CARTON AND A CARTON BLANK

Abstract: A carton and a carton blank constructed from paperboard or like foldable sheet material for enclosing one or more articles, for example a tray of foodstuff, comprising a plurality of wall panels for forming a tubular structure including top and base wall panels (16, 12, 20), opposed side wall panels (14, 18) and one or more end retention wall panels (22, 24) connected to one end of said top wall panel (16). The end retention wall panel (22) is connected to the base wall panel (20) by a corner arrangement (26). The corner arrangement (26) is so constructed and arranged to cause the end retention wall panel (22) to be secured in an erected position.

Description: CARTON AND A CARTON BLANK Background of the Invention The present invention relates to a carton for holding articles and more particularly, to a flat tubular carton for use in enclosing a tray of foodstuff. Numerous food product containers have been provided in the prior art that are adapted to protect food products. For example, in the prior art, it is possible for foodstuffs to move within the tray, which is undesirable. Furthermore, the prior art discloses complicated end retention structures that require a lengthy and/or complicated folding process during the carton folding stage. One example of an end retention structure is illustrated in WO 97/29972 to The Mead Corporation which discloses a wraparound carton which has a side wall contacting arrangement to lock a base end retention panel, and is connected to a top wall contacting panel through a number of intermediate panels. The present invention seeks to overcome, or at least mitigate the problems of the prior art. Summary of the Invention One aspect of the invention provides a carton constructed from paperboard or like foldable sheet material for enclosing one or more articles, for example a tray of foodstuff, comprising a plurality of walls for forming a tubular structure including top and base walls, opposed side walls and one or more end retention walls, connected to one end of said top wall wherein the end retention wall is connected to the base wall by a corner arrangement which is so constructed and arranged to cause the end retention wall to be secured in an erected condition. According to an optional feature of this aspect of the invention the corner arrangement may comprise an anchor structure and one or more gusset panels, the anchor structure comprising a first anchor panel connected to and in face contacting relationship with the base wall, and a second anchor panel connected to said first anchor panel and in face contacting relationship with the corresponding side wall. Preferably, the one or more gusset panel may be connected to the second anchor panel. According to another optional feature of this aspect of the invention the fold line between the first anchor panel and the second anchor panel may overlie the fold line between the corresponding side wall and the base wall. According to another optional feature of this aspect of the invention the one or more gusset panels and the anchor structure may be severed from the adjacent side wall and/or a part of the top wall by an aperture. Preferably, the aperture may be shaped to receive and retain a protruding portion of the article. A second aspect of the invention provides a tubular carton constructed from paperboard or like foldable sheet material for enclosing one or more articles, for example a tray of foodstuff including a flange, which carton comprises a top wall, a base wall, opposed side wall and a pair of opposed end retention walls connected respectively to the opposite ends of the top wall, wherein each one retention wall is connected to the base wall by a corner arrangement including an aperture provided between the corner arrangement and the top wall to allow article flange to protrude therethrough. Preferably, each corner arrangement may further comprise one or more gusset panels interconnecting the base wall and the corresponding end retention wall and is spaced from the adjacent side wall to define said aperture. A third aspect of the invention provided a blank for forming a carton constructed from paperboard or like foldable sheet material comprising a first base panel, a first side panel, a top panel, a second side panel and a second base panel hingedly interconnected in series, the top panel further having at least one end retention panel hingedly connected thereto wherein a corner arrangement comprising a gusset panel and an anchor structure connects the end retention panel to the first base panel, and when erected to form a carton, secures the end retention panel in an erected condition. According to an optional feature of the third aspect of the invention the anchor structure may comprise a first anchor panel and a second anchor panel wherein the first and second anchor panels are capable of being placed in face contacting relationship with the first base panel and the first side panel respectively. According to another optional feature of the third aspect of the invention the second anchor panel may be hingedly connected to the first side panel. According to another optional feature of the third aspect of the invention an aperture may be provided between the anchor structure and the first side panel. According to a further optional feature of the third aspect of the invention a second gusset panel may be provided which, when the blank is erected to form a carton, traverses the adjacent corner of the top panel. 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 blank according to a first embodiment of the invention; FIGURE 2 A is a perspective view of one example of an article to be packaged by the blank shown in Figure 1 ; FIGURES 2B and 2C are perspective view of the carton being formed from the blank of Figure 1 shown during construction and in an erected form; FIGURE 3 is a blank according to a second embodiment of the invention; FIGURES 4A and 4B are perspective views of the carton formed from the blank Figure 3 shown during construction and in an erected form; FIGURE 5 is a blank according to a third embodiment of the invention; FIGURES 6A and 6B are perspective views of the carton formed from the blank of Figure 5 shown during construction and in an erected form; FIGURE 7 is a blank according to a fourth embodiment of the invention; and FIGURES 8 A & 8B are perspective views of the carton formed from the blank of Figure 7 shown during construction and in an erected form. Detailed Description of the Preferred Embodiments Referring to Figure 1 , there is shown a blank 10 for forming a wraparound carton made from paperboard or like foldable sheet material to package an article, for example a tray for holding food stuff, such as meat or frozen foodstuff. In this embodiment the blank 10 comprises a plurality of panels for forming a tubular structure including a first base panel 12, first side wall panel 14, a top wall panel 16, a second side wall panel 18, and a second base panel 20 hingedly connected in series along fold lines 42, 44, 46 and 48 respectively. A pair of end retention panels 22 and 24 are hingedly connected to the opposite ends of top wall panel 16 along fold lines 50 and 52 respectively. The first and second base panels 12, 20 comprise suitable panel securing means for securing each panel together. In this embodiment, the panel securing means comprises one or more locking apertures 64 into which known locking tabs 66 on second side panel 20 may engage. Figure 1 shows three sets of locking tabs 66 and corresponding apertures 64. Alternatively, other securing means, such as glue, may be used to connect the panels forming the opposing ends of the blank to form a tubular structure. There further comprises one or more corner arrangements 26, 28; 30, 32 hingedly interconnecting the base panels 12, 20 with respective side edges of the adjacent end retention panels 22; 24. Each corner arrangement is substantially identical, therefore, only corner arrangement 26 will be discussed in more detail. In this embodiment, the corner arrangement 26 comprises an anchor structure and one or more gusset panels. It will be seen from Figure 1 that the gusset structure comprises one or more panels, for example a first gusset panel 38 and a second gusset panel 40. The anchor structure may comprise one or more panels, for example a first anchor panel 34 and a second anchor panel 36. The first anchor panel 34 is hingedly connected to the second base panel 20 along fold line 54. The fold line 54 extends at an acute angle from fold line 48, and, optionally, a cut line 55 extends from the one end of fold line 54 to the free edge of the base panel 20 to separate anchor panel 34 from base panel 20. The second anchor panel 36 is hingedly connected to the first anchor panel 34 along fold line 56. Preferably, fold line 56 terminates at the intersection of fold line 54 with fold line 48 and the free edge of second side panel 18. The orientation of the fold lines 54, 56 allows first and second anchor panels to be folded into overlapping arrangement described below. Preferably, fold lines 54 diverge from the point of intersection to define a triangular panel portion. The gusset structure is arranged so that first gusset panel 38 is hingedly connected to the second anchor panel 36 along fold line 58, and is further hingedly connected to the second gusset panel 40 along fold line 60. In turn, second gusset panel 40 is hingedly interconnected to an edge of the end retention panel 22 along fold line 62. The panels 34, 36, 38, 40 comprising the corner arrangement 26 are so constructed and arranged as to be separated from second side panel 18 and top panel 16. Preferably, an aperture A is provided to space the aforesaid panels to define an opening to receive a tray, described below. In Figure 2 A, there is shown one example of an article to be packaged for example, a substantially rectangular tray T comprising a compartment for holding foodstuff F, and a flange L extending around at least part of the perimeter of the tray T. Turning now to the construction of the carton illustrated in Figures 2B and 2C tray T is brought into contact with the top panel 16 with the flange L abutting the inner face of the top panel 16. Thereafter, the end retention panels 22, 24 are erected by folding the comer arrangements 26, 28, 30, 32. Referring again to comer arrangement 26, first anchor panel 34 is folded along fold line 54 such that it is placed in face contacting relationship with base panel 20. The folding operation additionally causes second anchor panel 36 to be placed in face contacting relationship with side panel 18. Preferably, fold line 56 overlies fold line 48 in a substantially parallel relationship thereto. In addition, the folding operation causes first gusset panel 38 to be folded out of alignment with the second anchor panel 36, and for end retention panel 22 and second gusset panel 40 to be folded out of alignment with top panel 16, to automatically erect the end retention structure, as shown in Figure 2B. The carton construction is completed by reference to Figure 2C, whereby side panels 14 and 18 are folded out of alignment with the top panel 16 along fold lines 44 and 46 respectively. This folding action causes second anchor panel 36 to be brought into substantially face contacting relationship with first gusset panel 38 along fold line 58. In the embodiment, the second anchor panel 36, and first and second gusset panels 38 and 40 together with fold lines 58, 60 and 62 are sized and angled such that end retention panel 22 is substantially perpendicular to the top panel 16. However, the second gusset panel 40 may taper inwardly towards the base of the carton 12, 20 by changing the dimensions of the above mentioned panels. First and second base panels 12 and 20 are then folded around the article T and placed in abutment, whereby locking tabs 66 on second base panel 20 are engaged in the corresponding locking aperture 64 on the first base panel 12, to form a composite base structure. Thus the carton is in its fully erected and loaded state, as illustrated in Figure 2C. The second gusset panel 40 may traverse the comer of top panel 16. Aperture A forms a slit 68 (Figure 2B) which permits the comer of flange L to protrude therethrough, to hold the tray in place. Comer arrangements 28, 30 and 32 are also folded in a similar manner to comer arrangement 26 by folding in directions indicated by arrows X. The end retention structure is held in place because as fold line 56 overlies fold line 48, first anchor panel 34 is simultaneously folded out of alignment with second anchor panel 36. First base panel 20 is folded out of alignment with side panel 18. This angled relationship between the first anchor panel 34 and the second anchor panel 36 maintains first gusset panel 38 in abutting relationship thereto. It is possible to adjust the shape and angle of the end retention panel 34 and second gusset panel 40 according to the shape and configuration of the base and side panels. Beneficially the comer structures do not need to be glued. Turning now to the second embodiment of the present invention as illustrated in Figures 3 to 4B, like numerals have been used for like parts with the addition of numeral "1". Referring now in particular to Figure 3, there is shown a blank 1 10 for forming a wraparound carton. Blank 1 10 is similar to blank 10, but top panel 116 has rounded comers, and is, therefore, suited for trays of foodstuffs which also have rounded comers. The remainder of the panels 112, 114, 118, 120, 122 and 124 and comer structures 126, 128, 130 and 132 are identical to the corresponding panels and comer structures of the first embodiment, and it is, therefore, unnecessary to describe the blank 110 in any greater detail. Figures 4 A and 4B show the folding process but without the article present in the carton. It can be seen that the comer structures are folded in a direction X as described above, and the base panels are subsequently brought together in overlapping engagement such that locking tabs 166 engage with apertures 164 in like fashion. Turning now to the third embodiment of the present invention as illustrated in Figures 5 and 6A to 6B, like numerals have been used for like parts of the blank 10 in Figure 1 with the addition of the numeral "2". Referring in particular to Figure 5, there is shown a blank 210 for forming a wrap-around carton formed from paperboard of like foldable sheet material. The blank 210 comprises a first base panel 212, first side wall panel 214, a top panel 216, a second side wall panel 218 and a second base panel 220 hingedly connected in series along fold lines 242, 244, 246 and 248 respectively. End retention panels 222 and 224 are hingedly connected to the top panel 216 along fold lines 250 and 252 respectively. Like the first and second embodiment the first and second base panels 212, 220 comprises suitable securing means 264, 266 to form a composite base structure. There further comprises one or more comer arrangements 226, 228; 230, 232 that hingedly interconnect the base panels 212 and 220 with respective edges of the adjacent end retention panels 222, 224 respectively. Each comer arrangement is substantially identical, therefore, only comer arrangement 226 will be discussed in more detail. In this embodiment, the comer arrangement 226 differs from comer arrangements 26 and 126 of the first two embodiments in that the gusset structure is provided by a single gusset panel 238. The comer arrangement 226 comprises an anchor structure, which in this embodiment comprises a first anchor panel 234, a second anchor panel 236 and a gusset panel 238 foldably connected together along fold lines 256 and 258. First anchor panel 234 is hingedly connected to base panel 220 along fold line 254 and gusset panel 238 is foldably connected to end retention panel 222 along fold line 260. Preferably, fold lines 246, 258, 260 and 250 thereby all intersect at a comer of top panel 216. Fold line 254 is in an angular relationship with fold line 248 so that fold lines 256 and 258 are placed in alignment with fold lines 248, 246 when the tray is set up. The comer arrangement 226 defines an aperture A between the panels forming the comer arrangement and second side panel 218. Turning now to the carton forming process as illustrated in Figures 6A and 6B and referring in particular to Figure 6A, which for clarity shows the carton forming process without the contents of the carton in place, the folding of two of the four comer arrangements is shown. The folding process is similar to the method outlined above for the first embodiment. It can be seen that first anchor panel 234 and second anchor panel 236 are folded in direction X out of alignment with second side panel 218 and second base panel 220 into face contacting relationship therewith. In this embodiment, fold line 256 is caused to overlie fold line 248, and fold line 258 is caused to overlie fold line 246. Thereafter, gusset panel 238 and end retention panel 222 are caused to be folded out of alignment with top panel 216 to form an end retention structure which is held in place in a similar manner to the method described above. Side panels 214 and 218 are then folded out of alignment with top panel 216, and base panels 212 and 220 are likewise folded out of alignment with side panels 214 and 218, and are brought into overlapping relationship to form a tubular structure shown in Figure 6B. Base panels 212, 220 are secured together by the securing means, whereby engagement tabs 266 are engaged in apertures 264. The gusset panel 238 is shaped to be brought into face contacting relationship with side contacting panel 236, and fold line 260 is brought into contact with side edge 219 of second side panel 218 as the tubular structure is formed. The trapezoidal shape of end retention panel 222 and second side panel 218, causes these panels to taper inwardly towards the base of the erected carton to hold the article in place because the flange is not able to move in the Y or Z planes due to the taper, as shown in Figure 6B. Comer arrangements 228, 230 and 232 are also folded in a similar manner to comer arrangement 226 by folding in directions indicated by arrows X. In other embodiments the gusset panel 238 may traverse the comer of top panel 216. Aperture A forms a slit 268 which permits the comer of flange L to protrude therethrough, to hold the tray in place. If the carton is required to be cuboid in shape when erected, the shape of end retention panel 222 and side panel 218, as well as the shapes of the panels in the comer arrangement would need to be adjusted. Turning now to the fourth embodiment of the present invention as illustrated in Figures 7, 8 A and 8B. Like numerals have been used for like parts with the addition of the numeral "3". Referring now in particular to Figure 7, there is shown a blank 310 which comprises a first base panel 312, first side panel 314, top panel 316, second side panel 318 and second base panel 320 hingedly interconnected in series along fold lines 342, 344, 346, 348 respectively. End retention panels 322 and 324 are hingedly connected to the top panel 316 along fold lines 350 and 352 respectively. The first and second base panels 312, 320 comprise similar securing means to that described above. As in the other embodiments, comer arrangements 326, 328, 330, 334 hingedly interconnect the base and, in this embodiment the side panels, with the respective side edges of the end retention panels. Each comer arrangement is substantially identical, therefore, only one comer arrangement 326 will be discussed in more detail below. Comer arrangement 326 comprises a first anchor panel 334, a second anchor panel 336, and a gusset panel 338. The first anchor panel 334 is hingedly connected to the base panel 320 along fold line 354. In this embodiment, fold line 354 extends substantially perpendicular to fold line 348. Second anchor panel 336 is hingedly interconnected to first anchor panel along fold line 356, which in this embodiment is co-linear with fold line 348. Second anchor panel 336 is further hingedly connected to gusset panel 338 along fold line 358. Second anchor panel 336 is optionally hingedly interconnected to side panel 318 along fold line 357, which in this embodiment, is co-extensive with fold line 354. Gusset panel 338 is hingedly interconnected with end retention panel 322 along fold line 360. In this embodiment fold line 360 is an extension of fold line 346. Fold lines 346, 360 and 350 and projections of fold lines 357 and 358 converge at a comer of top panel 316. Side contacting panel and gusset panel 338 are shaped to define two sides of an aperture A. To construct the carton shown in Figure 8B, it will be seen from Figure 8A that first anchor panel 334 and second anchor panel 336 are folded into face contacting relationship with second base panel 320 and second side panel 318 respectively, and fold line 356 thereby overlies fold line 348. This folding operation is identical to that described above to cause end retention panel 332 and gusset panel 338 to be folded out of alignment with top panel 316 to form an end retention structure. Similarly the tubular stracture is formed around the article as shown in Figure 8B. First and second base panels are secured together to from a composite base wall. As can be seen from Figure 8B, side panels 314 and 318, and end retention panels 322 and 324 are substantially perpendicular to the composite base wall comprising panels 312 and 320, and the top panel 316. It should, however, be understood that in alternative classes of embodiment the shapes of the panels, and positions of the fold lines may be altered such that the carton may taper inwardly from top to base. It is envisaged that the carton of any of the embodiments referred to above can be formed by a series of sequential folding 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 process is not limited to that described above and can be altered to particular manufacturing requirements. It will be understood that in all the above embodiments, due to the fact that the gusset panel is folded out of alignment with the anchor structure, the or each anchor panel can be retained in abutting relationship with the side panel. This prevents the corresponding end retention panel from being moved out of its desired plane relative to the top panel once the carton is erected, thus holding the contents within the carton. Furthermore, the apertures provided at the comers of some of the embodiments of the invention locate the comers of the contents of the carton to prevent unwanted movement thereof. It will be recognised that as used herein, the terms used "top" "base" "side" and "end" with respect to the panels of the carton and carton blank are relative terms and that the carton formed from the blank may be re-orientated as necessary or as desired. Furthermore, it will be recognised that rather than the base wall being formed from the interlocked panels, the carton blank may be re-arranged whereby some other wall such as a top wall or side wall is formed from the interlocked panels. Any reference to hinged connection should not be construed as necessarily referring to a single fold line only: indeed it is envisaged that hinged connection can be formed from one or more of one of the following, a score line, a frangible line or a fold line, without departing from the scope of invention. The present invention and its preferred embodiments relate to an article carrier which is shaped to provide satisfactory rigidity to hold items such as a tray for foodstuff securely but with a degree of flexibility. The shape of the blank minimises the amount of paperboard required for the carton. The items can be applied to the carrier by hand or automatic machinery. It is anticipated that the invention can be applied to a variety of cartons or tray types and not limited to those of the flat tubular sort, for example the flat tubular structure could be replaced by a carton with longer sides and end panels to receive articles such as cans or bottles.

Claims: CLAIMS 1. A carton constructed from paperboard or like foldable sheet material for enclosing one or more articles, for example a tray of foodstuff, comprising a plurality of walls for forming a tubular stracture including top and base walls, opposed side walls and one or more end retention walls, connected to one end of said top wall wherein the end retention wall is connected to the base wall by a comer arrangement which is so constructed and arranged to cause the end retention wall to be secured in an erected position. 2. The carton as claimed in claim 1, wherein the comer arrangement comprises an anchor stracture and one or more gusset panels, the anchor stracture comprising a first anchor panel connected to and in face contacting relationship with the base wall, and a second anchor panel connected to said first anchor panel and in face contacting relationship with the corresponding side wall. 3. The carton as claimed in claim 2 wherein the one or more gusset panels is connected to the second anchor panel. 4. The carton as claimed in claim 2 or claim 3 wherein the fold line between the first anchor panel and the second anchor panel overlies the fold line between the corresponding side wall and the base wall. 5. The carton as claimed in any one of claims 2 to 5 wherein the one or more gusset panels and the anchor stracture are severed from the adjacent side wall and/or a part of the top wall by an aperture. 6. The carton as claimed in claim 5 wherein the aperture is shaped to receive and retain a protruding portion of the article. 7. A tubular carton constructed from paperboard or like foldable sheet material for enclosing one or more articles, for example a tray of foodstuff including a flange, which carton comprises a top wall, a base wall, opposed side walls and a pair of opposed end retention walls connected respectively to the opposite ends of the top wall, wherein each retention wall is connected to the base wall by a comer arrangement including an aperture provided between the comer arrangement and the top wall to allow the article flange to protrude therethrough. 8. The carton as claimed in claim 7 wherein each comer arrangement comprises one or more gusset panels interconnecting the base wall and the corresponding end retention wall and is spaced from the adjacent side wall to define said aperture. 9. A blank for forming a carton constracted from paperboard or like foldable sheet material comprising a first base panel, a first side panel, a top panel, a second side panel and a second base panel hingedly interconnected in series, the top panel further having at least one end retention panel hingedly connected thereto wherein a comer arrangement comprising a gusset panel and an anchor structure connects the end retention panel to the first base panel, and when erected to form a carton, secures the end retention panel in an erected condition. 10. The blank as claimed in claim 9, wherein the anchor structure comprises a first anchor panel and a second anchor panel, wherein the first and second anchor panel are capable of being placed in face contacting relationship with the first base panel and the first side panel respectively. 11. The blank according to claim 10 wherein the second anchor panel is hingedly connected to the first side panel. 12. The blank according to any of claims 9 to 11 wherein an aperture is provided between the anchor stracture and the first side panel. 13. The blank according to any of claims 9 to 12 wherein a second gusset panel is provided which, when the blank is erected to form a carton, traverses the adjacent comer of the top panel.

Inventors: SAULAS ALAIN, SAULAS, ALAIN
Applicants: MEAD CORP, SAULAS ALAIN, SAULAS, ALAIN, THE MEAD CORPORATION
Application year: 2000
Main classification: B65D77
IPC codes: B65D5, B65D77