WO2005113368A1

WO2005113368A1 - Carton blank

Info

Publication number: WO2005113368A1
Application number: PCT/US2005/017845
Authority: WO
Inventors: Tamio Ikeda
Original assignee: Meadwestvaco Packaging Systems Llc
Priority date: 2004-05-19
Filing date: 2005-05-19
Publication date: 2005-12-01
Also published as: CN101001793A; JP2005329967A; JP4365268B2; CN101001793B

Abstract

A carton blank includes panels (2, 4, 8A, 8B) arranged in a row along the length of the blank. Each panel is formed along either of its opposed free end edges with a cutout (10) so that the blank is provided along either of its opposed longitudinal edges with tabs (11) each interposed between adjacent cutouts. At least one of the tabs comprises an end retention structure (13) and is disposed astride a panel fold line (3) a long which two adjacent panels (2, 4) are connected. The at least one tab comprises an anchoring portion (15) connected to one (4) of the two adjacent panels along an anchor fold line (14), a gusset portion (16) connected to the anchoring portion, and a web portion (17) onnected to the gusset portion. The anchor fold line (14) emanates substantially from the panel fold line (3) and extends obliquely away from the gusset portion into the one adjacent panel (4) such that the anchor fold line defines an acute angle with respect to the panel fold line.

Description

CARTON BLANK

Background of the Invention

The present invention relates to a carton blank, and particularly to a carton blank for forming a tubular carton for packaging a plurality of articles.

Tubular or sleeve-shaped cartons for multiple articles are known in the art. Such cartons are used to bind a plurality of articles such as bottles, cans, brick or the like for the purpose of storage, transport and/or display of the articles.

Figure 4 shows conventional carton blanks 41 arranged in a mutually nested condition. As shown in Figure 4, each carton blank 41 has a plurality of panels including a top panel 42, a pair of side wall panels 43 and a bottom panel 44. The panels hingedly connected one to the next to form a series of connected panels so that each panel may be folded with respect to the adjacent panel(s) along the respective fold line(s) 45, 46. Each blank is designed to form a tubular carton having opposed open end.

Cutouts 48 are formed along each of the opposed longitudinal edges of each blank so that each panel is formed with a cutout 48 along each end edge thereof. As a result, each blank 41 is provided with a plurality of tabs 49 along either longitudinal edge of the blank at the position between the two adjacent cutouts 48. Each cutout 48 is dimensioned such that the depth of the cutout is less than 10% of the width or maximum transverse size of the carton blank 41.

The tabs 49 have an identical size and configuration and are complementary to those intermediate cutouts 48 each being sandwiched by the adjacent tabs 49. The intermediate cutouts 48 have an identical size and configuration while the end cutouts are of a size and configuration different from that of the intermediate cutouts.

The carton blanks 41 are formed from cardboard or another foldable sheet material. In Figure 4, the blanks 41 are placed in a mutually nested position where the tabs 49 of one of the blanks 41 along one of its longitudinal edges snugly fit in the adjacent cutouts 48 of the other blank 41 respectively. Because carton blanks 41 can be arranged in such a nested position, the blank 41 requires minimum amount of paperboard, which makes it possible to achieve material savings (see Japanese Patent Laid-Open Publication Number 2003-034354).

However, even the above-discussed blank uses redundant material which is not necessarily essential to accommodate all the articles if the blank is to package articles each having, for example, a cylindrical configuration,

What is needed accordingly is a carton blank that would enable further material savings.

Such a blank is desirable in view of environmental protection as well as to achieve a low cost. The blank should also be able to securely retain the packaged articles when erected into a carton such that the articles are well prevented from being dislodged and falling out from the carton through the open ends.

Summary of the Invention

The present invention provides an elongate blank for forming a tubular carton. The blank includes panels arranged in a row along the length of the blank. The panels are hingedly connected one to the next in series. Each panel has a pair of opposed free end edges disposed generally along the length of the blank. Each panel is formed along its either free end edge with a cutout so that the blank is provided along its either longitudinal edge with a plurality of tabs each interposed between the adjacent ones of the cutouts. The cutouts are dimensioned and configured such that the tabs have an identical size and configuration and are complementary to at least some of the cutouts. At least one of the tabs provides an end retention structure for preventing the contents of the carton from dislodging from the carton when the blank is erected into the carton. The at least one tab is disposed astride a panel fold line along which two adjacent ones of the panels are hingedly connected. The at least one tab includes an anchoring portion hingedly connected to one of the two adjacent panels along an anchor fold line to be folded into face contacting relationship with the one adjacent panel, a gusset portion hingedly connected to the anchoring portion, and a web portion hingedly connected to the gusset portion. The web portion is connected to the other of the two adjacent panels to be in a folded position for engagement with one of the contents of the carton. The anchor fold line emanates substantially from the panel fold line and extends obliquely away from the gusset portion into the one adjacent panel such that the anchor fold line defines an acute angle with respect to the panel fold line.

According to the carton blank of the invention, the ratio of the total surface area of the tabs to the surface area of the entire carton blank may be increased as compared to a conventional blank. Stated differently, the arrangement of the invention can increase the ratio of the total surface area of the cutouts to the surface area of the entire carton blank. The increased cutout area may be used to form the tabs of a second blank that is nested with the first blank (see Figure 3). This enables a more efficient use of the sheet material, which in turn enables further savings of the material.

According to the carton blank of the invention, a wider area of an end article may be covered by the gusset portion and the web portion. This allows the end article to be held safely, preventing the end article from being dislodged from the carton.

In a preferred embodiment of the invention, each of the at least some cutouts may have a depth along the panel fold line. The depth may be no less than 15% of the maximum width or transverse size of the carton blank. The depth may be further increased so that it is no less than 20%) of the maximum width or transverse size of the carton blank.

In another preferred embodiment, the gusset fold line connecting between the gusset portion and the anchoring portion may be disposed generally perpendicular to the panel fold line while the web fold line connecting between the web portion and the gusset portion may be disposed in general alignment with the panel fold line.

In a further embodiment of the invention, the at least one tab may further comprise a covering portion hingedly connected to the web portion along a cover fold line. Such a covering portion may be integrally formed with the other adj acent panel. The cover fold line may be in general alignment with the anchor fold line. In a still further embodiment, the cutouts may include two end cutouts and intermediate cutouts. The end cutouts may be formed in the two end ones (8A, 8B) of the panels located at the opposite ends of the blank respectively while the intermediate cutouts may be formed in the others of the panels. The intermediate cutouts may have an identical size and configuration to provide the aforementioned some cutouts.

In a still further embodiment, each of at least some tabs other than the at least one tab may be disposed astride a further panel fold line along which two neighboring ones of the panels are hingedly connected. A content-receiving aperture may be formed in one of the two neighboring panels adjacent to the further panel fold line. The content-receiving aperture may be disposed adjacent to each of the at least some tabs. The content-receiving aperture may even be formed at least in part in the each of the at least some tabs. The content- receiving aperture may extend into the other of the two neighboring panels so as to interrupt the further panel fold line.

Brief Description of the Drawings

Figure 1 is a plan view of a carton blank according to the present invention;

Figure 2 is a fragmentary perspective view of a carton formed from the blank of Figure 1, showing end, cans packaged in the carton;

Figure 3 is a plan view showing two blanks each identical to the blank of Figure 1, wherein the two blanks are arranged in a mutually nested relationship; and

Figure 4 is a plan view showing two conventional carton blanks that are arranged in a mutually nested position. Detailed Description of the Preferred Embodiment

Figure 1 illustrates a carton blank according to the present invention. While the carton blank is formed from cardboard or paperboard in this embodiment, it can be also formed from corrugated board, sheet plastic or any other foldable sheet material.

The carton blank is designed to package, for example, a group of similarly dimensioned, cylindrical articles each having a recess at the bottom. In this particular embodiment, the blank is dimensioned to accommodate six cans arranged in a 2 x 3 configuration. This carton blank includes a rectangular top panel 2 at the center of the blank. The top panel 2 is hingedly connected at its opposite side edges to side wall panels 4 and 4 along panel fold lines 3 and 3 respectively.

Each side wall panel 4 includes a beveled strip portion 5 that extends along the lower edge 7 of the panel 4. The beveled strip portion 5 is hingedly connected to the respective side wall panel 4 along a fold line 6 that is disposed parallel to the lower edge 7. When the blank is erected into a carton, the beveled strip portion 5 is disposed inclined at an angle with respect to the bottom of the carton. The side wall panels 4 and 4 are hingedly connected at their lower edges to bottom panels 8 A and 8b along panel fold lines 7 and 7 respectively. In an erected carton, the bottom panels 8 A and 8B are secured together to form the bottom of the carton. Stated differently, the top panel 2, the side wall panels 4 and 4 and the bottom panels 8A and 8B are arranged in a row and hingedly connected in series to form the elongate blank. The carton formed from this blank is tubular in shape and has openings at the opposite ends.

Cutouts 10 are formed in the blank along each of the longitudinal edges of the blank. More specifically, each of the top panel 2, side wall panels 4 and 4 and the bottom panels 8 A and 8B is provided at its end edges with a pair of cutouts 10 respectively. The formation of the cutouts 10, in turn, provides tabs 11 arranged along each longitudinal edge of the blank 1. Each tab 11 is sandwiched or interposed between the two adjacent cutouts 10 and 10 while it is disposed astride the respective panel fold line 3 or 7 along which the two adjacent panels are hingedly connected. The cutouts 10 are dimensioned and configured such that the tabs 11 have an identical size and configuration and are complementary to the intermediate cutouts 10 formed in the top and side wall panels 2, 4 and 4. The end cutouts in the bottom panels 8A and 8B have a size and configuration different from that of the intermediate cutouts. Each tab 11 is generally trapezoidal in shape and has a pair of side edges of the same length. The shorter end edge of the tab 11 defines the free distal end of the tab 11 while the longer end edge of the tab 11 defines the proximal end that is joined to the blank 1. The corners defined by the free distal end and the respective side edges of the tab 11 are rounded. In like manner, the complementary corners of each cutout 10 are also rounded.

The cutouts 10 are arranged so that each cutout 10 defines the respective side edges of the adjacent tabs 11 of an identical size and configuration. The depth "D" of each cutout 10 that is the size of each cutout measured along a panel fold line 3 or 7, preferably, is equal to or more than 15% of the maximum width "W" or transverse size of the blank measured along the panel fold line 3 or 7. The depth "D" may be even more than 20% of the maximum width "W" of the blank if desirable.

The four intermediate tabs 11 each disposed astride the respective panel fold line 3 are designed to provide end retention structures 13 respectively. Each end retention structure 13 is adapted to engage the adjacent article to retain it within the carton. Each end retention structure 13 includes an anchoring portions 15, a gusset portion 16, a web portion 17 and a covering portion 18. The anchoring portion 15 is triangular in shape and is hingedly connected to the respective side wall panel 4 along an anchor fold line 14. The gusset portion 16 is rectangular in shape and is hingedly connected to the gusset panel 15 along a gusset fold line 21. The web portion 17 is also triangular in shape and is hingedly connected the gusset panel 16 along a web fold line 20. The covering portion 18 is formed integrally with the top panel 2 and hingedly connected to the web portion 17 along a cover fold line 22.

The anchor fold line 14 is arranged in the position where it defines an acute angle θ (Figure 1) with the adjacent panel fold line 3. More specifically, the anchor fold line 14 emanates generally from the adjacent panel fold line 3 and extends obliquely into the respective side wall panel 4 away from the free distal end of the respective tab 11. In this particular embodiment, the anchor fold line 14 extends between the adjacent panel fold line 3 and the bottom of the adjacent cutout 10. In other words, the anchor fold lines 14 in each side wall panel 4 emanate generally from the respective panel fold line 3 and extend obliquely toward each other so that the angle θ becomes an acute angle. The web fold line 20 is disposed in general alignment with the adjacent panel fold line 3. Stated differently, the web fold line 20 is an extension of the adjacent panel fold line 3. The gusset fold line 21 is arranged such that it defines approximately a right angle with the web fold line 20 or with the adjacent panel fold line 3. Also, the cover fold line 22 is disposed in general alignment with the anchor fold line 14.

The blank of Figure 1 typically is erected into a carton while it is applied to a group of articles to package such a group. The blank is lowered to the group of articles to place the top panel 2 onto the group, and the side wall panels 4 and 4 are downwardly folded about the fold lines 3 and 3 to bring then into contact with the articles. The bottom panels 8 A and 8B are then folded toward each other about the fold lines 7 and 7 to bring themselves into an overlapping relationship. The folding of the beveled strip portions 5 and 5 about the fold lines 6 and 6 occurs naturally in response to the folding of the bottom panels 8 A and 8B toward each other. The overlapped bottom panels 8A and 8B are then secured together by conventional securing means such as glue or a mechanical locking arrangement. In this particular embodiment, a mechanical locking arrangement 32 and 36 is used to secure the bottom panels 8A and 8B as will be described later in more details. A completed carton is shown in Figure 2 wherein two end cans 39 and 39 are exposed to view through one of the open ends of the tubular carton and upper ends of the cans 39 and 39 are engaged by the respective end retention structures 13 formed from the respective tabs 11.

The tabs 11 are manipulated, typically by machine elements, into the end retention structures during the course of erecting a carton. More particularly, the formation or erection of the end retention structures 13 takes place simultaneously with the step of downward folding the side wall panels 4 and 4. To erect each end retention structure 13, the anchoring portion 15 is folded inwardly along the anchor fold line 14 into a face-contacting relationship with the inside surface of the adjacent side wall panel 4. At the same time, gusset portion 16 is folded outwardly about the gusset fold line 21 into a face-contacting relationship with the anchoring portion 15. This allows the gusset portion 16 to protrude outwardly from the end edge of the adjacent side wall panel 4 as best shown in Figure 2. After the anchoring and gusset portions 15 and 16 are properly folded into the respective positions, the downward folding of the adjacent side wall panel 14 is completed so that the anchoring portion 15 is tucked between the side wall panel 4 and the adjacent article 39. The folding of the side wall panel 14 also induces folding of the web portion 17 along fold lines 20 and 22, which brings the web panel into the folded position shown in Figure 2 wherein it is placed snugly on the tapered upper end portion of the adjacent article. As shown in Figure 2, the gusset portion 16 also placed near the tapered upper end portion of the same article 39 to assist the web portion 17 in retaining the article 39. The covering portion 18 is placed on the top of the article 39. In this manner, the anchoring portion 15, the gusset portion 16, the web portion 17 and the covering portion 18 cooperate with each other to retain the adjacent article 39 inside the carton 23.

A pair of finger tabs 26 is struck from the top panel 2 and hingedly connected to the top panel 2 along the respective fold lines 24 and 24. The finger tabs 26 and 26 define fmger apertures 25 and 25 in the top panel 2. The carton 23 may be easily lifted and carried by the finger apertures 25 and 25.

A pair of severance lines 27 and 27 are formed in the top panel 2. Each severance line 27 extends from one end edge of the top panel 2 to the other end edge. As a result, a removable panel is defined between the two severance lines 27 and 27 to facilitate opening of the carton 23. By grasping the removable panel near one end edge of the top wall 2 and pulling it upward and toward the other end edge, the removable panel can be detached from the carton 23 along the severance lines 27 and 27 to allow a use to access the packaged articles.

Content-retaining apertures 28 are formed in each side wall panel 4 to receive the respective lower end portions of the articles 39 contained in the carton 23. The content-receiving apertures 28 in each side wall panel 4 are arranged along the fold line 7 in such a manner that they interrupt the respective beveled strip portion 5. The content-retaining apertures 28 are formed such that each aperture 28 is formed at least in part in the respective beveled strip portion 5 and extend upwardly into the area of the respective side wall panel 4 above the respective fold line 6. As shown in Figure 1, at least one of the content-receiving apertures 28 may be formed in part in the adjacent one of the four end tabs 11 each being disposed astride the respective panel fold line 7. Each content-receiving aperture 28 may extend into the respective bottom panel 8A or 8B if desired.

An article engaging tab 30 is provided along the lower edge of each content-receiving aperture 28 so as to engage the bottom of the associated article. The engaging tabs 30 are hingedly connected to the respective bottom panel 8A or 8B along the respective fold lines 29. The lower end portion of each article fits the respective content-receiving aperture 28 when the article engaging tabs 30 engage the bottoms of the articles such as recessed bottoms of cans. The lower end portions of the packaged articles can be locked in this manner in the carton 23.

Conventional locking tabs 32 are struck from the bottom panel 8A by means of cut lines 33. Ecah locking tab 32 is shaped in the form similar to a mushroom. These tabs 32 are arranged along the free side edge of the bottom panel 8A at spacings. Each locking tab 32 is hingedly connected to the bottom panel 8A along a fold line 34. Conventional retaining tabs 36 are struck from the bottom panel 8B to define locking apertures 37 in the bottom panel 8B. These retaining tabs 36 and the locking apertures 37 are adapted to cooperate with the locking tabs 32 to secure the bottom panels 8A and 8B together. The locking tabs 32 are aligned with the retaining tabs 36 respectively when the bottom panels 8A and 8B are brought into a mutually overlapping position. The locking tabs 32 are then folded out of the plane of the bottom panel 8 A and inserted into the associated locking apertures 37 whereupon each retaining tab 36 is folded into a bracing position where the associated locking tab 32 leans against the free end of the retaining tab 36 so that the associated locking tab 32 is locked in the aperture 37. In this manner, the tabs 32 and 36 (i.e., the mechanical locking arrangement) secure the bottom panels 8A and 8B together in an overlapping relationship. It is however apparent according to the present invention that the mechanical locking arrangement may be replaced for example by adhesive as well known in the art.

While the present invention has been described with a preferred embodiment, it should be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and the scope of the claims appended hereto.

It should be readily apparent that each end (or lower) tab 11 may be replaced by a tab structurally equivalent to each intermediate (or upper) tab 13. In such an arrangement, the content-receiving apertures 28 may be omitted. It should be also apparent that the locations of the upper and lower tabs 13 and 11 may be exchanged. In such an arrangement, the beveled strip portion 5 of each side wall panel 4 and the associated content-receiving apertures 28 should be relocated to the area along the upper edge 3 of that side wall panel 4.

It will be recognized that as used herein, directional references such as "top", "bottom", "end", "side", "upper" and "lower" 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.

Claims

CLALMS

1. An elongate blank for forming a tubular carton, said blank comprising a plurality of panels arranged in a row along a length of the blank, said panels being hingedly connected one to another in series, each of said panels having a pair of opposed free end edges disposed generally along the length of the blank, said each panel being formed along either free end edge thereof with a cutout so that said blank is provided along either longitudinal edge thereof with a plurality of tabs each interposed between adjacent ones of said cutouts, said cutouts being dimensioned and configured such that said tabs have an identical size and configuration and are complementary to at least some of said cutouts, at least one of said tabs comprising an end retention structure for preventing contents of the carton from dislodging from the carton when said blank is erected into the carton, wherein said at least one tab is disposed astride a panel fold line along which two adjacent ones of said panels are hingedly connected, wherein said at least one tab comprises an anchoring portion hingedly connected to one of said two adjacent panels along an anchor fold line to be folded into face contacting relationship with said one adjacent panel, a gusset portion hingedly connected to said anchoring portion, and a web portion hingedly connected to said gusset portion, said web portion being connected to the other of said two adjacent panels to be in a folded position for engagement with a content of the carton, characterized in that said anchor fold line emanates substantially from said panel fold line and extends obliquely away from said gusset portion into said one adjacent panel such that said anchor fold line defines an acute angle with respect to said panel fold line.

2. The blank according to claim 1, wherein each of said at least some cutouts has a depth along said panel fold line, and said depth is no less than 15% of a maximum transverse size of said carton blank.

3. The blank according to claim 2, wherein said depth is no less than 20% of a maximum transverse size of said carton blank..

4. The blank according to any one of the preceding claims, wherein said gusset portion is connected to said anchoring portion along a gusset fold line, and said web portion is connected to said gusset portion along a web fold line, said gusset fold line being disposed generally perpendicular to said panel fold line, said web fold line being disposed in general alignment with said panel fold line.

5. The blank according to any one of the preceding claims, wherein said at least one tab further comprises a covering portion hingedly connected to said web portion along a cover fold line, said covering portion being integrally formed with said other adjacent panel.

6. The blank according to claim 5, wherein said cover fold line is in general alignment with said anchor fold line.

7. The blank according to any one of the preceding claims, wherein said cutouts include two end cutouts and intermediate cutouts, said end cutouts being formed in two end ones of said panels located at opposite ends of said blank respectively, said intermediate cutouts being formed in the others of said panels, said intermediate cutouts comprising said at least some cutouts and having an identical size and configuration.

8. The blank according to any one of the preceding claims, wherein each of at least some of said tabs other than said at least one tab is disposed astride a further panel fold line along which two neighboring ones of said panels are hingedly connected, wherein a content- receiving aperture is formed in one of said two neighboring panels adjacent to said further panel fold line, and said content-receiving aperture is disposed adjacent to said each of said at least some tabs.

9. The blank according to claim 8, wherein said content-receiving aperture is formed at least in part in said each of said at least some tabs.

10. The blank according to claim 8, wherein said content-receiving aperture extends into the other of the two neighboring panels so as to interrupt said further panel fold line.