AU8963198A - Crate and blank therefore - Google Patents

Description

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AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): EZY HOLDINGS PTY LTD A.C.N. 067 181 251 Invention Title: CRATE AND BLANK THEREFOR The following statement is a full description of this invention, including the best method of performing it known to me/us: -1- 2 CRATE AND BLANK THEREFOR The present invention relates to a blank suitable for forming a crate and a crate formed therefrom. In particular the present invention relates to a blank suitable for forming a crate for storage and transportation of produce.

Crates are routinely used for transport and storage of goods, particularly fresh produce such as fruit and vegetables or prepared foodstuffs such as bread and S" pastries. Crates are suitable for all types of transport including road and rail transport and can be manufactured S 15 in a convenient size range for manual lifting.

Crates are usually manufactured of plastic or polymers and commonly comprise a rectangular base and four walls located at the four edges of the base. The base and 20 walls often comprise numerous perforations or are of relatively open structure to allow sufficient airflow S "around the produce to suppress mould formation or formation S of sweat by the produce. Crates may have a top or lid depending on the design and the type of goods carried in the crate. Plastic or polymeric crates are generally preferred over cardboard boxes and the like because plastic S or polymers have superior strength, are less likely to be crushed and are impervious to moisture which may exude from the produce. Plastic and polymers also tend to be easier to recycle than cardboard.

Crates are usually designed to be as light as possible in order to minimise manufacturing costs.

However, as well as being light, crates must also be very strong to contain the produce and withstand the rigours of transport and storage.

K:\Xaria\Keep\EZY HOLICS PP0123 CRATE.doc 30/10/98 r~9-~n ~ralrrcP rmcps% 3 It is very common to store crates by stacking one on top of the other and this inflicts particular stresses on the crate. The loading weight for the crate at the bottom of a stack could be as high as 250 kg.

There are a number cf different crate designs currently in use, but the present invention is concerned with crates which are known in the relevant technology as "self hinged", that is, crates which have an integral, moulded hinge. The parts of self hinged crates which are most likely to suffer damage are the integral, moulded hinges. In general, self hinged crates of the prior art are moulded as one-piece blanks of plastic or polymer. Each blank typically comprises a base and four walls, each wall SI 15 being connected along the length of one edge to an edge of the base by an integral hinge. The hinge comprises a thin membrane of plastic or polymer. Hinges must be folded or coined or creased to orientate the molecules in the same direction. In general, to form a blank, plastic or polymer 20 is injected into a mould; the depth of the mould is the same for the walls and base while the depth of the mould is reduced in the part of the mould which forms the hinge.

j The hinge is thus formed as a thin membrane of the plastic or polymer. In general the mould is formed such that the base and all four walls share the same longitudinal plane.

In other words, the entire blank is moulded generally flat.

The thin membrane is designed to have suitable flexibility to act as the hinge between the wall and base. Hence to assemble the crate, each wall is bent about the hinge until p the plane of the wall is perpendicular to the plane of the base. Snap fittings and the like on adjacent edges of the walls holds them in position in the assembled crate.

In the assembled crate, the hinges form four edges at the bottom of the crate and are unsupported. That is, the weight of the contents of the crate is borne

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entirely by the hinges. Compression and outward forces H:4Maria\Xk p\EZT HOLDIGS PP0123 CRAT.doc 30/10198 ^wa^^i~ -4such as those exerted on the crate during stacking, are transmitted through the walls to the hinge. One of the problems associated with these hinges is that the stacking forces in combination with the damage incurred during handling tend to cause the hinge to weaken and tear A single small rent or tear in the hinge due to stress fatigue is often propagated along the length of the entire hinge or a substantial part thereof, destroying the integrity of the crate.

Furthermore, in general, the self hinged crates of the prior art are generally assembled once and remain in the assembled condition for their working life. Self hinged crates of the prior art are not well adapted for 15 disassembly. Accordingly they cannot be flattened out for *storage when not in use. In order to design crates which can be disassembled and flattened out, it has been necessary in the past to utilise far more sophisticated hinge designs which permit free 180* rotation by the wall 20 about the hinge. This type of design allows the walls to be folded flat against the upper surface of the base to S "form a relatively small, flat-packed crate.

I It is an object of the present invention to S 25 provide a crate which ameliorates or removes the problems of crates and crate blanks of the prior art that is, crates S .and crate blanks having integral moulded hinges. In particular, it is an object of the present invention to ameliorate or overcome the disadvantages associated with f 30 using hinges, particularly unsupported hinges.

The present invention therefore provides a hinge for use in joining adjacent panels of a crate blank wherein the hinge is integral with the adjacent edges of the panels and one panel can be rotated about the hinge such that an edge of the panel abuts an edge or face of the other panel.

SThe present invention further comprises a crate blank )H\4aria\Xe*p',EZ HOLDINGS PPOL23 CAAMZ.d- 3O1//98 5 comprising one or more of the aforementioned hinges and a crate assembled from such a crate blank.

The panels of the crate blank may be adapted to form the walls or the base of an assembled crate.

Typically the hinge is located between the base and wall and, during assembly of the crate blank to form a crate, the wall can be rotated about the hinge such that the edge of the wall adjacent the hinge abuts the upper surface of the base.

In another embodiment of the present invention, the crate blank comprises two or more panels which are I adapted to form sections of a single wall of the assembled crate. The hinge may be a hinge of the type described in the present invention or alternatively any convenient hinge known in the art. Typically a hinge is located between S* adjacent upper and lower wall sections such that the upper wall section can be rotated about the hinge such that in 0 the assembled crate the edge of the upper wall section adjacent the hinge abuts the upper edge of the lower wall section.

Typically the hinge between adjacent wall sections is located adjacent the surfaces of the wall sections which form the interior of the crate. Typically in this embodiment the upper wall section can be folded inwards until it rests on the upper surface of the base.

This permits the crate to be disassembled and reduced to a compact size and shape for storage.

Typically the crate blank comprises a rectangular base attached at each edge to a wall, at least two of the i walls being joined to the base by one or more hinges of the present invention. Preferably all four walls are joined to the base by one or more hinges of the present invention.

In forming the crate blank, typically the walls adjacent a H:\Maria\Kep\EZY HOLDINGS PF0123 CRATE.doc 30/10/9B -6 hinge of the present invention are not coplanar with the base. Typically the walls lie in a single plane parallel, but not coplanar with the base. Where the crate blank comprises wall sections joined by a hinge of the present invention, typically the wall sections are not coplanar.

The crate blank may comprise just one hinge between each wall and the base or between adjacent wall sections. However, typically the crate blank of the present invention comprises two or more small hinges between each wall and the base or between adjacent wall sections.

Typically when the crate blank is assembled to 15 form a crate, adjacent pairs of walls are held together by retaining means. Typically the retaining means comprises a tab on one wall and a correspondingly shaped slot on the S" other wall, the tab and slot interlocking or alternatively being held together by interference fit. Typically the 20 retaining means comprises a snap lock fitting. Typically the retaining means is located at any convenient position at or near adjacent edges pairs walls. Preferably each pair of walls comprises two retaining means, one near the base of the crate and the other near the top of the crate.

|U As stated above, it is preferable that the crate and crate blank be light, yet sufficiently strong to withstand the rigours associated with containing goods during transport and stacking.

It is particularly preferred that the assembled crates comprise strength members which comprise a structural element or combination of structural elements vertically aligned. The strength member may comprise a rib and/or a pair of vertical ribs which are joined along at least part of their length to define a channel. The strength member is typically of H-shaped or U-shaped cross H:\Maria\Keep\ET HCODINGS PP0123 CRATE.doc 30/10/98 7 section.

In a particularly preferred embodiment, the strength member of the crate of the present invention comprises a pair of vertical ribs in the wall of the crate Iwhich are joined along at least part of their length to form a generally U-shaped channel, which is in vertical alignment with a rib in the base of the assembled crate.

Where the wall comprises two or more wall sections, typically the vertical ribs in one wall section will align with the vertical ribs in the wall sections Sabove or below.

As stated above, crates are frequently formed *into stacks. Often the crates are stacked in alignment, that is, with each crate located directly above the crate below.

20 Optimally, the strength member of each crate in Sthe stack aligns vertically with a strength member in the crate above and below in the stack, thus contributing to the formation of a strong, stable stack.

25 Typically, when the crates are stacked in alignment, the lower end of a strength member of one crate I may fit into a complimentary shaped recess in the top edge of a wall of the crate below. Typically the recess is located adjacent the upper end of a strength member of the crate below.

Optimally, in this embodiment, there is load transfer through the strength member of one crate to the strength member of the crate below. The strength members effectively align to form a column of strength members running the height of the stack. Preferably, the columns are located near the corners of the crates.- ??S123 3LILZe 011')13 8- 8 As an alternative to stacking in alignment, the crates may be cross stacked. When crates are cross stacked each crate is located on top of two or more other crates, the crates in each layer rotated 900 to the crates in the adjacent layer.

Accordingly, the crates of the present invention may be configured such that they can be cross-stacked. For example the base of the crate may be quite flat and comprise a continuous rim and/or flat ledge which can be placed on the upper edge of the walls of a crate below. In S' this embodiment the upper edge of the walls may be generally flat. There are no recesses in the top of the 15 walls as described in the previous embodiment. The Sstrength members of one crate transfer load through to the continuous rim to upper edge of the wall which distributes load to the strength members of the crate below.

S 20 Small registration pads or alternatively small recesses on the upper edge of walls may prevent slippage and guide placement of one crate on top of another.

The crate blank and crate of the present invention may be made in any convenient size or shape with the walls, base and hinges being of any convenient proportions.

The present invention is described further by way of example with reference to the accompanying drawings in which: Figure l(a) is a plan view of part of a crate blank and wall of the prior art; Figure 1(b) is a plan view of the part base and wall of the prior art shown in Figure 1(a); H I:I.Mana\KCpXEZ HOLIWPS P0123 CRATM.doc 30110fl i-9 Figure 2(a) is a plan view of a hinged part of a crate blank according to the present invention showing part of the base, the hinge and a wall; Figure 2(b) is a plan view of the part base and wall of Figure 2(a) configured to form a crate; Figure 2(c) is a plan view of an unhinged part of a crate blank according to the present invention showing part of the base and a wall; Figure 2(d) is a plan view of the part base and wall of Figure 2(c) configured to form a crate; Figure 3(a) is a perspective view of two edges of adjacent walls which respectively comprise a tab and recess which can interlock to hold the walls in place; 20 Figure 3(b) is a perspective view of two edges of adjacent walls of a further embodiment of the crate blank of the present invention; Figure 4 is a perspective view in part cut away of the walls showing the snap fitting; Figure 5 is a perspective view of a crate assembled from the crate blank of Figure 2(a); Figure 6 is a perspective view of one corner of a crate assembled from the crate blank of Figure 2(c); Figure 7 is a perspective view of corresponding corners of two crates of the type shown in Figure 5 showing alignment of the crates prior to stacking; and Figure 8 is a perspective view of corresponding H1NMarialeeplE^S yCuiNGS P?3123 CATE.doc 30/11C/s 10 corners Of three crates which have been stacked.

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Figure 9 is a view Oz two edges of adjacent walls and part of the base of a furtr emoieto h rt 5 blank~ Of the present -nve tn eboiet ftert Figure 10 is a persPective view of one corner of a crate assembled from the Craze blank~ of Ficrure 9 Figure 11 is a perspective view of corresponding corners Of Itwo crates Of the tYPe shown in Figure Figure 12 is a perspective view of the corners of three crates Of Figure 10 which have been cross s tacked.

Figure 13 is a perspective view of a crate assembled from the crate blankc of Figure _q.

Figure 14(a) is a plan view of a hinged part o crate blankj according to the Present invention showing part of the crate base and a wall comprising two wall sections joined by a secondary.hinge.

Figure 14(b) is a Plan view of the part base and wall of Figure 14(a) Configured to form a crate.

Figure 15(a) is a Plan view Of an unhinged part of a crate blank according to the present invention showing Part Of the crate base and a wall comprising two wall 30 sections.

Figure 15(b) is a plan view Of the unhinged part of a crate blank~ of Figure 15(a) Configured to form a crate.

Figure 16 is a Perspective view of one corner of a crate assembled from the crate blank of Figure 14.

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t~ Figure~ 17 is a pers .pective I Iiew of the corners of three crates formed from three different embodiments of crate blanks according to the present invention.

and 7 igure l(a) Shows a plan view Of part Of the base adawall Of a crate blank, Of the prior art. The base 1 and wall 5 are connected by an integral Moulded hinge i0 which comprises a thin membrane of the plastic/Polymer integral with the base 1 and wall It is noted that the base 1, hinge 10 and wall 5 are all moulded in the same longitudinal plane.

Figure 1(b) shows the Prior art crate blank of 15 Figure 1 folded to form a crate. The wall 5 has been rotated about the integral mloulded hinge 1.0 such that the wall 5 and base 1 are Perpendicular. The hinge 10 which has been bent, and constitutes the corner edge Of the crate and is unsupported.

Figure 2 shows a Plan view of part of a crate blank according to the present invention which is suitable for forming a crate. The crate blank comprises four walls attached to a base,' each wall being attached by at least two hinges. The drawing shows a cross section through a hinged portion of the blank.* The wail 20 and base 11 are connected by a hinge 15. It is noted that the longitudinal Plane of the wall 20 is Parallel but not Coplanar with the longitudinal plane of the base 11.

Figure 2(b) Shows the part of the blank depicted in Figure 2 after the wall 20 has been rotated about the hinge IS to a Position Perpendicular to the base 11. In this Position one edge of the wall 20 abuts the upper surface of the base ii.

Figure 2(c) shows a cross section through another R.\4azjd\Ej-p ,=r 12part of the crate blank shown in Figures 2(a) and In this drawing the cross section is taken through the unhinged portion of the crate blank.

Figure 2(d) shows the part of the blank depicted in Figure 2(c) after the wall 20 has been rotated to a position at right angles to the base 11 in forming the crate. In this position the edge of the wall 20 abuts the upper surface of the base 11. The wall 20 folds over raised portion 14 of the base 11. If the wall 20 is subject to outward forces, the raised portion 14 acts as a stop and contributes to the wall 20 withstanding the outward force.

Figure 3(a) is a perspective view of two edges of adjacent walls 24, 24' in a crate blank. In use, the walls are folded perpendicular to the base aad located in position by restraining means comprising a tab 28 on one wall and a correspondingly shaped recess 30 on the other 20 wall. When the walls are perpendicular to the base, the tab 28 and recess 30 are held together by interference fit.

Figure 3(b) is a perspective view of part of two adjacent walls 33, 35 in another embodiment of the crate blank of the present invention. In this embodiment, two restraining means are used to locate and restrain adjacent walls of a crate. One restraining means comprises an interlocking tab 37 and recess (not shown) near the base as depicted in Figure The other restraining means comprises a snap-lock fitting 40 located distant from the Sbase, near the upper edge 42 of the wall.

Figure 4 shows the edges of adjacent walls of a crate formed from a crate blank of the present invention and comprising a restraining means having a snap-lock fitting. The snap-lock fitting comprises a shaped tab on one wall and a correspondingly shaped recess 46 on the ri. PPO 3 C 3 Hs\ ria~~e~p.E2TH~m~CS ?1)12 CKAE~do 30/0/58- i 2 2 t 44*0 o e to *444 44444 *9*4 44 4 4 9 13 other wall. The tab 45 or recess 46 deform slightly when forced together, the tab 45 being permanently located in the recess 46.

Figure 5 is a perspective view of a crate.

assembled from a crate blank of Figure 2(a) of the present invention. In this view the strength members 13 located near the corner edges of the crate can be clearly seen.

Each strength member comprises a pair of vertical ribs in the wall of the crate which are joined along at least part of their length to define a generally box-shaped or Ushaped channel, in alignment with a small rib in the base of the crate. Other vertical and horizontal ribs 18, 18' are present in the walls and base of the crate but these do 15 not form part of the strength members and are merely for general support of the crate.

Figure 6 is a perspective view of one corner of an assembled crate of Figure showing the strength 20 members in greater detail. Each strength member comprises a pair of vertical ribs 50, 50' which are joined along their length (join not shown) to define a channel, which aligns at its lower end with a small rib 60 to form the complete strength member.

Figure 7 is a perspective view of corresponding corners of two crates o f the type shown in Figure 6 showing alignment of the crates prior to stacking to form a column of crates. Each rib 60 forming the lower end of the strength member fits within a recess 65 in the wall 35' of the crate below. Each recess is located in the channel defined between two vertical ribs 50, 50' of the strength member. The strength members in each crate are aligned with the strength members in the crates above and below thus forming a column of strength members which provide structural strength and support to the stack of crates.

Load is also transferred from the strength members to the HA:.K-a\ep\EZ HO PPD123 CRA7E.. 3C/1012a 7 I

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-14 base and from the base to the edge of the wall of the crate below to form a system of load bearing support members.

Figure 8 is a perspective view of corresponding corners of three crates according to Figure 6 which have been stacked. This view clearly shows how the rib the lower end of one structural member fits into the recess in the top of the channel in the structural member of the crate below. In this stacking configuration, load on the crates can be transferred through the ribs, of the strength members to the base of each crate and through to the surface on which the stack of crates rests.

Figure 9 is a perspective view of two edges of adjacent walls in another embodiment of the crate blank of the present invention. This embodiment is similar to that shown in Figure However in this embodiment the base of the crate blank comprises a continuous peripheral rim so that the ribs 60 on the base are not exposed. The crate S 20 may sit on the peripheral rim. Similarly, when these crates are stacked, there are no recesses in the upper edge of the walls. The load on the vertical strength members is transferred to the base and peripheral rim and the flat bottom edge of the rim transfers load to the top edge of

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S 25 the wall of the crate below. In this embodiment, one crate may be cross stacked on the crate below, that is, positioned at 900 to the crate above and below.

Figure 10 is a perspective view of one corner of an assembled crate of Figure 9. The vertical ribs defining a channel and ribs on the base which together comprise the strength members are clearly seen. Registration pads 72 are located on the top edge of each wall 74 and act merely to help position crates during cross-stacking and to resist crate slipping.

Figure 11 is a perspective view of corresponding H:.fri\KWp\Y Wlt 23 CiATE.d- J0f3./98 S ,0*

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'a Ca a 15 corners of two crates of the type shown in Figure showing alignment of the crates prior to stacking. Each registration pad on the top edge of each wall can be used to help position the base of one crate on top of another.

Figure 12 is a perspective view Of corresponding Corners of three crates of Figure 10 which have been cross stacked, that is, with each crate rotated 90' relative to the crate above and below. In this cross stacked configuration, load on the crates can be transferred through the strength members, particularly through the column of vertically aligned strength members directly onto the base and peripheral rim. The load is also distributed to the upper edge of the wall of the crate below.

Figure 13 is a perspective view of a crate assembled from the crate blank of Figure 9. In this crate there is a continuous peripheral rim around the base (that is there are no exposed ribs on the base as per the crate of Figure 5 and no recesses in the upper edge of the walls). The crate sits on the peripheral rim.

Figure 14(a) shows a plan view of part of a crate blank according to the present invention. The drawing shows a cross section through a hinged portion of the crate blank. The wall comprises an upper wall section 74 and a lower wall section 72 j oined by a hinge 75. The lower wall sectioni 72 and the base 70 are joined by a hinge 77. in this embodiment of the crate blank of the present invention the longitudinal plane of the base 70 and lower wall section ?2 are parallel but not coplanar. The longitudinal plane of the lower wall section 72 and upper wall section also differ 74.

Figure 14(b) shows the part blank depicted in Figure 14(a) configured to form part of a crate. The lower wall section 72 has been rotated about the hinge 77 to a M HOWUIM PnI 23 cMSA 30/ 10199 16 position perpendicular to the base 70. In this position the lower edge of the lower wall section 72 abuts the upper surface of the base 70. The upper wall section 74 has been rotated about the hinge 75 such that the lower edge of the lower wall section 74 abuts the upper edge of the upper wall section 72.

When the crate is to be disassembled when not in use, the upper wall section 74 can be folded inwards about the hinge 75 towards the upper surface of the base 70 to the position shown by the dotted outline. Thus the crate can be disassembled and reduced to a compact size and shape.

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15 Figure 15(a) is a plan view of an unhinged portion of the part crate blank shown in Figure 14(a). The upper wall section 74, lower wall section 72 and base are clearly shown. The base 70 additionally comprises tab perpendicular to the plane of the base 70. The lower S 20 wall section comprises a recess 82 of a shape suitable for receiving the tab Figure 15(b) shows the part blank depicted in Figure 15(a) configured to form part of a crate. The lower wall section 72 has been rotated to a position perpendicular to the base 70, the tab 80 being received in the recess 82. The tab 80 is shaped such that the lower wall section 72 can be readily located in position perpendicular to the base, but the tab resists rotation of the lower wall section out of this position.

Figure 16 is a perspective view of one corner of a crate formed from the crate blank of Figure 14. One side of the crate comprises a one-piece wall 86 perpendicular to the base 70, the wall 86 and base being joined by a hinge 77 (not shown) of the present invention. The adjacent wall comprises an upper wall section 74 and a lower wall section H:\Maria\eeplEZT HOLDINGS PP0123 CATE.doe 30110/98

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17 72 joined by a hinge 75 (not shown)- Figure 17 is a perspectiv view of three staced crates. The lowest crate ha one wall 90 which comprises wall single panel The adjacent wall comprise three wall t i sectio an upper wall section 92, a middle wall section cio and a lower wall section 96 The lower wall section 96 and base loo are joined by a hinge of the present and base are joined bya tion 94 and .lower wall invention. The middle wall section o9 and pereent section 96 are also joined by a hinge of the present ll invention The middle wall section 94 and upper wall section 92 are also joined by a hinge of the present 4 invention.

The middle crate has one wall 102 which comries a single panel joied to the base 104 by a hinge of the pesen inenio e adjacent wall comprises an upper present invention. The adjacnresent invention wall section 106 joined by a hinge of the presen ivention wall section 108 to the lower wall section 108. The lower wall section 108 20 is joined by a hinge of the present invention to the base 104.

The uppermost crate als has one wall 110 which 1 a dtae aal wah comprises a single panel and a on adjacent lower wahich comprises an upper 112 section a awall section 114. The middle and uppermost crates differ in the seltiv of the upper wall sections and lower wall relative sizes of the upper 9 sectionsions ma be made to the preferred Many modifications ion described embodiment of the device of the present invention described above without departing from the spiri and cop present invention.

Claims (4)

1. A crate includes a base and walls and one or more than one hinge which connects together at least one wall and the base so that the hinged wall or walls can be rotated between an upright position and folded-down position, and wherein the base/wall hinge is formed so that when the wall or walls are in the upright position a surface of the hinged wall or walls that is adjacent the base/wall hinge abuts a surface of the base which defines a support surf ace. The crate defined in claim 1 wherein the surface of the base is an upper surface of the base. :t The crate defined in claim I or claim 2 wherein each hinged wall includes an upper wall section and a lower wall section and a hinge which connects together the wall sections so that the wall sections can rotate relative to each other, wherein the base/wall hinge is connected to the .4 lower wall section, and wherein the hinge connections are C positioned so that when the wall is in the upright position the upper wall section can be rotated inwardly or outwardly about the wall section hinge to a folded down positionl. A. The crate defined in any one of the preceding claims further comprises a retaining means which locks together adjacent pairs of walls when the walls are in the upright position. The crate defined in claim 4 wherein the retaining means include a tab on one wall of the pair of adjacent walls and a correspondingly shaped slot in the other wall of the pair.

6. The crate defined in any one of the preceding claims wherein the walls include strength members. 1. HGj\Ke\ETyLnI*~s ?P0123 C 3ILXl 19

7. The crate defined in claim 6 wherein the strength memibers include vertical ribs.

8. A crate substantially as hereinbef ore described herein with reference to Figures 2 to 17. Dated this 3 0 day of October 1998 EZY HOLDINGS PTY LTD By Its Patent Attorney GRIFFITH HACK Fellows institute of Patent Attorneys of Australia. 1£ C CI 4£ S 4 CC 4 C CCCI 44£ LI LC'( C C CC 41 1 C I 4. I- Hz\4a U-P\MT CtZ!'nS F?01123 CPA-E.d- 3C/10/98 F