MULTI-PLY CARTON, BLANK, AND FORMATION METHOD

Abstract: A multiply carton tray base or lid comprising a paperboard substrate (S) to which an outer sheet material (16) is secured. The tray has a main panel (m) across which the sheet material is strected so that it is normally out of contact with a substantial part of the main panel and is secured to the tray only at locations internally of the carton side panels (s) and end panels (e) and not at all to the main panel (m).

Description: MULTI-PLY CARTON, BLANK, AND FORMATION METHOD Tlϋs invention relates to a multiply carton blank for setting up into * tray base or lid lim in a relatively loose outer ply imparting to the carton (formed from a combined has* and liH) n hand-wrapped appearance. T he invention also relates to a cat toπ thus p vid d, in a method of forming the multiply blank and further to means for forming the multiply lank More particularly, a preferred embodiment of (he blank according to the invention cwmrii's :ι papeiboard substrate to one face of which is secured a decorative out er laminate i* a plastics ' foil material. The laminate is secured to the paperboard substrate only at sHerc locations in older to achieve in the finished carton the desired ' hand r a e lo ' ιo facilitate the selting-up process and to ensure a neat appearance to (lie finished cat ion A machine which is specifically adapted and ideal fot setting up cai ton blan s according t" this invention is disclosed in international patent application number WO 96/ 1 '198 I lo w hich the t ender is directed One ns p u of (h invention provides a multiply canon tray base oi lid l ompi isi'ip. a paperboard substrate structure to which an outer sheet material is secured the said havni a mam anel arrows which the sheet material ι« stretched so that it is ιιoι m.ι | l y out of ront v i with a substantial part of the main panel and which sheet material is secured to the n ay onl) at locations internally thereof 2 Λccoidiπg lo a feature of this aspect of the invention, the sheet mnteiial may be adhered to the papciboard st ctuie only internally of the carton side panels »nd end panels and not at all to said main panel Another aspect of the invention pioυi es a method of forming a multiply carton blank for setting υp into a tray base of lid which method comprises feeding β web of material is to form an outer ply oTthe blaπl; from an in feed station to an outfeed station, a lying adhesive to the exposed face of the web at preselected and iπleπupted transverse and longitudinal locations thereof during feeding of the web, between said stations, applying a paperboard layer to the pre glued face of the web and cutting the multiply web thus formed at intervals along its length to create a plurality of multiply sheets In some constructions, the multiply sheets may be cut and creased to form multiply carton blanks in which the cutting and creasing lakes p ce fust thiough the outer ply Preferably, adhesive is applied to the oufr ply m spaced longitudinal strips and in spaced transverse stiips and al otbei discrete locations between the adjacent ends of each longitudinal and transveisc strip According to another feature of tins aspect of the invention, 'lie longitudinal strip 1 - in.iy be spaced apart so as to correspond with parts of the paperboard which are to heromr opposed end walls of the tray base or lid and ihe transverse strips are spaced apail so as lo correspond with pans of the papcrboaid which me to become opposed side walls of the Irav base or hd Preferably, the discrete locations correspond with parts of the papcrboaid which are to become foldable webs hinged to adjacent ends or each of the side and end anels Where this prefctence is adopted, ihe longitudinal strip9 may be spaced apart so as to correspond with parts of the paperboard which are to become the innermost end wall panels of double ply end J walls of the trny base or lid and the transver se stops ai spaced apai t so us to cor respond with parts of the paperboard which, are to become the innermost side wall «-f <'<'nbl' ply sid « walls of the tray base or lid Another aspect of the invention provides a multiply carton blank, formed hy a etho according to any of the four immediately preceding paragiaphs. Yet anolhet aspect of the invention provides in or for an applicator e ice Tor applying adhesive to a web of material which is to form an outci ply of a multiply car ton blank, an applicator cylinder which includes adhesive applying areas comprising a pair of raised zones which will produce a generally i cctangυlar adhesive pattern on said web, w hich zones at one of their adjacent transvei se ends have a common u aπsvei se t aised O MM and ar e •■p.iced apan from one another at their opposite tr ansv erse ends Preferably, a disri et" ι aκed ii ea is provided at or adjacent each corner of each said zone A still further aspect of the invention provides a multiply cai toπ blank (or formmp, a n ay base or hd which blank compr ises a paper boar d subsli nte lo which an out ei slieci mai cπal is seem ed, the blank compri<sinp a iinin panel to eac h of a pair of pp se lon iludmnl edges of which is hinged a pan of side wall panels lb" foi πnπe respec tively inner and outer side wall panels of a double ply side wall of the base or lid , and lo each of n pair of opposite transverse edges of which is hinged a pan or end wall panels for forming respectively inner and outer end wall panels of a double ply side wall of the base or lid and wherein the outer sheet material is secured only to those areas of the paperboard substrate which will be disposed internally oi the base or lid when the blank is set up and left detached from other areas ol the blank According lo a feature of this aspect of the invention, the ratio of thickness between the paperboard substrate and the outer sheet material respectively is substantially within the tange 18.75 1 to 62 5: 1 but preferably within the range 25. 1 to 35. 1. According to another feature of this aspect of the invention, thft thickness of the paperboard substrate is substantially within the range 0.015" to 0.025" and the thickness of tl outer sheet material is substantially within the range 0.0004" to 0.0008". Embodiments of the various aspects of the invention will now be described, by way of example only, with reference lo the accompanying drawings, in which - Figure 1 is a schematic side view of the laminating equipment according to one aspect of the invention, Figured 2 and 3 are perspective views of an adhesive toller applicator according to the invention for use Ln providing A tray base, Figure A is a plan view of a paperboard sheet prior to the application of ndlies-ivo to illustrat e the layout of carton blanks to be al'"''- rmm it Figure 5 is a view similar to Figure 4 but shows the adhesive pattern applied to the βncct . Figure 6 is n perspective corner section of o tray base or lid viewed internally thereof, Figure 7 is a perspective corner section of a tray bas or lid intπmllv ιh « κ » c , f during set up; and Figure 8 is a schematic cross-sectional view through a tray base w lid arm m to the. invention.. Referring first lo Figuie I, the infeed end 10 of the equipment includes a su rt 1.7 on v .Jiich a roll 14 of laminate material 16 is journalled Preferably the laminate ;ι>aieιial is a metallised and decorative plastics thin film of approximately 00006" or 13 micron-! ι i«~kn »«« s I Inwevor. the laminate material may be formed from other types of thin sheet nialernl such Λ < IW way of example only, a treated tissue paper The thickness of the papciboatd substrate relative to the thin sheet maien.il ,s im nant in order to provide a carton with the desired characteristics Thus, the paperboard should not be too tliin since otherwise a flimsy structure will result, nor too thick since then the material cost will be inhibiting and folding oT the carlon blank moie difficult 1 ikcvvise, the thin sheet material should be thin enough to achieve a hand wra e wnnkle ' np[>earan< e V I without beiuβ so thin that H is susceptible to tearing Accordingly, the ratio of the thickness of the papeibonid substiale to that of ihe. thm sheet material is substantially within the range 1875 I to 6 ' S 1 but preferably within the range 25 I to 31 I However, it is envisaged that the thickness of the pnpeiboaid suhslrπte cnild l>e substantially within the range of 0.015" to 0.025" and the thickness of the thin shee< material substantially Hlhin the range 00004" to 0.0008". Λ reasonably robust carton with the requisite 'hand-wrapped look" has ben n iievΗ <<iιh a papcrboaid thickness of 0017" (17 point board) and a plastics film laminate thic r, "* r-f 0.0006". Ihe film is printed with a decorative pattern or plain colour on one face 16α only, lli* oth'.r face 16b usually left uπdecorated but cxliibiting the metallised finish on the underside of face 16a The film passes through a set of rollers shown generally by lefetenre 'R' nt the infoed end of the equipment, passes over a processing platform 18 and Ihrouch the nip of a t r-f drive rollers 20 One of the toilets 20 is powered by suitable means -,wcli a a small ele'Ui motor, to put the film under tension as the film is unravelled from the roll I ' Ihe set of toilets 'R' includes a pair of guide rollers 22, 24 respectively winch direct the film between an applicator cylindei 26 and a co-operatmg transfer roller 2H w ich transfers clnvc to the applicator cylinder by movement of Ihe film Ihus, the film asse through the mp between the applicator cylinder and the transfer lollet such that its dnection of trnvc 1 i s revet sed by passing around the ttansfer lollei Λs the film is advanced along the processing plaifoim Us substantial engagement with ttansfet toller 28 causes the lollei to lotate whereby rotational drive is transmitted to the applicator cylinder 26 lo this end. the ti nsfei rollet ι« formed from a high friction material, such as rubber, which is in driving engagement with liigh friction pails of the applicator cylindei as dcscitbed below Referring now to Figures 2 and 3, the applicator cylinder 26 is illustrated so that its circumferential configuration is apparent Cylinder 26 includes a circumferential band of high friction material 30, 32 at each of its opposite axial ends. These bands are raised from the 5 surface 34 of the cylinder and engage with the transfer roller as referred to above. The circumferential surface of the cylinder is provided with two zones 36 and 38 respectively which are defined by raised pads and which provide two side by side rectangular patterns of adhesive on a linear length of material passing through the nip between the applicator cylinder 10 and the transfer roller during one ftill revolution thereof. For convenience, the zones on the cylinder will be referred to as 'rectangular- zones 36 and 38 respectively Rectangular zone 36 is defined in part by spaced circumferential raised strips 40 and 42 respectively joined together at one of their ends by a transversely (axially) extending raised strip 44 At it s opposite end (Figure 3) the circumferential raised strips 40 and 42 are also j oined togethei by n transversely 15 extending raised strip 46 The transverse raised strip 46 is also common to rectangular zone 38 in that it joins together one end of circumferential raised strips 46, 50 which, in part, define the rectangular zone 38 The opposite ends of the circumferential raised strips 48, 50 are joined together by transverse raised strip 52 (Figure 2} ■'•0 I lif- applicator cylindei also has further discrete raised pads wit hin cadi n-ι tangulai z e I us pads 4 and 56 are disposed adjacent the comers formed between stnps 40 and 44 ami bet ween strips 42 and 44. respectively al one end of zone 36 Likewise, pads 58 and 60 are disposed adjacent the comers formed between strip 40 and 46 end between stπps 4 and 46. respectively, at the opposite end of zone 36 Similaily, pads 62 and 64 ai c disposed adjacent 8 the comers fonmed between strips 48 and 46 and between strips 50 and 46, respectively, at one end of zone 38. Likewise, pads 66 and 68 are disposed adjacent the corners formed between strips 48 and 46 nnd between strips 50 and 46 respectively, at the opposite end of zone 36. The particular applicator cylinder shown is particularly suitable for use in forming a blank to provide a tray base. The precise layout of the circumferential and transverse strips and the disposition of all the further discrete pads is variable and is dependant upon the dimensions of the carton blank to be produced or, indeed, the number of carton blanks to be struck from the sheet For example, in order to produce a blank to provide a tray top, the corner pads referred to above may be disposed fully within the corners of the rectangular zones so that they are contiguous with rather than adjacent the associated circumferential and transverse str ips a own In some cases, whei e a lar ger blank is requited only one rectangular ?.on . may be t equn ed, whereas in other cases where smaller blanks are required, a multiplicity of rfc.t ang.ulai 7onrs may be required Referring again to Figure 1 , the applicator cylinder is in rolling abutment with a lowei roller 27 which rotntes in a bath of adhesive When the opplicator cylinder end lower l ollei l oiai c together, adhesive is u ansfcπed fi om the lowei r oller 27 to the raised sn ips and pads c ien ed to above on the applicator cylinder axially within the circumfetential bnnd r . .to ;ιnd M A doctor blade 66 is located adjacent the lower roller to rid it of excess adhesive Accordingly, as the web of material is fed adhesive is applied to it, on its non-ti cated lacr 16b, by the applicator cylinder, in a particular array so that a pattern of successive adhesive areas is 9 exposed to view on the web as it is advanced along the processing table In this regard, the width of the web is not sufficient to extend across circumferential bands 30 and 32 so that the bands are left free to Frictionally engage the applicator cylinder The paperboard substrate is superposed upon, and thereby adhered to, the film web as it is advanced along the processing table. In the particular embodiment shown, individual sheets of paperboard material 'S' are deposited upon the film web wherein each sheet is sized so that a pair of like carton blanks can be struck from it. However, a different number of carton blanks may be required from a similar or different sized sheet. This general arrangement is shown in Figure 4. Thus, the pattern of adhesive which is laid down by one revolution of the applicator cylinder is intended to receive a paperboard sheet from which two blanks can be obtained In Figure 5, the outline of the two blanks B , and Bj to be struck from a sheet of paperboard ' S is shown and the adhesive areas are s o jn by shading It is nevertheless envisaged il-at > continuous υ. eb of paperboard material may be applied to the film web and the multi-ply * ■ " κ thus formed is sheeted thereafter rather than applying pre-sheetcd papeiboutd lo the web It will be appreciated that the axial length of roller 27 is less than that of the applicator cylinder so that adhesive is transferred onto all the raised strips and puds inboard of the circumfer ential bands 30 and 32 but not on the circumferential bands themselves Bct ause the film web is led under tension it is stretched under the paperboard substrate and this causes the paperboard to adopt a slightly upward arc or a so-called 'down-curl' Paperboard exhibiting a down-curl \ - difficult to cut and crease and hence the multiply sheet is inveitcd and cut and creased in an up-curl disposition so that the cutting and creasing takes place f st through the film outer plv 9a Figure 4 shown the layout of blanks Bi and Bj on the paperboard sheet before the adhesive pattern is laid down. By comparing Figures 4 and 5, it will be seen that the longitudinal strips of adhesive / t and j cover the foldable base panels b, and bj and portions of adjacent inner end panels β| and ej on blank Bi and cover the foldable base panels bv and b ( and portions of adjacent inner end panels e, and 3 on blank Bj 10 Similarly, the transverse strips of adhesive t) and t ? cover foldable base panels b, and b Λ and portions of adjacent inner side panels s ( and s» on blanks Bi and B2 respectively whereas the central transverse strip of adhesive t>. covers the foldable base panels bi and b t and portions of the adjacent inner side panels sj and on blank B t and BΪ respectively The adhesive rectangles R t lo R t in the main cover the foldable web panels Wi to Wj In this particular embodiment, the spacing between raised transverse strips 44 and 52 corresponds to the gap between successive sheets S laid down on the web 16 Referring to Figures 6 and 7, the foldable base panels are thus called because when the blank is set up into a ttay base or lid, the foldable base panels are disposed internally thereof in superposed contact with the main panel M of the blank The inner side and end panels arc thus Called becau se when the blank is set up into a tray base of lid, the and end paneK are of double ply thickness in which the inner side and end panels are disposed internally of the tray " base or lid The web panels W, to W» are folded internally of the tray base or ltd I he manner and means by which the carton blank is set up into a tray base or lid is descπbed in the aforementioned international patent application No WO 96/14981 It will be appi eciated thcrefot c, that the lamination process of the pi '-seπl invention f.ust substantially all nf ihe adhesive contact between the laminate mai r-r l and apc hoar d substrate to be at locations which aie not exposed to view in the set up base 01 lid Accordingly the 'loose' or 'hand' wtap effect of a carton formed from such a combined ti ay and lid is much enhanced because substantially none of the laminate which is seen exlernall of the carton is adh?ι cd to the papetboatd It has been found that the laminate material c overing 1 1 the foldable web panels w, to w, is particularly susceptible to tearing because of the folding action performed on the webs which can lead to an unsatisfactory corner appearance in a finished carton and hence the adhesive contact between the laminate material and paperboard substrate is advantageous The 'loose' or 'hand' wrap appearance is also enhanced by the lack of any significant contact between the laminate material and the paperboard over a substantial area of the main panel Tension of the laminate across the main panel is created during the setting up of the prccrcascd blank to produce a relatively taut skin over the main panel M wlϋch is thereby caused to adopt a substantially bowed configuration as shown in Figure 8 It has been found advantageous to the cutting and creasing operation and to the appearance and folding of the carton blank that the cut ting and creasing opei ation by which the blank 1 - <" •' stmck from the sheet should be performed through the laminate side of the sheet fn ^t rntliei than paperboard to laminate It is envisaged that the carton blanks may be partially pre-glued to facilitate set up Therefore, in figure 7 the inner side walls V would be adhered lo the outei side wall ' sT and optionally the base panel 'b' adhered to the mam panel 'm' Accoidingly, the double-ply side walls t nus formed can be readily put into an upright attitude and the end wall panels c, Cι. and b m e manipulated together with web panels w to provide upright double-ply end panels wluch .ιι e held in position by interlocking co-operation of the tab 'lb' and recess ' rs' m adjacent ends of respective base panels b Other locking oi securing means could be prov ided instead ol the co-operating tab ' tb' and tece.ss rs Moreover, it is (Anther envisaged that the base panels of the end and/or side panels c ould be omitted altogether

Claims: T US97/16913 12 CLAIMS 1 A multiply cftrton tray base or lid comprising a paperboard substrate structure to which an outer sheet material is secured the said tray having a main panel across which the sheet material is stretched so that it is normally out of contact with a substantial part of the main panel and which sheet material is secured to the tray only at locations internally thereof 2 A multiply carton tray base or lid according to claim 1 and wherein the sheet material is adhered to the paperboard structure only Internally of the carton side panels and end panels and not at all to said main panel 3 A method of forming a multiply carton blank fot setting up into a tray base or lid which method comprises feeding a web of material wluch is to form an outet ply of the blank from an in-feed station to an outfeed station, applying adhesive to the exposed (ate of the web at preselected and interrupted transverse and longitudinal locations thereof dunng feeding of ( he web, between said stations, applying a paperboard layer to the pre-glued face of the web and cutting the multiply web thus formed at intervals along its length to create a plurality of multiply sheets 4 Λ method according to claim 3 wherein the 1 multiply sheets are αit and ( t eased to form multiply carton blanks in which the cutting and creasing takes place first through the outer ply 13 5 A method according to claim 3 wherein adhesive is applied to the outer ply in s: s • : : longitudinal strips and in spaced transverse strips and at other discrete locations between m adjacent ends of each longitudinal and transverse strip. 6 A method according to claim 4 wherein adhesive is applied to the outer ply in spaced longitudinal strips and in spaced transverse strips and at other discrete locations between tne adjacent ends of each longitυdinal and transverse strip. 7. A method according to claim 3 wherein the longitudinal strips are spaced αpou so as to correspond with parts of the paperboard which are to become opposed end walls υt tin; tr.> ,' base or lid and the transverse strips are spaced apart so as to correspond A-UII an , : paperboard which are to become opposed side walls of the ti ay base 01 lid 8 A method according to claim 6 wherein the discrete locations cot respond • • . it! 1 j ? ' " J the paperboard wluch are to become foldable webs hinged to adjacent eiK's ' >! e.u ' » "! f- and end panels 9 A method according to claim 7 wherein the longitudinal str ips ni c <ψn< ι-d np<> i i • • ' correspond wnh parts o( the papetboard which are to become the innermost < nd wi-h y?' - * < double ply end walls of the tray base or lid and the transverse strips are sptn ci u JI » <■-,' : • ■ > to correspond n pans of the papetboard which ate lo become the inncrnii ' si sui- .' ?'i ; ' i i" oi double ply side walls of the tray base or lid 14 10 A method according to claim 8 wherein the longitudinal stπps are spaced apart so as to correspond with parts of the paperboard which are to become the innermost end wall panels of double ply end walls of the tray bast or lid and the transverse strips are spaced apart so as to correspond with parts of the paperboard which are to become the innermost side wall panels of double ply side walls of the tray base or lid 11 A multiply carton blank formed by a method according to claim 3 12 In or for an applicator device for applying adhesive to a web of material which is to form an outer ply of a multiply carton blank, an applicator cylinder which includes adhesive applying areas comprising a pair of raised zones which will produce a generally rectangular adhesive pattern on said web, which zones at one of their adjacent transverse ends have a common transverse raised area and are spaced apart from one another at their opposite transverse ends 13 In or for an applicator device according to claim 12 wherein a discrete raised area is provided at or adjacent each corner of each said zone 14 A multiply carton blank for forming a tray base or lid whic blanV. . u p ri i' paperboar d substtate to which an outer sheet material is secured, the blank compr ising a mam panel to each of a pair of opposite longitudinal edges of which is hinged a pair of side wall panels for forming respectively inner and outer side wall panels of a double ply side wall of the base or lid, and to each of a pair of opposite transverse edges of which is hinged a pair of end wall panels for forming respectively inner and outer end wall panels of a double plγ side wall I S of the base or lid and wherein the outer sheet material is secured only to thosir at en* of th; paperboard substrate which will be disposed interrlally of the base or lid when the blank is s^; up and left detached from other areas of the blank 15 A multiply carton blank according to claim 14 wherein the ratio of thickness between the paperboard subslrale and the outer sheet material respectively is substantially within the range 18.75: 1 to 62.5: 1 but preferably within the rjmge 25: 1 to 35: 1. 16. A multiply carton blank according to clairr 1 wherein the thickness of the paperboard substrate is substantially within the range 0.015" lo 0 025", and the thickness of the υutci sheet aiei i al is substantially within the range 0 0004" to 0 0008"

Inventors: CANNING TIMOTHY A, CANNING, TIMOTHY, A.
Applicants: FIDELITY INT INC, FIDELITY INTERNATIONAL, INC.
Application year: 1997
Main classification: B65D5
IPC codes: B31B7, B65D5