Carton and carton blank

Information

  • Patent Grant
  • 6568585
  • Patent Number
    6,568,585
  • Date Filed
    Wednesday, February 6, 2002
    22 years ago
  • Date Issued
    Tuesday, May 27, 2003
    21 years ago
Abstract
An article carrier and a blank for an article carrier for holding an article, for example a tray, comprising a top wall, opposed side walls and a base wall hingedly connected together to form a tubular structure and wherein there further comprises an article retention structure hingedly connected to the top wall and the base panel. The article retention structure is formed by a pair of interconnected panels formed from adjacent carton walls and inwardly folded to retain the article within the carrier.
Description




BACKGROUND OF THE INVENTION




This invention relates generally to a carton having an article retention feature and more particularly to a wraparound type article carrier designed for articles such as connected plastic cups containing yogurt or other similar foodstuff.




The prior art illustrates wraparound cartons with end closure panels for closing the ends of the carton that are connected to respective side and base panels by a series of gusset panels that assist in forming the end closure panels. There are many arrangements of gusset panels, examples of which are shown in U.S. Pat. No. 5,180,054, FR-A-1 44 536. Prior art structures illustrate carriers for carrying articles with planar sides for example cans or bottles and end retention structures are therefore formed in a planar relationship with respective sides and ends of the corner.




When articles with tapered sides or articles provided with flanges, for example yogurt pots, are packaged in groups or meat trays, there will tend to be relative movement between article(s) and the carrier which is undesirable. Prior art carriers do not provide satisfactory retention for articles of this type.




Another problem associated with the prior art is that the retention structure in some cases tends to collapse within the carrier.




SUMMARY OF THE INVENTION




The present invention and its preferred embodiments seek to overcome or at least mitigate the problems of the prior art.




One aspect of the invention provides an article carrier for holding one or more articles, for example connected plastic cups or a tray, comprising a first wall, opposed side walls and a second wall hingedly connected together to form a tubular structure and wherein there further comprises an article retention structure hingedly connected to said first wall and said second wall. The article retention structure is formed by a pair of interconnected panels formed from adjacent carton walls and inwardly folded to retain the articles within the carton.




Beneficially, the article carrier can be applied to articles with tapered or planar sides where it is desired to provide a retention structure that does not need to be glued.




Preferably, the pair of interconnected panels may include an inwardly folded panel hingedly connected to the first wall to be disposed in face contacting relationship therewith and wherein the other of the interconnected panels is hingedly connected to the second wall.




According to an optional feature of this aspect of the invention the pair of interconnected panels may comprise a gusset panel connected to a side retention panel wherein the gusset panel is hingedly connected to the first wall and is adapted to be placed intermediate the first panel and an article so that the side retention panel is retained in a set up condition. Preferably, there further comprises an anchoring tab for placement between the packaged article and the first wall. More preferably, the anchoring tab projects inwardly of the inwardly folded gusset panel.




According to another optional feature of this aspect of the invention an aperture may be defined between side retention panel and the adjacent side wall and wherein the tab projects inwardly into the aperture beyond the hinged connection between the interconnected panel when in a flat collapsed condition.




According to an optional feature of this aspect of the invention, an inner edge of the side retention panel may be arranged to abut against an article.




According to another optional feature of this aspect of the invention the side retention panel may comprise upper and lower parts hingedly connected together to be temporarily folded out of alignment during construction of the article retention structure to assist with construction of the second wall.




A second aspect of the invention provides an article retention structure for retaining articles within a tubular carton, which article retaining structure may comprise a side retention panel hingedly connected to a side wall, a top gusset panel hingedly connected to a top wall and hingedly connected to the side retention panel. Preferably, there may further comprise an aperture struck from a portion of the side walls, wherein an edge for which aperture tapers inwardly towards the base.




A third aspect of the invention provides a carton blank for forming an article carrier for holding an article for example a tray, comprising a first side panel, a first wall panel, a second side panel and a second wall panel hingedly connected together in series, wherein there further comprises an article retention structure hingedly connected to said first wall panel and said second wall panel. The article retention structure is formed by a plurality of panels including a side retention panel so constructed and arranged to taper inwardly towards said second wall panel to substantially conform to the shape of an adjacent article held in a set up carton.




Preferably, the plurality of panels may further comprise a gusset panel connected to the side retention panel wherein the gusset panel is hingedly connected to the second wall panel and includes a tab adapted to be placed intermediate the second wall panel and an article so that the side retention panel is retained in a set up condition.




More preferably, an aperture may be defined between side retention panel and the adjacent side wall and wherein the tab projects inwardly into the aperture beyond the hinged connection between the gusset panel and side retention panel.











BRIEF DESCRIPTION OF THE DRAWINGS




Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:




FIG


1


. illustrates a blank for forming a carton according to an aspect of the invention;





FIGS. 2

,


3


and


4


illustrate the carton during the different stages of construction from the blank shown in

FIG. 1

;





FIG. 5

illustrates the carton loaded with articles formed from the blank of

FIG. 1

;





FIG. 6

illustrates a blank for forming a carton according to a second embodiment of the invention;





FIGS. 7

,


8


,


9


and


10


illustrate the carton during the stages of construction from the blank shown in

FIG. 1

; and





FIGS. 11 and 12

illustrate the carton loaded with an article formed from the blank of FIG.


6


.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




Referring to the drawings, and in particular

FIG. 1

, there is shown a carton blank for forming a carton made from paperboard or similar foldable sheet material. In these embodiments, wraparound type cartons can be formed from the blanks. It will be recognized that rather than the bottom wall being formed from the interlocked panels, the carton blank may be rearranged whereby some other wall such as a top wall or a side wall is formed from the interlocked panels.




Turning to the embodiment shown in

FIG. 1

the blank


10


comprises a first base panel


12


, first side wall panel


14


, top panel


16


, second side wall panel


18


, second base panel


20


hingedly connected one to the next along fold lines


22


,


24


,


26


and


28


respectively.




A series of panels for forming an article retention structure is provided along one side and end of the carton. The article retention arrangement


29


at one corner of side and base panels


18


,


20


comprises an upper gusset panel


30


hingedly connected to top panel


16


along an extension of fold line


26


. There further comprises a side retention panel


32


hingedly connected to base panel


20


along fold line


36


. Side retention panel


32


and upper gusset panel


30


are interconnected by a fold line


34


. In this embodiment, fold lines


26


,


34


and


36


are substantially parallel, although the orientation of these fold lines can be altered according to the shape of article to be packaged.




An aperture


38


may be provided which in

FIG. 1

is formed intermediate side wall panel


18


and side retention panel


32


and, preferably, extends into base panel


20


.




Upper gusset panel


30


is separated from side panel


18


by cut line


40


and it may further comprise a tab portion


31


extending from panel


30


into the aperture


38


beyond fold line


34


. In use, tab portion


31


is adapted to project inwardly of the side retention structure


29


to be retained between the top panel


16


and an outer article to retain the side retention panel


32


in a set up condition.




Likewise, the opposing side of base and side wall panels


20


and


18


further comprises a similar article retention arrangement


47


comprising an upper gusset panel


42


hingedly connected to top panel


16


along an extension of fold line


26


. There further comprises a side retention panel


44


hingedly connected to base panel


20


along fold line


48


. Side retention panel


44


and upper gusset panel


42


are interconnected by a fold line


46


.




An aperture


50


may be provided which in

FIG. 1

is formed intermediate side wall panel


18


and side retention panel


44


and, preferably, extends into base panel


20


.




Upper gusset panel


42


is separated from side panel


18


by cut line


52


and it may further comprise a tab portion


43


extending from panel


42


into the aperture


50


beyond fold line


46


. In use, tab portion


43


functions in the same manner as tab portion


31


described above.




In one class of embodiments, the lower edge


39


,


51


of the apertures


38


,


50


may diverge away from a point of intersection with fold line


28


to define an obtuse angle with fold line


28


, thereby to define a protruding portion of the base in a set up condition. Optionally, the inner edges


54


,


55


of side retention panels


32


,


44


may taper inwardly or otherwise conform to the shape of the articles with respect to a notional vertical plane and/or correspond to the difference in distance between the bottom of the cup and the top flange of the cup.




A second embodiment shown in

FIG. 6

is adapted to package meat trays. The blank


110


comprises a first base panel


112


, first side wall panel


114


, top panel


116


, second side wall panel


118


, outer base panel


119


and inner base panel


120


hingedly connected one to the next along fold lines


122


,


124


,


126


,


117


and


128


respectively.




A series of panels for forming one or more article retention structures


129


,


147


is provided along one side and end of the carton. Preferably, the article retention arrangement


129


is positioned at one end of side wall panel


118


and inner and outer base panels


119


,


120


. The article retention arrangement


129


comprises a pair of interconnected panels including an inwardly folded panel hingedly connected to the base wall to be disposed in face contacting relationship therewith and wherein the other of the interconnected panels is hingedly connected to the top wall.




It will be seen from

FIG. 6

that the pair of interconnected panels comprise a gusset panel


130


hingedly connected to outer base panel


120


along an extension of fold line


128


. There further comprises a side retention panel


132


hingedly connected to top panel


116


along an extension of fold line


126


. Side retention panel


132


and gusset panel


130


are interconnected by a fold line


134


.




Preferably, side retention panel


132


comprises upper and lower parts


132




a


and


132




b


hingedly interconnected along fold line


136


.




An aperture


138


may be provided, which in

FIG. 6

is formed intermediate side panel


118


and side retention panel


132


and may extend adjacent to inner base panel


119


.




Preferably, gusset panel


130


is separated from inner base panel


119


by cut line


140


and it may further comprise a tab portion


131


extending from gusset panel


130


into the aperture


138


beyond fold line


134


. In use, tab portion


131


is adapted to project inwardly of the side retention panel to be retained between the base panel


120


and the article T to retain the side retention panel


132


in a set up condition, shown in FIG.


11


.




Likewise, the opposing end of inner and outer base panels


119


,


120


and side wall panel


118


further comprises a similar article retention arrangement


147


comprising a gusset panel


142


hingedly connected to base panel


120


along an extension of fold line


128


. There may further comprise a “two part” side retention panel


144




a


and


144




b


hingedly connected to top panel


116


along fold line


126


. Side retention panel


144


and gusset panel


142


are interconnected by a fold line


146


.




An aperture


150


may be provided which is preferably formed intermediate side panel


118


and side retention panel


144


and may extend adjacent to inner base panel


119


.




Similarly, gusset panel


142


is separated from side panel


118


by cut line


152


and it may further comprise a tab portion


143


extending from panel


142


into the aperture


150


beyond fold line


146


. In use, tab portion


143


also projects inwardly of the side retention panel


144


to be retained between the outer base panel


120


and the article T to retain the side retention panel


144


in a set up condition.




The blank may further comprise securing means for securing together the opposed ends of the blank to form a wraparound carton. In this embodiment, the securing means comprises a pair of support panels


160


and


164


extending beyond the ends of base panels


112


and


120


and hingedly connected thereto along fold line


162


and interrupted fold line


166


respectively. In use, the support panels form a two ply structure to provide additional support where the panels engage, which is commonly the weakest part of the carton. The securing means of this embodiment further comprises a locking arrangement comprising a plurality of locking tabs


172




a,




172




b


and


172




c


extending outwardly from support panel


164


. There also comprises corresponding apertures for receiving the locking tabs which are defined by cut lines


168




a,




170




a,




168




b,




170




b


and


168




c,




170




c


extending substantially along interrupted fold line


162


. It is envisaged that other known securing means could be used, for example glue or other locking arrangements without departing from the scope of invention.




In one class of embodiments, there further comprises one or more display windows to view the contents of the article contained in the carrier. In this embodiment, there comprises two display windows


176


and


178


struck from top panel


116


.




Turning to the construction of the carton from a carton blank as illustrated in

FIGS. 1 and 6

, the blanks


10


or


110


require a series of sequential folding and gluing operations which is preferably performed in a straight line machine so that the carton is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and can be altered according to particular manufacturing requirements.




As the carton blank of the first embodiment is moved forward continuously, it is constructed in the manner shown in

FIGS. 2

to


5


and is applied to an array of articles A, for example four articles A arranged in a two by two formation, whereby the top panel


16


is supported by the tops of the articles.




The first stage is shown in

FIG. 2

whereby the side panel


18


is folded out of alignment with top panel


16


along fold line


26


and base panel


20


is folded out of alignment with side panel


16


along fold line


28


so that side and base panel


18


and


20


are folded inwardly in direction X. As side panel


18


and base panel


20


are folded the construction of the article retention structures


29


,


47


, described below, may take place, automatically.




Each article retention structure is formed in a substantially like manner so only the construction of article retention structure


29


will now be described. It is usual for the retention structures on a blank to be formed at substantially the same time by a suitable arrangement of guides and/or locating means.




Thus, article retention structure


29


is formed by, first, folding upper gusset panel


30


about fold line


26


such that it is folded into face contacting relationship with top panel


16


shown in

FIGS. 2 and 3

.




As upper gusset panel


30


is folded inwards in direction Y (

FIG. 3

) towards top panel


16


, it is folded out of alignment with side retention panel


32


along fold line


34


into a substantially perpendicular relationship which causes the side retention panel


32


to be moved out of alignment along fold line


36


with side wall panel


18


and into an angular relationship with base panel


20


. Thus, the side retention panel


32


may be caused to taper inwardly towards the base panel


20


, as shown in FIG.


3


. Optionally the upper gusset panel


30


, and in those embodiments with tab


31


can be secured to the top panel


16


by glue or other suitable means known in the art.




The opposing article retention structure


47


is formed in a similar manner, as shown in

FIGS. 2 and 3

.




The articles A are then loaded into the carrier from the side or from the end by suitable packaging machinery with the tabs


31


,


43


positioned between the top of the adjacent articles and the inner face of the top panel, shown in FIG.


4


. The articles are held in place by abutment with the inner edges


54


,


56


of panels


32


and


44


. The shape of the base panel


20


allows articles to be placed in the protruding portion


58


of base panel


20


, adjacent side wall panel


18


.




Thereafter, the folding of base and side wall panels


12


,


14


is completed by folding these panels along fold lines


22


and


24


respectively so that a portion of base panel


12


is placed in face contacting relationship with a corresponding overlapping portion of base panel


20


and is secured together to form a base structure, by glue or other means known in the art as illustrated in FIG.


5


. Thus, the carton is in a fully erected and loaded condition.





FIG. 5

illustrates a carton formed from a blank of the first embodiment shown in FIG.


1


. More particularly, there is illustrated an article carrier for holding articles with tapered sides, for example connected plastic cups, comprising a top wall


16


, opposed side walls


14


,


18


and a base


12


,


20


hingedly connected together to form a tubular structure and wherein there further comprises an article retention structure


29


,


47


hingedly connected to one of said side walls


14


and said base


12


. The article retention structure is formed by a pair of interconnected panels formed from adjacent carton walls and inwardly folded to retain the articles within the carton.




Beneficially, the articles are held in place by the article retention structures, to prevent unwanted removal. The retention structures are prevented from collapsing by the tabs


31


,


43


being engaged between the articles A and the top panel


16


.




The carton blank


110


of the second embodiment is constructed in a similar manner to the first embodiment, whereby it is moved forward continuously as it is constructed in the manner shown in

FIGS. 7

to


11


. It is applied to an article T, for example a tray, whereby the top panel


116


is supported by the top of the article.




The first stage of construction is shown in

FIGS. 7 and 8

whereby the top panel


116


is brought into contact with the top of the tray T. Thereafter, side panels


114


and


118


are folded out of alignment with top panel


116


along fold lines


124


and


126


respectively to wraparound the article. Outer base panel


120


is folded out of alignment with inner base panel


119


along fold line


128


, shown in

FIG. 9

, so that base panel


120


is folded outwardly in direction X. As side panel


118


and outer base panel


120


are folded the construction of the article retention structures occurs, described in more detail below.




Each article retention structure is formed in a like manner so only the construction of article retention structure


129


will now be described. It is usual for the retention structures on a blank to be formed at substantially the same time by a suitable arrangement of guides and/or locating means.




Thus, article retention structure


129


is formed by, first, folding gusset panel


130


inwardly about fold line


134


. In one class of embodiments, this is achieved automatically when the outer base panel


120


is folded out of alignment with inner base panel


119


.




This folding action is illustrated in FIG.


9


and it will be seen that as gusset panel


130


is folded inwardly, it is also folded out of alignment with side retention panel


132


along fold line


134


into a substantially perpendicular relationship. Also, side retention panel


132


is caused to be moved out of alignment with side panel


118


and into an angular relationship with top panel


116


along fold line


126


. Thus, the side retention panel


132


may be caused to taper inwardly with respect to side panel


118


because fold lines


128


and


134


are offset, in the vertical plane.




Thereafter, inner base panel


119


is folded out of alignment with side panel


118


along fold line


117


and side retention panels


132




a


and


132




b


are caused to be folded out of alignment along fold line


136


.




The opposing article retention structure


147


is formed in a similar manner, as shown in

FIGS. 7

,


8


and


9


.




As the side panels


114


,


118


continue to be folded towards the sides of article T, inner base panel


119


is folded inwardly in direction W, shown in

FIG. 10

, which increases the spacing between the side retention panel


132


and side wall panel


118


. Base panel


119


is folded into abutment with the base of the article T along fold line


117


and outer base panel


120


is folded towards gusset panels


130


and


142


in direction Y along fold line


128


into face contacting relationship with gusset panels


130


,


142


and tabs


131


,


142


. At this stage of the construction, side retention panels


132


and


144


are thus positioned across the end face of the carton to prevent the tray from sliding out of either end of the carton.




Optionally gusset panel


130


, and in those embodiments with tab


131


, can be secured to the top panel


116


by glue or other suitable means known in the art.




Base panels


112


,


120


are secured together by suitable means known in the art, whereby the locking tabs


172


are inserted through the slits


168


,


170


to be engaged therewith. The shoulder portions are engaged by the abutment with securing panel


160


shown in FIG.


11


.




Thus, the article carrier is in a set up and erected condition as shown in

FIG. 12

in which there comprises a top wall


116


, opposed side walls


114


,


118


and a base wall


120


,


112


hingedly connected together to form a tubular structure and wherein there further comprises an article retention structure hingedly connected to said top wall and said base wall. The article retention structure is formed by a pair of interconnected panels


130


,


132


formed from adjacent carton walls and inwardly folded to retain the article within the carton.




The article T is held in place by abutment with the inner edges of side retention panels


132


and


144


to prevent unwanted removal.




It will be seen from

FIG. 12

that gusset panels


130


,


142


and/or tabs


131


,


143


are positioned between the bottom of the article T and the inner face of base panel


120


to prevent the retention structures from collapsing.




It will also be recognised that as used herein, directional references such as “top”, “base”, “end”, “side”, “inner” and “outer” do not limit the respective panels to such orientation, but merely serve to distinguish these panels one from another. 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 one of the following, a score line, a frangible line or a fold line, without departing from the scope of invention.




The present invention and its preferred embodiment relates to an article carrier that is shaped to provide satisfactory strength to hold articles securely, but with a degree of flexibility so that during transit the articles are retained within the carrier. The shape of the blank minimises the amount of paperboard required and the carrier can be applied to an array of articles by hand or automatic machinery. It is anticipated that the invention can be applied to a variety of carriers and is not limited to those of the wraparound type hereinabove described. Further or alternatively, the carton may be adapted to carry a greater or lesser number of articles without departing from the scope of the invention.



Claims
  • 1. An article carrier for holding at least one article, comprising a first wall, opposed side walls, a second wall hingedly connected together to form a tubular structure and an article retention structure hingedly connected to said first wall and said second wall, wherein said article retention structure is formed by a pair of interconnected panels formed from adjacent ones of said first, second and side walls and inwardly folded to retain said at least one article within said tubular structure, wherein said pair of interconnected panels comprises a gusset panel and a side retention panel hingedly connected together, and wherein said gusset panel is hingedly connected to said first wall along a first fold line extending inwardly from one of opposed ends of said tubular structure, and said gusset panel is folded inwardly along said first fold line to be in face contacting relationship with said first wall and includes a part that is adapted to be placed intermediate said first wall and said at least one article so that said side retention panel is retained in a set up position.
  • 2. An article carrier as claimed in claim 1 wherein said side retention panel is hingedly connected to said second wall along a second fold line extending inwardly from said one end of said tubular structure, said first and second fold lines being parallel to each other.
  • 3. An article carrier according to claim 1 wherein said gusset panel includes a tab portion projecting inwardly of said tubular structure beyond a hinged connected between said gusset panel and said side retention panel.
  • 4. An article carrier as claimed in claim 1 wherein an inner edge of said side retention panel is arranged to abut against said at least one article.
  • 5. An article carrier as claimed in claim 1 wherein said side retention panel comprises upper and lower parts hingedly connected together to be temporarily folded out of alignment during construction of said article retention structure to assist with construction of said second wall.
  • 6. An article carrier for holding at least one article, comprising a first wall, opposed side walls, a second wall hingedly connected together to form a tubular structure and an article retention structure hingedly connected to said first wall and said second wall, wherein said article retention structure is formed by a pair of interconnected panels formed from adjacent ones of said first, second and side walls and inwardly folded to retain said at least one article within said tubular structure, wherein said pair of interconnected panels comprises a gusset panel and a side retention panel hingedly connected together, and wherein said gusset panel is hingedly connected to said first wall and includes a part that is adapted to be placed intermediate said first wall and said at least one article so that said side retention panel is retained in a set up position, wherein said gusset panel includes a tab portion extending inwardly of said tubular structure from said gusset panel to be placed between said at least one article and said first wall, wherein an aperture is defined between said side retention panel and an adjacent one of said side walls, and wherein said tab portion projects inwardly into said aperture beyond a hinged connected between said gusset panel and said side retention panel when the carrier is in a flat collapsed condition.
  • 7. A carton blank for forming an article carrier for holding at least one article, comprising a first side panel, a first wall panel, a second side panel and a second wall panel hingedly connected together in series, and an article retention structure hingedly connected to said first wall panel and said second wall panel, wherein said article retention structure is formed by a plurality of panels including a side retention panel so constructed and arranged to taper inwardly towards said second wall panel to substantially conform to the shape of said at least one article held in a set up carton, wherein said plurality of panels comprises a gusset panel hingedly connected to said side retention panel, said gusset panel being hingedly connected to said second wall panel and including a part adapted to be placed intermediate said second wall panel and said at least one article so that said side retention panel is retained in a set up position, and wherein an aperture is defined between said side retention panel and an adjacent one of said first and second side wall panels, and wherein said gusset panel includes a tab portion projecting inwardly into said aperture beyond a hinged connection between said gusset panel and said side retention panel.
Parent Case Info

This is a continuation of international application No. PCT/US00/21479, filed Aug. 7, 2000, which is hereby incorporated by reference.

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Continuations (1)
Number Date Country
Parent PCT/US00/21479 Aug 2000 US
Child 10/068562 US