CARTON AND CARTON BLANK

Abstract

A carton (1) comprising a plurality of panels for forming a base panel (12), first and second side walls (14, 24) and first and second top panels (16, 22) coupled to one another by first and second handle panels (18, 20) wherein the first and second handle panels are in substantial face contacting relationship such that the first and second top panels form a top wall of the carton and wherein a reinforcing panel (34a, 34b) is provided in face contacting relationship with both the first and second top panels such that the reinforcing panel forms a bridge connecting between the first and second top panels whereby a portion of each of the first and second top panels is at least two-ply in structure.

Description

FIELD OF THE INVENTION

The present invention relates to a carton and a blank for forming a carton. More particularly, but not exclusively, the invention relates to a carton and blank therefore, having an access means for accessing products contained therein and being adapted for returning products to a point of sale or to a recycling point.

BACKGROUND OF THE INVENTION

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers, such multi-packs are desirable for shipping and distribution and for display of promotional information.

In the field of packaging it is often desirable to provide consumers with a carton which can be used by a consumer to transport primary product containers including a product from a point of sale, the carton having a means for gaining access to the primary product container contained therein. It is further desirable that the carton retain sufficient integrity to be used to return the empty primary product containers to a point of sale or to a recycling point for easy transportation of the primary product containers.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a carton comprising a plurality of panels for forming a base panel, first and second side walls and a first and second top panel coupled to one another by a first and second handle panel wherein the first and second handle panels are in face contacting relationship such that the first and second top panels form a top wall of the carton and wherein a reinforcing panel is provided in face contacting relationship with both the first and second top panels whereby forming a bridge between the first and second top panels such that a portion of each of the first and second top panels is at least two-ply in structure.

Preferably the reinforcing panel is hingedly connected to the first top panel and is secured to the second top panel.

Preferably the reinforcing panel is connected to the first top panel along a first fold line, the first top panel being folded about the first fold line into face contacting relationship with an inside surface of the first top panel.

Preferably the first fold line extends along an end edge of the first top panel, the first fold line being disposed transversely with respect to a hinged connection between the first top panel and the first handle panel.

Preferably the reinforcing panel include an extension portion disposed along an end edge of the second top panel, the end edge of the second top panel extending transversely with respect to a hinged connection between the second top panel and the second handle panel.

According to a second aspect of the present invention there is provided a carton comprising a plurality of panels for forming a base panel, first and second side walls and first and second top panels coupled to one another by first and second handle panels wherein the first and second handle panels are in substantial face contacting relationship such that the first and second top panels form a top wall of the carton and wherein a first reinforcing panel is hinged to the first top panel, the first reinforcing panel being folded into face contacting relationship with the first top panel and wherein the first reinforcing panel comprises an extension portion which is secured to the second top panel whereby forming a bridge between the first and second top panels.

Preferably a second reinforcing panel is hinged to the second top panel, the second reinforcing panel being folded into face contacting relationship with the second top panel and wherein the extension portion of the first reinforcing panel is in face contacting relationship with either the second reinforcing panel or the second top panel.

Preferably, the top panel comprises a plurality of apertures each for receiving a portion of a respective article and being struck from the top panel wherein an access device comprising a weakened line of severance is provided for displacement or removal of a portion of the top panel disposed between two adjacent apertures.

According to a third aspect of the present invention there is provided a carton comprising a plurality of panels for forming a base panel, first and second side walls and a top panel, a carrying handle being provided coupled to the top panel wherein there comprises a plurality of apertures each for receiving a portion of a respective article and being struck from the top panel wherein an access device comprising a weakened line of severance is provided for displacement or removal of a portion of the top panel disposed between two adjacent apertures.

Preferably the weakened line of severance is formed at least in part in the top panel.

Preferably the weakened line of severance extends between at least one of the apertures and another or the other one of the apertures.

Preferably the weakened line of severance is formed solely in the top panel.

Preferably the weakened line of severance is formed at least in part in each of the side walls.

Preferably the carton further comprises the access device herein before described.

According to a fourth aspect of the present invention there is provided a blank comprising panels for forming the carton herebefore described.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

FIG. 1. is a plan view from above of a blank for forming a carton according to a first embodiment of the present invention;

FIG. 2. is a perspective view from above of a first stage of construction of a carton from the blank of FIG. 1;

FIG. 3. is a perspective view from above of a second stage of construction of a carton from the blank of FIG. 1;

FIG. 4. is a perspective view from above of a third stage of construction of a carton from the blank of FIG. 1;

FIG. 5. is a perspective view from above of a carton according to the first embodiment of the invention assembled about a group of articles;

FIG. 6. is a perspective view of an end of a carton according to the first embodiment of the invention assembled about a group of articles;

FIG. 7. is a perspective view from above of a carton according to the first embodiment of the invention assembled about a group of articles wherein a handle has been deployed for use;

FIG. 8. is a close up perspective view of a user operating an access means in the carton of FIG. 5;

FIG. 9. is a perspective view of the access means of the carton of FIG. 5 in a deployed condition;

FIG. 10. is a perspective view of a user removing an article from the carton of FIG. 5;

FIG. 11. is a perspective view of the carton of FIG. 5 in which empty articles have been replaced in the carton;

FIG. 12. is a plan view from above of a blank for forming a carton according to a second embodiment of the present invention;

FIG. 13. is a perspective view from above of a carton according to the second embodiment of the present invention assembled about a group of articles;

FIG. 14. is a perspective view of the access means of the carton of FIG. 13 in a deployed condition;

FIG. 15. is a plan view from above of a blank for forming a carton according to a third embodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

Referring to FIG. 1 there is shown a plan view of a blank 10 for forming a carton 1, which blank 10 is formed from foldable sheet material such as paperboard or similar material. The blank comprises a series of main panels for forming a base panel, first and second side panels, top panel and first and second handle panels.

First base panel 12 is coupled to first beveled panel 12A by fold line 42; beveled panel 12A is coupled to first side panel 14 by fold line 42A. First side panel 14 is coupled to first top panel 16 along fold line 44. First top panel 16 is coupled to first handle panel 18 by fold line 46. First handle panel 18 is coupled to second handle panel 20 along fold line 50. Second top panel 20 is coupled to second top panel 22 by fold line 54. Second top panel 22 is coupled to second side wall 24 by fold line 56. Second side panel 24 is coupled to second beveled panel 26A by fold line 58A and second beveled panel 26A is coupled to second base panel 26 by fold line 58.

First handle panel 18 comprises fold line 48 which is interrupted by a first aperture 94a for forming a carrying handle a first handle flap 92a is hingedly connected to the first handle panel 18 along a fold line 90a wherein in use the fold line 90a connecting the first handle flap 92a to the first handle panel 18 forms an engagement edge for lifting the carton 1.

Second handle panel 20 comprises fold line 52 which is interrupted by a second aperture 90b for forming the carrying handle a second handle flap 92b is hingedly connected to the second handle panel 20 along a fold line 90b wherein in use the fold line 90b connecting the second handle flap 92b to the second handle panel 20 forms an engagement edge for lifting the carton 1.

Fold line 48 and fold line 52 are both parallel to and equidistant from fold line 50 coupling the first handle panel 18 to the second handle panel 20, such that in an a set up carton 1 fold line 48 and fold line 52 are in registry with one another. Likewise, first aperture 94a, first handle flap 92a and fold line 90a are arranged to be in registry with second aperture 94b, second handle flap 92b and fold line 90b when the first handle panel 18 is folded about the fold line 50 to be in face contacting relationship with second handle panel 20. It will be seen in subsequent embodiments to be described that the exact shape and nature of the handle structure is adaptable, though preferably similar handle structures are provided in each of the first and second handle panels 18 and 20 such that when these panels are brought into registry a composite handle structure is formed. In other embodiments of the invention, the handle structure comprises only a pair of apertures; in yet further embodiments of the invention, the handle structure comprises other means for facilitating a user's grasp of the carton 1.

First top panel 16 and second top panel 22 each comprise three article receiving apertures H1, H2 and H3. Article receiving apertures H1, H2, H3 are each adapted to receive an upper portion of an article B, article receiving apertures H1, H2, H3 are substantially “egg-shaped” although other shapes are envisaged including but not limited to elliptical, circular, square and rectangular. A weakened line 84 optionally extends between each article receiving aperture H1, H2 and H3 and the respective fold line 46, 54 coupling each top panel 16, 22 to the respective one of the first and second handle panels 18, 20.

An arcuate weakened line of severance 82 is optionally provided in each of the top panels 16, 22 between the article receiving apertures H1 and H2 similarly there is an arcuate weakened line 82 in each of the top panels 16, 22 between the article receiving apertures H2 and H3. Each of the arcuate weakened lines of severance 82 comprises three cut lines. Optionally, there may also be linear cut lines 45, 57 disposed between the article receiving apertures H1 and H2 and between the article receiving apertures H2 and H3 which cut lines are disposed in registry with the fold lines 44, 56 respectively. The arcuate weakened lines of severance 82 form an access device for gaining access to an article B within the carton 1. It is envisaged, as described below that the access device can take various formats compared to that aforedescribed, without departing from the invention.

Apertures 72a, 72b, 76 are provided for receiving a portion of the base of an article B. A central aperture 76 is struck in part from each of first and second beveled panels 12A and 26A and from the respective one of the first and second side wall 14, 24. Two further apertures 72a, 72b are struck in part from first base panel 12, from first beveled panel 12A and first side panel 14. Similarly, two further apertures 72a, 72b are struck in part from second base panel 26, from second beveled panel 26A and second side panel 14. Apertures 72a and 72b comprise heel engaging tabs 74a, 74b respective for engaging with the heel of an article B whereby securing the base of the article B. These heel apertures 72a, 72b and heel engaging tabs 74a, 74b facilitate the secure containment of articles B within the carton 1. In embodiments where a greater or a fewer number of articles B are contained, fewer or greater heel engaging tabs are provided. The specific structure of the heel engaging tabs 74a, 74b is also adaptable and in some embodiments, no heel engaging tabs 74a, 74b and/or apertures 72a, 72b are provided.

Base panel 12 comprises recesses or rebates 78a, 78b struck from opposing side edges, recesses 78a, 78b form a first part of a first panel locking mechanism for securing first base panel 12 to second base panel 26. Recesses 78a,78b comprise a waist such that a tab 80a, 80b, forming the second part of the first panel locking mechanism and struck from base panel 26, can be locked in position.

The base panels 12, 26 additionally may optionally comprise a second panel locking mechanism having a first part 70a forming a female locking member struck from base panel 12 for receiving a second part 70b for forming a male locking member. The second panel locking mechanism may be adapted such that the base panels 12, 26 of a setup carton 1 may receive a portion of a tertiary packaging container such as the “star-post” of a crate. In such an embodiment the second panel locking mechanism is arranged such that it is disposed to be in registry with a void between articles B in a group of articles B to be packaged by the carton 1. It is envisaged that a variety of mechanical locking mechanisms could be used to secure the base panels 12, 26 together. In alternative embodiments of the present invention the composite locked bottom wall may be replaced by a single bottom wall that is securable directly to one of said first or second side walls 14, 24.

Reinforcing structures R are provided hinged to opposing side edges of the first and second sidewalls 14, 18 and the first and second top panels 16, 22. Each reinforcing structure R comprises a first reinforcing panel 30a, 30b, 36a, 36b.

First reinforcing panels 30a, 30b are hinged to opposing side edges of first side wall 14 along fold line 60a, 60b respectively whereas first reinforcing panels 36a, 36b are hinged to opposing side edges of second side wall 24 along fold line 66a, 66b respectively.

A second reinforcing panel 32a, 32b is provided hinged to opposing side edges of top panel 16 along fold line 62a, 62b respectively. Second reinforcing panel 32a is hinged to first reinforcing panel 30a and second reinforcing panel 32b is hinged to first reinforcing panel 30b.

A second reinforcing panel 34a, 34b is provided hinged to opposing side edges of top panel 22 along fold line 64a, 64b respectively. Second reinforcing panel 34a is hinged to first reinforcing panel 36a and second reinforcing panel 34b is hinged to first reinforcing panel 36b.

Second reinforcing panels 32a, 32b comprise recesses or cut-outs shaped to be complementary to article receiving apertures H1 and H3 when folded about fold line 62a, 62b into face contacting relationship with first top panel 16.

Second reinforcing panels 34a, 34b are each provided with an extension portion 35a, 35b respectively. These extension portions 35a, 35b are disposed adjacent the second handle panel 20 but are free from connection, or alternatively are severably connected, to second handle panel 20. Edges 88a, 88b of extension portions 35a, 35b are similarly shaped to complement the article receiving apertures H1 and H3 when folded into face contacting relationship with second reinforcing panels 32a, 32b. Likewise, edges 86a, 86b of reinforcing panels 32a, 32b are shaped similarly to the adjacent article receiving apertures H1 and H3 formed in first top panel 16.

Turning to the construction of the carton 1 as illustrated in FIGS. 2, 3 and 4 it is envisaged that the carton 1 can be formed by a series of sequential folding operations in a straight line machine so that the carton 1 is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

Glue (or other securing means) is applied to the first reinforcing panels 30a, 30b, 36a, 36b, to the second reinforcing panels 32a, 32b and to the second reinforcing panels 34a, 34b but not the extension portions 35a, 35b. The reinforcing panels 30a, 30b, 36a, 36b, 32a, 32b, 34a, 34b are folded into face contacting relationship with their respective side walls 14, 24 and top panel 16, 22 and secured in position as shown in FIG. 2. Glue or other adhesive is applied to one of the first or second handle panels 18, 20; Glue G is also applied to the second reinforcing panel 32a, 32b as illustrated in FIG. 1. The second handle panel 20 is folded about fold line 50 into face-contacting relationship with the first handle panel 18; the first handle panel 18 is secured to the second handle panel 20 and the extension portion 35a, 35b is secured to the second reinforcing panel 32a, 32b as shown in FIG. 3 and FIG. 4.

The blank 10 is then wrapped around a group of articles B, upper portion of the articles B being received in a respective article receiving aperture H1, H2, H3. First and second base panels 12, 26 are folded about the base of the group of articles B and the male parts 70b, 80a and 80b of the first and second panel locking mechanisms are punched through the first base panel 12 and second base panel 26 to engage the respective female parts 70a, 78a, 78b of the first and second panel locking mechanisms whereby locking the first base panel 12 in partial overlapping relationship with the second base panel 26.

The first and second handle panels 18, 20 can be folded about fold lines 48 and 52 respectively such that an upper edge of the handle panels 18, 20 engages with a protruding portion of the articles B whereby retaining the handle panels 18, 20 in a stowed position below the upper surface of the articles B as shown in FIGS. 5 and 6. The carrying handle can be deployed to a position of use by unfolding the handle panels 18, 20 as shown in FIG. 7.

FIG. 8 illustrates a user F initiating tearing or breaking of the weakened line of severance 82 whereby operating the access device to gain access to the articles B. The user F severs each of the portions 23 of the top panel 22 between the articles B such that the central article B can be removed from the carton 1 as shown in FIG. 10. Access can then be gained to the other two articles B via the opening created as a consequence of deploying the access device. In other embodiments where more or less than six articles B contained in two rows of three are held within the carton 1 and wherein the access device has alternative formats, deploying the access device may provide access to more than one article B at a time and/or the endmost articles B.

Use of the access means reduces the amount of material in the top panels 16, 22 connecting the first and second side walls 14, 24 to the handle panels 18, 20. However, despite this the carton 1 retains sufficient structural integrity after the access device has been deployed, such that the carton 1 is reusable for collating and transporting the empty articles B. Reinforcing structures R strengthen the carton such that the carton 1 can be carried by the carrying handle when the access device has been deployed. Extension portions 35a, 35b ensure that there is at least a two ply structure at the point where the handle panels 18, 20 are hinged to the first and second top panels 16, 22. It can be seen in FIGS. 9, 10 and 11 that the portions 23 of the top panel 22 between the articles B have been divided into two components one hinged to the second handle panel 20 and another hinged to the second sidewall 24 each the components being folded internally of the carton 1 when the articles B are replaced therein.

An alternative embodiment of the present invention is illustrated with reference to FIG. 12 in which like numerals have, where possible, been used for like parts, with the addition of the prefix “1”. To avoid duplicating description of parts similar to both the first and second embodiments only the differences from the embodiment illustrated in FIGS. 1 to 11 will be described in any greater detail.

The embodiment of FIG. 12 comprises four alternative access devices 196 provided in the first and second side walls 114, 124 and disposed between adjacent article receiving apertures H1/H2, H2/H3. Each access device 196 comprises a pair of weakened lines of severance 197, 199 coupled by a further weakened line of severance 198. The weakened lines of severance 197, 198, 199 are collectively arcuate in shape and substantially “U-shaped”. Each terminus of each of the weakened lines 197, 198, 199 is disposed in the vicinity of the point where an article receiving aperture H1, H2, H3 is closest to a respective one of the first or second sidewalls 114, 124. Each weakened line of severance 197, 198, 199 comprises a plurality of cut-lines spaced in close proximity to another. A fold line 195 may be provided each with weakened lines 197, 198, 199 to create a tab to aid a user F to initiate tearing of the access device 196. The access device 196 when deployed separates those portions of the top panel 122 between the article receiving apertures H1 and H2 and H2 and H3 from the side wall 124 said portions being hinged to the second handle panel 120 as shown in FIGS. 13 and 14. Optionally said portions may be severably connected to the second handle panel 120 by a further weakened line of severance.

Yet a further alternative embodiment of the present invention is illustrated with reference to FIG. 15, in which like numerals have, where possible, been used for like parts, with the addition of the prefix “3”. To avoid duplicated description of features similar in the third embodiment to features of the first and second illustrated embodiments, only the differences from the embodiments illustrated in FIGS. 1 to 14 will be described in any greater detail.

In FIG. 15 it can be seen that the four access means are provided each being disposed between adjacent article receiving apertures H1/H2, H2/H3 and each access means comprising a single arcuate weakened line of severance 396 formed from a series of slits and nicks. The terminus of each end of the access means is proximate a nick 397 or extensively weakened portion that intercepts the adjacent fold line 344, 356, preferably in the region of cut lines 345, 357 provided along said fold lines 344, 356. In this way, the access means can be deployed by a user to rip out a portion of the first and/or second side panel 314, 324 and an integral adjacent portion of the associated top panel 316, 322 using the nick or extensively weakened portion 397 to assist in ripping across the adjacent fold line 344, 356. As in the previous embodiments, after ripping out each of the access means access to the articles B contained within the carton is gained and thereafter, the carton retains sufficient structural integrity (at least in part due to the structural strength provided by the reinforcing means R and assisted by the size and shape of the access means 396) such that the carton is reusable for collating the articles B for return to a recycling point for example.

In the third embodiment described, the punch lock of the complementary locking mechanism in bottom panel 312, 326 has an alternative shape to that shown in the first and second embodiments. It will be understood as mentioned above that in other embodiments of the invention, a variety of complementary bottom locking or securing means as is known in the art is used.

It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape. In other embodiments of the invention it is envisaged that more or less than six articles will be the intended contents for the carton and as such the blank will be sized and the panels of the blank sized and shaped to accommodate such articles. It is also envisaged that the article receiving apertures may each have a different shape where the invention is applied to cartons for containing a mixture of articles; in such and indeed other embodiments the access means neighbouring those article receiving apertures may be alternatively shaped and sized to effect the removal of a portion of the carton of sufficient size to enable articles B to be withdrawn and replaced and yet at the same time not compromise the structural integrity of the carton as a whole. It is further envisaged that the reinforcing means R may be altered from that herein described and yet the performance and function of such a reinforcing means R will remain unaltered from that taught herein. Preferably, an extension portion of the reinforcing means is positioned, shaped and sized or otherwise structured, arranged and configured, such that it can provide a bonded link between one side of the carton and the other. In this way, when pressure is applied in a downward manner to the first and/or second top panels 16, 22, 116, 122, 316, 322 or alternatively in a substantially perpendicular manner to first and/or second side walls 14, 24, 114, 124, 314, 324, to break open the access means 96, 196, and 396, the carton has sufficient structural rigidity that this application of force does not cause failure of the carton such that the carton can be reused. In some arrangements the extension panels 35a/35b, 135a/135b, 335a/335b provide a brace or strengthening ply to the first and/or second top panels 16, 22, 116, 122, 316, 322, through which the articles B are intended to be withdrawn. In alternative embodiments the carton may be provided without beveled panels 12A, 26A.

It will be recognised that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. For example it is preferable that the reinforcing means R is disposed to reinforce the panels in which the access means is at least in part disposed and/or through which the articles B are accessed. Any reference to hinged connection should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from one or more of the following, a short slit, a frangible line or a fold line without departing from the scope of the invention. Any reference to weakened line or extensively weakened line can be formed from one or more of the following, a short slit, nick, half-depth cut, full depth cut, angled perforations and/or any combination of the aforementioned features without departing from the scope of the invention.

Claims

1. A carton comprising a plurality of panels for forming a base panel, first and second side walls and first and second top panels coupled to one another by first and second handle panels wherein the first and second handle panels are in substantial face contacting relationship such that the first and second top panels form a top wall of the carton and wherein a reinforcing panel is provided in face contacting relationship with both the first and second top panels such that the reinforcing panel forms a bridge connecting between the first and second top panels whereby a portion of each of the first and second top panels is at least two-ply in structure.

2. A carton according to claim 1, wherein the reinforcing panel is hingedly connected to the first top panel and is secured to the second top panel.

3. A carton according to claim 2, wherein the reinforcing panel is connected to the first top panel along a first fold line, the reinforcing panel being folded about the first fold line into face contacting relationship with an inside surface of the first top panel.

4. A carton according to claim 3, wherein the first fold line extends along an end edge of the first top panel, the first fold line being disposed transversely with respect to a hinged connection between the first top panel and the first handle panel.

5. A carton according to claim 1, wherein the reinforcing panel include an extension portion disposed along an end edge of the second top panel, the end edge of the second top panel extending transversely with respect to a hinged connection between the second top panel and the second handle panel.

6. A carton comprising a plurality of panels for forming a base panel, first and second side walls and first and second top panels coupled to one another by first and second handle panels wherein the first and second handle panels are in substantial face contacting relationship such that the first and second top panels form a top wall of the carton and wherein a first reinforcing panel is hinged to the first top panel, the first reinforcing panel being folded into face contacting relationship with the first top panel and wherein the first reinforcing panel comprises an extension portion which is secured to the second top panel whereby forming a bridge between the first and second top panels.

7. A carton according to claim 6, wherein a second reinforcing panel is hinged to the second top panel, the second reinforcing panel being folded into face contacting relationship with the second top panel and wherein the extension portion of the first reinforcing panel is in face contacting relationship with either the second reinforcing panel or the second top panel.

8. A carton comprising a plurality of panels for forming a base panel, first and second side walls, a top panel, and a carrying handle, wherein the carrying handle is coupled to the top panel wherein the top panel comprises an access device and a plurality of apertures each for receiving a portion of a respective article, the apertures being struck from the top panel, the access device comprising a weakened line of severance for displacement or removal of a portion of the top panel disposed between two adjacent apertures.

9. A carton according to claim 8, wherein the weakened line of severance is formed at least in part in the top panel.

10. A carton according to claim 8, wherein the weakened line of severance extends between at least one of the apertures and an adjacent one of the apertures.

11. A carton according to claim 8, wherein the weakened line of severance is formed solely in the top panel.

12. A carton according to claim 8, wherein the weakened line of severance is formed at least in part in each of the side walls.

13. A carton according to claim 1 further comprising an access device, each of the first and second top panels includes apertures each for receiving a portion of an article, the access device comprising a weakened line of severance for displacement or removal of a portion of at least one of the first and second top panels disposed between two adjacent ones of the apertures of the at least one of the top panels.

14. (canceled)