WO2009091998A1

WO2009091998A1 - Blank for forming carton and method of making same

Info

Publication number: WO2009091998A1
Application number: PCT/US2009/031281
Authority: WO
Inventors: Jean-Michel Auclair; Philippe Lebras
Original assignee: Meadwestvaco Packaging Systems, Llc
Priority date: 2008-01-18
Filing date: 2009-01-16
Publication date: 2009-07-23
Also published as: EP2244951A1; GB0800929D0; AU2009205982A1; NZ587395A; CN101983160A

Abstract

A package, carton and blank for forming the same for containing articles. The carton is tubular in structure and has interconnected top (20), bottom (12) and first and second side walls (16, 24). End closure panels (50a, 52a, 54a, 58a) are provided for forming composite end closure structures. At least the top wall and the first side wall are interconnected by a corner panel (18) and a web structure (84a, 86a) is provided between an end closure panel (54a) hinged to the top wall (20) and an adjacent end closure panel hinged to the first side wall (16). The web structure comprises two articulating portions to facilitate the construction of the composite end wall. The corner panels (18) are angled similarly to the tapered upper and lower rim portions of articles to be contained by the carton. When corner panels are provided between each adjacent pair of main panels, a tubular structure having an octagonal cross section is created. Each corner panel is aligned with the tapered upper or lower rim of a series of articles disposed side by side within the carton to provide for secure retention of the articles within the fully enclosed carrier using an optimum quantity of material.

Description

BLANK FOR FORMING CARTON AND METHOD OF MAKING SAME

FIELD OF THE INVENTION

The invention relates to a blank for forming a carton; web or sheet of material comprising a number of said blanks; a carton made from the blank; a package comprising a carton formed from the blank and a plurality of articles; and a method of making the same. More specifically, but not exclusively, the invention relates to a blank comprising a corner arrangement structured to enable a carton for containing articles to be constructed from a reduced amount of web or sheet material.

BACKGROUND OF THE INVENTION

In the field of packaging it is often required to provide consumers with a grouped array of articles, such as cans. This makes it easier for the consumer to pick up the required number of articles by grasping a single carton rather than a plurality of individual articles. Additionally, such multi-packs are often more economically priced. It is known to form multi-packs or cartons from paperboard of other foldable sheet material.

In the interests of economical production, it is desirable to manufacture such cartons from a minimum amount of material, at the same time it is necessary to ensure that such cartons are fit for purpose and will be sufficiently strong to hold the weight of a plurality of articles without failure of the carton. The process of constructing a carton comprises the general steps of cutting a blank from a sheet of material; folding the blank into a carton; loading the carton with articles and closing the carton to secure the articles therein. It is desirable for the steps of this process to be conducted efficiently and at maximum product throughput to ensure efficiency in manufacture.

A carton structure capable of packaging a number of articles is shown in EP0013479, the proprietor of which is the same as the applicant of the present invention. Figure 1 of this patent document is repeated as Figure 8 in the accompanying drawings attached hereto. This figure illustrates a blank for forming a carton with increased strength and rigidity said to be accomplished through the utilisation of an improved carton structure.

The present invention seeks to provide an improvement over the prior art by providing a more economically produced carton. SUMMARY OF INVENTION

A package, carton and blank for forming the same for containing articles. The carton is tubular in structure and has interconnected top, bottom and first and second side walls. End closure panels are provided for forming composite end closure structures. At least the top wall and the first side wall are interconnected by a corner panel and a web structure is provided between an end closure panel hinged to the top wall and an adjacent end closure panel hinged to the first side wall. The web structure comprises two articulating portions to facilitate the construction of the composite end wall. The corner panels are angled similarly to the tapered upper and lower rim portions of articles to be contained by the carton. When corner panels are provided between each adjacent pair of main panels, a tubular structure having an octagonal cross-section is created. Each corner panel is aligned with the tapered upper or lower rim of a series of articles disposed side-by-side within the carton to provide for secure retention of the articles within the fully enclosed carrier using an optimum quantity of material.

According to a first aspect, the invention provides a carton for containing articles having a top, bottom and first and second side walls interconnected to form a tubular structure and end closure panels hinged to each end of the top, bottom and first and second side walls of the carton for forming composite end closure structures, wherein the top wall and the first side wall are interconnected by a corner panel and wherein a web structure is provided between an end closure panel hinged to the top wall and the adjacent end closure panel hinged to the first side wall, said web structure comprising two articulating portions to facilitate the construction of the composite end wall.

Preferably, the articulating portions of the web structure are defined by hinge connections and wherein a first of the articulating portions is disposed in overlaying alignment with a hinged connection between the first side wall and its associated end closure panel.

Optionally, a corner panel is provided between each adjacent wall of the carton such that the tubular structure is substantially octagonal in cross-section.

Preferably, wherein the end closure structure further comprises a bevelled panel between the end closure panel and the top wall which bevelled panel is disposed at a substantially perpendicular angle to the corner panel.

According to a second aspect, the invention provides a blank for forming a carton for containing articles, the blank comprising a series of main panels for forming top, bottom and first and second side walls of the carton interconnected to form a tubular structure and end closure panels hinged to each end of the top, bottom and first and second side walls of the carton for forming composite end closure structures, wherein a corner panel interconnects the top wall and the first side wall and wherein a web structure is provided between an end closure panel hinged to the top wall and the adjacent end closure panel hinged to the first side wall, said web structure comprising two articulating portions to facilitate the construction of the composite end wall.

Preferably the articulating portions of the web structure are defined by hinge connections and wherein a first of the articulating portions is defined by hinge lines co - linear with hinge connections between the corner panel and the top and the first side wall respectively.

According to a further aspect, the invention provides a sheet of paperboard material having a width in the range 1390mm to 1400mm and a height in the range 864mm to 1010mm comprising four blanks, each blank formed in accordance with either of claims 5 or 6 and for forming a carton for containing 12 cans each having a maximum height of 150mm and a maximum diameter of 66mm.

According to yet a further aspect, the invention provides a method of forming a blank for forming a carton for containing 12 cans each can having a maximum height of 150mm and a maximum diameter of 66mm, the method comprising, providing a sheet of paperboard material having a first dimension in the range 1390mm to 1400mm and a second dimension in the range 864mm to 1010mm and printing and cutting four blanks arranged in a 2 x 2 array from said sheet.

According to yet a further aspect, the invention provides a package comprising a plurality of articles each having a tapered upper and lower rim portion and a carton of the fully enclosed type containing said articles, the carton having top, first side, bottom and second side walls arranged in a tubular structure and corner panels disposed between adjacent panels of the tubular structure, the corner panels being angled similarly to the tapered upper and lower rim portions thus creating a tubular structure having an octagonal cross-section wherein each corner panel is aligned with the tapered upper or lower rim of a series of articles disposed side-by-side within the carton.

Preferably comprising end closure panels hinged to each end of the top, bottom and first and second side walls of the carton for forming composite end closure structures, wherein a web structure is provided between an end closure panel hinged to the top wall and the adjacent end closure panel hinged to the first side wall, said web structure comprising two articulating portions to facilitate the construction of the composite end wall.

Optionally, the articulating portions of the web structure are defined by hinge connections and wherein a first of the articulating portions is disposed in overlaying alignment with a hinged connection between the first side wall and its associated end closure panel.

Optionally, a second of the articulating portions, is disposed in overlaying relationship with a tapered upper or lower rim of an article.

BRIEF DESCRIPTION OF THE DRAWINGS

An exemplary embodiment of the invention will now be described with reference to the accompanying drawings, in which:

Fig. 1 shows a plan view of a blank for forming a carton according to a first embodiment of the invention; Fig. 2 shows a first portion of a carton formed from the blank of Figure 1 comprising a can (C); Fig. 3 shows a second portion of a carton formed from the blank of Figure 1 comprising a can (C); Fig. 4 Illustrates the first and second portions of Figures 2 and 3 in an open-ended carton shown in perspective view;

Fig. 5 shows a step in the construction of the first corner portion of Figure 2; Fig. 6 shows a step in the construction of a second corner portion of Figure 3; Fig. 7 shows a perspective view of a fully loaded carton formed from the blank of Figure

1; Fig. 8 Is a drawing taken from a Prior Art document and shows Figure 7 of EP 0013479

(the reference numerals shown on this drawing relate to the prior art document from which it has been taken and do not relate to the reference numerals provided on Figures 1 to 7 listed above. Only reference 'P' has been added to indicate the blank shown in this figure); Fig. 9 shows a plan view of a web of material of standard size comprising three of the blanks 'P' shown in Figure 8; and Fig. 10 shows a plan view of a web of material of standard size comprising four of the blanks 10 shown in Figure 1.

Fig. 11 shows a schematic perspective view of a standard can that can be packaged in the carton of the first embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT The invention relates to a blank for forming a carton and a method of manufacturing the same. A blank 10 according to a preferred embodiment of the invention is shown in Figure 1, the carton and enlarged portions of it are shown in Figures 7 and 2-6 respectively. The blank 10 and carton constructed therefrom seek to provide an improvement over a carton formed from and blank 'P' of the prior art shown in Figure 8 and seek to provide a more efficient method of manufacturing blanks for forming cartons.

The blank 'P' of the prior art and blank 10 of the present invention are foldable to form cartons that can each accommodate 12 similarly sized cans, in this case twelve 440ml cans arranged in four rows of three cans each. The cans (C) (as shown illustratively in Figures 2 - 4 and schematically in figure 11) are substantially cylindrical and have chamfered or tapered portions around their upper and lower rims. Such beverage cartons are of standard dimensions, having a height (L) of 150mm, a maximum diameter (Dl) of 66mm and an inner minor diameter (D2) of approximately 57mm.

The aforementioned blanks 10, 'P' and resulting cartons are formed of paperboard. It is envisaged that other suitable foldable sheet material could be used; however a beneficial aspect of the invention is derived from the fact that cutting machines used in the field of packaging have limitations in the size of sheet material they can accommodate and the present invention presents a method of optimising the number of blanks that can be formed from a single sheet. In one known cutting and printing machine, a paperboard sheet having the maximum dimensions of 1018mm x 692mm can be accommodated, for larger sheets of material a different machine having an increased sheet capacity is required for example a Format 6 cutting and printing machine can accommodate a sheet of material up to maximum dimensions of 1400mm x 1010mm. A Format 7 cutting and printing machine is needed to accommodate larger sheets up to maximum dimensions of 1590mm x 1082mm.

The maximum dimensions of sheet material that a cutting and printing machine can accommodate determines the number of blanks that such a machine can cut at any one time. The throughput of the machine can be measured by the number of carton blanks that can be printed and cut within an hour of machine running time. It is advantageous to maximise this. The size of articles to be accommodated within a carton is a factor in determining the total area of a single blank which, when folded can securely contain a grouped array of articles. The specific dimensions of a single blank and their nested arrangement on a sheet of material determine the number of blanks that can be cut from a single sheet of material at a time by a cutting and printing machine having a set capacity as described above. The factors of article size and number; area of blank; nested arrangement of blank and capacity of printing and cutting machine, thus determine the number of blanks that can be printed and cut per hour. The throughput of a cutting and printing machine will now be calculated in two worked examples, the first wherein the prior art carton blank 'P' of Figure 8 is used to package twelve 440ml cans and the second wherein the blank of the present invention (Figure 1) is used to package twelve 440ml cans. Reference will be made to Figures 9 and 10.

Example 1 - Prior Art

In order to accommodate twelve 440ml cans arranged in a 4 x 3 configuration, the blank 'P' is provided with four main panels for forming the top, bottom and side walls of a carton having a rectangular cross-section. Each of the top, bottom and side walls are hinged to an end closure panel which are constructed to form an end closure structure to secure the articles therein. The construction of the end closure structure is facilitated by the use of web structures hinging between adjacent ones of the end closure panels. These web structures cause one of the associated end closure panels automatically to be brought into a closed position when the other of the end closure panels is folded upwardly. Additionally, these web structures cause the automatically set-up end closure panel to "snap" into position and as such adhesion of only a top end closure panel to a bottom end closure panel is required in order to secure the articles within the carton. (This is described in full in EP 0013479).

The blank 'P' already known in the art has a total length Bl (see Figure 9) of 721.5mm and a width of 432mm. The area required on a larger sheet of material from which this blank is cut is therefore 311688mm².

As described above, machines for printing and cutting blanks from larger sheets have finite capacities. In order to minimise the amount of wastage and optimise the number of blanks that can be cut at one time, it is known to arrange 3 blanks 'P' on a sheet of material 1296mm x 721.5mm. This is shown in Figure 9 where Bl is the overall length of one blank 'P' and the dimension indicated by Al equates to the sum of the widths of three blanks (3 x 432mm = 1296mm).

The cutting and printing machine that can accommodate a sheet of maximum dimension of 1400mm x 1010mm can accommodate a sheet comprising three blanks 'P' (as shown in Figure 9). This machine is known to be able to operate at a rate of 3000 sheets per hour. As such, with blank 'P', a maximum of 9000 blanks per hour are produced.

Example 2 - Present Invention

In order to accommodate twelve 440ml cans arranged in a 4 x 3 configuration, the blank 10 of Figure 1 is provided with four main panels 12, 16, 20, 24 for forming the top 20, bottoml2 and side walls 16, 24 of a carton. These main panels 12, 16, 20, 24 are interconnected by corner panels or bevelled panels 14, 18, 22, 26 defined by pairs of fold lines 3O₇ 32, 34, 36, 38, 40 and 42, 44. A glue panel 28 is provided to secure the side wall 24 to the bottom wall 12. The resulting carton sleeve has an octagonal cross-section. Hinged to each of the top 20, bottom 12 and side walls 16, 24 are end closure panels. Since the blank is symmetrical about its centre, only the left hand side of the blank 10 and one of the end closure structures will be described in detail, it being understood that the other side is the same. End closure panels 54a, 50a, 52a and 58a are hinged to the top 20, bottom 12 and side walls 16, 24, respectively. These end closure panels can be folded to construct an end closure structure to secure the articles therein. The construction of the end closure structure is facilitated by the use of web structures 82a/86a, 80a/76a, 90a/88a, 96a/98a hinging between adjacent ones of the end closure panels 54a/52a, 52a/50a, 54a/58a and 58a/50a respectively. These web structures operate in a similar way to those shown in the prior art. When a top or bottom end closure panel 52a, 58a is folded upwardly or downwardly respectively, the associated end closure panel 50a, 54a, is caused to be is folded inwardly and automatically brought into a closed position. Additionally, these web structures 82a/86a, 80a/76a, 90a/88a, 96a/98a cause the automatically set-up end closure panels 50a, 54a to "snap" into position and as such adhesion of only one of the side end closure panels 52a to the other side end closure panel 58a is required to secure the articles within the carton.

The blank 10 has a total length D (see Figure 10) of only 695mm. This reduction in length is achieved because of the introduction of corner panels 14, 18, 22, 26 which utilise the tapered shape of the cans (C) to cut across the corners producing a carton (see Figure 7) of octagonal cross-section that more closely follows the contour and shape of the packaged group of articles. The width of this blank 10 is 432mm. The area required on a larger sheet of material from which this blank is cut is therefore 300240mm². Due to the reduced length of the blank 10, it is now possible to nest four blanks 10 on a sheet of material that can be accommodated by the format 6 printing and cutting machine. The new arrangement of blanks 10 of the present invention is illustrated in Figure 10. It can be seen that due to the reduction in the overall length of the blank 10 it is now possible to place two blanks end-to-end on a sheet of material. In this way, not only has the total amount of material required to contain twelve 440ml cans been reduced, but the throughput of blank production is now increased. The present invention provides for the arrangement of four blanks 10 on a sheet of material 1390mm x 864mm. This is shown in Figure 10 where B is the width of two blanks 10 and the dimension indicated by A equates to the sum of the lengths of two blanks (2 x 695mm = 1390mm). After application of the present invention, the cutting and printing machine that can accommodate a sheet of maximum dimension of 1400mm x 1010mm can now accommodate a sheet comprising four blanks 10 (as shown in Figure 10). This new method of manufacture operates at a rate of 12000 blanks per hour. A further advantage provided by the present invention will now be described with specific reference to Figures 1 -6. Each web structure 82a/86a, 80a/76a, 90a/88a, 96a/98a comprises two articulating portions or gusset panels 82a, 86a, 80a, 76a, 90a, 88a, 96a and 98a. A first of the articulating portions 98a, 88a, 86a and 76a is defined by two fold or hinge lines 44a, 42a, 38a, 40a, 36a, 34a, 30a and 32a. These fold lines 44a, 42a, 38a, 40a, 36a, 34a, 30a and 32a are co-linear with the fold lines 44, 42, 38, 40, 36, 34, 30 and 32 which define the corner panels. As a result the web structures of the present invention enable the automatic set-up of the smaller end closure panels 54a, 50a, by virtue of the major end closure panel 52a, 58a (being folded upwardly and downwardly), pulling the web structures and folding the web structures about angled fold line 94a, 92a, 82a and 80a. In addition, the web structures 82a/86a, 80a/76a, 90a/88a, 96a/98a enable the carton to have an octagonal cross section and yet be securely closed by a substantially rectangular end closure structure (see Figure 7).

A step in the construction of the end closure structure is shown in Figure 4. Here the open - ended loaded tubular structure is shown from one end. Side end closure panels 52a, 58a have been folded outwardly of the carton causing the web structures to fold about hinge lines 82a, 92a and causing the top end closure panel 54a and associated bevel panel 56a to be folded into a closed position wrapping around an endmost can (C). It can be seen that first articulating portions 86a, 88a, are each folded atop the endmost can (C) and into overlapping relationship therewith. Second articulating portions 84a, 90a are drawn towards the side end closure panels 52a, 58a. The position of the web structure at this point in the construction of the carton is shown in enlarged view in Figures 2, 3, 5 and 6. Once the side end closure panels 52a, 58a, are folded into a closed position overlapping the end closure structures 54a, 50a, the second articulating portions 96a, 90a, 82a, 78a are disposed in flat-face contacting relationship with an inside face of a side end closure panel 58a, 52a. Fold lines 42a, 40a, 34a and 32a are aligned with fold lines 60a and 70a respectively and the first articulating portions overlay a portion of an article C. As such only a portion of the web structure creates a two-ply thickness in the corner of the carton and the end closure panels 52a, 58a are easily folded into a closed position.

The web structures provide a further advantage given that the fully enclosed carton as shown in Figure 7 comprises bevelled corners defined by panels 56a and 66a/64a. These bevelled corner panels enable the carton to be supported by the contents and advantageously create a carton with high stacking strength. Because the carton fits closely around the contents, even though they may be curved, the are no or only very few empty spaces within a fully loaded carton and as such the cartons susceptibility to crushing or damage at empty corners is substantially eliminated. These bevelled panels enable the minor end closure panels 54a, 50a/62a to follow the contour of a cylindrical or at least non- rectangular article (see figure 4). As a result of this cornered bevelled edge 56a, 66a/64a, the completely formed package of carton and articles is secure. The articles fit tightly within the carton and cannot rattle or bump into other articles. Such bumping could cause damage to the articles and/or failure of the carton. The bevelled corners of the end closure structure are disposed at 90 degrees or at least substantially perpendicularly (see blank of figure 1 and relation between fold lines 72a/74a and 34/36). Once the blank is set up into a carton the web structures having two articulating portions and the shaped aperture formed therebetween assists in the formation of an end closure structure that is substantially rectangular for a tubular structure of octagonal cross-section.

It can be appreciated that various changes may be made within the scope of the present invention, for example, the exact size and shape of the panels, corner panels and web structures may be adjusted to accommodate articles of differing size or shape tolerance relative to the precise measurements given in the afore described example. For example, in other embodiments of the invention it is envisaged that the total length of a single blank is in the range 1390 to 1400mm. In other embodiments the packaged articles have a differently angled taper at their upper rim compared to their lower rim and therefore the width of the corner panel between panel 16 and panels 12, 20 may be different from the width of the corner panel between panel 24 and panels 12 and 20. The total width of the blank in other embodiments is sized according to the height and maximum and minimum diameter of an article. It is envisaged that to accommodate articles within a carton having a fully enclosed structure sized such that the blank for forming the carton can be nested in a 4x4 array having a maximum length of 1400mm, 12 articles could be contained having a maximum height of 150mm and a maximum diameter of 66mm. The total number of articles container may be altered. For example, 24 articles of maximum height 75mm could be accommodated; 6 articles of diameter greater than 66mm could likewise be accommodated.

It will be recognised that as used herein, directional references such as "top", "bottom", "front", "back", "end", "side", "inner", "outer", "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 the following, a short slit, a frangible line or a fold line without departing from the scope of the invention.

Claims

1. A carton for containing articles having a top, bottom and first and second side walls interconnected to form a tubular structure and end closure panels hinged to each end of the top, bottom and first and second side walls of the carton for forming composite end closure structures, wherein the top wall and the first side wall are interconnected by a corner panel and wherein a web structure is provided between an end closure panel hinged to the top wall and the adjacent end closure panel hinged to the first side wall, said web structure comprising two articulating portions to facilitate the construction of the composite end wall.

2. A carton according to claim 1 wherein the articulating portions of the web structure are defined by hinge connections and wherein a first of the articulating portions is disposed in overlaying alignment with a hinged connection between the first side wall and its associated end closure panel.

3. A carton according to claim 2 wherein a corner panel is provided between each adjacent wall of the carton such that the tubular structure is substantially octagonal in cross-section.

4. A carton according to claim 3 wherein a the end closure structure further comprises a bevelled panel between the end closure panel and the top wall which bevelled panel is disposed at a substantially perpendicular angle to the corner panel.

5. A blank for forming a carton for containing articles, the blank comprising a series of main panels for forming top, bottom and first and second side walls of the carton interconnected to form a tubular structure and end closure panels hinged to each end of the top, bottom and first and second side walls of the carton for forming composite end closure structures, wherein a corner panel interconnects the top wall and the first side wall and wherein a web structure is provided between an end closure panel hinged to the top wall and the adjacent end closure panel hinged to the first side wall, said web structure comprising two articulating portions to facilitate the construction of the composite end wall.

6. A blank according to claim 5 wherein the articulating portions of the web structure are defined by hinge connections and wherein a first of the articulating portions is defined by hinge lines co -linear with hinge connections between the corner panel and the top and the first side wall respectively.

7. A sheet of paperboard material having a width in the range 1390mm to 1400mm and a height in the range 864mm to 1010mm comprising four blanks, each blank formed in accordance with claim 5 and for forming a carton for containing twelve cans each having a maximum height of 150mm and a maximum diameter of 66mm.

8. A method of forming a blank according to claim 5 for forming a carton for containing 12 cans each can having a maximum height of 150mm and a maximum diameter of 66mm, the method comprising, providing a sheet of paperboard material having a first dimension in the range 1390mm to 1400mm and a second dimension in the range 864mm to 1010mm and printing and cutting four blanks arranged in a 2 x 2 array from said sheet.

9. A package comprising a plurality of articles each having a tapered upper and lower rim portion and a carton of the fully enclosed type containing said articles, the carton having top, first side, bottom and second side walls arranged in a tubular structure and corner panels disposed between adjacent panels of the tubular structure, the corner panels being angled similarly to the tapered upper and lower rim portions thus creating a tubular structure having an octagonal cross-section wherein each corner panel is aligned with the tapered upper or lower rim of a series of articles disposed side-by-side within the carton.

10. A package according to claim 9 comprising end closure panels hinged to each end of the top, bottom and first and second side walls of the carton for forming composite end closure structures, wherein a web structure is provided between an end closure panel hinged to the top wall and the adjacent end closure panel hinged to the first side wall, said web structure comprising two articulating portions to facilitate the construction of the composite end wall.

11. A package according to claim 10 wherein the articulating portions of the web structure are defined by hinge connections and wherein a first of the articulating portions is disposed in overlaying alignment with a hinged connection between the first side wall and its associated end closure panel.

12. A package according to claim 10 wherein a second of the articulating portions, is disposed in overlaying relationship with a tapered upper or lower rim of an article.