Carrier and blank therefor

Aspects of the invention are directed toward a folded carton (90) for holding a roll (R) of film web (F) such as catering foil and the like, having an integral feature (S1. S2) to assist with retention of the roll (R) of film web (F), to mitigate against the roll undesirably, inadvertently, falling out of the folding carton (90) during use.

TECHNICAL FIELD

The present invention relates to a re-closeable folding carton for holding a web roll of material such as plastic wrap, aluminum foil, and the like. More specifically, but not exclusively, the invention relates to a folding carton having an integral retaining device feature which mitigates against the roll undesirably or inadvertently falling out of the folding carton when open.

BACKGROUND

In both domestic households and in the catering and hospitality industries, food preparation and storage products, such as foil, baking paper, films and the like, are used, for example, to preserve the freshness of a foodstuff and/or assist in the baking or roasting of a food product. Many applications exist for such films, plastic wraps, grease-proof paper, baking paper, oven liners, foils and the like. Such products are typically provided in rolled form, with a web of film wound around a roll. It is known to house such film-rolls in an outer protective package, which keeps the roll clean and provides a branding surface for use during retail.

For example, in EP 2,586,728, a package for films for product freshness is disclosed which aims to improve handling by a user when gripping and peeling the film web. The package disclosed therein comprises a film roll arranged such that one end of the film web, that is wound on the film roll, emerges from an opening. An adhesive is provided on an outside of the package, by means of which the end of the film web is detachably fixable. This enables a user to be able to easily find the leading end of the film web and prevents it from being re-wound onto the film-roll. On the outside of the package, protruding from at least one wall, a tab is formed; and the adhesive for detachably fixing the film web is provided on the surface of the tab for releasably fixing the end of the film web.

A known problem associated with packages or carriers for film-rolls is that once the carrier has been opened, the film-roll is vulnerable to accidental egress from the carton. However, because it is desirable for the film web to be able to unwind from the roll in an unfettered manner during deliberate dispensing of the film web, any means for retaining the film-roll will not provide a good solution if it actually interferes with the dispensing of the film. Worse still, if the means for retaining the film-roll actually causes a snagging point, it can result in undesirable tearing of the film and lead to frustration for the end-user and possible wastage.

In US2008190257 a dispenser is disclosed which has a hollow elongated rectangular base in which a roll of pliable material such as plastics film for dispensing from the dispenser is supported rotatably by means of end supports for rotational movement about its longitudinal axis. The dispenser additionally includes an upper cover incorporating a severing mechanism. The cover includes a fixed body part and an upper jaw carrier pivotally coupled to the fixed body part and a second jaw carrier part, as well as a blade for severing the dispensed film. Such dispensers are of the re-fillable type, typically formed from a thermoplastic material. As such they can be expensive to produce and limit a customer's future purchasing choices to only the compatible re-fill film-rolls sized especially for the re-fillable dispenser. Such dispensers are not necessarily recyclable. Accordingly, it is desirable to overcome these and other drawbacks associated with prior art film-roll dispensers.

Other considerations in the field of dispensing-cartons for housing film-rolls, having a web of material wound thereon, include: the strength of the carton and its suitability for holding and transporting the film-roll and web; use of eco-friendly materials; the ease of which the dispensing carton can be initially opened by a user; and the ease with which a user can grasp the leading or emerging edge of the film for dispensing. It is desirable for the dispensing-carton to be recloseable; and for any re-closing mechanism to be suitable for repeated use without failure or damage. 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. Furthermore, it is desirable for the carrier to be erectable from a blank of foldable sheet material using automated gluing and folding machinery.

The present invention seeks to provide an improvement in the field of cartons, typically formed from paperboard or the like suitable for housing and facilitating the dispensing of a wound roll of webbed material, such as but not limited to substrates such as foil, baking paper, films and the like. It will be appreciated that the present invention may have many and various applications, including applications outside of the food industry. For example, a roll of a paper-based material, such as tracing paper, art paper, graph paper, squared paper or the like, may be housed in a carton of the present disclosure for use in a wide variety of places including homes, craft and art groups, businesses and offices, schools, colleges and other educational establishments, as mere examples.

SUMMARY

A first aspect of the present disclosure provides a carton for storing and dispensing a rolled web of material, the carton comprising: a rear wall, a bottom wall, a front wall, a first end wall and a second end wall arranged to form a tubular roll-storage container; a closure that is hinged to a top edge of said rear wall, the closure comprising a top panel and a lid panel, the lid panel being hinged to the top panel; and the carton comprising at least a first retaining device having a first portion hinged to the rear wall; and a second portion hinged to the first end wall, the first and second portions being affixed together.

The affixed first and second portions are spaced from and overhang the bottom wall of the carton.

The lid panel is optionally directed downward so that the lid panel is located substantially adjacent an upper portion of the front wall of the tubular roll storage container when the carton is closed.

The carton is optionally a folded structure formed from sheet materials, such as paperboard and the like.

Optionally, said first retaining device has a width that is less than the width of the first end wall. Optionally, said first retaining device is free of direct connection to the front wall. Optionally, a front edge of said first retaining device is spaced from the front wall and is acutely angled relative to a top edge of the first end wall. Optionally, said first portion of said first retaining device is provided by a first retention tab that is formed from material that would otherwise have formed part of the top panel. Optionally, said first portion of said first retaining device is defined by: a free edge of the top panel; part of a fold line between the top panel and the rear wall; a severance line which defines said front edge; and a partial cut line.

Optionally, said partial cut line extends approximately perpendicularly relative to said fold line between the top panel and the rear wall; and wherein said severance line is formed generally contiguously with the partial cut line and extends at an angle relative thereto. Optionally, said first portion of said first retaining device is further defined by a reverse partial cut oriented substantially parallel to the partial cut line, and said reverse partial cut may be angled at one end and terminates on said partial cut line. Optionally, a thin section of the first portion of said first retaining device has a thickness that is less than the thickness of the remainder of the first portion; and the thin section of the first portion may be defined by the partial cut line and the reverse partial cut.

Optionally, the first end wall comprises: first, second and third end closure flaps hinged to the front wall, bottom wall and rear wall respectively, the first, second and third end closure flaps being affixed together and said second portion of said first retaining device may be provided by a first supplementary securing flap that is hinged by a fold line to first end wall. Optionally, the first supplementary securing flap is hinged by a fold line to the second end closure flap.

Optionally, the carton has a second retaining device, the second retaining device being formed at the opposite end of the tubular roll storage container to the first retaining device. Optionally, the second retaining device comprises: a first portion hinged to the rear panel; and a second portion hinged to the second end wall and wherein the first and second portions are affixed together.

Optionally, said second retaining device has a width that is less than the width of the first end wall, said second retaining device may be free of direct connection to the front wall; and a front edge of said second retaining device may be spaced from the front wall and may be acutely angled relative to a top edge of the first end wall.

Optionally, said first portion of said second retaining device is provided by a second retention tab that is formed from material that would otherwise have formed part of the top panel; and may be defined by: a free edge of the top panel; part of a fold line between the top panel and the rear wall; a severance line which defines said front edge; and a partial cut line. Optionally, said partial cut line extends approximately perpendicularly relative to said fold line between the top panel and the rear wall. Optionally, said severance line is formed generally contiguously with the partial cut line and extends at an angle relative thereto. Optionally, said first portion of said second retaining device is further defined by a reverse partial cut oriented substantially parallel to the partial cut line; and said reverse partial cut may be angled at one end and terminates on said partial cut line. Optionally, a thin section of the first portion of said second retaining device has a thickness that is less than the thickness of the remainder of the first portion; and the thin section of the first portion is defined by the partial cut line and the reverse partial cut.

Optionally, the second end wall comprises: fourth, fifth and sixth end closure flaps hinged to the front wall, bottom wall and rear wall respectively, the fourth, fifth and sixth end closure flaps being affixed together and said second portion of second first retaining device may be provided by a second supplementary securing flap that is hinged by a fold line to first end wall. Optionally, the second supplementary securing flap is hinged by a fold line to the fifth end closure flap.

According to another aspect of the disclosure, there is provided a foldable paperboard blank for forming a folded paperboard carton for storing and dispensing a rolled web of material, the blank comprising: a rear wall panel, a bottom wall panel, a front wall panel, flaps for forming a first end wall and flaps for forming a second end wall, which together defined a tubular roll storage container; panels for forming a closure comprising: a top panel; and a lid panel, the lid panel being connected to the top panel along a fold line; and components for forming at least a first retaining device, said components comprising: a first portion hinged to the rear panel; and a second portion hinged to a flap for forming first end wall, the first and second portions for being affixed together, wherein said first portion of said first retaining device is provided by a first retention tab that is formed from material that would otherwise have formed part of the top panel.

Optionally, said first portion of said first retaining device is defined by: a free edge of the top panel; part of a fold line between the top panel and the rear wall; a severance line which defines said front edge; and a partial cut line. Optionally, said partial cut line extends approximately perpendicularly relative to said fold line between the top panel and the rear wall; and said severance line may be formed generally contiguously with the partial cut line and may extend at an angle relative thereto.

Optionally, said first portion of said first retaining device is further defined by a reverse partial cut oriented substantially parallel to the partial cut line, and wherein said reverse partial cut is angled at one end and terminates on said partial cut line.

Optionally, the components for forming the first end wall comprise: first, second and third end closure flaps hinged to the front wall, bottom wall and rear wall respectively, wherein said second portion of said first retaining device is provided by a first supplementary securing flap that is hinged by a fold line to the second end closure flap.

Optionally, the blank has components for forming a second retaining device comprising: a first portion hinged to the rear panel; and a second portion hinged to a flap for forming the second end wall, wherein the first and second portions are for being affixed together. Optionally, said first portion of said second retaining device is provided by a second retention tab that is formed from material that would otherwise have formed part of the top panel; and is defined by: a free edge of the top panel; part of a fold line between the top panel and the rear wall; a severance line which defines said front edge; and a partial cut line.

Optionally, said partial cut line extends approximately perpendicularly relative to said fold line between the top panel and the rear wall panel. Optionally, said severance line is formed generally contiguously with the partial cut line and extends at an angle relative thereto. Optionally, said first portion of said second retaining device is further defined by a reverse partial cut oriented substantially parallel to the partial cut line. Optionally, said reverse partial cut is angled at one end and terminates on said partial cut line.

Optionally, the second end wall comprises: fourth, fifth and sixth end closure flaps hinged to the front wall, bottom wall and rear wall respectively, the fourth, fifth and sixth end closure flaps for being affixed together. Optionally, said second portion of second first retaining device is provided by a second supplementary securing flap that is hinged by a fold line to first end wall.

Within 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.

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.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the carriers, blanks and methods 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 carriers, blanks and methods 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.

Referring toFIG.1, there is shown a plan view of a blank10capable of forming a roll-holding, recloseable folding-carton or carrier90, as shown inFIGS.2,3and4, for holding a product such as, but not limited to a web, film or substrate of planar, flexible material ‘F’, wound on a roll ‘R’. The wound film ‘F’ may include materials, such as but not limited to: aluminium foil, baking paper, cling-film, plastic wrap, grease-proof paper, oven liner material, pre-cut baking sheets, pre-cut baking foil sheets, other paper-based material, such as tracing paper, art and craft paper, graph paper, and squared paper. It will be appreciated that the dispensing carrier90of present invention may have many and various applications for holding a rolled web ‘R’ of material ‘F’ and such applications may include, as mere examples only, domestic use, food catering and hospitality industry, offices, schools and other educational establishments. Whereas in the foregoing description, refence is made to a web of material ‘F’ wound on a roll ‘R’, it will be appreciated that a wound web of material ‘F’ may be formed on a mandrel and then removed therefrom, accordingly the presence of an actual roll per se is not necessary. Furthermore, whereas reference in the foregoing may be made to a web of material ‘F’ in the singular, which web can be cut to size by the end user as required, the dispensing carrier90disclosed herein may also be useful in holding a rolled web ‘R’ containing a contiguous series of individual, cut or part-cut lengths or sheets of film or web material ‘F’.

Referring now to the blank10itself, the blank10is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” in reference to the blank10includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognised that one or other numbers of blanks may be employed, where suitable, for example, to provide the carrier structure90described 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, tear resistance or moisture resistance. Examples of such sheet material are PrintKote® Poly paperboard and CustomKote™ Poly paperboard made by WestRock Company. It should be noted that the resistant materials may be provided by more than one layer, to help improve the moisture or 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 moisture resistance, tear-resistance, good glue-ability, heat sealability, or other desired functional properties.

The blank10may include a paperboard substrate and may also include a moisture resistant layer laminated together. It optionally includes an adhesive layer between the paperboard substrate and the tear resistant layer. The material of the paperboard substrate may be selected from any conventional paperboard, for example, ranging in weight upwardly from about 10 pt., preferably from about 11 pt. to about 14 pt. An example of such a substrate is a 14-point SBS board or CNK® board manufactured by WestRock Company. The paperboard substrate may be a bleached or unbleached board. The board may be coated on at least one side, optionally the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and board composition.

The moisture 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 moisture resistant layer imparts toughness to the laminate structure. The moisture 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 or moisture 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/moisture resistant layer to secure the tear/moisture resistant layer to the substrate.

Suitable tear/moisture resistant materials may include, but not be limited to, tear resistant laminated sheet material, e.g., NATRALOCK® paperboard made by WestRock Company, which may include a layer of an n-axially oriented film, e.g. MYLAR®, 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).

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 holding and carrying a product. It is contemplated that the teachings of the invention can be applied to various products as discussed above.

Referring toFIG.1, it can be seen that the blank10comprises: a front wall panel12; a bottom panel14; a rear wall panel16; a top panel18and a lid panel20. The front wall panel12, bottom panel14, rear wall panel16, top panel18and lid panel20are hinged one to the next in a linear series by means of fold lines13,15,17, and19.

The blank10comprises end closure structures for closing each end of a tubular structure that is defined by the plurality of main panels12,14,16,18,20.

A first end closure structure22a/24a/26aat least partially closes a first end of the tubular structure. The first end closure structure22a/24a/26acomprises a plurality of end closure flaps22a,24a,26ahinged along a first end of the blank10. A first end closure flap22ais hingedly connected to the front wall panel12by a hinged connection in the form of a fold line21a. A second end closure flap24ais hingedly connected to the bottom panel14by a hinged connection in the form of a fold line23a. A third end closure flap26ais hingedly connected to the rear wall panel16by a hinged connection in the form of a fold line25a.

A second end closure structure22b/24b/26bat least partially closes a second end of the tubular structure. The second end closure structure22b/24b/26bcomprises a plurality of end closure flaps22b,24b,26bhinged along a second end of the blank10. A fourth end closure flap22bis hingedly connected to the front wall panel12by a hinged connection in the form of a fold line21b. A fifth end closure flap24bis hingedly connected to the bottom panel14by a hinged connection in the form of a fold line23b. A sixth end closure flap26bis hingedly connected to the rear wall panel16by a hinged connection in the form of a fold line25b.

The second and fifth end closure flaps24a,24bform major end closure flaps. The first, third, fourth and sixth end closure flaps22a,26a,22b,26bform minor end closure flaps or “dust flaps”.

The blank10comprises components for assembly into retaining devices S1, S2(seeFIG.4). The retaining device is provided to securely maintain the film-roll ‘R’ within a dispensing-carton90formed from the blank10; and to at least mitigate, if not prevent, unintentional egress of the film-roll ‘R’ out of the dispensing carton90, particularly during dispensing of the film ‘F’. Optionally, and as is the case in the illustrated arrangement, the blank10comprises components for forming two, oppositely arranged retaining devices. Each retaining device is formed from similar components, provided at opposite ends of the blank10.

Top panel18is provided with a first and second retention tabs30a,30b. The first retention tab30ais formed at the first end of the top panel18; and the second retention tab30bis formed at the second end of the top panel18.

The first retention tab30ais defined by a portion of fold line17; a partial cut line31aextending approximately perpendicularly relative to fold line17and terminating before reaching fold line19(seeFIG.1); and a severance line29a. The severance line29amay be formed from a series of cuts, interrupted by one or more temporarily connecting nick portions. The severance line29amay comprise a series of three cuts interrupted by two temporarily connecting nick portions. The severance line29amay be formed generally contiguously with the partial cut line31a. The severance line29amay be formed at an angle relative to the partial cut line31a. The severance line29amay extend toward the first-end edge of top panel18and may terminate at a location along that first end edge, which location is spaced from the fold line19. An optional reverse partial cut33amay be scored into the surface of the blank10sheet material and may be oriented substantially parallel to the partial cut line31a. The reverse partial cut33amay be formed on a side of the partial cut line31athat is spaced further from the first-end edge of top panel18than the partial cut line31a. The reverse partial cut33amay taper at one end and terminate on the partial cut line31a. The reverse partial cut33amay terminate within the top panel18and before reaching fold line17. By “reverse partial cut line” it is meant a cut, severance or other breakable line or demarcation that is made by cutting into the reverse (brown-side, non-coated side, inside surface) of the blank10; that extends only partially and not completely through the substrate.

The second end closure flap24ais provided with a first supplementary securing flap28a, hingedly connected thereto by means of a hinge connection in the form of an alternating cut-crease line27a. The first supplementary securing flap28ais specifically dimensioned to have a width that is less than the width of the bottom panel14and the top panel18. Further beneficially an edge of the first supplementary securing flap28amay be shaped in a tapered manner in order to provide a narrower open region for the emerging or leading front edge of a film or sheet material ‘F’ as it is unwound from a roll. This is described in greater detail below. The first supplementary securing flap28amay be shaped, dimensioned and arranged in a similar manner to the shape and size of the first retention tab30a. The first supplementary securing flap28amay be similarly shaped and dimensioned slightly smaller than the shape and size of the first retention tab30a.

The second retention tab30bis defined by a portion of fold line17; a partial cut line31bextending approximately perpendicularly relative to fold line17and terminating before reaching fold line19(seeFIG.1); and a severance line29b. The severance line29bmay be formed from a series of cuts, interrupted by one or more temporarily connecting nick portions. The severance line29bmay comprise a series of three cuts interrupted by two temporarily connecting nick portions. The severance line29bmay be formed generally contiguously with the partial cut line31b. The severance line29bmay be formed at an angle relative to the partial cut line31b. The severance line29bmay extend toward the second-end edge of top panel18and may terminate at a location along that second-end edge, which location is spaced from the fold line19. An optional reverse partial cut33bmay be scored into the surface of the blank10sheet material and may be oriented substantially parallel to the partial cut line31b. The reverse partial cut33bmay be formed on a side of the partial cut line31bthat is spaced further from the second end edge of top panel18than the partial cut line31b. The reverse partial cut33bmay taper at one end and terminate on the partial cut line31b. The reverse partial cut33bmay terminate within the top panel18and before reaching fold line17.

The fifth end closure flap24bis provided with a second supplementary securing flap28b, hingedly connected thereto by means of a hinge connection in the form of an alternating cut-crease line27b. The second supplementary securing flap28bis specifically dimensioned to have a width that is less than the width of the bottom panel14and the top panel18. Further beneficially an edge of the second supplementary securing flap28bis shaped in a tapered manner in order to provide a narrower open region for the emerging or leading front edge of a film or sheet material ‘F’ as it is unwound from a roll ‘R’. This is described in greater detail below. The second supplementary securing flap28bmay be shaped, dimensioned and arranged in a similar manner to the shape and size of the second retention tab30b. The second supplementary securing flap28bmay be similarly shaped to but dimensioned slightly smaller than the shape and size of the second retention tab30b.

An optional feature51for enabling the lid panel20to be initially secured to the front wall panel12, is provided by a plurality of (optionally) substantially circular glue pads51formed proximate an upper edge of the front wall panel12. The glue pads51are each formed by a partial cut-line, such as but not limited to a half-depth cut line. Optionally the plurality of glue pads51comprises a series of15evenly spaced, uniformly sized, circular glue pads, arranged in a line spanning the length of the front wall panel12. In other embodiments, the plurality of glue pads may comprise a different number of glue pads, which, may or may not be evenly spaced, uniformly sized or circular; and which may or may not be arranged in a single straight line.

The glue-pads51are optional, and if included, are provided for affixing the front wall panel12and the lid panel20together such that a carrier90having a securely enclosed tubular structure can be formed. A rolled-web ‘R’ of sheet material ‘F’ can be securely housed and retained, until it is required to open the carton90and commence dispensing of the web of sheet material ‘F’.

As can be seen inFIG.1, the lid panel20may comprise, at first and second ends thereof, linear, short crease or severance lines35a;35b, angled acutely with respect to the fold line19. These short crease or severance lines35a;35bmay aid in the manipulation of the lid panel20into a re-closed position, wherein the lid panel20sits inside of the front wall panel12. The angled, short score lines35a,35bextending from end edges of the lid panel20, may be useful when the lid panel20is manipulated such that at least part of its leading edge is caught within appropriately located slots formed by severance lines37b,37a.

The severance lines37b,37aare optionally provided in the front wall panel12, at opposite ends thereof. The first and second severance lines37a,37bmay each be formed as cut lines, optionally interrupted by small connecting portions.

The first severance line37aextends in a generally perpendicular manner from the fold line21aat the first-end of the blank10(and optionally disposed below the glue-pads51), to a curved termination. The curved termination may be a curvilinear or J-shaped ending to the first severance line37a, which may curve towards the bottom of the front wall panel12, in a direction towards fold line13.

Similarly, the second severance line37bextends in a generally perpendicular manner from the fold line21bat the second-end of the blank10(and optionally disposed below the glue-pads51) to a curved termination. The curved termination may be a curvilinear or J-shaped ending to the second severance line37b, which may curve towards the bottom of the front wall panel12, in a direction towards fold line13.

The first and second severance lines37b,37aprovide a slot or catch, may be useful when the lid panel20is (repeatedly) manipulated into a re-closed position, and part of its leading edge can be caught within the appropriately located slots formed by the first and second severance lines37b,37a.

Turning to the construction of the carrier90(illustrated inFIGS.2,3and4), the carrier90may be formed by hand; or optionally, may be assembled by a series of sequential folding and adhering operations (not shown), in a machine. The folding process is not limited to that described below and may be altered according to particular manufacturing or processing requirements. In some arrangements the blank10may be folded-glued and part formed into a flat-collapsed carrier90for shipping and transport. The flat-collapsed carrier may be opened into an open-topped tubular structure, and a film-roll ‘R’ top-loaded into the tubular structure as described below. In the present illustrated arrangement, the folding carton90may be hand-assembled about a film roll ‘R’ from the blank10.

For example, the blank10, which may be pre-creased or pre-folded about its fold lines13,15,17,19,21a,23a,25a,21b,23b,25b, may be disposed on its outer facing side, with its inner-surface facing upwards. The front wall panel12may be folded, upwardly, about fold line13; and the rear wall panel16may be folded, upwardly, about fold line15. In this way, the front wall panel12and rear wall panel16are brought into spaced relationship and the outer surfaces of bottom panel14and front wall panel12may face outwards.

The first and second end closure structures22a/24a/26a;22b/24b/26bare then assembled in order to close the first and second ends of the tubular structure. The first and second end closure structures22a/24a/26a;22b/24b/26bare constructed in the same manner and therefore the assembly of the first and second end closure structures22a/24a/26a;22b/24b/26bwill be described only once, with reference to the first end closure structure22a/24a/26a; it being understood that the assembly of the second end closure structure22b/24b/26b, is the same.

The first and third end closure flaps22a,26aare folded, approximately 90°, about fold lines21aand25arespectively. In this way the first open end is partially closed. Optionally, adhesive or other affixing means may be applied to the outer surfaces of the first and third end closure flaps22a,26a. The second end closure flap24a, together with the first supplementary securing flap28a, is folded about fold line23aand brought into overlapping relationship with the first and third end closure flaps22a,26a. The second end closure flap24ais thereby affixed to the first and third end closure flaps22a,26a, to thus form a first closed end of the carrier90.

The second end is formed in the same way; and then, optionally, a roll of web ‘R’ may be placed onto the inside surface of the bottom panel14.

The first and second supplementary securing flaps28a,28bmay be folded, approximately 90°, about fold lines23aand23brespectively; relative to the second and fifth end closure flaps24a,24b. Glue, adhesive or other suitable affixing means may be applied to the outer surface of the first and second supplementary securing flaps28a,28bin readiness for attaching the first and second supplementary securing flaps28a,28bto the first and second retention tabs30a,30bof the top panel18.

Glue, adhesive or other suitable affixing means may be applied to the glue-pad regions51. The top panel18, together with the lid panel20may then be folded about fold lines17and19(by approximately 90°), in order to bring the inner surface of the top panel18into a spaced and opposing position facing the bottom panel14; and to bring the inner surfaces of the first and second retention tabs30a,30bof the top panel18into face to face contacting relationship with the first and second supplementary securing flaps28a,28b, such that the first and second supplementary securing flaps28a,28bare attached to the first and second retention tabs30a,30b.

The lid panel20may then be further folded about fold line19(approximately by another 90°) in order to bring the inner surface of the lid panel20into face to face contacting relationship with part of the front wall panel12, such that the lid panel20is affixed to the front wall12. In this way a fully enclosed tubular carton90is formed in which the roll ‘R’ is securely housed. SeeFIG.2.

To access the roll ‘R’, the lid panel20is broken free of its connection to the front wall panel12. This may be achieved by the application of sufficient pulling force on the lid panel20in a direction away from the front wall panel12, such that the glue pads51, (which are formed by a partial cut-line), are torn out of the front wall panel12. The adhesive bond between the lid panel20and the glue pads51being stronger than the internal fibre bond of the paperboard material within the glue pads51.

Once the lid panel20is released from its attachment to the front wall panel12, then the top panel18can be folded outwardly about fold line17in order to expose the roll ‘R’ disposed within the carrier90. In moving the top panel18in this way, the reverse partial cuts33a,33b; the partial cut lines31a,31b; and the temporarily connecting nick portions interrupting the severance lines29a,29bare all broken and the first and second retention tabs30a,30bare separated from the top panel18, remaining, instead firmly affixed to the first and second supplementary securing flaps28a,28brespectively. The combination of the partial cut lines31a;31brelative to the reverse partial cuts33a;33ballows, an approximately half-depth portion T1, of the top panel18to be torn out from the main remaining section of top panel20. These approximately half-depth torn-out portions T1of the top panel18remain contiguous with the first and second retention tabs30a,30b. Corresponding, approximately half-depth portions T2, remain attached and contiguous with the top panel18. This is illustrated inFIG.3.

Also shown inFIG.3is the manner in which the retaining devices S1, S2, overhang the roll ‘R’, such that, even in an open condition (such as that shown inFIGS.3and4), if the carrier90was inverted, the roll ‘R’ would not just drop freely from the carrier90, but instead, would be held or retained therein by the presence of the retaining devices S1, S2.

To remove a section of the film ‘F’ from the roll ‘R’, a free end ‘E’ of the film ‘F’ is located withdrawn from the carton90as shown inFIG.4. With the roll ‘R’ prevented from inadvertently falling out of the carton90, a user can support the carton90with one hand; and withdraw the film ‘F’ by pulling it (causing the roll ‘R’ to rotate) with their other hand. Upon withdrawal of sufficient film ‘F’, the dispensed portion can be cut or otherwise separated and the carrier90can be reclosed.

The free-end edge ‘E’ of the roll of film ‘F’ can be placed inside the carrier90and the top panel18and lid20folded back into the original positions in order to re-close the carton90. With the feature51for enabling the lid panel20to be initially secured to the front wall panel12having been utilized, the lid panel20can now be retained in a re-closed position by catching end sections of the lid panel20into the slots, which may need to be formed by breaking any small connecting portions interrupting the severance lines37b,37aprovided in the front wall panel12.

Alternatively, the lid panel can be folded inside of the front wall panel12and held in a re-closed position in that manner (thus the slots formed by the severance lines37b,37abeing entirely optional).

The first and second supplementary securing flaps28a,28b; as well as the first and second retention tabs30a,30bare specifically dimensioned to have a width that is less than the width of the bottom panel14and the top panel18. In this way the retaining devices S1, S2formed therefrom are not full-width and stop short of reaching the front wall panel12. SeeFIGS.3and4. This provides space for the emerging or leading front edge ‘E’ of the film ‘F’ to be withdrawn from the roll ‘R’.

The first and second supplementary securing flaps28a,28bas well as the first and second retention tabs30a,30b, may be shaped in a tapered manner at their front edges (as viewed inFIGS.3and4—i.e. the edges closest to the front wall12) in order to provide not only a narrower open region for the emerging or leading front edge ‘E’ of a film or sheet material ‘F’ as it is unwound from a roll, but also to optionally provide a guide for the film ‘F’.

By integrally forming each retaining device S1, S2from material folded to the body of the carton90, the retaining devices S1, S2, are easily created, without the necessity for much, if any, additional material beyond that required to fully enclose a roll ‘R’. Furthermore, by a first portion (first retention flap30a) of the retaining device S1being hinged to the rear wall panel16of the carton90; and by a second portion (first supplementary securing flap28a) of the retaining device S1being hinged to the first end closure structure, the retaining device has sufficient rigidity to at least mitigate against, if not prevent, inadvertent dropping of the roll from the carton90. At the same time, should it be required to remove the roll ‘R’ (for example to locate the free end edge ‘E’) from the carton90, the retaining devices S1, S2, each have enough natural resilience that either of them can be displaced (upwardly) a sufficient extent to enable a user to deliberately and purposefully manipulate the roll out of the carton90and still return to their normal, retaining position afterwards.

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 rolls of differing, length and diameter. In some arrangements the provision of only one retaining device S1at one end of the carton may be sufficient; however, it is considered to be of particular benefit to have a retaining device at each end of the roll.

It will be recognised 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, a single half-cut, an interrupted cut line, 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 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.

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.