GB2508170A

GB2508170A - Carton blank with inner liner for liquids or greasy products

Info

Publication number: GB2508170A
Application number: GB1220990.4A
Authority: GB
Inventors: Peter Mann
Original assignee: STOTT O CONNELL AND Co Ltd
Current assignee: STOTT O CONNELL AND Co Ltd
Priority date: 2012-11-22
Filing date: 2012-11-22
Publication date: 2014-05-28
Also published as: GB201220990D0

Abstract

A method of manufacturing a lined folding carton is provided for use primarily as packaging or as containers for liquids and moist, wet and high-fat greasy products. The method comprises providing a cut and creased and/or scored blank 2 and a predetermined length of a layflat tubing 16. One or more patches of adhesive 18, 18A are applied to parts of the blank adapted to form at least a first of opposing first and second sides of the carton when erected. Thereafter, either one side of the length of layflat tubing is adhered to one or more of the patches of adhesive on at least that part of the blank adapted to form said first side of the carton and one or more further patches of adhesive are applied on parts of the blank adapted to form at least the second side of the carton when erected or vice versa. A part of the blank adapted to form the second side of the carton is then folded over to oppose the first side and adhered either directly or indirectly to an opposite side of the layflat tubing. Edges of the blank are then secured together to form a folded carton. When such a folded carton is erected, the fact that opposite sides of the layflat tubing are adhered directly or indirectly to opposing sides of the carton means that the tube opens out and forms a lining for the carton. If the layflat tubing is impervious the method enables folding cartons to be manufactured in the form of a liquid-tight cup or similar container.

Description

IMPROVEMENTS TO FOLDING CARTONS

The present invention relates to a method of manufacturing lined folding cartons for use as packaging or as containers for liquids and moist, wet or high-fat products.

Conventionally, folding cartons are shipped flat (knocked down) to the packager and then erected immediately prior to use. They may be lined with impervious or grease-proof materials so that they can be used for packaging wet, moist or high-fat products such as foodstuffs that would otherwise damage or stain the carton, which is typically made of paperboard or similar. Usuafly, they are made out of a single piece of paperboard that.

dependent on the need, may be waxed or coated with polyethylene to form a moisture barrier. However, the production of such paperboard is relatively complex and does not allow window cartons to be used without an additional transparent window sheet or further item of transparent packing to be used to create the window itself The object of the present invention is to provide a method of manufacturing a lined folding carton that is simpler to produce than many conventional methods and that in some embodiments speeds up the subsequent packaging process. In other embodiments, the folding carton may be made liquid-tight to enable the carton to form a cup-like container for holding liquids.

According to the present invention there is provided a method of manufacturing a lined folding carton comprising the following steps: providing a cut and creased and/or scored blank; providing a predetermined length of a layfiat tubing; applying one or more patches of adhesive on parts of the blank adapted to form at least a first of opposing first and second sides of the carton when erected; either adhering one side of the length of layflat tubing to one or more of said patches of adhesive on at least that part of the blank adapted to form said first side of the carton; and applying one or more further patches of adhesive on parts of the blank adapted to form at least the second of said opposite sides of the carton when erected; or vice versa; folding over a part of the blank adapted to form the second side of the carton to oppose said first side and adhering said second side either directly or indirectly to an opposite side of the layflat tubing; and securing edges of the blank together to form a folded carton.

When such a folded carton is erected, the fact that opposite sides of the layfiat tubing are adhered directly or indirectly to the opposing first and second sides of the carton means that the tube opens out and forms a lining to the carton. The automatic opening out of the lining is advantageous to the packer using the carton as it saves time when goods are packaged within it.

In some embodiments it also means that the erected carton can become a plastics-lined, liquid-tight bottle or cup.

Preferably, the layfiat tubing is comprised of a plastics material.

Preferably also, the layflat tubing is seamless.

Preferably also, the layfiat tubing is gusseted with folds or pleats along opposing, closed longitudinal sides of the tube.

In some embodiments, the folding carton preferably defines a cuboid when erected and is provided with one or more hinged. first flaps at one end for use in opening and closing the carton.

Preferably also, an open end of the layflat tubing is secured to an interior side of one of the first flaps.

Preferably also, said open end of the layfiat tubing is secured to the interior side of one of the first flaps by one or more patches of adhesive that define outer edges angled with respect to one another such that they taper towards the edge of said first flap.

Preferably also, third and fourth sides of the blank located between said opposing first and second sides are creased and/or scored with centrally located longitudinal folds to enable the second side of the blank to lie directly opposed to said first side when it is folded over.

Preferably also, the blank defines a window and the layflat tubing is secured to the blank by adhesive applied around the edges of the window.

In other embodiments, the second side of the carton opposite to said first side is adhered directly to said one side of the layflat tubing and when the part of the blank defining the other side is folded over the layflat tubing is also folded into two parts, the method comprising the additional step of applying one or more additional patches of adhesive to said opposite side of the layflat tubing in order that when it is folded over the adjacent opposite sides of the tubing adhere to one another thereby indirectly adhering said second side of the carton to an opposite side of the layflat tubing. When the layflat tubing is impervious such an arrangement enables the carton to form a liquid-tight cup or similar container.

Preferably also, an open end of the layflat tubing secured to the first side of the carton is prevented from opening by one or more second flaps that are adhered to the opposite side of the layflat tubing over at least part of its open end.

Preferred additional features of the invention are described in the dependent daims appended hereto.

The present invention will now be described by way of example with reference to the accompanying drawings, in which:-Fig. I is a plan view of a blank for use in the manufacture of a first embodiment of folding carton in accordance with the present invention; Fig. 2 is a perspective view of a carton erected from the blank shown in Fig. 1; Fig. 3 is a perspective view from one open end of a carton similar to that shown in Fig. 2; Fig. 4 is a plan view of a second embodiment of blank for use in the manufacture of a first embodiment of folding carton in accordance with the present invention; Fig. 5 is a plan view of another blank for use in the manufacture of a third embodiment of folding carton in accordance with the present invention; and Fig. 6 is perspective view of an erected carton manufactured from the blank shown in Fig. 5.

A first embodiment of a folding carton I in accordance with the invention is shown erected in Figs. 2 and 3. Such a folding carton comprises a lined carton and is suitable for packaging moist and high-fat products such as foodstuffs and the like. Another embodiment of folding carton 25 in accordance with the invention is shown erected in Fig. 6. Dependent on the lining used, such a carton may form a liquid-tight container and has been designed specifically as an inexpensive, disposable specimen cup or bottle for use in healthcare establishments such as hospitals and surgeries. However, it will be appreciated that with suitable minor modifications, if necessary, both embodiments of carton may have widespread uses in many different fields. It will also be appreciated that many different shapes of blanks maybe used in the method of the present invention to provide many different shapes of erected cartons and containers.

The cartons shown in Figs. 2, 3 and 6 are erected from the blanks 2 and 26 shown in Figs. I and 5 respectively. A cuboid carton similar but not identical to that shown in Figs. 2 and 3 may be manufactured from the blank 2A shown in Fig. 4, which is similar to that shown in Fig. 1 but with minor modifications. The blanks 2, 2A, and 26 may be made of any suitable material but it is expected that in most cases they will be made of paperboard as this is inexpensive. As the cartons in all cases are lined, there is no requirement that the blanks be made from a more expensive food-grade material or a waxed or coated board.

Blanks 2 and 2Aas shown in Figs. land 4 respectively and the method of manufacturing folding cuboid cartons therefrom will now be described in more detail.

The blanks 2, 2A each have a conventional overall shape for erection into a cuboid carton and have each been cut and creased and/or scored along the dashed lines in Figs. I and 4 to define a first side 3, a second side 4 that will lie directly opposite opposing the first side 3 in the erected carton, and third and fourth sides 5 and 6 respectively that are located between and adjoin the first and second sides 3 and 4 on opposite sides of the erected carton. In addition, in the blank 2 a first pairs of flaps 7 are formed at the ends of the first side 3 whereas in the blank 2A the flaps 7 are formed at the ends of the second side 3 and a second pair of flaps S are formed at the ends of the first side 3. The flaps 8 are provided with a projecting tab 9 that in the erected carton I may be pushed through slots 10 cut in opposite ends of the second side 4. Alternatively, the tabs 9 can be omitted so that the flaps 8 are simply tucked thside the erected carton to lie adjacent the outer flaps 7, in which case the slots 10 need not be cut. It will be appreciated that in modified arrangements, the flaps 8, with or without the tabs 9 may be provided adjoining the second side 4 and the flaps 7 may be provided adjoining the first side 3. In a further modification, the flaps 8 may be omitted altogether. The flaps 7 may then adjoin the second side 4 or the first side 3 as shown in Fig. I. Two pairs of flaps 11 are also provided at opposite ends of the third and fourth sides 5 and 6 respectively along with a long flap i2 which runs the full length of the free edge of the second side 4. The pairs of flaps 7,8 and 11 are for use in opening and closing the erected carton 1.

The sides 3 and 4 are also cut to define windows 13 and 14 respectively so that in the erected carton the contents can be viewed without the need to open it. This is advantageous in embodiments wherein edges 15 of the flaps 7 are stuck down to an outer face of the carton I to seal it. the other flaps 8 and 11 being folded in beneath the flaps 7. In embodiments similar to that shown in Fig. 1, the edges 15 of the flaps 7 may be simply tucked into the carton to seal it when it is erected. In all cases the windows 13 and 14 can be made any desired size and shape and do not have to be identical.

Also included in a carton according to the invention is a length of layflat tubing 16 that forms a lining for the carton. It is expected that in most embodiments the tubing 16 will be layflat. plastics tubing, which is conventionally made from transparent or translucent polyethylene at thicknesses up to 1000 gauge. It is typically supplied in a roll and a predetermined length of the tubing 16 is cut off for each carton dependent on the size of the latter. Preferably, the tubing 16 is seamless and may be gusseted, which means that it is folded inwards or pleated along both opposing, closed longitudinal sides of the tube. This means that the tubing 16 will open out and fit snugly against the interior sides of the carton when it is erected. In some embodiments, instead of being impervious the tubing 16 may be made of a perforated plastics material so that it is breathable. In other embodiments it may be fabricated from a flexible, grease-proof material, such as grease-proof paper or the like.

The method of manufacturing folding cartons in accordance with the invention from the blanks 2 and 2Awill now be described.

First, the blank 2, 2A should be produced as shown in Figs. land 4 by conventional means. The dashed lines show the position of folds for use in the assembly of the carton. Unlike most conventional blanks for the production of a cuboid carton 1, the sides 5 and 6 and adjoining flaps 11 are each creased and/or scored with a fold line 17 that runs longitudinally down the centre of each side 5, 6 and the flaps 11. The reason for these additional fold lines 17 is described below.

After production of the blank 2, 2A at least its face that will form the interior sides of the carton has patches of adhesive ISA, l8B, 19 applied to it.

Conveniently, the adhesive is applied in two separate operations, first to one, 3. of the two opposing sides 3 and 4 of the blank 2, 2Aprior to application to the other side 4. Between these two operations, the length of layfiat tubing 16 may be adhered to the side 3. This enables adhesive to also be applied to the upper side of the tubing 16 also, if required. However, it may be convenient in some embodiments to apply the adhesive to opposing sides of a Hank in a single operation prior to adhering the layflat tubing to the blank.

In the present example, two separate operations are used. The patches ISA and I, which are applied on the side 3, are preferably applied by stencilling a water-based adhesive to the blank 2, 2A in a known manner whereas the patches 18B, which are applied on the opposite side 4, are preferably applied using a gluing head. Stencilling permits the adhesive patches to be applied in long elongate patches whereas use of a glue head enables the adhesive to be appfied both in discrete patches and in a smeared strip. as required.

The patches 19 are located on the flap 7 or 8 adjoining the side 3. The patch or patches on the flap 12 may be applied on the interior face of the blank 2, 2A if the flap 12 is to be adhered to the outside of the carton but if it is preferred that the flap 12 sit inside the erected carton then the patch or patches of adhesive should be applied on the opposite exterior face of the blank 2. 2A further patches of adhesive may also be applied to the edges 15 of theflaps7.

On the sides 3 and 4, the patches 18A and 18B are applied adjacent the longitudinal edges of the sides adjacent the folds between them and the adjoining sides 5 and 6 and the flap 12. They are also provided, if necessary, around the edges of the windows 13 and 14. On the flap 7 or 8 the patches 19 are applied with outer edges 20 that are angled with respect to one another and that taper towards the outer edges of the flap 7 or 8. This is best achieved by stencilling two tapering strips 19 of adhesive as shown in Figs. I and 4. In the embodiment shown in Fig. 1, the edges 15 of the flaps 8 may also be provided with patches of adhesive 18B that are then covered by release paper so that they can be adhered to the outside of the face 3 when the carton has been erected and filled.

After application of the adhesive patches 18A, 19 to the side 3 of the blank 2, 2A, one side of the length of layflat tubing 16 is adhered to the side 3 and by means of the patches 18A, 19. The position of the tubing 16 is indicated by the dot-dash rectangles in Figs. land 4. The length of the tubing 16 is the same total length of the side 3 and its flaps 7 or 8 not including the folding edges 15 or the tabs 9.

After the tubing 16 has been adhered, then the patches of adhesive ISB may be applied to the other side 4 and to its adjoining flaps, namely flaps? and 12 in the case of Fig. 1. If the flap 12 is to adhere to the outside of the carton, the edge of the blank defined by the free haff of the side 6 maybe folded over along the fold 17 to lie directly above the other half of the side 6.

Otherwise, the blank 2 is first folded along the fold line 17 that lies between the first and second sides 3 and 4. This brings the side 4 into direct alignment with the side 3. The adhesive patches 1SB on the side 4 and it adjoining flaps 8 then adhere to the opposite side of the tubing 16 so that the tubing is secured to both inner sides 3 and 4 of the blank. If the flap 12 is to adhere to sit inside the carton, the edge of the blank defined by the free half of the side 6 is then folded over along the fold 17 to lie directly above the other half of the side 6 and above the flap 12, which having an adhesive patch or patches on its exterior face will thereby be secured to the side 6.

Alternatively, the adhesive patch or patches on the flap 12 is adhered to the outer face of the free half of the side 6. Securing the edges comprising the flap 12 and the free half of the side 6 together forms a tubular folded carton ready for filling.

In this state, the folded carton may be supplied to a third party for filling. When subsequently erected into a rectangular tube, the gussets in the layflat tubing 16 open out and line the sides 5 and 6 of the blanks 2, 2A. The whole interior of the carton is therefore lined by the tubing 16. After erection into a rectangular tube, the carton may be filled and the end flaps 7, 8 and 11 folded in to close it. The flaps II are first folded into the carton over its ends.

If provided, the flaps 8 are then folded in and the tabs 9 slotted through the slits 10. The flaps 7 are then secured either by being adhered via their edges to an exterior face 3 or 4 of the erected carton or by simply being tucked into the end of the carton.

The tapering adhesive patches 19 on the flaps 8 facilitate the folding in of the tubing 16 when the carton is closed as they are adhered to the tubing and automatically fold the tubing in over itself in a neat way so that it does not project from any unsealed edges of the closed flaps 7, 8.

The method of manufacturing the third embodiment of folding carton shown in Fig. 6 will now be described. As indicated above, this carton 25 forms a liquid-tight container and is generally in the form of a pillar pack.

While the particular embodiment has been designed with the intention it will form an inexpensive and disposaMe specimen container for use in healthcare, it will be apparent to a person skilled in the art that many -j_o -different forms ofcontainer in accordance with the present invention maybe produced by appropriate changes to the shape of the blank used.

In the present embodiment the blank 26 for the carton 25 comprises a first flap 27 that will form one side of the carton 25 that is bordered on its longitudinal sides by two pairs of flaps 28, 29 that are formed from a single flap that is transversely cut along line 30a. Along the bottom edge of the flap 27 is a second flap 31 which forms a side of the carton 25 opposite to the side formed by the flap 27. The flap 31 is joined to the flap 27 by a central bridging section 32 which is creased and/or scored with arced folds 33 where it adjoins the flaps 27 and 31. In use, this region forms a push-up' section that is used to erect the carton 25 from its folded state. The flap 27 is not otherwise joined to the flap 31, the lines 30b and 30c indicating cut lines between the flaps 27, 31. It will also be appreciated that the length of the flap 31 is no greater than the length of the flap 27 between the cut lines 30a and 30b.

Once the blank as shown in Fig. 5 has been cut and creased and/or scored, adhesive patches 34 are applied to it, typically by stencilling or by a glue head. The patches 34 are applied to the inner faces of flaps 27, 28, 29 and 31, typically in vertical strips as shown in Fig. 5. However, they could be applied in other discrete patches or patterns as appropriate. After application of the adhesive, one side of a predetermined length of layflat tubing 35 is adhered to the flaps 27 and 31. The ayflat tubing 35 is preferab'y identical to that described above and should be impervious but it need not be gusseted.

The position of the tubing 35 is again indicated by the dot-dash rectangle in Fig. 5. The length of the tubing 35 is such that its free end at the top of the blank is positioned between the cut lines 30 and a top edge 36 of the flap 27.

The other end free end of the tubing 35 is secured close to the bottom edge 37oftheflap3i.

After securement of the tubing 35 to the flaps 27 and 31, patches of adhesive are then also applied to the upper face of the tubing 35. These -11 -patches are located overlying the strips 34 and a patch or patches 38 maybe applied across the tubing 35 just below the level of the cut lines 30.

Thereafter, the flap 31 and the section of tubing 35 secured to it are folded over the flap 27 and the tubing 25 secured to the flap 27 along a fold line 39 bisecting the bridging section 32.

In view of the adhesive patches on the tubing 35, the folded tubing 35 adheres to itself and thereby indirectly adheres the flap 31 to the flap 27.

However, in view of the size of the flap 31 and the tubing adhered thereto, the tubing 35 attached to the flap 27 above the level of the cut lines 30 is not covered. The flaps 29 are then folded in over this portion of the tubing 35 and adhered thereto and the adjoining edge 36 of the flap 27 thereby closing this free end of the tubing 35. The flaps 28 are also folded in and secured to the outer side of the flap 31.

The carton 25 is now complete and in a folded condition. When it is desired to erect it, opposite sides of the carton should be squeezed along the fold lines between the flaps 27 and 28. At the same time the bridging section 32 which projects from the base of the carton 25 should be pushed upwards into the carton. The section 32 then adopted a second position within the carton 25 and forms a base for same that retains the carton 25 in an erected state in the form of a cup or container. As the two flaps 25 and 3i are squeezed apart, the tubing 35 secured to the flap 31 opens out and lines both sides of the carton 25, which forms a cup-like container. The tubing 35 attached to the flap 27 does not open out as it is retained by the flaps 29 and as it is secured to one side of the tubing also secured to the flap 31 assists in opening out the tubing secured to this latter flap 31. The carton is now ready for use. It will be appreciated that for use a specimen container, the flaps 29 are preferab'y enlarged in height to act as a sp'ash guard.

Hence, the invention provides an inexpensive way of providing lined folding cartons for a variety of uses including packaging and liquid -12 -containers. Erection of the cartons when required is also easy to accomplish manually.

Claims

-j_3 -CLAIMS1. A method of manufacturing a lined folding carton comprising the following steps: providing a cut and creased and/or scored blank; providing a predetermined length of a layflat tubing; applying one or more patches of adhesive on parts of the blank adapted to form at least a first of opposing first and second sides of the carton when erected; either adhering one side of the length of layflat tubing to one or more of said patches of adhesive on at least that part of the blanlc adapted to form said first side of the carton; and applying one or more further patches of adhesive on parts of the blank adapted to form at least the second of said opposite sides of the carton when erected; or vice versa; folding over a part of the blank adapted to form the second side of the carton to oppose to said first side and adhering said second side either directly or indirectly to an opposite side of the laytlat tubing; and securing edges of the blank together to form a folded carton.
2. A method as daimed in Claim 1, wherein the layflat tubing is comprised of a plastics material.
3. A method as claimed in Claim I or Claim 2, wherein the layflat tubing is seamless.
4. A method as claimed in any of Claims Ito 3, wherein the layflat tubing is gusseted with folds or pleats along opposing, closed longitudinal sides of the tube.

-j_4 -
5. A method as claimed in any of Claims I to 4, wherein the folding carton defines a cuboid when erected and is provided with one or more hinged, first flaps at one end for use in opening and closing the carton.
6. A method as daimed in Claim 5, wherein an open end of the layflat tubing is secured to an interior side of at least one of the first flaps.
7. A method as claimed in Claim 6, wherein said open end of the layflat tubing is secured to the interior side of one of the first flaps by one or more patches of adhesive that define outer edges angled with respect to one another such that they taper towards the edge of said first flap.
8. A method as claimed in any ofClaims Ito 7, wherein third and fourth sides of the blank located between said opposing first and second sides are creased and/or scored with centrally located longitudinal folds to enable the second side of the blank to lie directly opposed to said first side when it is folded over.
9. A method as claimed in any of Claims 1 to 8, wherein the blank defines a window and the byfiat tubing is secured to the blank by adhesive applied around the edges of the window.
10. A method as claimed in any of Claims Ito 4, wherein the second side of the carton opposite to said first side is adhered directly to said one side of the layflat tubing and when the part of the blank defining the second side is folded over the ayflat tubing is also folded into two parts.
11. A method as claimed in Claim 10. comprising the additional step of applying one or more additional patches of adhesive to said opposite side of the layflat tubing in order that when it is folded over the adjacent opposite sides of the tubing adhere to one another thereby -i_s -indirectly adhering said second side of the carton to the opposite side of the layflat tubing.
12. A method as claimed in any of Claims 9 to 11. wherein an open end of the layflat tubing secured to the first side of the carton is prevented from opening by one or more second flaps that are adhered to the opposite side of the layflat tubing over at least part of its open end.
13. A lined folding carton manufactured according to the method as claimed in any of Claims ito 12.
14. A method of manufacturing a lined folding carton substantially as described herein with reference to any of Figs. Ito 3, Fig. 4 or Figs 5 and 6 of the accompanying drawings.
15. A lined folding carton substantially as described herein with reference to any of Figs. ito 3, Fig. 4 or Figs 5 and 6 of the accompanying drawings.