HEAVY DUTY ARTICLE CARRIER

Abstract: An article carrier and a blank for forming an article carrier for accommodating a plurality of articles such as cans which carrier comprises a top wall (66, 76), a base wall (46, 50), side and end walls (12, 14) interconnecting the top wall (66, 76) and the base wall (46, 50), a handle strap (64) formed in the top wall (66, 76) and defined at least in part by hand apertures (74, 84) in the top wall (66, 76), score lines (96, 98) provided in the top wall (66, 76) to enhance local folding in the top wall so that the top wall is encouraged to bow upwardly when lifted by the handle strap (64), and a stress relief cut (101, 105) operatively associated with the local folding-enhancing score lines (96, 98) and provided in the top and side walls (66, 12) adjacent a corners of the top wall so that the lifting stresses are transmitted to the side and end walls (12, 14) to relieve the stresses acting on the handle strap (64) when the carrier is lifted by the handle strap (64).

Description: HEAVY DUTYARTICLE CARRIER Background of the Invention This invention relates generally to hand held article carriers for accommodating one or more articles, for example bottles or the like formed from one or more blanks of paperboard or other suitable foldable sheet material. More particularly, the invention is concerned with providing a handle structure including score lines formed in the top wall together with weakened severance lines which interrelate these score lines with diagonal score lines at each corner thereof. US Patent No 5 307 932 issued May 3, 1994 and owned by the proprietor of this invention discloses a fully enclosed article carrier having special score lines formed in its top wall and arranged so as to aid in distributing the load of the carrier. Another example is illustrated in US 5, 379, 944 which shows a top wall with score lines arranged to extend from the end of the hand gripping aperture outwardly in an emerging path toward corners of the top wall. The score lines terminate at cut lines extending across the top wall and into the adjacent side and end walls. Notably, the corners are formed from the top, side and end wall panels secured together to form a fully enclosed corner. Multiple ply handles are also common in cartons of the end loading type usually by overlapping part of the wall panels forming the top wall panel. However, for cartons of the "over the top" style in which articles are loaded from above or below, the known approach of overlapping wall panels is unsatisfactory as it relies on accurate alignment of wall panels during the loading process which is undesirable to the packaging speeds of known machines. The present invention and its preferred embodiments seek to overcome or at least mitigate the problems of the prior art by providing an improved structure for distributing the stresses around the handle and an improved multiply handle arrangement. Summary of the Invention According to one aspect of the invention, there is provided an article carrier for accommodating a plurality of articles such as cans which carrier comprises a top wall, a base and side and end walls interconnecting the top and the base thereby forming a tubular structure and top and bottom end closure wall panels for closing opposite ends of the tubular structure. A handle strap formed in the top wall is defined at least in part by hand apertures provided in the top wall, wherein each of the end closure wall panels is formed with means adjacent the top wall to enhance local folding of the top wall so that the top wall is encouraged to bow upwardly when lifted by the handle, the means to enhance local folding in the top wall being operatively associated with the stress relief means. The stress relief means is provided in the top and side walls adjacent the corners thereof so that the lifting stresses are transmitted to those articles to relieve the stresses acting on the handle when the carrier is lifted. According to an optional feature of this aspect of the invention, the means to enhance local folding of the top wall may comprise a plurality of score lines formed in the top wall each one of which extends from one of the hand apertures to terminate at the stress relief means. Preferably, the score lines may be arranged in pairs and diverge outwardly from the hand apertures to the comer of the top wall. According to another optional feature of this aspect of the invention, there may further comprise a pair of diverging fold lines extending from a central portion of the hand aperture to terminate at a side edge of the top. According to a further optional feature of this aspect of the invention the stress relief means may comprise one or more weakened severance lines formed in the top wall and extending into the side wall and disposed adjacent each corner thereof. According to yet another optional feature of this aspect of the invention the or each weakened severance line may be diagonally oriented at each corner thereof. Alternatively, the or each weakened severance line may be generally arcuate at each corner thereof. A second aspect of the invention provides a blank for forming an article carrier for accommodating a plurality of articles which carrier may comprise a top wall, a base and side and end walls interconnecting the top and the base thereby forming a tubular structure and top and bottom end closure wall panels for closing opposite ends of the tubular structure. A handle strap is formed in the top wall defined at least in part by hand apertures provided in the top wall, wherein the top wall comprises a plurality of score lines, each one of which extends from one of the hand apertures to terminate at stress relief means provided in the top and side walls adjacent the corners. The score lines encourage the top wall to bow upwardly when lifted by the wall panel, and the stress relief means transmit the lifting stress to the side and end walls when the carrier is held, so that the top wall is encouraged to bow upwardly when lifted by the handle. The means to enhance local folding in the top wall is operatively associated with the stress relief means, the stress relief means provided in the top and side walls adjacent the corners thereof and means to enhance local folding of the top wall so that the lifting stresses are transmitted to those articles to relieve the stresses acting on the handle when the carrier is lifted. According to an optional feature of the second aspect of the invention the stress relief means may comprise one or more weakened severance lines formed in the top wall and extending into the side wall and disposed adjacent each corner thereof. A third aspect of the invention provides an article carrier for accommodating a plurality of articles such as cans which carrier comprises a top, a base and side and end walls interconnecting the top and the base thereby forming a tubular structure and top and bottom end closure wall panels for closing opposite ends of the tubular structure. The base is formed by securing together overlapping oppositely disposed base wall panels by locking means and wherein the bottom end closure wall panels are secured to the outer surfaces of the base wall panels. A fourth aspect of the invention provides a method of forming the base of an article carrier, according to the preceding paragraph which method comprises the steps of overlapping the oppositely disposed base wall panels, securing the base wall panels together folding the base end wall panels into face contacting relationship with the base wall panels and securing the base end wall panels to the outer surface of the base wall panels. A fifth aspect of the invention provided an article carrier for accommodating a plurality of articles such as cans which carrier comprises a top, a base and side and end walls interconnecting the top and the base thereby forming a tubular structure and top and bottom end closure wall panels for closing opposite ends of the tubular structure. A handle strap is formed in the top wall defined at least in part by hand apertures are provided in the top wall, wherein the handle strap is a triple ply structure formed from the overlapping portion of oppositely disposed top wall panels and a support wall panel extending from one of the top wall panels and foldable into face contacting relationship with one of the top wall panels. Preferably, the support wall panel comprises two parts hingedly connected to lateral free edges of one of the top wall panels. Alternatively, the support wall panel is hingedly connected to a longitudinal free edge of one of the top wall panels. Brief Description of the Drawings Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: FIGURE 1 is a plan view of a blank for forming a carton according to one preferred embodiment of the invention; FIGURE 2 is a plan view of a blank for forming a carton according to a second preferred embodiment of the invention; FIGURE 3 is a plan view of a blank for forming a carton according to another preferred embodiment of the invention; FIGURE 4 shows the position which the carrier parts occupy when the blank of FIGURE 1 is manipulated into a collapsed carrier; FIGURE 5 illustrates a carton in a set up condition formed from the blank shown in FIGURE 1; and FIGURE 6 is an enlarged view of the corner arrangement of the carton shown in Figure 5. Detailed Description of the Preferred Embodiments Referring first to Figure 1 there is shown a blank 10 for forming a carton or article carrier made from one or more blanks of paperboard of similar foldable sheet material. The blank 10 comprises in series of a first side wall panel 12, first end wall panel 14, second side wall panel 16, second end wall panel 18 hingedly connected together. In this embodiment, opposed side and end wall panels 12, 16; 14, 18 may be separated by corner panels 20, 22, 24, 26 adapted to form bevelled corners for the carton^ corner panel 20 is hingedly connected to side wall panel 12 along fold line 28 and to first end wall panel 14 along fold line 30. Corner panel 22 is hingedly connected to first end wall panel 14 along fold line 32 and to second side wall panel 16 along fold line 34. Corner panel 24 is hingedly connected to second side wall panel 16 along fold line 36 and to second end wall panel 18 along fold line 38. Corner panel 26 is hingedly connected to second end wall panel 18 by fold line 40. Preferably, there may further comprise a glue flap 42 connected to the second end wall panel 18 and more preferably to the lateral edge of corner panel 26 along fold line 44. The base of the carrier is formed from a plurality of base panels which in this embodiment is provided by base panels 46, 48, 50 and 52 hingedly connected to side wall panel 12, end wall panel 14, second side wall panel 16 and second end wall panel 18 respectively along fold lines 54, 56, 58 and 60. In some embodiments, there may comprise an intermediate panel 62 hingedly connected to base panels 46, 48, 50 and 52 and to the corresponding side or end wall panels, as shown in Figure 1. The top wall of the carrier is a composite structure formed of two main parts designated by numerals 66 and 76. A hand gripping aperture 74 is formed in wall panel 66, and a similar hand gripping aperture 84 is formed in wall panel 76. Top wall panel 66 may be hingedly connected to an upper edge of side wall panel 12, although in this embodiment, an intermediate panel 70 is provided to interconnect the top and side wall panels 66, 12 along fold lines 72, 68 respectively. Preferably, there comprises one or more score lines extending outwardly from hand aperture 74 towards the opposed comer structure of top wall 66 adjacent intermediate panel 70. In this embodiment, a pair of diverging score lines 92, 94 and 96, 98 extend outwardly to each comer structure. There may further comprise a similar pair of score lines 106, 108 extending outwardly and diverging away from a substantially central portion of hand aperture 74. Likewise, second top wall panel 76 is joined to opposing side wall panel 16 by intermediate panel 80 along fold lines 82 and 78 respectively. Second top wall panel 76 also comprises similar complementary pairs of score lines which correspond substantially to score lines 92, 94; 96, 98; 106,108 of first top wall panel 66 and are therefore designated by the suffix "a" and are not described in any greater detail. There may further comprise one or more upper end flaps 86, 90: upper end flap 86 is hingedly joined to end wall panel 14 along fold line 88 and complementary end flap 90 is hingedly joined to opposing end wall panel 18 along fold line 87. The comer structure of the top wall is now described by reference to first top wall panel 66. There comprises one or more weakened severance lines 100, 104 and ? 101, 105 formed at each comer of the top wall panel 66 which are configured in like but opposed fashion. Turning in detail to the construction of severance line 100, it preferably extends from the inner end of fold line 102 diagonally to terminate at fold line 72. Of course, in other embodiments the fold line could be arcuate or parallel to a side edge of top wall panel. A second cut line 104 extends beyond the cut line 100 into side wall panel 12 to terminate at a point towards the upper comer of side wall panel 12 shown in Figure 1. It will be seen that score lines 92 and 94 terminate at cut line 100. The opposing corner structure likewise includes a severance line 101 extending from the inner end of fold line 103 to terminate at fold line 72. Preferably, severance line 101 is oriented diagonally across the comer, although it could be arcuate or parallel to a side edge of top wall panel without departing from the scope of invention. A second cut line 104 extends beyond cut line 100 across bevelled panel 70 and into side wall panel 12 to terminate at a point towards the upper comer of side wall panel 12, shown in Figure 1. The comer structures of the second top wall panel 76 are similar to severance lines 100, 104; 103, 105, and are designated by the suffix "a". They are not therefore described in any more detail. In one class of embodiments, there may further comprise a support panel 110 hingedly connected to one of the main top wall panels 66, 76 along fold line 112. In use, the support panel 110 is folded about fold line 112 to abut the inner surface of top wall panel 76 to provide a multiply handle thereby to provide additional support. It is envisaged the cartons can vary depending upon the shape and/or quantity of articles to be packaged. The principal arrangements which are likely to be varied are shown in Figure 1 is the overall height of the set up carton equivalent to the distance of the side or end wall and the overall length and/or width of the carton when the base panels have been closed. Turning to the second and third embodiments illustrated in Figures 2 and 3 respectively, the blanks 210, 310 substantially correspond to blank 10 shown in Figure 1, so the reference numerals are prefixed by "2" or "3" respectively and therefore only the differences are described below. In the second embodiment shown in Figure 2, the handle structure 264 includes a support panel formed from two parts 293, 295 hingedly connected to lateral edges of top wall panel 276 along fold lines 297, 299 respectively. In use, the handle parts are folded to abut the underside of top wall panel 276 and are contiguous therewith, thereby providing a multiply handle strap 264 to improve the strength. Also, panel engaging means is provided to secure base panels 243, 245 together, described in more detail below. In the third embodiment, shown in Figure 3 support for the handle strap 364 is provided by the upper end flaps 386, 390 which are shaped to correspond with the end regions of handle apertures 374, 384 respectively. Thus, pairs of recesses 385; 391, 393 are formed along the free end edges of end flaps 386 and 390 respectively. The construction of the carton from the blank shown in Figure 1 is illustrated with reference to Figures 4 and 5: whereby end wall panel 18, top end flap 90 and base panel 52 are folded along fold line 38 and into face contacting relationship with the side wall panel 16, top wall panel 76 and base panel 50. Thereafter, side wall panel 12, top wall panel 66 and base panel 46 are folded about fold lines 30 and into face contacting relationship with end wall panel 14, end flap 86 and base support panel 48, such that side wall panel 12 overlaps glue flap 42 to be secured together by glue or other suitable means known in the art. The glue flap 42 can be connected to the inner or outer surface of side wall panel 12. After this operation is complete, the carton is in a flat collapsed condition ready to be supplied to a user for loading with articles. In order to load the carton, the side and end wall panels are moved out of face contacting relationship and into a substantially rectangular arrangement whereby a sleeve is formed. In this embodiment, the bevelled comers are also constructed by folding bevelled comer panels 20, 22, 24, 26 along fold lines 28, 30; 32, 34; 36, 38, 40 respectively and out of alignment with their adjacent side and end wall panels. Thereafter, articles are loaded by relative vertical movement between the carton and articles from above or below, as is well known in the art and the top and base are constructed, as described below. It is envisaged that one or more layers of articles can be stored within the carton in horizontal or vertical positions according to user requirements. In this embodiment, it is preferred the sleeve is placed over the top of the articles held in vertical orientation and the base is then formed by folding base panels 46, 50 inwardly into overlapping relationship to be secured together by glue, or other suitable securing means. For example the second embodiment is provided with the locking tab 243 and tab receiving flap 245 in base panels 250; 246 for forming and securing the base panels together. Thereafter base support panels 48, 52; 248, 252 are secured to base panels 46, 50; 246, 250 by glue or other suitable means known in the art. It is envisaged the folding steps for forming the base structure can be altered so that for example the support panels 48, 52 are first folded and thereafter base panels 46, 50 are folded into abutment with base support panels 248, 252 and are secured together by suitable means for example glue. In all three embodiments described above, the top structure is preferably provided with a multiply carrying means or handle strap 64. In the first embodiment, the handle support panel 110 is folded about fold line 112 into face contacting relationship with top wall panel 76 and is secured thereto by glue or other suitable means known in the art. In the second embodiment the handle support panels 293, 295 are folded about fold lines 297, 299 respectively into face contacting relationship with top wall panel 276 and are secured by glue or other suitable means known in the art. The composite top wall is then formed, by reference to Figures 4 and 5, whereby top end flaps 86, 90 are folded in a downward direction and into a substantially perpendicular relationship with end wall panels 14, 18. Thereafter, top wall panels 66, 86 are folded in an inward direction to abut top end flaps 86, 90. It will be seen from Figure 5 that portions of top wall panel 66, 76 forming the handle panels are brought into overlapping face to face relationship and are secured together by glue or other suitable means known in the art to form a triple ply handle structure 64. In some embodiments, the support panel 110 may be sandwiched between top panels 66, 76 to form an integral multiply structure. The composite top wall can be additionally secured to end flaps, particularly at the portion of the comer structure between fold lines 102, 72 and cut line 100. Thus, the carton is in a set up and loaded condition, as shown in Figure 5. The carton of the present invention can be formed by a series of sequential folding and gluing operations which can be performed in a straight line machine so that the carton is not required to be rotated or inverted to complete its construction. The folding processes are not limited to that described above and can be altered according to particular manufacturing requirements. In use, each pair of score lines 92, 94; 96, 98; 106, 108 interconnects with the diagonal (or arcuate) comer weakened severance lines sections 100, 103 to avoid unintended or unwanted folding of the top wall panel structure by directing any folding along these fold lines. Thus a significant reduction in stress which is transmitted to the handle occurs due to the collection of the score lines with the weakened severance lines from each comer of the top wall. Commonly, the comer structure of known cartons is fully enclosed and the fold lines defining top or bottom, and side and end wall panels intersect to define the comers. This approach is undesirable, because it can cause a concentration in stresses at the comers when the carton is lifted. By contrast, the carton of the present invention incorporates bevelled comers between the side and end walls and preferably include bevelled upper and lower carton walls which results in comer structures with apertures 120, shown in Figure 5. Thus, by providing a comer arrangement as shown in Figure 6$, the aperture 120 leads to a reduction in stress, but it can be less rigid. The portion 122 of top and side wall panels is formed by the extension of severance lines 104 extending across the upper bevelled panel and into the side walls. In use, the central portion of bevelled panels 70, 80 and/or the upper portions of side wall panels 12, 16 between opposing cut lines 68, 72; 78, 82 flex when the top wall structure is lifted whilst the integrity of the comer arrangement is retained. Thus, the stresses from the lifting action of the handle panel are transmitted through to the side wall panels of the carrier. With significant reductions of stress provided by this invention it is possible to reduce the calliper of paperboard required to form a secured package for the cans. Thus, according to this invention significant savings in the cost of paperboard are achieved without impairing the package integrity. Furthermore, the combination of locking and gluing the base in which the bottom panels are first locked then the end flaps are glued onto the lapped panels provides a more secure base structure to support articles contained in the carrier than other known base structures. It will be recognized that as used herein directional references such as top, base, end and side do not limit the respective panels to such orientation but merely serve to distinguish these panels from one another. Any reference to hinged connection should not be construed as necessarily referring to a single fold line only: indeed it is envisaged that the hinged connection can be formed from one or more of the following: a score line, frangible connection or a fold line without departing from the scope of invention. The present invention and its preferred embodiments relate to a package, carton or article carrier which is shaped to provide a satisfactory rigidity to hold items such as cans with a degree of flexibility. The shape of the blank minimizes the amount of paperboard required for the carton. The carton can be constructed from a flap collapsed condition to a position of use by hand or automatic machinery. It is anticipated that the invention can be modified, without departing from the scope of invention, for example the top wall panel stmcture can be applied to wraparound or end loaded cartons of a known type.

Claims: CLALMS 1. An article carrier for accommodating a plurality of articles such as cans which carrier comprises a top wall, a base wall, side and end walls interconnecting the top wall and the base wall, a handle strap formed in the top wall and defined at least in part by hand apertures in the top wall, means for enhancing local folding in the top wall so that the top wall is encouraged to bow upwardly when lifted by the handle strap, and stress relief means operatively associated with the local folding-enhancing means and provided in the top and side walls adjacent a comer of the top wall so that the lifting stresses are transmitted to the side and end walls to relieve the stresses acting on the handle strap when the carrier is lifted by the handle strap. 2. An article carrier according to claim 1 wherein said local folding enhancing means comprises a plurality of score lines formed in said top wall, each of said score lines extending from one of said hand apertures to terminate at said stress relief means. 3. The article carrier according to claim 2 wherein said score lines diverge outwardly from said one hand aperture to said comer of the top wall. 4. The article carrier according to any of claims 1 to 3 further comprising a pair of diverging fold lines extending from a central portion of each hand aperture to terminate at an adjacent side edge of the top wall. 5. An article carrier according to any preceding claim wherein said stress relief means comprises a weakened severance line formed in said top wall and extending into the side wall, said weakened severance line being disposed adjacent said comer of the top wall. 6. An article carrier according to claim 5 wherein said weakened severance line is diagonally oriented at said comer. 7. An article carrier according to claim 5 wherein said weakened severance line is generally arcuate at said comer. 8. An article carrier according to any preceding claim further comprising a comer panel disposed between said side and end panels to form a bevelled comer stmcture at a comer of the carrier. 9. An article carrier according to claim 8 wherein the comer panel is separated from the top wall thereby to reduce handling stress. 10. A blank for forming an article carrier for accommodating a plurality of articles which carrier comprises a top wall, a base wall, side and end walls interconnecting the top wall and the base wall, a handle strap formed in the top wall and defined at least in part by hand apertures in the top wall, means for enhancing local folding in the top wall so that the top wall is encouraged to bow upwardly when lifted by the handle strap, and stress relief means operatively associated with the local folding-enhancing means and provided in the top and side walls adjacent a comer of the top wall so that the lifting stresses are transmitted to the side and end walls to relieve the stresses acting on the handle strap when the carrier is lifted by the handle strap. 11. A blank as claimed in claim 10 wherein said stress relief means comprises a weakened severance lines formed in said top wall and extending into the side wall, said weakened severance line being disposed adjacent said comer of the top wall. 12. An article carrier for accommodating a plurality of articles such as cans which carrier comprises a top wall, a base wall, side and end walls interconnecting the top wall and the base wall thereby forming a tubular stmcture, and top and bottom end closure panels for closing opposite ends of the tubular stmcture, wherein the base wall is formed by securing together overlapping oppositely disposed base panels by locking means and wherein said bottom end closure panels are secured to the outer surfaces of said base panels. 13. A method of forming the base of an article carrier according to claim 12, which method comprises the steps of overlapping said oppositely disposed base panels, securing said base panels together, folding the bottom end closure panels into face contacting relationship with said base panels and securing said bottom end closure panels to the outer surface of the base panels. 14. An article carrier for accommodating a plurality of articles such as cans which carrier comprises a top wall, a base wall, side and end walls interconnecting the top wall and the base wall thereby forming a tubular stmcture, top and bottom end closure panels for closing opposite ends of the tubular stmcture, and a handle strap formed in the top wall and defined at least in part by hand apertures in the top wall, wherein said top wall comprises a pair of oppositely disposed top wall panels overlapping each other, and the handle strap is a triple ply stmcture formed from an overlapping portion of said top wall panels and a support panel extending from one of the top wall panels, said support panel being foldable into face contacting relationship with said one of the top wall panels. 15. An article carrier according to claim 14 wherein the support panel comprises two parts hingedly connected to lateral free edges of said one of the top wall panels. 16. An article carrier according to claim 15 wherein the support panel is hingedly connected to a longitudinal free edge of said one of the top wall panels. 17. A package comprising a plurality of articles supported by an article carrier as claimed in any of claims 1 to 9, claim 12 or claims 14 to 16.

Inventors: AUCLAIR JEAN-MICHEL, LEBRAS PHILIPPE, AUCLAIR, JEAN-MICHEL, LEBRAS, PHILIPPE
Applicants: AUCLAIR JEAN MICHEL, LEBRAS PHILIPPE, MEAD CORP, AUCLAIR, JEAN-MICHEL, LEBRAS, PHILIPPE, THE MEAD CORPORATION
Application year: 1999
Main classification: B65D
IPC codes: B65D71