US20160039586A1

US20160039586A1 - Package with handle, blank therefor and part-formed structure

Info

Publication number: US20160039586A1
Application number: US14/780,857
Authority: US
Inventors: Julien D. MERZEAU
Original assignee: WestRock Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2013-03-28
Filing date: 2014-03-28
Publication date: 2016-02-11
Also published as: CN105408224A; KR20150138283A; MX2015013662A; EP2978679B1; CA2908070A1; JP2016514655A; EP2978679A1; AU2014240899A1; GB201305793D0; WO2014160977A1; KR102176527B1

Abstract

A carton includes a bottom panel (12/22), and first (14/16) and second (side panels (24/26) each having upper (16, 26) and lower (14, 24) portions. The first side panel has first (32 a, 32 b) and second (30 a, 30 b) apertures. The first side panel (14/16) is arranged to be disposed on opposing sides of an article B while the second side panel (24/26) is arranged to be disposed on opposing sides of a second article B. The carton includes a reinforcing panel (20 a, 20 b, 20 c, 20 d) coupling the first and second side panels together. The reinforcing panel is disposed in face contacting relationship with the upper portions (16, 26) of the first and second side panels so as to substantially ‘V’ shaped.

Description

FIELD OF THE INVENTION

The present invention relates to an article carrier having an improved article retention feature. More specifically, but not exclusively, the invention relates to a blank for forming a carrier and a part-formed structure used in the assembly of the carrier having an improved article retention feature for securely holding articles contained by the package carrier, the automated assembly of which is readily achieved. Additionally, the carrier may have a shape that is characteristic of the brand of product being packaged.

BACKGROUND OF THE INVENTION

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers, such multi-packs are desirable for shipping and distribution and for display of promotional information. For cost and environmental considerations, such cartons or carriers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Another consideration is the strength of the packaging and its suitability for holding and transporting large weights of articles. Carriers are often provided with article retention features so that the articles can be securely held within the carton. An example of a carrier with an article retention feature is disclosed in GB 2,279,065. The carton has a planar base for supporting the articles and three retaining sections arranged in an oblique and zig-zag orientation relative to the plane of the base. A package is manually assembled by passing the base of a bottle horizontally through an aperture in an intermediate retaining section and then passing the base of the bottle through an aperture in the a lower retaining section. The bottle neck is then passed through an aperture in an upper retaining section by movement of the bottle in the opposite direction. Threading a bottle such that it is partially bottom loaded and then partially top loaded into the carton is highly disadvantageous since automation of the assembly of the carrier and packaging of the bottles cannot be readily achieved and manual loading and assembly is slow and costly. It is therefore desirable to have a carrier that can be loaded and assembled in an automated manner by packaging machinery.
Yet another consideration is the eye-catching or aesthetically pleasing qualities of the package which may aid in the marketing of the packaged products to consumers.
The present invention seeks to overcome or at least mitigate the problems of the prior art.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a carton for packaging a plurality of articles comprising:

- a bottom panel;
- a first side panel and a second side panel each having upper and lower portions;
- the first side panel having first and second apertures for receiving a first article, the first aperture being struck from the upper portion of the first side panel and the second aperture being struck from the lower portion of the first side panel;
- the second side panel having third and fourth apertures for receiving a second article, the third aperture being struck from the upper portion of the second side panel and the fourth aperture being struck from the lower portion of the second side panel;
- wherein the first side panel is folded between the first and second apertures such that a first portion of the first side panel is disposed on a first side of the first article and a second portion of the first side panel is disposed upon a second side of the first article; and
- wherein the second side panel is folded between the third and fourth apertures such that a first portion of the second side panel is disposed on a first side of the second article and a second portion of the second side panel is disposed upon a second side of the second article;
- the carton comprising a reinforcing panel coupling the first and second side panels together;
- the reinforcing panel comprising a first and second cutaway or aperture each for receiving a respective one of the first or second articles;
- the reinforcing panel comprising a first fold line disposed between the first and second cutaways or apertures; and
- the reinforcing panel being disposed in face contacting relationship with the upper portions of the first and second side panels so as to be substantially ‘V’ shaped.

Optionally, a handle strap may be struck from the reinforcing panel and is displaced out of the reinforcing panel for carrying the carton.
Optionally, the first side panel comprises a second fold line disposed between first and second aperture and the second side panel comprises a third fold line disposed between the third and fourth apertures, the second fold line being disposed adjacent and proximate to the third fold line.
Preferably, the second and third fold lines are disposed proximate to the first fold line.
According to a second aspect of the present invention there is provided a package comprising a first article and a second article and a carton as described in the foregoing paragraphs wherein the first article is received in the first and second apertures of the first side panel such that a portion of the first article is disposed externally of the first side panel and wherein the second article is received in the third and fourth apertures of the second side panel such that a portion of the second article is disposed externally of the second side panel.
Optionally, a neck portion of the first article is disposed externally of the first side panel and a neck portion of the second article is disposed externally of the second side panel.
In some embodiments, the handle strap may extend over a top or crown of the first and second articles.
In some embodiments, the handle strap may be shaped such that a portion of is disposed over the top or crown of the first and second articles.
Optionally, the handle strap is hinged to the upper portion of the first side panel and to the upper portion of the second side panel such that in use the handle panel tightens the upper portions of the first and second side panels and the reinforcing panel about the first and second articles.
According to a third aspect of the present invention there is provided a blank for forming a carton comprising:

- a first panel forming a reinforcing panel;
- a second panel for forming a first upper side panel hinged to a first edge of the first panel;
- a third panel for forming a second upper side panel hinged to a second edge of the first panel, the second edge opposing the first edge;
- a fourth panel for forming first lower side panel hinged to the second panel;
- a fifth panel for forming a second lower side panel hinged to the second panel; and
- a sixth panel for forming bottom panel hinged to the fourth or fifth panels.

Optionally, a handle panel may be struck at least in part from the first panel and is coupled to each of the second and third panels.
Optionally, the first panel comprises one or more apertures for receiving an article and the second and third panels each comprise apertures each of which is arranged to be in at least partial alignment with a respective aperture in the first panel, and wherein the fourth and fifth panels each comprise apertures each of which is arranged to be in at least partial alignment with a respective aperture in the first panel and a respective aperture in the second or third panels when the second, third, fourth and fifth panels are folded so as to overlie, at least in part, the first panel.
In some embodiments, the sixth panel comprises a first part hinged to the fourth panel and a second part hinged to the fifth panel.
According to a fourth aspect of the present invention there is provided a part-formed structure for forming a package comprising:

- a first panel forming a reinforcing panel;
- a second panel for forming a first upper side panel hinged to a first edge of the first panel;
- a third panel for forming a second upper side panel hinged to a second edge of the first panel, the second edge opposing the first edge;
- a fourth panel for forming first lower side panel hinged to the second panel;
- a fifth panel for forming a second lower side panel hinged to the second panel; and a sixth panel for forming bottom panel hinged to the fourth or fifth panels, and
- wherein the first panel comprises one or more apertures for receiving an article and the second and third panels each comprise one or more apertures and the fourth and fifth panels each comprise one or more apertures,
- wherein the second and third panels are each folded about a respective hinge line, coupling the second or third panel to the first panel, to overlay a portion of the first panel such that each of the apertures in the second and third panels is arranged to be in at least partial alignment with a respective aperture in the first panel,
- the fourth and fifth panels are each folded about a respective hinge line, coupling the fourth or fifth panel to a respective one of the second or third panels, to bring a portion of each of the fourth and fifth panels into an overlapping arrangement with the respective one of the second or third panels to which they are hinged and to overlay the respective portion of the first panel which the second or third panel overlays;
- wherein each one of the apertures in the first panel is brought into at least partial alignment with one of the apertures in the second or third panels and with one of the apertures in the fourth or fifth panels.

In some embodiment of this aspect, a handle panel may be struck at least in part from the first panel and may be coupled to each of the second and third panels;
According to a fifth aspect of the present invention there is provided a method of packaging one or more articles comprising:

- providing a blank having:
  - a first panel forming a reinforcing panel including a plurality of apertures or cutaways each for receiving an article respectively and a first fold line extending transversely thereacross;
  - a second panel for forming a first upper side panel hinged to a first edge of the first panel by a second fold line, the second panel comprising one or more apertures each for receiving a respective article;
  - a third panel for forming a second upper side panel hinged to a second edge of the first panel by a third fold line, the second edge opposing the first edge, the third panel comprising one or more apertures each for receiving a respective article;
  - a fourth panel for forming first lower side panel hinged to the second panel by a fourth fold line, the fourth panel comprising one or more apertures each for receiving a respective article;
  - a fifth panel for forming a second lower side panel hinged to the second panel by a fifth fold line, the fifth panel comprising one or more apertures each for receiving a respective article; and
  - a sixth panel for forming bottom panel hinged to the fourth or fifth panels by a sixth fold line,
- folding the second panel to overlay a first portion of the first panel to bring each of the one or more apertures in the second panel into at least partial alignment with a respective one of the plurality of apertures in the first panel;
- folding the third panel to overlay a second portion of the first panel to bring each of the one or more apertures in the third panel into at least partial alignment with a respective other one of the plurality of apertures in the first panel;
- folding the fourth panel to overlay the second panel and the first portion of the first panel to bring each of the one or more apertures in the fourth panel into at least partial alignment with an aperture in the first panel and an aperture in the second panel;
- folding the fifth panel to overlay the third panel and the second portion of the first panel to bring each of the one or more apertures in the fifth panel into at least partial alignment with an aperture in the first panel and an aperture in the third panel;
- providing a group of articles;
- moving the blank in a folded state relative to the group of articles;
- receiving an article in each of the plurality of cutaways or apertures of the first panel and a respective aperture in the second or third panels and a respective aperture in the fourth or fifth panels with which the plurality of cutaways or apertures of the first panel are aligned,
- unfolding, at least partially, the fourth and fifth panels about the fourth and fifth fold line respectively and
- folding the first panel about the first fold line into a substantially “V” shaped arrangement.

Optionally, a handle panel may be struck at least in part from the first panel and may be coupled to each of the second and third panels.
Optionally, the method may comprise:

- deforming or folding the fourth and fifth panels about the opposing side of the group of articles;
- folding the sixth panel about the base of the group of articles; and
- securing the sixth panel to form a carrier.

Optionally, the method may comprise:

- at least partially unfolding the handle panel with respect to the second and third panels.

Optionally, the method may comprise:

- securing the first panel respective portions of the second and third panels in face contacting relationship.

In some embodiments, the handle panel may be unfolded with respect to the second and third panels simultaneously with the at least partial folding of the first panel in response to receiving the group of article in the blank.
Optionally, the method comprises engaging an inner surface of the handle panel with the ends of the articles.
According to a sixth aspect of the present invention there is provided a package comprising a group of articles and a carrier, the carrier comprising: a handle panel, a retention wall, first and second side walls, and a bottom wall,

- wherein each end of the handle panel is foldably connected to an upper and outer edge of the retention wall and extends across the top of the group of articles for use as a strap-type-handle deployable above the top of the group of articles;
- wherein the retention wall is substantially “V”-shaped in cross-section and comprises two retention structures, each retention structure comprises at least one article retention aperture for receiving a first portion of an article of the group and each retention structure is angled obliquely and inwardly toward an internal centre of the carrier;
- wherein each of the first and second side panels comprises at least one article receiving aperture, a part of each article receiving aperture being disposed in vertical registry with a part of one of said article retention apertures in a retention structure for receiving a second portion of said article of the group;
- wherein each of the first and second side walls are hinged along an upper edge thereof to portions of the retention wall that are disposed proximate to the internal centre of the carrier, such that the first and second side walls each diverge from their upper edges toward an outer side of the group of articles.

Within the scope of this application it is envisaged and intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a plan view from above of a blank for forming a carrier according to a first embodiment of the invention;

FIG. 2 is a perspective view from above of the blank of FIG. 1 being folded, optional locations for the application of adhesive are indicated;

FIG. 3 is a perspective view from above of the blank of FIG. 1 having been folded and affixed into a part-formed structure—the underside of the part-formed structure is shown;

FIG. 4 is a perspective view from above of the blank of FIG. 1 having been folded and affixed into a part-formed structure—the outer-side of the part-formed structure is shown;

FIG. 5 is a perspective view of the part-formed structure of FIGS. 3 and 4 having been opened up and being assembled about a group of articles to form a package comprising a carrier assembled about the articles;

FIG. 6 is a perspective view from above of a package according to a first embodiment of the invention comprising a carrier formed from the part-formed structure of FIGS. 3 and 4 assembled about a group of articles that are thereby securely grouped as a unit that can be carried by a handle of the carrier; and

FIG. 7 is an end view of the package of FIG. 6.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

Detailed descriptions of specific embodiments of the package, blank, carrier and part-formed structure are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the package, blank, carrier and part-formed structure described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.
In the embodiments detailed herein, the terms “carton” and “carrier” refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging, carrying, and/or dispensing articles, such as bottles. However, it is contemplated that the teachings of the invention can be applied to various containers, which may or may not be tapered and/or cylindrical. Other exemplary articles include bottles (for example metallic, glass or plastics bottles), cans (for example aluminium cans), tins, pouches, packets and the like.
The blank 10 shown in FIG. 1 is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the carrier structure described in more detail below. Where a printable or coatable substrate material is used, for example, paperboard, the term “outerside” as used herein may be taken to mean the coated and/or printed side that is more exposed in the finished package. The term “underside” as used herein may be taken to mean the uncoated and/or unprinted side that is less exposed in the finished package.
In the exemplary embodiment, the blank 10 is sized and configured to form a carton or carrier for packaging an exemplary arrangement of exemplary articles. In this example, the arrangement is a 2×2 matrix or array and the articles are bottles. In an optional aspect of the present invention, the shape of the carrier formed from the blank 10 has characteristics that are evocative and/or suggestive of aspects of the brand of product contained in packaged bottles. In this way the package of the present invention has an improved marketing quality because the package itself is not only physically structured for being a useful carry-pack, but its appearance is also evocative of the product brand packaged. The blank 10 can be alternatively configured to form a carrier for packaging other articles, other brands of product, different numbers of articles and/or different arrangements of articles.
The blank 10 comprises a linear series of interconnected panels that are foldable and affixable (optionally by adhesive) to form, in the first instance, a part-formed structure 80 (see FIGS. 3 and 4) and thereafter, a carrier 90 which forms part of a completed package comprising the carrier and a group of articles B (see FIG. 6).
Returning to FIG. 1, the linear series of interconnected panels comprises: a first bottom panel 12, a first lower side panel 14, a first upper side panel 16 (also referred to herein as a first retention panel 16), a first pair of reinforcing panels 20 a, 20 b, a handle panel 18, a second pair of reinforcing panels 20 c, 20 d, a second upper side panel 26 (also referred to herein as a second retention panel 26), a second lower side panel 24 and a second bottom panel 22. The linear series of interconnected panels 12, 14, 16, 20 a, 20 b, 18, 20 c, 20 d, 26, 24 and 22 are hinged together one to the next along transversely arranged fold lines: 38, 40, 42, 44, 46 a, 46 b, 48, 50, 52 and 54.
The first and second lower side panels 14, 24 are larger in dimension than the respective first or second upper side panel 16, 26 to which they are hinged. The first and second lower side panels 14, 24 are longer or taller than the respective first or second upper side panel 16, 26 to which they are hinged. In other embodiments other arrangements are envisaged depending upon the shape and configuration of the articles B.
Preferably, the first and second lower side panels 14, 24 and first and second upper side panels 16, 26 are arranged such that the first and second lower side panels 14, 24 extend from the base of an article B to a shoulder region where a neck portion of the article B meets a body portion. The first and second upper side panels 16, 26 extend from the shoulder region and extend over the neck portion to the top of the article B.
The first and second bottom panels 12, 22 are optionally provided with complementary parts 70, 72 of a mechanical locking mechanism for affixing the first and second bottom panels 12, 22 together to form a composite bottom wall 12/22. Such mechanisms are known in the art and are typical of wraparound style carriers, where the mechanical locking mechanism provides for some adjustability to enable the carrier to be tightly wrapped about a group of articles B for securing the articles B within the carrier. However, it is envisaged that aspects of the present invention may be applied advantageously in other styles of carrier and therefore the mechanical locking mechanism 70, 72 is entirely optional. In a wraparound style of carrier or in another style of carrier, the mechanical locking mechanism may be replaced by other types of affixing means, for example, adhesive, tuck flaps and/or staples.
Between the first bottom panel 12 and first lower side panel 14; and between the second bottom panel 22 and second lower side panel 24, heel locking features 74 are provided. These again are optional features, typically provided in wraparound style carriers where the tight fit of the carrier 90 to the articles B is important in ensuring that the articles B are securely held. It will be recognised that where the invention is implemented in another style of carrier that such heel locking features 74 may be omitted. In embodiments in which such heel locking features 74 are provided, their style and type, size, number and configuration all may be adapted from that illustrated in order to accommodate articles B of varying style, type, shape, position and number.
The blank 10 comprises a series of article receiving apertures and openings 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d, 34 a, 34 b, 34 c, 34 d. Two approximately elongated-oval-shaped article receiving apertures 30 a, 30 b are struck from the first lower side panel 14; and two approximately elongated-oval-shaped article receiving apertures 30 c, 30 d are struck from the second lower side panel 24. Two approximately oval-shaped article receiving apertures 32 a, 32 b are struck from the first retention panel 16; two approximately oval-shaped article receiving apertures 32 c, 32 d are struck from the second retention panel 26. The shape of the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d is illustrated in FIG. 1 and is not limited to that shown in the exemplary illustrated embodiment. Upon consideration of FIG. 6 and the following description, it will be recognised that the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d are shaped such that when the carrier 90 is constructed from the blank 10 and the first and second lower side panels 14, 24 and the first and second retention panels 16, 26 are disposed at oblique angles relative to the articles B contained in the completed package and relative to one another, that the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d fit about a portion of an article B. In other embodiments of the invention where the panels 14, 16, 24, 26 are disposed at different angles relative to one another and/or relative to the articles B, and/or where the articles B have a different shape, that the shape of the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d may differ from that shown.
Optionally, the blank 10 is additionally provided with partial apertures or openings 34 a, 34 b and 34 c, 34 d disposed in the first pair of reinforcing panels 20 a, 20 b, and second pair of reinforcing panels 20 c, 20 d respectively. These openings 34 a, 34 b, 34 c, 34 d are shaped similarly to corresponding portions of the apertures 32 a, 32 b and 32 c, 32 d provided in the first and second retention panels 16, 26 respectively. This is so that when the first pair of reinforcing panels 20 a, 20 b overlay the first retention panel 16; and when the second pair of reinforcing panels 20 c, 20 d overlay the second retention panel 26 (see FIGS. 2, 3 and 4 along with the further description below of the construction of the blank 10), the openings 34 a, 34 b, 34 c, 34 d do not interrupt the article receiving apertures 32 a, 32 b and 32 c, 32 d provided in the first and second retention panels 16, 26 and, at the same time, the first pair of reinforcing panels 20 a, 20 b, and second pair of reinforcing panels 20 c, 20 d provide a maximum amount of reinforcement. Therefore, it is preferable that the openings 34 a, 34 b and 34 c, 34 d are similarly shaped to the corresponding portions of the apertures 32 a, 32 b and 32 c, 32 d. In other embodiments, the openings 34 a, 34 b and 34 c, 34 d may be significantly larger than the apertures 32 a, 32 b and 32 c, 32 d and/or not similarly shaped. This however would reduce the amount of reinforcement provided by the first pair and second pair of reinforcing panels 20 a, 20 b and 20 c, 20 d to the first and second retention panels 16, 26.
The blank 10 is configured for forming a carton or carrier 90 that houses four similarly sized and shaped bottles B in a 2×2 arrangement. The completed package with bottles B is shown in FIG. 7. FIG. 7 depicts a notional vertical axis ‘Y’ (running between the crown of the bottle B and the base of the bottle B) and a notional orthogonal, horizontal axis ‘X’. The bottles B have a generally circular cross-sectional shape, when considering cross-sections taken through the bottle B in a plane that is orthogonal to the vertical ‘Y’ axis. The first and second retention panels 16, 26 in a set-up carrier 90 (see FIG. 6 and FIG. 7) are disposed at an angle (V) of between about 35° and about 45° relative to the horizontal ‘X’ axis. Sections of the first and second lower side panels 14, 24 are disposed at an angle (W) of between about 25° and about 45° relative to the horizontal ‘X’ axis. Cross-sections taken through the bottles B at angles of between about 25° and about 45° are not circular, but rather oval in shape. To accommodate the shape of the article, when the panel 14, 24, 16, 26 is disposed at an oblique angle, the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d are shaped similarly to the ovaloid shape of the bottle B on an oblique angle. In other embodiments where the articles B accommodated by the package are differently shaped, sized and/or configured; and/or where the panels 14, 24, 16, 26 are differently angled in the finished package, the article receiving apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d may have a different shape and/or size. The benefit of the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d acting as article retention features in the overall package 90 will be described in more detail with reference to the completed package and its construction.
Turning to the construction of the carton 90 as illustrated in FIGS. 2, 3, 4 and 5 it is envisaged that the part-formed structure 80 and carton or carrier 90 can be formed by a series of sequential folding operations in a straight line machine so that the part-formed structure 80 and/or carrier 90 is not required to be rotated or inverted to complete its construction. The folding process is not necessarily limited to that described below and may be altered according to particular manufacturing requirements.
Affixing means, for example adhesive may be applied in the regions illustrated by ‘G’ in FIG. 2. The regions illustrated by ‘G’ are optional, but provide for a linear application of adhesive in four interrupted strips at positions that: facilitate affixing the inside faces of the first pair of reinforcing panels 20 a, 20 b to the inside face of the first retention panel 16; and facilitate affixing the inside faces of the second pair of reinforcing panels 20 c, 20 d to the inside face of the second retention panel 26. The first retention panel 16 is folded about fold lines 44 and 42 to bring part of its inside surface into face contacting relationship with each panel of the first pair of reinforcing panels 20 a, 20 b; and into face contacting relationship with part of the handle panel 18. Similarly, the second retention panel 26 is folded about fold lines 48 and 50 to bring part of its inside surface into face contacting relationship with each panel of the second pair of reinforcing panels 20 c, 20 d; and into face contacting relationship with part of the handle panel 18. The first and second retention panels 16, 26 are not affixed to the handle panel 18. The resulting part-formed structure 80 is shown in FIGS. 3 and 4.
In FIG. 3 it can be seen from the underside of the part-formed structure 80 that as the first and second retention panels 16, 26 are folded about fold lines 44/42 and 48/50, the first and second lower side panels 14, 24 are brought toward one another, such that their top folded edges, defined by fold lines 42 and 50 respectively, are disposed side-by-side. In this way, the first and second retention panels 16, 26 have been affixed together such that their hinged edges 42, 40 with the first and second lower side panels 14, 24 respectively are immediately side-by-side (see FIG. 3). Disposed on top of the hinged edges 42, 50 are the fold lines 46 a, 46 b between the first and second pairs of reinforcing panels 20 a, 20 b, 20 c, 20 d. A top structure is thereby formed comprising the handle panel 18 and a composite retention wall 16/26/20 a/20 b/20 c/20 d. In the finished package, the composite retention wall 16/26/20 a/20 b/20 c/20 d is “V”-shaped (see FIGS. 6 and 7).
In the part-formed structure 80, the first and second lower side panels 14, 24 have their upper edges 42, 50, disposed side-by-side and each hanging from a substantially common position, disposed centrally of the composite retention wall 16/26/20 a/20 b/20 c/20 d.
To reduce the overall length of the part-formed structure 80 in readiness for transportation to a converting plant one of the first or second side panels 14, 24 may be folded on top of the other second or first side panel 24, 14. This folding step may be completed at the same time as the folding of the first and second retention panels 16, 26 or as a subsequent step. The term part-formed structure 80 therefore refers to the structure formed when the first pair of reinforcing panels 20 a, 20 b have been affixed to the first retention panel and the second pair of reinforcing panels 20 c, 20 d have been affixed to the second retention panel 26. This is irrespective of whether the first and second lower side panels 14, 24 are folded into overlapping relationship with one another or remain in an “open” state, as depicted in FIGS. 3 and 4.
The part-formed structure 80 may be transported to a converting plant, whereat a package of articles B and carrier 90 is formed from the part-formed structure 80 and a group of articles B. The part-formed structure, if necessary is unfolded and placed into its “open”-state, ready for it being applied to an assembled group of articles B. Reference is now made to FIG. 5, wherein it can be seen that the part-formed structure 80 is placed over an article group. This may be performed manually or in an automated manner using a packaging assembly.
To assist construction of the package, the part-formed structure 80 is arranged such that the apertures 30 a, 30 b, 30 c, 30 d, of the first and second lower side panels 14, 24 (which now form part of an inner most layer of the part-formed structure 80), are in at least partial alignment with the apertures 32 a, 32 b, 32 c, 32 d, of the first and second retention panels 16, 26 (which now form an intermediate layer of the part-formed structure 80), and are in at least partial alignment with the openings 34 a, 34 b, 34 c, 34 d, of the first and second pairs of reinforcing panels 20 a, 20 b, 20 c, 20 d (which now form part of an outermost layer of the part-formed structure 80). The alignment of each set of three apertures and openings 30 a/32 a/34 a, 30 b/32 b/34 b, 30 c/32 c/34 c, 30 d/32 d/34 d is illustrated in FIGS. 3 and 4 by the directional arrow D′. The arrangement of the sets of apertures and openings 30 a/32 a/34 a, 30 b/32 b/34 b, 30 c/32 c/34 c, 30 d/32 d/34 d in this way makes the application of the part-formed structure 80 onto the bottles B simpler, and therefore easier to automate, than a method involving loading the neck portion of each bottle B first through a side wall aperture 30 a, then through a retention wall aperture 32 a and then finally through an opening 34 a. As such the wraparound style carrier of the illustrated embodiment is loaded by movement (of either the bottles or the carrier) in a single direction which places each bottle into a set of apertures. This enables automation of the loading and assembly process to be carried out simply and quickly. This is in stark contrast to the prior art where manual weaving or threading of articles B is required in order to assemble a carrier with oppositely directed, obliquely angled panels.
During assembly, the part-formed structure 80 may be gripped to keep part of each of the first and second lower side panels 14, 24 in contact with, or at least close to, the first or second retention panel 16, 26. The apertures and openings 30 a/32 a/34 a, 30 b/32 b/34 b, 30 c/32 c/34 c, 30 d/32 d/34 d may, thereby, be maintained in their sets, at least until, a bottle B has been loaded into each set 30 a/32 a/34 a, 30 b/32 b/34 b, 30 c/32 c/34 c, 30 d/32 d/34 d. Thereafter, the first and second lower side panels 14, 24 will be released from being maintained in contact with, or at least close to, the first or second retention panel 16, 26. The size and shape of the apertures 30 a, 30 b, 30 c, 30 d in the first and second side panels 14, 24, will allow the first and second lower side panels 14, 24 to move further down the bottle B (in the direction of axis ‘Y’ as shown in FIG. 7) compared to the apertures 32 a, 32 b, 32 c, 32 d in the first and second retention panels 16, 26 and openings 34 a, 34 b, 34 c, 34 d that together moved down from the crown of the bottle B slightly down the neck of the bottle B.
The first and second lower side panels 14, 24 are thereafter folded about the sides of the group of bottles B and the first and second bottom panels 12, 22 are then folded about fold lines 38, 40, 52 and 54 to locate the heel of each article B in a heel locking feature 74 and to bring the first and second bottom panels 12, 22 into overlapping relationship. The complementary locking mechanism 70, 72 is then deployed, as is known in the art, to connect the two panels 12, 22 together and thereby form a composite bottom wall and secure the carrier in a tightly wrapped form about the articles B.
It will be recognised that the articles B may be loaded into a respective one of the aperture/opening sets 30 a/32 a/34 a, 30 b/32 b/34 b, 30 c/32 c/34 c, 30 d/32 d/34 d by relative movement of the part-formed structure 80 and articles B. In other words, the bottles B may be moved toward the part-formed structure 80 and/or the part-formed structure 80 may be moved toward the articles B.
The handle panel 18 is preferably sized and shaped such that it contacts or partially overlaps (in superposition) part of the top or crown of each bottle B in the finished package.
The completed package is shown in FIG. 6; the package comprises four articles B disposed within the carton 90. The articles are disposed upon the composite base panel 12/22. The carton 90 comprises a first side panel 14/16 formed from first lower side panel 14 and first upper side panel 16 and a second side panel 24/26 formed from second lower side panel 24 and second upper side panel 26. A first article B is received in the article receiving aperture 30 a struck from the first lower side panel 14 and a second article B is received in the article receiving aperture 30 b struck from the first lower side panel 14, a third article B is received in the article receiving aperture 30 c struck from the second lower side panel 24 and a fourth article B is received in the article receiving aperture 30 d struck from the second lower side panel 24. The first article B is received in the article receiving aperture 32 a struck from the first upper side panel 16 and the second article B is received in the article receiving aperture 32 b struck from the first upper side panel 16, the third article B is received in the article receiving aperture 32 c struck from the second upper side panel 26 and the fourth article B is received in the article receiving aperture 32 d struck from the second upper side panel 26. The first side panel 14/16 is folded such that a first portion “100” of the first side panel 14/16 is disposed upon a first side of the first and second articles B and a second portion “200” of the first side panel 14/16 is disposed upon a second, opposing, side of the first and second articles B. The second side panel 24/26 is folded such that a first portion “300” of the second side panel 24/26 is disposed upon a first side of the third and fourth articles B and a second portion “400” of the second side panel 24/26 is disposed upon a second, opposing, side of the third and fourth articles B (see FIG. 7). The reinforcing panel 20 a/20 b/20 c/20 d couples the first side panel 14/16 to the second side panel 24/26. The reinforcing panel 20 a/20 b/20 c/20 d is hinged at one end to the first upper side panel 16 and at an opposing end to the second upper side panel 26. The reinforcing panel 20 a/20 b/20 c/20 d comprises openings such as recesses, cutaways or apertures 34 a, 34 b, 34 c, 34 d each of which receives a respective one of the articles B. It will be appreciated that the reinforcing panel 20 a/20 b/20 c/20 d comprises a fold line 46 a defined therein and extending transversely across the reinforcing panel 20 a/20 b/20 c/20 d. The fold line 46 a is disposed between the openings 34 a, 34 b and the openings 34 c, 34 d. The reinforcing panel 20 a/20 b/20 c/20 d is disposed in face contacting relationship with the respective first or second upper side panels 24, 26, and is substantially ‘V’ shaped. The carton 90 comprises a handle strap 18 struck from the reinforcing panel 20 a/20 b/20 c/20 d which is displaced out of the reinforcing panel 20 a/20 b/20 c/20 d when carrying the carton 90. The handle strap or top panel 18 when not in substantially rests upon the tops of the articles B and may be in contacting relationship with at least a portion of the top of each article B.
It will be appreciated that the handle strap 18 extends over the top of the articles B and may be considered to be a top panel since it partially covers the tops of the articles B.
FIG. 6 shows that the first retention panel 16 is disposed at an angle (V) relative to a notional horizontal axis (X) as depicted in FIG. 7. An upper section of the first lower side panel 14 is also disposed at an angle (W) relative to a notional horizontal axis (X) as depicted in FIG. 7. The first retention panel 16 and upper section of the first lower side panel 14 are disposed at an angle relative to one another of about angle (V) plus angle (W). The sum of angles (V) and (W) may total between about 60° and about 90°. The second retention panel 26 and upper section of the second lower side panel 24 are similarly configured. As such, in end view, the package has a shaped form that is substantially ‘X’ shaped in part. It can be seen from FIG. 7, that the upper sections of the first and second lower side panels 14, 24 may bow to some extent. This is due to the lower side panel 14, 24 intersecting a bottle B and being tightly wrapped about it; and having a lower section of each lower side panel 14, 24 that is substantially parallel with the straighter sides of the bottle B. Each bottle B is retained by two obliquely angled retaining panels (part of the retention wall 16/26/20 a/20 b/20 c/20 d and part of a side wall 14, 24).
Each obliquely angled retaining panel (part of the retention wall 16/16/20 a/20 b/20 c/20 d and part of a side wall 14, 24) is disposed at an angle relative to the bottle B such that the edges of each aperture or opening 30 a, 30 b, 30 c, 30 d 32 a/34 a, 32 b/34 b, 32 s/34 c, 32 d/34 d, secure the bottle B at a range of heights. For example, the upper article retention apertures or openings 32 a/34 a, 32 b/34 b, 32 c/34 c, 32 d/34 d in the composite retention wall 16/26/20 a/20 b/20 c/20 d are angled such that the uppermost and lower most edges of the upper article retention apertures or openings 32 a/34 a, 32 b/34 b, 32 c/34 c, 32 d/34 d are spaced apart by the greatest diameter of the upper article retention apertures or openings 32 a/34 a, 32 b/34 b, 32 c/34 c, 32 d/34 d, which may be between about 3 cm and about 6 cm and preferably about 4 cm. The lower article retention apertures 30 a, 30 b, 30 c, 30 d in the first and second lower side panels 14, 24 are angled such that the uppermost and lower most edges of the lower article retention apertures 30 a, 30 b, 30 c, 30 d are spaced apart by the greatest diameter of the lower article retention apertures 30 a, 30 b, 30 c, 30 d, which may be between about 6 cm and about 9 cm and preferably about 7.3 cm.
The upper article retention apertures or openings 32 a/34 a, 32 b/34 b, 32 c/34 c, 32 d/34 d and indeed the “V”-shaped composite retention wall 16/26/20 a/20 b/20 c/20 d are inwardly angled. By that it is meant that the uppermost edge 44, 48 of each upper retention panel 16/20 a/20 b and 26/20 c/20 d is outermost and that each upper retention panel 16/20 a/20 b and 26/20 c/20 d is angled inwardly towards the centre of the carrier 90; and it is meant that the uppermost edge 42, 50 of the lower retention panels 14, 24 are disposed innermost (and centrally of the carrier 90), whereas the lowermost sections of the lower retention panels 14, 24 are disposed outermost.
Due to the uppermost retention panels 16/20 a/20 b and 26/20 c/20 d being inwardly angled, the handle panel 18 can be formed as a strap handle that extends across the top of the article B group and which bows upwardly above the tops of the bottles B. This provides a convenient and comfortable way to lift the carrier 90.
Because the upper and lower retention panels 16/20 a/20 b, 26/20 c/20 d and 14, 24 are disposed at opposite angles, movement of the bottles B, once packaged within the carrier 90, is even further restricted. This configuration of two obliquely angled retention panels connected to the top and bottom of the carrier 90 provides for very secure retention of the articles B and due to the alignment of the aperture sets 30 a/32 a/34 a, 30 b/32 b/34 b, 30 c/32 c/34 c, 30 d/32 d/34 d in the part-formed structure 80, assembly of the carrier 90 is simple enough to be effectively automated.
The optional, cross end shape of the package gives an aesthetically pleasing quality which may make the package stand-out to a consumer for an improved marketing effect. This may be especially so, where the brand or branding associated with the packaged product has a connection to the cross-end shape of the package.
It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and shape of the panels and apertures may be adjusted to accommodate articles B of differing size or shape. In other embodiments of the invention it is envisaged that one or more or all of the apertures and openings 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d, 34 a, 34 b, 34 c, 34 d may comprise one or more or a series of foldable tabs. Such tabs may increase the tightness of fit of an aperture or cut-out about an article. Optionally, however, it is preferred to have clean-cut aperture and cut-outs for the aesthetic appeal of the overall package and the retention mechanism provided by the present invention is sufficient that foldable tabs are not necessarily required. It is also envisaged that the number, position and shape of the apertures 30 a, 30 b, 30 c, 30 d, 32 a, 32 b, 32 c, 32 d and cut- outs 34 a, 34 b, 34 c, 34 d shown in the illustrated example may be different in other embodiments in order to support different types, sizes, number and configurations of articles B.
In other embodiments, sticking tape, other chemical bonding agent or a mechanical fixing means such as staples, Velcro, a mechanical lock, may be used for fastening the bottom panels together.
In other envisaged embodiments, the reinforcing panels 20 a, 20 b, 20 c, 20 d may not comprise cut-outs as such, but rather may serve only to attach the first and second retention panels 16, 26 to one another. In such embodiments, the reinforcing panels may be rectangular in shape and of uniform width. In blank form, their innermost edge may or may not be defined by the handle panel 18.
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 necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.
As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line is typically a scored line, an embossed line, or a debossed line. Any reference to hinged connection or fold line should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from any one or more of the following, a short slit, a frangible line or a fold line without departing from the scope of the invention.
As used herein, the term “severance line” refers to all manner of lines that facilitate separating portions of the substrate from one another or that indicate optimal separation locations. Severance lines may be frangible or otherwise weakened lines, tear lines, cut lines, or slits.
As used herein, the word “opening” refers to a recess, a cutaway or an aperture.
As used herein, the term “upper side panel” refers to the upper portion 16 or 26 of the first or second side panel while the term “lower side panel” refers to the lower portion 14 or 24 of the first or second side panel.
It should be understood that hinged connection, severance lines and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

Claims

1. A carton for packaging a plurality of articles, comprising:

a bottom panel;

a first side panel and a second side panel each having upper and lower portions;

the first side panel having first and second apertures for receiving a first article, the first aperture being struck from the upper portion of the first side panel and the second aperture being struck from the lower portion of the first side panel;

the second side panel having third and fourth apertures for receiving a second article, the third aperture being struck from the upper portion of the second side panel and the fourth aperture being struck from the lower portion of the second side panel;

wherein the first side panel is folded between the first and second apertures such that a first portion of the first side panel is disposed on a first side of the first article and a second portion of the first side panel is disposed upon a second side of the first article;

and wherein the second side panel is folded between the third and fourth apertures such that a first portion of the second side panel is disposed on a first side of the second article and a second portion of the second side panel is disposed upon a second side of the second article;

the carton further comprising a reinforcing panel coupling the first and second side panels together;

the reinforcing panel comprising first and second openings each for receiving a respective one of the first and second articles;

the reinforcing panel comprising at least one first fold line disposed between the first and second openings; and

the reinforcing panel being disposed in face contacting relationship with the upper portions of the first and second side panels so as to be substantially ‘V’ shaped.

2. The carton according to claim 1 wherein at least one handle strap is struck from the reinforcing panel and is displaced out of the reinforcing panel for carrying the carton.

3. The carton according to claim 1 wherein the first side panel comprises at least one second fold line disposed between first and second aperture, and the second side panel comprises at least one third fold line disposed between the third and fourth apertures, the at least one second fold line being disposed proximate to the at least one third fold line.

4. The carton according to claim 3 wherein the at least one second fold line and the at least one third fold line are disposed proximate to the at least one first fold line.

5. The carton according to claim 1 wherein the first article is received in the first and second apertures of the first side panel such that at least one portion of the first article is disposed externally of the carton and wherein the second article is received in the third and fourth apertures of the second side panel such that at least one portion of the second article is disposed externally of the carton.

6. The carton according to claim 5 wherein the at least one portion of the first article is a neck portion of the first article and the at least one portion of the second article is a neck portion of the second article.

7. The carton according to claim 2 wherein the handle strap extends over tops of the first and second articles.

8. The carton according to claim 7 wherein the handle strap is shaped such that a portion of the handle strap is disposed over the tops the first and second articles.

9. The carton according to claim 7 wherein the handle strap is hinged to the upper portions of the first and second side panels such that in use the handle panel tightens the upper portions of the first and second side panels and the reinforcing panel about the first and second articles.

10. A blank for forming a carton comprising:

a first panel forming a reinforcing panel of the carton;

a second panel hinged to a first edge of the first panel to form an upper portion of a first side panel of the carton;

a third panel hinged to a second edge of the first panel to form an upper portion of a second side panel of the carton, the second edge opposing the first edge;

a fourth panel hinged to the second panel to form a lower portion of the first side panel;

a fifth panel hinged to the third panel to form a lower portion of the second side panel; and

a sixth panel hinged to at least one of the fourth and fifth panels to form a bottom panel of the carton.

11. The blank according to claim 10 wherein the first panel comprises openings for receiving an article, wherein the second and third panels each comprises at least one aperture which is arranged to be in at least partial alignment with a respective one of the openings in the first panel, and wherein the fourth and fifth panels each comprise at least one aperture which is arranged to be in at least partial alignment with a respective one of the openings in the first panel and with a respective one of the at least one aperture in the second or third panel when the second, third, fourth and fifth panels are folded so as to overlie, at least in part, the first panel.

12. The blank according to claim 10 wherein the first panel comprises openings for receiving an article, wherein the second and third panels each comprises at least one aperture which is arranged to be in at least partial alignment with a respective one of the openings in the first panel, and wherein the fourth and fifth panels each comprise at least one aperture which is arranged to be in at least partial alignment with a respective one of the openings in the first panel and with a respective one of the at least one aperture in the second or third panel when the second, third, fourth and fifth panels are folded so as to overlie, at least in part, the first panel.

13. The blank according to claim 10 wherein the sixth panel comprises a first part hinged to the fourth panel and a second part hinged to the fifth panel.

14. A part-formed structure for forming a carton comprising:

a first panel forming a reinforcing panel of the carton;

a sixth panel hinged to at least one of the fourth and fifth panels, and wherein the first panel comprises openings for receiving articles and the second and third panels each comprise at least one aperture and the fourth and fifth panels each comprise at least one aperture,

wherein the second and third panels are each folded about a respective hinge line, coupling the second or third panel to the first panel, to overlay a portion of the first panel such that each of the apertures in the second and third panels is arranged to be in at least partial alignment with a respective one of the openings in the first panel,

the fourth and fifth panels are each folded about a respective hinge line, coupling the each of the fourth and fifth panels to a respective one of the second and third panels, to bring a portion of each of the fourth and fifth panels into an overlapping arrangement with the respective one of the second or third panels to which the fourth and fifth panels are hinged and to overlay the respective portion of the first panel which the second or third panel overlays.

15. The part-formed structure according to claim 14 wherein a handle panel is struck at least in part from the first panel and is coupled to each of the second and third panels.

16-26. (canceled)