WO2003059758A1

WO2003059758A1 - A carton and blank

Info

Publication number: WO2003059758A1
Application number: PCT/US2003/000918
Authority: WO
Inventors: Philippe Le Bras
Original assignee: Meadwestvaco Packaging Systems Llc
Priority date: 2002-01-11
Filing date: 2003-01-13
Publication date: 2003-07-24
Also published as: GB0200584D0; AU2003207532A1

Abstract

A carton and blank for forming a carton for holding foodstuff or the like which carton is formed from paperboard or like foldable sheet material, the carton comprising a plurality of panels for forming a top (26), a base (12), opposed side (14, 28; 16, 22) and end walls (44a, 44b). One or more of the end walls comprises an end panel (46b) hinged to the top (26) and a support panel (50b) hinged to the end panel (46b) and adapted to be placed in overlapping arrangement with an outer part of the base (12). There further comprises an engaging panel (86b) hinged to one of the base or side walls and adapted to be placed in overlapping arrangement with the support panel (50b) and secured thereto to maintain the end wall in a set up condition.

Description

A CARTON AND BLANK

Background of the Invention

The present invention relates to a carton (or tray) for accommodating foodstuff, for example fish or meat, and more particularly to a carton formed from one or more blanks of paperboard or other suitable foldable sheet material.

Tray structures for meat are commonly formed from plastics material, for example polystyrene. One alternative approach is to use paperboard or the like foldable sheet material, but the construction of such trays can be complex and require several folding actions.

In particular, the construction of an end wall structure is complex, particularly when it is required to use glue to secure such walls together.

Summary of the Invention

The present invention and its preferred embodiments seek to overcome or at least mitigate the problems of the prior art, by providing a carton with an end wall structure that is not required to be glued.

According to the first aspect of this invention there is provided a carton for holding foodstuff or the like. The carton is formed from paperboard or like foldable sheet material and comprises a plurality of panels for forming a top, a base, opposed side and end walls. One or more of the end walls comprises an end panel hinged to the top and a support panel hinged to the end panel and adapted to be placed in overlapping arrangement with an outer part of the base. There further comprises an engaging panel hinged to one of the base or side walls and adapted to be placed in overlapping arrangement with the support panel and secured thereto to maintain the end wall in a set up condition. Optionally, there further comprises a gusset structure to connect the end wall to the opposed side walls. Preferably, the gusset structure comprises a first web panel hinged to the side wall panel, and a second web panel hingedly connected to the end wall panel and adapted to be folded inwardly so that the first web panel is placed in face contacting arrangement with the side wall panels thereby to maintain the end wall in a substantially perpendicular arrangement with respect to one of the top wall, base wall.

More preferably, the gusset structure further comprises a web panel hingedly connected to the second web panel and to the support panel, to be folded inwardly to maintain the support panel in overlapping relationship with the base.

According to an optional feature of this aspect of the invention, there is provided a carton wherein the engaging panel is secured to the end wall by securing means.

The securing means may be provided by one or more tabs protruding outwardly of the engaging panel. The or each tab may be adapted to be engaged by an aperture formed in the end wall panel.

According to another optional feature of this aspect of the invention, the engaging panel extends outwardly so as to be placed in face contacting arrangement with the web panel in order to maintain the web structure in a set up condition.

A second aspect of this invention provides a blank for holding foodstuff or the like which blank is formed f om paperboard or like foldable sheet material and comprises a plurality of panels for forming a top, a base, opposed side and end walls. One or more of the end walls comprises an end panel hinged to the top and a support panel hinged to the end panel. There further comprises an engaging panel hinged to one of the base or side walls and adapted to be placed in overlapping arrangement with the support panel and secured thereto to maintain the end wall in a set up condition. Preferably, there further comprises a gusset structure to connect the end wall to the opposed side walls.

More preferably, the gusset structure comprises a first web panel hinged to one of the side walls, and a second web panel hingedly connected to the end wall panel, and a third web panel hingedly connected to the second web panel and to said support panel.

According to an optional feature of this aspect of the invention, the engaging panel may be secured to the end wall by securing means. Preferably, the securing means is provided by one or more tabs protruding outwardly of said engaging panel, the or each said tab is adapted to be engaged in an aperture formed in said end wall panel.

Brief Description of the Drawings

Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIGURE 1 illustrates a blank for forming a tray according to a first embodiment of the invention;

FIGURES 2, 3, 4 and 5 illustrate the construction of the tray from the blank of Figure 1 ; and

FIGURE 6 illustrates the tray in a set-up condition formed from the blank shown in Figure 1.

Detailed Description of the Preferred Embodiments

Referring first to Figure 1 there is shown a blank 10 for forming a collapsible tray or carton made from one or more blanks of paperboard or similar foldable sheet material. The blank 10 is unitary and comprises a plurality of panels for forming a top, a base, opposed side and end walls. In this embodiment there comprises a first lower side wall panel 14, base panel 12, and second lower side wall panel 16 hingedly connected together in series along foldlines 18, 20 respectively. There further comprises an upper side wall structure 21 hingedly connected to side wall panel 16 respectively along fold line 24.

Turning to the construction of the upper side wall structure 21, there comprises a first upper side wall panel 22, top panel 26, a second upper side wall panel 28 hingedly connected onto the next along fold lines 32 and 34 respectively.

There further comprises securing means for securing the ends of the blank together which, in this embodiment, is provided by a securing flap 30 hingedly connected to second upper side wall panel 28 along fold line 36.

In one class of embodiments, the top panel 26 is provided with a display window W and at least part of the top panel 26 is split into two parts 38 and 40, hingedly connected together along fold line 42, which serves to provide a degree of flexibility in the top panel. There further comprises opposing end wall structures 44a, 44b, which are hingedly connected to the opposing ends of base panel 12 and top panel 26. The construction of each end structure 44a,

44b is identical and like references have been used with the addition of the letter "a": and "b".

Therefore, only end structure 44a is described in more detail. The end structure 44a comprises an end panel 46a hingedly connected to top panel 26 along fold line 48.

There further comprises a support panel 50a hingedly connected to end panel 46 along fold line 52a. The support panel 50a is adapted to be placed in contact with base panel 12 in a set up condition. Preferably, there further comprises retaining means to retain an end panel engaging flap 86a which flap is hingedly connected to base panel 12 along fold line 88a. In this embodiment the retaining means comprises one or more protruding part(s) 87a which is adapted to be inserted into corresponding aperture(s) A. In this embodiment the or each aperture A is formed by flaps defined in support panel 50a and cut lines 54a, 56a, which extend inwardly of fold line 52a. Preferably fold line 52a is terminated at each end by perpendicular cut lines 58a and 60a respectively, which also serve to define part of the aperture A. T U 03/00918

In one class of embodiments, each end wall structure 44a, 44b further comprises a gusset arrangement along each side of the end panel 46a arranged to maintain the end panel 46a and, preferably, the support panel 50a in a set up arrangement, which in this embodiment is in a perpendicular relationship. The gusset arrangement on one side comprises a first web panel 62a hingedly connected to second upper side wall panel 28 along fold line 64a. There may further comprise second and, preferably, third gusset panels 66a and 77a hingedly connected to first web panel 62a along fold line 68a and to end support panels 46a, and 50a along an extension of fold line 34. In one class of embodiments fold line 70a bisects panels 72a and 66a.

The gusset arrangement on the opposing side comprises a first web panel 74a hingedly connected to first upper side wall panel 22 along fold line 76a. There may further comprise second and third gusset panels 78a and 84a hingedly connected to first web panel 74a along fold line 80a and to end and support panel 46a, 50a along an extension of fold line 32. In one class of embodiments fold line 82a bisects panels 78a and 84a.

In one class of embodiments there further comprises a plurality of flaps 90, 92 for supporting the lower side wall panels 14 and 16 in a set up arrangement, which are, in some embodiments, hingedly connected to engaging flap 86a.

Although there are shown a unitary blank for the tray, it is envisaged that a two part blank could be used without departing from the scope of invention.

The construction of the tray is described by reference to Figures 2, 3, 4 and 5. It is envisaged that the construction and loading of the tray of the present invention can be formed by a series of sequential folding and gluing operations which can be performed in one or more straight line machines, so that the tray is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and can be altered according to particular manufacturing requirements. P T/US03/00918

- 6 -

The tray T (Figure 6) is constructed by forming a tubular structure whereby the securing flap 30 is secured to the first lower side wall panel 14, as illustrated in Figure 2. The top panel 26 and upper side wall panels 22 and 28 are folded about fold lines 24, 32, and 34 and the lower structure along fold lines 18 and 20 so that panels 14 and 30 are placed in overlapping arrangement and secured thereto by glue, G (shown in cross hatch), or other suitable means known in the art.

Thus, the tray T is in a tubular form as shown in Figure 3 to be supplied to the user so one or more articles can be inserted into it. In some embodiments, the tray is supplied in a flat form.

Once loaded with articles, the end structures 44a, 44b are formed, as shown in Figures 4 and 5. Each end wall structure 44a, 44b is constructed in like manner and therefore only one end 44b will be described in any detail.

In the illustrated embodiment, end wall panel 46b is first folded inwardly along fold line 48b, which causes the gusset structures to be folded inwardly, as shown in Figure 4. The first, second and third web panels 74b, 78b, 84b, are folded inwardly along fold lines 76b, 80b, 82b, and 32 respectively, so that web panel 74b is placed in face contacting relationship with upper side wall panel 22. In some embodiments, second web panel 78b is placed in overlapping arrangement with end wall panel 46b and third web panel 84b is placed in face contacting relationship with lower side wall 16 to provide a rigid support structure. At the same time, support flap 50b is folded out of alignment with end panel 46b along fold line 52b to reveal the apertures Al and A2 formed from cut lines 56b, 54b.

The opposing gusset structure is formed at the same time and in like manner so shall not be described in any greater detail. The tray is at an intermediate stage of construction as shown in Figure 5.

Finally, the engaging flap 86b is folded inwardly in direction W to be placed in overlapping arrangement with support flap 50b and is secured thereto by engaging the protruding elements

87b into the apertures Al, A2 formed in the end panel 46b. In those embodiments with flaps 90, the flaps are folded over the third web panels to maintain the web structure in a set up condition.

The end structure is in a set up and secured position and provides a rigid support structure to protect the articles contained therein.

Thus, the tray T is in a set up condition ready to display the article through the display window D, as shown in Figure 6.

It is envisaged that the end wall structure can be erected automatically by employing configurations other than those described above, without departing from the scope of invention. For example, the or each support structure could be provided by the end panels.

Beneficially, the two ply embodiment hereinbefore described provides a structure that is strengthened to retain foodstuff. The use of paperboard material provides an "environmentally friendly" alternative to trays formed from plastics material and the tray can include printed matter for marketing purposes, as the board can be recycled. The arrangement of the panels for the tray in the embodiment described above allows printed matter to be placed on the internal and external side and end walls of the tray.

In some embodiments, the tray portion and cover can be formed from a two part blank. One advantage of the arrangement described above is that the material used for the tray and cover can differ. For example a different caliper of paper can be used, or the insert could be a food grade material, whilst the cover could be a material that is more suited to the application of printed matter.

It will be recognised that as used herein, directional references such as "top", "base", "end", and

"side" do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another . Any reference to hinged connection should not be construed as necessarily referring to a single fold line only: indeed it is envisaged that hinged connection can be formed from one or more of one of the following, a score line, a frangible line or a fold line, without departing from the scope of invention.

The present invention and its preferred embodiment relates to a tray which is shaped to provide satisfactory rigidity to hold items such as meat or fish securely but with a degree of flexibility. The shape of the blank minimises the amount of paperboard required for the carton. The items can be applied to the carrier by hand or automatic machinery. It is anticipated the invention can be applied to a variety of carton or tray types and not limited to those of the flat tubular sort, for example a wraparound type carton or fully enclosed carton or a clip, without departing from the scope of invention.

Claims

1. A carton for holding foodstuff or the like which carton is formed from paperboard or like foldable sheet material, the carton comprising a plurality of panels for forming a top, a base, opposed side and end walls wherein one or more of the end walls comprises an end panel hinged to the top and a support panel hinged to the end panel and adapted to be placed in overlapping arrangement with an outer part of the base, there further comprising an engaging panel hinged to one of the base or side walls and adapted to be placed in overlapping arrangement with the support panel and secured thereto to maintain the end wall in a set up condition.

2. A carton as claimed in claim 1 wherein there further comprises a gusset structure to connect the end wall to the opposed side walls.

3. The carton as claimed in claim 2 wherein said gusset structure comprises a first web panel hinged to one of said side walls, and a second web panel hingedly connected to said end wall panel, which first and second web panels are adapted to be folded inwardly so that said first web panel is placed in face contacting arrangement with one of said side walls thereby to maintain the end wall in a substantially perpendicular arrangement with respect to one of the top walls or base walls.

4. A carton as claimed in claim 3 wherein said gusset structure further comprises a third web panel hingedly connected to said second web panel and to said support panel, to be folded inwardly to maintain said support panel in overlapping arrangement with said base.

5. A carton as claimed in claim 4 wherein the engaging panel extends outwardly so as to be placed in face contacting arrangement with the said third web panel in order to maintain the web structure in a set up condition.

6. A carton as claimed in any one of the preceding claims wherein said engaging panel is secured to the end wall by securing means.

7. A carton as claimed in claim 6 wherein said securing means is provided by one or more tabs protruding outwardly of said engaging panel, the or each said tab is adapted to be engaged in an aperture formed in said end wall panel.

8. A blank for holding foodstuff or the like which blank is formed from paperboard or like foldable sheet material and comprises a plurality of panels for forming a top, a base, opposed side and end walls wherein one or more of the end walls comprises an end panel hinged to the top and a support panel hinged to the end panel, there further comprising an engaging panel hinged to one of the base or side walls and adapted to be placed in overlapping arrangement with the support panel and secured thereto to maintain the end wall in a set up condition.

9. A blank as claimed in claim 8 wherein there further comprises a gusset structure to connect the end wall to the opposed side walls.

10. The blank as claimed in claim 9 wherein said gusset structure comprises a first web panel hinged to one of said side walls, and a second web panel hingedly connected to said end wall panel and comprises a third web panel hingedly connected to said second web panel and to said support panel.

14. A blank as claimed in any of claims 8 to 10 wherein said engaging panel is secured to the end wall by one or more tabs protruding outwardly of said engaging panel, the or each said tab is adapted to be engaged in an aperture formed in said end wall panel.

15. A package comprising one or more articles and a carton as claimed in any of claims 1 to 7.