Note: Descriptions are shown in the official language in which they were submitted.
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LAMINATED ARTICLE CARRIER AND BLANK THERFOR
TECHNICAL FIELD
The present invention relates to article carriers and to blanks for forming
the same. More
specifically, but not exclusively, the invention relates to a carrier of the
top-gripping or top-
engaging style having one or more apertures for receiving and retaining an
article therein.
BACKGROUND
In the field of packaging it is known to provide cartons for carrying multiple
articles. Cartons
are well known in the art and are useful for enabling consumers to transport,
store and access
a group of articles for consumption. 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. Further considerations
are the strength
of the carton and its suitability for holding and transporting large weights
of articles. It is
desirable that the contents of the carton are secure within the carton.
It is well known to provide top gripping article carriers in which an aperture
is formed in a panel
of the carrier, tabs may be defined about said aperture. The tabs are
displaceable out of the
plane of said panel. When an article is received in the aperture said tabs
engage the article
generally about a flange or lip of the article.
The present invention seeks to provide an improvement in the field of cartons,
typically formed
from paperboard or the like.
SUMMARY
A first aspect of the invention provides a method of forming a top-engaging
article carrier
comprising:
providing a first paperboard substrate;
providing a second paperboard substrate;
applying an adhesive treatment to a first surface of the first paperboard
substrate
uniformly thereacross;
securing a surface of the second paperboard substrate to the first surface of
the first
paperboard substrate to form a laminated paperboard structure;
cutting one or more blanks from the laminated paperboard structure.
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Optionally, cutting one or more blanks from the laminated paperboard structure
comprises
cutting one or more top engaging devices each having a top-receiving opening
from the
laminated paperboard structure.
Optionally, the method comprises;
applying the blank to one or more articles to form a package;
engaging the one or more a top engaging devices with a respective one of the
one or
more articles.
Optionally, the one or more top engaging devices each the comprise at least
one tooth, the at
least one tooth comprising a uniformly bonded multiply laminate structure and
wherein
engaging the one or more a top engaging devices with a respective one of the
one or more
articles comprises;
engaging an edge of the at least one tooth with a flange of the respective one
of the
one or more articles.
A second aspect of the invention provides a top-engaging article carrier for
packaging at least
one article. The article carrier comprises a main panel including at least one
a top engaging
device having a top-receiving opening. The main panel comprises a laminated
structure
formed from two or more layers of a substrate uniformly bonded together.
Optionally, the top engaging device comprises one or more teeth for engaging
an article, the
one or more teeth comprising two or more layers of substrate which are
uniformly bonded
together.
Optionally, each of the two or more layers of substrate comprises at least one
uncoated side.
Optionally, each of the two or more layers of substrate comprises a coated
side and wherein
the coated side of a first layer is bonded to the coated side of a second
layer.
Optionally, each of the two or more layers of substrate comprises an uncoated
side opposite
the coated side.
Optionally, each of the two or more layers of substrate comprises an uncoated
side and
wherein the uncoated side of a first layer is bonded to the uncoated side of a
second layer.
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Optionally, each of the two or more layers of substrate comprises a coated
side opposite the
uncoated side.
Optionally, each of the two or more layers of substrate comprises a second
uncoated side
opposite a first uncoated side.
Optionally, each of the two or more layers of substrate comprises an uncoated
side and
wherein an uncoated side of a first layer is bonded to an uncoated side of a
second layer.
Optionally, the laminated structure comprises;
a first layer having a coated side and an uncoated side opposite the coated
side; and
a second layer having an uncoated side;
wherein an uncoated side of a first layer is bonded to an uncoated side of a
second
layer.
Optionally, the substrate is a paperboard material.
A third aspect of the invention provides a blank for forming a top-engaging
article carrier. The
blank comprises a main panel including at least one a top engaging device
having at least one
top-receiving opening. The main panel comprises a laminated structure formed
from two or
more layers of a substrate uniformly bonded together.
A fourth aspect of the invention provides an article carrier for packaging at
least one article.
The article carrier comprises a main panel including at least one an article
retention device
having at least one article-receiving opening. The main panel comprises a
laminated structure
formed from two or more layers of a paperboard material uniformly bonded
together.
A fifth aspect of the invention provides a laminated paperboard structure for
forming an article
carrier comprising two or more layers of a paperboard substrate including a
first layer having
a first surface and a second layer comprising a second surface. The second
surface is
disposed adjacent to the first surface and is uniformly bonded thereto.
VVithin the scope of this application it is envisaged or 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 considered or
taken
independently or in any combination thereof.
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Features or elements described in connection with, or relation to, one
embodiment are
applicable to all embodiments unless there is an incompatibility of features.
One or more
features or elements from one embodiment may be incorporated into, or combined
with, any
of the other embodiments disclosed herein, said features or elements extracted
from said one
embodiment may be included in addition to, or in replacement of one or more
features or
elements of said other embodiment.
A feature, or combination of features, of an embodiment disclosed herein may
be extracted in
isolation from other features of that embodiment. Alternatively, a feature, or
combination of
features, of an embodiment may be omitted from that embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will now be described with reference to
the
accompanying drawings, in which:
Figure 1 is a plan view from above of a plurality of connected blanks, each
blank
capable of forming a carrier according to a first embodiment;
Figure 2 is a plan view from above of one of the blanks of Figure 1;
Figure 3 is a perspective view from above of a carrier formed from the blank
of Figure
2;
Figure 4 is a plan view from above of a plurality of connected blanks, each
blank
capable of forming a carrier according to a second embodiment; and
Figures 5A to 5E are schematic illustrations of multiply structures formed
from
paperboard substrates according to various embodiments of present disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
Detailed descriptions of specific embodiments of the package, blanks and
carriers 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 packages, blanks
and carriers
described herein may be embodied in various and alternative forms. The Figures
are not
necessarily to scale and some features may be exaggerated or minimized 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
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merely as a basis for the claims and as a representative basis for teaching
one skilled in the
art to variously employ the invention.
Referring to Figure 1, there is shown a plan view of a plurality of connected
blanks 10A, 10B,
.. 100, 10D, 10D, 10E, 10F; an individual blank 10 is shown in Figure 2 which
is capable of
forming a carton or carrier 90, as shown in Figure 3, for containing and
carrying a group of
primary products such as, but not limited to, bottles or cans, hereinafter
referred to as articles
B, as shown in Figure 3. The blank 10 forms a secondary package for packaging
at least one
primary product container or package. An alternative blank 110 is shown in
Figure 4.
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 and
carrying articles, such as primary product containers. It is contemplated that
the teachings of
the invention can be applied to various product containers, which may or may
not be tapered
and/or cylindrical. Exemplary containers include bottles (for example
metallic, glass or plastics
bottles), cans (for example aluminum cans), tins, pouches, packets and the
like.
The blanks 10,110 are 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,
where suitable,
for example, to provide the carrier structure described in more detail below.
The packaging structures or cartons described herein may be formed from a
sheet material
such as paperboard, which may be made of or coated with materials to increase
its strength.
An example of such a sheet material is tear-resistant NATRALOCKO paperboard
made by
WestRock Company. It should be noted that the tear resistant materials may be
provided by
more than one layer, to help improve the tear-resistance of the package.
Typically, one surface
of the sheet material may have different characteristics to the other surface.
For example, the
surface of the sheet material that faces outwardly from a finished package may
be particularly
smooth and may have a coating such as a clay coating or other surface
treatment to provide
good printability. The surface of the sheet material that faces inwardly may,
on the other hand,
be provided with a coating, a layer, a treatment or be otherwise prepared to
provide properties
such as one or more of tear-resistance, good glue-ability, heat sealability,
or other desired
functional properties.
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In the illustrated embodiments, the blank 10 is configured to form a carton or
carrier 90 for
packaging an exemplary arrangement of exemplary articles B. In the embodiment
illustrated
in Figures 1, 2 and 3, the arrangement is a 2 x 2 matrix or array; in the
illustrated embodiment
two rows of two articles are provided, and the articles B are beverage cans.
In the
embodiments illustrated in Figure 4, the arrangement is a 3 x 2 matrix or
array; in the illustrated
embodiments three rows of two articles are provided, and the articles B are
beverage cans.
Alternatively, the blanks 10, 110 can be configured to form a carrier for
packaging other types,
number and size of articles and/or for packaging articles in a different
arrangement or
configuration.
Referring to Figure 1 there is shown a plurality of connected blanks referred
to generally by
reference sign 1, specifically there are six blanks 10A, 10B, 100, 10D, 10E,
1OF arranged in
a 3 x 2 matrix or array. Each blank 10A, 10B, 100, 10D, 10E, 1OF comprises a
main panel 12
for forming a top wall or engaging panel of a carrier 90 (see Figure 3). Each
blank 10A, 10B,
100, 10D, 10E, 1OF is connected to at least two adjacent blanks 10A, 10B, 100,
10D, 10E,
1OF by frangible connections 14.
The main panel 12 includes at least one article retention structure RT1, RT2,
RT3, RT4, see
Figure 2. In the embodiment of Figures 1 and 2 the main panel 12 comprises a
plurality of
article retention structures RT1, RT2, RT3, RT4, specifically four article
retention structures
RT1, RT2, RT3, RT4 arranged in 2 x 2 matrix or array. Each of the article
retention structures
RT1, RT2, RT3, RT4 comprise an aperture Al, A2, A3, A4.
Each of the article retention structures RT1, RT2, RT3, RT4 is substantially
similar in
construction and will therefore be described in detail with reference to the
second article
retention structure RT2.
The second article retention structure RT2 comprises an article receiving
opening defined in
part by an aperture A2.
The second article retention structure RT2 comprises a first segment and a
second segment.
The first segment S1 defines a first arc S1 and the second segment defines a
second arc S2.
The first segment may be 'toothed', the second segment may be 'toothless'.
That is to say the
aperture A2 comprises a plurality of teeth disposed about the first arc S1, in
a perimeter region
of the aperture A2 defined by the first segment S1. A perimeter region, the
second arc S2, of
the aperture A2 defined by the second segment is free from teeth. In the
embodiment
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illustrated in Figure 2 the second segment comprises an arcuate edge having a
pair of spaced
apart relief notches 08, 09.
The 'toothed' region comprises a plurality of teeth or tabs formed in the main
panel 12 about
the aperture A2.
Each tooth comprises an engaging or tooth edge 31. Each tooth edge 31 may be
linear in
shape or may be arcuate. The tooth edges 31 may be defined by an arc or
portion of a circle.
The aperture A2 comprises a perimeter which may approximate, or define, a
notional circle
having a center.
The 'toothed' region of the main panel 12 surrounding the aperture A2 may
comprise cutaways
Cl, 02, 03, 04, 05, 06, 07 in the form of recesses or notches. The cutaways
Cl, 02, 03, 04,
05, 06, 07 are substantially "U" shaped, in other embodiments the cutaways Cl,
02, 03, 04,
05, 06, 07 may be alternatively shaped such as but not limited to "V" shaped.
The cutaways
Cl, 02, 03, 04, 05, 06, 07 extend radially outward from the notional circle
NC.
Each of the teeth or tabs is defined, at least in part, by a pair of cutaways
Cl, 02, 03, 04, 05,
06, 07. The cutaways Cl, 02, 03, 04, 05, 06, 07 may form relief elements
extending radially
away from the center of the notional circle.
The toothless or tooth free region S2 of the main panel 12 surrounding the
aperture A2
comprises an engaging or free edge 37 (also referred to herein as continuous
supporting
edge). The engaging edge 37 is curvilinear or arcuate in shape.
The toothless or tooth free region of the main panel 12 surrounding the
aperture A2 may be
defined in, or occupy, an arc subtending an angle of about 180 , in other
embodiments the
angle may be less than 180 , for example but not limited to 170 .
In this way substantially half of the perimeter of the aperture A2 comprises
teeth or tabs.
The second article retention structure RT2 comprises two adjacently disposed
relief elements
Cl, 07 between which the engaging edge 37 is defined. The engaging edge 37 may
be
interrupted by one or more relief elements 08, 09. In the illustrated
embodiment, the engaging
edge 37 is interrupted by two relief elements 08, 09.
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The main panel 12 may optionally comprise a handle structure H. The handle
structure H may
comprise a handle opening. The handle opening is defined in the main panel 12
and is located
in a region disposed centrally between a first pair of article retention
structures RT1, RT2 and
a second pair of article retention structures RT3, RT4. The handle opening may
be defined at
least in part by a cushioning tab 16 hinged to the main panel 12 by fold line
15.
Optionally, the side edges of the main panel 12 may be arranged in a
curvilinear or undulating
shape. In this way, a first blank 10 may be arranged in a nested arrangement
with a second
blank 10. The undulating shape provides that the first and second blanks 10
together define a
width which is less than twice the maximum width of an individual blank 10.
This may have
economic and environmental benefit by reducing the amount of substrate
required to produce
a given number of blanks 10.
The main panel 12 includes at least a paperboard substrate. The material of
the paperboard
substrate may be selected from any conventional paperboard, for example,
ranging in weight
upwardly from about 1Opt. (0.010"/-0.25mm), preferably from about 16pt.
(0.016"/-0.41mm)
to about 28pt. (0.028"/-0.7mm). The paperboard substrate may be a bleached or
unbleached
board. The board may be coated on at least one side with a conventional
coating selected for
compatibility with the printing method and board composition.
An example of such a substrate is a 28 point (pt.) SBS board (solid bleached
sulfate
paperboard coated on one side, trade name PrintKote0), unbleached uncoated
kraftboard
(UUK) or CNKO board (Coated Natural Kraft -an unbleached kraft paperboard
having a clay
coating on one side, trade name CarrierKoteTM) manufactured by WestRock
Company.
In the illustrated embodiment the main panel 12 is formed from two layers of a
paperboard
substrate bonded together to form a laminated paperboard material. An adhesive
treatment
or glue may form a glue layer between two layers of paperboard substrate.
Figures 5A to 5E
illustrate a various embodiments of a laminated paperboard material for
forming the article
carrier 90.
Figure 5A shows an embodiment comprising a laminated paperboard structure
comprising a
first ply L1 of paperboard having a coating 52 on one side of a fibre layer
50. The first ply L1
of paperboard is bonded to a second ply L2 of paperboard having a coating 52
on one side of
a fibre layer 50. The uncoated side, the fibre layer 50 of the first layer L1
is bonded to the
uncoated side, the fibre layer 50 of the second layer L2; an adhesive
treatment or glue forms
a glue or adhesive layer 54 therebetween. The laminated structure of Figure 5A
may be
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resistant to curling, due for example, but not limited to, to moisture
sorption (absorption or
adsorption) and/or desorption by the fibre layers. The laminated paperboard
structure
comprises coatings on opposed surfaces which may inhibit moisture sorption
and/or
desorption by the fibre layers.
Figure 5B shows an embodiment comprising a laminated paperboard structure
comprising a
first ply L1 of paperboard having a coating 52 on one side of a fibre layer
50. The first ply L1
of paperboard is bonded to a second ply L2 of paperboard having a coating 52
on one side of
a fibre layer 50. The coated side of the first layer L1 is bonded to the
coated side of the second
layer L2; an adhesive treatment or glue forms a glue or adhesive layer 54
therebetween.
Figure 50 shows an embodiment comprising a laminated paperboard structure
comprising a
first ply L1 of paperboard having a coating 52 on one side of a fibre layer
50. The first ply L1
of paperboard is bonded to a second ply L2 of paperboard having a coating 52
on one side of
a fibre layer 50. The uncoated side, the fibre layer 50 of the first layer L1
is bonded to the
coated side of the second layer L2; an adhesive treatment or glue forms a glue
or adhesive
layer 54 therebetween.
Figure 5D shows an embodiment comprising a laminated paperboard structure
comprising a
first ply L1 of paperboard having a coating 52 on one side of a fibre layer
50. The first ply L1
of paperboard is bonded to a second ply L2 of uncoated paperboard having a
fibre layer 50.
The uncoated side, the fibre layer 50 of the first layer L1 is bonded to one
of the uncoated
sides of the second layer L2; an adhesive treatment or glue forms a glue or
adhesive layer 54
therebetween.
Figure 5E shows an embodiment comprising a laminated paperboard structure
comprising a
first ply L1 of uncoated paperboard having a fibre layer 50. The first ply L1
of paperboard is
bonded to a second ply L2 of uncoated paperboard having a fibre layer 50. One
of the
uncoated sides of the first layer L1 is bonded to one of the uncoated sides of
the second layer
L2; an adhesive treatment or glue forms a glue or adhesive layer 54
therebetween.
In one example a first sheet of a 28pt CBS or CNK board is bonded to a second
sheet a 28pt
CBS or CNK board. This produces a substrate having a thickness of about 0.056"
around
1.4mm having a coating on opposing faces thereof. An advantage of such a
substrate is
increased strength without the inclusion of a polymeric material or plastics
material, such
substrates may provide environmental benefit and be more easily recycled. In
other
embodiments the coated side of one layer or sheet of material is bonded to the
uncoated side
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of another layer or sheet of material. In alternative embodiments the coated
side of one layer,
or sheet, of material is bonded to the coated side of another layer, or sheet,
of material.
It will be appreciated that the thickness or caliper (density or weight) of
the paperboard
substrates selected for bonding together may be of different thicknesses or
weights. It will also
be appreciated that the thickness or caliper (density or weight) of the
paperboard substrates
selected may be selected based upon the weight or load that the article
carrier is intended to
support, for example article carriers for packaging larger volume/heavier
beverage cans or a
greater number of beverage cans may be formed from thicker (or heavier weight)
paperboards
substrates. Similarly, when the article carrier is intended to support larger
loads the article
carriers may be formed from a greater number of layers or plies of paperboard
substrate
bonded together.
The glue layer may be formed of any adhesive having a good affinity to
paperboard such as
an aqueous glue (e.g., white craft glue, yellow wood glue and Polyvinyl
acetate ¨PVA glue).
Two or more sheets of paperboard are laminated together into a laminated
paperboard and
then the laminated paperboard may be die-cut into carrier blanks 10 such as
that of Figure 1.
In some embodiments the blanks and article carriers are formed from two or
more sheets or
rolls of paperboard stock which are commercially available which sheets or
rolls are bonded
together to form a laminated structure. It is envisaged that the laminated
structure is formed
from paperboard stock which has been dried in a paper mill, the paperboard
stock may also
have been subject to one or more dry-end treatments such as, but not limited
to, calendering
and/or finishing with a coating prior to being bonded together.
In some embodiments a surface of the paperboard substrate which is to be
bonded to another
paperboard substrate may be treated or conditioned to improve cohesion, such
as, but not
limited to, by perforating or otherwise interrupting the surface for example
with partial depth
cuts.
The top-engaging carrier 90 comprises uniformly bonded layers. In those
embodiments in
which the top-engaging carrier 90 comprises engaging teeth, each tooth has
uniformly bonded
paperboard layers. This is advantageous over article carriers having multiple
paperboard
layers having an unglued structure and over article carriers having a post-
glued structure in
which the paperboard layers are adhered after each layer of paperboard was die-
cut. In such
post-glued article carriers because each layer is already die cut the layers
are adhered
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together by spot gluing and therefore carrier does not have uniformly glued
layers. Where the
carrier comprises engaging teeth the teeth do not comprise uniformly glued
layers and may
be formed from unbonded layers.
In some embodiments at least one tear resistant layer may be disposed between
the first and
second layers of the substrate, such a substrate may be formed by bonding two
sheets of
material at least one of which comprises a tear resistant layer laminated
thereto. This may
have the advantage of increasing the strength of the substrate.
The main panel 12 may include a tear resistant layer laminated to the
paperboard layer. It
optionally includes an adhesive layer between the paperboard substrate and the
tear resistant
layer. The tear resistant layer may be disposed over the uncoated side of the
paperboard
substrate and may be formed of polymeric material and secured to the
substrate. The tear
resistant layer imparts toughness to the laminate structure. Suitable tear
resistant materials
may include, but not be limited to, tear resistant laminated sheet material,
e.g., NATRALOCKO,
which may include a layer of an n-axially oriented film, e.g. MYLARO, which is
a bi-axially
oriented polyester, oriented nylon, cross-laminated polyolefin or high density
polyolefin. The
orientation and cross-laminated structure of these materials contribute to the
tear resistant
characteristic. Also, tear resistance may be attributed to the chemical nature
of the tear
resistant material such as extruded metallocene-catalyzed polyethylene (mPE).
Alternatively, the tear resistant layer may be a layer of linear low-density
polyethylene (LLDPE).
In embodiments where linear low-density polyethylene (LLDPE) or mPE is used,
it is not
necessary to incorporate an adhesive layer. Other suitable materials having a
high level of
tear resistance may also be used.
The adhesive layer may be formed of polyolefin material such as a low-density
polyethylene
(LDPE). The adhesive layer may be placed between the substrate and the tear
resistant layer
to secure the tear resistant layer to the substrate.
Turning to the construction of the carrier 90 from the blank 10, the blank 10
may be applied to
a group of articles B. The blank 10 is lowered with respect to the group of
articles B. Each of
the article retention structures RT1, RT2, RT3, RT4 of the blank 10 are
aligned with a
respective article B in the group. Portions of the articles B pass through the
main panel 12.
The toothed regions of the main panel 12 about each of the article retention
structures RT1,
RT2, RT3, RT4 may be folded out of the plane of the main panel 12.
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Each toothed region of the main panel 12 may be folded about one of the
articles received in
the respective one of the article retention structures RT1, RT2, RT3, RT4; the
blank 10 may
deform about the article B for example but not limited to a shoulder portion
of the article B,
where the article B is a can the shoulder portion may be provided by the neck-
in.
The engaging edges 31 of the teeth and the engaging edge 37 of the tooth free
region of the
main panel 12 engage beneath a projection. The projection may be located about
the neck or
chime of the article B (which may provide a flange) of an article B. When the
article B is a can
the projection may be provided by a canner's end seam. In other embodiments it
may be
provided by a ridge or undercut shaping of the article B or by an end closure
of the article B
for example but not limited to a crown cork or closure. In this way, the
engaging edges 31, 37
grip or hold the article B and prevent or inhibit the article B from
unintentionally separating
from the main panel 12. The assembled carrier 90 is shown in Figure 3.
The teeth comprise two layers of substrate uniformly bonded together which
provide secure
engagement of the article B.
Another optional feature of the carrier 90 is that the main panel 12 is
defined by a perimeter
to which no other part of the carrier 90 is connected. That is to say, the
carrier 90 is free of
connection to other panels for example, but not limited to, side or end wall
panels which extend
about the sides of the article group. The perimeter of the main panel 12 is
therefore defined in
its entirety by free, cut or unhinged edges.
Another optional feature of the carrier 90 is that the main panel 12 is
defined by a perimeter
including convexly curved edges and concavely curved edges, wherein the radius
of curvature
of the convexly curved edges is substantially equal to the radius of curvature
of the concavely
curved edges, thus allowing two similar blanks 10 to be placed in a nested or
tessellated
arrangement.
In some embodiments the plurality of blanks 1 is applied simultaneously to a
first group of
articles B. The first group of articles B is divisible into a plurality of
second groups of articles
B. Each second group of articles B is thus formed from a subset of the first
group of articles
B. The embodiment illustrated in Figure 1 the first group of articles B
comprises twenty-four
articles arranged in a 4x6 matrix or array, and each individual blank 10A,
10B, 100, 10D, 10E,
1OF accommodates four articles in a 2x2 matrix or array.
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The frangible connections 14 between the individual blanks 10A, 10B, 100, 10D,
10E, 1OF
may separate upon application of the plurality of blanks 1 to the first group
of articles B.
Alternatively, the frangible connections 14 may remain intact, individual
blanks 10A, 10B, 100,
10D, 10E, 1OF may be separated from the others at a point of sale or
distribution.
Referring now to Figures 4, there is shown an additional embodiment of the
present disclosure.
In the second illustrated embodiment like numerals have, where possible, been
used to denote
like parts, albeit with the addition of the prefix "100", to indicate that
these features belong to
the second embodiment. The additional embodiment shares many common features
with the
first embodiment and therefore only the differences from the embodiment
illustrated in Figures
1 to 3 will be described in detail.
Figure 4 illustrates a second embodiment and shows a plurality of connected
blanks referred
to generally by reference sign 101 specifically there are four blanks 110A,
110B, 1100, 110D,
arranged in a 2 x 2 matrix or array. Each blank 110A, 110B, 1100, 110D
comprises a main
panel 112 for forming a top wall or engaging panel of a carrier (not shown).
Each blank 110A,
110B, 1100, 110D is connected to two adjacent blanks 110A, 110B, 1100, 110D,
by frangible
connections 114.
The main panel 112 of each blank 110A, 110B, 1100, 110D includes at least one
article
retention structure RT1, RT2, RT3, RT4, RT5, RT6. The main panel 112 comprises
a plurality
of article retention structures RT1, RT2, RT3, RT4, RT5, RT6, specifically six
article retention
structures RT1, RT2, RT3, RT4, RT5, RT6 arranged in 3 x 2 matrix or array.
Each of the article
retention structures RT1, RT2, RT3, RT4, RT5, RT6 comprise an aperture Al, A2,
A3, A4, AS,
A6.
Each of the article retention structures RT1, RT2, RT5, RT6, also referred to
as endmost article
retention structures RT1, RT2, RT5, RT6, is substantially similar in
construction to the article
retention structures RT1, RT2, RT3, RT4 of the embodiment of Figures 1 and 2.
These article
retention structures comprise six teeth disposed about the perimeter of the
apertures Al, A2,
AS, A6. The article retention structures RT1, RT2, RT5, RT6 are disposed in
corners or the
main panel 112.
The article retention structures RT3, RT4, also referred to as intermediate
article retention
structures RT3, RT4, are disposed medially on the main panel 112, between a
first pair of end
most article retention structures RT1, RT2 and a second pair of end most
article retention
structures RT5, RT6.
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The intermediate article retention structures RT3, RT4 comprise three teeth
each tooth is
defined in part by a pair of relief elements C. Each tooth comprises an
engaging edge 131,
132, 133. The engaging edges 131, 132, 133 of the teeth occupy a portion of
the perimeter of
the aperture A3, A4. The portion defines a first arc of a notional circle
having a center, the
angle subtended by the arc may be less than 120 , it may be greater than 60
and may be
around 90 . The first arc is defined between two relief elements
The retention structures RT3, RT4 comprises a toothless or tooth free portion.
The tooth free
portion defines a second arc complimentary to the first arc. The tooth free
region comprises
an engaging edge 137.
The main panel 112 may optionally comprise a handle structure H1, H2. The
handle structure
H1, H2 may comprise a first opening formed at least in part by a first handle
aperture. The first
handle aperture is struck from the main panel 112 and is located in a region
disposed centrally
between a first pair of article retention structures RT1, RT2 and a second
pair of article
retention structures RT3, RT4. The first opening may be defined in part by a
first cushioning
tab hinged to the main panel 112 by a fold line. The first handle aperture may
be substantially
crescent or "C" shaped. The handle structure H1, H2 may comprise a second
opening formed
at least in part by a second handle aperture. The second handle aperture is
struck from the
main panel 112 and is located in a region disposed centrally between the
second pair of article
retention structures RT3, RT4 and a third pair of article retention structures
RT5, RT6. The
second opening may be defined in part by a second cushioning tab hinged to the
main panel
112 by a fold line. The second handle aperture may be substantially crescent
or "C" shaped.
The first and second openings may be arranged in opposition to each other,
such that the first
and second cushioning flaps are hinged to the main panel 112 in opposition to
each other.
The present disclosure provides a carrier of the top engaging type having
article retention
structures or article top engaging devices formed in a laminated substrate
formed from two or
more layers of a paperboard substrate uniformly bonded together. The laminated
substrate is
formed prior to die cutting a blank therefrom.
The laminated substrate may be formed from two or more sheets or rolls of
paperboard at
least one of which is preprinted with graphics or other indicia. The two or
more sheets or rolls
are laminated after printing of one of the layers. In this way a laminated
substrate with printed
graphics or other indicia on at least one side is formed. The printed
laminated substrate is then
cut to form carrier blanks. In some embodiments where the laminated substrate
is formed from
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rolls of paperboard the laminated substrate may be cut into sheets prior to
cutting the carrier
blanks. In other embodiments where the laminated substrate is formed from
rolls of
paperboard it is not necessary to cut the laminated substrate into sheets, the
carrier blanks
may be cut directly from the laminated substrate using an inline die cutting
device.
The laminated substrate may be formed from bonding two or more sheets or rolls
of unprinted
paperboard together. Once the laminated substrate is formed at least one side
may be printed
with graphics or other indicia. In this way a laminated substrate with printed
graphics or other
indicia on at least one side is formed. The printed laminated substrate is
then cut to form
carrier blanks. In embodiments where the laminated substrate is formed from
rolls of
paperboard the laminated substrate may be printed inline or may be cut into
sheets which are
then printed.
It will be recognized that as used herein, directional references such as
"top", "bottom", "base",
"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.
Any reference to
"hinged connection" should not be construed as necessarily referring to a
single fold line only;
indeed a hinged connection can be formed from two or more fold lines wherein
each of the
two or more fold lines may be either straight/linear or curved/curvilinear in
shape. When linear
fold lines form a hinged connection, they may be disposed parallel with each
other or be
slightly angled with respect to each other. When curvilinear fold lines form a
hinged connection,
they may intersect each other to define a shaped panel within the area
surrounded by the
curvilinear fold lines. A typical example of such a hinged connection may
comprise a pair of
arched or arcuate fold lines intersecting at two points such that they define
an elliptical panel
therebetween. A hinged connection may be formed from one or more linear fold
lines and one
or more curvilinear fold lines. A typical example of such a hinged connection
may comprise a
combination of a linear fold line and an arched or arcuate fold line which
intersect at two points
such that they define a half moon-shaped panel therebetween.
As used herein, the term "fold line" may refer to one of the following: a
scored line, an
embossed line, a debossed line, a line of perforations, a line of short slits,
a line of half-cuts,
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a single half-cut, an interrupted cutline, a line of aligned slits, a line of
scores and any
combination of the aforesaid options.
It should be understood that hinged connections 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 cutline, an interrupted
cutline, slits, scores,
embossed lines, debossed lines, 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.
The phrase "in registry with" as used herein refers to the alignment of two or
more elements
in an erected carton, such as an aperture formed in a first of two overlapping
panels and a
second aperture formed in a second of two overlapping panels. Those elements
in registry
with each other may be aligned with each other in the direction of the
thickness of the
overlapping panels. For example, when an aperture in a first panel is "in
registry with" a second
aperture in a second panel that is placed in an overlapping arrangement with
the first panel,
an edge of the aperture may extend along at least a portion of an edge of the
second aperture
and may be aligned, in the direction of the thickness of the first and second
panels, with the
second aperture.
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