Basket style carrier, shipping carton and package system

The invention provide a package system comprising: at least one secondary packaging container (95) holding at least one primary container (‘B’); and a tertiary packaging carton (57; 157) holding the at least one secondary packaging container (95). The at least one secondary packaging container (95) is of the basket carrier style having an open-topped structure and comprises a base wall (78/80); opposed first and second side walls (14, 18); opposed first and second end walls (12, 16); and a medial handle structure (20/22) connected to the first and second end walls (12, 16) and disposed between the first and second side walls (14, 18). Additionally, at least one corner structure (14a) is disposed between the first side wall (14) and the first end wall (12) of the secondary packaging container (95). At least one corner structure (43a) is also disposed between the first side wall and the first end wall of the tertiary packaging carton.

FIELD OF THE INVENTION

The present invention relates to secondary package containers such as basket style carriers comprising a medial handle and optionally partitioned cells each for holding an individual item. More specifically, but not exclusively, the invention relates to a package system comprising a basket style carrier and a tertiary shipping carton having a similar shape, such that the basket style carrier can be fitted and nested into the tertiary shipping carton.

BACKGROUND OF THE INVENTION

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers. Such multi-packs are desirable for shipping and distribution purposes and for the display of promotional information. Basket style carriers are known in which a top loaded structure comprises a medial handle panel and optionally a medial partition. Further lateral partitions are often used to divide the carrier into cells, each for holding an individual item. Such basket style carriers are particularly popular for the packaging and display of premium products contained in bottles, where the tops of the bottles are well presented within the basket style carrier for marketing purposes and where the partitioned cells help to protect the bottles and prevent, or at least mitigate against, adjacent bottles knocking against one another.

Typically, such basket style carriers are collapsible into a flat form and are easily erected into a top-loaded structure. For example, in U.S. Pat. No. 5,645,162 to Harrelson, a basket style carrier having an automatic bottom (also referred to as “crash bottom”) and having lateral partition straps (36,37,38,39) is shown. The basket carrier shown can hold six articles in two rows of three articles each, with the two rows being separated by a central partition and handle structure which provides an easy means by which the basket style carrier can be held and carried. The blank can be assembled into a pre-glued and folded, flat-form, collapsed structure, from which the basket carrier of U.S. '162can be readily erected.

Typically, such basket style carriers are not stackable. The present invention offers an improvement in the field of packaging by providing a tertiary shipping carton. For transportation of such basket style carriers, once loaded with articles, it is advantageous if the basket style carriers are loaded into the tertiary package. The strength of the tertiary package and its suitability for holding and transporting large weights of articles is an important consideration.

For cost and environmental considerations, it is preferable if such tertiary shipping cartons and secondary package basket style carriers are formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Furthermore, since the basket style carriers are often used to promote the sale of premium products the appearance of the tertiary shipping cartons is also an important consideration.

It is also desirable if the basket style carrier and shipping carton can each be assembled on existing automatic machines such that no alteration, or no significant alteration, of existing automatic machines is required.

The present invention seeks to provide an improvement in the field of packaging by providing a tertiary shipping carton having at least one corner structure and/or at least one mitred corner. Beneficially, the strength and stackability of the shipping carton is thereby improved. Additionally, there is provided a secondary package basket carrier having at least one corner structure and/or mitred corner of a similar shape to the mitred corner structure of the tertiary shipping carton so that the basket carrier can fit within and nest within the shipping carton. The overall appearance of the package system may have an improved aesthetic quality which may be an important attribute in encouraging consumers to purchase the products held therein.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a package system comprising at least one secondary packaging container holding at least one primary container; and a tertiary packaging carton holding the at least one secondary packaging container. The at least one secondary packaging container is of the basket carrier style having an open-topped structure and comprising a base wall, opposed first and second side walls, opposed first and second end walls, a medial handle structure connected to the first and second end walls and disposed between the first and second side walls, and at least one corner structure disposed between the first side wall and the first end wall. The tertiary packaging carton comprises a base wall, opposed first and second side walls, opposed first and second end walls, a top closure, and at least one corner structure disposed between the first side wall and the first end wall. The at least one corner structure of the secondary packaging container is sized, configured and arranged to fit internally of one of the at least one corner structures of the tertiary packaging carton.

Optionally, the at least one corner structure of the at least one secondary packaging container comprises a first corner structure having a first corner panel disposed between the first side wall and the first end wall. The first corner panel is hinged to both the first side wall and the first end wall.

Optionally, the first corner panel is sized to provide an acutely angled first corner structure.

Optionally, the at least one corner structure of the at least one secondary packaging container further comprises a second corner structure having a second corner panel disposed between the first side wall and the second end wall. The second corner panel is hinged to both the first side wall and the second end wall. A third corner structure has a third corner panel disposed between the second side wall and the second end wall, which second corner panel is hinged to both the second side wall and the second end wall.

Optionally, the secondary packaging container comprises a first securing panel hinged to the medial handle structure and affixed to the first end wall. The at least one corner structure of the at least one secondary packaging container further comprises a fourth corner structure having a fourth corner panel disposed between the second side wall and the first securing panel. The fourth corner panel is hinged to both the second side wall and the first securing panel.

Optionally, the package system comprises four secondary packaging containers. The at least one corner structure of the tertiary packaging carton comprises four corner structures. Each corner structure of the tertiary packaging carton fits adjacent to a similarly formed and shaped corner structure of one of the four secondary packaging containers.

Optionally, the tertiary packaging carton is end loaded, or the tertiary packaging container is top-loaded, and the tertiary packaging container is a fully enclosed container and stackable container.

Optionally, the at least one corner structure of the tertiary packaging carton comprises a first corner panel disposed between the first side wall and first end wall. The corner panel is hinged to both the first side wall and the second side wall.

Optionally, there is provided a secondary packaging container for use in a package system.

Optionally, there is provided a tertiary packaging container for use in a package system.

Optionally, there is provided a set of blanks for forming a secondary packaging container and a tertiary packaging container for use in a package system.

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

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the package system, shipping cartons, basket carriers and blanks 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 in which the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the package system, shipping cartons, basket carriers and blanks described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

In the embodiments detailed herein, the terms “secondary package”, “tertiary package”, “carton” and “carrier” refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging, carrying, and/or dispensing articles, such as secondary packages or primary product containers. It is contemplated that the teachings of the invention can be applied to various primary product containers, which may or may not be tapered and/or cylindrical. Optional containers include bottles (for example metallic, glass or plastics bottles), cans (for example aluminum cans), tins, pouches, packets and the like. It should also be contemplated that the teachings of the invention may also be applied to various secondary package containers, which may or may not have top/cover panels. Optional containers include top/bottom-loading basket style carriers, end-loading tubular cartons having full or partial end closure panels, wraparound style carriers having full or partial end closure panels, top-gripping carriers and top/bottom-loading tubular cartons.

A package system97is disclosed herein (seeFIG.9) that comprises a tertiary shipping carton57;157(seeFIGS.8and11), a secondary package basket style carrier95(seeFIG.6); and a plurality of articles ‘B’, arranged in groups and held within each basket carrier95. The tertiary shipping cartons57;157are formed from blanks13;113(seeFIGS.7and10) formed from a sheet of suitable substrate; and the basket carrier95is formed from a blank10(seeFIG.1) formed from a sheet of suitable substrate. The blanks10,13;113may be formed from the same or from different substrates.

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 that may be coated, uncoated, printed or not printed. It should be recognized that one or other numbers of blanks may be employed, where suitable, for example, to provide the structures described in more detail below. Optionally, the blank10for forming the basket carrier95may be formed from a paperboard that is bleached, coated and printed on one surface thereof and which is not bleached, coated or printed on the other (inside) surface thereof (“the brownside”). Optionally, the blanks13;113for forming the shipping cartons57;157are formed from a corrugated board which provides structural rigidity and stacking strength such that the shipping cartons57;157can accommodate a heavy load of articles.

In an illustrated and optional embodiment, the blank10is configured to form a basket style carrier95for packaging an optional arrangement of articles. In this illustrated embodiment, the arrangement is a 2×3 matrix and the articles are 12 oz. bottles ‘B’. Optionally each bottle ‘B’ is held within an individual cell defined by medial and lateral partition structures. However, this is entirely optional and in other arrangements, the articles may not be bottles and/or the bottles may not be held in individual cells as such. The blank10can be alternatively configured to form a carrier for packaging other types, number and size of article and/or for packaging articles in a different arrangement or configuration.

In the illustrated and optional embodiment, the blank13;113is configured to form a shipping carton57;157that can optionally accommodate four basket style carriers95; and as such the shipping carton57;157may comprise 24, 12 oz. bottles ‘B’. Accordingly, the package system97accommodates a significant load.

Referring now toFIG.1, the blank10comprises a series of main panels for forming the main walls of the basket carrier95. The series of main panels comprises: a first end panel12, a first corner panel14a, a first side panel14, a second corner panel14b, a second end panel16, a third corner panel18a, a second side panel18, a fourth corner panel18b, a first securing panel12b, a first medial handle panel20, a second medial handle panel22, a handle reinforcing panel24, a second securing panel26, a first bottom panel78and a second bottom panel80. Optionally the series of main panels12,14a,14,14b,16,18a,18,18b,12b,20,22,24,26,78,80are hinged together along fold lines44,46,48,50,52,54,56,58,60,61,62,63,96,68a74,76.

More specifically, a first edge of first end panel12is hinged by a fold line44to a first edge of first corner panel14a. A second edge of first corner panel14ais hinged by a fold line46to a first edge of first side panel14. A second edge of first side panel14is hinged by fold line48to a first edge of the second corner panel14b. A second edge of second corner panel14bis hinged by a fold line50to a first edge of second end panel16. A second edge of second end panel16is hinged by a fold line52to a first edge of third corner panel18a. A second edge of third corner panel18ais hinged by a fold line54to a first edge of second side panel18. A second edge of second side panel18is hinged by fold line56to a first edge of fourth corner panel18b. A second edge of fourth corner panel18bis hinged by fold line58to a first edge of a first securing panel12b. A second edge of the first securing panel12bis hinged by spaced fold lines60,61to a first edge of the first medial handle panel20. A second edge of first medial handle panel20is hinged by fold line62to a second securing panel26; and a lower edge of the first medial handle panel20is hinged by fold line96to the second medial handle panel22. The handle reinforcing panel24is hinged to the first edge of first medial handle panel20by means of a section of fold line60. Handle reinforcing panel24is separated from the upper edges of the first securing panel12b, fourth corner panel18b, second side panel18and third corner panel18aby a cut line. The handle reinforcing panel24is also hinged to a connecting panel28which is attached by a small connecting portion to an upper portion of the second edge of the second end panel16.

The first bottom panel78is hinged to a bottom edge of first side panel14by fold line74. The second bottom panel80is hinged to a bottom edge of the second side panel18by fold line76. The first and second bottom panels78,80are each free of connection to the first, second, third and fourth corner panels14a,14b,18a,18b. Optionally, in the illustrated arrangement, components for forming a punch-locking system (complementary male and female locking tabs, seeFIG.1) are provided in bottom panels78and80. Such a mechanism for forming the bottom wall structure78/80is not essential and in other arrangements, other mechanical locking mechanisms may be used and/or adhesive may be used to affix first and second bottom panels78,80together.

The handle reinforcing panel24, and first and second medial handle panels20,22each comprises components H1, H2, H3that together form a handle structure. The configuration, shape, size, position and overall arrangement of the handle structure is entirely optional. In the illustrated optional arrangement, the first medial handle panel20comprises a segment-shaped aperture92, and a cushioning flap88hinged by a fold line84to the first medial handle panel20and separated from the first medial handle panel20by arcuate cut lines. The second medial handle panel22comprises an aperture94, shaped and positioned in a similar manner to the outline shape of the cushioning flap88and segment-shaped aperture92, such that once the first and second medial handle panels20,22are overlaid, the aperture94is aligned with the outer edges of the handle component H2. The handle reinforcing panel24comprises a segment-shaped aperture90, and a cushioning flap86hinged by a fold line82to the handle reinforcing panel24. Once the second medial handle panel22is sandwiched between the first medial handle panel20and the handle reinforcing panel24, the aperture94is aligned with the outer edges of the handle components H1, H3.

In the illustrated arrangement of the blank10forming the basket carrier95, the first and second medial handle panels20,22are hinged together about a bottom fold line96, and each has a height sufficient such that each medial handle panel20,22can divide or partition the basket carrier95once formed from the blank10into two major sections. Additionally, each of the first and second medial handle panels20,22comprises an optional lateral partition structure arrangement. In other embodiments, there may be no lateral partition structure arrangement. InFIG.1, however, it can be seen that a first lateral partition flap30is hinged to the first medial handle panel20by part of a fold line66; and is hinged to a third securing panel42by a further fold line60b. A second lateral partition flap32is hinged to the first medial handle panel20by a fold line64and is hinged to the third securing panel42by a lower part of fold line66. A third lateral partition flap36is hinged to the second medial handle panel22by a fold line70and is hinged to fourth securing panel38by a section of fold line72. A fourth lateral partition flap34is hinged by a further section of fold line72to the second medial handle panel22, and is hinged to the fourth securing panel38by a fold line63. To assist in attaching the second medial handle panel22to the first end panel12, a fifth securing panel40is provided, hinged along fold line68to the second medial handle panel22.

Turning to the construction of the basket carrier95as illustrated inFIG.6, it is envisaged that the basket carrier95can be formed by a series of sequential folding operations in a straight line machine so that the basket carrier95is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and as illustrated inFIGS.2to5, and may be altered according to particular manufacturing requirements.

Affixing means such as adhesive, more specifically a hot melt glue, may be applied to sections of the inside (non-printed) of the second medial handle panel22in regions around aperture94and handle structure H3, and proximate to the fold line96. The second medial handle panel22is then folded, as shown by arrow F1inFIG.2, about fold line96. The second medial handle panel22is then disposed in face contacting relationship with the first medial handle panel20and is attached thereto in the regions around aperture94, and proximate to fold line96. In other arrangements affixing means could be applied to corresponding regions of the first medial handle panel20as well as, or instead of, applying affixing means to the second medial handle panel22.

As shown inFIG.2, affixing means G such as adhesive, more specifically a hot melt glue, may be applied to sections of the inside (non-printed) of the connecting panel28, handle reinforcing panel24(in the region of the handle component H1), and to regions of the inside surface of the second side panel18as shown. Then, as shown inFIG.3, the first and second medial handle panels20,22are together folded as a unit about fold lines60and61, as shown by arrow F2. In this way, the handle reinforcing panel24is affixed to the outside surface of the second medial handle panel22, in the region of the second handle component H3; the fourth securing panel38is affixed to the inside surface of the second side panel18; and the connecting panel28is affixed to an upper portion of second securing panel26. In other arrangements affixing means could be applied to corresponding regions of the first medial handle panel20, fourth securing panel38, and second securing panel26as well as, or instead of, applying affixing means to the connecting panel28, handle reinforcing panel24and second side panel18.

As also illustrated inFIG.3, affixing means G such as adhesive, more specifically a hot melt glue, may be applied to sections of the inside (non-printed) of the first side panel14and second end panel16. The blank10, as shown inFIG.4, is then folded as indicated by arrow F3, about fold line52to bring the second securing panel26, first medial handle panel20, and third securing panel42into face contacting relationship with second end panel16, second corner panel14band first side panel14. In this way, an outside surface of the second securing panel26is affixed to the inside surface of the second end panel16; and an outside surface of the third securing panel42is affixed to the first side panel14. In other arrangements affixing means could be applied to corresponding regions of the second securing panel26and third securing panel42, as well as or instead of to the first side panel14and second end panel16.

As also illustrated inFIG.4, affixing means G such as adhesive, more specifically a hot melt glue, may be applied to sections of the outside (coated and/or printed) of the first securing panel12band fifth securing panel40. As illustrated by arrow F4inFIG.5, the blank10is then folded about fold line44, to bring the first end panel12into face contacting relationship with the first securing panel12band the fifth securing panel40. In this way, the first end panel12is affixed to the first securing panel12band fifth securing panel40. In other arrangements affixing means could be applied to corresponding regions of the first end panel12as well as, or instead of, the first securing panel12band fifth securing panel40.

The part-formed, flat folded blank shown inFIG.5may be shipped in that condition to a converting plant, whereat the assembly of the basket carrier95is completed.

To complete the construction of a basket carrier95from the blank10, the part-formed, flat folded blank shown inFIG.5is opened, optionally by pushing on the first and second end wall panels12,16in order to push apart the first and second side panels14,18. In doing this the first, second, third and fourth lateral partition flaps30,32,36,34are automatically erected and a medial handle structure20/22/24, optionally comprising three plies (first and second medial handle panels20,22and reinforcing handle panel24), is set up and is disposed between the opposed and spaced apart first and second side panels14,18. The medial handle structure20/22/24is connected to the first and second end panels12,16by means of connecting panel28, and first, second, third, fourth and fifth securing panels12b,26,42,38,40. The first and second bottom panels78,80can then be folded about fold lines74and76respectively until they overlap sufficiently such that the complementary locking mechanism can be deployed to affix the first and second bottom panels78,80together to form a bottom structure78/80. Optionally, the bottom structure78/80is shaped to match the otherwise open bottom end of the basket carrier95and has at least one mitred corner in order to follow the shape created by the at least one corner panel14a,14b,18a,18bprovided within the basket carrier95. In other arrangements, the medial handle structure20/22/24may comprise more or fewer plies than three plies; and/or may be connected to the first and second end walls12,16by more or fewer securing panels; and/or may have a different height relative to the first and second end walls12,16; and/or may extend to a further or lesser extent towards the bottom structure78,80. In various arrangements, the bottom structure78/80may have a shape that is not similar to the outline shape of the otherwise open bottom end of the basket carrier95and gaps may exist between the edges of the bottom structure and the walls of the basket carrier.

The completed basket carrier95is shown inFIG.6. As can be seen the basket carrier95is open-topped; has a generally centrally disposed carrying handle; and has an eight sided shape comprising: the spaced and facing first and second side walls14,18; the spaced and facing first and second end walls12,16; and the four angled corner panels14a,14b,18a,18b. The four corner panels14a,14b,18a,18bare disposed at an angle and cut across a perpendicular corner that would otherwise have existed between the first end panel12and first side panel14; the first side panel14and second end panel16; the second end panel16and the second side panel18; and the second side panel18and the first end panel12respectively. The provision of each of the four mitred corner panels14a,14b,18a,18ballows for the lengths of the first and second side panels14,18to be reduced compared to what they would otherwise need to be in a basket style carrier with four perpendicular corners. Similarly, the provision of each of the four corner panels14a,14b,18a,18ballows for the widths of the first and second end panels12,16to be reduced compared to what they would otherwise need to be in a basket style carrier with four perpendicular corners. Overall, the end to end length of the blank10is reduced compared to the end to end length of a blank configured to form a straight edged basket carrier capable of holding the same number of same sized articles. In this way the provision of at least one corner structure having a mitred corner panel provides a material saving, reduces the cost and environmental impact of the carton and, further beneficially, may allow for a greater integer number of blanks to be struck from a single standard-sized sheet of paperboard material.

Articles such as bottles ‘B’ may be top-loaded into the basket carrier95into each of the six individual cells created by the medial handle structure20/22/24and lateral partition structures30,32,36,34. In this way a secondary packaging container95, in the form of a basket carrier that is open-topped and that has a medial handle structure disposed between the opposed first and second side panels and connected to the first and second end panels, is provided. The secondary packaging container95is suitable for holding at least one primary container, optionally a bottle ‘B’. As shown inFIGS.6and8, each secondary packaging container95formed from a blank10has six cells arranged in 2×3 array such that each secondary packaging container95is capable of holding up to six articles. In other arrangements, the blank may be configured such that secondary packaging container is capable of holding a greater or fewer number of articles B.

The completed, loaded secondary packaging basket carrier style containers95cannot be stacked reliably and without risking damage to the articles B contained therein. Accordingly, transportation of the basket carriers95can be improved by providing tertiary shipping cartons57;157into which at least one of the secondary containers95can be loaded. Beneficially, the present disclosure provides blanks13,113for forming the tertiary shipping carton57,157, which also comprises one or more corner structures comprising mitred corner panels. Accordingly, the tertiary shipping cartons57;157may also benefit from a reduction in overall packaging material required to create a structure capable of enclosing at least one secondary container. Advantageously, the tertiary shipping cartons57;157can securely and tightly (snugly) fit the at least one secondary basket-style container95therein such that wear or damage to the basket carrier95once contained in the tertiary carton57is minimized or completely prevented.

Referring now toFIG.7, the blank13comprises: a first side panel15, bottom panel17, second side panel19, top panel21and securing panel23. The first side panel15, bottom panel17, second side panel19, top panel21and securing panel23are hinged one to the next in series along fold lines25,27,29and31respectively. Additionally, the blank13comprises first and second corner panels43a,43b; and third and fourth corner panels45a,45b. The first and second corner panels43a,43bare hinged to first and second ends of the first side panel15by fold lines55band55arespectively. The third and fourth corner panels45a,45bare hinged to the first and second ends of the second side panel19by fold lines59band59arespectively.

The main panels15,17,19,21are folded to form a tubular structure. To close the open ends of the tubular structure, end closure flaps35b,37b,39b,41b,35a,37a,39a,41aare provided. A first end closure flap35bis hinged by fold line47bto the first corner panel43a. A second end closure flap37bis hinged by fold line49bto a first end of the bottom panel17. A third end closure flap39bis hinged by fold line51bto third corner panel45a. A fourth end closure flap41bis hinged by fold line53bto a first end of top panel21.

A fifth end closure flap35ais hinged by fold line47ato the second corner panel43b. A sixth end closure flap37ais hinged by fold line49ato a second end of the bottom panel17. A seventh end closure flap39ais hinged by fold line51ato fourth corner panel45b. An eighth end closure flap41ais hinged by fold line53ato a second end of top panel21.

To form a flat, collapsed, part-formed shipping container, the blank13is folded about fold line25to bring the first side panel15into overlapping relationship with part of the bottom panel17. Affixing means may applied to the inner surface of the glue panel23. Then the blank13may be folded about fold line29to bring the top panel21into face contacting relationship with the second side panel19and to bring the glue panel23into face contacting relationship with the first side panel15. In this way the securing panel23is attached to the outside surface of the first side panel15.

The flat form part assembled blank13can then be opened out into an open-ended tubular structure which can be loaded through one or both of the open ends with at least one, and in this arrangement with four, secondary packaging basket style containers95. The first end of the shipping carton57is then closed by folding the first and third corner panels43a,45aabout fold lines55b,59b. Then, the first and third end closure flaps35b,39bare folded about fold lines47b,51b, followed by the second end closure panel37bbeing folded about fold line49band then the top end closure panel41bbeing folded about fold line53b. Affixing means such as adhesive may be applied to appropriate regions of one or more or all of the first, second, third, and fourth end closure flaps35b,37b,39b,41b, such that as they are folded into overlapping relationship they are secured together to form a composite end wall35b/37b/39b/41b. The second end of the shipping carton57is closed in a similar manner. The two open ends may be closed at the same time. The completed tertiary shipping carton57, comprising four secondary basket style containers95and twenty-four bottles, is shown inFIG.8. The folding and assembly arrangement described is optional and the tertiary shipping carton57may be assembled in a different manner.

To illustrate the close fitting nature of the secondary packaging containers95within the tertiary carton57, inFIG.9there is shown a plan view from above of a packaging system97comprising a tertiary shipping carton57wherein the top wall21and top end closure flaps41a,41bhave been removed in order to illustrate the four secondary packaging containers95disposed therein, each having four corner panels14a,14b,16a,16band each holding articles ‘B’. As can be seen, four corner panels14a,14b,16a,16bof the four secondary packaging containers95are sized, configured and arranged to fit internally of and against a corresponding one of the four corner structures43a,43b,45a,45bof the tertiary shipping carton57. The nested basket carriers95fit snugly within the shipping carton57and the package system97thereby produced is readily and reliably stackable.

Referring now toFIGS.10and11there is a further embodiment of a tertiary shipping carton157, which may be used in conjunction with one or more secondary packaging containers95such as the basket style secondary container95shown inFIG.6. InFIGS.10and11like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “100” to differentiate these features from the tertiary shipping carton57shown inFIGS.7,8and9. The adaptation of tertiary shipping container157as illustrated inFIGS.10and11shares many common features with the shipping container ofFIGS.7,8and9and therefore only the differences will be described in any greater detail.

Blank113comprises a first corner panel145b, a first end panel115, a second corner panel143a, a first side panel117, a third corner panel145a, a second end panel119, a fourth corner panel143b, a second side panel121and a first securing panel123a. The first corner panel145bis hinged along fold line161to a first edge of the first end panel115. The first end panel115is hinged by fold line125to the second corner panel143a, which in turn is hinged by fold line155ato first side panel117. First side panel117is hinged by fold line127to third corner panel145a, which in turn is hinged along fold line159ato second end panel119. Second end panel119is hinged by fold line159bto fourth corner panel143b, which in turn is hinged by fold line129to second side panel121. Second side panel121is hinged by fold line131to first securing panel123a.

To close the top and bottom of the tertiary shipping container157, a series of end closure flaps135b,137b,139b,141b,135a,137a,139a,141ais provided. A first end closure flap135bis hinged by fold line147bto the first end panel115. A second end closure flap137bis hinged by fold line149bto the first side panel117. A third end closure flap139bis hinged by fold line151bto the second end panel119. A fourth end closure flap141bis hinged by fold line153bto the second side panel121. Each of the first, second, third and fourth end closure flaps135b,137b,139b,141bis not connected to a corner panel145b,143a,145a,143b. Together the first, second, third and fourth end closure flaps135b,137b,139b,141bform a composite top wall135b/137b/139b/141b.

A fifth end closure flap135ais hinged by fold line147ato the first end panel115. A sixth end closure flap137ais hinged by fold line149ato the first side panel117. A seventh end closure flap139ais hinged by fold line151ato second end panel119. An eighth end closure flap141ais hinged by fold line153ato the second side panel121. Each of the fifth, sixth, seventh, and eighth end closure flaps135a,137a,139a,141ais not connected to a corner panel145b,143a,145a,143b. Together the fifth, sixth, seventh, and eighth end closure flaps135a,137a,139a,141aform a composite bottom wall135a/137a/139a/141a.

To form a flat, collapsed, part-formed shipping carton157, the blank113is folded such that securing panel123ais affixed to first corner panel145b. This may optionally be achieved by folding the blank113about fold line125to bring the first corner panel145binto face contacting relationship with the second side panel117, and then applying adhesive to either the first corner panel145band/or the securing panel123abefore folding the second side panel121and securing panel123aabout fold line129and into adhering contact with the first corner panel145b.

The flat form, part-assembled blank113can then be opened out into an open ended tubular structure and the bottom wall formed by folding and affixing the fifth, sixth, seventh, and eighth end closure flaps135a,137a,139a,141a. The open topped structure can then be top-loaded with at least one secondary packaging container95. Optionally four secondary packaging containers95can be loaded into the tertiary shipping carton157(shown inFIG.11). The four corner panels14a,14b,16a,16bof the four secondary packaging containers95are sized, configured and arranged to fit internally of and fit snugly against a corresponding one of the four corner structures143a,143b,145a,145bof the tertiary shipping carton157. Once loaded, the tertiary shipping carton157can be closed by folding and affixing the first, second, third and fourth end closure flaps135b,137b,139b,141bthereby forming a composite top wall. Multiple tertiary shipping cartons157can be stacked one on top of the next due to the robust and strong structure. The stacking strength of the tertiary shipping carton157may be enhanced by the provision of the four corner structures145b,143a,143b,145a.

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.

It will be recognized that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.

As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line is typically a scored line, an embossed line, or a debossed line. Any reference to hinged connection or fold line should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from any one or more of the following, a short slit, a frangible line or a fold line without departing from the scope of the invention.

As used herein, the term “severance line” refers to all manner of lines that facilitate separating portions of the substrate from one another or that indicate optimal separation locations. Severance lines may be frangible or otherwise weakened lines, tear lines, cut lines, or slits.

It should be understood that hinged connection, severance lines and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.