sealing a portion of the first panel portion 12 onto a portion of the third panel portion 18 in a single operation to form a side seam 58 and seal the edge 60 of the third panel portion 18. The sealing device 44 includes an upper heating rod 46 and a lower heating rod 48, wherein the upper heating rod 46 can be associated with a press body (not shown) via a support finger 54. The upper heating rod 46 and the lower heating rod 48 may be provided with forming surfaces 50 and 52, respectively, to facilitate heating and / or cooling of the working surfaces of the upper heating rod 46 and / or the lower heating rod 48. The forming surfaces 50, 52 may include one or more channels that at least partially extend through the working surfaces of the upper heating rod 46 and / or the lower heating rod 48. A temperature probe 56 measures the temperature of the working surface of the upper heating rod 46.

[0123] In use, it is conceivable that a portion of the stacked first and third panel portions can be unfolded, such that the first and third panel portions form a generally V-shaped opening, preferably approximately 15° to 45°. Before compressing the first and third panel portions to approximately 60% of their original thickness (e.g., approximately 12 mm to 4 mm) using a heating rod, the inner surfaces of the first and third panel portions can be pretreated using hot air, plasma treatment, corona discharge treatment, etc., to fuse the inner surfaces together without damaging the polymer sheet. The heating rod can be set at a temperature below the melting point of the polymer sheet, and when hot air is applied, it essentially protects the polymer sheet through heat transfer. Applying hot air to the foam insulation layer causes it to soften and transform into a molten or semi-molten form. Subsequently, secondary compression forces, under high pressure, bring together the molten inner lining, the semi-molten foam insulation material, and the heated outer polymer sheet. The application of secondary heating completes the melting of all material layers, thus forming a single material at the outer edge of the seam or edge-sealing joint. It provides a waterproof bond and also helps prevent delamination of the material layers.

[0124] exist Figure 4The image shows a partially formed side seam (or bottom seam) 62. The sealing method of the present invention provides a robust, waterproof, and heat-resistant seam and shapes adjacent layers of the container to allow the liner to fold over itself (for flat packaging) without deforming the seam.

[0125] exist Figure 5 The image shows a partially assembled container blank 64 prior to the formation of the bottom seam. A first baffle member 22 of the first panel portion 12 adjacent to the side seam 42 and a third baffle member 24 of the third panel portion 18 adjacent to the side seam 42 can be sealed to the edge 66 of the second panel portion (not shown) to form the bottom seam.

[0126] exist Figure 6 and 7 The image shows a reinforcing tab 68 welded to the complete side joint 42. A molding heat stamp 70 is used to weld the reinforcing tab 68 within the side joint 42 to help hold the first baffle member 22 of the first panel portion 12 near the third baffle member 24 of the third panel portion 18. The reinforcing tab 68 is welded at the junction of the side joint 42 and the bottom joint 72. A manifold 78 supplies hot gas to the molding heat stamp 70, and exhaust gas exits the manifold 78 through a port 80. A temperature probe 82 measures the temperature of the molding heat stamp 70. During assembly, it is conceivable that the reinforcing tab 68 helps reduce stress around joints 42 and 72.

[0127] exist Figure 8 and 9 The image shows a monitoring device 74 embedded in a container blank 10. The monitoring device 74 is embedded in the container blank 10 using hot gas supplied by a manifold 84 and a molding heat stamp 76.

[0128] exist Figure 10The image shows an assembled container 100 formed according to a process according to the present invention. The assembled container 100 is assembled by folding a portion of a first panel portion 12 of a container blank along a first fold line, wherein when folded, the first panel portion (front wall) 12 is substantially perpendicular to a second panel portion (bottom wall, not shown) of the container blank, and by folding a third panel portion (rear wall) 18 of the container blank along a second fold line, wherein when folded, the third panel portion 18 is substantially perpendicular to the second panel portion (bottom wall, not shown) and substantially parallel to the first panel portion 12. A side seam 42 is formed by sealing a portion of the first panel portion 12 to a portion of the third panel portion 18, and a bottom seam 72 is formed by sealing a portion of the first panel portion 12 adjacent to the side seam 42 and a portion of the third panel portion 18 adjacent to the side seam 42 to the edge 66 of the second panel portion (not shown). A reinforcing sheet 68 is applied to the side seam 42 and the junction between the side seam 42 and the bottom seam 72. The assembled container 100 includes an embedded sensor 74 located within the first panel portion (front wall) 12.

[0129] In use, the sub-panel 28 of the third panel portion 18 forms the lid portion of the container, and the sub-panel portion 30 of the first panel portion 12 and the sub-panel portion 32 of the third panel portion help to reusably seal the container.

[0130] In this specification and claims (if any), the word “comprising” and its derivatives include “comprises” and “comprise”, which include each of the stated integers, but do not exclude the inclusion of one or more additional integers.

[0131] Throughout this specification, references to "an embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of the invention. Therefore, the appearance of the phrase "in one embodiment" or "in an embodiment" throughout this specification does not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics may be made in one or more combinations in any suitable manner.

[0132] According to law, the invention has been described in language more or less specific to structural or methodological features. It should be understood that the invention is not limited to the specific features shown or described, as the means described herein include preferred forms for carrying out the invention. Therefore, the invention is claimed in any form or modification within the appropriate scope of the appended claims (if any) as properly interpreted by those skilled in the art.

Claims

1. A method of forming a container from a blank, the method comprising the steps of: thermally inducing one or more fold lines on at least one surface of a container blank made from a thermally insulating sheet material, wherein the blank comprises: a first panel portion; a second panel portion located adjacent to the first panel portion and sharing a first common edge therewith; and a third panel portion located adjacent to the second panel portion and sharing a second common edge therewith, the second common edge being parallel to the first common edge, wherein the first panel portion and the third panel portion are each associated with a pair of flap members adapted for a folding motion relative to the respective first panel portion and third panel portion, such that when assembled, each flap member covers an edge of the second panel portion perpendicular to the first common edge and the second common edge, folding the first panel portion of the container blank along a first fold line, wherein when folded, the first panel portion is perpendicular to the second panel portion of the container blank; folding the third panel portion of the container blank along a second fold line, wherein when folded, the third panel portion is perpendicular to the second panel portion and parallel to the first panel portion; sealing a portion of each of the pair of flap members of the first panel portion to a portion of each of the pair of flap members of the third panel portion to form a side seam; and sealing a portion of the first panel portion adjacent to the side seam and a portion of the third panel portion adjacent to the side seam to an edge of the second panel portion to form a bottom seam.

2. The method of forming a container from a blank according to claim 1, further comprising the step of: sealing one or more edges of the container blank to form one or more edge seals.

3. The method of forming a container from a blank according to claim 1, further comprising the step of: folding the third panel portion along a fold line to form a sub-panel portion, wherein when folded, the sub-panel portion of the third panel portion is parallel to the second panel portion, and wherein when assembled, the sub-panel portion encloses the container.

4. The method of forming a container from a blank according to claim 2, wherein, The one or more edge seals, one or more side seams, and / or one or more bottom seams are sealed using a heat treatment under pressure.

5. The method of forming a container from a blank according to claim 1, wherein, sealing a portion of the first panel portion to a portion of the third panel portion to form a side seam, the method comprising the steps of: stacking the first panel portion on the third panel portion such that an inner surface of the first panel portion abuts an inner surface of the third panel portion; placing at least a portion of the stacked panel portions in a sealing device such that a portion of the flap members of the stacked panel portions extend outwardly from the sealing device; preconditioning the stacked panel portions; and heat treating the stacked panel portions under pressure to fuse the respective inner and / or outer surfaces of the flap members of the first panel portion and the third panel portion together.

6. The method of forming a container from a blank according to claim 5, wherein, The preconditioning step comprises pre-compressing the stacked panel portions prior to the stacked panel portions being compressed together.

7. The method of forming a container from a blank according to claim 5, wherein, The preconditioning step comprises preparing the inner surfaces of the flap members of the first panel portion and the third panel portion prior to the stacked panel portions being pressed together.

8. The method of forming a container from a blank of claim 1, wherein a portion of the first panel portion adjacent to the side seam and a portion of the third panel portion adjacent to the side seam are sealed to the edge of the second panel portion to form a bottom seam, the method comprising the steps of: overlapping a portion of the first panel portion adjacent to the side seam and a portion of the third panel portion adjacent to the side seam over a portion of the second panel portion such that the inner surfaces of the first and third panel portions abut the inner surface of the second panel portion; placing at least a portion of the overlapped panel portions in a sealing device such that a portion of the overlapped panel portions extends outward from the sealing device; preconditioning the overlapped panel portions; and heat treating the overlapped panel portions under pressure to fuse the fused inner surfaces and / or fused outer surfaces of the first and third panel portions to the respective inner and / or outer surfaces of the second panel portion. The preconditioning step includes pre-compressing the overlapped panel portions prior to the overlapped panel portions being compressed together.

9. The method of forming a container from a blank according to claim 8, wherein, The preconditioning step includes preparing the inner surfaces of the first and third panel portions and the second panel portion prior to the overlapped panel portions being pressed together.

10. The method of forming a container from a blank according to claim 8, wherein, The one or more edge seals, one or more side seams, and / or one or more bottom seams are sealed simultaneously using heat treatment under pressure and trimmed to remove excess material.

11. The method of forming a container from a blank according to claim 2, wherein, 12. The method of forming a container from a blank of claim 2, further comprising the steps of: welding at least a portion of the seam and / or edge seal, and / or the intersection of two or more seams and / or edge seals, wherein the seam is a side seam and / or the bottom seam is leak resistant. welding one or more reinforcing patches to at least a portion of the seam, edge seal, and / or intersection of two or more seams and / or edge seals.

13. The method of forming a container from a blank according to claim 12, wherein, welding one or more reinforcing patches to the intersection of two or more seams and / or edge seals using a profiled heat stamp.

14. The method of forming a container from a blank according to claim 13, wherein, welding one or more reinforcing patches to the intersection of two or more seams and / or edge seals using impulse welding.

15. The method of forming a container from a blank according to claim 13, wherein, 16. The method of forming a container from a blank of claim 1, further comprising the steps of: embedding one or more monitoring devices into at least one surface of the container blank. embedding the monitoring device into the container blank using a profiled heat stamp.

17. The method of forming a container from a blank according to claim 16, wherein, embedding the monitoring device into the container blank using impulse welding.

18. The method of forming a container from a blank according to claim 16, wherein, 19. The method of forming a container from a blank of claim 1, wherein the insulating sheet material comprises two or more layers, wherein one or more of the layers is a layer of crosslinked closed cell foam.

20. The method of forming a container from a blank of claim 19, wherein the layer of crosslinked closed cell foam is encapsulated between one or more layers of reflective material and one or more layers of food grade antimicrobial material.

21. The method of forming a container from a blank of claim 19, wherein the insulating sheet material is a flexible insulating sheet material.

22. The method of forming a container from a blank of claim 19, wherein the insulating sheet material is a waterproof insulating sheet material. ​

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