EP4140905A1

EP4140905A1 - A blank and an article of packaging erected therefrom

Info

Publication number: EP4140905A1
Application number: EP21192833.8A
Authority: EP
Inventors: Raúl Bengoa
Original assignee: Smurfit Kappa Services Ltd
Current assignee: Smurfit Kappa Services Ltd
Priority date: 2021-08-24
Filing date: 2021-08-24
Publication date: 2023-03-01

Abstract

A blank for forming a box comprising outer side wall panels, outer bottom panels, and inner side wall panels overlying associated outer side wall panels;a bottom edge of each inner side wall panel being connected to a respective outer bottom panel about a respective bottom fold line extending parallel to and spaced from the bottom edge of the associated outer side wall panel;a top edge of each of each inner side wall panel being connected to the associated outer side wall panel along a respective top fold line, each inner side wall panel having an intermediate fold line adjacent and parallel to the respective top fold line, wherein, when the blank is erected into an article of packaging, said inner side wall panels are spaced from said outer side wall panels.

Description

FIELD OF THE INVENTION

This invention relates to an article of packaging with improved protection for fragile items during transportation and to a blank for forming same.

BACKGROUND OF THE INVENTION

Fragile products, or products vulnerable to hits and drops, can be easily deformed, broken or otherwise rendered unusable when sent by postal or courier services. It is desirable to increase protection for parcel delivery of such fragile products when packaged in boxes by creating a packaging envelope surrounding the products to increase the shock-absorbing properties of the packaging and to separate the products from the outer walls of the box.
Known solutions to this problem range from using packing peanuts, typically made from EPS foam, to creating custom cardboard pieces which conform to the product and fit inside the box to distance the product from the outer walls of the box. However, one thing that current solutions have in common is that they all require the use of two or more differentiated packaging pieces (i.e. the exterior box and the packaging materials and structures used to create the protective envelope around the products when placed in the box). This increases handling time during packaging as well as increasing required storage space, hence increasing packaging storage cost. In cases where a custom piece or box has to be made, the cost of tooling has to be added.
An object of the invention is to provide an integrated packaging solution, providing a blank and an article of packaging erected therefrom which is easy to handle and assemble while keeping as many protective qualities as possible and the versatility of a generic box.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a blank for forming an article of packaging, the blank comprising a plurality of outer side wall panels arranged consecutively one after the other along a longitudinal direction and foldably connected to each other along fold lines extending in a transverse direction, a plurality of outer bottom panels, each outer bottom panel being foldably connected to a bottom edge of an associated outer side wall panel, and a plurality of inner side wall panels overlying associated outer side wall panels;

a bottom edge of each inner side wall panel being connected to a respective outer bottom panel about a respective bottom fold line extending parallel to and spaced from the bottom edge of the associated outer side wall panel;
a top edge of each of each inner side wall panel being connected to the associated outer side wall panel along a respective top fold line, each inner side wall panel having an intermediate fold line adjacent and parallel to the respective top fold line, wherein, when the blank is erected into an article of packaging, said inner side wall panels are spaced from said outer side wall panels.

In one embodiment said plurality of outer side wall panels comprise first, second, third and fourth outer side wall panels; said plurality of bottom panels comprise first, second, third and fourth outer bottom panels; the blank further comprising first, second, third and fourth outer top panels, each outer top panel being foldably connected to a top edge of an associated outer side wall panel;
first, second, third and fourth inner side wall panels arranged consecutively one after the other along said longitudinal direction and having gaps therebetween.
The respective top fold line of each inner side wall panels may be aligned with a top edge of the associated outer side wall panel.
Preferably the width of the each inner side wall panel is less than the width of the associated outer side wall panel.
In one embodiment the first and third outer bottom panels may each include an intermediate fold line adjacent and parallel to an outer edge of the respective outer bottom panel; respective inner bottom panels being provided overlying the first and third bottom panels; a first edge of each of said inner bottom panels being connected to a respective one of said first and third outer bottom panels about a respective first fold line extending parallel to and located between the respective intermediate fold line and the outer edge of the respective inner bottom panel; a second edge of each of said first and third inner bottom panel being connected to the associated outer bottom panel along a respective second fold line extending in said transverse direction, each of said first and third inner bottom panels having an intermediate fold line adjacent and parallel to the respective second fold line, wherein, when the blank is erected into an article of packaging, said inner bottom panels are spaced from said outer bottom panels.
Preferably the sum of the distance between the bottom edge of the first side wall panel and the intermediate fold line of the first bottom panel and distance between the bottom edge of the third side wall panel and the intermediate fold line of the third bottom panel is equal to the width of the second and fourth outer side wall panels.
In one embodiment the distance between the bottom edge of the first side wall panel and the intermediate fold line of the first bottom panel may be equal to the distance from the bottom edge of the third side wall panel and the intermediate fold line of the third bottom panel.
Said first and third outer top panels may each include an intermediate fold line adjacent and parallel to an outer edge of the respective outer top panel; respective inner top panels being provided overlying the first and third top panels, a first edge of each of inner top panel being connected to a respective one of said first and third top panels about a respective first fold line extending parallel to and located between the respective intermediate fold line and the outer edge of the respective inner top panel; a second edge of each inner top panel being connected to the associated outer top panel along a respective second fold line extending in said transverse direction, each of said inner top panels having an intermediate fold line adjacent and parallel to the respective second fold line, wherein, when the blank is erected into an article of packaging, said inner top panels are spaced from said outer top panels. The sum of the distance between the top edge of the first side wall panel and the intermediate fold line of the first top panel and distance between the top edge of the third side wall panel and the intermediate fold line of the third top panel may be equal to the width of the second and fourth outer side wall panels. The distance between the top edge of the first side wall panel and the intermediate fold line of the first top panel may be equal to the distance from the top edge of the third side wall panel and the intermediate fold line of the third top panel.
Said outer side wall panels, outer top panels and outer bottom panels may comprise a first single sheet of foldable substrate, said inner side wall panels comprising a second single sheet of foldable substrate affixed to said first sheet. The inner bottom panels, where provided, preferably comprise parts of said second sheet. Said inner top panels, where provided, may comprise parts of said second sheet. Preferably the second sheet includes second and fourth inner bottom panels, at least a portion of which are affixed to the second and fourth outer bottom panels of the first sheet respectively and at least a portion of the second and fourth inner top panels affixed to the second and fourth outer top panels of the first sheet respectively. The inner bottom panels and the inner top panels of the second sheet may be respectively joined together by perforations or lines of weakness permitting separation of the inner bottom and top panels from one another when the blank is erected into an article of packaging.
One or more of said inner side wall panels may incorporate at least one spacing flap foldably connected to the respective inner side wall panel along a respective inner fold line and having a distal portion affixed to a respective outer side wall panel, said distal portion being connected to the remainder of the respective spacing flap via an intermediate fold line. The distance between the inner and intermediate fold lines of the or each spacing flap may be equal to the distance between the intermediate fold line of each inner side wall panel and the adjacent top fold line.
According to a second aspect of the present invention there is provided article of packaging erected from a blank of the first aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

A blank and an article of packaging erected therefrom in accordance with an embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:-

Figure 1 is a plan view of a first sheet of a blank in accordance with an embodiment of the present invention;
Figure 2 is a plan view of a second sheet of a blank in accordance with an embodiment of the present invention;
Figures 3 and 4 are views of a blank formed from the first and second sheets of Figures 1 and 2;
Figures 3 to 8 illustrate the steps of erecting the blank of Figures 3 and 4 to form an article of packaging; and
Figure 9 and 10 illustrate the thus erected article of packaging prior to filling.

DETAILED DESCRIPTION OF THE DRAWINGS

As illustrated in the drawings a blank for forming a box in accordance with an embodiment of the present invention comprises first and second sheets 2,4 of foldable substrate, preferably comprising a paper-based material, such as card, more preferably corrugated card, said first and second sheets 2,4 being arranged one top of the other and affixed together and having respective fold lines, as will be described in more detail below, to form a double walled box when the blank is erected.
The first sheet 2, defining outer walls of the resulting box, comprises first, second, third and fourth outer side wall panels 6,7,8,9 arranged consecutively one after the other along a longitudinal direction and foldably connected to each other along fold lines extending in a transverse direction. The first sheet further comprises first, second, third and fourth outer bottom panels 10,11,12,13, each outer bottom panel being foldably connected to a bottom edge of an associated outer side wall panel. The first sheet 2 further comprises first, second, third and fourth outer top panels 14,15,16,17, each outer top panel being foldably connected to a top edge of an associated outer side wall panel 6,7,8,9.
A tab 18 is provided along one side edge of said first outer side wall panel 6 to be affixed to the fourth outer side wall panel 9, for example by means of a suitable adhesive, such that the outer walls panels 6,7,8,9 define a open ended enclosure, said outer bottom panels 10,11,12,13 and outer top panels 14,15,16,17 being adapted to close the ends of said enclosure to define a cuboid box when the blank is erected.
The second sheet 4 comprises first, second, third and fourth inner side wall panels 19,20,21,22 arranged consecutively one after the other along said longitudinal direction and having a width less that the respective first, second, third and fourth outer side wall panels 6,7,8,9, gaps being defined between adjacent lateral sides of the inner side wall panels 19,20,21,22. The second sheet 4 further comprises first, second, third and fourth inner bottom panels 23,24,25,26, each inner bottom panel being foldably connected to a bottom edge of an associated inner side wall panel. The second sheet 4 further comprises first, second, third and fourth inner top panels 27,28,29,30, each inner top panel being foldably connected to a top edge of an associated outer side wall panel.
Preferably the first, second, third and fourth inner bottom panels 23,24,25,26 and the first, second, third and fourth inner top panels 27,28,29,30 of the second sheet 4 are respectively connected to each by lines of perforations 32 permitting the inner bottom and inner top panels 23,24,25,26,27,28,29,30 to be separated from one another during erection of the blank to a box, as will be described below in more detail.
As shown in Figure 2, lines or patches of glue 34 are preferably provided on the inner bottom panels 23,24,25,26 and inner top panels 27,28,29,30 to affix said panels to the respective outer bottom panels 10,11,12,13 and outer top panels 14,15,16,17.
A bottom edge of each of said first, second, third and fourth inner side wall panels 19,20,21,22 is foldably connected to the associated outer bottom panel 10,11,12,13 about a respective bottom fold line 36,37,38,39 extending parallel to and spaced from the bottom edge of the associated outer side wall panel 6,7,8,9. A top edge of each of said first, second, third and fourth inner side wall panels 19,20,21,22 is foldable along a respective top fold line 40,41,42,43, preferably aligned with the upper edge of the associated outer side wall panel 6,7,8,9, each of said first, second, third and fourth inner side wall panels 19,20,21,22 having an intermediate fold line 44,45,46,47 adjacent and parallel to the respective top fold line 40,41,42,43, wherein, when outer bottom wall panels 10,11,12,13 are folded up to extend perpendicular to the adjacent outer side wall panels 6,7,8,9, said inner side wall panels 19,20,21,22 fold about the respective bottom, top and intermediate fold lines such that the inner side wall panels 19,20,21,22 are spaced apart from said outer side wall panels 6,7,8,9, as illustrated in Figures 4 and 5. Preferably, for each inner side wall panel 19,20,21,22, the distance between the bottom fold line 36,37,38,39 and the adjacent bottom edge of the associated outer side wall panel 6,7,8,9 is substantially equal to the distance between the top fold line 40,41,42,43 and the intermediate fold line 44,45,46,47 of the respective inner side wall panel 19,20,21,22 so that each inner side wall panel 19,20,21,22 remains parallel to the associated outer side wall panel 6,7,8,9 as the blank is erected into a box.
Each of the inner side wall panels 19,20,21,22 further incorporates a spacing flap 48,49,50,51 foldably connected to the respective inner side wall panel 19,20,21,22 along a respective inner fold line and having a distal portion affixed to a respective outer side wall panel 6,7,8,9, said distal portion being connected to the remainder of the respective spacing flap via an intermediate fold line, wherein the distance between inner and intermediate fold lines of each spacing flap is equal to the distance between the intermediate fold line of each inner wall side panel and the adjacent top fold line.
The first and third outer bottom and top panels 10,12,14,16 each include an intermediate fold line 57 adjacent and parallel to an outer edge of the respective panel. A first edge of each of the first and third inner bottom and top panels 23,25,27,29 is foldable about a respective first fold line 52 extending parallel to and located between the respective intermediate fold line 57 and the outer edge of the associated first and third outer side wall panel 6,8; a second edge of each of the first and third inner bottom and top panels 23,25,27,29 being foldable about a respective second fold line 54 extending in said transverse direction and spaced inwardly from the adjacent top fold line 40,42, of the associated first and third inner side wall panel 19,21, each of said first and third inner bottom and top panels 23,25,27,29 having an intermediate fold line 56 adjacent and parallel to the respective second fold line 54, wherein, when the first and third outer bottom and top panels 10,12,14,16 are folded about their respective intermediate fold lines 57 said inner bottom and top panels 23,25,27,29 are spaced away from the associated outer bottom and top panels 10,12,14,16 to define gaps therebetween.
Further flaps 58,59,60,61,62,63 may be provided on the lateral sides of each of said first and third inner bottom and top panels 23,25,27,29, foldable to close the sides of the respective gaps defined between the outer bottom and top panels 10,12,14,16 and inner bottom and top panels 23,25,27,29. Said lines of perforations 32 may be provided between a portion of said further flaps 58,59,60,61,62,63 and respective portions of said second and fourth inner bottom and top panels 24,26,28,30 to temporarily join the inner panels of the second sheet together so that the inner panels may be formed in a single sheet of foldable substrate.
Preferably the distance between the first fold line 52 of each of the first and third inner bottom and top panels 23,25,27,29 and the intermediate fold line 57 of the associated first and third outer bottom and top panels 10,12,14,16 is substantially equal to the second fold line 54 and the intermediate fold line 56 of each of the first and third inner bottom and top panels 23,25,27,29 so that the first and third inner bottom and top panels 23,25,27,29 remain parallel to the associated first and third outer bottom and top panels 10,12,14,16.
Preferably the distance between upper edge of each of the first outer wall panel 6 and the intermediate fold line 57 of the associated first outer top panel 14 is substantially equal to distance between upper edge of each of the third outer wall panel 8 and the intermediate fold line 57 of the associated third outer top panel 16, and the distance between the lower edge of the first outer wall panel 6 and the intermediate fold line 57 of the associated first outer bottom panel 10 is substantially equal to distance between the lower edge of the third outer wall panel 8 and the intermediate fold line 57 of the associated third outer bottom panel 12, such that the first and third top and bottom inner and outer panels form respective halves of the ends of the box formed by the erected blank.
The first and third inner top panels 27,29 may incorporate locking tabs, flaps or apertures adapted to secure the top panels in a closed position, for example engaging corners of the second and fourth outer top panels.
Rows of slots or other openings 66 may be provided in the second and fourth inner side wall panels 20,22 in the region of the respective intermediate fold lines 45,47 for receiving dividers (not shown) when the blank is erected into a box. Further slots 68 may be provided in the first and third inner bottom panels 23,25 for receiving bottom mounting tabs of such dividers, as best shown in Figures 9 and 10.
The present invention provides a packaging a box with an integrated fitment, which deploys when said box is erected, and forms a packaging envelope separating the contents from the outer walls of the box. The internal fitment (second sheet) comes glued together with the outer box (first sheet) and the erection procedure of the blank is very similar to that of a standard single walled box.
When the bottom and top walls of the box are folded, the inner fitment (inner walls) deploys automatically, forming a separation between itself and the outer walls of the box, in every direction. The interior sides of the fitment may be slotted so dividers can be inserted in, separating the internal volume into independent chambers, if needed.
The top and bottom walls incorporate formations which, when folded, also deploy a double wall creating a separation along the top/bottom of the box, in such way that the product ends up completely isolated from the outer box.
As illustrated in Figures 4 to 10, the blank can be supplied to the point of use with the first and second sheets 2,4 affixed together, as described above. In a first step the inner panels are separated from one another by tearing the lines of perforations 32 and the second and fourth outer bottom panels 11,13, with the second and fourth inner bottom panels 24,26 affixed thereto, are folded to extend perpendicular to the second and fourth outer side panels 7,9, causing the second and fourth inner side panels 20,22 to fold about their bottom 37,39, top 41,43 and intermediate 45,47 such that the second and fourth inner side panels 20,22 are raised away from the second and fourth outer bottom panels 11,13, as shown in Figure 5.
Next the first and third outer bottom panels are folded with respect to the first and third outer side wall panels 6,9 and about the intermediate fold lines 57, also causing the first and third inner wall panels 23,25 to fold about the respective first, second and intermediate fold lines 52,54,56 such that the first and third inner wall panels 23,25 are raised away from the first and third outer bottom panels 10,12, as shown in Figure 7.
The outer walls panels 6,7,8,9 are then folded about their transverse fold lines to define a tubular enclosure and the tab 18 is secured to the fourth outer side wall panel 9, the outer bottom panels 10,11,12,13 closing the lower end of the resulting cuboid box, as shown in Figures 9 and 10.
As can be seen from Figures 9 and 10, the inner side wall panels 19,20,21,22 are spaced inwardly from the outer side wall panels 6,7,8,9, creating a protective envelope between products placed in the box and the outer side wall panels 6,7,8,9.
Once items have been placed into the box, optionally with the use of dividers inserted into the slots 66,68, the outer top panels are folded in the same manner as the bottom panels to create a double walled closure.
The invention is not limited to the embodiment described herein but can be amended or modified without departing from the scope of the present invention as defined by the appended claims.

Claims

A blank for forming an article of packaging, the blank comprising a plurality of outer side wall panels arranged consecutively one after the other along a longitudinal direction and foldably connected to each other along fold lines extending in a transverse direction, a plurality of outer bottom panels, each outer bottom panel being foldably connected to a bottom edge of an associated outer side wall panel, and a plurality of inner side wall panels overlying associated outer side wall panels;
a bottom edge of each inner side wall panel being connected to a respective outer bottom panel about a respective bottom fold line extending parallel to and spaced from the bottom edge of the associated outer side wall panel;

a top edge of each of each inner side wall panel being connected to the associated outer side wall panel along a respective top fold line, each inner side wall panel having an intermediate fold line adjacent and parallel to the respective top fold line,

wherein, when the blank is erected into an article of packaging, said inner side wall panels are spaced from said outer side wall panels.
A blank as claimed in claim 1, wherein the width of each of each inner side wall panel is less than the width of the associated outer side wall panel.
A blank as claimed in claim 1 or claim 2, wherein said plurality of outer side wall panels comprise first, second, third and fourth outer side wall panels; said plurality of bottom panels comprise first, second, third and fourth outer bottom panels wherein the first and third outer bottom panels each include an intermediate fold line adjacent and parallel to an outer edge of the respective outer bottom panel; respective inner bottom panels being provided overlying the first and third bottom panels; a first edge of each of said inner bottom panels being connected to a respective one of said first and third outer bottom panels about a respective first fold line extending parallel to and located between the respective intermediate fold line and the outer edge of the respective inner bottom panel; a second edge of each of said first and third inner bottom panel being connected to the associated outer bottom panel along a respective second fold line extending in said transverse direction, each of said first and third inner bottom panels having an intermediate fold line adjacent and parallel to the respective second fold line, wherein, when the blank is erected into an article of packaging, said inner bottom panels are spaced from said outer bottom panels.
A blank as claimed in claim 3, wherein the sum of the distance between the bottom edge of the first side wall panel and the intermediate fold line of the first bottom panel and distance between the bottom edge of the third side wall panel and the intermediate fold line of the third bottom panel is equal to the width of the second and fourth outer side wall panels.
A blank as claimed in claim 4, wherein the distance between the bottom edge of the first side wall panel and the intermediate fold line of the first bottom panel is equal to the distance from the bottom edge of the third side wall panel and the intermediate fold line of the third bottom panel.
A blank as claimed in any of claims 3 to 5, wherein the blank further comprises first, second, third and fourth outer top panels, each outer top panel being foldably connected to a top edge of an associated outer side wall panel; the first and third outer top panels each including an intermediate fold line adjacent and parallel to an outer edge of the respective outer top panel; respective inner top panels being provided overlying the first and third top panels, a first edge of each of inner top panel being connected to a respective one of said first and third top panels about a respective first fold line extending parallel to and located between the respective intermediate fold line and the outer edge of the respective inner top panel; a second edge of each inner top panel being connected to the associated outer top panel along a respective second fold line extending in said transverse direction, each of said inner top panels having an intermediate fold line adjacent and parallel to the respective second fold line, wherein, when the blank is erected into an article of packaging, said inner top panels are spaced from said outer top panels.
A blank as claimed in claim 6, wherein the sum of the distance between the top edge of the first side wall panel and the intermediate fold line of the first top panel and distance between the top edge of the third side wall panel and the intermediate fold line of the third top panel is equal to the width of the second and fourth outer side wall panels.
A blank as claimed in claim 7, wherein the distance between the top edge of the first side wall panel and the intermediate fold line of the first top panel is equal to the distance from the top edge of the third side wall panel and the intermediate fold line of the third top panel.
A blank as claimed in any preceding claim, wherein said outer side wall panels, and outer bottom panels comprise a first single sheet of foldable substrate, said inner side wall panels comprising a second single sheet of foldable substrate affixed to said first sheet.
A blank as claimed in claim 9, when dependent upon claim 3, wherein said inner bottom panels comprise parts of said second sheet and, when dependent upon claim 6, wherein said inner top panels comprise parts of said second sheet.
A blank as claimed in 10, wherein the second sheet includes second and fourth inner bottom panels, at least a portion of which are affixed to the second and fourth outer bottom panels of the first sheet respectively and at least a portion of the second and fourth inner top panels affixed to the second and fourth outer top panels of the first sheet respectively.
A blank as claimed in claim 11, wherein the inner bottom panels and the inner top panels of the second sheet are respectively joined together by perforations or lines of weakness permitting separation of the inner bottom and top panels from one another when the blank is erected into an article of packaging.
A blank as claimed in any preceding claim, wherein one or more of said inner side wall panels incorporates at least one spacing flap foldably connected to the respective inner side wall panel along a respective inner fold line and having a distal portion affixed to a respective outer side wall panel, said distal portion being connected to the remainder of the respective spacing flap via an intermediate fold line.
A blank as claimed in claim 13, wherein the distance between inner and intermediate fold lines of the or each spacing flap is equal to the distance between the intermediate fold line of each inner side wall panel and the adjacent top fold line.
An article of packaging erected from a blank as claimed in any preceding claim.