WO2011049947A1

WO2011049947A1 - Reinforced beam structure for a carton and blank for forming same

Info

Publication number: WO2011049947A1
Application number: PCT/US2010/053200
Authority: WO
Inventors: Jean-Michel Auclair
Original assignee: Meadwestvaco Packaging Systems, Llc
Priority date: 2009-10-19
Filing date: 2010-10-19
Publication date: 2011-04-28
Also published as: KR20120098634A; EP2490961A1; AU2010308307A1; GB0918250D0; RU2012120725A; CN102596746A; JP2013508234A; JP5997049B2

Abstract

A carton for packaging articles, which carton (100) comprises a composite wall (2/10), a beam structure (29) and a reinforcing arrangement (50), wherein the beam structure (29) comprises first (20) and second (24) beam side panels each formed from, and hinged to, an inner panel (10) of the composite wall (2/10) of the carton (100) such that the beam structure (29) is erectable by folding the first (20) and second (24) beam side panels out of a plane of said inner panel (10), and wherein the reinforcing arrangement (50) is formed from an outer panel (2) of the composite wall (2/10), the reinforcing arrangement (50) being disposed in the beam structure (29) such that the reinforcing arrangement (50) extends through an aperture in said inner panel to abut at least one of the beam side panels (20, 24) to prevent the beam side panels (20, 24) from hinging back into the plane of said inner panel (10).

Description

Reinforced Beam Structure for a Carton and Blank for forming Same

Field of the Invention

The present invention relates to a reinforced beam structure for a carton for packaging one or more articles and a blank for forming the same. More specifically, though not exclusively, the invention relates to a beam structure that is provided by one part of the carton, and a reinforcing arrangement that is provided by another part of the carton, which reinforcing arrangement is foldable to abut the beam structure and thereby to prevent the beam structure from collapsing.

Background to the Invention

Cartons are used to package articles that benefit from a maintained spacing between one another, or from, for example, a wall of the carton. For example, many articles are joined together at one end, but spaced from one another at another, and it is desirable to keep these spaced ends from moving relative to one another. In another example, the articles may be fragile, formed of a brittle material such as glass, and it is desirable to prevent them damaging one another by keeping them spaced apart.

Means of spacing articles as they are held in a carton may utilise beam structures to create a relatively rigid obstruction between adjacent articles, or between the articles and a side wall of the carton. Some of the most material efficient beam structures are those that are formed from hinged panels that initially all lie in the same plane and which can be erected into a position for use by a single folding movement.

However, a known disadvantage of beam structures that are formed in the above manner is that these structures have a tendency to resist folding into the position of use, and to return to their initial planar disposition when the articles are not present to physically obstruct the structure from doing so.

There is, therefore, a need for an improved beam structure, which can resist this natural tendency to return to a planar disposition, even in the absence of articles to obstruct it.

Summary of the Invention

A first aspect of the present invention provides a carton for packaging articles, which carton comprises a composite wall, a beam structure and a reinforcing arrangement, wherein the beam structure comprises first and second beam side panels each formed from, and hinged to, an inner panel of the composite wall of the carton such that the beam structure is erectable by folding the first and second beam side panels out of a plane of said inner panel, and wherein the reinforcing arrangement is formed from an outer panel of the composite wall, the reinforcing arrangement being disposed in the beam structure such that the reinforcing arrangement extends through an aperture in said inner panel to abut at least one of the beam side panels to prevent the beam side panels from hinging back into the plane of said inner panel.

Preferably, the reinforcing arrangement is hingeable from a first position in which it lies in a plane of said outer panel, and a second position in which it abuts said at least one of the beam side panels.

Preferably, the reinforcing arrangement abuts a surface of a detent extending from the said inner panel to prevent hinging of the reinforcing arrangement out of the beam structure.

Preferably, a fold line, along which said at least one of the beam side panels is hinged to said inner panel, is interrupted by a cut line that defines a terminal edge of said detent, which detent necessitates deformation of the reinforcing arrangement as it is hinged into the beam structure. Preferably, the reinforcing arrangement comprises a primary flap that is hinged to said outer panel and that is disposable at an angle with respect to said at least one of the beam side panels, such that a side edge of that primary flap abuts said at least one of the beam side panels.

Preferably, the reinforcing arrangement further comprises a first side tab hinged to said side edge of the primary flap which first side tab is disposable in face contacting relationship with said at least one beam side panel.

Preferably, the first side tab is foldable out of the plane of the primary flap such that an edge of the first side tab adjacent the detent abuts a surface of the detent to prevent hinging of the primary flap out of the beam structure.

Preferably, an edge of the first side tab is offset from a proximate surface of said detent so as to accommodate the thickness of the detent and allow hinging of that first side tab about the primary flap.

Preferably, the reinforcing arrangement further comprises a second side tab hinged to the primary flap along an edge opposite said first side tab, which second side tab is one or more of a) foldable into a position of abutment with a surface of an article contained in the carton, when present; or b) tapered portion to encourage folding of that second side tab as the primary flap is folded into the beam structure.

Preferably, the carton further comprises, two or more beam structures that share a common beam side panel such that reinforcement of any one beam structure at least partially reinforces the other beam structure sharing that common beam side panel.

Alternatively, the beam structure further comprises a beam top panel hingedly connected to both the first and second beam side panels, and wherein said reinforcing arrangement is disposed in abutment with a lower surface of the beam top panel. A second aspect of the present invention provides a blank for forming a carton for packaging articles, which blank comprises panels for forming a composite wall, panels for forming a beam structure and panels for forming a reinforcing arrangement, wherein the beam structure includes first and second beam side panels each formed from, and hinged to, a panel for forming an inner panel of the composite wall of the carton such that the beam structure is erectable by folding the first and second beam side panels out of a plane of said inner panel, and wherein the reinforcing arrangement is formed from an outer panel of the composite wall, the panels for forming the reinforcing arrangement being disposable in the beam structure, when set up, such that the reinforcing arrangement extends through an aperture in said panel for forming an inner panel of the composite wall , to abut at least one of the beam side panels to prevent the beam side panels from hinging back into the plane of said inner panel.

Preferably, the panels for forming the reinforcing arrangement are foldable, in the set up carton, to abut a surface of a detent extending from the said panel for forming the inner panel of the composite wall to prevent hinging of the reinforcing arrangement out of the beam structure.

Preferably, the panels for forming the reinforcing arrangement comprise a primary flap that is hinged to the outer panel that is foldable into the beam structure when the carton has been set up, which primary flap is angled to one of the beam side panels of the beam structure such that a side edge of the primary flap can be brought into abutment with said one of the beam side to prevent the beam side panels from hinging back into the plane of said inner panel.

Preferably, a fold line along which said one of the beam side panels is hinged to the inner panel, is interrupted by a cut line that defines a terminal edge of a detent that extends from the inner panel of the composite wall, and wherein the reinforcing arrangement further comprises a first side tab hinged to said primary flap to define said side edge of the primary flap. Preferably, the first side tab is foldable out of the plane of the primary flap such that an edge of the first side tab adjacent the detent abuts a surface of the detent to prevent hinging of the primary flap out of the set up beam structure.

Preferably, the first side tab has a lowermost edge that is offset from the fold line by which the primary flap is hinged to the outer panel so as to accommodate the thickness of the detent when the first side tab is folded into the beam structure of the erected carton.

Preferably, the reinforcing arrangement further comprises a second side tab hinged to the primary flap along an edge thereof opposite said first side tab, which second side tab is foldable into a position of abutment with a surface of an article contained in the set up carton, when present.

Preferably, the second side tab has a tapered portion to encourage folding of that second side tab as the primary flap is folded into the beam structure.

Preferably, the blank further comprises panels for forming two or more beam structures that share a common beam side panel such that reinforcement of any one set up beam structure at least partially reinforces the other beam structure sharing that common beam side panel.

A third aspect of the present invention provides a carton for packaging articles, which carton comprises a composite wall formed from a pair of inner and outer overlapping panels provided respectively with mutually engaged male and female punch-lock locking tabs and stabilizing means for mitigating rotation of the inner and outer panels about the locking tabs with respect to each other, the stabilizing means comprising a beam structure and a reinforcing arrangement, wherein the beam structure comprises first and second beam side panels each hinged to an inner panel of the composite wall and hinged to one another by a beam top panel such that it is erectable by folding the first and second beam side panels out of a plane of said inner panel, and wherein the reinforcing arrangement is formed from the outer panel of the composite wall and is foldable into the beam structure. Brief Description of the Figures

An exemplary embodiment of the invention will now be described with reference to the accompanying drawings, in which:

Figure 1 illustrates a blank for forming a carton according to a first embodiment of the preferred embodiment;

Figure 2 illustrates a first step in a possible sequence of folding operations to erect the carton from the blank of Figure 1 ;

Figure 2 illustrates a second step in the sequence of folding operations;

Figure 3 illustrates a third step in the sequence of folding operations;

Figure 4 illustrates a fourth step in the sequence of folding operations;

Figure 5 illustrates a fifth step in the sequence of folding operations;

Figure 6 illustrates an erected carton, according to the first preferred embodiment, from beneath;

Figure 7 illustrates an enlarged view of the a portion of the carton of Figure 6;

Figure 8 illustrates the carton of Figure 6 in an orientation of use; and Figure 9 illustrates the carton of Figure 8 wherein the contents of the carton have been shown in ghost-outline to reveal the interior of the carton.

Detailed Description of Preferred Embodiment of the Invention

Detailed descriptions of specific embodiments of the package, blanks and cartons are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the packages, blanks and cartons described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

A first embodiment of a carton blank 1 for forming a carton 100 (best shown in Figure 8) is shown in Figure 1. This blank 1 comprises panels for forming a reinforced beam structure according to a first embodiment of the present invention. This beam structure advantageously is simple to erect, through a single folding operation, and comprises a reinforcing arrangement that is foldable into a reinforcing position within the beam structure, to prevent collapse thereof, through a second simple folding operation.

The blank 1 comprises an outer bottom panel 2, a first side panel 4, a top panel 6, a second side panel 8, an inner bottom panel 10 and a second beam side panel 24 hinged one to the next in linear series by respective fold lines 44, 42, 40, 38, 36. This configuration of panels allows the blank 1 to be wrapped around a group of articles A such that the inner and outer bottom panels 10, 2 may be at least partially overlapped to provide a tubular structure around those articles A whilst the beam structure (described below) separates selected ones of those articles A.

The inner bottom panel 10 comprises panels for forming two beam structures 29 (one of which is shown best in erected condition in Figure 8), each comprising a first beam side panel 20 defined within the inner bottom panel 10 and hinged thereto the along a fold line 30. This first beam side panel 20 is then hinged, by a further fold line 32 along an opposite edge thereof, to a beam top panel 22 defined within the second beam side panel 24. This further fold line 32 preferably consists of a curved cut line that defines a convex edge extending outwardly of the first beam side panel 20, and which terminates at an offset from a proximate edge of the first beam side panel 20 to leave weakened connecting portions between that first beam side panel 20 and the beam top panel 22 about which they may hinge relative to one another. This beam top panel 22 is then, in turn, hinged by a fold line 34 along an opposing edge thereof to the second beam side panel 22.

The fold lines 34, 36 by which the beam top panel 22 and the inner bottom panel 10 are respectively hinged to the second beam side panel 24, are offset with respect to one another by a distance substantially equal to the length of the first beam side panel 20. This arrangement allows the erection of a beam structure 29 of rectilinear cross section (as is most clearly illustrated in Figure 8), and preferably square cross section, by simultaneously folding the first and second beam side panels 20, 24 perpendicular to the inner bottom panel 10.

The fold line 30 hinging the first beam side panel 20 to the inner bottom panel 10 is interrupted by cut line 31 that extends partially into the first beam side panel 20 to form a detent 26. Thus, when the first beam side panel 20 is erected into a condition of use, this detent 26 extends into an aperture in the inner bottom panel 10 that is vacated by the first beam side panel 20 (this is shown best in Figure 7). The detent 26 has substantially uniform width, and is rounded at one corner thereof to act as a guide for an abutting edge in the folding process described below. The second arrangement of panels for forming a beam structure 29 in the inner bottom panel 10 is identical to that described above, and the second beam side panel 24 is common to both, extending along the entire width of the inner bottom panel 10 transverse to a longitudinal axis of the linear series of panels.

The outer bottom panel 2 comprises panels for forming reinforcing arrangements 50 for reinforcing the corresponding two beam structures 29, each reinforcing arrangement 50 comprising a primary flap 51 that is defined within the outer bottom panel 2 and hinged thereto by a fold line 66. Opposing sides of the primary flaps 51 adjacent this fold line 66 are hinged, by respective first and second fold lines 60, 61 to first and second side tabs 52, 54, one either side. Fold line 66 hinging the primary panel 51 to the outer bottom panel 2 is disposed substantially perpendicular to the end of that outer bottom panel 2 such that, when folded into the carton 100 in the manner described below, the primary panel 51 is perpendicular to the side panels 20, 24 of the beam structure 29.

Each first side tab 52 extends, from the primary flaps 51 , in the direction of the first side panel 4, and has a uniform width over a substantial majority of its length. However, at one terminal end of the first side tab 52, proximate the fold line 66 hinging the primary flap 51 to the outer bottom panel 2, the first side tab 52 tapers inwardly such that an external edge of each first side tab 52, defined by a cut line 63 in the outer bottom panel 2, intersects with a terminal end of that fold line 66. An opposing end of each first side tab 52 terminates at a small offset inwardly from a corresponding terminal end of the primary flap 51 , such that the length of the first side tab 52 is slightly shorter that the primary flap 51.

On an opposing side of the primary flaps 51 , each second side tab 54 extends away from the first side panel 4. The second side tabs 54 have uniform width over their entire length. Both ends of the second side tab 54 are offset from the corresponding adjacent ends of the primary flap 51 , such that they are shorter in length than the first side tab 52 and such that each is offset relative to the fold line 66 hinging the primary flap 51 to the outer bottom panel 2. To facilitate alignment between the reinforcing arrangement 50 and the beam structure 29, a locking arrangement 90/91 , 96/99 is preferably provided in proximate parts of the inner bottom paneM O and the outer bottom panel 2. Preferably, the locking arrangement 90/91 , 96/99 comprises a punch-lock structure comprising apertures 91 , 99 formed in the inner bottom panel 10 and engaging tabs 90 formed in the outer bottom panel 2. In the illustrated embodiments, two apertures 91 , 99 are provided, as are two corresponding engaging tabs 90, 96. When the inner 10 and outer 2 bottom panels are overlapped in the manner described below, the engaging tabs 90, 96 may be struck from the outer bottom panel 2 and folded through the apertures 91 , 99, thereby to engage the inner 10 and outer 2 bottom panels together.

Specifically, a first engaging tab 90 is defined by a cut line 94 and hinged to the outer bottom panel 10 along a fold line 95. This first engaging tab 90 has detents along its opposing sides, adjacent the fold line 95. These detents warp as the first engaging tab 90 is passed through the corresponding one of the apertures 91 in the inner bottom panel 10, and, once inserted, take up a position substantially in abutment with portions of an internal surface of the inner bottom panel 10, thereby to prevent the first engaging tab 90 being removed from that aperture 91. The first aperture 91 is created as a first aperture flap defined in the inner bottom panel 10 by a cut line 92 hinges out of that inner bottom panel 10 in response to an inward folding force upon the first engaging tab 90.

The second engaging tab 96 is defined by a cut line 97 and is hinged to the outer bottom panel 2 along a fold line 98. This second engaging tab 96 has one detent. This one detent is formed on one of it's sides, and warps as the second engaging tab 96 is inserted into the second of the corresponding apertures 99. Once inserted, this one detent abuts portions of an inner surface of the inner bottom panel 10 and prevents the second engaging tab 96 from being withdrawn from the second apertures 99. This second aperture 99 is formed as a second aperture flap defined by a cut line 89 in the inner bottom panel 10 hinges out of the plane of the inner bottom panel 10 in response to an inward force on the second engaging flap 96. It is contemplated that, for enhanced securing strength between the inner 10 and outer 2 bottom panels, the second engaging tab 96 may me provided with more than one detent. The top panel 6 comprises a detent 71 , extending from a side thereof, for each article A that is intended to be located adjacent the corresponding side panel 4,8, for example two per side as illustrated in the Figures. The detents 71 extend from an edge of the top panel 6 into the corresponding side panel 4, 8 in the blank 1 , and the detents 71 are struck from the side panels 4, 8 by the carton erection process described below. The detents 71 are defined by cut lines 70 that interrupt the fold lines 42, 40 hinging the top panel 6 to the first side panel 4 and second side panel 8 respectively. Short portions 75, of these cut lines 70 continue across the aforementioned fold lines 42, 40 to extend a short distance into the top panel 6. From two points, on each cut line 70, extend cut lines 74 away from the top panel, into the corresponding first and second side panels 4, 8. Between these cut lines 74 is defined an upper yieldable tab 72.

Each of the first and second side panels 4, 8 comprise an arrangement of cut lines 78, 80, 81 for each detent 71 , to form tabs 76 in edges of those side panels 4, 8 adjacent the respective inner or outer bottom panels 2, 10. These cut lines 78, 80, 81 comprise a linear portion 80 that is co-axial with, and interrupts, the fold lines 44, 38 hinging the first and second side panels 4, 8 to the outer bottom panel 2 and inner bottom panel 10 respectively. Extending perpendicular to this linear portion 80 are short terminal cut lines 81 and a midpoint cut line 78 each of which extend toward the top panel 6 and form between them (either side of the midpoint cut line 78) two lower yielding tabs 76.

One preferred method of erecting the carton 100 (shown in various stages of erection between Figures 2 and 8) from the blank 1 is now described.

The blank 1 is disposed upon the top of a group of articles A, such that top panel 5 overlies a top surface of those articles A. First and second side panels 4, 8 are then folded down around the sides of that group of articles A. Upper portions of the articles A include flanges portion of which locate under the detents 71 of the top panel 6 and extend through apertures formed by the vacated portion of the first and second side panels 4, 8 from which the detents 71 have been struck. As necessary, the upper yielding tabs 72 deform to accommodate a rounded exterior of upper portions of adjacent articles A as the first 4 and second 8 side panels are urged against the exterior surfaces of those adjacent articles A. The inner bottom panel 10 is then folded into contact with a portion of an underside of the group of articles as each beam structure 29 is being erected by folding the first and second beam side panels 20, 24 internally of the carton 100, toward a perpendicular position relative to the inner bottom panel 10, as best shown in Figure 2. By the point at which the beam structures 29 become interposed between adjacent articles A of the group of articles, they are sufficiently erected to locate between those articles A. The outer bottom panel 2 is then folded up, in manner shown in Figure 3, into contact with a portion of the underside of the group of articles A, and a portion of the inner bottom panel 10, to result in the tubular structure shown in Figure 4. The lower yielding tabs 76 in the first and second side panels 4, 8 deform as necessary to accommodate a rounded exterior surface of the articles A abutting interior portions thereof as the first 4 and second 8 side panels are urged against the exterior surfaces of those adjacent articles A.

The beam structures 29 are formed from end regions of the inner bottom panel 10. Once erected, the entirety of this end region of the inner bottom panel 10 is disposed between selected ones of the articles A. The articles themselves further augment the robustness of the beam arrangements 29, as their external surfaces abut the beam structures 29 and prevent them from collapsing.

The locking arrangements 90/91 , 96/99 are activated to secure the inner and outer bottom panels 10, 2 together around the articles, and to form a composite bottom wall of the carton. The locking arrangements 90/91 , 96/99 function not only to interlock the inner and outer bottom panels 10, 2, but also to stabilize the position of the reinforcing arrangements 50 with respect to the erected beam structures 29 and thereby subsequently to assist the reinforcing arrangements 50 in remaining engaged with the beam structures 29. The reinforcing arrangements 50 also aid the locking arrangements 90/91 , 96/99 in the sense that the engagement of the reinforcing arrangement 50 with the beam structure 29 prevents the inner and outer bottom panels 2, 10 from being rotated about the locking arrangements 90/91 , 96/99, when in use. The foregoing sequence of folding operations results in the reinforcing arrangements 50 being brought into vertical alignment beneath the erected beam structures 29, such that the primary flap 51 of each reinforcing arrangement 50 may then be folded internally of the corresponding beam structures 29 (as best shown in the sequence of illustrations of Figures 5 to 7), about the fold line 66 hinging it to the outer bottom panel 2, through the apertures, formed in the inner bottom panel 10, vacated by the erection of the first beam side panel 20. One side edge of each primary flap 51 , to which the second side tab 54 of that reinforcing arrangement 50 is hinged, is substantially aligned with the fold line 30 hinging the first beam side panel 20 to the inner bottom panel 10. Thus, inward folding of each primary flap 51 is opposed by the abutment of the second side tab 54 with the inner bottom panel 10, and also by abutment of detent 26 with portions of the primary flap 51.

It is envisaged that some warping of the primary flap 51 is necessary to hinge that primary flap 51 into the beam structure 29, which warping is made possible by the flexibility of the material from which the reinforcing arrangement 50 is constructed. This warping of the primary flap 51 is aided by the rounded corner of the detent 26 which acts as a wedge to gradually increase the warping of the primary flap 51 as it is hinged into the beam structure 29. The fold line 61 hinging the second side tab 54 to the primary flap 51 yields as the primary panel 51 is pushed into the beam structure 29 thereby causing the second side flap 54 to fold out of a plane of the primary flap 51. As the primary flap 51 hinges inwardly of the carton 100, an outside surface of the second side tab 54 slides over a leading edge of the detent 26 until eventually the second side tab 54 entirely clears the detent 26. The offset between the fold line 66 and the proximate end of the second side tab 54 allows a degree of clearance above a resultant upper surface of the detent 26 to allow the second side tab 54 to hinge about the side of the primary flap 51. Similarly, the offset between the other end of the second side tab 54 and the proximate edge of the primary flap 51 helps the second side tab 54 to be folded about the fold line 61 with respect to the primary flap 51. At this point, the natural bias of the material from which the reinforcing arrangement 50 is formed urges the second side tab 54 back toward the plane of the primary flap 51 , until it comes into abutment with the first beam side panel 20. This abutment or frictional contact of the second side tab 54 with the first beam side panel 20 prevents the beam structure 29 from being collapsed, or otherwise prevents the beam panels 20, 22, 24 from hinging back into the plane of the inner panel 10. The free upper edge of the primary flap 51 is preferably also brought into abutment with the lower surface of the beam top panel 22, which also prevents the beam structure 29 from being collapsed. At this point, as is best shown in Figure 7 (from beneath) and Figure 8 (from above), the second side tab 54 abuts an upper surface of the detent 26, and hinging of the primary flap 51 out of the beam structure is prevented by this abutment.

Simultaneously with the above described folding of the second side tab 54, the first side tab 52 is similarly urged against a lowermost surface of an article A disposed in part thereupon. The fold line 60 along which the first side tab 52 is hinged to the primary flap 51 yields in response, and the first side tab 52 is hinged out of the plane of the primary flap 51 , an outer surface of the first side tab 52 sliding over an exterior surface of the lower portion of that article A. The tapered portion of the end of the first side tab 52 aids this process by graduating the folding of this first side tab 52, rather than requiring the side tab 52 be substantially perpendicular to the primary flap 51 before any hinging thereof inwardly of the carton 100 could take place.

Thus, by folding each primary flap 51 perpendicular to the inner bottom panel 10, the second side tab 54 of each primary flap 51 comes to rest in coplanar contact or abutment with the first beam side panel 20 of the respective beam structure 29, and a lower edge of the second side tab 54 abuts the upper surface of the detent 26. These abutments of the reinforcing arrangement 50 on the respective beam structure 29 prevent the primary flap 51 from hinging back into the plane of the outer bottom panel 2 and, thus maintain it in a perpendicular relationship to the outer bottom panel 2. The upper edge of the primary flap 51 preferably abuts the lower surface of the top beam panel 22 and also prevents the primary flap 51 f from hinging back into the plane of the outer bottom panel 2. This is aided by the abutment of the opposing side edge of the primary flap 51 (i.e., the first side tab 52) with a lower portion of an adjacent article A (see Figs. 8). By virtue of the first beam side panel 20 being hingedly connected to the second beam side panel 24 via the beam top panel 22, this abutment also prevents the beam top panel 22 and the second beam side panel 24 from returning to the plane of the inner bottom panel 10 also, and maintains the beam structure 29 in question in an erected position. In a fully erected and loaded package, the primary panel 51 of each reinforcing arrangement 50 forms a brace between, on the one side, an article and, on an opposing side, a side of the beam structure 29.

Because both the first and second beam structures 29 are formed using a common second beam side panel 24, the reinforcement of each augments the reinforcement of the other. Thus, even if the reinforcement of a first of the two beam structures 29 were to fail for a reason such as the corresponding reinforcing arrangement 50 being damaged or folded out of the beam structure 29, the maintenance of the second beam side panel 24 in perpendicular relation to the inner bottom panel 10 would nonetheless aid maintenance of the second of the beam structures in an erected position.

It will be appreciated that the carton 100 according to the preferred embodiment advantageously provides for ease of construction by requiring only two folding operations to set up each beam structure 29 and to insert the reinforcing arrangement 50. The operation of folding the reinforcing arrangement 50 into the beam structure is achievable even after the inner 10 and outer 2 bottom panels are in overlapping relationship. This avoids potentially disadvantageous manufacturing issues that might arise if the reinforcing arrangement instead needed to be correctly folded and inserted directly into the beam structure simultaneously with the outer bottom panel 2 being folded into contact with the inner bottom panel 10.

The final arrangement of the completed carton 100 is illustrated in Figure 9, with four articles A disposed therein. For enhanced clarity, Figure 9 shows the same view of the carton 100 with the articles A illustrated only in ghost outline, to illustrate the relative positioning of those articles and the beam structure 29.

It is contemplated that the blank 1 may comprise any number of beam structures 29 and corresponding reinforcing panel arrangements 50. The illustrated blank is suitable for storing articles in two-by-two arrays, and therefore acts to separate each article of each row from each other article in that row. It is, however, contemplated that more beam structures 29 and associated reinforcing arrangements 50 may be provided to suit the desired group size and layout of the articles, this includes separating articles in one row from adjacent articles in another row or separating articles from adjacent walls of the carton.

The illustrated blank 1 is suitable for forming a wrap-around style carton 100. It is, however, contemplated that the beam structure of the present invention may be applied to other forms of carton also, including amongst others end loaded cartons, and trays. Depending on the nature of the carton the erection process of the carton from the blank will be varied. For example, a tray like carton may be more suitable for pre-formation of the erected beam structures prior to insertion of the articles.

It can be appreciated that various changes may be made within the scope of the present invention as defined by the claims, for example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape.

Differing article array configurations or other facts may require different beam structure cross sections. Whereas in the first embodiment described above the first and second beam side panels 20, 24 and the beam top panel 22 are each of substantially similar length to create a beam structure of square cross section, it is contemplated that, for example, the sides of the beam structure may be longer or shorter than the beam top panel. As a result, it is contemplated that the beam top panel may be defined also in part in the inner bottom panel 10 as well as the second beam side panel 24, if the width of the beam structure is such that this is necessary to accommodate the resultant length of the beam top panel.

Further, it is contemplated that the second beam side panel 24 my instead not be common to both (or all) the beam structure 29, and that each beam structure 29 would have it's own independent second beam side wall 24.

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. 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.

Claims

1. A carton for packaging articles, which carton comprises a composite wall, a beam structure and a reinforcing arrangement, wherein the beam structure comprises first and second beam side panels each formed from, and hinged to, an inner panel of the composite wall of the carton such that the beam structure is erectable by folding the first and second beam side panels out of a plane of said inner panel, and wherein the reinforcing arrangement is formed from an outer panel of the composite wall, the reinforcing arrangement being disposed in the beam structure such that the reinforcing arrangement extends through an aperture in said inner panel to abut at least one of the beam side panels to prevent the beam side panels from hinging back into the plane of said inner panel.

2. The carton according to claim 1 , wherein the reinforcing arrangement is hingeable from a first position in which it lies in a plane of said outer panel, and a second position in which it abuts said at least one of the beam side panels.

3. The carton according to claim 1 or claim 2, wherein the reinforcing arrangement abuts a surface of a detent extending from the said inner panel to prevent hinging of the reinforcing arrangement out of the beam structure.

4. The carton according to claim 3, wherein a fold line, along which said at least one of the beam side panels is hinged to said inner panel, is interrupted by a cut line that defines a terminal edge of said detent, which detent necessitates deformation of the reinforcing arrangement as it is hinged into the beam structure.

5. The carton according to claim 3 or claim 4, wherein the reinforcing arrangement comprises a primary flap that is hinged to said outer panel and that is disposable at an angle with respect to said at least one of the beam side panels such that a side edge of that primary flap abuts said at least one of the beam side panels.

6. The carton according to claim 5, wherein the reinforcing arrangement further comprises a first side tab hinged to said side edge of the primary flap which first side tab is disposable in face contacting relationship with said at least one beam side panel.

7. The carton according to any one of claim 3 to 6, wherein the first side tab is foldable out of the plane of the primary flap such that an edge of the first side tab adjacent the detent abuts a surface of the detent to prevent hinging of the primary flap out of the beam structure.

8. The carton according to claim 7, wherein an edge of the first side tab is offset from a proximate surface of said detent so as to accommodate the thickness of the detent and allow hinging of that first side tab about the primary flap.

9. The carton according to any one of claims 6 to 8, wherein the reinforcing arrangement further comprises a second side tab hinged to the primary flap along an edge opposite said first side tab, which second side tab is one or more of: a) foldable into a position of abutment with a surface of an article contained in the carton, when present; or, b) 7 tapered portion to encourage folding of that second side tab as the primary flap is folded into the beam structure.

10. The carton according to any one of claims 1 to 9, comprising two or more beam structures that share a common beam side panel such that reinforcement of any one beam structure at least partially reinforces the other beam structure sharing that common beam side panel.

1 1. The carton according to claim 1 , wherein the beam structure further comprises a beam top panel hingedly connected to both the first and second beam side panels, and wherein said reinforcing arrangement is disposed in abutment with a lower surface of the beam top panel.

12. A blank for forming a carton for packaging articles, which blank comprises panels for forming a composite wall, panels for forming a beam structure and panels for forming a reinforcing arrangement, wherein the beam structure includes first and second beam side panels each formed from, and hinged to, a panel for forming an inner panel of the composite wall of the carton such that the beam structure is erectable by folding the first and second beam side panels out of a plane of said inner panel, and wherein the reinforcing arrangement is formed from an outer panel of the composite wall, the panels for forming the reinforcing arrangement being disposable in the beam structure, when set up, such that the reinforcing arrangement extends through an aperture in said panel for forming an inner panel of the composite wall, to abut at least one of the beam side panels to prevent the beam side panels from hinging back into the plane of said inner panel.

13. The blank according to claim 12, wherein the panels for forming the reinforcing arrangement are foldable, in the set up carton, to abut a surface of a detent extending from the said panel for forming the inner panel of the composite wall to prevent hinging of the reinforcing arrangement out of the beam structure.

14. The blank according to claim 12 or claim 13, wherein the panels for forming the reinforcing arrangement comprise a primary flap that is hinged to the outer panel, that is foldable into the beam structure when the carton has been set up, which primary flap is angled to one of the beam side panels of the beam structure such that a side edge of the primary flap can be brought into abutment with said one of the beam side panels to prevent the beam side panels from hinging back into the plane of said inner panel.

15. The blank according to claim 14, wherein a fold line along which said one of the beam side panels is hinged to the inner panel, is interrupted by a cut line that defines a terminal edge of a detent that extends from the inner panel of the composite wall, and wherein the reinforcing arrangement further comprises a first side tab hinged to said primary flap to define said side edge of the primary flap.

16. The blank according to claim 15, wherein the first side tab is foldable out of the plane of the primary flap such that an edge of the first side tab adjacent the detent abuts a surface of the detent to prevent hinging of the primary flap out of the set up beam structure.

17. The blank according to claim 15 or claim 16, wherein the first side tab has a lowermost edge that is offset from the fold line by which the primary flap is hinged to the outer panel so as to accommodate the thickness of the detent when the first side tab is folded into the beam structure of the erected carton.

18. The blank according to any one of claims 15 to 17, wherein the reinforcing arrangement further comprises a second side tab hinged to the primary flap along an edge thereof opposite said first side tab, which second side tab is foldable into a position of abutment with a surface of an article contained in the set up carton, when present.

19. The blank according to claim 18, wherein the second side tab has a tapered portion to encourage folding of that second side tab as the primary flap is folded into the beam structure.

20. The blank according to any one of claims 12 to 19, comprising panels for forming two or more beam structures that share a common beam side panel such that reinforcement of any one set up beam structure at least partially reinforces the other beam structure sharing that common beam side panel.

21. A carton for packaging articles, which carton comprises a composite wall formed from a pair of inner and outer overlapping panels provided respectively with mutually engaged male and female punch-lock locking tabs and stabilizing means for mitigating rotation of the inner and outer panels about the locking tabs with respect to each other, the stabilizing means comprising a beam structure and a reinforcing arrangement, wherein the beam structure comprises first and second beam side panels each hinged to an inner panel of the composite wall and hinged to one another by a beam top panel such that it is erectable by folding the first and second beam side panels out of a plane of said inner panel, and wherein the reinforcing arrangement is formed from the outer panel of the composite wall and is foldable into the beam structure.