Method for forming a container

Abstract

1. A process for forming a container from a blank, the process comprising: thermally creating one or more fold lines on at least one surface of a container blank made from insulating sheet material; folding a first panel portion of the container blank along the 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 bond; and sealing a portion of the panel portion adjacent the side seam bond to an edge of the second panel portion to form a bottom seam bond.

Description

Technical Field

[0001] The present invention relates to a process for forming a container from a blank and to a container formed therefrom.

Background Art

[0002] Known packaging for the storage and transport of temperature-sensitive items such as seafood includes Styrofoam boxes and polyethylene-coated or wax-impregnated cardboard boxes, which are packed together with a coolant such as ice to maintain the refrigeration of the items even after leaving cold-chain storage and to ensure delivery while remaining within the recommended temperature range (usually 2°C to 8°C in the case of seafood).

[0003] The disadvantages of using Styrofoam boxes are that their lifespan is limited until the boxes are damaged during use. Furthermore, since polystyrene is easily decomposed into small pieces with poor biodegradability, Styrofoam has an adverse impact on the environment. In addition, this type of packaging material tends to have low shielding properties and as a result, is easily contaminated by the contents. Other thermal insulation containers use disposable plastic liner bags in the transport boxes, so their reusability is limited. Furthermore, even if some thermal insulation containers can prevent leakage, since they are composed of disposable plastic liner bags or liner bags with a pouch-like structure, they do not spread to the entire space within the packing box, and there are limitations in that they are difficult to clean for reuse. Some of the liners fit the shape of the box, but since these have a foldable structure or consist of multiple members, not all edges are completely sealed and leakage cannot be prevented. Furthermore, these liners often have folds, pleats, and other extra members, so contaminants tend to accumulate or they are difficult to clean.

[0004] Also, conventional thermal insulation containers have fixed dimensions and cannot be folded, so they are bulky for transportation and storage when not in use, and their usage efficiency is limited.

[0005] Therefore, it would be advantageous if an improved container or at least a container that ameliorates the aforementioned problems could be provided.

[0006] It should be clearly understood that when prior art documents are referred to herein, such reference does not admit that the document forms part of the common general knowledge in the art in Australia or any other country. SUMMARY OF THE INVENTION

[0007] The present invention has been made in view of a process of forming a container from a blank and the container formed therefrom, and thereby can at least partially overcome at least one of the above-mentioned drawbacks, or can provide useful or commercial options for consumers.

[0008] In view of the above, in one aspect, the present invention broadly relates to a process for forming a container from a blank, the process comprising thermally creating one or more fold lines on at least one surface of a container blank made from a heat-insulating sheet material, the blank comprising a first panel portion, a second panel portion positioned adjacent to the first panel portion and sharing a first common edge with the first panel portion, and a third panel portion positioned adjacent to the second panel portion and sharing a second common edge with the second panel portion, the second common edge being substantially parallel to the first common edge, the first panel portion and the third panel portion each having a pair of flap members, each pair of flap members being adapted for relative folding movement with respect to the corresponding first panel portion or third panel portion, each flap member overlapping, when assembled, an edge of the second panel portion substantially 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, the first panel portion being substantially perpendicular to the second panel portion of the container blank when folded, folding the third panel portion of the container blank along a second fold line, the third panel portion being substantially perpendicular to the second panel portion and substantially parallel to the first panel portion when folded, sealing a respective part of each pair of flap members of the first panel portion to a respective part of each pair of flap members of the third panel portion to form a side seam joint, and sealing a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint to an edge of the second panel portion to form a bottom seam joint.

[0009] Throughout this specification and the claims, the terms "container blank" and "blank for forming a container" are used interchangeably.

[0010] The container blank may be formed by any suitable method. However, it will be understood that the method of forming the container blank may vary depending on a plurality of factors such as the type of material from which the container blank is manufactured and the complexity of the container blank. Such methods will be known to those skilled in the art. For example, the container blank may be formed by applying a template to a heat insulating sheet material and cutting or punching out the container blank from the heat insulating sheet material. In one embodiment of the present invention, the container blank may be formed by a die-cutting process. Any suitable die-cutting process may be used. For example, the die-cutting process may be a flat bed die cut, a laser cut, a water jet cut, a press cut, a rotary die cut, or any suitable combination thereof.

[0011] In one embodiment of the present invention, the container blank may be formed by a rotary die cut. Any suitable rotary die-cutting process may be used. In some embodiments of the present invention, the rotary die-cutting process may use a flexible cylindrical rotary die or a solid cylindrical rotary die. In a preferred embodiment of the present invention, the container blank may be formed using a flexible cylindrical rotary die process. In this example, it will be understood that the template (die) may be a thin sheet of flexible material. In some embodiments of the present invention, the rotary die cutter may be passed substantially through or at least partially through the heat insulating sheet material and cut into the design shape. In this example, it will be understood that the rotary die cutter may cut through one or more layers of the heat insulating sheet material.

[0012] The first panel part, the second panel part, and the third panel part may have any suitable size relative to each other. For example, in some embodiments of the present invention, each of the first panel part, the second panel part, and the third panel part may be substantially the same size as each other. Alternatively, at least one of the first panel part, the second panel part, and the third panel part may have a different size from the others. The first panel part, the second panel part, and the third panel part may differ from each other in any suitable dimensions, particularly in length and width. It is considered that the thickness of the blank may be substantially constant.

[0013] In one embodiment of the present invention, the third panel part may be larger than the first panel part and the second panel part. In particular, it is considered that the length of the third panel part may be longer than the lengths of the first panel part and the second panel part. In a specific embodiment, the length of the third panel part may be approximately close to the combined length of the first panel part and the second panel part. In this example, when assembled, a part of the third panel part is considered to overlap at least a part of the second panel part and the first panel part to form the lid part of the container. In one embodiment of the present invention, when assembled, a part of the third panel part may overlap at least a part of the first panel part to form the outer surface of the container. Alternatively, when assembled, a part of the third panel part may overlap at least a part of the first panel part, and when folded into the container, it may be configured to contact the inner surface of the first panel part to substantially close the container.

[0014] The first panel part and the third panel part may include one or more sub-panel parts. The sub-panel parts may be of any suitable size, shape, or configuration. For example, the third panel part may include a sub-panel part that forms the lid of the container when assembled. In this example, the sub-panel part forming the lid may be at least the width of the second panel part (which forms the bottom of the container when assembled) and at least the length of the sub-panel part of the third panel part (which forms the side wall of the container when assembled). For example, the first panel part and the third panel part may each include a sub-panel part that seals the edge when folded. In this example, the sub-panel part is considered to extend substantially along the longitudinal direction of each of the first panel part and the third panel part, but its width is relatively narrow. For example, the first panel part and the third panel part may each include a sub-panel part that facilitates reusable closing of the container when assembled. In this example, the sub-panel part may be at least the length of each of the first panel part and the third panel part.

[0015] The first panel part and the third panel part may be accompanied by a pair of flap members. The flap members may be associated with the first panel part and the third panel part in any suitable manner. For example, the flap members may be integrally formed with the container blank or may be formed separately and attached to the container blank. In one embodiment of the present invention, the flap members may be integrally formed with the container blank.

[0016] In one embodiment of the present invention, at least one of the first panel part and the third panel part may include two or more pairs of flap members. For example, the third panel part may include a first pair of flap members associated with a part of the third panel part that may form the wall (and preferably the rear wall) of the container when assembled, and a second pair of flap members associated with a sub-panel part that may form the lid of the container when assembled. In this example, the two or more pairs of flap members may be folded independently of each other.

[0017] In one embodiment of the present invention, each flap member of the pair of flap members is located adjacent to the corresponding first panel portion and third panel portion, and may share a common edge with the corresponding first panel portion or third panel portion. The pair of flap members may be associated with any suitable edge of each of the first panel portion and the third panel portion. However, preferably, the pair of flap members may be associated with the opposing edges of each of the first panel portion and the third panel portion. In one embodiment, when assembled, each flap member of the pair of flap members may be arranged substantially parallel to each other.

[0018] The pair of flap members may be of any suitable size, shape, and configuration. For example, in some embodiments of the present invention, each flap member of the pair of flap members may be substantially the same size, shape, and configuration as each other. Alternatively, the first flap member of the pair of flap members may be a different size from the second flap member of the pair of flap members. The first flap member and the second flap member of the pair of flap members may be of any suitable dimensions, particularly their lengths and widths may differ from each other. The thickness of the container blank is considered to be substantially constant.

[0019] For example, in some embodiments of the present invention, each pair of flap members of the first panel portion and the third panel portion may be substantially the same size, shape, and configuration as each other. Alternatively, the pair of flap members associated with the first panel portion may be of a different size than the pair of flap members associated with the third panel portion. Each pair of flap members of the respective first panel portion and third panel portion may have any suitable dimensions, particularly their lengths and widths may differ from each other. Preferably, the length of the pair of flap members of the third panel portion may be longer than the length of the pair of flap members of the first panel portion. In one embodiment of the present invention, the length of the pair of flap members of the third panel portion may be substantially approximated to the length of the third panel portion. In an alternative embodiment of the present invention, the length of the pair of flap members of the third panel portion may be shorter than the length of the third panel portion. In one embodiment of the present invention, one or more fold lines may be disposed in a part of the pair of flap members such that they are substantially aligned with one or more fold lines located in adjacent panel portions. In this example, it is considered that the fold lines may facilitate folding the flap members into the same configuration as the adjacent panel portions.

[0020] However, preferably, when assembled, the flap members may be of a sufficient size such that each flap member corresponding to the first panel portion and the third panel portion overlaps an edge of the second panel portion that is substantially perpendicular to the first common edge and the second common edge.

[0021] Preferably, the flap members may be adapted to a relative bending movement with respect to each of the first panel portion and the third panel portion. In use, it is considered that one or more fold lines may be provided along a part of the common edge shared by the flap members and the corresponding panel portions.

[0022] In one embodiment of the present invention, at least one flap member of the pair of flap members and each sub-panel portion of the first panel portion and the third panel portion may share a common edge. In a preferred embodiment of the present invention, each flap member of the pair of flap members and each sub-panel portion of the first panel portion and the third panel portion may share a common edge. In this example, in order to facilitate bending the flap member and the sub-panel portion relative to each other, one or more fold lines may be arranged along a part of the common edge. Alternatively, at least a part of the flap member and / or the sub-panel portion may be cut off so that the amount of overlapping material is minimized when the flap member and the sub-panel portion are bent relative to each other. In an alternative embodiment of the present invention, each flap member of the pair of flap members and each sub-panel portion of the first panel portion and the third panel portion do not have to share a common edge. In this example, each flap member and sub-panel portion of each of the first panel portion and the third panel portion may be bent independently of each other.

[0023] When assembled, the second panel portion may form the bottom panel of the container, the first panel portion may form the wall of the container (particularly the front wall of the container), the third panel portion may form the wall of the container (particularly the rear wall) and the lid portion, and the flap member may form the side wall of the container.

[0024] When assembled, the first panel portion may be disposed at any suitable position relative to the second panel portion. For example, the first panel portion may be disposed at an angle between 40° and 140° relative to the second panel portion. More preferably, the first panel portion may be disposed at an angle of 60° or more and 120° or less relative to the second panel portion. Even more preferably, the first panel portion may be disposed at an angle of 80° or more and 100° or less relative to the second panel portion. Most preferably, the first panel portion may be disposed at an angle of 85° or more and 95° or less relative to the second panel portion.

[0025] When assembled, the third panel portion may be disposed at any suitable position relative to the second panel portion. For example, the third panel portion may be disposed at an angle between 40° and 140° relative to the second panel portion. More preferably, the third panel portion may be disposed at an angle of 60° or more and 120° or less relative to the second panel portion. Even more preferably, the third panel portion may be disposed at an angle of 80° or more and 100° or less relative to the second panel portion. Most preferably, the third panel portion may be disposed at an angle between 85° and 95° relative to the second panel portion.

[0026] In a preferred embodiment, both the first panel portion and the third panel portion may be disposed substantially perpendicular to the second panel portion when the container is assembled. Preferably, the first panel portion and the third panel portion may be disposed substantially parallel to each other. In a preferred embodiment of the present invention, the flap member may be disposed substantially perpendicular to the first panel portion, the second panel portion, and the third panel portion.

[0027] The blank for forming the container may be made from any suitable material. Preferably, the container blank may be made from any suitable type of material having heat insulating properties. In one embodiment of the present invention, the container blank may be made from a sheet material. In a preferred embodiment of the present invention, the container blank may be made from a flexible sheet material. Preferably, the flexible sheet material may be in a roll form. In one embodiment of the present invention, the container blank may be made from a heat insulating sheet material. Any suitable heat insulating sheet material may be used. However, it is considered that the heat insulating sheet material reflects radiant heat during use, thereby reducing or minimizing the temperature rise of an object at least partially surrounded by the heat insulating sheet material.

[0028] The heat insulating sheet material may include at least one layer. In one embodiment of the present invention, the heat insulating sheet material may have a multilayer structure. In one embodiment of the present invention, the heat insulating sheet material includes a heat insulating layer disposed between at least one upper layer and at least one lower layer. In a preferred embodiment of the present invention, the heat insulating layer may include a foam layer, and the foam layer may be made from an extruded polymer, an expanded polymer, a foamed polymer, or any suitable combination thereof. In some embodiments of the present invention, the heat insulating layer may be made from a closed-cell foam material or an open-cell foam material. In a preferred embodiment of the present invention, the heat insulating layer may be made from a closed-cell foam material. Preferably, the heat insulating layer may be made from a 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 heat insulating layer may be made from a cross-linked closed-cell polyethylene foam layer.

[0029] In a preferred embodiment of the present invention, at least one upper layer and at least one lower layer may be formed from a polymer sheet material, and the polymer sheet material may be made from polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, polycarbonate, acrylonitrile butadiene styrene, etc., or any suitable combination thereof. In some embodiments of the present invention, at least one upper layer and at least one lower layer may be made from 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 from polyethylene.

[0030] In one embodiment of the present invention, the heat insulating sheet material includes at least one polymer sheet material laminated on the heat insulating layer. In use, the laminated heat insulating sheet material is considered to contain no cavities behind the polymer sheet material that resists contamination of the heat insulating layer. In one embodiment of the present invention, the heat insulating sheet material may be laminated before being used in the process of the present invention. In a preferred embodiment of the present invention, the heat insulating sheet material may be laminated in one step of the process of the present invention. Preferably, the heat insulating sheet material may be laminated before one or more fold lines are generated on at least one surface of the container blank formed from the heat insulating sheet material. Advantageously, the heat retained from the lamination process may contribute to thermally generating fold lines in the heat insulating sheet material.

[0031] In one embodiment of the present invention, the heat insulating sheet material includes a foam layer encapsulated between one or more layers of a reflective material and one or more layers of an antibacterial material. Preferably, the heat insulating sheet material may be composed of a cross-linked closed-cell foam layer encapsulated between an outer layer of a metal vapor-deposited polyethylene film and an inner layer of an antibacterial film.

[0032] Preferably, the blank for forming the container may be made from a flexible heat insulating sheet material. Preferably, the blank for forming the container may be made from a water-resistant heat insulating sheet material. Preferably, the blank for forming the container may be assembled from a heat insulating sheet material that has obtained food grade approval. As used herein, the term "food grade" means that the blank for forming the container is permitted to come into contact with food consumed by humans or animals.

[0033] In a preferred embodiment, the container blank may be resistant to one or more environmental factors. For example, the container blank may have water resistance, waterproofness, ultraviolet resistance, chemical resistance, impact resistance, fire resistance, or a combination thereof. In a preferred embodiment of the present invention, the container blank may be at least water resistant. Preferably, the container blank may be substantially waterproof such that when the coolant or frozen product stored in the container formed from the container blank thaws, the resulting water does not contaminate the inner layer of the container blank.

[0034] Any suitable means for imparting water resistance to the container blank may be used. For example, the container blank may be formed of a substantially water-resistant heat-insulating sheet material, may be provided with a water-repellent coating, may be provided with a lining having high moisture-proof properties, or may be treated with a combination thereof. Preferably, the heat-insulating sheet material may have a sealed edge. In this way, the heat insulation of the material may be improved, and the sheet material may have improved water resistance. Any suitable technique for sealing the edge of the sheet material may be used. However, it will be understood that the sealing technique may vary depending on a plurality of factors such as the type of sheet material to be sealed, the thickness of the sheet material, and the degree of sealing required. For example, the edge of the sheet material may be sealed using an adhesive or adhesive tape, heat impulse treatment, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof.

[0035] Preferably, when assembled, the reflective layer of the heat-insulating sheet material forms the outer surface of the container, and the antibacterial layer of the heat-insulating sheet material forms the inner surface of the container.

[0036] The process of forming a container from a blank includes forming one or more fold lines on at least one surface of a container blank made from a heat-insulating sheet material. The one or more fold lines may be disposed on any suitable surface of the container blank. For example, the fold lines may be disposed on the inner surface of the container blank, the outer surface of the container blank, or both the inner and outer surfaces of the container blank. In a preferred embodiment of the present invention, the one or more fold lines may be disposed on the inner surface of the container blank. The fold lines may be disposed on any suitable part of the container blank. For example, the fold lines may be disposed near the edge of the container blank, within the region defined by the panel portions of the container blank, between two adjacent panel portions, or any suitable combination thereof. However, preferably, the fold lines are disposed on a part of the container blank that facilitates folding of the panel portions to form edge seals and / or facilitates folding of at least a part of the peripheral edge of the container blank.

[0037] The fold lines may be of any suitable size, shape, and configuration. However, it will be understood that the size, shape, and configuration of the fold lines may vary depending on a plurality of factors such as the type and thickness of the material from which the container blank is made, the configuration of the container blank, and the desired end configuration of the panel portions to be folded.

[0038] The fold lines may be of any suitable depth. However, it is considered that the fold lines may be of a depth sufficient to facilitate folding of the panel portions. For example, the fold lines may extend at least partially into the heat-insulating layer of the container blank from the inner surface of the container blank, at least partially into the heat-insulating layer of the container blank from the outer surface of the container blank, or at least partially into the heat-insulating layer of the container blank from both the inner and outer surfaces of the container blank.

[0039] One or more fold lines may be oriented relative to one or more other fold lines. For example, the container blank may comprise a fold line that is positioned perpendicular to a second fold line to form an L shape, a fold line that is positioned perpendicular to the second fold line to form a T shape, a fold line that is positioned perpendicular to the second fold line to form an X shape, a fold line that is positioned perpendicular to the second fold line to form an L shape, a fold line that is positioned at an angle of 45° relative to the second fold line, a pair of fold lines that are positioned at an angle of 45° relative to a third fold line and at an angle of 90° to each other, or other arrangements of fold lines.

[0040] The container blank may comprise one or more pairs of parallel fold lines. Each of the pairs of parallel fold lines may be spaced apart by any suitable thickness. In an embodiment, the first spacing is approximately the same as the thickness of the container blank. Providing one or more pairs of parallel fold lines in the container blank during use is thought to facilitate folding of the panel portions. For example, the pairs of parallel fold lines may reduce stress on the material, facilitate ensuring a predictable angle between adjacent panel portions, allow a panel portion to fit within a fold formed between two adjacent panel portions, allow a fold formed between two adjacent panel portions to fit within a fold formed between two different adjacent panel portions, and the like.

[0041] The process of forming a container from a blank includes forming one or more fold lines on at least one surface of a container blank made from a heat-insulating sheet material. The one or more fold lines may be formed at any suitable stage of the process of forming the container blank. For example, the one or more fold lines may be formed before the cutting or punching of the container blank, during the cutting or punching of the container blank, after the cutting or punching of the container blank, or at any suitable combination of those stages. In one embodiment of the present invention, the template of the container blank may include one or more fold line positioning portions. In this example, it is considered that the fold line positioning portion may enable the position of the fold line to be marked on the surface of the container blank. Any suitable means for marking the position of the fold line on the surface of the container blank may be used. In one embodiment of the present invention, the fold line may be formed using one or more fold line positioning portions.

[0042] The fold line may be formed by any suitable method. For example, the fold line may be formed by cutting or perforating, heating, laser irradiation, pressing the material between a forming die part and an anvil part, pressing the material between complementary co-acting forming die parts, a heat-sensitive adhesive, or a similar method. In a preferred embodiment of the present invention, the one or more fold lines may be thermally generated on at least one surface of a container blank made from a heat-insulating sheet material. Preferably, the fold line may be formed by impulse heating, heating, compression, or any suitable combination thereof. However, it is preferable that the method of forming the fold line does not cause the container material to break, be damaged, or affect its resistance to environmental factors such as water resistance. In a preferred embodiment of the present invention, the one or more fold lines may be formed during a rotary die cut process. In this example, it is considered that one or more forming die parts may compress the heat-insulating sheet material towards the anvil part until the fold line is formed. Preferably, the one or more formed die parts may be heated.

[0043] In one embodiment of the present invention, the container blank comprises one or more monitoring devices embedded in at least one surface of the container blank. The monitoring device may be in any suitable form and may monitor any suitable parameter related to the container blank and / or the container formed from the container blank. However, preferably, the one or more monitoring devices provide information regarding the state of the container blank and / or the container formed from the container blank. For example, a suitable monitoring device may be an electronic monitoring device. The electronic monitoring device may include an electronic chip, an IoT (Internet of Things) module, a data logger, an RFID (radio frequency identification) chip, an NFC (near field communication) tag, a smart tag, and the like. The monitoring device may be used to track and / or trace the container blank and / or the container formed from the container blank during use, identify worn or damaged parts, monitor the temperature or humidity at one or more locations within the container formed from the container blank, or perform a combination thereof.

[0044] The one or more monitoring devices may be disposed at any suitable part of the container blank. However, it will be understood that the position of the monitoring device may vary depending on a plurality of factors such as the function of the monitoring device and the transmission frequency (in the sense of both the temporal frequency at which the monitoring device transmits and / or the radio frequency at which the monitoring device transmits). In one embodiment of the present invention, the monitoring device may be disposed on the surface of the container blank. In this example, it is considered that a polymer film may at least partially cover the monitoring device as a protective barrier for the monitoring device and also to fix the monitoring device to the container blank. In one embodiment of the present invention, the monitoring device may be disposed within the container formed from the container blank.

[0045] In one embodiment of the present invention, the process of forming a container from a blank includes the step of embedding one or more monitoring devices in at least one surface of a container blank made from a heat-insulating sheet material. The monitoring device may be in any suitable form and may monitor any suitable parameter related to the container blank and / or the container formed from the container blank. However, preferably, one or more monitoring devices provide information regarding the state of the container blank and / or the container formed from the container blank. For example, a suitable monitoring device may be an electronic monitoring device. The electronic monitoring device may include an electronic chip, an IoT (Internet of Things) module, a data logger, an RFID (radio frequency identification) chip, an NFC (near field communication) tag, a smart tag, and the like. In use, the monitoring device may be used to track and / or trace the container blank and / or the container formed from the container blank, identify worn or damaged parts, monitor the temperature and / or humidity at one or more positions within the container formed from the container blank, or a combination thereof.

[0046] One or more monitoring devices may be disposed at any suitable part of the container formed from the container blank. However, it will be understood that the position of the monitoring device may vary depending on a plurality of factors such as the function of the monitoring device and the transmission frequency (in the sense of both the temporal frequency at which the monitoring device transmits and / or the radio frequency at which the monitoring device transmits). In one embodiment of the present invention, the monitoring device may be disposed on the surface of the container formed from the container blank. In this example, it is contemplated that the monitoring device may be at least partially covered by a polymer film to provide a protective barrier to the monitoring device and to secure the monitoring device to the container formed from the container blank. In one embodiment of the present invention, the monitoring device may be disposed within the container formed from the container blank.

[0047] One or more monitoring devices may be embedded at any suitable stage of forming the container blank. For example, one or more monitoring devices may be embedded before the cutting or punching of the container blank, during the cutting or punching of the container blank, after the cutting or punching of the container blank, or at any suitable combination of those stages. In a preferred embodiment of the present invention, one or more monitoring devices may be embedded in the container blank during the cutting or punching of the container blank.

[0048] One or more monitoring devices may be embedded using any suitable method. For example, one or more monitoring devices may be adhered to the container blank using an adhesive or adhesive tape, heat impulse treatment, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof. In this example, it is considered that the monitoring device may include a substrate such as a thermoplastic material configured to adhere to the container blank. For example, the monitoring device may be embedded in one or more layers of the heat insulating sheet material during the manufacture of the heat insulating sheet material. For example, one or more monitoring devices may be printed or engraved on the container blank.

[0049] In some embodiments of the present invention, one or more monitoring devices may be embedded on at least one surface of the container blank using hot air welding and / or profiled heat stamping. In a preferred embodiment of the present invention, one or more monitoring devices may be embedded during a rotary die cut process. In this example, it is considered that one or more formed die parts may press a part of the monitoring device against the heat insulating sheet material. Preferably, one or more formed die parts may be heated.

[0050] In one embodiment of the present invention, the process of forming a container from a blank includes sealing one or more edges of the container blank. Any suitable edge of the container blank may be sealed. Preferably, one or more edges of the container blank that are not likely to be joined to adjacent edges of the container blank may be sealed. In one embodiment of the present invention, a portion of the edge of the surface on one side of the container blank may be sealed, and a portion of the same edge may not be sealed. In this example, the portion of the container blank where the edge is not sealed may be considered to be joined to an adjacent portion where the edge is not sealed. In one embodiment of the present invention, at least a portion of the peripheral edge of the container blank may be sealed. In an alternative embodiment of the present invention, substantially all of the peripheral edge of the container blank may be sealed. By doing so, the heat insulation property of the container blank is improved, and the container blank has improved water resistance. In one embodiment of the present invention, at least a portion of the peripheral edge of the container blank may be sealed before assembling the container blank into a container. Alternatively, at least a portion of the peripheral edge of the container blank may be sealed during the assembly of the container blank into a container.

[0051] Any suitable sealing device may be used to seal the edges of the container blank. However, it will be understood that the method of forming the edge seal may vary depending on a plurality of factors such as the type of heat insulating sheet material to be sealed, the thickness of the heat insulating sheet material, and the degree of sealing required. For example, the edges of the container blank may be sealed using an adhesive or adhesive tape, heat impulse treatment, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof.

[0052] In one embodiment of the present invention, before forming the edge seal, a part of the heat insulating sheet material may be pre-compressed to reduce the thickness of the inner heat insulating layer. In this example, it is considered that a part of the heat insulating sheet material may constitute one or more edges of the heat insulating sheet material. In one embodiment of the present invention, a part of the heat insulating sheet material may be pre-treated to facilitate edge sealing. Any suitable pre-treatment may be used. For example, one or more edges may be pre-treated by application of an adhesive, chemical treatment, heat treatment (such as, but not limited to, hot air treatment, etc.), discharge treatment (such as, but not limited to, corona discharge treatment, plasma treatment, etc.), or any suitable combination thereof. During use, the pre-treatment step may be considered to facilitate the formation of an edge seal having improved water resistance and heat resistance.

[0053] In one embodiment of the present invention, one or more edges of the container blank may be sealed using heat treatment. In this example, it is considered that one or more layers of the heat insulating sheet material may be heat-sealed to adjacent layers of the heat insulating sheet material to substantially enclose the heat insulating layer therein and form an edge seal. In a preferred embodiment of the present invention, one or more edges of the container blank may be sealed using heat treatment under a compressive force. In this example, it is considered that the compressive force may reduce the thickness of the inner heat insulating layer in the vicinity of the region where the edge is sealed. In one embodiment of the present invention, one or more edges of the container blank may be sealed using impulse welding. In this example, it is understood that the portion of the edge to be sealed remains under pressure during heating. Preferably, the sealing step includes a cooling stage, and the portion of the edge to be sealed remains under pressure during the heating and cooling cycles. In one embodiment of the present invention, one or more edges of the container blank may be sealed during a rotary die cut process. In this example, it is considered that one or more forming die parts may compress the heat insulating sheet material against the anvil part until the edge seal is formed. Preferably, one or more forming die parts may be heated.

[0054] In one embodiment of the present invention, after the edge seal is formed, excess material may be removed. In this example, it is contemplated that a cutting bar associated with the sealing device may be used to remove the excess material. In one embodiment of the present invention, a rotary die cut process may simultaneously perform compression and removal of excess material to form an edge seal. Alternatively, at least a portion of the peripheral edge of the container blank may be bent before forming the edge seal. In this example, it is contemplated that the bent portion of the container blank may be heat sealed to the container blank to form an edge seal.

[0055] The process of forming a container from a blank includes folding a first panel portion of the container blank along a first fold line, such that when folded, the first panel portion is substantially perpendicular to a second panel portion of the container blank.

[0056] The first fold line may be disposed at any suitable location of the container blank. However, preferably, the location of the first fold line facilitates folding the first panel portion relative to the second panel portion. In a preferred embodiment of the present invention, the first fold line may be disposed along a portion of a common edge shared by the first panel portion and the second panel portion, which is a first common edge. The first fold line may be continuous along a portion of the first common edge or may be discontinuous. However, it will be understood that the configuration of the first fold line may vary depending on a plurality of factors such as the type of material being folded, the shape and size of the container blank being folded, and the length of the first common edge.

[0057] The first panel portion may be bent in any suitable direction along the first fold line. However, preferably, the inner surface of the first panel portion is bent towards the inner surface of the second panel portion. The first panel portion may be bent at any suitable angle along the first fold line. However, preferably, when bent, the first panel portion is substantially perpendicular to the second panel portion. It will be understood that the first panel portion need not be positioned so as to extend at exactly a 90° angle to the second panel portion, and relatively small deviations from perpendicularity are acceptable and do not affect the performance of the present invention.

[0058] The process of forming a container from a blank includes folding a third panel portion of the container blank along a second fold line, which, when folded, is substantially perpendicular to the second panel portion and substantially parallel to the first panel portion.

[0059] The second fold line may be disposed at any suitable position of 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 present invention, the second fold line may be located along a part of a common edge shared by the third panel portion and the second panel portion, which common edge is the second common edge. The second fold line may be continuous along a part of the second common edge or may be discontinuous. However, it will be understood that the configuration of the second fold line may vary depending on a plurality of factors such as the type of material being folded, the shape and size of the container blank being folded, and the length of the second common edge.

[0060] The third panel portion may be bent in any suitable direction along the second fold line. However, preferably, the inner surface of the third panel portion is bent toward the inner surface of the second panel portion. The third panel portion may be bent at any suitable angle along the second fold line. However, preferably, the third panel portion is substantially perpendicular to the second panel portion when bent. It will be understood that the third panel portion need not be arranged to extend at an exact 90° angle to the second panel portion, and relatively small deviations from perpendicularity are tolerated and do not affect the performance of the present invention.

[0061] Preferably, the second common edge may be substantially parallel to the first common edge. In this example, it will be understood that when the first panel portion is bent along the first fold line and the third panel portion is bent along the second fold line such that the first panel portion and the third panel portion are substantially perpendicular to the second panel portion, the first panel portion and the third panel portion may be substantially parallel to each other. It will be understood that the first panel portion need not be arranged to extend at an exact 180° angle to the third panel portion, and relatively small deviations from parallelism are tolerated and do not affect the performance of the present invention.

[0062] The process of forming a container from a blank includes a step of sealing a respective part of each pair of flap members of the first panel portion to a respective part of each pair of flap members of the third panel portion to form a side seam joint. Any suitable part of the flap member and / or the first panel portion may be sealed to any suitable part of the flap member and / or the third panel portion to form a side seam joint. For example, the inner surfaces may be sealed to each other, the outer surfaces may be sealed to each other, the inner insulation layers may be sealed to each other, or any suitable combination thereof may be sealed. Preferably, both the inner and outer surfaces of the flap member and / or the first panel portion may be sealed to the corresponding inner and outer surfaces of the flap member and / or the third panel portion, respectively. In this example, it will be understood that the step of sealing the respective inner and / or outer surfaces to each other may involve welding or soldering the materials together such that the resulting layer may be substantially resistant to peeling. In use, the side seam joint and / or the bottom seam joint formed by the process of the present invention may include a laminate, and it is contemplated that the corresponding insulation sheet materials of each of the flap members and / or the panel portions may be substantially welded together.

[0063] In one embodiment of the present invention, the inner and outer surfaces of the flap member and / or the first panel portion may be sealed to the corresponding inner and outer surfaces of the flap member and / or the third panel portion, respectively, substantially simultaneously. Preferably, the respective inner surfaces may be sealed before the respective outer surfaces may be sealed. However, it will be understood that the order in which the respective inner and outer surfaces may be sealed may vary depending on the type and combination of the sealing device used, the type and composition of the insulation sheet material, and the desired properties of the side seam joint and / or the bottom seam joint.

[0064] Preferably, the laminate of the side seam joint and / or the bottom seam joint formed by this process may have substantially watertightness and leak prevention properties. Preferably, the laminate of the side seam joint and / or the bottom seam joint formed by this process may have substantially resistance to delamination. In this example, it will be understood that under tensile stress, the joined polymer sheet layers of the laminate resist delamination. In use, welding the inner surfaces of the heat insulating sheet materials together at the side seam joint and / or the bottom seam joint forms a leak-proof container, reduces the risk of contaminant intrusion associated with reusing the container, and welding the outer surfaces of the heat insulating sheet materials together at the side seam joint and / or the bottom seam joint may prevent the intrusion of contaminants, particularly when the container may be in a flat-packed state, and may prevent delamination of the outer surface in the vicinity of the side seam joint and / or the bottom seam joint that is under stress. In one embodiment of the present invention, welding the inner surfaces together and welding the outer surfaces together may form a seam joint in the laminate that is more resistant to delamination under stress than a seam joint formed by laminating only the inner layer of the film.

[0065] Any suitable part of each of the pair of flap members of the first panel portion may be sealed to a part of each of the pair of flap members of the third panel portion to form a side seam joint. In a preferred embodiment of the present invention, a part of each of the pair of flap members of the first panel portion and / or the third panel portion includes the edge of each flap member. Preferably, a part of the first panel portion may be a first flap member that is located adjacent to the first panel portion and shares an edge therewith, and preferably, a part of the third panel portion may be a third flap member that is located adjacent to the third panel portion and shares an edge therewith. In this example, it is considered that the first flap member may be sealed to the third flap member to form a side seam joint. In use, the common edge between the panel portion and the flap member may be provided with one or more fold lines to facilitate folding the flap member relative to the panel portion.

[0066] In one embodiment of the present invention, the side seam joint extends along at least a portion of the length of each pair of flap members of the first panel portion and / or the third panel portion. The side seam joint may extend along any suitable length of each pair of flap members of the first panel portion and / or the third panel portion. For example, the side seam joint may extend along substantially the entire length of each pair of flap members of the first panel portion, may extend along substantially the entire length of each pair of flap members of the third panel portion, may extend along at least a portion of the length of each pair of flap members of the first panel portion, may extend along at least a portion of the length of each pair of flap members of the third panel portion, or may extend in any suitable combination thereof. The side seam joint may extend along the same length as each of the first panel portion and the third panel portion, or may extend along a different length than each of the first panel portion and the third panel portion. In use, when the third panel portion is longer than the first panel portion, it is contemplated that the side seam joint may extend along substantially the entire length of the first panel portion and also along at least a portion of the length of the third panel portion.

[0067] In one embodiment of the present invention, the process of forming a container from a blank includes, in a single operation, sealing a portion of each pair of flap members of the first panel portion to a portion of each pair of flap members of the third panel portion to form a side seam joint and sealing an end of the third panel portion. In this example, the side seam joint and the edge seal are considered to be continuous along the length of the third panel portion.

[0068] Any suitable technique may be used to seal a portion of each pair of flap members of the first panel portion to a portion of each pair of flap members of the third panel portion to form a side seam joint. However, it will be understood that the method of forming the side seam joint may vary depending on a plurality of factors such as the type of heat insulating sheet material to be sealed, the thickness of the heat insulating sheet material, the degree of sealing required, and the like. For example, the side seam joint of the container blank may be formed by the use of an adhesive or an adhesive tape, heat impulse treatment, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof. In one embodiment of the present invention, a portion of the first panel portion may be sealed to a portion of the third panel portion using heat treatment. In this example, one or more layers of the heat insulating sheet material associated with the first panel portion may be heat-sealed to one or more adjacent layers of the heat insulating sheet material associated with the third panel portion to form a side seam joint. In one embodiment of the present invention, at least a portion of the peripheral edge of the first panel portion and / or the third panel portion may be bent before forming the side seam joint.

[0069] In use, the first panel portion and the third panel portion may be overlapped with each other such that the inner surface of the first panel portion abuts against the inner surface of the third panel portion and at least a portion of the overlapped panel portions placed in the sealing device. Preferably, each pair of flap members of the first panel portion and the third panel portion may be overlapped with each other such that the inner surface of each pair of flap members of the first panel portion abuts against the inner surface of each pair of flap members of the third panel portion and at least a portion of the overlapped panel portions placed in the sealing device. In one embodiment of the present invention, a portion of the overlapped panel portions placed in the sealing device may extend outwardly from the sealing device. Preferably, a portion of the flap members of the overlapped panel portions placed in the sealing device may extend outwardly from the sealing device. In this example, the portion of the overlapped first panel portion and the third panel portion extending outwardly from the sealing device may be considered to form a part of the side seam joint.

[0070] In a preferred embodiment of the present invention, the overlapped first panel portion and third panel portion may be pretreated before forming the side seam joint. Preferably, the overlapped flap members of the first panel portion and the third panel portion may be pretreated before forming the side seam joint. In use, it is contemplated that the pretreatment step may be performed before or after the overlapped panel portions are placed in the sealing device. In this example, the sealing device may hold the overlapped panel portions in place while the pretreatment operation is being performed, or may perform the pretreatment of the overlapped panel portions before sealing the overlapped panel portions to each other, or may perform any suitable combination thereof. Advantageously, the pretreatment step may facilitate the formation of a side seam joint having improved water resistance and heat resistance.

[0071] Any suitable type of pretreatment may be used. For example, the overlapped flap members of the first panel portion and the third panel portion may be pre-compressed to reduce the thickness of the heat insulating layer before forming the side seam joint and / or the bottom seam joint. In this example, it is contemplated that at least a portion of the flap members of the first panel portion and the third panel portion may be continuously pre-compressed. In this example, the rotary die cut and / or the sealing process may facilitate the formation of the side seam joint and / or the bottom seam joint by pre-compressing the heat insulating layer. For example, the inner surface of the overlapped panel portions may be subjected to adhesive application, chemical treatment, heat treatment (such as, but not limited to, hot air treatment), discharge treatment (such as, but not limited to, corona discharge treatment, plasma treatment), or any suitable combination thereof. In this example, after the inner surface of the overlapped panel portions has been pretreated, the sealing device may provide a heat source and / or a pressure source for performing the sealing process. For example, the outer surface of the overlapped panel portions may be directly heated by contact with the surface of the sealing device, or may be indirectly heated by contact with the semi-molten insulating layer.

[0072] In one embodiment of the present invention, the overlapping flap members of the first panel portion and the third panel portion may be pre-treated to facilitate sealing the overlapping flap members to each other. In one embodiment of the present invention, a part of the overlapping flap members of the first panel portion and the third panel portion may be expanded so that the overlapping flap members of the first panel portion and the third panel portion form an opening. Any suitable opening may be formed. However, preferably, the angles formed when the overlapping panel portions may be expanded may be substantially symmetric. In this example, it will be understood that the opening is narrowest at the portion close to the sealing device and the opening may form a substantially V-shaped configuration. The V-shaped opening between the flap members of the first panel portion and the third panel portion may form any suitable angle. In one embodiment of the present invention, the V-shaped opening may form an angle 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°, preferably up to 10°. Preferably, the V-shaped opening between the flap members of the first panel portion and the third panel portion may form an angle of about 5° to 90°, preferably about 10° to 80°, preferably about 15° to 70°, preferably about 15° to 60°, preferably about 15° to 50°, preferably about 15° to 45°.

[0073] In a preferred embodiment of the present invention, a hot air source and / or a discharge treatment may be applied to the V-shaped opening to soften and weld the inner surfaces of the flap members of the first panel portion and the third panel portion to each other.

[0074] To form side seam joints and / or bottom seam joints, any suitable sealing device may be used. For example, the sealing device may be a rotary welding machine, a hot plate welding process, etc. For example, the sealing device may apply heat directly (such as hot air welding, hot wedge welding, etc.) or indirectly (such as ultrasonic welding, electromagnetic welding, high frequency welding, etc.). However, preferably, the sealing device may apply sufficient heat and pressure to seal each part of the flap member of the first panel part to each part of the flap member of the third panel part. In one embodiment of the present invention, the sealing device used to form a side seam joint between each part of the flap member of the first panel part and each part of the flap member of the third panel part is the same sealing device used to form an edge seal in the vicinity of at least a part of the peripheral edge of the container blank. Alternatively, different sealing devices may be used. In some embodiments of the present invention, two or more sealing devices may be used. For example, an impulse welding device and a rotary die device may be used. It is considered that two or more sealing devices may be used to perform sealing of different components of the heat insulating sheet material during use.

[0075] In one embodiment of the present invention, the sealing device includes at least an upper heating bar, and the upper heating bar may be accompanied by a pressure frame. In a preferred embodiment of the present invention, the sealing device includes an upper heating bar and a lower heating bar, and the upper heating bar may be accompanied by a pressure frame. In one embodiment of the present invention, the upper heating bar and / or the lower heating bar may be provided with a profiled surface to facilitate heating and / or cooling of the working surface of the upper heating bar and / or the lower heating bar. In a preferred embodiment of the present invention, the profiled surface comprises one or more channels extending at least partially through the working surface of the upper heating bar and / or the lower heating bar. In this example, it is considered that when the heat insulating sheet material is pretreated by blowing hot air onto the container blank during sealing, the inner heat insulating layer of the heat insulating sheet material is softened, the thickness of the side seam joint is reduced, and the suitability for flat-packing the container is improved. In a further embodiment of the present invention, the upper heating bar and / or the lower heating bar may be accompanied by a cooling manifold to facilitate cooling of the working surface of the upper heating bar and / or the lower heating bar. In use, it is considered that by cooling the compressed seam joint under pressure, the molten or semi-molten polymer in the heat insulating sheet material solidifies during contact, and the water resistance and heat resistance of the side seam joint are improved.

[0076] The upper heating bar of the sealing device may be accompanied by a pressure frame. In this example, it is considered that the pressure frame may provide compressive support to the upper heating bar that facilitates compression of the heat insulating layer of the heat insulating sheet material and significantly reduces the thickness of the joint portion. The pressure frame may provide compressive support to the upper heating bar by any suitable means. Preferably, when the welded panel portion is compressed using heat treatment under compressive force, a laminate is formed at the side seam joint and / or the bottom seam joint.

[0077] In one embodiment of the present invention, a part of each flap member of the first panel portion may be sealed to a part of each flap member of the third panel portion of the container blank using impulse welding. In this example, it is understood that a part of the container blank to be sealed remains pressurized even during heating. Preferably, the sealing process includes a cooling stage, and pressure is applied to the edge portion to be sealed during the heating and cooling cycles.

[0078] In one embodiment of the present invention, the sealing device includes one or more rotating wheels (rollers, cylinders, drums, etc.), and each of the one or more rotating wheels may be configured at a specific operating temperature and clearance and may be used to form a side seam joint. In this example, it is considered that the sealing device may include an upper rotating wheel and a lower rotating wheel, and a thermoplastic insulating sheet may pass between them to form a welded portion. In use, the surfaces of both rotating wheels may have opposing curved shapes, and it is considered that when the thermoplastic insulating sheet passes between both rollers during use, it is compressed or sandwiched between both curved surfaces to form a seal. In use, the rotating wheel may be heated directly and / or indirectly to seal the thermoplastic sheet material while applying heat and compressive force.

[0079] In one embodiment of the present invention, after the side seam joint is formed, excess material may be removed. In this example, it is considered that the excess material may be removed using a cutting bar associated with the sealing device. In one embodiment of the present invention, the rotary die cut process may remove excess material simultaneously with forming the side seam joint by thermocompression.

[0080] The process of forming a container from a blank includes the step of sealing a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint to the edge of the second panel portion to form a bottom seam joint. Preferably, the process of forming a container from a blank seals a first flap member of the first panel portion adjacent to the side seam joint and a third flap member of the third panel portion adjacent to the side seam joint to the edge of the second panel portion, such that when assembled, each flap member overlaps the edge of the second panel portion that is substantially perpendicular to the first common edge and the second common edge.

[0081] Any suitable technique may be used to seal a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint to the edge of the second panel portion to form a bottom seam joint. However, it will be understood that the method of forming the bottom seam joint may vary depending on a plurality of factors such as the type of heat insulating sheet material to be sealed, the thickness of the heat insulating sheet material, and the degree of sealing required. For example, the bottom seam joint of the container blank may be formed by the use of an adhesive or adhesive tape, heat impulse treatment, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof. In one embodiment of the present invention, a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint may be sealed to the edge of the second panel portion using heat treatment. In this example, one or more layers of the heat insulating sheet material associated with each of the first panel portion, the second panel portion, and the third panel portion may be heat-sealed to form the bottom seam joint. In one embodiment of the present invention, at least a part of the peripheral edge of the second panel portion may be bent before forming the bottom seam joint. Preferably, the step of laminating the inner surfaces of the heat insulating sheet materials and the step of laminating the outer surfaces of the heat insulating sheet materials may be performed substantially simultaneously to form the side seam joint and / or the bottom seam joint.

[0082] In use, a part of the first panel portion adjacent to the side joint and a part of the third panel portion adjacent to the side joint may be overlapped on a part of the second panel portion such that the inner surfaces of the part of the first panel portion adjacent to the side joint and the part of the third panel portion adjacent to the side joint contact the inner surface of the part of the third panel portion placed in the sealing device and at least a part of the overlapped panel portions.

[0083] In one embodiment of the present invention, the sealing device and the sealing technique used to form the bottom joint may be the same as the sealing device and the sealing technique used to form the side joint. Alternatively, the sealing device and the sealing technique used to form the bottom joint may be different from the sealing device and the sealing technique used to form the side joint. In one embodiment of the present invention, the method of pre-treating the panel portions overlapped to form the bottom joint may be the same as the method of pre-treating the panel portions overlapped to form the side joint. Alternatively, the method of pre-treating the panel portions overlapped to form the bottom joint may be a different method from the method of pre-treating the panel portions overlapped to form the side joint.

[0084] In one embodiment of the present invention, after the bottom joint is formed, excess material may be cut away. In this example, it is considered that the cutting bar associated with the sealing device may be used to cut away the excess material. In one embodiment of the present invention, the rotary die cut process may cut away the excess material simultaneously with forming the bottom joint by thermocompression.

[0085] In one embodiment of the present invention, the process of forming a container from a blank includes a step of welding at least a part of a seam joint and / or an edge seal. Any suitable seam joint and / or edge seal may be welded. For example, the seam joint and / or edge seal may be a side seam joint, a bottom seam joint, an edge seal, or any suitable combination thereof. In one embodiment of the present invention, the process of forming a container from a blank includes a step of welding at least a part of a panel portion adjacent to a seam joint to a part of an adjacent panel portion sharing the same seam joint. In one embodiment of the present invention, the process of forming a container from a blank includes a step of welding at least a part of a side seam joint to a bottom seam joint. In one embodiment of the present invention, the process of forming a container from a blank includes a step of welding at least a part of a side seam joint to an edge seal. It is considered that the seam joint and / or edge seal may be reinforced by welding at least a part of the seam joint.

[0086] Any suitable part of the seam joint and / or edge seal may be welded. For example, the seam joint and / or edge seal may be spot welded at one or more locations along the longitudinal direction of the seam joint and / or edge seal, or at least a part of the longitudinal direction of the seam joint and / or edge seal may be welded, or the seam joint and / or edge seal may be welded substantially over the longitudinal direction, or welded in any suitable combination of these. In use, the welding may be considered to be used to reinforce high-load locations.

[0087] In one embodiment of the present invention, the plastic welding rod may be used during welding to supply a material for joining a seam joint and / or edge sealing. Alternatively, the welding process may soften the material adjacent to the seam joint and / or edge sealing, allowing the softened material to join the seam joint and / or edge sealing. In this example, it is considered that a part of the outer polymer layer of the container blank may be melted to form a weld. In a preferred embodiment of the present invention, one or more reinforcing tags may be welded to the seam joint and / or the intersection of two seam joints. Any suitable reinforcing tag may be used. For example, the reinforcing tag may be a part of a plastic welding rod, a plastic disk, a plastic sheet material, etc. The reinforcing tag may be made of any suitable material. In some embodiments of the present invention, the reinforcing tag may be the same type of material as the outer layer of the heat insulating sheet material or a different type of material. Preferably, the reinforcing tag may be the same type of material as the outer layer of the heat insulating sheet material.

[0088] The reinforcing tag may be of any suitable size, shape or configuration. However, preferably, the reinforcing tag may be of a sufficient dimension to cover the seam joint and extend beyond the edge of the seam joint. The reinforcing tag may be of any suitable thickness. For example, the reinforcing tag may be substantially similar to the outer layer of the heat insulating sheet material and thinner than the outer layer of the heat insulating sheet material, or thicker than the outer layer of the heat insulating sheet material. Preferably, the reinforcing tag may be thicker than the outer layer of the heat insulating sheet material. In use, the reinforcing tag may be considered to be used to reinforce high load locations and / or to facilitate stress reduction along the seam joint.

[0089] Any suitable welding technique may be used. For example, the welding technique may be hot air welding, speed tip welding, extrusion welding, contact welding, hot plate welding, non-contact / IR welding, high frequency welding, impulse welding, induction welding, injection welding, ultrasonic welding, friction welding, spin welding, laser welding, solvent welding, etc. However, it will be appreciated that the welding technique may vary depending on a plurality of factors such as the type of material being welded, the size of the seam joint and / or edge seal, and the type and use of the container. In a preferred embodiment of the present invention, the process of forming a container from a blank includes the step of hot air welding at least a portion of the seam joint and / or edge seal. Preferably, the process of forming a container from a blank comprises the step of welding one or more reinforcing tags along at least a portion of the seam joint and / or edge seal. In one embodiment of the present invention, one or more reinforcing tags may be welded to the seam joint and / or edge seal using a profiled heat stamp.

[0090] In one embodiment of the present invention, a compressive force may be applied to the seam joint and / or edge seal after welding such that the joint portions are held in contact until the weld cools and re-solidifies to form a permanent bond.

[0091] When assembled, a portion of the first panel portion may be folded into the space formed within the container so as to contact a portion of the third panel portion that extends across the space formed within the container. In use, a portion of the third panel portion may extend across the space formed within the container so as to cover the outer surface of the first panel portion. In this way, the first panel portion and the third panel portion close the container to form a substantially watertight container without permanently sealing the container.

[0092] In a second aspect of the present invention, the present invention is broadly related to a container formed from a blank according to the process of the first aspect of the present invention. Preferably, the present invention is broadly related to a container formed from a blank according to the process of the first aspect of the present invention, wherein the heat insulating sheet material includes two or more layers, and one or more layers are cross-linked closed cell foam layers.

[0093] In a third aspect of the present invention, the present invention relates extensively to a container formed from a blank according to the process of the first aspect of the present invention, where the first panel portion forms the front wall of the container, the third panel portion forms the rear wall of the container, the second panel portion forms the bottom wall of the container, a part of the third panel portion forms the lid portion of the container, and a part of the third panel portion and a part of the first panel portion cooperate to close the container.

[0094] The present invention provides a plurality of advantages over the prior art. For example, the present invention can be conveniently "transported cost-effectively" and, when not in use, can be folded (flat-packed) for convenient storage without applying excessive force to the packaging material or seam joints, thereby improving the flexibility of use. Further, the process of forming the container generates a laminate at the seam joints, where the inner and outer surfaces of each of the joined panels are substantially watertight and leak-proof and substantially peel-resistant. For example, the present invention is environmentally friendly because it eliminates the need to use disposable plastic liner bags to ensure the leak-proofness of shipping boxes. Further, the present invention having a box-like configuration substantially conforms to the available space within the packing box, minimizes wasted space, prevents damage to the articles being transported, essentially eliminates creases and folds, and facilitates reuse. Particularly advantageous is that since the entire surface is laminated with a heat-insulating sheet material having no cavities behind the surface protection film, it prevents contaminants from entering even when the surface film is broken by sharp or pointed contents.

[0095] Any of the features described herein may be combined in any combination with any one or more of the other features described herein within the scope of the present invention.

[0096] Any reference to prior art herein is not to be construed as an admission that such prior art forms part of the common general knowledge or as any form of suggestion or as being so received. BRIEF DESCRIPTION OF THE DRAWINGS

[0097] Preferred features, embodiments and variations of the present invention can be found in the following detailed description, which provides sufficient information for those skilled in the art to practice the present invention. The detailed description should not be construed as limiting the scope of the above-described summary of the invention in any way. In the detailed description, the following multiple drawings are referred to.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0098] Figure 1 shows a template for a blank 10 for forming a container according to an embodiment of the present invention. The container blank 10 includes a first panel portion 12, a second panel portion 14 located adjacent to the first panel portion 12 and sharing a first common edge 16 therewith, and a third panel portion 18 located adjacent to the second panel portion 14 and sharing a second common edge 20 therewith. The second common edge 20 is substantially parallel to the first common edge 16. Each of the first panel portion 12 and the third panel portion 18 is accompanied by a pair of flap members 22, 24 adapted for bending movement relative to the first panel portion 12 and the third panel portion 18, such that when assembled, each of the flap members 22, 24 overlaps an edge 26 of the second panel portion 14 that is substantially perpendicular to the first common edge 16 and the second common edge 20.

[0099] One or more fold lines 34 in the container blank 10 facilitate bending a part of the container blank relative to an adjacent part of the container blank. For example, a fold line 34 located along the first common edge 16 facilitates bending the first panel portion 12 relative to the second panel portion 14.

[0100] An additive 36 located near a part of the peripheral edge of the container blank may be used to form an edge seal, a side seam joint, and / or a bottom seam joint.

[0101] When assembled, a sub-panel 28 of the third panel portion 18 forms a lid portion of the container, and sub-panel portions 30 of the first panel portion 12 and 32 of the third panel portion facilitate re-closably closing the container.

[0102] Figure 2 shows a partially assembled container blank 40 in a flat pack configuration. The second panel portion 14 may be folded along a fold line 34 such that, during assembly (and in the flat pack configuration), the first panel portion 12 and the third panel portion 18 are overlapped with each other and the inner surface of the first panel portion 12 abuts the inner surface of the third panel portion 18. A part of the first panel portion 12 may be sealed to a part of the third panel portion 18 to form a side seam joint 42.

[0103] Figure 3 shows the first panel portion 12 and the third panel portion 18 that are overlapped within the sealing device 44. The sealing device 44 can seal a part of the first panel portion 12 to a part of the third panel portion 18 in one operation to form a side joint 58 and seal the edge 60 of the third panel portion 18. The sealing device 44 includes an upper heating bar 46 and a lower heating bar 48, and the upper heating bar 46 may be accompanied by a pressure frame (not shown) via support fingers 54. The upper heating bar 46 and the lower heating bar 48 may each be provided with profile surfaces 50, 52 for facilitating heating and / or cooling of the working surfaces of the upper heating bar 46 and / or the lower heating bar 48. The profile surfaces 50, 52 may include one or more channels that extend at least partially through the working surfaces of the upper heating bar 46 and / or the lower heating bar 48. The temperature probe 56 measures the working surface temperature of the upper heating bar 46.

[0104] In use, a part of the overlapped first panel portion and third panel portion may be spread so that the first panel portion and the third panel portion preferably form a substantially V-shaped opening of about 15° to 45°. The inner surfaces of the first panel portion and the third panel portion are pretreated using hot air, plasma treatment, corona discharge treatment, etc. to weld the inner surfaces without damaging the polymer sheet material, and then compressed by the heating bar to about 60% of the original thickness (for example, from about 12 mm to 4 mm). The heating bar is set at a temperature lower than the melting point of the polymer sheet material to essentially protect the polymer sheet material by heat conduction when hot air is applied. By applying hot air to the foamed heat insulating layer, the foamed heat insulating layer softens and transitions to a molten or semi-molten state. Then, by the secondary compressive force, the welded inner surface, the semi-molten foamed heat insulating material, and the heated outer polymer sheet material are integrated under high pressure. By applying secondary heating, the fusion of all layers of materials is completed, and a single material is formed at the outer edge of the joint or edge seal joint. This contributes to achieving a watertight bond and preventing delamination of the material layers.

[0105] Figure 4 shows a partially formed side seam joint (or bottom seam joint) 62. The sealing method of the present invention provides a strong water-resistant and heat-resistant seam joint, forms adjacent layers of the container, and allows the liner to fold over itself (flat pack) without placing a burden on the seam joint.

[0106] Figure 5 shows a partially assembled container blank 64 before forming the bottom seam joint. The first flap member 22 of the first panel portion 12 adjacent to the side seam joint 42 and the third flap member 24 of the third panel portion 18 adjacent to the side seam joint 42 may be sealed to the edge 66 of a second panel portion (not shown) to form the bottom seam joint.

[0107] Figures 6 and 7 show a reinforcing tag 68 welded to the completed side seam joint 42. The reinforcing tag 68 is welded into the side seam joint 42 using a profiled heat stamp 70, facilitating holding the first flap member 22 of the first panel portion 12 close to the third flap member 24 of the third panel portion 18. The reinforcing tag 68 is welded to the joint between the side seam joint 42 and the bottom seam joint 72. The manifold 78 supplies hot gas to the profiled heat stamp 70 with exhaust gas exiting the manifold 78 through the port 80. The temperature probe 82 measures the temperature of the profiled heat stamp 70. When assembled, the reinforcing tag 68 is thought to contribute to reducing stress in the vicinity of the seam joints 42, 72.

[0108] Figures 8 and 9 show a monitoring device 74 embedded in the container blank 10. The monitoring device 74 is embedded in the container blank 10 by a profiled heat stamp 76 using hot gas supplied by a manifold 84.

[0109] FIG. 10 shows an assembled container 100 formed in accordance with the process of the present invention. When the assembled container 100 is assembled, a portion of the first panel portion 12 of the container blank is folded along a first fold line so that the first panel portion (front wall) 12 is substantially perpendicular to the second panel portion (bottom wall, not shown) of the container blank, and the third panel portion 18 is substantially perpendicular to the second panel portion (bottom wall, not shown) and parallel to the first panel portion 12, and the third panel portion (rear wall) 18 of the container blank is folded along a second fold line. The side seam joint 42 is formed by sealing a portion of the first panel portion 12 to a portion of the third panel portion 18, and the bottom seam joint 72 is formed by sealing a portion of the first panel portion 12 adjacent to the side seam joint 42 and a portion of the third panel portion 18 adjacent to the side seam joint 42 to the edge 66 of the second panel portion (not shown). The reinforcing tag 68 is applied to the side seam joint 42 and the joint between the side seam joint 42 and the bottom seam joint 72. The assembled container 100 includes an embedded sensor 74 within the first panel portion (front wall) 12.

[0110] 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 facilitate re-closably closing the container.

[0111] As used herein and in the claims, if any, the words "comprising" and "comprises" and their derivatives include each integer of the description but do not exclude including one or more further integers.

[0112] References to "one embodiment" or "an embodiment" throughout this specification mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, when the phrases "in one embodiment" or "in an embodiment" appear in various places throughout this specification, they are not necessarily all referring to the same embodiment. Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0113] In accordance with the law, the present invention has been described in terms more or less specific to structural or methodical features. Since the means described herein consist of preferred forms for carrying out the present invention, it is understood that the present invention is not limited to the specific features shown or described. Accordingly, the present invention is claimed in any form or modification within the suitable scope of the appended claims (if any), as appropriately interpreted by those skilled in the art.

Claims

1. A process for forming a container from a blank by thermally generating one or more fold lines on at least one surface of a container blank made from a heat-insulating sheet material, wherein the container blank comprises a first panel portion, a second panel portion located adjacent to the first panel portion and sharing a first common edge with the first panel portion, and a third panel portion located adjacent to the second panel portion and sharing a second common edge substantially parallel to the first common edge with the second panel portion, the first panel portion and the third panel portion each have a pair of flap members, and each pair of the flap members is adapted to a bending movement relative to the corresponding first panel portion or third panel portion, and each of the flap members, when assembled, overlaps an edge of the second panel portion substantially perpendicular to the first common edge and the second common edge, a step of bending the first panel portion of the container blank along a first fold line so as to be substantially perpendicular to the second panel portion of the container blank, a step of bending the third panel portion of the container blank along a second fold line so as to be substantially perpendicular to the second panel portion and substantially parallel to the first panel portion, a step of sealing a part of each of the pair of flap members of the first panel portion to a part of each of the pair of flap members of the third panel portion to form a side seam joint, and a step of sealing a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint to an edge of the second panel portion to form a bottom seam joint.

2. The process for forming a container from a blank according to claim 1, further comprising a step of bending the third panel portion along a fold line so as to be substantially parallel to the second panel portion to form a sub-panel portion that substantially closes the container during assembly.

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

4. One or more edge seals, one or more side seam joints and / or one or more bottom seam joints are sealed using heat treatment under compressive force. ​ ​ A process for forming a container from a blank according to any one of claims 1 to 3.

5. A process for sealing a part of the first panel portion to a part of the third panel portion to form a side seam joint, a step of overlapping the first panel portion on the third panel portion such that the inner surface of the first panel portion substantially abuts the inner surface of the third panel portion; a step of placing at least a part of the overlapped panel portions into the sealing device such that a part of the flap member of the overlapped panel portions extends outward from the sealing device; a step of pretreating the overlapped panel portions; a step of performing a heat treatment while applying a compressive force to the overlapped panel portions to weld the inner surface of the flap member of the first panel portion and the inner surface of the flap member of the third panel portion and / or to weld the outer surface of the flap member of the first panel portion and the outer surface of the flap member of the third panel portion to each other, A process for forming a container from a blank according to any one of claims 1 to 4.

6. The step of pretreating includes a step of pre-compressing the overlapped panel portions before the overlapped panel portions are compressed together. A process for forming a container from a blank according to claim 5.

7. The step of pretreating includes a step of preparing the inner surfaces of the flap members of the first panel portion and the third panel portion before the overlapped panel portions are compressed together. A process for forming a container from a blank according to claim 5.

8. The step of sealing a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint to an edge of the second panel portion to form a bottom seam joint includes a step of overlapping a part of the first panel portion adjacent to the side seam joint and a part of the third panel portion adjacent to the side seam joint on a part of the second panel portion such that the inner surfaces of the first panel portion and the third panel portion substantially abut the inner surface of the second panel portion; a step of placing at least a part of the overlapped panel portions into the sealing device such that a part of the overlapped panel portions extends outward from the sealing device; a step of pretreating the overlapped panel portions; A step of welding the welded inner surface and / or welded outer surface of the first panel part and the third panel part to the corresponding inner surface and / or corresponding outer surface of the second panel part by performing heat treatment while applying a compressive force to the overlapped panel parts. A process for forming a container from a blank according to any one of claims 5 to 7.

9. The step of preprocessing includes a step of pre-compressing the overlapped panel parts before the overlapped panel parts are compressed together. A process for forming a container from a blank according to claim 8.

10. The step of preprocessing includes a step of preparing the inner surfaces of the first panel part and the third panel part and the second panel part before compressing the overlapped panel parts together. A process for forming a container from a blank according to claim 8.

11. One or more edge seals, one or more side seam joints and / or one or more bottom seam joints are simultaneously sealed using heat treatment under compressive force and trimmed to remove excess material. A process for forming a container from a blank according to any one of claims 1 to 10.

12. Further includes a step of welding at least a part of the seam joint and / or edge seal, and / or the intersection of two or more seam joints and / or edge seals. The seam joint is a side seam joint and / or a bottom seam joint and is leak-proof. A process for forming a container from a blank according to any one of claims 1 to 11.

13. One or more reinforcing tags are welded to at least a part of the seam joint, the edge seal, and / or the intersection of two or more seam joints and / or edge seals. A process for forming a container from a blank according to claim 12.

14. The one or more reinforcing tags are welded to the seam joint, the edge seal, and / or the intersection of two or more seam joints and / or edge seals using a profiled heat stamp. A process for forming a container from a blank according to claim 13.

15. The one or more reinforcing tags are welded to the seam joint, the edge seal, and / or the intersection of two or more seam joints and / or edge seals using impulse welding. A process for forming a container from the blank according to claim 13.

16. Further comprising the step of embedding one or more monitoring devices in at least one surface of the container blank, A process for forming a container from the blank according to any one of claims 1 to 15.

17. Embedding the monitoring device in the container blank using a profiled heat stamp, A process for forming a container from the blank according to claim 16.

18. Embedding the monitoring device in the container blank using impulse welding, A process for forming a container from the blank according to claim 16.

19. The heat insulating sheet material includes two or more layers, and one or more of the layers are cross-linked closed cell foam layers, A process for forming a container from the blank according to any one of claims 1 to 18.

20. The cross-linked closed cell foam layer is encapsulated between one or more layers of reflective material and one or more layers of food grade antibacterial material, A process for forming a container from the blank according to claim 19.

21. The heat insulating sheet material is a flexible heat insulating sheet material, A process for forming a container from the blank according to claim 19 or claim 20.

22. The heat insulating sheet material is a water-resistant heat insulating sheet material, A process for forming a container from the blank according to any one of claims 19 to 21.

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