WO2010096741A1

WO2010096741A1 - Package with structural support and blank therefor

Info

Publication number: WO2010096741A1
Application number: PCT/US2010/024868
Authority: WO
Inventors: Bradford J. Walling; Aaron Bates; James S. Shortt; Elizabeth E. Coulson
Original assignee: Meadwestvaco Corporation
Priority date: 2009-02-23
Filing date: 2010-02-22
Publication date: 2010-08-26
Also published as: TW201033087A

Abstract

A carton comprising carton walls (12, 14, 16, and 18) and a compression resistant structure (20) disposed adjacent to an inside face of at least one (14) of the carton walls. The compression resistant structure is structured and arranged such that the compression resistant structure does not interfere with corners of the carton formed between adjacent ones (12, 14; 14, 16) of the carton walls. At least a section of the compression resistant structure is sized and shaped similarly to the size and shape of one (14) of the carton walls and fits within the perimeter of the one carton wall.

Description

PACKAGE WITH STRUCTURAL SUPPORT AND BLANK THEREFOR

FIELD OF THE INVENTION

The invention relates to a package with structural support and blank therefor. More specifically, but not exclusively, the invention relates to a package having means for providing compression resistance for enhancing the load bearing quality of the package especially but not exclusively when stacked with other similar articles.

BACKGROUND OF THE INVENTION

In the field of multi-article packaging, it is often required to provide consumers and/or retailers with a grouped assembly of products in a single package; such multi-article packages may be required to be shipped or transported by a distributor or other carrier and/or by the end consumer. Such packages are required to be durable, robust and capable of supporting and protecting the articles contained inside. In addition, it is preferable that these packages are materially efficient to save on costs; it is desirable that they are easy to construct and preferable that they can be stacked one upon another without damaging the packages or the articles therein. It is also a consideration in this field that the number or amount of articles or product within the packages is optimised so that shipping is efficient and transportation costs are minimised.

It is known from US 6158653 to Kanter to provide a package having an internal corner support for increasing the stacking strength of the container. The container has multiple wall panels. The internal corner support includes first and second panel sections attached pivotally to one another which are adjacent a corner of the container for providing additional stacking support. The drawback of such designs is that the corner support structures take up some of the internal volume of the package thus reducing the capacity of the package; in addition the shape of the corner structure is not suitable for efficiently accommodating the shape of articles to be contained within the package and the capacity of the package can be further reduced. The present invention seeks to avoid or at least mitigate these and other problems of the prior art.

Furthermore the present invention seeks to provide a package having a means of improving compression resistance which has a reduced or minimal effect upon the storage capacity of the package. SUMMARY OF INVENTION

According to first aspect of the present invention, there is provided a blank for forming a carton having panels for forming the carton walls, the blank comprising a compression resistant structure disposed adjacent to or affixed to an inside face of the blank and being structured and arranged such that the compression resistant structure does not prevent the blank being foldable and manipulatable to form the carton, said compression resistant structure having material and/or structural properties such that the compression strength of the carton formed has an increased compression strength compared to a carton formed from the blank and not comprising the compression resistant structure.

Preferably, at least a section of the compression resistant structure is sized and shaped similarly to the size and shape of a panel of the blank and fits within the confines of the perimeter of that panel of the blank.

Preferably, the compression resistant structure is formed of corrugated material and the compression resistant structure comprises at least three sections and wherein the direction of the corrugations of said sections are orientated such that compression resistant is improved in three notional mutually perpendicular axes.

Preferably, the compression resistant structure comprises two, three, four or more panels. More preferably, at least two of the panels are hinged to one another.

Optionally, the compression resistant structure comprises a pair of structures each comprising two hinged panels.

Preferably, a hinged connection between two adjacent panels comprises apertures, cut lines or other lines of severance whereby reducing the folding resistance and/or reducing the quantity of material present about the hinged connection.

Preferably, the compression resistant structure has a panel which is "H-shaped" or "I- shaped".

Preferably, the compression resistant structure has a panel which is "C-shaped" or "U- shaped".

Preferably, the blank comprises a handle structure and wherein compression resistant structure cooperates with the handle structure whereby reinforcing the handle structure.

According to second aspect of the present invention, there is provided a part-formed carton erected into flat collapsed form from the blank described hereinabove. According to third aspect of the present invention, there is provided a carton having panels for forming the carton walls, the carton comprising a compression resistant structure disposed adjacent to or affixed to an inside face of the carton and being structured and arranged such that the compression resistant structure does not interfere with corners of the carton formed between adjacent carton walls, said compression resistant structure having material and/or structural properties such that the compression strength of the carton has an increased compression strength compared to a carton not comprising the compression resistant structure.

Preferably, at least a section of the compression resistant structure is sized and shaped similarly to the size and shape of a panel of the carton and fits within the confines of the perimeter of that panel of the blank.

Preferably, the compression resistant structure is formed of corrugated material and the compression resistant structure comprises at least three sections and wherein the direction of the corrugations of said sections are orientated such that compression resistance is improved in three notional mutually perpendicular axes.

According to fourth aspect of the present invention there is provided a compression resistant structure for use with a carton or blank described hereinabove.

BRIEF DESCRIPTION OF THE DRAWINGS

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

Figure 1 shows a plan view of a blank for forming a carton comprising a compression resistant structure according to a first embodiment of the invention;

Figure 2 shows a carton formed of the blank of Figure 1 with the compression resistant structure being manually placed inside the carton;

Figure 3 shows a blank for forming a carton comprising two compression resistant structures according to the first embodiment of the invention;

Figures 4 to 8 show blanks for forming a carton, each blank comprising four compression resistant structures according to the first embodiment, albeit orientated in different, optional, configurations;

Figure 9a shows a blank for forming a carton comprising two compression resistant structures according to a second embodiment of the invention; Figure 9b Shows a carton formed from the blank of Figure 9a in a part open and unloaded state thereby illustrating the position of said two compression resistant structures;

Figures 10 to show a blank for forming a carton showing a compression resistant 12 structure according to the first embodiment and a compression resistant structure according to a third embodiment of the invention, ready for loading onto that blank and loaded onto that blank;

Figures 13 & 14 show blanks for forming a carton each having two compression resistant structures according to the third embodiment of the invention being affixed thereto, albeit the configuration of the compression resistant structures of Figure 13 is orientated differently compared to those of Figure 14;

Figure 15 shows a compression resistant structure of a fourth embodiment for use with a blank such as that of Figure 1;

Figure 16 shows a compression resistant structure of a fifth embodiment for use with a blank such as that of Figure 1; Figure 17 shows a compression resistant structure of a sixth embodiment for use with a blank such as that of Figure 1; Figure 18 shows a carton formed from the blank of Figure 1 with the compression resistance structure disposed therein; Figure 19 is a schematic illustration of the compression structure of a sixth embodiment showing how reinforcement is provided against an applied

Load; and

Figure 20 shows a blank for forming a carton comprising two compression resistant structure according to a seventh embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Exemplary embodiments of a compression resistant structure and cartons containing the same will now be described with reference to all of the Figures. Figures 1 to 8 illustrate uses of a compression resistant structure according to a first embodiment; Figures 9a and 9b illustrate an application of a compression resistant structure according to a second embodiment; Figures 10 to 14 illustrate uses of a compression resistant structure according to a third embodiment of the invention and Figures 15 and 16 illustrate a compression resistant structure according to a fourth and fifth embodiment respectively and Figures 17 to 19 illustrate a compression resistance structure according to a sixth embodiment. In those figures illustrating different applications of the same embodiment of the invention, the same reference numerals are used to denote the same features. Since the different alternative embodiments of the invention differ in only certain details, similar reference numerals to those used in respect of the first embodiment will be used to denote similar features of the second to sixth embodiments, albeit, the numbers are raised by a factor '100', '200', '300', '400' and '500' respectively.

Figures 1, 3, 4 to 9a, 10 to 15, 17 and 20 each illustrate blanks 10, 110, 210, 310, 510 and 610 respectively; it is envisaged that the blanks 10, 110, 210, 310, 510, 610 may be formed from a printable paperboard; however other suitable foldable sheet material may be used. The blanks 10, 110, 210, 310, 510 and 610 are each structured to form a carton having four walls and a composite top and base, as such, each blank 10, 110, 210, 310 510, 610 comprises: a first side wall 12; 112; 212; 312; 512; 612 a second side wall 14; 114; 214; 314; 514; 614, a third side wall 16; 116; 216; 316; 516; 616, a fourth side wall 18; 118; 218; 318; 518; 618, top end flaps 22b, 24b, 26b, 28b; 122b, 124b, 126b, 128b; 222b, 224b, 226b, 228b; 322b, 324b, 326b, 328b; 522b, 524b, 526b, 528b; 622b, 624b, 626b, 628b and bottom end flaps 22a, 24a, 26a, 28a; 122a, 124a, 126a, 128a; 222a, 224a, 226a, 228a; 322a, 324a 326a, 328a; 522a, 524a, 526a, 528a; 622a, 624a, 626a, 628a.

Reference is now made to the numbered features of Figure 1 only (it being understood that other depicted embodiments may carry the same features); the side wall panels 12, 14, 16, 18 are hinged one to the next in a linear series along fold lines 30, 32 and 34 respectively. The top end flaps 22b, 24b, 26b, 28b are hinged to an adjacent side wall 12, 14, 16, 18 along fold lines 44b, 42b, 40b, and 38b respectively. Bottom end flaps 22a, 24a, 26a, 28a are hinged to an adjacent side wall 12, 14, 16, 18 along fold lines 44a, 42a, 40a, 38a respectively. A glue flap 19 (or manufacturers seam) is hinged to side wall panel 20 along fold line 36 and is provided to secure first side wall panel 12 and fourth side wall panel 18 together. Preferably, the first and fourth side wall panels 12, 18 are secured together only after a compression resistant structure 20 (to be described below) has been secured in place on the blank 10. However, in other optional applications of the invention the compression resistant structure 20 is secured in place within an empty carton in other words after a carton has been formed from the blank 10, 110, 210, 310, but prior to the carton being loaded with articles. In yet a further alternative, the compression resistant structure 20 may be placed within a carton loaded with articles the compression resistant structure 20 being inserted between the articles and the carton or between the articles themselves. Each of the blanks 10, 110, 210, 310, 510 is further provided with a compression resistant structure 20, 120 225, 325, 525, 520. In the first embodiment illustrated in Figures 1 to 8, the compression resistant structure 20 takes the form of a planar piece of corrugated board. The corrugations or flutes of the corrugated board are vertically aligned with a notional vertical, stacking axis of the carton to be formed from the blank 10. In other words, the corrugations or flutes are aligned substantially parallel or perpendicular to the vertices of the carton. Preferably, the compression structure 20 is adhered or otherwise fixably attached to a side wall panel 12, 14, 16, 18 of the blank 10. As illustrated in Figure 1 the compression resistant structure 20 is sized and shaped similarly to the fourth side wall panel 18 of the blank 10. The thickness of the compression resistant structure 20 and/or material composition and/or its corrugated fluting and/or other physical characteristics increases the compression resistance of the carton formed from the blank 10 compared to a carton formed from the blank 10 without the compression resistant structure 20.

In a Compression Caliper Study, it has been found a carton (not loaded with articles) formed from a .030 inch (30 Caliper) thick board without a compression resistant structure 20 could withstand an average compression load of around 60 - 70 lbs in all directions before failure. This weight was determined using a machine designed to show compression resistance. The general process was a slow and gradual lowering of the top plate onto the formed carton. When the top of the carton was reached the machine recorded the pressure exerted on the carton until the carton failed. This was typically shown by a sharp drop in the pressure and possible visible bending or creasing locations on the formed carton. Three directions were tested: horizontal, length and width and the average of the three directions was recorded as the average compression resistance for the overall carton. Using the same Study, a carton having a compression resistant structure comprising an/a pair of adhered planar sheet of corrugated board, aligned such that the fluting of the corrugated board is disposed parallel to the stacking axis of the carton could withstand an average compression load in all directions of 350 lbs before failure. The compression resistant structure 20 therefore provides around a four to five time fold increase in compression resistance using the same Caliper board for the carton and C-Flute insert panels. As such a single/double compression resistant structure provides an increase in compression resistance, yet with only a small reduction of the internal capacity of the package.

Additionally, the present invention has the advantage that the construction of the carton from the blank 10 is no more complex. An initial step of fixably attaching the compression resistant structure 20 to the blank 10 can be done during the manufacture of the blank 10 itself. Then, once the compression resistant structure 20 is secured in place, the composite blank 10 and compression resistant structure 20 can be folded and the first and fourth side wall panels 12, 18 secured together. A flat form or knocked-down part-formed carton is then formed. This structure is then shipped in the flat-form or knocked-down state to a converting plant where the flat-form blank is opened; the bottom end flaps 22a, 24a, 26a, 28a secured together to form a bottom wall structure; the carton top loaded with articles; and then the top end flaps 22b, 24b, 26b, 28b folded and secured (as is known in the art) to complete the construction, loading and sealing of the carton.

Alternatively, the blank 10 can be shipped without the compression resistant structure 20 having been fixably attached and the compression resistant structure 20 can simply be inserted during the construction of the carton. An example of the compression resistant structure 20 being inserted when the carton is constructed is depicted in Figure 2. It is preferred however, that the compression resistant structure 20 is secured by adhesive or other suitable mechanical or chemical fixing means to the blank 10 prior to the blank 10 being formed into a carton. This alleviates the need for the plant equipment where the blank is converted into a carton and loaded with articles to be sophisticated enough to carefully align the planar reinforcing structure 20 on a panel of the carton. It is preferable, in order to maximise the additional compression resistant of the carton formed, that the compression resistant structure 20 is as close to the dimension and shape of the panel to which it is affixed as possible. Consideration must be given to the final internal size of the carton since the thicknesses of the paperboard from which the blank 10 is formed and material from which the compression resistant structure 20 is formed are not negligible.

In a variation of this embodiment, two compression resistant structures 20 are provided within the same blank 10. In Figure 3 the careful alignment of two compression resistant structures 20 onto the second and fourth panels 14, 18 of the blank is shown. It is necessary that the compression resistant structures 20 do not impede the hinging of adjacent panels i.e. the movement about fold lines 30, 32, 34, 36. Therefore, each compression resistant structure 20 is accurately sized smaller than, but similar in dimension to, the panel 14, 18 to which it is adhered. Each compression resistant structure 20 is accurately aligned and secured within the area of that panel 14, 18 to ensure that the fold lines 30, 32, 34, 36 remain unhindered.

In yet further variations of this embodiment of the invention where a planar reinforcement panel (sized similarly to a single carton panel), three or four such similarly formed compression resistant structures 20 are provided (see Figures 4 to 8). In Figure 5, it is shown that each compression resistant structure 20 is orientated such that the corrugated fluting of each compression resistant structure 20 is in alignment with a vertical axis 'FV of the carton (in other words running between the composite top and bottom panels). In yet a further variation, shown in Figure 6, the corrugated fluting of each compression resistant structure 20 is disposed in alignment with a notional horizontal 'FH' axis of the carton. In both Figure 5 and Figure 6, the direction of the fluting of the compression resistant structure 20 is illustrated by an arrow labelled with a corresponding reference 'FH' or 'FV to denote fluting in horizontal angle; fluting in vertical angle.

In Figure 4, three compression resistant structures 20 are provided. The compression resistant structure 20 affixed to second side panel 14, is vertically oriented 'FV; the compression resistant structures 20 affixed to third and fourth side panels 16, 18, are each horizontally oriented 'FH'. In this way, when the carton is constructed, whether the carton is laid to rest on the top wall structure 22b, 24b, 26b, 28b or bottom wall structure 22a, 24a, 26a, 28a, the 'FV oriented compression resistant structure 20 affixed to second side panel 14 has its fluting (corrugations) running parallel to a load imparted on the actual uppermost surface of the carton and thereby provides additional compression resistance. Similarly, when the carton is laid to rest upon either its second side panel 14 or fourth side panel 18, the 'FH' oriented compression resistant structure 20 affixed to third side panel 16 has its fluting (corrugations) running parallel to a load imparted on the actual uppermost surface of the carton and thereby provides additional compression resistance. Finally, when the carton is laid to rest upon either its first side panel 12 or third side panel 16, the 'FH' oriented compression resistant structure 20 affixed to fourth side panel 18 has its fluting (corrugations) running parallel to a load imparted on the actual uppermost surface of the carton and thereby provides additional compression resistance. In this way the three compression resistant structures 20 provide an increase in the overall compression strength of the carton irrespective of which face of the carton acts as the base. It should be noted that when the compression resistant structures 20 are folded to form a carton they form a "C-Shaped" or "U-shaped" section; the fluting of the centrally disposed compression resistant structure 20 should be orientated such that the fluting runs between the two endmost compression resistant structures 20 which are disposed at opposing ends of the centrally disposed compression resistant structure 20 furthermore the fluting of the two endmost compression resistant structures 20 when viewed in unfolded, planar, form should be perpendicular to one another.

As such the carton formed from the blank shown in Figure 3 having a compression resistant structure 20 on three carton panels has at least one compression resistant structure 20 having fluting (corrugations) that runs parallel to the direction of load imparted upon the carton, regardless of which carton face is used as the base of the carton. (Though reference has been made to top and bottom structures of the carton; this nomenclature serves solely to distinguish the physical features of the blank and carton from one another during description and in no-way limits the spatial position of the carton in use to any particular orientation).

Thus, once the carton is loaded and sealed and the compression resistant structures 20 are occluded from view, no matter which way around the carton is placed for stacking (in other words no matter whether side wall panel 12, 14, 16, 18, the top structure 22b, 24b, 26b, 28b or bottom structure 22a, 24a, 26a, 28a acts as the base of the carton), additional support running parallel to the load direction is provided. This is beneficial because it alleviates the need for marking the outer graphics of the completed carton with a preferred orientation for stacking and also alleviates the need for those working with the packages to consider the stacking orientation. It will be understood that a minimum of three compression resistant structures 20 are required with a six sided carton structure.

In Figures 7 and 8, four compression resistant structures 20 are provided. At least two of these are on different carton panels and are orientated in the vertical 'FV direction and at least two of these are affixed to different carton panels and are orientated in the horizontal 'FH' direction. Therefore additional compression strength, by virtue of two panels being parallel to the load direction, is achieved when the carton is laid to rest on either the composite top wall structure 22b, 24b, 26b, 28b or bottom wall structure 22a, 24a, 26a, 28a. The addition of more compression resistant structures 20 simply increases the compression resistance of the overall carton structure. An entirely optional embodiment of the invention is shown in Figures 9a and 9b wherein each compression resistant structure 121 has at least one cutout that is designed to be positioned in alignment with at least one handle (or handle flap) H defined in the carton wall panels 112 and 116. More specifically, each compression resistant structure is 'H' or "I" shaped in the illustrated embodiment. Though the compression resistant structure 121 comprises less material compared to the compression resistant structure 20 of the first embodiment, the carton produced is still strengthened compared to a carton made from the blank 110 and comprising no compression resistant structure 121 at all. In addition, the shape of the compression resistant structure 121 allows for the incorporation of a handle H formed in the paperboard of the first side panel 112 of the blank 110. It would be difficult for a user to break through a perforation provided in the corrugated material of the compression resistant structure 121 in an attempt to operate the handle. Therefore, shaping the compression resistant structure 121 to allow for an area where no compression resistant structure 121 is present, the user does not need to break through the corrugated material of the compression resistant structure 121, in order to use the handle. The handles H depicted are simply defined by a frangible line that can be broken by a user to form a handle opening with a lifting edge, but before then the carton remains intact and does not allow the ingress of dust or dirt into the carton. Each handle H can hinge about fold line 23 and thereby can define the handle opening. Other shapes, size, configuration of handle H can be incorporated. Many handle structures known in the art would be suitable for these purposes. It will be understood that a greater or lesser number of handle structures may be provided or other handle variations may be used; for example only one handle opening may be provided in each panel, that handles need not be provided in all the panels for example a handle may be provided in a single panel or in a pair of oppositely disposed panels; indeed an H shaped compression resistant structure 121 could also be used in combination with one or more compression resistant structures 20 of a square shape as described previously. Alternatively, a "C-shaped" or "U-shaped" compression resistant structure 621 could be provided for incorporating a handle H (see Figure 20); the "C-shaped" or "U-shaped" compression resistant structure forming in part a lifting edge. Again, such "C-shaped" or "U- shaped" compression resistant structure 621 could be used in combination with one or more compression resistant structures 20 of the first embodiment and/or "H-shaped" compression resistant structure 121 of the present embodiment and/or with a compression resistant structure 225 of the third embodiment to be described. It will be understood that such compression resistant structure would reinforce the handle structures H. The "C- shaped" or "U-shaped" compression resistant structures 621 shown in Figure 20 are arranged in opposite directions merely for illustrative purposes of one way the "C-shaped" or "U-shaped" compression resistant structure 621 could be configured. In other embodiments, only one "C-shaped" or "U-shaped" compression resistant structure 621 could be used, or where more than one "C-shaped" or "U-shaped" compression resistant structure 621 is used, they may be arranged in similar fashion such that the handle panels H or lifting edges thereby provided are disposed at substantially the same height. Though the addition of a second, third or fourth compression resistant structure 20 further increases the compression resistance of the overall package, manipulating and securing the two compression resistant structures is made simpler by having two or more structures hinged together. Reference is now made to Figures 10, 11 and 12. In a third embodiment of the invention a compression resistant structure 225 comprises two panels 220a, 220b hinged together along a crease line 250. Means for reducing the overall amount of material that is present along the crease line 250 is provided so that the blank 210 can hinge about fold lines 230, 232, 234, 236 without the compression resistant structure 225 impeding the folding. In the illustrated example, the means for reducing the overall amount of material that is present along the crease line 250 takes the form of a series of apertures. In other embodiments a series of interrupted half depth cuts may be sufficient.

Whereas each panel 220a, 220b of the compression resistant structure 225 can be affixed to the corresponding panel 214, 216 of the blank 210; it is only necessary that one of the panels 220a or 220b of the compression resistant structure is affixed to one of the panels 214 or 216 of the blank 210. By virtue of the hinged connection between the two panels 220a, 220b of compression resistant structure, the non-affixed panel 220b or 220a of the compression resistant structure automatically, will be held in position. During construction of the carton from the blank 210 however, the non-affixed panel 220b or 220a, will be free to "float" within the manipulated blank 210 and will allow for the easy manipulation of the blank 210 into a carton without any hindrance or impedance to the adjacent hinged connection of the blank 210.

In a variation of the third embodiment, a pair of compression resistant structures 225 is used. Figures 13 and 14 illustrate such a variation. The configuration of the Figure 14 structure, wherein one of the compression resistant structures 225 has corrugations aligned vertically 'FV and the other compression resistant structure 225 has corrugations aligned horizontally 'FH' provides for increased compression strength in all 3-dimensions and as such, regardless of the panel of the carton upon which the carton rests, the load applied to the opposite face will be borne at least in part by the compression resistant structure 225.

To further maximise the ease of construction of adding a compression resistant structure 325 into a carton or carton blank, in a fourth embodiment, (shown in Figure 15), the compression resistant structure 325 is a single unitary piece of material having a greater compression strength than the material from which the blank 310 is formed. In the illustrated arrangement, the blank 310 is formed of paperboard of a standard caliper for carton formation and the compression resistant structure 325 is formed of corrugated board having the corrugations or fluting running in a vertical direction 'FV (i.e. the corrugations run parallel to a notional line between an upper edge and a lower edge of the compression resistant structure 325, when the compression resistant structure 325 is laid flat as in Figure 15). The compression resistant structure 325 is provided with three fold lines 250, each having means for reducing the total amount of material present at an internal corner once the compression resistant structure 325 is folded. The compression resistant structure 325 can therefore be aligned with each of the four panels of the carton blank 310. As suggested above, the compression resistant structure 325 can be affixed by any known suitable means to the blank 310 and only part of the compression resistant structure 325 needs to be affixed to the blank 310, thus allowing one, two or three sections of the compression resistant structure 325 to move about their hinge lines 350 during construction of a composite part-formed blank (shown in bottom half of Figure 15). Beneficially, this arrangement allows for the manipulation of a single, unitary compression resistant structure 325, whilst at the same time enhancing the compression performance of the carton constructed from the composite blank. However, as explained above, such an arrangement will not provide for optimum increased compression performance for the material added irrespective of the orientation of the finished carton. For example, when disposed on say the first side panel, such that load is imparted onto the third side panel, each section of the corrugated compression resistant structure 325, will have fluting running "side-to-side" at a 90° angle to the direction of the load. Whereas the presence of the additional corrugated material will, even in that orientation provide an improvement to the compression strength of the overall carton that improvement is not as great as when the corrugations are aligned and run parallel to the direction of the imparted load.

In a further embodiment, not illustrated, a three section compression resistant structure is used in combination with a single-panel-compression resistant structure disposed in blank form with its corrugations running at 90° to the corrugations of the three section compression resistant structure such that the carton formed will have optimised additional compression strength regardless of its orientation. This arrangement does still require the manipulation of three pieces of material: a blank; a single-panel-compression resistant structure and a three-panel-compression resistant structure. The control and alignment of this many pieces of material, whilst possible to manipulate, by hand or by known packaging machines, does impart a degree of complexity. The final illustrated embodiment, is a single piece compression resistant structure 425 comprising four main panels 412a, 414a, 416a, 418a, each sized and configured to be similar to the corresponding panel of a blank for forming a carton (not shown) and each hinged along a materially reduced fold line 450. In addition, a glue panel 419 is provided.

The compression resistant structure 425 may therefore be constructed into a tubular four- sided sleeve by means of adhering section 412a to 418a using glue panel 419a. The specific order of construction will depend on manufacturing requirements and the following options are possible:

1) Affix glue panel 419a to first panel 412 to form the compression resistant structure 425 into a flat-folded pre-glued sleeve and ship alongside the blank; once blank formed into carton and compression resistant structure 425 opened into a tubular sleeve, load tubular sleeve into carton; insert articles and seal carton.

2) Affix glue panel 419a to first panel 412 to form the compression resistant structure 425 into a flat-folded pre-glued sleeve and ship alongside the blank; affix a panel, say 414a, to a blank (such as that in Figure 1) for forming a carton; part-form blank into part-glued, flat-formed sleeve and ship; complete construction of carton by opening blank and opening tubular compression resistant structure 425; load articles into carton and seal.

3) Affix each panel 412a, 414a, 416a, 418a or only two or three panels of the compression resistant structure 425 to the corresponding panels of the blank; affix glue panel of blank to first panel of the blank and at the same time affix the glue panel of the compression resistant structure 425 to the first panel 412a of the compression resistant structure 425; maintain pre-glued structure in flat-form for shipping; open composite structure; load and seal. The handling flexibility introduced by having a compression resistant structure 425 that can itself form a tubular sleeve that can be completely or partly formed and completely affixed to, partly affixed to or shipped separately from the blank is beneficial. However, the increase in flexibility means that the corrugations of the fluted cardboard from which the compression resistant structure 425 is formed do not run parallel to the load direction when the carton is disposed upon any of its side panels. However, by using four panels, there will always be two oppositely positioned panels of cardboard disposed within the carton to improve the compression strength of the carton and furthermore, the use of the glue panel 419a imparts an additional structural aspect to the compression resistant structure 425 which may further improve the compression strength of the overall carton. It is to be understood that these panels may not be affixed and placed in the carton at the time of loading.

It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and/or shape and/or number and/or configuration of the panels of the blank may be adjusted to form a carton having a variety of features or to form a carton that can accommodate articles of different size and/or shape and/or configuration and correspondingly the format of the compression resistant structure provided may also be altered. In other embodiments of the invention (not illustrated) it is envisaged that the various forms of compression resistant structure may be combined, for example, an 'H'- shaped compression resistant structure may be hinged to one or more other panels of the compression resistant structure. Though many embodiments have been described with reference to the construction materials being paperboard and corrugated cardboard, it will be appreciated that other suitable materials could be used instead of or in combination with the materials discussed and as such the materials mentioned represent non-limiting examples of suitable materials, but other materials may also be used. It is envisaged that the compression resistant structures of the present invention may be applied to a wide range of cartons of varying constructions and it should be understood that the invention is not limited in its application to a carton of the shape shown and/or comprising four walls, a top and a base. Indeed, it is envisaged that the compression resistant structures of the present invention may be applied to cartons formed from a non- unitary blank as well as from a unitary blank as depicted here.

Preferably, the compression resistant structures are formed of corrugated board, however, it will be understood that other materials will offer suitable compression resistance and for example, the following materials could also be used, either singularly or in combination to create compression resistant structures in accordance with the present invention: paperboard, corrugated board, plastics material, Coated Natural Kraftboard.

Whereas in the aforedescribed embodiments, the compression resistant structure is formed of corrugated cardboard and whereas in the aforedescribed embodiments, the compression resistant structure has been formed such that the corrugated channels or flutes of the cardboard can be disposed in substantially parallel alignment with a vertical load applied in a direction normal to the uppermost planar surface of the carton, in the sixth embodiment of the invention one or more compression resistant structures 520, 525 are formed such that the corrugated channels or flutes of the cardboard are disposed at an angle of about 45 degrees relative to the adjacent edges of the panel to which the compression resistant structure is affixed. The compression resistant structure 520 comprises a single panel of corrugated cardboard, wherein the corrugated channels run at 45° or substantially 45° to the edges of first side panel 512. As such, once the compression resistant structure 520 is incorporated into a carton the direction of the corrugated channels (indicated by FA2 in Figure 17) can be aligned at 45° relative to a vertical load (L) applied in a direction normal to the uppermost planar surface of the carton. This is illustrated schematically in Figure 19. In the illustrated arrangement, two compression resistant structures are utilised having a total of three corrugated panels. The first compression resistant structure 520 has, in planar form, (see Figure 17) corrugations arranged at 45 degrees relative to the edges of the side panel 512, as indicated by FA2 in Figure 17. The second compression resistant structure 525 comprises two panels connected by a hinged line 550 with corrugations also arranged at 45 degrees relative to the edges of the side panel 512, as indicated by FAl in Figure 17.

The resulting carton formed from the combination of the blank 510 and compression structures 520, 525 is shown in Figure 18. The carton has not been loaded and is shown with the composite top wall structure in an opened arrangement. However it will be understood that in order to obtain improved compression performance in each of the primary axes of the carton (x, y and z) a compression resistant structure(s) comprising only two panels with corrugated channels aligned at 45°, could provide increased compression performance irrespective of the panel of the carton that acts as the base of the carton. In planar form, the angled corrugations do not need to be oppositely oriented and as such use of a single compression resistant structure having two panels, such as the compression resistant structure 525 shown in Figure 17, is sufficient to provide improved compression performance in each of the primary axes of the carton (x, y and z).

It is to be understood that compression resistance may by important for stacking product packages prior to sale or important for moving the packages during storage and transportation. The direction of the external compression may vary (e.g. side compression via clamps or other similar warehouse tools used to move the packages and vertical compression due to product stacking). The cartons disclosed herein may provide increased compression resistance for both types of compression. It is to be further understood that an opening feature may be added to a side lacking a compression insert structure.

Using the same Compression Resistance Study described before, compression resistance was tested in a variety of different directions. Using a .021 inch thick board (21 Caliper board) for the carton and a C-Flute insert covering four of the six carton sides, the compression resistance from the length direction withstood between 360-375 lbs of pressure and around 310 - 329 lbs or pressure from a width direction and around 540-590 lbs of pressure from a horizontal direction resulting in an average compression resistance of between 400 - 440 lbs of pressure. Using a .027 inch thick board (27 Caliper board) for the carton and a C-flute insert wherein the flutes are set at around a 45 degree angle covering 3 panels, the carton had a horizontal compression resistance of around 694 lbs, a length resistance of around 431 lbs, and a width resistance of around 394 lbs resulting in an average compression resistance of over 500 lbs. Overall, using the various designs described herein compression resistance in the horizontal direction over a variety of Caliper cartons ranging from 21 Caliper to 30 Caliper and using C-Flute inserts ranged from 300 lbs up to 960 lbs with the average resistance falling between 400-500 lbs, in the length direction it ranged from 270 lbs up to 475 lbs with the average resistance falling between 300-400 lbs, in the width direction 300 up to 425 lbs with the average resistance falling between 300-400 lbs and having an average compression resistance in all directions ranging from 350 -510 lbs with the average resistance falling between 350-450 lbs. The resistance achieved depends on the calliper of the carton and the placement of the C-Flute insert panels. It is to be understood that corrugated board with other sized flutes may be used and may result in different compression values.

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 blank for forming a carton, the blank comprising panels for forming the carton walls and a compression resistant structure disposed affixed to an inside face of at least one of the panels of the blank, the compression resistant structure being structured and arranged such that the compression resistant structure does not prevent the blank from being foldable and manipulatable to form the carton, wherein at least a section of the compression resistant structure is sized and shaped similarly to the size and shape of one of the panels of the blank and fits within the perimeter of the one panel of the blank.

2. A blank according to claim 1 wherein the compression resistant structure is formed of corrugated material, and the compression resistant structure comprises at least three sections and wherein the direction of the corrugations of said sections, when the blank is erected into a carton, are orientated such that compression resistance is improved in three notional mutually perpendicular axes of the carton.

3. A blank according to claim 1 or 2 wherein the compression resistant structure comprises at least one section formed of corrugated material configured such that corrugations of the material are angled at substantially 45 degrees relative to the edges of the panel of the blank to which the section of the compression resistant structure is affixed.

4. A blank according to claim 1 wherein the compression resistant structure comprises a plurality of panels.

5. A blank according to claim 4 wherein at least two of the panels of the compression resistant structure are hinged to one another.

6. A blank according to claim 4 or 5 wherein the compression resistant structure comprises a pair of structures each comprising two hinged panels.

7. A blank according to either of claims 5 or 6 wherein a hinged connection between two adjacent panels comprises apertures, cut lines or other lines of severance whereby reducing the folding resistance and/or reducing the quantity of material present about the hinged connection.

8. A blank according to claim 1 wherein the compression resistant structure has a panel which is "H-shaped" or "I-shaped".

9. A blank according to claim 1 wherein the compression resistant structure has a panel which is "C-shaped" or "U-shaped".

10. A blank according to either claim 8 or 9 comprising a handle structure and wherein the compression resistant structure cooperates with the handle structure whereby reinforcing the handle structure.

11. A part-formed carton erected into flat collapsed form from the blank according to claims 1 to 10.

12. A carton comprising carton walls and a compression resistant structure disposed adjacent to an inside face of at least one of the carton walls, the compression resistant structure being structured and arranged such that the compression resistant structure does not interfere with corners of the carton formed between adjacent ones of the carton walls, wherein at least a section of the compression resistant structure is sized and shaped similarly to the size and shape of one of the carton walls and fits within the perimeter of the one carton wall.

13. A carton according to claim 12 wherein the compression resistant structure is formed of corrugated material and the compression resistant structure comprises at least three sections and wherein the direction of the corrugations of said sections are oriented such that compression resistance is improved in three notional mutually perpendicular axes.

14. A carton according to claim 12 or 13 wherein the compression resistant structure comprises at least one section formed of corrugated material configured such that corrugations of the material are angled at substantially 45 degrees relative to the edges of the carton wall to which the section of the compression resistant structure is adjacent.

15. A carton according to claim 14 wherein the at least one section comprises two sections and wherein the sections are affixed to the carton and oriented such that compression resistance is improved in three notional mutually perpendicular axes.

16. A compression resistant structure formed from corrugated material, comprising two hinged sections and having corrugations running at substantially 45 degrees relative to the edges of the two hinged sections or having corrugations running at substantially 90 degrees relative to at least two edges of the two sections.

17. A compression resistant structure according to claim 16 for use with a carton or blank according to any one of claims 1-15.

18. A blank according to claim 10 wherein the handle structure comprises a handle opening defined in the one panel of the blank, and the compression resistant structure comprises a cut-out that is disposed in alignment with the handle opening.

19. A carton according to claim 12 wherein the compression resistant structure is affixed to the inside face of the carton.

20. A carton according to claim 12 wherein the compression resistant structure comprises a cut-out that is disposed in alignment with a handle opening defined in the one carton wall.