GB2406089A

GB2406089A - Partition structure for a carton

Info

Publication number: GB2406089A
Application number: GB0419155A
Authority: GB
Inventors: Clifford White Kelso
Original assignee: MAY K Ltd
Current assignee: MAY K Ltd
Priority date: 2003-08-28
Filing date: 2004-08-27
Publication date: 2005-03-23
Anticipated expiration: 2024-08-27
Also published as: GB0419155D0; GB2406089B; GB0320177D0

Abstract

A carton comprises four sides (17, 17, 18, 18), top and bottom end faces, and a two or more piece insert (2,3) for creating compartments within the carton. A first insert piece (2) includes a cut-away portion (5) and a second insert piece (3) includes a tab portion (8) engageable with the cut-away portion (5) to prevent, or at least restrict, relative displacement of the first and second pieces of the insert (2,3) in a direction normal to the end faces. One of the insert pieces is fixed to one of the sides of the carton so that as the carton is opened into a substantially rectangular configuration from a flat-packed configuration the insert becomes opened up such that the carton is divided with substantially rectangular compartments when viewed from its top end face. The tab portion may alternatively have a triangular shape.

Description

CARTON WITH INSERT

This invention relates to cartons having an insert for creating compartments within the carton, particularly for use in the carriage of fragile items, for example bottles, glassware and ceramics.

Cartons are usually constructed from corrugated cardboard, fibreboard or plastics. The carton typically comprises four sides with flaps extending from each of the sides to be folded over to create a lid and a base of the carton. Upon sealing the base of the carton, an insert is positioned within the carton to create a plurality of cells within which items to be carried may be placed. The lid is then sealed to complete the package.

The four sides of the carton and the flaps for forming the base and the lid are typically die cut from planar sheet material. The insert pieces are typically cut as separate items in a similar fashion. The number of insert pieces required is dependent on the number of cells to be formed within the carton.

Cartons are usually manufactured so as to be able to be transported to a packaging plant in a flat-packed configuration. The carton manufacturing and packaging processes are generally as automated as possible. Typical prior art cartons are assembled in a two-step process in which interlocked flat-packed insert pieces are opened into a crossing configuration. The carton is also erected from a flat-packed configuration and then the flaps folded to form the base. The insert is then positioned within the carton.

Where the insert has a height substantially less than the height of the carton the insert has a tendency to fall to the base of the carton providing reduced protection for adjacent items packaged near the top of the carton. Unless the items occupy the cells to the full height of the carton this can create problems when sealing the top of the carton since the flaps at the top of the carton are unsupported.

Where the insert has substantially the same height as the sides of the carton there exists a problem in that the insert pieces must be vertically aligned exactly with one another in order to facilitate sealing of both the base and the lid of the carton.

The present invention seeks to overcome many of the disadvantages of prior art cartons by providing a carton I which may be assembled from a flat-packed configuration in an automated process with a fewer number of steps and in which the carton may be assembled with a much lower possibility of failure.

According to the present invention a carton comprises four sides, top and bottom end faces, and a two or more piece insert for creating compartments within the carton, wherein a first insert piece includes a cut-away portion and a second insert piece includes a tab portion engagable with the cut-away portion to prevent, or at least restrict, relative displacement of the first and second pieces of the insert in a direction normal to the end faces, and wherein one of the insert pieces is fixed to one of the sides of the carton.

A method of manufacturing the carton in accordance with the present invention comprises the steps of preparing from sheet material a carton blank from which the sides and end faces of the carton are formed; preparing at least two insert pieces; joining the insert pieces together such that the tab portion of the second insert piece engages with the cutaway portion of the first insert piece; and fixing one of the insert pieces to one of the sides of the carton.

Preferably the method also includes the step of joining edges of the die cut carton blank together to form a closed loop.

Such a carton can then be erected by opening the! carton into a substantially rectangular configuration and in so doing opening up the insert so that the carton is divided with substantially rectangular compartments when viewed from its top end face, and then closing the bottom end face of the carton.

Slots are preferably formed extending partially through the insert pieces such that the insert pieces are interengagable. The second insert piece may include a flared opening to its slot. The flared opening is preferably formed adjacent the tab in order to facilitate assembly of the insert pieces. I In order to open the sides of the carton and the insert simultaneously, when the insert pieces have a tendency to deform, the first insert piece may be fixed to one of the sides of the carton and the second insert piece fixed to a different side of the carton. Where more than two insert pieces are required to create the requisite number of cells, a connecting panel may be provided linking the two insert pieces. The connecting panel may be the part of the insert which is fixed to one side of the carton.

The insert preferably has a length which is substantially identical to the length of the sides between the top and bottom end faces of the carton. If further items are required to be carried within the carton, but not within the cells, the insert may have a length substantially less than the length of the sides between the top and bottom end faces such that these further items occupy the remaining space between the top edge of the insert and the top end face of the carton. Preferably the insert forms substantially square compartments when viewed from the end faces of the carton.

The top and bottom end faces may be formed of flaps extending from the sides of the carton which are folded over the ends of the carton and which may be fixed to one another by staples, glue or adhesive tape.

Preferred embodiments of the present invention will! now be described with reference to the accompanying drawings in which: Figure 1 is a plan view of a carton blank; Figures 2 and 3 are plan views of die cut insert pieces in accordance with a first embodiment; Figure 4 is a perspective view of the erected carton in accordance with the first embodiment; Figure 5 is a partial perspective view of the insert, of Figure 4; Figures 6 and 7 are plan views of die cut insert pieces in accordance with a second embodiment; I Figure 8 is a perspective view of the erected carton in accordance with the second embodiment; and Figure 9 is a partial perspective view of the insert of Figure 8.

Referring to the drawings there is shown a corrugated cardboard six bottle wine case. The die cut sides 17,18 and flaps 10,11 of the carton are shown in Figure 1 where the carton comprises two broad sides 18 and two narrow sides 17 to form a rectangular shaped carton. The first insert piece 2 is shown in Figure 2 or Figure 6. The second insert piece 3 is joined to a further insert piece 14 by a connecting panel 15 as shown in Figure 3 or Figure 7.

Manufacture of the flat-packed carton will now be described. A carton blank is die cut from sheet material as shown in Figures 1 to 3 or Figures 1, 6 and 7.

Alternatively, the blank can be formed by scoring and slotting operations. The connecting panel 15 is glued or otherwise fixed to the centre of one of the broad sides 18 of the carton. The second insert piece 3 is folded over such that it is positioned on top of the connecting panel 15. The first insert piece 2 is inserted through the openings 7 or 7 in the second insert piece 3 such that the slots 4 formed in the first insert piece 2 engage with the slots 6 formed in the second insert piece 3. The cut-away portion 5 or 5 in the first insert piece 2 engages with! the tab portions 8 or 8 in the second insert piece 3. The sides 17, 18 are then folded such that a narrow side 17 of the carton lies on top a broad side 18 of the carton, and the other broad side 18 of the carton lies on top the other narrow side 17 of the carton. The tab 22 extending from one of the sides is glued, stapled or otherwise fixed such that the four sides 17,18 form a closed loop around the insert 2,3. The carton now exists in its flat-packed configuration.

In the first embodiment, shown in Figures 1 to 5, the tab portion 8 engages cut-away portion 7 in a shoulder I abutting fashion to prevent relative displacement of the first and second pieces of the insert in a direction normal to the faces of the carton. In the second embodiment, shown in Figures 1 and 6 to 9, the tab portion 8 engages cut-away portion 7 such that relative displacement of the first and second pieces of the insert is restricted by frictional engagement. A limited degree of relative displacement is acceptable, that is approximately 3 to 5mm.

Prior to filling the carton with items to be packaged the carton must be transformed from the flat-packed configuration to the fully assembled configuration. If the insert 2,3 is constructed of sufficiently rigid material then, upon opening the sides 17,18 of the carton, an edge 16 of the first insert piece 2 will abut an interior surface of one of the narrow sides 17 of the carton. Since the connecting panel 15 has already been fixed to one of the broad sides 18 of the carton, opening the sides 17,18 of the carton simultaneously opens the insert 2,3 to the fully assembled configuration. The flaps 11 are then folded over such that the bottom end face of the carton can be sealed. The bottom end face is sealed by either gluing, stapling or adhesively taping the flaps 11 together. The carton now exists in its fully assembled configuration capable of accepting the items to be packaged as shown in Figure 4 or Figure 8. A detailed view of the interconnected insert pieces 2,3 is shown in Figure 5 or! Figure 9.

Once the items to be packaged have been inserted into the cells formed by the insert 2,3 the remaining flaps 10 are folded over to form the top end face of the carton which is sealed in the same manner as the bottom end face.

Since the insert pieces 2,3 are restrained from relative movement in a direction normal to the end faces and since the insert 2,3 occupies the full height of the interior of the carton, the flaps 10 at the top end face of the carton abut the upper edge 20,21 of the insert 2,3 which provides support during sealing of the top end face.

If the insert pieces 2,3 are not sufficiently rigid then they may flex or deform when the sides 17,18 of the carton are opened. In this case, opening the sides 17,18 may well not to be sufficient to open the insert 2,3 as described above. An optional tab may be provided on the first insert piece 2 and fixed to a narrow side 17 of the carton during the carton manufacturing process. This will ensure that the insert 2,3 forms the cells within the carton upon opening the sides 17,18 of the carton.

The exemplary cartons described above are suitable for six wine bottles to be packaged. Clearly the cartons described can be adapted for a greater or fewer number or items. For example, a nine bottle case may be constructed by providing two sets of identical slots 6, openings 7, 7 and tab portions 8, 8 on the second insert piece 3 described above. Another first insert piece 2 may then be inserted in the second pair of slots 6 formed in the second insert piece 3. Similarly, a twelve bottle case may be constructed using three first insert pieces 2. Typically 4, 6, 12 or 15 cells are provided within the carton.

The carton may be adapted such that further connecting panels 15 are provided linking the second insert piece 3 to yet further insert pieces and the connecting panels may be alternately fixed to each of the broad sides 18 of the carton. The quantity of cells within the carton can thus be varied according to requirements.

In all of the embodiments described above the carton has an insert 2,3 which occupies the full height of the interior of the carton. Although the lower edge of the insert 2,3 is positioned adjacent the bottom of the carton, other products, for example a wine book or a box of miniature liqueur bottles, could be provided between the top edge 20,21 of the insert 2,3 and the flaps 10 forming the top end face of the carton. In order to ensure that the advantages of providing resilience to the flaps 10 for sealing the top end face of the carton, the height of the insert 2, 3 could be selected such that the height of the insert 2,3 and the height of an item positioned on top of the insert 2,3 occupies the full height of the carton.

The embodiments described indicate a very simple tab portion 8, 8 positioned at the upper end of the second insert piece 3. This tab could take many forms in order to ensure that relative displacement of the first and second insert pieces 2,3 is prevented, or at least restricted, in a direction normal to the end faces of the carton.

The tab 8 described with reference to the first embodiment has a rectangular shape with a lowermost chamfered free corner 23 to facilitate insertion of the first insert piece 2. The tab portions 8, to prevent relative movement of the insert pieces in the direction normal to the end faces of the carton, may take any shape but should have a linear lower free edge 24 parallel with the end faces of the carton such that the tab portions 8 can move freely to a position for preventing said relative movement of the first and second insert pieces 2,3.

The tab 8 described with reference to the second embodiment has a triangular shape. The tab portions 8 to restrict relative movement of the insert pieces in the direction normal to the end faces of the carton, may take any shape but should be suitable to enable easy assembly of the insert pieces 2,3 whilst providing adequate friction between the insert pieces 2,3 to at least restrict said relative movement therebetween.

The tab portions 8 need not be provided adjacent the upper edge 20 of the second insert piece 3. The tab portion 8 may be located at any suitable position adjacent the slot 6 so as to prevent, or at least restrict, relative movement of the first and second insert pieces 2,3 as described.

Multiple sets of carton components 1,2,3 may be cut in a single die cut and so the invention is not limited to the layouts shown in Figures 1 to 9.

Claims

1. A carton comprising four sides, top and bottom end faces, and a two or more piece insert for creating compartments within the carton, wherein a first insert piece includes a cut-away portion and a second insert piece includes a tab portion engageable with the cut-away portion to prevent, or at least restrict, relative displacement of the first and second pieces of the insert in a direction normal to the end faces, and wherein one of the insert pieces is fixed to one of the sides of the carton.

2. The carton according to claim 1, wherein slots are formed extending partially through the insert pieces such that the insert pieces are interengageable.

3. The carton according to claim 2, wherein the second insert piece includes a flared opening to its slot.

4. The carton according to claim 3, wherein the flared opening is formed adjacent the tab portion.

5. The carton according to any one of the preceding claims, wherein the first insert piece is fixed to one of the sides of the carton and the second insert piece is fixed to a different side of the carton.

6. The carton according to any one of the preceding claims, wherein the second insert piece is connected to a third insert piece identical to the second insert piece by a panel, the panel being fixed to one side of the carton.

7. The carton according to any one of the preceding claims, wherein the insert forms substantially square compartments when viewed from the end faces of the carton.

8. The carton according to any one of the preceding claims, wherein the insert either has a length substantially identical to the length of the sides between the top and bottom end faces, or has a length substantially less than the length of the sides between the top and bottom end faces.

9. The carton according to any one of the preceding claims, wherein the carton further comprises flaps extending from the sides which are folded over to form the end faces of the carton.

10. The carton according to claim 9, wherein the flaps are fixed to one another by either staples, glue or adhesive tape.

11. A method of manufacturing a carton in accordance with any one of the preceding claims, comprising the steps of: 20preparing from sheet material a carton blank from which the sides and end faces of the carton are formed; preparing at least two insert pieces; joining the insert pieces together such that the tab portion of the second insert piece engages with the cut away portion of the first insert piece; and fixing one of the insert pieces to one of the sides of the carton.

12. The method according to claim 11, further comprising the step of joining edges of the die cut carton blank together to form a closed loop.

13. The method according to claim 12, further comprising the step of opening the carton into a substantially rectangular configuration and in so doing opening up the insert so that the carton is divided with substantially rectangular compartments when viewed from its top end face, and then closing the bottom end face of the carton.

14. A carton substantially as described with reference! to the accompanying drawings.