IE980349A1 - A carton blank and a carton - Google Patents

Abstract

A carton blank (1) comprising a lid panel (4) for forming into a lid (53), a base panel (3) and an insert panel (2) for forming into an insert (55) insertable in the base (54), the base panel (3) being disposed between the lid panel (4) and the insert panel (2) and the lid panel (4), the base panel (3) and the insert panel (2) being contiguous.

Description

This invention relates to a carton blank and a carton and more particularly to a carton blank and a carton having an integral insert.

The use of separate inserts in combination with packaging cartons is known. More particularly, separate inserts are typically used in cartons to house or support the contents of the carton in the insert. The insert therefore secures the contents within the carton and prevents the contents from being displaced and potentially damaged in the carton. Generally, such inserts are moulded from plastics materials, and the dimensions of the insert are tailored to match the dimensions of the contents of the carton.

Accordingly, when the dimensions and/or volume of the contents of the carton are adjusted, the insert must be varied accordingly. Moreover, where the insert is manufactured from a plastics material such as Polyethylene Terephthalate (PET), fresh moulds for manufacturing the inserts must be made which can give rise to delays and increase the cost of the packaging.

* As· an alternative to using specially moulded plastics IBIT Cl ’w 5d sfcc> BNSDOCID: inserts, the contents of a packaging carton are generally simply wrapped with plastics bubble wrap and the like where no suitable plastics inserts are available. Nevertheless, even where wrapping is used, the contents of a carton may still be displaced within the carton thereby causing damage to the contents. Moreover, the use of plastics inserts and wrappings in packaging is environmentally undesirable.

In known packaging cartons, it is frequently necessary 10 to assemble the carton using glue or other fixing devices to secure the various components of the carton together. However, the use of glue in the manufacture of cartons from carton blank clearly increases the complexity of the assembly of the carton from the carton blank thereby further increasing the cost of the packaging.

Particular difficulties are experienced with the use of inserts where the insert is intended to contain one or more objects - any of which may vary from time to time according to marketing and manufacturing requirements and the contents it is desired to house in the package.

For example, in the computer industry, objects such as computer hardware and software including printed BNSDOCID: circuit boards, compact discs, instruction manuals and cables are packed within a carton generally using an insert. However, according to the nature of the computer software and hardware being packaged, the dimensions of any of the contents of the package may be varied such that preformed plastics inserts can rapidly become obsolete.

An object of the invention is to overcome the problems of the prior art.

A further object of the invention is to provide a carton and a carton blank having an integral insert.

According to the invention there is provided a carton blank comprising a lid panel for forming into a lid, a base panel for forming into a base and an insert panel for forming into an insertable in the base, the base panel being disposed between the lid panel and the insert panel and the lid panel, the base panel and the insert panel being contiguous.

Preferably, the blank comprises a fold line transverse to the longitudinal axis defined by the carton blank between the lid panel and base panel and a second fold line parallel to the first fold line between the insert panel and the base panel such that the lid BNSDOC1D: panel and the insert panel are pivotable about the first and second fold lines. More preferably, the base panel comprises laterally extending flaps for forming into side walls.

Advantageously, the laterally extending flaps comprise a fold line disposed parallel to the longitudinal axis defined by the carton blank such that the laterally flaps are foldable to form the side walls.

Preferably, the laterally extending flaps are 10 connected to the base panel at fold lines disposed parallel to the longitudinal axis defined by the carton blank.

Suitably, the blank comprises a secondary top panel disposed between the base panel and the lid panel and a secondary bottom panel disposed between the base panel and the insert panel the secondary top and bottom panels being defined by transverse elongate fold lines disposed between the lid panel and the base panel and the insert panel and the base panel respectively.

Preferably, the insert panel comprises receiving means for receiving the contents of a carton.

Advantageously, the receiving means comprises a BNSDQCID: recess.

Suitably, the recess is defined by cut lines in the insert.

Preferably/ the recess is defined by fold lines in the 5 insert.

Advantageously, the insert panel is pivotable about the transverse fold line disposed between the insert panel and the base panel towards the base panel. More preferably, the insert panel comprises laterally extending security flaps.

Suitably, the security flaps are foldable over the insert panel. Advantageously, the security flaps are foldable to define a blind end to prevent access to the insert panel.

Preferably, the lid panel comprises a flap locatable adjacent the base panel.

Suitably, the flap comprises closing means engagable with the base panel.

Preferably, the closing means comprises a tab 20 insertable in a complimentary slot in the panel base BNSDOCID: panel.

Advantageously, the flap comprises laterally engaging flaps engagable with the base.

Preferably, the carton blank of the invention is adhesive free.

The invention also extends to a carton comprising a lid, a base and an insert in the base characterised in that the lid, the base and the insert comprise an integral single unit. Preferably, the carton is adhesive free. More preferably, a storage chamber is defined between the insert and the base.

Preferably, the insert comprises security flaps for preventing access to the insert, and more preferably, the security flaps comprise a blind end.

An embodiment of the invention will now be described having regard to the accompanying drawings, in which: Fig. 1 is a plan of view from above of the bottom face of a carton blank in accordance with the invention with printed matter on the bottom face; Fig. 2 is a perspective view from above of the BNSDOCID: top face of the carton blank of Fig. 1 partially assembled; Fig. 3 is a perspective view from above of the partially assembled carton of Fig. 2 with the insert inserted in the base of the carton; Fig. 4 is a perspective view from above of the carton of Fig. 3 with a compact disc and a printed circuit board mounted in the recess of the insert; Fig. 5 is a perspective view from above of the carton of Fig. 4 with the dust/security flaps folded over the printed circuit board and the compact disc in the recess; Fig. 6 is a perspective view from above of the carton of Fig. 5 with the top panel of the carton closed; Fig. 7 is a transverse cross sectional view along the line VII-VII of Fig. 6, and Fig. 8 is a longitudinal cross sectional view > along the line VIII-VIII of Fig. 6.

BNSDOCID: As shown in the drawings, a carton blank 1 in accordance with the invention is generally rectangular in shape and made up of a bottom primary insert panel 2, a primary centre panel 3 and a primary top panel 4, the primary bottom insert panel 2 and the primary centre panel 3 being separated by an elongate separating wall 5 defined by parallel elongate folds 7, 8 disposed transverse to the longitudinal axis of the blank 1.

The primary centre panel 3 and the primary top panel 4 are also separated by an elongate separating wall 6 defined by elongate fold lines 9, 10.

Following assembly of the carton blank 1, the primary insert panel 2 defines an insert 55, the primary centre panel 3 a base 54 and the primary top panel 4 a lid 53 as shall be explained more fully below.

The blank 1 of the invention is provided with a top face 11 and a bottom face 12. The top face 11 is adapted to receive printed matter 56. The printed matter 56 can be distributed throughout the top face 11 or on portions of the top face 11 as required.

The bottom primary insert panel 2 is made· up of a central primary wall 13 having an elongate fold line BNSDOCID; disposed transverse to the longitudinal axis of the blank 1 at its end remote from the primary centre panel 3 to define an end flap 15 at its free end. The end flap 15 extends the length of the primary wall 13 of the primary insert panel 2.

The primary wall 13 is cut to define an internal recess 16 made up of a first recess portion 17 and a second recess portion 18. The first recess portion 17 and the second recess portion 18 are formed from scored lines 57 and cut lines 58. The first recess portion 17 and the second recess portion 18 are adapted to receive at least some of the contents of the carton of the invention as shall be explained more fully below. A cut line 19 in the primary wall 13 of the insert panel 2 defines a notch 20 in the primary wall 13 at the recess portion 17.

The insert panel 2 is further provided with two laterally extending security/dust flaps (hereinafter referred to as security flaps) 21, 22 which extend laterally outwards from each side of the primary wall 13. The first and second dust flaps 21, 22 are rectangular in shape, having a longitudinal axis extending transverse to the longitudinal axis of the carton blank 1, and are separated from the primary wall 13 by intermediate walls 23, 24 respectively BNSDOCID: ίο disposed parallel to the longitudinal axis of the blank 1 either side of the primary wall 13. The intermediate wall 23 is defined by spaced apart elongate fold lines 25, 26 disposed parallel to the longitudinal axis of the blank 1 while the intermediate wall 24 is defined by spaced apart longitudinal fold lines 27, 28 also disposed parallel to the longitudinal axis of the blank 1.

The security flaps 21, 22 are each provided with 10 centrally located double fold lines 29, 30 respectively. The double fold lines 29, 30 also extend parallel to the longitudinal axis defined by the blank 1 and sub divide each security flap 21, 22 into first and second sub flaps 31, 32 and first and second sub flaps 33, 34 respectively. The double fold lines 29, 30 therefore facilitate the folding over of the second sub flaps 32, 34 onto the first sub-flaps 31, 33 respectively to cover and protect the recess 16 in the assembled carton.

The primary centre panel 3 is made up of a central wall 35 having dimensions slightly greater than the dimensions of the primary centre wall 13 of the insert panel 2 so that the insert panel 2 can be accommodated against the centre wall 35 (which forms the base 54 of the assembled carton) of the centre panel 3 as shall BNSDOCID: be explained more fully below.

The centre wall 35 of the primary centre panel 3 is provided with two laterally extending side panels 36, 37 adapted to form the side walls 59, 60 of the base 54 of the carton of the invention. More particularly, each side panel 36, 37 is provided with a centrally located elongate double fold line 38 extending parallel to the longitudinal axis defined by the carton blank 1. The double fold lines 38 therefore facilitate folding over of the side panels 36, 37 to define the side walls 59, 60 of the carton 1.

The side panels 36, 37 of the primary centre panel 3 are shaped to define upper tabs 39, 40 and lower tabs 41, 42 at each end of the side panels 36, 37. More particularly, the upper tabs 39, 40 extend laterally outwards either side of the separating wall 6 disposed between the primary centre panel 3 and the primary top panel 4 while the lower tabs 41, 42 extend laterally outwards either side of the separating wall 5 disposed between the primary bottom insert panel 2 and the primary centre panel 3.

Two fold lines 43, 44 are disposed parallel to the respective double fold lines. 38 of the side panels 36, 37 and extend parallel to the longitudinal axis BNSDOCID: defined by the blank 1 so that the side panels 36, 37 may be folded about the axis defined by the double fold lines 38 and disposed in an upright disposition with respect to the centre wall 35 or base 54 about the fold lines 43, 44 to define the side walls 59, 60 of the assembled carton. More particularly, the side panels 36, 37 are first folded about the double fold lines 38 and the upper tabs 39, 40 and the lower tabs 41, 42 are located between the fold lines 43, 44 and their respective double fold lines 38 so that the upper tabs 39, 40 and the lower tabs 41, 42 are sandwiched effectively between and secured by the side panels 36, 37.

The primary top panel 4 is provided with a top wall 45 substantially equivalent in dimensions to the centre wall 35 of the primary centre panel 3. At its end remote from the primary centre panel 3, the top wall 45 is provided with a top panel 47 extending transverse to the longitudinal axis defined by the blank 1 and being defined by a transverse fold line 48. The top panel 47 is further provided with laterally extending corner tabs 49, 50 at each end of the panel 47. The cover tabs 49, 50 are insertable in the sandwich side walls 59, 60 defined by the side panels 36, 37 to close the carton of the invention as shall be explained more fully below.

BNSDOCID·.

At its outer edge, the top panel 47 is provided with an outwardly extending centrally located closing tab 51. The closing tab 51 is foldable about a fold line 61 defined between the closing tab 51 and the top panel 47 insertable in a corresponding slot 52 defined in the fold line 8 between the primary insert panel 2 and the primary centre panel 3 to close the carton.

Figs. 2 to 6 show perspective views of the blank 1 in various stages of assembly through to a completely assembled carton as shown in Fig. 6 while Figs. 7 and 8 show cross sectional views through the assembled carton of Fig. 6 along the lines VII-VII and VIIIVIII respectively.

As shown in the drawings, in order to assemble the blank 1 into a finished carton, the blank 1 is placed on a flat surface with the top face 11 facing upwards. The printed matter 56 is usually applied to the bottom face 12 of the carton blank 1 before assembly. The carton blank 1 is laid on a flat surface with the top face 11 facing upwards and the bottom face 12 with the printed matter 56 facing downwards. As shown in Fig. 2, the primary centre panel 3 is first formed into the base 54 by raising the primary insert bottom panel 2 and the primary top panel 4 about the fold lines 8, 9 such that the separating walls 5, 6 define the bottom BNSDQCID: and top walls 62, 63 respectively of the base 54.

The upper tabs 39, 40 and the lower tabs 41, 42 of the side panels 36, 37 are then folded about the fold lines 43, 44 so that the upper tabs 39, 40 are disposed towards their respective bottom tabs 41, 42 along the longitudinal axis defined by the fold lines 43, 44 respectively. The side panels 36, 37 are then folded about the double fold lines 38 over the top tabs 39, 40 so that the tabs 39, 40, 41, 42 are gripped by the side panels 36, 37.

The side panels 36, 37 are dimensioned such that the side walls 59, 60 formed from the side panels 36, 37 are secured by frictional engagement of the tabs 39, 40, 41, 42 and the folded side panels 36, 37 with the centre wall 35 of the primary centre panel 3.

Accordingly, the side panels 36, 37 define the side walls 59, 60 of the base 54 while the separating walls 5, 6 define the bottom wall 62 and top wall 63 respectively of the base 54.

The primary insert panel 2 is then pivoted about the fold line 7 at the separating wall 6 and the end flap 15 pivoted about the fold line 14 .towards the base 54 so that the primary insert panel 2 is inserted in the BNSDOCID: base 54 to define the insert 55 in the base 54.

The end flap 15 is therefore disposed parallel to and adjacent the top wall 63 of the base 54.

As shown in Fig. 3, the printed matter 56 on the 5 bottom face 12 of the carton blank 1 is therefore disposed upwards in the carton as shown in Figs. 3, 4 and 5.

The carton shown in Fig. 3 with the insert 55 inserted in the base 54 is therefore ready to receive items to be contained within the carton of the invention as desired. For example, as shown in Fig. 4, a printed circuit board 64 is inserted in the recess portion 17 while a compact disc 65 is inserted in the recessed portion 18. The printed circuit board 64 and the compact disc 65 are held within their respective recessed portions 17, 18 by the cut line 58 defining the recess 16 together with the fold lines 57 also defining the shape of the recess 16. In the manufacture of the carton blank 1, the cut lines 58 and the fold lines 57 may be varied in shape and construction such that recessed portions 17, 18 of differing dimensions and shapes may be produced in accordance with the dimensions and shapes of the items it is desired to place in the insert 55.

BNSDOCID; le As shown in Fig. 8, a storage chamber 66 is defined beneath the insert 55 between the insert 55 and the centre wall 35 of the base 54. The storage chamber 66 can be exploited to place other items it is desired to contain within the carton of the invention beneath the insert 55; For example, as shown in Fig. 8, a cable 67 may be stored beneath the insert 55 adjacent the printed circuit board 64.

As shown in the drawings, the end flap 15 together 10 with the bottom wall 62 support the insert 55 above the centre wall 35 of the base 54.

Following locating of the items such as the printed circuit board 64 and the compact disc 65 in the insert 55, the security flaps 21, 22 are folded over the printed circuit board 64 and the compact disc 65 as shown in Fig. 5. The printed matter 56 on the second sub flaps 32, 34 is therefore disposed upwards towards the lid 53 so that upon opening of the carton 1 the printed matter 56 on the sub flaps 32, 34 is immediately visible. The lid 53 is then pivoted about the fold line 10 towards the base 54 to close the carton.

. The carton of the invention is closed by inserting the closing tab 51 into the slot 52 and simultaneously by BNSDOCID: inserting the corner tabs 49, 50 of the top panel 47 on the lid 53 into respective flap slots 67, 68 defined between the base side walls 60, 59 and the bottom tabs 42, 41.

The lid 53 is therefore secured over the base 64 to close the carton of the invention without the use of glue or other fixing devices.

As shown in Fig. 8, the lid 53 abuts the top surface of the base side walls 59, 60. However, access to the contents of the carton by inserting a hand or other object between the lid 53 and the side walls 59, 60 is prevented by the security flaps 22, 21 respectively. More particularly, the arrangement of the sub flaps 31, 32, 33 and 34 due to the folding of the security flaps 22, 21 about the double fold lines 30, 29 prevents access to the contents of the carton by directing hands etc. inserted between the lid 53 and the side walls 59, 60 into the security flaps 22, 21.

The assembled carton as shown in Fig. 6 is therefore secure and fully assembled without the aid of adhesives etc. More particularly, the insert 55 is an integral unit within the carton and can be modified as required by varying the cut lines 58 and fold lines 57 to receive items of varying dimensions and shapes.

BNSDOCID: Moreover, printed matter 56 can be placed on multiple surfaces of the carton to present information and other material to a user. For example, the printed matter 56 may be disposed throughout the outer surfaces visible to a user and also on the security flaps 21, 22 and indeed the insert 55 as required.

An important advantage of the carton blank 1 of the invention is that printed matter may be applied to one side e.g. the top face 11 or the bottom face 12 of the sheet of flute material to be formed into the carton blank and the carton blank 1 when assembled will display the printed matter 56 in the desired locations.

In addition, the primary insert panel 2 when inserted 15 into the primary centre panel 3 facilities the holding of the base side walls 59, 60 in a secure fashion without the use of adhesives and tabs or the like. Moreover, the absence of tabs and the like enhances the aesthetic appearance of the carton of the invention.

The carton blank and carton of the invention may be manufactured from any suitable material. Typically, the carton blank 1 and the carton of the invention will be manufactured from a corrugated or flute type BNSDOCID: card material. In the process of manufacture of the carton blanks and cartons, such a sheet of flute type material (for example F flute, B flute, C flute or the like) is first covered with printed matter in the form of a pre printed sheet on a laminator such as a Grassi (Trade Mark) semi-automatic laminator. The printed sheet is adhered to the flute by applying a water based adhesive to the top surface of the flutes as will be appreciated by those skilled in the art. The printed sheet is then allowed to cure on the adhesive. The sheet of material is then placed on a die cutter such as a fully automatic Simon (Trade Mark) die cutter to cut the carton blank 1 of the invention from the sheet. The cut carton blank 1 may then be assembled when and as required.

Claims (15)

1. A carton blank comprising a lid panel for forming into a lid, a base panel for forming into a base and an insert panel for forming into an insert insertable

2. A carton blank as claimed in Claim 1 characterised in that the blank comprises a fold line

3. A carton blank as claimed in Claim 1 or Claim 2 characterised in that the base panel comprises laterally extending flaps for forming into side walls.

4. A carton blank as claimed in Claim 3 20 characterised in that the laterally extending flaps comprise a fold line disposed parallel to the longitudinal axis defined by the carton blank such that the laterally flaps are foldable to form the side walls. BNSDOCID: 5. Engagable with the base panel. 17. A carton blank as claimed in Claim 16 characterised in that the closing means comprises a tab insertable in a complimentary slot in the base panel. 5 lines in the insert. 5 carton blank.

5. A carton blank as claimed in Claim 4 characterised in that the laterally extending flaps are connected to the base panel at fold lines disposed parallel to the longitudinal axis defined by the 5 in the base, the base panel being disposed between the lid panel ; and the insert panel and the lid panel, the base panel and the insert panel being contiguous.

6. A carton blank as claimed in Claim 5 characterised in that the blank comprises a secondary top panel for forming into a top wall disposed between the base panel and the lid panel and a secondary

7. A carton blank as claimed in any of Claims 1 to 6 characterised in that the insert panel comprises receiving means for receiving the contents of a carton. 20

8. A carton blank as claimed in Claim 7 characterised in that the receiving means comprises a recess. • V

9. A carton blank as claimed in Claim 8 BNSDOCID: characterised in that the recess is defined by cut lines in the insert. 10. 18. A carton blank as claimed in any of Claims 15 to 17 characterised in that the flap comprises laterally engaging flaps engagable with the base. 19. A carton blank as claimed in any of Claims 1 to 18 characterised in that it is adhesive free. 15 20. A carton comprising a lid, a base and an insert in the base characterised in that the lid, the base and the insert are formed from an integral single unit. 21. A carton as claimed in Claim 20 characterised in 20 that it is adhesive free. BNSDOCID: 22. A carton as claimed in Claim 20 or Claim 21 characterised in that a storage chamber is defined between the insert and the base. 23. A carton as claimed in any of Claims 20 to 22 5 characterised in that the insert comprises security flaps for preventing access to the insert. 24. A carton as claimed in Claim 23 characterised in that the security flaps comprise a blind end. 25. A carton blank substantially as hereinbefore 10 described with reference to and/or as shown in the accompanying drawings. 26. A carton substantially as hereinbefore described with reference to and/or as shown in the accompanying drawings. 10 panel. 10 characterised in that the insert panel is pivotable about the transverse fold line disposed between the insert panel and the base panel towards the base

10. A carton blank as claimed in Claim 8 or Claim 9 characterised in that the recess is defined by fold 10 bottom panel for forming into a bottom wall disposed between the base panel and the insert panel the secondary top and bottom panels being defined by transverse elongate fold lines disposed between the lid panel and the base panel and the insert panel and 15 the base panel respectively. 10 transverse to the longitudinal axis defined by the carton blank between the lid panel and base panel and a second fold line parallel to the first fold line between the insert panel and the base panel such that the lid panel and the insert panel are pivotable about 15 the first and second fold lines. 11. Characterised in that the insert panel comprises laterally extending security flaps.

11. A carton blank as claimed in any of Claims 1 to

12. A carton blank as claimed in any of Claims 1 to

13. A carton blank as claimed in Claim 12 15 characterised In that the security flaps are foldable over the insert panel. 14. Characterised in that the lid panel comprises a flap locatable adjacent the base panel. 16. A carton blank as claimed in Claim 15 characterised in that the flap comprises closing means

14. A carton blank as claimed in Claim 13 characterised in that the security flaps are foldable to define a blind end to prevent access to the insert 20 panel. 15. A carton blank as claimed in any of Claims 1 to BNSDQCID:

15. 27. A carton whenever formed from a carton blank as claimed in any of Claims 1 to 25.