GB2321237A - Re-closable carton formed from blank - Google Patents

Abstract

A carton is formed from a blank having a lid portion 70 and a body portion 80. The lid portion is provided with a cover panel 20 and a closure flap 22 which is secured to the main body portion of the carton. The lid is provided with means, e.g. a tear strip (40, Fig. 1) for detaching the lid portion from the main body portion to open the carton. The lid portion and body portion are provided with mutually engageable formations preferably in the form of a tab 46 and slot 64a to re-close the carton after opening. The tab may be formed either by providing a flange 44 extending from the body portion which has a die cut tab 46, or by a similar flange (45, Fig. 6) which just overlaps the side of the carton (72, 74, Fig. 6). The slot is preferably provided by having an indentation 64a in an end flap 32 of the cover flap 22, such that in the assembled carton a slot 64a exists between the edge of the end flap and the underside of the cover panel 20. A detachable section 48 in the end flaps of the base panel, formed by a line of weakness 57, may be provided so that evidence of tampering is clear from the sides of the carton.

Description

TITLE: Cartons DESCRIPTION The present invention relates to improved cartons, especially cartons suitable for solid or semi-solid food materials, such as ice cream.

Folding cartons are well known in the packaging art. These cartons are constructed from flat blanks, being pre-cut and pre-scored cardboard sheets. The carton blanks have four main panels which are adapted to form the top, rear, base and front of the assembled carton. Each flap has a pair of end flaps which are hingedly connected by score lines formed in the cardboard.

The blanks are folded into the required shape and secured by means of known adhesives to form carton sleeves which are used for packaging retail products, particularly consumable goods. During the filling operation, packaging machinery is used to form and seal fully assembled cartons according to a prescribed folding sequence and adhesive pattern.

State of the art cartons formed from blanks of cardboard include cartons suitable for such food products as ice cream and frozen yoghurt. For example, one such prior art blank is composed of the aforementioned four main panels plus a cover flap which folds over the front panel and is secured thereto with adhesive. One of the panels is provided with end flaps which are not sealed to an underlying or overlying closure flap but remain free to be used to reclose the carton after opening by means of slotting the flaps between the other sealed flaps. The cover flap usually includes a severable portion such as a zip-tear strip to enable easy opening of the carton.

In certain types of carton, the cover flap is also provided with end flaps which are folded over and sealed to the end flaps of the top panel to form a lid portion which fits over the main body of the assembled carton. The end flaps of the rear panel may each be provided with a detachable tab for adhering to the end flaps of the front panel which become detached from their respective end flap upon opening of the carton.

Whilst the aforementioned types of cartons are suitable for packaging food products which may not be consumed entirely at one time, such as ice cream, the cartons are not ideal since the lid cannot be easily and effectively secured to the body of the carton after the opening thereof. If a frozen food product such as ice cream is stored in a carton of the prior art, a gap may develop between the body and the lid portion of the carton due to the lid not being securely fastened down. This allows ice crystals to form on the food product which is detrimental to the quality thereof.

The construction of the cartons of the prior art is also such that, from an end view of the carton, it is not clearly evident whether the carton has been tampered with. Furthermore, the assembling of the carton involves multiple folding sequences and applications of adhesive.

It is an object of the present invention to provide an improved carton, particularly for solid and semi-solid food products in which the carton may be effectively and easily re-closed after opening. More particularly, it is an object of the present invention to provide a carton having a lid which can be easily secured to the rest of the carton after the initial opening thereof.

A further object of the present invention is to provide an improved carton which is tamper evident. Yet a further object of the present invention is to provide a blank for a carton having a simplified assembling sequence thereby enabling increased output of filled cartons by packaging machinery.

Accordingly, the present invention provides a carton, suitable for a solid or semi-solid food product, made up from a blank to form a three dimensional rectangular section carton comprising: a main body portion having a front, rear and base panel sealed together by means of overlapping end flaps provided at each end of the panels which are adhered to each other; a lid portion having a cover panel and closure flap, each being provided with end flaps being folded and sealed to each other, part of the lid being adherable to the panel of the main body portion to seal the contents in the carton; the lid portion being provided with means for detaching the lid from the main body portion to open the carton; wherein the lid portion and the body portion have mutually engageable formations to re-close the carton after opening.

Preferably, the main body portion and lid portion are provided respectively with at least one complimentary tab and slot whereby the tab fits into the slot when placing the lid portion over the main body portion to secure the lid thereto.

The at least one tab may protrude from an upper edge of the body portion of the assembled carton. For example, the tab may consist of an extension of the upper edge of the front panel. Alternatively, the tab may be provided by extending a portion of the upper edge of the end flap of the front panel. Preferably, both end flaps of the front panel are provided with tabs extending from their upper edges. The tab is preferably folded to protrude substantially perpendicularly from the upper edge of the assembled carton.

More preferably, the tabs are formed by the provision of a flange extending from the upper edge of the front panel and/or the end flaps thereof having a die-cut pocket formed therein to produce the required tab. This provides the simplest mechanism for providing a tab perpendicular to the upper edges of the carton.

The die-cut pocket is preferably inserted into the end flap up to the fold line between the end flap and flange towards the fold line of the end flap with the front panel.

Alternatively, the at least one tab may be provided by a lip on the upper edge of the front panel which extends beyond at least one of the sides of the front panel substantially parallel to the end flaps of the base panel. Fold lines are preferably provided where the lip passes over the side of the front panel to form the tab for mating with the slot. Preferably, two tabs are provided, one at each end of the lip, to mate with complimentary slots.

The at least one slot for engagement with the tab is provided in the lid portion at a position corresponding to the positioning of the tab when the lid portion is placed over the main body portion. The slot may be provided by the provision of a slit through the lid portion. Preferably, the construction of the assembled panels and flaps of the lid portion is such as to create a slot therein. More preferably, the slot is provided by the end flap of the cover flap having an indentation such that in the assembled carton a slot exists between the edges of the end flap and the edge of the top panel.

Preferably, the flange provided on each of the end flaps of the front panel extends along the entire length of the side of the end flap. The sides of the end flaps may also be indented along a part thereof.

The end flaps of the base panel are preferably substantially rectangular in shape. Preferably, the end flaps are each provided with a small lip protruding from the outermost edge thereof.

Preferably, the end flaps of the rear panel have substantially parallel sides which are shorter in length than the end flaps of the front and base panels. Each of the flaps are preferably provided with a detachable section nearest to the end flaps of the top panel. Preferably, the detachable section is in the form of a triangular tab which is continuous with the end flap but separated therefrom by means of a line of weakness, such as perforations.

Each of the end flaps of the top panel is preferably provided with one side extending in the same direction as the fold line between the top panel and cover flap and having its opposite side angled, whereby in the assembled carton, the angled side coincides substantially with the line of weakness of the detachable tab in the end flaps of the rear panel, preferably being slightly above the line of weakness. The outermost edge of each of the end flaps of the top panel is preferably provided with a small notch nearest the side adjacent the end flap of the cover panel.

The cover flap preferably comprises a first section and a second section. The first section is continuous with the top panel and separated therefrom by fold lines.

The first section is preferably provided with end flaps having substantially parallel sides which are indented to form a tag. Preferably, the indentation of the side nearest the top panel is a minor indentation, with the opposite indentation being greater in depth. Preferably, the length of the indentations corresponds to the length of the tab provided in the body portion of the assembled carton, for example that produced by the die-cut pocket provided in each of the flanges of the end flaps of the front panel.

The minor indentation forms the slot in the lid portion of the assembled carton for engagement with the tab.

The second section of the cover flap is preferably free from end flaps and is provided with a tear-away strip across the entire length thereof for detaching the lid portion from the main body portion on first opening of the carton. Preferably, the strip has cut lines into but not through the carton material above and below the strip and is provided with a tab at one end to assist in the removal thereof.

The carton is preferably made of cardboard and the intended inner surface thereof is preferably provided with a barrier coating such as polyethylene or wax.

In the assembled carton, the end flaps of the front and rear panels are folded and adhered to the end flaps of the base panel, with the exception of the tabs formed in the end flaps of the rear panel, thereby forming the main body portion of the carton. The flanges of the end flaps of the front panel are folded inwards over the edge of the end flaps of the base panel such that the flanges lie on the indentation formed by the provision of the small lip in the end flaps of the base panel. The lip which extends along the upper edge of the front panel is also folded inwards to lie over a part of the opening of the main body portion. The lid portion is formed by folding the cover flap and adhering the second section thereof to the front panel of the main body portion by a strip of adhesive provided on the innermost side of the cover flap. The end flaps of the top panel are adhered to the detachable tabs of the end flaps of the rear panel and the end flaps of the first section of the cover flap.

The carton may be opened by removing the tear-way strip provided in the cover flap. Lifting the lid portion also results in the tabs provided in the end flaps flaps of the rear panel becoming detached therefrom. This provides evidence that the carton has been tampered with from the end view thereof since the end flap of the top panel does not extend over the detachable tab. The carton may then be re-closed by placing the lid portion over the body portion such that the tab of the die-cut pocket formed in the flanges is inserted into the slot formed by the provision of the minor indentation in the end flap of the cover flap.

For a better understanding of the present invention and to show more clearly how it may be carried into effect reference will now be made, by way of example only, to the accompanying drawings in which: Figure 1 shows a blank for a carton according to a preferred embodiment of the present invention; Figure 2 is a perspective view of a sealed carton made from the blank of Figure 1; Figure 3 is a perspective view of the open carton shown in Figure 2; Figure 4 is a perspective view of the carton of Figures 2 and 3, partially closed after opening; Figure 5 is a blank for a carton according to an alternative embodiment of the present invention; and Figure 6 is a perspective view of an open carton made from the blank of Figure 5.

Referring to the accompanying drawings, a carton 10 is constructed from a blank 12, as shown in Figure 1. The blank 12 is cut and folded from cardboard having its intended inner surface coated with polyethylene or wax as a barrier, thereby preventing seepage of contents of the carton through the board. The blank has, in the given order and separated by fold lines, a front panel 14, a base panel 16, a rear panel 18, a top panel 20 and a cover flap 22.

Each panel 14, 16, 18, 20, and the cover flap 22 has at both ends a flap 24, 26, 28, 30 and 32 respectively, separated from their respective panels by fold lines.

The flaps 24 at each end of the front panel 14 have parallel sides with a block indentation 51 over a minor part of their length furthest from the front panel 14 and adjacent the flap 26 of the base panel 16. The outer edge which forms the upper edge of the front panel in the assembled box has a narrow lip 45 along the entire length thereof. However, it is to be appreciated that the lip 45 may be omitted from the blank, if so desired. The side of the flaps 24 opposite the flaps 26 of the base panel are each provided with a flange 44 along the entire length thereof, being separated from their respective end flaps by fold lines. A die-cut pocket is inserted into the flap 24 up to the fold line separating the flap from flange 44 near to the front panel 14, thereby forming a tab 46.

The flaps 26 at the ends of the base panel 16 are generally rectangular in shape, with the side of the flap adjacent the end flap 24 being of equal length whilst the opposite end of the flap is provided with a small lip portion 53 in the outermost edge thereof.

The flaps 28 at the ends of the rear panel 18 have substantially parallel sides with an indentation 55 nearest the cover panel 20, which forms a tab 48. The tab 48 is provided with a diagonal line of weakness, for example using perforations 57. The side of the flaps 30 at the ends of the top panel 20 adjacent the tab 48 are diagonal such that the line of weakness 57 and side of the end flap 30 meet to form an apex at the folding line between the back panel 18 and top panel 20, the diagonal lines extending from the fold line at substantially the same angle. The outermost edge of the flaps 30 nearest the cover flap 22 is provided with a small indentation 59.

The cover flap 22 comprises a first section 22A and a second section 22B.

The first section 22A is continuous with the top panel 20 and separated therefrom by fold lines. End flaps 32 are provided at either end of the first section which are shaped to form a tag 62. The tag is formed by the flaps having substantially parallel sides which are both indented equidistant from the first section 22A. The indentation 64a nearest the end flap 30 of the top panel 20 is a minor indentation, with the opposite indentation 64b being greater in depth. The length of the indentations 64a and 64b corresponds to the length of the tab 46 provided by the die-cut pocket in the flange 44 of end flaps 24 and is positioned equidistant from the first section 22A as the die-cut pocket is positioned from the front panel 14.

The second section 22B of the cover flap 22 is not provided with end flaps but has a tear-away strip 40 of the known zip type defined by upper and lower die-cuts or perforations. Above and below the zip 40 are cut lines 42 into but not through the carton material. These lines prevent the pulling away of the carton material above or below the strip when it is torn off. One end of the zip 40 is provided with a tab 41 to enable easy removal thereof.

In assembling the carton 10, the front panel 14, rear panel 18 and end flaps 26 of the base panel 16 are folded upwards and the end flaps 24 and 28 of the front and rear panels respectively are folded over the flap 26 and adhered thereto, except for the tab 48 of flap 28, thereby forming the main body portion of the carton. The flange 44 having the tab 46 folds over the top edge of the end flap 26 and rests in the indentation provided by the lip portion 53 and the lip 45 which is continuous with the upper edge of the front panel is folded inwards to lie over a part of the opening of the main body portion. The top panel 20 is then folded down towards the main body portion of the carton and the cover flap 22 is folded down and over the front panel 14 and adhered thereto by means of adhesive applied to the inner edge of the second section 22B of the cover flap. Adhesive is applied to the intended upper surface of the end flaps 32 of the first section of the cover flap 22 and the flaps are folded over the end flaps 24. Each of the end flaps 30 of the top panel are then folded down over the main body portion of the carton and adhered to the tabs 48 of the end flaps 28 of the rear panel 18 and to the end flap 32 to form a closed carton, as shown in Figure 2.

Referring to Figures 3 and 4 of the accompanying drawings, the assembled carton may be opened easily to expose the contents thereof by removing the tear-away strip 40 and lifting the opened lid portion 70 of the carton from the body portion 80.

The lid portion consists of the top panel 20, first section of the cover flap 22A and the end flaps 30 of the top panel which is held in its three-dimensional configuration by the end flaps 32 of the cover flap being adhered to the end flaps 30 of the top panel. The lifting of the lid portion away from the body portion causes the tab 48 to separate from the end flap 28 due to the presence of the perforations 57 and the tab being adhered to the end flap 30 whilst the rest of the flap 28 is adhered to the end flap 26 of the base panel 16. The breaking of the tab 48 away from the end flap 28 provides evidence from the end view that the carton has been tampered with. This is not found with the cartons of the prior art which have end flaps of the top panel which fold over the detachable tab and obscure the line of weakness.

More importantly, the opened carton may be easily and effectively re-closed to completely surround the contents thereof by placing the lid portion 70 over the body portion 80. The re-sealing of the lid portion to the body portion is achieved by the tab 46 of the die-cut pocket slotting into the indentation 64a of the tab of the end flap of the cover flap such that in order for the lid portion to be lifted, a sufficient amount of force has to be applied to cause the tab to become dislodged from the slot. Thus, the contents will not become exposed by the lid portion coming away from the body portion as occurs with the cartons of the prior art.

It is to be appreciated that the positioning of the complimentary tabs and slots to allow re-sealing of the lid portion after opening the box is not limited to that described above. For example, the flanges having the die-cut pockets which extend from the end flaps of the front panel may be replaced by the extension of the lip 45 of the front panel over the sides thereof protruding parallel to the end flaps of the front panel to form tabs 72, 74. The lip is extended just past the sides of the front panel by approximately 3mm to create a suitable tab, as illustrated in Figures 5 and 6.

In the assembled carton, these tabs fit into the slits 76 provided in the lid portion thereby sealing the carton.

The construction of the assembled carton of the present invention also involves a simplified folding sequence of the end flaps over previous cartons formed from blanks. The folding sequence is thus easier to carry out using packaging machinery having less moving parts. This results in there being less parts to replace and, more importantly, allows an increased output of filled cartons. The number of sites which require adhesive to be applied thereto is also reduced in the carton of the present invention.

The present carton is also more visually appealing than many of the earlier cartons which have a large number of flaps visible from their end view. The incorporation of the end flap of the cover flap inside the lid portion of the present carton results in the carton having a tidier appearance.

The carton of the present invention clearly provides cheap, disposable packaging for consumable items which may be opened to remove some of the contents thereof and be securely and easily re-closed to allow effective storage of the remaining product.

Claims (19)

1. A carton made up from a blank to form a three dimensional rectangular section carton comprising: a main body portion having a front, rear and a base panel sealed together by means of overlapping end flaps provided at each end of the panels which are adhered to each other; a lid portion having a cover panel and closure flap, each being provided with end flaps being folded and sealed to each other, part of the lid being adherable to the panel of the main body to seal the contents in the carton; the lid portion being provided with means for detaching the lid from the main body portion to open the carton, wherein the lid portion and the body portion have mutually engageable formations to re-close the carton after opening.

2. A carton as claimed in claim 1, wherein the main body portion and the lid portion are provided respectively with at least one complimentary tab and slot whereby the tab fits in the slot when placing the lid portion over the main body portion to secure the lid thereto.

3. A carton as claimed in claim 2, wherein the at least one tab protrudes from an upper edge of the body portion of the assembled carton.

4. A carton as claimed in claim 3, wherein the tab is provided by extending a portion of the upper edge of at least one of the end flaps of the front panel.

5. A carton as claimed in claim 2, 3 or 4, wherein the tab is formed by the provision of a flange extending from the upper edge of the body portion having a die cut pocket formed therein.

6. A carton as claimed in claim 2, 3 or 4, wherein the at least one tab is formed by the provision of a lip on the upper edge of the front panel extending just beyond a side of the front panel substantially parallel to the end flaps of the base panel thereby forming a tab.

7. A carton as claimed in any one of claim 2 to 6, wherein the at least one slot for engagement with the tab is provided in the lid portion at a position corresponding to the positioning of the tab when the lid portion is placed over the main body portion.

8. A carton as claimed in claim 7, wherein the slot is provided by a slit through the lid portion.

9. A carton as claimed in claim 7, wherein the construction of the panels and flaps in the assembled lid portion is such as to create a slot therein.

10. A carton as claimed in claim 9, wherein the slot is provided by the end flap of the cover flap having an indentation such that in the assembled carton a slot exists between the edges of the end flap and the edge of the top panel.

11. A carton as claimed in any one of the preceding claims, wherein the end flaps of the base panel are provided with a detachable section nearest to the end flaps of the top panel.

12. A carton as claimed in claim 11, wherein the detachable section is in the form of a triangular tab which is continuous with the end flap but separated therefrom by a line of weakness.

13. A carton as claimed in claim 12, wherein the each of the end flaps is provided with one side extending in the same direction as the fold line between the top panel and cover flap and having its opposite side angled whereby, in the assembled carton, the angled side coincides substantially with the line of weakness of the detachable tab in the end flaps of the rear panel.

14. A carton as claimed in any one of the preceding claims, wherein the cover flap comprises a first section and a second section, the first section being continuous with the top panel and separated therefrom by fold lines.

15. A carton as claimed in 14 wherein the first section is provided with end flaps having substantially parallel sides which are indented to form a tag whereby, in the assembled carton, the indentation forms a slot in the lid portion for engagement with a tab of the body portion.

16. A carton as claimed in claim 15, wherein the length of the indentation corresponds to the length of the tab protruding from an upper edge of the body portion of the assembled carton.

17. A carton as claimed in claim 14, 15 or 16, wherein the second section of the cover flap is free from end flaps and is provided with a tear-away strip across the entire length thereof.

18. A blank for assembling into a carton substantially as hereinbefore described and with reference to Figure 1 and Figure 5 of the accompanying drawings.

19. A carton substantially as hereinbefore described and with reference to Figures 2, 3 and 4 or Figure 6 of the accompanying drawings.