GB2155441A - Carton for cosmetics - Google Patents

Abstract

A carton for packaging cosmetics comprises a rectangular base portion (15) upright internal side wall panel portions (31), (34) and inclined or sloping outer side wall panel portions (16), the panel portions (16), (31), (34) being interconnected by folds to define double-skinned walls. Locking tabs or ears (33, 36) linked to said panel portions (16), (31), (34) join adjacent walls of the erected carton. A separate insert may include a lid flap (18). <IMAGE>

Description

SPECIFICATION Carton packaging This invention relates to carton packaging, which term is used herein to embrace any form of shaped container forming an enclosure or receptacle, for whatever purpose, and is particulariy, but not exclusively, concerned with carton packaging for cosmetics, such as soap, bath salts, (bottled) perfumery (e.g. toilet waters and scent), creams, lotions, make-up, body and face powders, eye shadow trays, mascara pencils etc. In such circumstances, the carton may form a primary or secondary external packaging to inner wrappings or (sealed) containers such as bottles, jars or tubs.

Such cartons may also be used for confectionery, e.g. sweets and chocolates.

Whilst the art of packaging is highly developed and refined, there is an ongoing need (especially in so-called over the counter (OTC) retailing where visually-competitive products predominate) for visually attractive, even striking, packaging design which affords a product considerable eye appeal to the prospective customer, thereby enhancing its commercial 'selectability' and yet is not inordi nately expensive in relation to the inherent product value and thus does not adversely effect overall profitability.

Since the printing and surface finishing of card and paper products is also highly developed, offer ing an enormous variety of surface appearance fairly readily contrived to suit particular requirements, there is an incentive to use such (card) material in forming packaging - as opposed to, say, synthetic plastics products where the material ingredient cost is high and (shape) forming and (surface) finishing processes are generally more elaborate and expensive.

The art of carton blank design for card material is also very refined, but manufacturing costs (par ticuiarly for modest production runs) still relate to the number and complexity of cuts and folds and adhesive application shapes required - since special purpose tooling must be set up and for producing the carton blanks and for folding the (2dimensional) blanks into (3-dimensional) erected cartons manual labour input becomes unduly high.

Sheet material wastage must also be considered and in this regard it is preferable if (carton blank) sheet wastage is peripheral (rather than within the 'enclosed' shape) - so that successive blanks may be cut close together, if not adjoining.

Moreover, card material is not well seif-supporting over large surface areas and is not inherently shock-absorbing without being arranged as a spacer and thus considerable ingenuity and often much attendant over-usage of material layers is often deployed in achieving a secure overall packaging design.

Still further demands are imposed if the overall 3-dimensionsal package shape and configuration is to be unusual or distinctive - whilst sufficiently rugged and self-supporting and yet still formed frorn flat sheet material, as a carton blank.

The present invention is concerned with forming a distinctive 3-dimensional shape for such flat sheet material - whether of (paper) card or 'hard' synthetic plastics sheet material, if so required.

According to one aspect of the invention, there is provided a carton blank shell portion comprising a flat sheet material incorporating a plurality of cuts and folds subdividing the sheet into separate panel and flap portions, including a base portion and a plurality of peripheral multiple interconnected flap portions at least one of which incorporates a pair of ears which internest with corresponding adjacent ears of the next adjoining flap portion, the cuts and folds being arranged whereby the blank may be folded into a truncated pyramidal shape.

Desirably, a supplementary carton blank insert portion is incorporated in said carton blank shell portion, folded and cut to define a plurality of panels forming the lid and a base liner.

According to another aspect of the invention there is provided a carton of generally truncated pyramidal shape comprising a generally flat base and a plurality of external sloping side walls and a hinged lid flap with a tuck, with a plurality of upright internal walls generally perpendicular to said base portion and external sloping or inclined walls, the base and wall portions being formed from a single sheet incorporating a plurality of cuts and folds defining a plurality of interconnected panels.

There now follows a description of some particular embodiments of the invention, by way of example only, with reference to the accompanying diagrammatic drawings in which: Figure 1 shows a general perspective view of a closed carton according to the invention; Figure 2 shows a section along the line 2-2 in Figure 1; Figure 3 shows a general open perspective view of a (base and lid) carton liner incorporated in the carton shown in Figures 1 and 2; Figure 4 shows a part-opened carton shell of the carton shown in Figures 1 to 3; Figure 5 shows an opened-out-flat carton blank for the carton shell shown in Figure 4; and Figure 6 shows an opened-out-flat carton blank for the carton liner shown in Figure 3.

Referring to the drawings, a carton 10 of generally truncated pyramidal outer shape or configuration comprises a flat rectangular, conveniently square, base portion 15 and a plurality of - in fact four - inwardly-sloping side wall portions 16 which intersect at sharply-defined sloping edges 17 formed by internally folded internesting lateral ears 33, 36 described in more detail later.

The carton 10 incorporates an outer carton shell 21 (shown individually in more detail in Figures 4 and 5) housing, a part-internal combined lid and base liner 20, shown individually in more detail in Figures 3 and 6.

The outer carton shell 21 and the inner liner 20 nest together in the open and closed conditions as shown in Figure 2.

The shell 21 has double-thickness or doubleskinned walls comprising inner upright (relative to the carton base 15) wall portions 31 in spaced rela tionship to the outer sloping side walls 16, with the spacing therebetween defined and maintained by inwardly tucked flap edges 32, 35.

The liner 20 is maintained in situ by a lip 27 tucking under one of the ledges 32 or 35 and thus interleaved between that ledge 32 and the carton base 15.

The double-skinned walls are interlocked at their corner edges by internesting flaps 33 and 36 as shown in Figures 4 and 5.

Discussing now the blanks for the shell and liner shown in Figures 5 and 6 respectively, each comprised by a (2-dimensional) flat sheet material incorporating a plurality of interconnecting cuts and folds defining relatively interconnected hinged flap portions and various locking ears and tabs to maintain the blanks securely in a folded 3-dimensional configuration, as described subsequently.

The blank for the shell 21 comprises a general cruciform outline peripheral shape with four mutually perpendicular arms arranged in two symmetrical sets about the central rectangular base portion 15 of the locking tabs and ears 33 and 36 intersect the corners of the arms as diagonal elements in parting an overall star-shape to the blank.

In one set of two opposed arms, each arm comprises an inner trapezoidal panel, which defines the outer sloping side 16, an intermediate rectangular panel 31, which defines an inner wall portion, and an outer rectangular panel 32 with rounded outer corner edges which defines an internal spacer ledge or leaf. The rounded corner edges facilitate internesting or tucking of the panels without creasing or jamming.

In the other set of opposed arms, each arm comprises an inner trapezoidal panel which defines an outer wall portion 16, an intermediate rectangular panel 34 which defines an inner wall portion 34 and an outer flap 35 with rounded outer corner edges which defines an inner spacer ledge or leaf.

The intermediate panels 16 which lie between the four contiguous arms are provided with spaced lateral ears or locking tabs 33 linked thereto by an inclined fold edge 37 which defines the sloping corner edges 17 of the assembled carton, as shown in Figure 1.

The rectangular panels 34 are provided with lateral ears or locking tabs 36 on opposite sides thereof and whose peripheral edges internest with the peripheral edges of the tabs 33 and panels 16 to lock the folded panels together.

The folds, indicated by broken lines in the drawings, are all in the same general, internally-directed or orientated sense, as shown in Figures 3 and 4.

Thus in Figures 5 and 6 all the folds are, as it were 'out of the page' towards the viewer so that, as the folding angle is increased, the outer panels 32 and 35 are brought internally until they overlie in faceto-face relationship with the inner surface of the base 15, at the outer edges thereof.

The liner blank 20 has an overall generally elongate rectangular outline peripheral shape and incorporates a series of spaced transverse folds, with interleaving cuts indicated by solid line portions in the broken line fold designations, to define pro K truding a lid rip 26 and an internal base retaining ledge 27, as shown operatively in Figure 2.

A square base liner panel 23 links to an intermediate rectangular panel which defines a supplementary inner wall portion and an adjoining square lid flap 18, with a depending tuck in lid flap 25.

It should be appreciated that the overall outer configuration of the carton 10 may be varied whilst retaining or still embodying the quasi-pyramidal, sloping sided, rectangular-based theme. For example an elongate tray configuration with a rectangular, rather than a square base may be employed.

The lid and base liner may be omitted if desired.

The use of a sheet blank is advantageous because printing and other surface finishing, such as overlay laminating may be applied before folding, and/or cutting, into a 3-dimensional form.

The internal tucking and double-skinned arrangement affords the assembled carton considerable structural rigidity, robustness and stiffness. Thus quite heavy, bulky, voluminous and otherwise substantial contents, for example soap(s) or bottles, may be located therein and the cartons stacked without fear of crushing. This is advantageous for bulk packaging, storage and display. If required, adjacent cartons may be stacked more intimately, by successively inverting adjacent cartons, so that the respective sloping sides are in face-to-face abutment.

A plurality of the cartons as described herein may be fitted, secured or joined together by suitable means such as adhesive bonding, peripheral tie, clips or other fastenings - even by interfitting tabs formed by cuts in the blanks, to achieve another polygonal shape. For example, two such cartons may be faced base-to-base.

Alternatively, a multiplicity of different-sized, otherwise similar-shaped cartons as described, may be nested one within another, with the external base of one carton fitting securely within the internal (receptacle) base of another carton.

Rippled, corrugated or otherwise contoured surfaces may be employed for the otherwise generally flat or planar panels and for this purpose moulded, vacuum formed or otherwise shaped synthetic plastics material may be employed.

The internal walls may be sealed together and to the base to achieve a seal for the storage of, say, powders. For such contents sealed panel surface finishes or treatments may be employed.

The panels may incorporate decorative and/or functional partial or full cut-outs.

The carton configuration described herein may be employed for larger-scale display or other promotional purposes; for example special combined product presentations and showcards.

The folding and cutting pattern described may readily be effected manually and/or mechanically and by automated machines, because, notwithstanding the elegant and complex overall 3-dimensional shape, the 2-dimensional blank is not unduly complex.

Claims (4)

1. A carton comprising: a rectangular base portion (15), a plurality of upright internal side wall panel portions (31), a plurality of inclined or sloping outer side (16) wall panel portions the panel portions being interconnected by folds, said internal and external wall portions being formed contiguously and defining a double skinned carton wall, a plurality of (33, 36) locking tabs or ears linked to said panel portions, arranged whereby said panel portions, when folded into a 3 dimensional configuration from a 2-dimensional flat sheet, may be secured interlinked, internested and interlocked in a rigid overall assembly.

2. A carton blank comprising: flat sheet material incorporating a plurality of interconnected cuts and folds, arranged as a grid within a plurality of cruciform arms with interven ing locking tab panels, symmetrically disposed in two corresponding mutually-opposed pairs of arms, each incorporating an outer tuck leaf panel, an intermediate panel to form a sloping outer carton side, and an inner panel to form an upright internal wall, disposed whereby the panels may be mutually inclined and stood upright with respect to a central base panel.

3. A carton substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.

4. A carton blank, substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.