GB2451281A

GB2451281A - Carton with inset base

Info

Publication number: GB2451281A
Application number: GB0714566A
Authority: GB
Inventors: Steve Hrynacz
Original assignee: Concept Packaging Services Ltd
Current assignee: Concept Packaging Services Ltd
Priority date: 2007-07-26
Filing date: 2007-07-26
Publication date: 2009-01-28
Also published as: GB0714566D0; IE20080634A1

Abstract

A blank 2, for forming a carton, has a side wall 4 having free ends, the side wall 4 comprising a first panel 6 connected to a second panel 8, a first lower flap 16 hingedly connected to the first panel 6, and a second lower flap 18 hingedly connected to the second panel 8. A hinged base panel 50 is hingedly connected to the first lower panel 16 and a base locking panel 56 hingedly connected to the second lower panel 18. The blank 2 is assembled by a method comprising the steps of folding the first lower flap 16 above the first panel 6, and folding the second lower flap 18 over the second panel 8. The hinged base panel 50 having a face furthest from the side wall is affixed to a corresponding part of the base locking panel 56. The first 6 and second panels 8 are then folded relatively towards each other, and the free ends of the side wall 4 fixed together, the hinged base panel 50 and the base locking panel 56 are then moved together to form the base of the carton. The carton may have an insert in the form of the retaining means (fig 5).

Description

Improvements In and Relating to Cartons

Field of the Invention

The present invention relates to cartons, to blanks suitable for the construction of such cartons and to methods of manufacturing cartons.

Background to the Invention

Cartons with bases are commonly used as containers for products, especially at a point of sale. However, the construction 0� such cartons often presents difficulties for the manufacturer/user. For instance, their construction can be complex which is a problem for the manufacturer. A user may find that the base of the carton does not sit well or is not sufficiently supported for it to be fit for purpose.

It is an aim of preferred embodiments of the present invention to obviate or overcome a disadvantage of the prior art, whether such prior art or disadvantage is referred to herein or otherwise.

Sunimary of the Invention According to the present invention in a first aspect, there is provided a method of construction of a carton from a blank, the blank comprising a side wall having free ends, the side wall comprising a first panel connected to a second panel, a first lower flap hingedly connected to the first panel, a second lower flap hingedly connected to the second panel, a hinged base panel hingedly connected to the first lower panel arid a base locking panel hingedly connected to the second lower panel, the method comprising Lhe steps of folding the first lower flap above the first panel, folding the second lower flap over the second panel, the hinged base panel having a face furthest from the side wall, affixing part of the face of the hinged base panel furthest from the side wall to a corresponding part of the base locking panel comprising folding the first and second panels relatively towards each other, fixing the free ends of the side wall and moving the hinged base panel and the base locking panel to form a base of the carton.

Where there are two panels forming the side wall, the free end of the first panel is affixed to the free end of the second panel, but if there are more than two panels, the relevant free ends are affixed together.

According to the present invention in a second aspect, there is provided a carton comprising a side wall comprising a first panel connected to a second panel, a first lower flap hingedly connected to the first panel, the first and second panels having free ends, a second lower flap hingedly connected to the second panel, a hinged base panel hingedly connected to the first lower panel and a base locking panel hingedly connected to the second lower panel, the first lower flap being folded over arid affixed to the first panel, the second lower flap being folded over arid affixed to the second panel, the hinged base panel being folded along a hinge line thereof and affixed to the base locking panel.

Suitably, a web extends between the first panel and an adjacent panel and being secured to both the panels between which the web extends.

Suitably, the web is capable of at least partly supporting a base panel.

Suitably, the carton additionally comprises a base panel, and the supporting web at least partly supports the base panel.

Suitably, the carton is of a single piece construction.

Suitably, the single piece construction comprises side walls and a base.

Suitably, each panel is connected to an adjacent panel by a web.

Suitably a web comprises a first web member associated with a panel and a second web member associated with another panel whereby the first web member is fixedly connected to the second web member. Suitably, a web glue flap extends from one of the web members and provides for glued connection of the first web member to the second web member.

Suitably, a web member is hingedly connected to a side panel (which may be via an intermediate flap) by a curved hinged connection. Suitably, the curvature of the curved hinged connection corresponds to the curvature of the side wall of the carton.

Suitably, a substantial proportion of the circumference of the base portion of the carton is supported.

Suitably, the first panel comprises a flap from which extends a part of the web.

Suitably, the end panel comprises a flap from which extends a part of the web.

Suitably, the carton comprises two side wall panels.

Suitably, the first panel is hingedly connected to the end panel.

Suitably, the base comprises a base panel hingedly connected to a side wall panel. Suitably, the base is hingedly connected to a side panel (which may be via an intermediate flap) by a curved hinged connection.

Suitably, the curvature of the curved hinged connection corresponds to the curvature of the side wall of the carton. Suitably, the base additionally comprises a hinged base panel. Suitably, the hinged base panel is hingedly connected to a side wall panel. Suitably, the hinged base panel is hingedly connected to a side panel (which may be via an intermediate flap) by a curved hinged connection. Suitably, the curvature of the curved hinged connection corresponds to the curvature of the side wall of the carton. Suitably, the hinged base panel is connected to the base panel. Suitably, the hinged base panel is hinged with a hinge line substantially perpendicular to a hinge between the first panel and another panel arid the portion of the hinged base panel distal from the hinged connection of the hinged base panel with the side wail is connected to the base panel.

Suitably, the walls of the carton are curved.

Suitably, there is no web connection between the first panel and the second panel.

According to the present invention in a third aspect, there is provided a carton comprising a side wall comprising a first panel connected to a second panel, a first lower flap hingedly connected to the first panel, the first and second panels having free ends, a second lower flap hingedly connected to the second panel, a hinged base panel hingedly connected to the first lower panel and a base locking panel hingedly connected to the second lower panel, the first lower flap being folded over and affixed to the first panel, the second lower flap being folded over and affixed to the second panel, the hinged base panel being affixed to the base locking panel, wherein the carton further insert retaining means for retaining an insert in the carton.

Suitably, the carton side wall is curved.

Suitably, the insert retaining means comprises at least one tab on an upper edge of the side wall. This can hold the insert in place by folding over a suitable lip thereof. Suitably, there is a plurality of tabs.

Suitably, the insert retaining means comprises a pushed in section of the side wall. Suitably, the pushed in section is formed by two cut out lines. Suitably there is a plurality of pushed in sections. Such sections can engage with a corresponding hole (which may be an indentation) on an insert. Alternatively such sections can engage with an end of an insert to block it from coming out.

Suitably, there is additionally provided an insert for fitting in the carton. Suitably, the insert is of a shape corresponding to the carton.

Suitably, the insert retaining means comprises at least one tab on an upper edge of the side wall and the insert comprises a lip over which the at least one tab is folded over.

Suitably, the insert retaining means comprises a pushed in section of the side waiLl and the insert comprises a hole to cooperate with the pushed in section. The hole can be an indentation or a cut out section of the insert.

Both a tab and a pushed in section can be used as insert retaining means if desired.

Brief Description of the Drawings

The present invention will now be described, by way of example only, with reference to the drawings that following; in which: Figure 1 is a plan view of a blank for producing a carton according to the present invention.

Figure 2 is a plan view of a carton constructed using the blank of Figure] Figure 3 is a side view of the carton shown in Figure 2.

Figure 4 is a bottom view of the carton shown in Figures 2 and 3.

Figure 5 is a schematic perspective illustration of an insert for use with the carton shown and described with reference to Figures 1 -4.

Figures 6-17 are views of alternative embodiments of the present invention.

Figure 18 is a plan view of a blank for producing a carton according to the present invention.

Figure 19 is a plan view of a carton constructed using the blank of Figure 18.

Figure 20 is a side view of the carton shown in Figure 19.

Figure 21 is a bottom view of the carton shown in Figures 19 and 20.

Description of the Preferred Embodiments

Referring to Figure 1 of the accompanying drawings, there is shown a one-piece carton board blank 2 comprising a side waIl 4. The side wall 4 comprises a first panel 6 and a second panel 8. In this case, the second panel 8 also is an end panel. First panel 6 is generally rectangular and is hingedly connected to the similarly shaped second panel 8 by a fold line 10 along a short edge thereof forming a hinged connection therebetween.

Extending from the short edge of first panel 6 distant from the fold 10 is a glue flap 12 connected to the first panel 6 by a fold line 14.

First panel 6 includes a lower flap 16. Second panel 8 also includes a corresponding lower flap 18. The lower flaps 16, 18 are not connected edge wise, being separated by a slot 20, but are hirigedly connected to first panel 6 and second panel 8 by hinge lines 60, 62 respectively.

Depending from the lower flap 16, 18 are members making up the first web arrangement 22 and a second web arrangement 24.

First web arrangement 22 comprises a firsL web member 26 depending from lower flap 16, a web glue flap 28 extending from first web member 26 and a second web member 30 depending from lower flap 18. Slot 20 extends to provide a separation between web glue flap 28 and second web member 30.

First web member 26 is hingedly connected to lower flap 16 by a curved hinge line 32. Web glue flap 28 is hingedly connected to first web member 26 by a straight fold line 34. Second web member 30 is hingedly connected to lower flap 18 by a curved fold line 36.

Second web arrangement 24 comprises a first web member 38 depending from lower flap 16, a web glue flap 40 extending from first web member 38 and a second web member 42 depending from lower flap 18.

First web member 38 is hingedly connected to lower flap 16 by a curved hinge line 44. Web glue flap 40 is hingedly connected to first web member 38 by a straight fold line 46. Second web member 42 is hingedly connected to lower flap 18 by a curved fold line 48.

Also extending from lower flap 16 is a hinged base panel 50, with a hinge line at 52, which hinged base panel 50 is hingediLy connected to lower flap 16 by a curved fold line 54.

Also extending from lower flap 18 is a base locking panel 56 hingedly connected to lower flap 18 by a curved fold line 58.

First panel 6 includes a cut-out section 64 made from two parallel cuts to form a pushed in section in the made-up carton as described below.

A method of construction of a carton from the blank 2 described above will now be set out. Typically construction is carried out using carton making machines, but can also be done by hand.

The constructed carton is shown in the accompanying Figures 2-4.

In a pre-application of glue and adhesive, contact adhesive is applied to the reverse (as shown) of the blank 2 along strips 60a, 60b, 60c and 60d. Glue is applied to the reverse of the distal end of the second panel 8 at 62.

Next the lower flaps 16, 18 are folded towards the first and second panels 6, 8 respectively so that the contact adhesive applied on the flaps 16, 18 and panels 6, 8 are pressed together to form a neat lower edge 64.

Then the outside glue flap is moved to contact strip of glue 62 to form the loop of the carton. First and second panels 6, 8 are thereby fixedly connected to form a carton wall.

The web arrangements 22, 24 are then constructed. For first web arrangement 22, glue is applied to web glue flap 28 and it is adhered to second web member 30 to form a first web 70. For second web arrangement 24, glue is applied to web glue flap 40 and it is adhered to second web member 42 to form a second web 72.

The base locking panel 56 is then glued to the distal part of hinged panel 50 (as illustrated by the shading on hinged base panel 50) . Ease panel 50 is not folded prior to being affixed to base locking panel 56. In this case, with reference to Figure 1, it is the non-visible faces of the panels, i.e. those away from the viewer when looking at Figure 1, that are affixed together. By not pre-folding hinged base panel 50, manufacturing of the carton is simple.

Referring to Figure 5 of the accompanying drawings, there is shown an insert 66 for use with the carton of Figures 2-4. The insert 66 is shaped and dimensioned to fit snugly into the interior of the carton. The insert comprises a hole 68, which can be a cut-out or an indentation.

As part of the manufacturing process the insert is pushed into the interior of the carton.

Cut-out section 70 is pushed into the interior of the carton to form a pushed in section 68 to block the egress of the insert from the carton and act as an insert retaining means. The pushed in section 70 cooperates with hole 68 of the insert 66 to block egress of the insert.

More than one pushed in section can be used in desired.

The curved connections 32, 36, 44, 48, 54 and 58 each enable the respective members/panels 26, 30, 38, 42, 50 and 56 to be folded into place in the constructed carton essentially at 90° to the side wall 4 without distorting the side wall 4. The curves are dimensioned so that they correspond to the curvature of the constructed side wall 4 in the made-up carton, i.e. they have corresponding radii.

The carton can be transported in a "flat" configuration with panels 6 and 8 pressed together and pushed into a usable configuration with pressure applied to fold lines and 14. Here base locking panel 56 is pressed down towards the bottom of the carton to lock the carton into shape. Looking down on the carton as in Figure 2, the base locking panel 56 overlies the hinged base panel 50 which overlies the first and second web arrangements 22, 24.

The web arrangements 22, 24 provide webs extending between a panel and an adjacent panel and being secured to both the panels between which the web extends. The webs are capable of supporting a base. The base can be a part of the carton blank or a separate element, in which case panels 50 and 56 need not he used. When the base is integral with the carton the webs still provide a supporting function.

It will be appreciated that variations to the method of construction of the carton can be made, such as to the order of construction and to the surface(s) to which adhesive is applied. Further, different methods of fixing panels together can be used.

A benefit of the construction described above is that a substantial proportion of the circumference of the base portion of the carton is supported, effectively at the curved hinged regions 32, 36, 44, 48, 54 and 58. This enhances the stability of the shape and the strength of the base portion when it is required to be load-bearing.

A wide variety of shapes can be achieved according to embodiments of the present invention. These can be with two panels or more. It is preferred that each panel is connected to the adjacent panel at either end thereof by a web as described above.

Other carton constructions according to the present invention are shown in Figures 6-17. These are described briefly as they apply the same principles of construction as the embodiment described in relation to Figures 1-4.

The embodiment of figures 1-4 can be modified for instance by changing the shape of hinged panel 50 from circular to rectangular and truncating the glued part of the panel 50 and folding it back so that when constructed it is a folded-back glue flap.

The accompanying Figure 6 is a generally square construction, with rounded walls and corners. It can he seen that the web 200 is formed as a one piece construction hingedly connected to one panel with a glue flap 202 fixedly attached to an adjacent panel. A blank suitable for the construction of the carton shown in Figure 6 is shown in the accompanying Figure 7.

A two-walled curved construction carton is shown in the accompanying Figure 8, a blank for which is shown in Figure 9.

The accompanying Figure 10 shows an oval carton, the blank for which is shown in Figure 11.

The accompanying Figures 12 and 13 shows, respectively, a plan view of a heart shaped carton construction and a suitable blank therefor.

The accompanying Figures 14 and 15 show, respectively, a plan view of a rectangular carton with curved ends and a suitable blank therefor.

Figure 16 is a plan view of a carton blank 300 for a carton with four panels 302, 304, 306 and 308, first to fourth respectively, to produce a four--sided carton with curved sides as shown by the plan view of a suitable separate base 310 illustrated in Figure 17.

In the embodiment of the invention, web arrangements are provided at 312 and 314.

The fourth panel 308 is the end panel in this embodiment.

Referring to Figure 18 of the accompanying drawings, there is shown a blank for a carton according to another embodiment of the present invention. The carton blank is similar in design in many ways to that shown in Figure 1 arid in relation to which corresponding reference numerals are used for like parts.

However in the blank of Figure 18 the webs 22, 24 are not present and instead of a cut out section to produce a pushed in section as the insert retaining means, a plurality of tabs 72 are provided for this function.

Surprisingly, it has been found that if the webs are not present, the base is still adequately strong for many applications, especially as the upturned edge of the lower flaps 16, 18 provide a ledge on which the free edge of the hinged base panel and the base locking panel 50, 56 respectively, can sit.

The tabs 72 provide an insert engaging means. The insert 66 is configured so that it has a lip extending to near the top of the inside of the carton over which the tabs 72 are folded. The curvature of the first and second panels 6, 8, respectively, encourages the tabs to stay in place.

A hole in the insert 66 is not needed in this case, but it does not matter if it is there.

Figures 19-21 of the accompanying drawings show a carton constructed from the blank shown in Figure 18. the method of construction is essentially similar to that described in relation to Figures 1-5, except that there are no webs to assemble and the insert retaining means is the folded over tabs.

It will be appreciated that the insert retaining means need not be present if no insert is intended to be used.

Also, the insert retaininq means of Figures 1-5 can be used in the embodiment described in relation to Figures 18-21 and vice versa.

It will also be appreciated that this embodiment of the present invention can be modified according to the embodiments shown in Figures 6-16 of the accompanying drawings.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, arid the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s) . The invention extends to any novel one, or any novel combination, of the features

disclosed in this specification (including any

accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

Claims 1. A method of construction of a carton from a blank, the blank comprising a side wall having free ends, the side wall comprising a first panel connected to a second panel, a first lower flap hingedly connected to the first panel, a second lower flap hingedly connected to the second panel, a hinged base panel hingedly connected to the first lower panel and a base locking panel hingedly connected to the second lower panel, the method comprising the steps of folding the first lower flap above the first panel, folding the second lower flap over the second panel, the hinged base panel having a face furthest from the side wall, affixing part of the face of the hinged base panel r.. furthest from the side wall to a corresponding part of the base locking panel comprising folding the first io and second panels relatively towards each other, (\J fixing the free ends of the side wall and moving the hinged base panel and the base locking panel to form a base of the carton.
2. A carton comprising a side wall comprising a first panel connected to a second panel, a first lower flap hingedly connected to the first panel, the first and second panels having free ends, a second lower flap hingedly connected to the second panel, a hinged base panel hingedly connected to the first lower panel and a base locking panel hingedly connected to the second lower panel, the first lower flap being folded over and affixed to the first panel, the second lower flap being folded over and affixed to the second panel, the hinged base panel being folded along a hinge line thereof and affixed to the base locking panel.
3. A carton as claimed in claim 1 or claim 2, wherein a web extends between the first panel and an adjacent panel and being secured to both the panels between which the web extends.
4. A carton as claimed in claim 3, wherein the web is capable of at least partly supporting a base panel.
5. A carton as claimed in any preceding claim, wherein the carton additionally comprises a base panel, and the supporting web at least partly supports the base panel.

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6. A carton as claimed in any preceding claim, wherein LO the carton is of a single piece construction. (sJ
7. A carton as claimed in claim 6, wherein the single piece construction comprises side walls and a base.
8. A carton as claimed in any preceding claim, wherein each panel is connected to an adjacent panel by a web.
9. A carton as claimed in claim 8, in which a web comprises a first web member associated with a panel and a second web member associated with another panel whereby the first web member is fixedly connected to the second web member.
10. A carton as claimed in claim 9, wherein a web glue flap extends from one of the web members and provides for glued connection of the first web member to the second web member.
11. A carton as claimed in claim 9 or claim 10, in which a web member is hingedly connected to a side panel (which may be via an intermediate flap) by a curved hinged connection.
12. A carton as claimed in claim 11, wherein the curvature of the curved hinged connection corresponds to the curvature of the side wall of the carton.
13. A carton as claimed in any preceding claim, in which a substantial proportion of the circumference of the base portion of the carton is supported.
14. A carton as claimed in claim 8, wherein the first panel comprises a flap from which extends a part of C\J the web.
15. A carton as claimed in claim 8, wherein the end panel comprises a flap from which extends a part of the web.
16. A carton as claimed in any preceding claim, wherein the carton comprises two side wall panels.
17. A carton as claimed in any preceding claim, wherein the first panel is hingedly connected to the end panel.
18. A carton as claimed in any preceding claim, wherein the base comprises a base panel hingedly connected to a side wall panel.
19. A carton as claimed in claim 18, wherein the base is hingedly connected to a side panel (which may be via an intermediate flap) by a curved hinged connection.

Suitably, the curvature of the curved hinged connection corresponds to the curvature of the side wall of the carton.
20. A carton as claimed in any preceding claim, wherein the base additionally comprises a hinged base panel.
21. A carton as claimed in claim 20, wherein the hinged base panel is hingedly connected to a side wall panel.
22. A carton as claimed in claim 20 or claim 21, wherein the hinged base panel is hingedly connected to a side Q panel (which may be via an intermediate flap) by a 1.0 curved hinged connection. c\J
23. A carton as claimed in claim 22, wherein the curvature of the curved hinged connection corresponds to the curvature of the side wall of the carton.
24. A carton as claimed in claim 18, wherein the hinged base panel is connected to the base panel.
25. A carton as claimed in claim 24, wherein the hinged base panel is hinged with a hinge line substantially perpendicular to a hinge between the first panel and another panel and the portion of the hinged base panel distal from the hinged connection of the hinged base panel with the side wall is connected to the base panel.
26. A carton as claimed in any preceding claim, wherein the walls of the carton are curved.
27. A carton as claimed in any preceding claim, in which there is no web connection between the first panel and the second panel.
28. A carton comprising a side wall comprising a first panel connected to a second panel, a first lower flap hingedly connected to the first panel, the first and second panels having free ends, a second lower flap hingedly connected to the second panel, a hinged base panel hingedly connected to the first lower panel and a base locking panel hingedly connected to the second lower panel, the first lower flap being folded over and affixed to the first panel, the second lower flap to being folded over and affixed to the second panel, the (\J hinged base panel being affixed to the base locking panel, wherein the carton further insert retaining means for retaining an insert in the carton.
29. A carton as claimed in claim 28, wherein the carton side wall is curved.
30. A carton as claimed in claim 28 or claim 29, wherein the insert retaining means comprises at least one tab on an upper edge of the side wall.
31. A carton as claimed in claim 30, in which there is a plurality of tabs.
32. A carton as claimed in any one of claims 28 to 31, in which the insert retaining means comprises a pushed in section of the side wall.
33. A carton as claimed in claim 32, wherein the pushed in section is formed by two cut out lines.
34. A carton as claimed in claim 32 or claim 33, wherein there is a plurality of pushed in sections.
35. A carton as claimed in any one of claims 28-34, wherein there is additionally provided an insert for fitting in the carton. Co
36. A carton as claimed in claim 35, wherein the insert is of a shape corresponding to the carton.

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37. A carton as claimed in any one of claims 28-36, wherein the insert retaining means comprises at least one tab on an upper edge of the side wall arid the insert comprises a lip over which the at least one tab is folded over.
38. A carton as claimed in any one of claims 28-37, wherein the insert retaining means comprises a pushed in section of the side wall and the insert comprises a hole to cooperate with the pushed in section.
39. A method of constructing a carton substantially as described herein, with reference to the accompanying drawings.
40. A carton substantially as described herein, with reference to the accompanying drawings. Co cD

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