CA2429513C

CA2429513C - Carton and carton blank therefor

Info

Publication number: CA2429513C
Application number: CA002429513A
Authority: CA
Inventors: Alain Saulas
Original assignee: Meadwestvaco Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2000-09-15
Filing date: 2001-09-15
Publication date: 2007-06-05
Anticipated expiration: 2021-09-15
Also published as: WO2002022450A2; AU2001290811A1; JP2004509023A; EP1320489A2; CA2429513A1; WO2002022450A3; BR0113919A; MXPA03002215A

Abstract

A carton and a blank for forming a carton for holding a plurality of articles, for example bottles, comprising a collapsible tubular corner post (70q, 70b, 70c, 70d) formed from an extension of a carton side wall (12, 16). The corner post is adapted to move from a flat collapsed condition when extending outwardly of the carton to be automatically erected by folding the corner post inwardly.

Description

CARTON AND CARTON BLANK THEREFOR
Background of the Invention The invention relates to a carton and to a blank for forming a carton for carrying a plurality of articles, for example flexible pouches or bottles, and one or more beam structures for improving the rigidity of the carton. It may further comprise a tear-open flap that can be reclosed.
The use of beam structures is known; for example, in US 5 673 840 there is shown a corner post structure for improving the rigidity of the carton. The invention is particularly useful where it is desirable for cartons containing articles to be enclosed to protect each article, for example information discs or foodstuffs.
One example of reclosable sleeves formed from one or more blanks of cardboard is found in US 3,078,030 which illustrates a carton having an integral hinged top that it reclosable. The top is provided by a front cover panel and a spacer panel secured to one side of the front cover panel to interfit with a mating upper portion of the front panel of a box.
Fastening means is formed from a detached double layer portion of the front panel. However, the detached 2o portion is attached to the inside surface of the cover flap, resulting in a stepped non-flat front surface.
In US 3,894,680 there is provided a dispensing spout in a carton box adapted to accommodate powdery materials, for example detergents, which spout is adapted to keep closed after it has been cut out. The fastening means is formed from a detached triple layer portion of the front panel but it does not define a pocket to retain the spout.
Further, supporting the weak parts of a carton, such as corners and the like, is well known.
For example, US 5 673 840 illustrates a corner post structure. However, in automated 3o packaging, it is necessary to load articles into the carton at high speeds;
therefore, it is undesirable to have a complicated arrangement for forming a corner post structure.

a "~.i .~oi~u_.,_11:34 H L ~ ~ Ul I~~' ~nnlu~ Nt, ;~ ~.~~ u..
Pr~ntec~ 16-12 20x2' D:ESCPAMD 005 01970856=US0v128504:
- . a : . ~ ,.

The present invention seeks to overcome ox at least mitigate the problems of the prior art.
One aspect of the invention provides a carton for holding a plurality of articles, fox example bottles, comprising a collapsible tubular Garner post, formed from a series of interconnected panels extending fmm a carton side wall, characterised in that the comer post is adapted by provision of a supplementary longitudinally-extending fold line to mane from a flat collapsed conditiozt when extending outwardly of the carton to be automatically erected by folding the comer post inwardly, said corner post further comprising a substantially triangular cross section to form a rigid structure in use, and in that one of said interconnected panels being secured to said carton watt.
One advantage of this arrangement is that the blank and corner post can be supplied to the end user in a flat collapsed condition, it can tlxen be automatically deployed by automatic packaging machinery by a simple folding process. Beneficially, the amount of board for the corner post can be reduced and standard equipment to secure the er~d panels can be used.
Preferably, the comer post nrtay have a triangular cross-section to serve as a rigid structure wherein the comer post has a longitudinally extending fold line to allow the comer post to be folded flat only outwardly of the carton. More preferably, the corner post may comprise an end panel, a bzacing panel and a securing panel hingedly connected together in series, and the securing panel is secured to the carton side wall. Uptivnally, the longitudinally extending fold line z~nay be farmed in the end panel.
According to an optional feature of this aspect of the invention the end panel may be adapted to secure an end flap of the carton to close the carton.
A second aspect of the invention provides a carton for holding a plurality of articles, for example bottles, which carton comprises a rectosable tear open flap formed from a first carton wall and a wall end-reinforcing member hinged to the $rst carton wall.The reinforcing :30 meraaber is affixed at least iz~ part to the inside surface ofthe first carton wall so that the reinforcing member underlies the first carton wall along at least a part of the tear Line.
W09934 w '1AMENDED SHEET '09-1~ p~na' Optionally the reinforcing member extends above the tear line to provide upon breaking of the tear line an engaging element for retaining the flap in a reclosed position.
A third aspect of the invention provides a carton for holding a plurality of articles, for example bottles, which carton comprises a reclosable tear open flap including a first panel formed from a first carton wall and an engaging panel affixed at least in part to the inside surface of the first carton wall. The engaging panel extends above the tear line to provide upon breaking of the tear line an engaging element for retaining the flap in a reclosed position.
According to an optional feature of the third aspect of the invention, the engaging panel is provided by a reinforcing member hinged to one of the panels adjacent the first carton wall panel. Preferably, the reinforcing member underlies the first carton wall at the corner with a second carton wall, thereby to reinforce the corner.
According to another optional feature of the second or third aspect of the invention, the tear open flap comprises a second panel hingedly connected to the first panel.
Preferably, the tear open flap further comprises a pull tab.
More preferably, the first carton wall is provided with a securing tab hingedly connected thereto, and a portion of the tear open flap or, as the case may be, the pull tab, is adapted to be placed intermediate the first carton wall and the securing tab to be retained therewith.
A fourth aspect of the invention provides a blank for forming a carton for holding a plurality of articles, for example bottles, which carton comprises a reclosable tear open flap formed from a first carton wall and a wall end-reinforcing member hinged to the first carton wall, wherein the reinforcing member is affixed at least in part to the inside surface of the first carton wall so that the reinforcing member underlies the first carton wall along at least a part 3o of the tear line.

Preferably, the corner post may have a longitudinally extending fold line to allow the corner post to be folded flat only outwardly of the carton. More preferably, the longitudinally extending fold line may be formed in the end panel.
A fifth aspect of the invention provides a blank for forming a carton for holding a plurality of articles, for example bottles, comprising a collapsible tubular corner post formed from an extension of a carton side wall, wherein the corner post comprises an end panel, a bracing panel and a securing panel hingedly connected together in series, wherein said securing panel is adapted to be secured to said carton side wall.
to Optionally, the corner post has a longitudinally extending fold line to allow the corner post to be folded flat only outwardly of the carton. Preferably, the longitudinally extending fold line is formed in said end panel.
15 A sixth aspect of the invention provides a blank for forming a carton for holding a plurality of articles, for example bottles, which carton comprises a reclosable tear open flap including a first panel formed from a first carton wall and an engaging panel affixed at least in part to the inside surface of the first carton wall wherein the reinforcing member extends above the tear line to provide upon breaking of the tear line an engaging element for retaining the flap in a 2o reclosed position, when the carton is in a set up condition. Optionally, the tear open flap further comprises a pull tab.
Brief Description of the Drawings 25 Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIGURE 1 illustrates the blank for forming the carton according to a first embodiment of the invention;

FIGURES 2 and 3 illustrate the construction of the corner support structure from the blank shown in Figure l;
FIGURES 4 and 5 illustrate the construction of the carton from the blank shown in Figure 1;
FIGURE 6 shows the carton from the blank shown in Figure 1 in an erected condition;
FIGURES 7 and 8 show the carton of Figure 7 with the reclosable tear open flap in open and closed positions;
to FIGURE 9 illustrates a cross-section through B 1-B2 of the carton in Figure 6;
FIGURE 10 illustrates the blank for forming a carton according to a second embodiment of the invention;
FIGURE 11 shows the carton formed from the blank of Figure 10 in an erected condition with the reclosable tear open flap in closed position; and FIGURE 12 illustrates a cross-section through B3-B4 of the carton in Figure 11.
Detailed Description of the Preferred Embodiments Referring to the drawings and in particular, Figure 1, there is shown an embodiment of a blank for forming a carton made from paperboard or similar foldable sheet material. In the embodiment described below, the carton is a "fully-enclosed" type, although it will be recognised that the invention could be applied to a "wraparound" type carton or "basket-type"
carton or other carton where it is required to provide a support structure at the corners of the carton.
3o The blank 10 comprises a plurality of panels for forming an enclosed carton. Turning to the embodiment shown in Figure 1, there comprises first side wall panel 12, a top panel 14, a second side wall panel 16 and bottom panel 18 hingedly connected one to the next along fold lines 20, 22 and 24 respectively.
The ends of the carton are constructed by one or more end flaps or panels. In this embodiment, end panels 30 and 42 are hingedly connected to the opposing ends of top wall panel 14 along fold lines 32 and 44 respectively. A second pair of end panels 34, 38 is provided along opposing end edges of bottom panel 18 and hingedly connected thereto along fold lines 36 and 40 respectively.
to Securing means are provided for securing together the first side wall panel 12 and bottom panel 18. In this embodiment, securing means are provided by a securing flap 26 hingedly connected to first side wall panel 12 along fold line 28.
There may further comprise an access structure to provide access to the interior of the carton.
15 The access structure comprises a reclosable tear open flap 50 formed from one of the carton wall panels. In this embodiment the flap comprises an upper access panel 53 struck from the top panel 14 and frangibly connected thereto along frangible lines 52 and 54 respectively.
Upper access panel 53 is hingedly connected to the second side wall panel along fold line 22.
Preferably, there further comprises a side access panel 51 from the first side wall panel 12 2o and frangibly connected thereto along frangible fold lines 55 and 56 respectively. It will be seen from Figure 1 that frangible lines 55 and 56 converge to a pull tab 58.
Optionally, there further comprises a securing tab 60 hingedly connected to the first side wall panel along fold line 61. The opening of the access structure 50 will be described in more detail below.
25 According to one aspect of the invention there comprise one or more beam structures formed internally of the carton. The beam structures are positioned intermediate the top and bottom panels of the carton to improve the rigidity of the carton when it is subjected to vertical compression. In this embodiment there are four corner posts 70a, 70b, 70c and 70d. Each corner post is substantially the same and therefore only the first beam structure 70a is 3o described in any further detail.

_7_ In the embodiment shown in Figure l, the corner post 70a comprises securing panel 74a and bracing panel 76a and an inner end panel 80a hingedly connected one to the next along fold lines 82a, 84a. The corner post 70a is hingedly connected to the first side wall panel along fold line 72a. In one class of embodiments, the fold line 82a is a shallow arcuate shape to assist in flexing the panels in the vertical plane, although in other embodiments it is linear or can be dispensed with. There may further comprise a flexing panel 78a intermediate bracing panel 76a and inner end panel 80a along fold lines 84a and 86a respectively.
In use, fold line 86a is used to place the corner post in a flat collapsed condition.
to It is envisaged that the panels for forming the corner post are not limited to the shape illustrated in Figure 1 and indeed could be replaced by other means to allow a beam to juxtapose the top and bottom panels. For example, bracing panel 76 could be arcuate in cross-section to better receive and retain the adjacent article.
15 Turning to the construction of the carton from the carton blank as illustrated in Figure l, each blank requires a series of sequential folding and gluing operations which are preferably performed in a straight line machine, so that the carton and blank are 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.
Turning to the construction of the corner structures from the blank 10, reference is made to Figures 2 and 3. The panels for forming each corner post structure 70a, 70b, 70c, 70d are folded inwardly in directions Wl, W, X1 and X along fold lines 86a, 86b, 86c, 86d to be secured to the respective one of the first or second side wall panels 12, 16.
In this embodiment, securing panel 74 is glued to the respective adjacent side wall panel by a strip of glue G (Figure 2).
Thereafter, the first side wall panel 12 and bottom wall panel 18 are secured together, whereby, in this embodiment, securing flap 26 is secured to bottom panel 18 by glue or other 3o suitable means known in the art. Thus, the carton is in a flat collapsed position ready to be supplied to an end user for loading with articles.

_g_ In order to erect the carton it is constructed by folding top panel 14, first side wall panel 12, bottom panel 18 and second side wall panel 16 out of alignment with each other along fold lines 28, 20, 22 and 24 respectively so as to form a tubular structure as shown in Figure 4.
The carton is at an intermediate stage of construction whereby the articles are inserted into the carton C from one of the ends. It will be seen from Figure 4, that end panels 30 and 34 are preferably folded outwardly along fold lines 32 and 36 respectively to guide the articles into the carton. Preferably, the opposing end wall is ~fonned prior to receiving the articles, l0 whereby corner post structures 70b and 70d are formed in the manner described below and end wall panels 38 and 42 are folded inwardly along the respective fold lines 40 and 44, to be secured together by glue or other suitable means known in the art.
Once the articles have been loaded into the carton, the corner post structures 70a and 70c are 15 then formed.
In order to form the corner post structure 70a, inner end panel 80a is folded inwardly in direction Y along fold line 72a. This action causes bracing panel 76a and intermediate panels 78a to be folded out of alignment with respect to securing panel 74a along fold lines 82a, 84a 2o and 86a respectively to automatically deploy the corner post within the carton. In this embodiment the corner post has a substantially triangular cross-section viewed in more detail in Figure 9. In one class of embodiments, the purpose of intermediate panel 78a is to provide a degree of resilience for the bracing panel 76a where for example it comes into abutment with the outermost article. However, in this embodiment, it is adapted to be placed in a co-25 linear arrangement with inner end panel 80a.
The opposing corner post structure 70c and the other structures 70b, 70d are formed in substantially the same manner as beam structure 70a and they are therefore not described in any greater detail hereinafter. Thus the carton is at the stage illustrated in Figure 4.

In order to complete construction of the carton C, the end wall panels are secured together.
To this end, glue G is applied to the inner faces of end wall panels 30 and 34 and then folded inwardly along fold lines 32 and 36 respectively and into abutment to be secured together.
Preferably, the end wall panels 30 and 34 are also secured to the inner end panels 80a and 80c of their respective corner post structures 70a and 70c to provide additional securing points.
In alternative embodiments glue may be applied to different areas of the blank such as where corner support structure are used. Thus the carton is in a set up condition and fully loaded with articles ready to be supplied to the user, as shown in Figure 6.
In order to gain access to the interior of the carton, the access structure can be opened whereby securing tab 60 is pushed inwardly to reveal the pull tab 58.
Thereafter, the pull tab 58 is pulled in an outward direction which causes the side access panel 51 to be separated from the first side wall panel 12 along frangible lines 55 and 56. By continued pulling on pull tab 58 in an upward direction, the upper access panel 53 is separated from top wall panel 14 along fold lines 52 and 54 respectively. The access structure is folded backwards along fold line 22 to reveal the contents of the carton, as shown in Figure 7.
To reclose the access structure, there are provided opposing tabs 75a and 75b, which are 2o secured to the inner face of one of the top or side wall panels. Tn this embodiment, tabs 75a and 75b are provided by the securing panels 74a and 74b. It is envisaged, however, that these tabs could be applied independently of the beam structure and, in fact, could be applied to cartons where no beam structures are provided. The tabs 75a and 75b are adapted so that the side access panel 51 can be placed within the carton such that the outer face of access panel 51 abuts the inner surface of insert 75a and 75b shown in Figure 8. In order to engage the side access panel 51, pull tab 58 or - as the case may be - paxt of access panel 51, is placed securing tab 60 and side wall panel 12, thereby providing a pincer arrangement to secure the pull tab 58 (or access panel 51) thereto and to provide a reclosable access structure shown in Figure 8.

Turning to a second embodiment of the present invention in Figures 10 to 12, there is shown a blank 110 .comprising a plurality of panels for forming an enclosed carton.
With reference to the embodiment shown in Figure 10, the blank comprises first side wall panel 112, a top panel 114, a second side wall panel 116 and bottom panel 118 hingedly connected one to the next along fold lines 120, 122 and 124 respectively.
The ends of the carton are constructed by one or more end flaps or panels. In this embodiment, end panels 130 and 142 are hingedly connected to the opposing ends of top wall panel 114 along fold lines 132 and 144 respectively. A second pair of end panels 134, 138 is to provided along opposing end edges of bottom panel 118 and hingedly connected thereto along fold lines 136 and 140 respectively.
Securing means are provided for securing together the first side wall panel 112 and bottom panel 118. In this embodiment it is provided by a securing flap 126 hingedly connected to 15 first side wall panel 112 along fold line 128.
There further comprises an access structure that provides access to the interior of the carton.
The access structure is similar to the first embodiment and comprises a reclosable tear open flap 150 formed from one of the carton wall panels. In this embodiment the flap comprises 2o an upper access panel 153 struck from top panel 114 and frangibly connected thereto along frangible lines 152 and 154 respectively. Upper access panel 153 is hingedly connected to end wall panel 130 along fold line 132.
Preferably, there further comprises a side access panel 151 struck from the first end wall 25 panel 142 and frangibly connected thereto along frangible fold lines 155 and 156 respectively.
It will be seen from Figure 10 that frangible lines 155 and 156 converge to a pull tab 158.
Optionally, there further comprises a securing tab 160 hingedly connected to the end wall panel 142 along fold line 161. The opening of the access structure 150 will be described in more detail below.

There further comprises one or more corner support structures formed internally of the carton.
In the first embodiment, the support structures are positioned intermediate the top and bottom panels of the carton to improve the rigidity of the carton at the weaker parts, for example the corners of the carton.
In the second embodiment there are four corner support structures 170a, 170b, 170c and 170d. Each corner support is substantially the same and therefore only the first corner support structure 170a is described in any further detail. In the embodiment shown in Figure 10, the corner support 170a comprises securing panel 174a and inner support panel 176a and to an outer support panel 180a hingedly connected one to the next along fold lines 184a, 186a.
The corner support 170a is hingedly connected to first side wall panel 112 along fold line 172a.
It is envisaged that the panels for forming the corner structure are not limited to the shape 15 illustrated in Figure 10, and could indeed be replaced by other means to allow the structure to juxtapose the top and bottom panels.
Turning to the construction of the carton from the carton blank as illustrated in Figure 10, again each blank requires a series of sequential folding and gluing operations which are 20 preferably performed in a straight line machine, so that the carton and/or blank are 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.
25 The panels for forming each corner support structure 170a, 170b, 170c, 170d are first folded inwardly along fold line 186a, 186b, 186c, 186d to be secured to the respective one of the first or second side wall panels 112, 116. In this embodiment, securing panel 174 is glued to the respective adjacent side wall panel.
30 Thereafter, the first side wall panel 112 and bottom wall panel 118 are secured together whereby, in this embodiment, securing flap 126 is secured to bottom panel 118 by glue or other suitable means known in the art. Thus, the carton is in a flat collapsed position ready to be supplied to an end user for loading with articles.
In order to erect the carton it is constructed by folding top panel 114, first side wall panel 112, bottom panel 118 and second side wall panel 116 out of alignment with each other along fold lines 128, 120, 122 and 124 respectively, so as to form a tubular structure.
The carton is at an intermediate stage of construction whereby the axticles are inserted into the carton C' from one of the ends. End panels 138 and 142 are preferably folded outwardly to along fold lines 140 and 144 respectively to guide the articles into the caxton C'. More preferably, the opposing end wall is formed prior to receiving the articles, whereby end wall panels 130 and 134 are folded inwardly along fold lines 132 and 136 respectively to be secured together by glue or other suitable means known in the art.
15 In order to complete construction of the carton C', the end wall panels are secured together.
To this end, glue is applied to the inner faces of end wall panels 138 and 142, and then folded inwardly along fold lines 132 and 136 respectively and into abutment to be secured together.
Preferably, the end wall panels 130 and 134 are also secured to part of the outer support panels 180a and 180c of the corner support structures 170a and 170c respectively to provide 2o additional securing points.
In further embodiments, glue may be applied to different areas of the blank such as where corner support structures are used. Thus the carton is in a set up condition and fully loaded with articles ready to be supplied to the user, as shown in Figures 11 and 12.
It will be seen from Figure 12 that the support structures 170a, 170b, 170c, 170d are located in the corners of the outer carton to provide additional support for the weaker parts of the caxton.
3o In order to gain access to the interior of the carton, the access structure can be opened whereby securing tab 160 is pushed inwardly to reveal the pull tab 158.
Thereafter, the pull tab 158 is pulled in an outward direction which causes the side access panel 151 to be separated from the first side wall panel 112 along frangible lines 155 and 156. By continuing to pull on pull tab 158 in an upward direction the upper access panel 153 is separated from top wall panel 114 along fold lines 152 and 154 respectively. The access structure is folded backwards along fold line 122 to reveal the contents of the carton.
In order to reclose the access structure, there are provided opposing tabs 175a and 175b that are secured to the inner face of one of the top or side wall panels. In this embodiment, tabs 175a and 175b are provided by the securing panels 174a and 174b. It will be seen from to Figure 11 that the corner structure 170a provides a tab to assist with the re-engagement of the end closure flap. Indeed, it is envisaged that the corner support structure could be replaced by a panel hingedly connected to side wall 112 to provide such a tab. It is envisaged that these tabs could be applied independently of the corner structure and, in fact, could be applied to cartons where no corner structures are provided.
The tabs 175a and 175b are adapted so that the side access panel 151 can be placed within the carton such that the outer face of access panel 151 abuts the inner surface of tab 175a and 175b, shown in Figure 11. In order to engage the side access panel 151, pull tab 158 or - as the case may be - part of access panel 151, may be placed securing tab 160 and side wall panel 112 thereby providing a pincer arrangement to secure the pull tab 158 (or access panel 151 ) thereto and to provide a reclosable access structure.
The present invention and its preferred embodiments relate to an arrangement for providing a corner post structure in a fully enclosed carton, and for providing a tear-open flap. However, it is anticipated that the invention can be applied to a variety of carriers and is not limited to those of the fully enclosed type hereinbefore described and could be used for numerous applications where it is desired to provide a carrier with improved rigidity.
It will be recognised that as used herein, directional references such as "top", "bottom", "end", "side", "inner" and "outer" 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 one of the following: a score line, a frangible line or a fold line; without departing from the scope of invention.
It should be understood 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, or alternative top and bottom closure structures may be used, without departing from the scope of the invention. A
single glue aperture may be provided in some embodiments. The carton may accommodate more than to one article in different arrays.

Claims

1. A carton for holding a plurality of articles, comprising a reclosable tear open flap defined at least in part in a first wall of the carton by a tear line and an engaging panel affixed at least in part to an inside surface of said first wall wherein said engaging panel is disposed astride said tear line to provide upon breaking of said tear line an engaging element for retaining said tear open flap in a reclosed position, and wherein said engaging panel is provided by a corner structure disposed between said first wall and a second wall of the carton, said first and second walls being disposed adjacent to each other to define a corner of the carton therebetween, said corner structure being affixed to an inside surface of said second wall and extending to said first wall to be affixed to said first wall.

2. A carton as claimed in claim 1 wherein said corner structure comprises a first panel affixed to said first wall and a second panel affixed to said second wall, and said engaging panel is provided by said first panel.

3. A carton as claimed in claim 2 wherein said first and second panels underlie said first and second walls respectively to reinforce said corner.

4. A carton as claimed in claim 1 wherein said tear open flap comprises primary portion formed from said first wall and a secondary portion hingedly connected to said primary portion and formed from a third wall of the carton disposed adjacent to said first and second walls.

5. A carton as claimed in claim 1, wherein said first wall is provided with a retaining tab hingedly connected thereto, and a portion of said tear open flap is adapted to be placed intermediate said first wall and said retaining tab to be retained therewith.