WO2004063027A2

WO2004063027A2 - Tray container and blank

Info

Publication number: WO2004063027A2
Application number: PCT/US2004/000479
Authority: WO
Inventors: Philippe Lebras
Original assignee: Meadwestvaco Packaging Systems, Llc
Priority date: 2003-01-09
Filing date: 2004-01-09
Publication date: 2004-07-29
Also published as: EP1594747A4; WO2004063027A3; GB0300438D0; EP1594747A2

Abstract

A carton and blank for forming a carton for holding one or more articles, for example foodstuff or the like, comprises a base panel (14), a pair of side panels (16, 18) and end wall panels (24, 28) hingedly connected to opposing edges of the base panel, and a corner arrangement (32a-d) hingedly connected to at least one of the side wall panels. The corner arrangement comprises a web panel (38a-d) and a securing panel (42a-d) extending from the web panel. The web panel is hingedly connected to an end edge of the one side wall panel and the securing panel is hingedly connected to the web panel. The securing panel in the set up carton is positioned intermediate the web panel and the end wall panel.

Description

TRAY CONTAINER AND BLANK

Background of the Invention

The present invention relates to a carton or tray for accommodating one or more articles, for example foodstuff or the like, formed from a blank of paperboard or other suitable foldable sheet material, and more particularly to an open top carton incorporating a comer arrangement for retaining liquid dispelled from the foodstuff.

Tray structures formed from board generally lack strength when compared to trays formed from plastics material so more commonly trays are formed from polystyrene or other plastics material and the foodstuff is protected by a plastics film.

It is known from WO93/15962 to provide a fluid tight packaging tray formed from cardboard comprising a single base panel surrounded by side and end wall structures connected by an enclosure arrangement to maintain a food tight seal and to prevent liquid from rising by capillarity.

Another example is illustrated in GB 1 237 895, which shows a box formed from a blank with a comer gusset arrangement to impart liquid-proofhess to the box body. However, such arrangements involve complex folding operations, which limits the carton construction speeds.

US 4 747 487 to Wood discloses an end loaded carton having an end closure structure comprising triangular comer panels hingedly connected with the lower edge of each side wall and a pair of closure panels hingedly connected to each comer panel and to a bottom end panel via a web panel.

Other examples of carton are to be found in US 5 253 802, GB 920 831, EPO 178 730 and GB 2237796. Such trays are commonly of a unitary size, which can cause the product to move within the tray, which is undesirable as it can lead to degradation of the tray and an unsightly appearance. Furthermore, trays often have a large "foot print" in relation to the size of article to be packaged. Therefore space is often wasted during storage and delivery of the tray.

The present invention and its preferred embodiments seek to overcome or at least mitigate the problems of the prior art.

Summary of the Invention

According to a first aspect of the invention there is provided a carton for holding one or more articles, for example foodstuff or the like, comprising a base panel, a pair of side wall panels and end wall panels hingedly connected to opposing edges of the base panel, a comer arrangement hingedly connected to at least one of the side wall panels which comer arrangement consists of a web panel and a securing panel extending therefrom. The web panel is hingedly connected to an end edge of the respective side wall panel and the securing panel is hingedly connected to the web panel and secured to the adjacent end wall panel.

Preferably, the or each side wall panel is constructed and arranged so as to be automatically erected inwardly and upwardly from a flat collapsed condition into a position of use by upwardly folding the opposed end wall panels.

According to an optional feature of this aspect of the invention, an upper edge of the one side wall panel may be hingedly connected to a retention panel. At least one of the opposite ends of the retention panel abuts the web panel of the adjacent comer arrangement.

According to another optional feature of this aspect of the invention, the end wall panels may be free of fold lines or cut lines apart from a fold line separating the respective end wall panel from the base panel. According to a second aspect of the invention there is provided a blank for forming a carton for holding one or more articles, for example foodstuff or the like, comprising a base panel, having first and second end and side wall panels hingedly connected thereto along opposed side and end edges thereof. The blank further comprises a comer arrangement hingedly connected to at least one of the side wall panels which comer arrangement consists of a web panel and a securing panel extending therefrom. The web panel is hingedly connected to an end edge of the respective side wall panel and the securing panel is hingedly connected to the web panel. This enables the securing panel to be placed intermediate the web panel and the adjacent end wall panel when the blank is erected to form a carton.

Preferably, the or each side wall panels are so constructed and arranged to be automatically erected from a flat collapsed condition into a position of use by upwardly folding the opposed end wall panels.

According to an optional feature of this aspect of the invention, an edge of the one side wall panel opposite to the base panel may be hingedly connected to a retention panel. At least one of the opposite ends of the retention panel retention panel abuts an end of the web panel of the adjacent comer arrangement.

According to another optional feature of this aspect of the invention, the end wall panels may be free of fold lines or cut lines apart from a fold line separating the respective end wall panel from the base panel.

According to an embodiment of this invention, there is provided a package comprising a carton and an article contained therein.

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 carton or tray according to a preferred embodiment of the invention;

FIGURES 2, 3 and 4 sequentially depict construction of a tray from the Figure 1 blank;

FIGURE 5 is a perspective view of the set-up tray formed from the blank of Figure 1 ;

FIGURES 6, 7 and 8 illustrate blanks according to second, third and fourth embodiments of the invention; and

FIGURES 9, 10 and 11 illustrate the blanks of Figures 6, 7 and 8 respectively in a set up condition.

Detailed Description of the Preferred Embodiments

Referring to the drawings and in particular Figure 1, there is illustrated a unitary blank for forming a collapsible tray (or carton) made from a blank of paperboard or similar foldable sheet material and adapted to hold foodstuff or the like. In the illustrated embodiment, the blank 10 for forming the tray comprises a base panel 14, and a first side wall panel 16 hingedly connected to a longitudinal edge of base panel 14 along linear fold line 20. A second side wall panel 18 is hingedly connected to the opposing longitudinal edge of base panel 14 along linear fold line 22. The blank further comprises opposed end wall panels 24 and 28 hingedly connected to the opposed transverse edges of base panel 14 along opposed linear fold lines 26 and 30 respectively.

A comer arrangement 32 (a to d) is provided for securing together each end and adjacent side wall panels of the tray. Optionally, each comer arrangement is adapted to retain liquid from the foodstuff.

Turning in detail to the comer arrangements 32a, 32b, 32c, 32d, each of the four comer arrangements is substantially identical and like reference numerals have been used to illustrate the features of each comer arrangement therefore only comer arrangement 32a is now described in greater detail.

The comer arrangement 32a consists of a web structure hingedly connected to the side panel 16 at one end thereof. In preferred embodiments, the web structure consists of a web panel

38a and a securing panel 42a hingedly connected to the web panel 38a along fold line 44a.

The generally triangular web panel 38a is connected to side wall panel 16 along fold line 40a.

Preferably, the web panel 38a is shaped according to the desired shape of the recess for receiving the article. Thus, in this embodiment, fold lines 40a and 44a diverge from the point of intersection of fold lines 20 and 30 whereby the web panel 38a is of substantially triangular form.

This arrangement can provide a flatter pack, when the carton is in a flat collapsed condition.

Preferably, fold line 40a is in an acute angular relationship with longitudinal fold line 20 so that during constmction, web panel 38a is folded inwardly to come into face contacting relationship in a flat condition with first side wall panel 16 and, optionally, part of the base panel 14.

In order to improve article retention within the tray, there further comprises an integrally formed retention panel 54 hingedly connected to one of the panels forming the side of the tray. Preferably, the retention panel 54 is hinged to the side wall panel 16 along linear fold line 58.

There further comprises a second retention panel 56 hingedly connected to the opposed side wall panel 18 along linear fold line 60. The opposed ends of the retention panels 54, 56 are separated from the adjacent web panels 38a, 38d and 38b, 38c by cut lines 37.

In the embodiment illustrated in Figure 1, the fold lines 40a and 40d and corresponding fold lines 40b and 40c terminate at fold lines 58 and 60, to define respective ends of the side wall panels 16 and 18. The construction of the tray from the blank 10 illustrated in Figure 1 and through Figures 2, 3 and 4 requires a series of sequential folding and gluing operations, which can be performed either manually or in a straight line machine so that the carton 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.

The compartments of the set up tray, shown in Figure 5 may be constructed with or without the use of glue. In the present embodiment, a method using glue is shown.

It will be seen from Figure 5 that the tray is formed with one or more compartments provided by inwardly sloping end wall panels 24, 28, outwardly sloping side wall panels 16, 18 and a pair of inwardly sloping retention panels 54, 56. The end wall structures are formed by folding each comer arrangement 32 as illustrated in Figures 2 and 3. The first step is for the retention panels 54, 56 to be folded inwardly whereupon web panels 38a, 38b, 38c, 38d are folded inwardly along fold lines 40a, 40b, 40c, 40d. The web panels 38 are thus placed in face contacting arrangement with the adjacent side wall panel 16 or 18 and in overlapping arrangement with the adjacent retention panel 54 or 56. The securing panels 42 are placed overlying a part of the base panel 14, similarly in face contacting relationship. Each web panel may remain in simple contacting or abutting relationship with the adjacent retention panel without being secured thereto. However, glue may optionally be applied to the web panels 38 to allow each web panel to be secured to the adjacent retention panel.

The inward folding action of the web panels 38 causes securing panels 42a, 42b, 42c, 42d to be folded therewith so as to overlie parts of the base wall panel 14 but not the end wall panels 28 and 24 respectively as depicted in Figure 3. End wall panels 24 and 28 are then folded inwardly as shown in Figure 4.

Portions of the end wall panels 24, 28 are, in this embodiment, secured to the securing panels 42 by glue. This folding action preferably causes part of fold line 20 to approximately overlie fold line 44. End wall panels 24 and 28 are thus inwardly folded about fold lines 26, 30 so that the tray is in a substantially flat collapsed condition as shown in Figure 4. The tray is ready to be supplied to a user to be loaded with the article(s) or foodstuffs.

In order to erect the tray from a flat collapsed condition in Figure 4, the end wall panels 24, 28 are folded outwardly and upwardly along fold lines 26 and 30 respectively. This folding action causes the retention panels 54, 56 to be automatically erected from the flat collapsed condition whereby the side wall panels 16, 18 are folded upwardly and inwardly about fold lines 20 and 22 respectively and retention panels 54, 56 become outwardly and upwardly folded about fold lines 58, 60 as shown in figure 5. The article is inserted into the tray and stretch film can thereafter be applied to the tray to close the open top and to thereby seal the package. An advantage of the tray is that the comer arrangements can be leak proof and a simple folding arrangement is provided to reduce "folding process" time.

Figure 5 illustrates the tray in an erected condition ready to receive one or more articles. The shape of the end wall structures provides compartments at each end of the tray to receive and retain part of the article contained in it. The tray is prevented from collapsing by the abutment of the end wall panels 24 and 28 against the article. Furthermore, the tray may be adapted so that the end wall panels 24, 28 and base panel 14 provide a "pincer" arrangement to receive and retain the article thereby to reduce article movement within the tray.

The blank depicted in Figure 6 represents a minor variation from the Figure 1 blank described above. The component parts generally correspond with those of the Figure 1 embodiment and the same reference numerals have been deployed save for the additional prefix thereto of the numeral 1. The Figure 6 blank can be folded, and glued if required, to form a set up tray for articles as depicted in Figure 9, using the same sequence of folding steps as described above with reference to Figures 2 to 4. As the components generally correspond, it will not be described further other than to observe the curvilinear, non-rectangular periphery of the end wall panels 124 and 128 and the curved fold lines separating the web panels 138a to 138d from the securing panels 142a to 142d of the blank 110. Similarly the blank 210 depicted in Figure 7 corresponds generally with the Figure 1 blank described above, and the same reference numerals are used save for the additional prefix numeral 2. The Figure 7 blank embodiment can be folded in similar sequence to the forms shown in Figures 2 to 4, to create a set up tray for articles as shown in Figure 10.

Similarly the blank 310 depicted in Figure 8 also corresponds generally with the Figure 1 blank, and the same reference numerals are used save for the additional prefix numeral 3. The Figure 8 blank embodiment can be folded in similar sequence to the forms shown in Figures 2 to 4, to create a set up tray for articles as shown in Figure 11. It is however of note in the Figure 8 blank that all four retention panels 342a to 342d are rectangular form, all web panels 338a to 338d are triangular form, and the cut lines (337) mostly defining the ends of the retention panels 354 and 356 extend over one complete side of the web panels and over part of the support panels 342a to 342d.

It is also of note in all embodiments depicted that the end wall panels 24, 124, 224, 324 and 28, 128, 228, 328 are free of cut lines or fold lines within their surfaces other than the fold lines which separate these panels from the base panel 14, 114, 214, 314 to which they are hingedly connected. This reduces complexity and formation time of the blanks as well as facilitating their assembly.

Beneficially, the tray described above 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.

It will be recognised that as used herein directional reference such as "top", "base", "end", "side", "inner", "outer", "transverse" and "longitudinal" 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 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 carton 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(s) minimises the amount of paperboard required for the carton. The items can be placed into the carton by hand or automatic machinery.

It is anticipated that the invention can be applied to a variety of carton or tray types and not limited to those of a tray like structure. For example, the end closure arrangement attached to, say the top or base panels, could be applied to cartons in the beverage field without departing from the scope of invention, where it is required to automatically construct end (or side) wall panels.

The end wall structure could be applied to wraparound or end closure type cartons: the end panels would be foldably connected to a base or top panel and the glue flap secured to the adjacent side panel. Thus, the wraparound carton could be supplied in a flat collapsed form, which would not look dissimilar to the end part of the tray shown in Figure 5. To erect the end wall structure, the side walls would be folded inwardly, by known means, to automatically erect the end wall structure. The carton would then be applied to an array of articles, for example bottles by suitable means and the carton base panels secured together to form a wraparound carrier. Of course, this would result in a further reduction in folding time for forming the carton.

Claims

1. A carton for holding one or more articles, comprising a base panel, a pair of side wall panels hingedly connected to opposing side edges of said base panel, a pair of end wall panels hingedly connected to opposing end edges of said base panel, and a comer arrangement hingedly connected to at least one of said side wall panels, said comer arrangement comprising a web panel and a securing panel extending from said web panel, said web panel being hingedly connected to an end edge of said one side wall panel, said securing panel being hingedly connected to said web panel and being secured to an adjacent one of said end wall panels.

2. A carton as claimed in claim 1 wherein said side wall panels are constructed and arranged so as to be automatically erected inwardly and upwardly from a flat collapsed condition into a position of use by upwardly folding the opposed end wall panels.

3. A carton as claimed in claim 1 wherein an upper edge of said one side wall panel is hingedly connected to a retention panel, at least one of opposed ends of said retention panel abutting said web panel of said comer arrangement.

4. A carton as claimed in claim 1 wherein each of said end wall panels is free of fold lines or cut lines apart from a fold line separating said each end wall panel from said base panel.

5. A blank for forming a carton for holding one or more articles, comprising a base panel, having a pair of first and second end wall panels hingedly connected to said base wall panel along opposed end edges thereof and a pair of first and second side wall panels hingedly connected to said base wall panel along opposed side edges thereof, said blank further comprising a corner arrangement hingedly connected to at least one of said side wall panels, said comer arrangement comprising a web panel and a securing panel extending from, said web panel, said web panel being hingedly connected to an end edge of said one side wall panel, said securing panel being hingedly connected to said web panel, said securing panel being placed intermediate the web panel and an adjacent one of said end wall panels when the blank is erected to form a carton.

6. A blank as claimed in claim 5 wherein an edge of said one side wall panel is hingedly connected to a retention panel, at least one of opposed ends of said retention panel abutting an end of said web panel of said comer arrangement.

7. A blank as claimed in claim 5 wherein each of said end wall panels is free of fold lines or cut lines apart from a fold line separating said each end wall panel from said base panel.

8. A package comprising a carton as claimed in claim land an article contained therein.