CN114302852A

CN114302852A - Laminated article carrier and blank therefor

Info

Publication number: CN114302852A
Application number: CN202080062827.9A
Authority: CN
Inventors: B·J·沃林; M·E·扎彻尔勒
Original assignee: WestRock Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2019-07-08
Filing date: 2020-05-22
Publication date: 2022-04-08
Also published as: US20220242637A1; MX2022000401A; WO2021006963A1; CL2022000046A1; AU2020311834A1; BR112022000421A2; CA3146415A1; KR20220030286A; EP3997008A1; JP2022540225A

Abstract

Aspects of the present disclosure relate to a carrier (90) for packaging one or more articles B, a blank (10) for forming a carrier, and a method of forming a carrier. In one aspect, a top-engaging article carrier for packaging at least one article is provided. The article carrier includes a main panel (12) including at least one top engagement means having a top receiving opening. The main panel comprises a laminate structure formed of two or more layers of L1, L2 substrate (50) uniformly bonded together.

Description

Laminated article carrier and blank therefor

Technical Field

The present invention relates to article carriers and blanks for forming article carriers. More particularly, but not exclusively, the invention relates to a top gripping or top engaging style carrier having one or more apertures for receiving and retaining articles therein.

Background

In the field of packaging, it is known to provide cartons for carrying a plurality of articles. Cartons are well known in the art and are useful for enabling a consumer to transport, store and access a group of articles for consumption. For cost and environmental reasons, such cartons or carriers need to be formed from as little material as possible and cause as little loss of material from which they are formed. A further consideration is the strength of the carton and its suitability for holding and transporting heavy weight articles. It is desirable that the contents of the carton be secured within the carton.

Article carriers providing top gripping are well known in which apertures are formed in the panels of the carrier about which tabs may be defined. These tabs may be displaced out of the plane of the panel. The tab engages the article substantially about the flange or lip of the article when the article is received in the aperture.

The present invention seeks to provide improvements in the field of cartons generally formed from paperboard or the like.

Disclosure of Invention

A first aspect of the invention provides a method of forming a top-engaging article carrier, the method comprising:

providing a first paperboard substrate;

providing a second paperboard substrate;

applying an adhesive treatment uniformly to the entire first surface of the first paperboard substrate;

securing a surface of a second paperboard substrate to a first surface of a first paperboard substrate to form a laminated paperboard structure;

one or more blanks are cut from the laminated paperboard structure.

Optionally, cutting the one or more blanks from the laminated paperboard structure includes cutting one or more top engaging means from the laminated paperboard structure, each top engaging means having a top receiving opening.

Optionally, the method comprises:

applying the blank to one or more articles to form a package;

engaging the one or more top engagement devices with a respective one of the one or more articles.

Optionally, the one or more top engaging means each comprise at least one tooth comprising a uniformly bonded multi-layer laminate structure, and wherein engaging the one or more top engaging means with a respective one of the one or more articles comprises:

engaging an edge of the at least one tooth with a flange of the respective one of the one or more articles.

A second aspect of the invention provides a top-engaging article carrier for packaging at least one article. The article carrier includes a main panel including at least one top engagement means having a top receiving opening. The main panel comprises a laminate structure formed of two or more layers of substrates uniformly bonded together.

Optionally, the top engaging means comprises one or more teeth for engaging the article, said one or more teeth comprising two or more layers of substrate uniformly bonded together.

Optionally, each of the two or more layers of the substrate comprises at least one uncoated side.

Optionally, each of the two or more layers of the substrate comprises a coated side, and wherein the coated side of the first layer is bonded to the coated side of the second layer.

Optionally, each of the two or more layers of the substrate comprises an uncoated side opposite a coated side.

Optionally, each of the two or more layers of the substrate comprises an uncoated side, and wherein the uncoated side of the first layer is bonded to the uncoated side of the second layer.

Optionally, each of the two or more layers of the substrate comprises a coated side opposite an uncoated side.

Optionally, each of the two or more layers of the substrate includes a second uncoated side opposite the first uncoated side.

Optionally, the laminated structure comprises:

a first layer having a coated side and an uncoated side opposite the coated side; and

a second layer having an uncoated side;

wherein the uncoated side of the first layer is bonded to the uncoated side of the second layer.

Optionally, the substrate is a paperboard material.

A third aspect of the invention provides a blank for forming a top-engaging article carrier. The blank comprises a main panel comprising at least one top engagement means having at least one top receiving opening. The main panel comprises a laminate structure formed of two or more layers of substrates uniformly bonded together.

A fourth aspect of the invention provides an article carrier for packaging at least one article. The article carrier includes a main panel including at least one article retention device having at least one article receiving opening. The main panel comprises a laminate structure formed of two or more layers of paperboard material that are uniformly bonded together.

A fifth aspect of the present invention provides a laminated paperboard structure for forming an article carrier, the laminated paperboard structure comprising two or more paperboard substrates, the two or more paperboard substrates comprising a first layer having a first surface and a second layer comprising a second surface. The second surface is disposed adjacent to and uniformly bonded to the first surface.

It is contemplated or contemplated within the scope of this application that various aspects, embodiments, examples, features, and alternatives set forth in the preceding paragraphs, claims, and/or in the following description and drawings may be considered or employed independently or in any combination thereof.

Features or elements described in connection with or in relation to one embodiment are applicable to all embodiments unless there is incompatibility of the features. One or more features or elements from one embodiment may be combined with or combined with any other embodiment disclosed herein, and the features or elements extracted from the one embodiment may be included in addition to or in place of one or more features or elements of the other embodiment.

Features or combinations of features of embodiments disclosed herein may be extracted in isolation from other features of the embodiments. Alternatively, a feature or a combination of features of an embodiment may be omitted from the embodiment.

Drawings

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

fig. 1 is a top plan view of a plurality of connected blanks, each blank capable of forming a carrier according to a first embodiment;

FIG. 2 is a top plan view of one of the blanks of FIG. 1;

FIG. 3 is a top perspective view of a carrier formed from the blank of FIG. 2;

FIG. 4 is a top plan view of a plurality of connected blanks, each blank capable of forming a carrier according to a second embodiment; and

fig. 5A-5E are schematic illustrations of a plurality of structures formed from a paperboard substrate, according to various embodiments of the present disclosure.

Detailed Description

Detailed descriptions of specific embodiments of packages, blanks, and carriers are disclosed herein. It is to be understood that the disclosed embodiments are merely exemplary of the ways in which certain aspects of the invention can be practiced and do not represent an exhaustive list of all the ways in which the invention may be embodied. As used herein, the word "exemplary" is used in a broad sense to refer to embodiments that are used as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packages, blanks, and carriers described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in 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 present invention.

Referring to fig. 1, a plan view of a plurality of

connected blanks

10A, 10B, 10C, 10D, 10E, 10F is shown; shown in fig. 2 is an individual blank 10 capable of being formed into a carton or carrier 90 (as shown in fig. 3) for containing and carrying a group of primary products, such as but not limited to bottles or cans, hereinafter referred to as articles B, as shown in fig. 3. The blank 10 forms a secondary package for packaging at least one primary product container or package. An alternative blank 110 is shown in fig. 4.

In the embodiments detailed herein, for non-limiting purposes of illustrating various features of the invention, the terms "carton" and "carrier" refer to a container for engaging and carrying articles, such as primary product containers. It is contemplated that the teachings of the present invention can be applied to a variety of product containers, which may or may not be tapered and/or cylindrical. Exemplary containers include bottles (e.g., metal, glass, or plastic bottles), cans (e.g., aluminum cans), tints, bags, pouches, and the like.

The blanks 10, 110 are formed from a sheet of suitable substrate material. It will be understood that, as used herein, the term "suitable substrate" includes a wide variety of foldable sheet materials, such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It will be appreciated that one or other number of blanks may be employed where appropriate, for example to provide a carrier structure described in more detail below.

The packaging structures or cartons described herein can be formed from a sheet material (such as paperboard) that can be made from or coated with various materials to increase its strength. An example of such a sheet material is tear resistant NATRALOCK paperboard made by Westrock Company. It should be noted that the tear resistant material may be provided by more than one layer to help improve the tear resistance of the package. Typically, one surface of the sheet material may have different properties than the other surface. For example, the surface of the sheet material facing outward from the finished package may be particularly smooth and may have a coating (such as a clay coating or other surface treatment) to provide good printability. On the other hand, the inwardly facing surface of the sheet material may be provided with a coating, layer, treatment or otherwise prepared to provide properties such as one or more of tear resistance, good adhesion, heat sealability or other desired functional properties.

In the illustrated embodiment, the blank 10 is configured to form a carton or carrier 90 for packaging the exemplary arrangement of exemplary articles B. In the embodiments illustrated in fig. 1, 2 and 3, the arrangement is a2 x 2 matrix or array; in the illustrated embodiment, two rows of two articles each are provided, and article B is a beverage can. In the embodiment illustrated in fig. 4, the arrangement is a3 × 2 matrix or array; in the illustrated embodiment, two articles in three rows are provided, and article B is a beverage can. Alternatively, the blanks 10, 110 can be configured to form carriers for packaging other types, numbers, and sizes of articles and/or for packaging articles in different arrangements or configurations.

Referring to fig. 1, there is shown a plurality of connected blanks (generally designated by reference numeral 1), in particular, there are six

blanks

10A, 10B, 10C, 10D, 10E, 10F arranged in a3 x 2 matrix or array. Each blank 10A, 10B, 10C, 10D, 10E, 10F includes a main panel 12 for forming a top wall or joining panel of a carrier 90 (see fig. 3). Each blank 10A, 10B, 10C, 10D, 10E, 10F is connected to at least two

adjacent blanks

10A, 10B, 10C, 10D, 10E, 10F by a frangible connection 14.

The main panel 12 includes at least one article retention structure RT1, RT2, RT3, RT4, see fig. 2. In the embodiment of fig. 1 and 2, main panel 12 includes a plurality of article holding structures RT1, RT2, RT3, RT4, specifically four article holding structures RT1, RT2, RT3, RT4 arranged in a2 x 2 matrix or array. Each of article retention structures RT1, RT2, RT3, RT4 includes an aperture a1, a2, A3, a 4.

Each of article retention structures RT1, RT2, RT3, RT4 are substantially similar in construction and therefore will be described in detail with reference to second article retention structure RT 2.

Second article retention structure RT2 includes an article receiving opening defined in part by aperture a 2.

The second article holding structure RT2 includes a first section and a second section. The first segment S1 defines a first arc S1 and the second segment defines a second arc S2.

The first segment may be 'toothed' and the second segment may be 'toothless'. That is, in a peripheral region of aperture a2 defined by first segment S1, aperture a2 includes a plurality of teeth disposed about first arc S1. The peripheral region of aperture a2 defined by the second segment (second arc S2) is free of teeth. In the embodiment illustrated in fig. 2, the second segment includes an arcuate edge having a pair of spaced relief notches C8, C9.

The 'toothed' region includes a plurality of teeth or tabs formed in the main panel 12 about the aperture a 2.

Each tooth includes an engaging edge or tooth edge 31. The shape of each tooth edge 31 may be linear or may be arcuate. The tooth edge 31 may be defined by an arc or a portion of a circle. The aperture a2 includes a perimeter that may approximate or define an imaginary circle having a center.

The "toothed" region of the main panel 12 surrounding the aperture a2 may include cutouts C1, C2, C3, C4, C5, C6, C7 in the form of recesses or notches. The cutaways C1, C2, C3, C4, C5, C6, C7 are substantially "U" shaped, and in other embodiments, the cutaways C1, C2, C3, C4, C5, C6, C7 may alternatively be shaped such as, but not limited to, "V" shaped. The cut-outs C1, C2, C3, C4, C5, C6, C7 extend radially outward from the imaginary circle NC.

Each of the teeth or tabs is at least partially defined by a pair of cut-outs C1, C2, C3, C4, C5, C6, C7. The cut-outs C1, C2, C3, C4, C5, C6, C7 may form relief elements extending radially away from the center of the imaginary circle.

The toothless or toothless region S2 of the main panel 12 surrounding the aperture a2 includes an engaging edge or free edge 37 (also referred to herein as a continuous support edge). The shape of the engagement edge 37 is curved or arcuate.

The toothless or toothless area of the main panel 12 surrounding the aperture a2 may be defined in or occupy an arc subtending an angle of about 180 °, in other embodiments the angle may be less than 180 °, such as but not limited to 170 °.

In this manner, substantially half of the perimeter of aperture a2 includes teeth or tabs.

The second article retention structure RT2 includes two adjacently disposed mitigation elements C1, C7 between which the engagement edge 37 is defined. The engagement edge 37 may be interrupted by one or more relief elements C8, C9. In the illustrated embodiment, the engagement edge 37 is interrupted by two relief elements C8, C9.

Optionally, the main panel 12 may include a handle structure H. The handle structure H may include a handle opening. A handle opening is defined in main panel 12 and is located in an area centrally disposed between the first pair of article retention structures RT1, RT2 and the second pair of article retention structures RT3, RT 4. The handle opening may be at least partially defined by a bumper tab 16 that is hinged to the main panel 12 by a fold line 15.

Alternatively, the side edges of the main panel 12 may be arranged in a curved or wavy shape. In this manner, the first blank 10 may be arranged in a nested arrangement with the second blank 10. The wavy shape provides that the first and second blanks 10 together define a width that is less than twice the maximum width of the blank 10 alone. This can have economic and environmental benefits by reducing the amount of substrate material required to produce a given number of blanks 10.

The main panel 12 comprises at least a paperboard substrate. The material of the paperboard substrate can be selected from any conventional paperboard, for example, ranging in weight from about 10 pt. (0.010 "/-0.25 mm) up, preferably from about 16 pt. (0.016"/-0.41 mm) to about 28 pt. (0.028 "/-0.7 mm). The paperboard substrate may be bleached or unbleached paperboard. The paperboard may be coated on at least one side with a conventional coating selected to achieve compatibility with printing processes and paperboard compositions.

Examples of such substrates are 28 Point (pt.) SBS cardboard manufactured by Westrock @ (solid bleached sulphate cardboard Coated on one side, under the trade name Print Kote), unbleached uncoated Kraft paper (UUKK) or CNK ® cardboard (Coated Natural Kraft @ -unbleached Kraft cardboard with a clay coating on one side, under the trade name CarrierKote).

In the illustrated embodiment, the main panel 12 is formed from two paperboard substrates that are bonded together to form a laminated paperboard material. The adhesive treatment or glue may form a glue layer between the two paperboard substrates. Fig. 5A-5E illustrate various embodiments of laminated paperboard material used to form article carrier 90.

Fig. 5A shows an embodiment comprising a laminated paperboard structure comprising a first layer L1 of paperboard having a coating 52 on one side of the fibrous layer 50. The first layer of L1 paperboard was bonded to a second layer of L2 paperboard having a coating 52 on one side of the fibrous layer 50. The uncoated side of the first layer L1 (fibrous layer 50) was bonded to the uncoated side of the second layer L2 (fibrous layer 50); the adhesive treatment or glue forms a glue or adhesive layer 54 therebetween. The laminate structure of fig. 5A may be curl resistant due to, for example, but not limited to, moisture sorption (absorption or adsorption) and/or desorption of the fibrous layers. The laminated paperboard structure includes coatings on opposing surfaces that inhibit moisture sorption and/or desorption of the fibrous layers.

Fig. 5B shows an embodiment comprising a laminated paperboard structure comprising a first layer of L1 paperboard having a coating 52 on one side of the fibrous layer 50. The first layer of L1 paperboard was bonded to a second layer of L2 paperboard having a coating 52 on one side of the fibrous layer 50. The coated side of the first layer L1 was bonded to the coated side of the second layer L2; the adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

Fig. 5C shows an embodiment comprising a laminated paperboard structure comprising a first layer of L1 paperboard having a coating 52 on one side of the fibrous layer 50. The first layer of L1 paperboard was bonded to a second layer of L2 paperboard having a coating 52 on one side of the fibrous layer 50. The uncoated side of the first layer L1 (fibrous layer 50) was bonded to the coated side of the second layer L2; the adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

Fig. 5D shows an embodiment comprising a laminated paperboard structure comprising a first layer L1 of paperboard having a coating 52 on one side of the fibrous layer 50. The first layer of L1 paperboard was bonded to the second layer of L2 uncoated paperboard with fibrous layer 50. The uncoated side of the first layer L1 (fibrous layer 50) was bonded to one of the uncoated sides of the second layer L2; the adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

Fig. 5E shows an embodiment comprising a laminated paperboard structure comprising a first layer L1 of uncoated paperboard with a fibrous layer 50. The first layer of L1 paperboard was bonded to the second layer of L2 uncoated paperboard with fibrous layer 50. One of the uncoated sides of the first layer L1 was bonded to one of the uncoated sides of the second layer L2; the adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

In one example, a first sheet of 28 pt CBS or CNK paperboard is bonded to a second sheet of 28 pt CBS or CNK paperboard. This produced a substrate having a thickness of about 0.056 "(about 1.4 mm) with a coating on opposite sides thereof. Such substrates have the advantage of increased strength without including polymeric or plastic materials, which may provide environmental benefits and are more easily recycled. In other embodiments, the coated side of one layer or sheet of material is bonded to the uncoated side of another layer or sheet of material. In an alternative embodiment, the coated side of one layer or sheet of material is bonded to the coated side of another layer or sheet of material.

It will be understood that the caliper or caliper (density or weight) of the paperboard substrate selected for bonding together may have different caliper or weight. It will also be appreciated that the thickness or caliper (density or weight) of the selected paperboard substrate may be selected based on the weight or load that the article carrier is intended to support, e.g., for packaging of larger volume/heavier beverage cans, or the article carrier for a greater number of beverage cans may be formed of a thicker (or heavier weight) paperboard substrate. Similarly, when the article carrier is intended to support a greater load, the article carrier may be formed from a greater number of layers (layers/plies) of paperboard substrates that are bonded together.

The glue layer may be formed from any binder having good affinity for the paperboard, such as aqueous glues (e.g., white craft glue, yellow wood glue, and polyvinyl acetate-PVA glue).

Two or more sheets of paperboard are laminated together to form a laminated paperboard, and the laminated paperboard can then be die cut into carrier blanks 10, such as the carrier blank of fig. 1.

In some embodiments, the blank and article carrier are formed from two or more commercially available sheets or webs of paperboard stock that are joined together to form a laminate structure. It is contemplated that the laminate structure is formed from paperboard stock that has been dried in a paper mill, which may also be subjected to one or more dry end treatments, such as, but not limited to calendering and/or finishing with a coating, prior to being bonded together.

In some embodiments, the surface of a paperboard substrate to be bonded to another paperboard substrate may be treated or adjusted to improve bonding forces, such as, but not limited to, by perforating or otherwise disrupting the surface, for example, disrupting the surface with a partial depth cut.

Top splice carrier 90 comprises uniformly bonded layers. In those embodiments where top engagement carrier 90 includes engagement teeth, each tooth has a uniformly bonded layer of paperboard. This is advantageous over article carriers having a plurality of paperboard layers with non-glued structures, and over article carriers having post-glued structures in which the paperboard layers are adhered after each layer of paperboard is die cut. In such post-glued item carriers, because each layer has been die-cut, the layers are adhered together by spot gluing and therefore the carrier does not have uniformly glued layers. Where the carrier includes engaging teeth, the teeth do not include a uniformly glued layer and may be formed from an unbonded layer.

In some embodiments, at least one tear resistant layer may be disposed between a first layer of substrate and a second layer of substrate, such substrates may be formed by bonding two sheets of material, at least one of which includes a tear resistant layer laminated thereto. This may have the advantage of increasing the strength of the substrate.

Main panel 12 may include a tear resistant layer laminated to a paperboard layer. Optionally, it includes an adhesive layer between the paperboard substrate and the tear resistant layer. The tear resistant layer may be disposed over the uncoated side of the paperboard substrate and may be formed of a polymeric material and secured to the substrate. The tear resistant layer imparts toughness to the laminate structure. Suitable tear resistant materials may include, but are not limited to, tear resistant laminate sheet material, for example NATRALOCK @, which may comprise a layer of n-axis oriented film, for example, MYLAR @, which is biaxially oriented polyester, oriented nylon, cross laminated polyolefin or high density polyolefin. The orientation and cross-lamination of these materials contributes to tear resistance. Furthermore, tear resistance can be attributed to the chemical nature of tear resistant materials, such as extruded metallocene catalyzed polyethylene (mPE).

Alternatively, the tear resistant layer may be a Linear Low Density Polyethylene (LLDPE) layer. In embodiments using Linear Low Density Polyethylene (LLDPE) or mPE, it is not necessary to incorporate an adhesive layer. Other suitable materials having a high level of tear resistance may also be used.

The adhesive layer may be formed from a polyolefin material, such as Low Density Polyethylene (LDPE). An adhesive layer may be placed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

Turning to the construction of the carrier 90 from the blank 10, the blank 10 may be applied to a group of articles B. The blank 10 is lowered relative to the set of articles B. Each of the article retention structures RT1, RT2, RT3, RT4 of blank 10 is aligned with a respective article B in the group. A portion of article B passes through main panel 12. The toothed region of the main panel 12 around each of the article retention structures RT1, RT2, RT3, RT4 may be folded out of the plane of the main panel 12.

Each toothed region of the main panel 12 is foldable about one of the articles received in a respective one of the article retention structures RT1, RT2, RT3, RT 4; the blank 10 may be deformed about the article B, such as, but not limited to, the shoulder portion of article B, which may be provided by a constriction in the case of article B being a can.

The engaging edge 31 of the teeth of the main panel 12 and the engaging edge 37 of the non-tooth-containing region engage under the projection. The protrusion may be positioned around the neck or flange of article B (which may be provided with a flange) of article B. When the article B is a can, the projection may be provided by an end seam of the can. In other embodiments, the protrusion may be provided by a ridge or undercut formation of article B, or by an end closure of article B, such as, but not limited to, a crown cork or closure. In this manner, the engagement edges 31, 37 grip or retain the article B and prevent or inhibit the article B from unintentionally separating from the main panel 12. The assembled carrier 90 is shown in fig. 3.

The teeth comprise two substrates uniformly bonded together, which provide a secure engagement of the article B.

Another optional feature of the carrier 90 is that the main panel 12 is defined by a perimeter that is not connected to other portions of the carrier 90. That is, the carrier 90 is not connected to other panels, such as, but not limited to, side or end wall panels that extend around the sides of the group of articles. The perimeter of the main panel 12 is thus defined entirely by the free, cut or unhinged edges.

Another optional feature of the carrier 90 is that the main panel 12 is defined by a perimeter that includes a convex curved edge and a concave curved edge, wherein the radius of curvature of the convex curved edge is substantially equal to the radius of curvature of the concave curved edge, thus allowing two similar blanks 10 to be placed in a nested or tessellated arrangement.

In some embodiments, a plurality of blanks 1 are applied to a first group of articles B simultaneously. The first group of articles B may be divided into a plurality of second groups of articles B. Thus, each second group of articles B is formed from a subset of the first group of articles B. In the embodiment illustrated in fig. 1, the first group of articles B comprises twenty-four articles arranged in a4 x 6 matrix or array, and each individual blank 10A, 10B, 10C, 10D, 10E, 10F holds four articles in a2 x 2 matrix or array.

The frangible connections 14 between the

individual blanks

10A, 10B, 10C, 10D, 10E, 10F may be severed when the plurality of blanks 1 is applied to the first group of articles B. Alternatively, the frangible connections 14 can remain intact and

individual blanks

10A, 10B, 10C, 10D, 10E, 10F can be separated from other blanks at the point of sale or distribution.

Referring now to FIG. 4, an additional embodiment of the present disclosure is shown. In the second illustrated embodiment, like numerals have been used, where possible, to designate like parts, except with the addition of the prefix "100" to indicate that these features belong to the second embodiment. This additional embodiment shares many common features with the first embodiment and therefore only the differences from the embodiment illustrated in fig. 1 to 3 will be described in detail.

Fig. 4 illustrates a second embodiment and shows a plurality of connected blanks generally designated by reference numeral 101, in particular there are four

blanks

110A, 110B, 110C, 110D arranged in a2 x 2 matrix or array. Each blank 110A, 110B, 110C, 110D includes a main panel 112 for forming a top wall or joining panel of a carrier (not shown). Each blank 110A, 110B, 110C, 110D is connected to two

adjacent blanks

110A, 110B, 110C, 110D by a frangible connection 114.

The main panel 112 of each blank 110A, 110B, 110C, 110D includes at least one article retention structure RT1, RT2, RT3, RT4, RT5, RT 6. Main panel 112 includes a plurality of article retention structures RT1, RT2, RT3, RT4, RT5, RT6, specifically six article retention structures RT1, RT2, RT3, RT4, RT5, RT6 arranged in a3 x 2 matrix or array. Each of article retention structures RT1, RT2, RT3, RT4, RT5, RT6 includes an aperture a1, a2, A3, a4, a5, A6.

Each of article retention structures RT1, RT2, RT5, RT6 (also referred to as endmost article retention structures RT1, RT2, RT5, RT 6) is substantially similar in construction to article retention structures RT1, RT2, RT3, RT4 of the embodiment of fig. 1 and 2. These article retention structures include six teeth disposed about the periphery of apertures a1, a2, a5, a 6. Article retention structures RT1, RT2, RT5, RT6 are disposed in the corners of main panel 112.

Article retention structures RT3, RT4 (also referred to as intermediate article retention structures RT3, RT 4) are disposed on main panel 112 intermediate between a first pair of endmost article retention structures RT1, RT2 and a second pair of endmost article retention structures RT5, RT 6.

The intermediate article retention structures RT3, RT4 include three teeth, each tooth being defined in part by a pair of relief elements C. Each tooth includes an

engaging edge

131, 132, 133. The engaging edges 131, 132, 133 of the teeth occupy a portion of the perimeter of the apertures A3, a 4. The portion defines a first arc of an imaginary circle having a center, the arc subtending an angle of less than 120 °, the angle may be greater than 60 ° and may be about 90 °. A first arc is defined between the two mitigation elements.

The retention structures RT3, RT4 include a non-toothed or non-toothed portion. The portion free of teeth defines a second arc complementary to the first arc. The area free of teeth includes an engaging edge 137.

Optionally, the main panel 112 may include handle structures H1, H2. The handle structures H1, H2 may include a first opening at least partially formed by a first handle aperture. The first handle aperture is struck from the main panel 112 and is located in a region centrally disposed between the first pair of article retention structures RT1, RT2 and the second pair of article retention structures RT3, RT 4. The first opening may be defined in part by a first bumper tab that is hinged to the main panel 112 by a fold line. The first handle aperture may be substantially crescent-shaped or "C" shaped. The handle structures H1, H2 may include a second opening formed at least in part by a second handle aperture. A second handle aperture is struck from the main panel 112 and is located in a region centrally disposed between the second and third pairs of article retention structures RT3, RT4, RT5, RT 6. The second opening may be defined in part by a second bumper tab that is hinged to main panel 112 by a fold line. The second handle aperture may be substantially crescent-shaped or "C" shaped. The first and second openings may be arranged in an opposing manner to each other such that the first and second cushioning flaps are hinged to the main panel 112 in an opposing manner to each other.

The present disclosure provides a top-engaging type carrier having an article retaining structure or article top engaging means formed in a laminated substrate formed from two or more paperboard substrates that are uniformly bonded together. The laminate substrate is formed prior to die cutting the blank therefrom.

The laminated substrate may be formed from two or more sheets or webs of paperboard, at least one of which is preprinted with graphics or other indicia. The two or more sheets or webs are laminated after printing one of the layers. In this manner, a laminated substrate having printed graphics or other indicia on at least one side is formed. The printed laminate substrate is then cut to form carrier blanks. In some embodiments where the laminate substrate is formed from a web of paperboard, the laminate substrate may be cut into sheets prior to cutting the carrier blank. In other embodiments where the laminate substrate is formed from a web of paperboard, it is not necessary to cut the laminate substrate into sheets, and the carrier blank may be cut directly from the laminate substrate using an in-line (inline) die cutting apparatus.

The laminate substrate may be formed from two or more sheets or webs of unprinted paperboard joined together. Once the laminated substrate is formed, at least one side may be printed with graphics or other indicia. In this manner, a laminated substrate having printed graphics or other indicia on at least one side is formed. The printed laminate substrate is then cut to form carrier blanks. In embodiments where the laminated substrate is formed from a web of paperboard, the laminated substrate may be printed in-line, or may be cut into sheets and the sheets then printed.

It will be appreciated that, as used herein, directional references (such as "top," "bottom," "base," "front," "back," "end," "side," "inner," "outer," "upper," and "lower") do not necessarily limit the respective panels to such an orientation, but may merely serve to distinguish the panels from one another.

As used herein, the terms "hinge connection" and "fold line" refer to a wide variety of lines that define hinge features of the blank, facilitate folding of portions of the blank relative to one another, or otherwise indicate an optimal panel folding position of the blank. Any reference to "hinged connection" should not be construed as necessarily referring to only a single fold line; in practice, the hinged connection can be formed by two or more fold lines, wherein each of the two or more fold lines can be rectilinear/linear or curved/curvilinear in shape. When the linear fold lines form a hinged connection, they may be arranged parallel to each other or at a slight angle with respect to each other. When the curved fold lines form a hinge connection, they may intersect one another to define a shaped panel in the area enclosed by these curved fold lines. Typical examples of such hinged connections may include pairs of arcuate or bow-shaped fold lines that intersect at two points such that they define an oval-shaped panel therebetween. The hinge connection may be formed by one or more linear fold lines and one or more curved fold lines. Typical examples of such hinged connections may include a combination of linear fold lines and arcuate or arcuate fold lines which intersect at two points such that they define a half moon panel therebetween.

As used herein, the term "polyline" may refer to one of: a score line, an embossed line, a recessed line, a row of perforations, a row of short slits, a row of half cuts, a single half cut, an interrupted cut line, a row of aligned slits, a row of scores, and any combination of the above.

It is to be understood that the hinge connection and fold line can each comprise an element formed in the base material of the blank, including a perforation, a row of perforations, a row of short slits, a row of half cuts, a single half cut, a cut line, an interrupted cut line, a slit, a score, an embossed line, a debossed line, any combination thereof, and the like. These elements can be sized and arranged to provide the desired functionality. For example, a row of perforations can be sized or designed with a weakness to define a fold line and/or a cut line. The row of perforations can be designed to promote folding and resist breaking, promote folding and promote breaking with more effort, or promote breaking with less effort.

The phrase "aligned with … …" as used herein refers to the alignment of two or more elements in an erected carton, such as an aperture formed in a first of two stacked panels, and a second aperture formed in a second of two stacked panels. Those elements that are aligned with each other may be aligned with each other in the thickness direction of the stacked panels. For example, when an aperture in a first panel is "aligned" with a second aperture in a second panel (which is placed in a stacked arrangement with the first panel), an edge of the aperture may extend along at least a portion of an edge of the second aperture and may be aligned with the second aperture in the thickness direction of the first and second panels.

Claims

1. A top-engaged article carrier for packaging at least one article, the article carrier comprising a main panel comprising at least one top engagement means having at least one top receiving opening, the main panel comprising a laminate structure formed from two or more layers of substrate material uniformly bonded together.

2. The top-engaged article carrier of claim 1, wherein the top engagement means comprises one or more teeth for engaging articles, the one or more teeth comprising two or more layers of substrate uniformly bonded together.

3. The top-engaging article carrier of claim 1, wherein each of the two or more layers of substrate material comprises at least one uncoated side.

4. The top-engaging article carrier of claim 1, wherein each of the two or more layers of substrate material comprises a coated side, and wherein the coated side of a first layer is bonded to the coated side of a second layer.

5. The top-engaging article carrier of claim 4, wherein each of the two or more layers of substrate material comprises an uncoated side opposite the coated side.

6. The top-engaging article carrier of claim 1, wherein each of the two or more layers of substrate material comprises an uncoated side, and wherein the uncoated side of a first layer is bonded to the uncoated side of a second layer.

7. The top-engaging article carrier of claim 6, wherein each of the two or more layers of substrate material comprises a coated side opposite the uncoated side.

8. The top-engaging article carrier of claim 6, wherein each of the two or more layers of substrate material comprises a second uncoated side opposite the first uncoated side.

9. The top-engaging article carrier of claim 1, wherein each of the two or more layers of substrate material comprises an uncoated side, and wherein the uncoated side of a first layer is bonded to the uncoated side of a second layer.

10. The top-engaging article carrier of claim 1, wherein the laminate structure comprises:

a second layer having an uncoated side;

11. The top-engaging article carrier of claim 1, wherein the substrate is a paperboard material.

12. A blank for forming a top-engaged article carrier, the blank comprising a main panel comprising at least one top engagement means having at least one top receiving opening, the main panel comprising a laminate structure formed from two or more layers of substrate material uniformly bonded together.

13. A method of forming a top-engaging article carrier, the method comprising:

providing a first paperboard substrate;

providing a second paperboard substrate;

securing a surface of said second paperboard substrate to said first surface of said first paperboard substrate to form a laminated paperboard structure;

cutting one or more blanks from the laminated paperboard structure.

14. The method of forming a top-engaged article carrier of claim 13, wherein cutting one or more blanks from the laminated paperboard structure comprises cutting one or more top engagement devices from the laminated paperboard structure, each top engagement device having a top receiving opening.

15. The method of forming a top-engaging article carrier of claim 14, comprising:

applying the blank to one or more articles to form a package;

16. The method of forming a top-engaged article carrier of claim 15, wherein the one or more top engagement devices each comprise at least one tooth comprising a uniformly bonded multi-layer laminate structure, and wherein engaging the one or more top engagement devices with a respective one of the one or more articles comprises:

17. An article carrier for packaging at least one article, the article carrier comprising a main panel comprising at least one article retention device having at least one article receiving opening, the main panel comprising a laminate structure formed of two or more layers of paperboard material uniformly bonded together.

18. A laminated paperboard structure for forming an article carrier, the laminated paperboard structure comprising two or more paperboard substrates, the two or more paperboard substrates comprising a first layer having a first surface and a second layer comprising a second surface disposed adjacent to and uniformly bonded to the first surface.