Abstract:
A carton for containing a group of bottles is constructed by combining a pair of complementary U-shaped structures ( 10, 20 ). One ( 10 ) of the U-shaped structures comprises a bottom panel ( 24 ) and opposing end walls ( 16, 18 ). The other ( 20 ) of the U-shaped structures comprises a top panel ( 22 ) and opposing side walls ( 12, 14 ).

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to a carton for containing a plurality of similar articles, such as bottles and a means for retaining the bottles within the carton and in particular to a means of accessing the articles. 
         [0002]    Cartons for encasing multiple articles are useful for enabling consumers to obtain and transport a desired quantity of individual articles such as soft drinks or other beverages. Such cartons need to be strong enough to support multiple articles, especially if the articles are bottles. It is also desirable for such cartons to be easy to handle and be portable. 
         [0003]    It is often desirable for the articles contained within the carton to be displayed and also for the carton to have large areas which can be printed with advertising graphics. It is also often desirable for the articles to be easily accessible and it is also preferable for the articles to be secured in place within the carton, especially if the articles are fragile, for example glass bottles. It is however undesirable for articles to be accessed too easily, for example, before being purchased. 
         [0004]    It is also desirable to have a carton which after the contents of the articles have been consumed can be used to return the empty articles to a recycling point. 
         [0005]    The present invention seeks to provide a means for displaying the articles or a portion of the articles in combination with an access means for removal of the articles where the access means leaves the carton with sufficient integrity for replacement of articles for the purpose of returning to a recycling point. 
       SUMMARY OF THE INVENTION 
       [0006]    According to a first aspect of the invention, a carton for containing a group of similar articles, such as bottles, the carton comprising a top panel, bottom panel, opposing side and end walls, wherein the carton is constructed by combining opposing complementary U-shaped structures, one of the U-shaped structures comprising a bottom panel and opposing end walls and the other of the U-shaped structures comprising a top panel and opposing side walls. 
         [0007]    Preferably the top panel is at an elevation below that of an upper extremity of the end wall and/or opposing side wall. 
         [0008]    Additionally one of the U-shaped structures comprises flaps which provide support to the side walls of the carton and additionally a surface to which the side walls can be secured. 
         [0009]    Preferably the top panel comprises apertures for receiving the articles or a portion thereof, wherein each aperture has a frangible connection with at least one other aperture to facilitate removal of the articles. The carton may further comprise at least one reinforced handle aperture being struck from one of said opposing walls. 
         [0010]    Preferably upon removal of the articles, the carton retains sufficient structural integrity such that it can be re-used for returning empty articles. 
         [0011]    According to a second aspect of the invention, a two part blank comprising a first part comprising a bottom panel and opposing end walls and a second part comprising a top panel and opposing side walls to form opposing complementary U-shaped structures when the carton is in a setup condition. 
         [0012]    Preferably the first part of the blank comprises flaps which provide support to the side walls of the carton and additionally a surface to which the side walls can be secured. 
         [0013]    Preferably the top panel is at an elevation below that of an upper extremity of the end wall panels. 
         [0014]    Additionally the top panel comprises apertures for receiving the articles or a portion thereof, wherein each aperture has a frangible connection with at least one other aperture to facilitate removal of the articles. 
         [0015]    According to a third aspect of the invention, a unitary blank for forming a carton comprising opposed side and end walls and top and bottom panels, wherein a plane of the top panel in a setup carton is lower than an upper edge of the opposed end walls and wherein there further comprises handle apertures struck from said end walls. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which; 
           [0017]      FIG. 1A  illustrates a first part of a blank for forming a crate style carton according to a first embodiment of the invention; 
           [0018]      FIG. 1B  illustrates a second part of a blank for forming a crate style carton according to a first embodiment of the invention; 
           [0019]      FIG. 1C  shows a first step in the process for erecting the crate style carton formed from the blanks of  FIGS. 1A and 1B ; 
           [0020]      FIG. 1D  shows a second step in the process for erecting the crate style carton formed from the blanks of  FIGS. 1A and 1B ; 
           [0021]      FIG. 1E  shows a third step in the process for erecting the crate style carton formed from the blanks of  FIGS. 1A and 1B ; 
           [0022]      FIG. 1F  shows the crate style carton formed from form the blanks of  FIGS. 1A and 1B ; 
           [0023]      FIG. 2A  illustrates a first part of a blank for forming a crate style carton according to a second embodiment of the invention; 
           [0024]      FIG. 2B  illustrates a second part of a blank for forming a crate style carton according to a second embodiment of the invention; 
           [0025]      FIG. 2C  illustrates a step in the process to erect a crate style carton from the blanks of  FIGS. 2A and 2B ; 
           [0026]      FIG. 2D  shows the crate style carton formed from form the blanks of  FIGS. 2A and 2B   
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0027]    A first embodiment of the present invention is shown in  FIGS. 1A-1F .  FIGS. 1A and 1B , show a first and a second part respectively, of a two-part blank for forming a crate style carton  30 , made from paperboard or similar foldable sheet material. In the first embodiment of the invention two blanks  10  and  20 , of  FIGS. 1A &amp; 1B  are formed into a tray and a cover respectively. Together the tray and cover form a crate style carton  30  which is shown in  FIG. 1F . The invention is designed to receive similar articles, such as bottles, but it is envisaged that the present invention could be used to contain other articles, without departing from the scope of the invention. 
         [0028]    Turning to  FIG. 1A , the tray blank  10  comprises a first end wall  16 , a bottom panel  24  and a second end wall  18 , hingedly connected, one to the next in series, along fold lines  44  and  48  respectively. Handle apertures  54  are struck from the first and second end walls  16 ,  18  and finger gripping tabs  58  protrude inward from the upper edges of the handle apertures  54 . The finger gripping tabs enable the erected crate style carton  30  to be easily grasped and lifted by the handle apertures  54 . 
         [0029]    The tray blank  10  further comprises corner flaps  66   a / 66   b  and  68   a / 68   b  hingedly connected to the first and second end walls  16  and  18  respectively. In this embodiment of the invention the corner flaps  66   a / 66   b  and  68   a / 68   b  provide additional protection to some of the bottles contained within the carton. In other embodiments of the invention it is envisaged that a greater of lesser number of corner flaps could be used in order to provide a crate style carton with a specific shape, to accommodate the different types of articles which may be contained within a crate style carton. 
         [0030]    In this embodiment of the invention the corner flaps  66   a / 66   b  and  68   a / 68   b  are hingedly connected to side flaps  76   a / 76   b  and  78   a / 78   b  along fold lines  86   a / 86   b  and  88   a / 88   b  respectively, as shown in  FIG. 1A  The side flaps  76   a / 76   b  and  78   a / 78   b  provide a means for securing the tray formed from blank  10  to the cover formed from blank  20  in erecting the crate style carton  30 . 
         [0031]    In this embodiment of the invention, the tray blank  10  further comprises bottom end flaps  74   a  and  74   b  hingedly connected to the bottom panel  24 , along fold lines  64   a  and  64   b . The bottom end flaps  74   a ,  74   b  provide an additional means for securing the tray and cover together. 
         [0032]    The tray blank  10  also comprises inner handle panels  26  foldably connected to the first and second end walls  16 ,  18  about fold lines  40  and  42 . The inner handle panels  26  comprise finger gripping tabs  58  and are shaped such that upon folding the inner handle panels  26 , 180° about the fold lines  40  and  42 , a 2 ply reinforced handle structure is created. 
         [0033]    In this embodiment of the invention the inner handle panels  26  are additionally provided with glue flaps  70   a / 70   b  and  72   a / 72   b , which can be secured to the inside faces of the corner panels  66   a / 66   b  and  68   a / 68   b  respectively. In this way some additional protection of the articles held within the corners of the crate style carton  30  may be provided. In other embodiments of the invention it is envisaged that the glue flaps  70   a / 70   b  and  72   a / 72   b  may not be required, or may in fact be secured to the inside faces of the side flaps  76   a / 76   b  and  78   a / 78   b  respectively. 
         [0034]    A second blank, cover blank  20  is shown in  FIG. 1B . The cover blank  20  is used to form a cover for the tray formed from the blank  10  of  FIG. 1A . Blank  20  comprises a top panel  22  which is hingedly attached to first and second side walls  12 ,  14  along fold lines  34   a ,  34   b . The first and second side walls  12 ,  14  comprise fold lines  32   a  and  32   b.    
         [0035]    A series of apertures  56  are struck from the top panel  22  and are structured to receive an upper portion of the articles which are to be contained within the crate style carton  30 . In this embodiment of the invention the crate style carton  30  is suitable for containing bottles and the apertures  56  are designed to receive the necks of the bottles. In this embodiment the apertures  56  are circular and further comprise tabs protruding toward the centre of each of the apertures  56 . The protruding tabs may help to provide a close fit of the bottle necks within the apertures  56 . This may help prevent the bottles from being subject to damage, which can occur if bottles knock against each other. In other embodiments of the invention the apertures  56  may not be circular and may or may not contain additional tabs. 
         [0036]    The top panel  22  further comprises a series of weakened lines or nicks  37  which connect each aperture  56  to at least one other aperture  56 . In the first embodiment the nicks  37  extend between the apertures  56  in lines perpendicular to the first and second side walls  12 ,  14 . In other embodiments of the invention it is envisaged that the configurations of the nicks  37  may differ from that described, for example, the nicks  37  may not fully extend to neighbouring apertures  56 , they may intersect each other or the nicks  37  may extend to the edges of the top panel  22 . The top panel  22  further comprises a series of glue flaps  36   a / 36   b  and  38   a / 38   b , which are used to secure the top panel  22  to the tray of blank  10 . 
         [0037]    Turning to the construction of the crate style carton  30  from the tray blank  10  and cover blank  20 , a series of sequential folding and gluing operations are required. Preferably these can be performed in a straight line machine, so that the blanks  10 ,  20  are not required to be rotated or inverted to complete the construction. The folding process is not limited to that described below and can be altered according to particular manufacturing requirements. 
         [0038]    The first stage is to secure the inner handle panels  26  to the inside faces of the end wall panels  16 ,  18  and secure the glue flaps  70   a / 70   b  and  72   a / 72   b  to the inside faces of the corner panels  66   a / 66   b  and  68   a / 68   b . The end wall panels  16 ,  18  are then folded about fold lines  44  and  48 , out of the plane of the bottom panel  24  to produce a tray. 
         [0039]    The tray is then loaded with bottles, as shown in  FIG. 1C  and the corner panels  66   a / 66   b  and  68   a / 68   b  and side flaps  76   a / 76   b  and  78   a / 78   b  are folded about fold lines  96   a / 96   b ,  98   a / 98   b ,  86   a / 86   b  and  88   a / 88   b . The bottom end flaps  74   a ,  74   b  are also folded inward of the tray. 
         [0040]    In preparation of the final folding and gluing operations to complete the erection of the crate style carton  30 , the cover blank  20  is folded about fold lines  34   a ,  34   b ,  32   a  and  32   b , as shown in  FIG. 1D . The side walls  12 ,  14  are folded  900  about fold lines  34   a  and  34   b , out of the plane of top panel  22 . The second side walls  12 ,  14  are then folded about fold lines  32   a  and  32   b  to bring bottom portions of the first and second side walls  12 ,  14  back into the plane of the top panel  22  as shown in  FIG. 1D . 
         [0041]    Cover blank  20  is then brought into registry with the bottles which have been loaded into the tray. Top portions of the first and second side walls are placed in flat face contact with the inner faces of the side flaps  76   a / 76   b  and  78   a / 78   b  respectively, and may be secured together by adhesive of other means known in the art. The bottom portions of the first and second side walls  12 ,  14  are further folded about fold lines  32   a  and  32   b  so that the bottom portions of the first and second side walls are in flat face contact with upper portions of the first and second side walls  12 ,  14  and the outer faces of the side flaps  76   a / 76   b  and  78   a / 78   b  respectively. In this way the fold lines  32   a  and  32   b  form upper edges of the side walls of the crate style carton  30 . Again glue or other means maybe used to secure the bottom portions of the first and second side walls  12 ,  14  to the outer faces of the side flaps  76   a / 76   b  and  78   a / 78   b  and the outer faces of the bottom end flaps  74   a  and  74   b , as shown in  FIG. 1E . 
         [0042]    In this way a two-ply upper portion of the side walls of the crate style carton is formed. In other embodiments of the invention it is envisaged that the first and second side walls  12 ,  14  could further be provided with handle apertures  54  struck from the first and second side walls  12 ,  14 . This could provide 2-ply handle structures in each wall of the erected crate style carton  30 , in other embodiments, without departing from the scope of the present invention. 
         [0043]    The crate style carton formed from the blanks  10  and  20  is shown in  FIG. 1F . It can be seen that the bottles are secured within the carton, once the cover made from blank  20  has been secured inside the tray, erected from blank  10 . Access to the bottles is gained by separating the nicks  37 , this may be achieved by lifting a bottle from the crate style carton  30  or in other embodiments it is envisaged that an initiating means may be provided to assist in the separation of the nicks  37 . 
         [0044]    The use of the nicks  37  allows each bottle can be accessed individually, whilst the structural integrity of the carton is maintained. Bottles not accessed are held in position by the apertures  56  in the cover. Therefore the carton provides an adaptable carrying container, the structural integrity of which is not destroyed when the bottles are accessed. This enables the carton to be reused for the convenient returning of the empty bottles. 
         [0045]    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 of differing size or shape. 
         [0046]      FIGS. 2A-2D  illustrate a second embodiment of the present invention, which will now be described by way of example only. This is to illustrate some of the changes that can be made, without departing from the scope of the present invention. In subsequent figures similar reference numerals have been used to denote like features, the reference numerals in the second embodiment of the invention are increased by ‘200’ to show that they represent features of the second embodiment. Since the second embodiment has features common to the first embodiment, only differences in the second embodiment will be highlighted. 
         [0047]    In the second embodiment of the present invention the first and second side walls  12 ,  14  are not provided with fold lines and can be sized such that when the cover from blank  220  is inserted into the tray formed from blank  210 , the position of the top wall panel  222  is adjustable. To accommodate this feature the side flaps  276   a / 276   b  and  278   a / 278   b  are also sized to allow the top panel  222  to have an adjustable elevation once the tray and cover have been formed into the crate style carton  230 . 
         [0048]    The crate style carton  230  is erected by carrying out a similar arrangement of folding and gluing operations as previously described however the operation of folding the first and second side walls  12 ,  14  about fold line  32   a  and  32   b , is not required in this embodiment. The second embodiment can be considered as a special case of the first embodiment wherein the fold lines  232   a ,  232   b  are positioned along the fold lines  234   a / 234   b . An intermediate step in the erection process is shown in  FIG. 2C . 
         [0049]    The present invention is designed such that a crate style carton can be formed from two blanks wherein the elevation of the top panel  22 ,  222  is adjustable by altering the depth of the bottom portion of the first and second side walls  12 ,  212 ,  14  and  214 . The depth of the bottom portion of the first and second side walls  12 ,  212 ,  14  and  214  is defined by the position of the fold lines  32   a ,  32   b ,  232   a  and  232   b  and the size of the first and second side walls  12 ,  212 ,  14  and  214 . 
         [0050]    The present invention also allows the height of the upper edge of the first and second side walls  12 ,  212 ,  14  and  214  to be adjustable relative to the height of the end walls  16 ,  18 ,  216  and  218 . The upper edge of the first and second side walls  12 ,  212 ,  14  and  214  is can also be considered as being defined by the position of the fold lines  32   a ,  32   b ,  232   a  and  232   b.    
         [0051]    It is envisaged that the features of the various embodiments herein described could be altered without departing from the scope of the present invention. For example in other embodiments of the invention the apertures formed within the top panel may not be circular and may also be provided with additional tabs protruding into the aperture, to aid retention of the bottle necks or other articles contained within the carton. 
         [0052]    It will be recognised that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. Any reference to hinged connection should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from one or more of the following, a score line, a frangible line or a fold line without departing from the scope of the invention.