CARTON WITH ACCESS STRUCTURE

Abstract: A carton (10) for accommodating a plurality of articles, for example bottles. The carton comprises a top (36), a base (12), opposed side panels (14, 16) and end panels (38, 40) wherein an access structure is provided by one of the carton panels to provide temporary access to the interior of the carton during and/or after the erection of the carton by creating an opening in the panel, the access structure comprising a hinged flap (17) which can be hinged from a closed position to an open position to create the opening, a flap limiter being provided to restrict hinging of the flap to prevent it from opening beyond a predetermined position.

Description: CARTON WITH ACCESS STRUCTURE This invention relates to a carton for accommodating articles, for example bottles, which is provided with at least one access structure for the introduction of promotional material, or the introduction or removal of the articles to or from the carton. The invention also provides a method of erecting a carton having at least one access structure. It is known from, for example, US-A-4,871,067 to produce a two part carton for accommodating articles wherein each part has two opposed side pieces folded out of alignment with the base/top panel to form a substantially 'U' shaped piece. Furthermore, it is known from US-A-4,752,029 to construct a carton with a display bin formed by outwardly moving a front panel thereby to reveal the contents of the carton. The known prior art, however, does not address the problem of how to introduce articles such as promotional material into a carton in an effective manner, and subsequently allow the removal of these articles and/or the main contents of the carton easily and without damaging the carton. The present invention and its preferred embodiments seek to overcome or at least mitigate the problems of the prior art. One aspect of the invention provides a carton for accommodating a plurality of articles, for example bottles which carton comprises a top, a base, opposed side panels and end panels wherein an access structure is provided by one of the carton panels to provide temporary access to the interior of the carton during and /or after the erection of the carton by creating an opening in said panel, the access structure comprising a hinged flap which can be hinged from a closed position to an open position to create said opening, a flap limiter being provided to restrict hinging of the flap to prevent it from opening beyond a predetermined position. Preferably, the flap limiter may comprise a guide tab which engages with a complementary engagement flap hingedly connected to an adjacent panel of the carton. According to an optional feature of this aspect of the invention at least one gusset panel hingedly connects the engagement flap to the end panels and is so folded as to maintain the engagement flap in a downturned position. According to another optional feature of this aspect of the invention securing means may be provided along the engagement flap to secure the or each access structure when closed. According to another optional feature of this aspect of the invention the carton may be constructed from a two part blank. According to a further optional feature of this aspect of the invention one access structure may be provided on each side wall. A second aspect of the invention provides a blank for forming a carton for accommodating articles, for example bottles, the blank comprising an interconnected series of panels including a base panel, side panels, and an access structure, wherein the access structure comprises a hingable access panel, and a flap limiter which when the blank is erected to form a carton prevents the panel opening beyond a pre-determined angle. According to an optional feature the flap limiter may comprise a guide tab hingedly connected to the access panel which tab is adapted to engage with a complementary engagement flap hingedly connected to an adjacent panel of the carton. According to another optional feature of the second aspect of the invention the blank may further comprise an interconnected series of panels including end panels, a top panel and the engagement flap. According to another optional feature of the second aspect of the invention a second blank may be provided, which blank may comprise an interconnected series of panels including the end panels and the top panel and the engaging flap. A third aspect of the invention provides a method of forming a carton for accommodating a plurality of articles, for example, bottles, having at least one access structure which method comprises the steps of: folding side panels out of alignment with a base panel to form a substantially 'U' shaped piece; introducing a grouping of articles into the carton; folding at least one end tab out of alignment with at least one access panel; folding downwardly at least one side engagement flap hingedly attached to a top panel and at least one retaining flap hingedly connected to a side panel of the carton; folding the carton so as to place the top panel in a position substantially covering the tops of the articles; inserting the article; closing the access structure. Exemplary embodiments are now provided, by way of example only, with reference to the accompanying drawings in which: FIGURE 1 is a plan view of the first carton blank of a two part blank according to an embodiment of the present invention; FIGURE 2 is a plan view of the second blank of the two part blank shown in Figure 1 ; FIGURES 3 and 4 are perspective views of a grouping of articles being introduced into a partially erected carton formed from the first blank of Figure 1 ; FIGURE 5 is a perspective view illustrating the second blank introduced on top of the grouping of articles shown in Figures 3 and 4; FIGURE 6 is a perspective view showing the carton in a set up condition; FIGURES 7 and 8 are perspective views of the embodiment in Figures 1 and 2 illustrating the access structures in open and closed positions; and FIGURE 9 is a perspective view showing the steps for forming the carton of the embodiment illustrated in Figures 1 and 2. Referring to the drawings, and in particular Figures 1 and 2, there is shown a two part blank for forming an article carrier, which blanks are formed from paperboard or other suitable foldable sheet material. In other embodiments, a unitary blank may be used to form the carrier shown in Figure 8. Referring now to Figure 1, a first blank 10 comprises a base panel, 12 to which side panels 14, 16 are hingedly connected along fold lines 114, 116 respectively. An end closure structure is provided, which in this embodiment is provided by lower end flaps 30, 30a connected to the opposing end edges of the base panel 12 by fold lines 130, 130a and side end flaps 26, 26a connected to the end edges of side panel 16 along fold lines 126, 126a. Likewise, side end flaps 22, 22a are connected to the end edges of side panel 14 by fold lines 122, 122a. In other embodiments alternative end closure structures may be used. An access structure shown in Figures 7 and 8 is provided by an access panel 17 connected to an edge of side panel 14 along fold line 117. In this embodiment the access panel 17 is connected to what will form the upper edge of the side panel in the erected article carrier. A similar access panel 19 may be connected to side panel 16 along fold line 119. There further comprises a panel (or flap) limiter to limit the movement of the access panel during and after carton loading described in more detail below. In this embodiment, the panel limiter is provided by a pair of guide tabs 24, 24a that are connected to the side edges of access panel 17 along fold lines 124, 124a. In this embodiment, the fold lines 124, 124a are inwardly offset with respect to fold lines 122, 122a to define an acute angle between fold lines 124, 124a and 117 so as to allow the end panels to taper inwardly once the carton is erected. Optionally, a similar panel limiter is provided for the access panel 19 comprising guide tabs 28, 28a that are connected to the access panel 19 along fold lines 128, 128a, which are configured in a similar manner to fold lines 122, 122a. In other embodiments, the panel limiter may be provided by a gusset panel or a strap connecting the access panel to the adjacent end or top panels. In this embodiment the guide tabs are of a similar construction and, therefore, only guide tab 24 shall be described in any further detail. Guide tab 24 comprises a protruding portion 25 which is adapted to act as an end stop to restrict hinging of the access panel 17 about fold line 117. The protruding portion 25 is provided with an edge that can abut a complementary engaging flap, hereinafter described. Preferably, the upper edge interconnecting the abutment edge and fold line 124 is arcuate so as to juxtapose the lower edge of the corresponding complementary engaging flap. In some embodiments the arcuate edge assists in guiding the access panel 17 between open and closed positions. Referring now to Figure 2, a second blank 34 comprises a top panel 36 to which panels for forming the end walls are hingedly connected along respective fold lines 138a, 140a on the end edges of the top panel 36. In this embodiment, end walls have been split into an upper end panel 38a, 40a, and a lower end panel 38, 40 by fold lines 138, 140 respectively. In alternative classes of embodiment, each end wall may comprise a single panel. Figure 2 illustrates engagement flaps 45, 46 that are connected to the side edges of the top panel 36 by fold lines 145, 146 respectively. Preferably, engagement flaps 45, 46 are also hingedly connected to the upper end panels 38a, 40a by one or more gusset panels. In this embodiment, the gusset panels are provided at each comer and are similar in construction, so only the panels forming one comer are described in any greater detail. Gusset panel 44 is hingedly connected to engagement flap 45 along fold line 150 and gusset panel 42 is hingedly connected to upper end panel 40a along fold line 142. Figure 2 shows gusset panels 42, 44 hingedly connected together along fold line 144, which is preferably at an acute angle with respect to fold line 150, to allow the upper end panel 38a to taper. Similarly, fold line 142 is preferably at an acute angle with respect to fold line 150 and, preferably, terminates approximately half way along the end wall, in line with fold line 140 so that in use, it does not interfere with the subsequent folding and securing operations during the erection of the carton. More preferably, the fold lines 142, 144 are arranged so as to converge at a comer 154 of the top panel 36. In an alternative embodiment, the carton may be erected from a single blank, with the top and sides being enclosed by, top and end panels 36, 38, 40, similar to those of the second blank. These panels would be hingedly connected to the base panel. Turning to the construction of the carrier illustrated in Figures 3 to 9, it is envisaged that the carton of the present invention can be formed by a series of sequential folding a 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. Of course, in this embodiment, the carrier is rotated to aid insertion of the articles, as described below. The folding process is not limited to that described below and can be altered according to particular manufacturing requirements. Figure 9 illustrates the preferred method of forming the carton and loading it with articles and subsequently other items according to one aspect of the invention. Referring then to Figures 3, 4 and 9, according to a preferred embodiment of the invention, the first blank 10 is partially erected to form a 'U' shape. The blank 10 is shown having a group of articles, for example bottles 'B', introduced into it in a direction generally indicated by the arrow 'X' as the first stage of a continuous carton forming process. In alternative embodiments the bottles could for example be introduced from above the blank. It will be seen from Figure 3 that the side panels 14, 16 are folded out of alignment with the base panel 12 along fold lines 114, 116 respectively to form the 'U' shape of a partially erected carton. In this embodiment, upper portions of the side panels 14, 16 are provided with the hingable access structure whose purpose will be described in more detail below. The embodiment shown has similar base and side end flaps at both ends of the first blank 10 and therefore the construction will be described with reference to the nearside end only. The grouping of bottles 'B' are introduced to the partially erected carton, the side end flaps 22, 26, are folded out of alignment with their respective panels in a direction indicated by the arrows Y' shown in Figures 3 and 4, along fold lines 122, 126. Lower end flap 30 is folded out of alignment with the base panel 12 along fold line 130 and into overlapping relationship with flaps 22, 26 to preferably be secured together by glue or other means known in the art, thereby to reinforce the structure of the carton. The hingable access structure is then formed, which in this embodiment is provided by the access panels 17, 19 and guide tabs 24, 24a, 28, 28a hingedly connected to their respective side edges. Although two access structures are shown in this embodiment the construction thereof will be described with reference to a single access structure. Thus, guide tabs 24, 28 are folded out of alignment with the access panels 17 and 19 along fold lines 124, 128 respectively, in a direction indicated by the arrows 'Y' in Figure 4 to be brought into abutment with the outermost articles B. Thereafter, the second blank 34 is, in the preferred embodiment, introduced onto the top of the articles as shown in Figures 5 and 6. The engagement flaps 45, 46 together with their respective gusset panels 42, 44; 42a, 44a; 47, 48; 47a, 48a and are folded downwardly out of alignment with the top panel 36 in direction Z. Optionally, this folding action may be carried out prior to introduction with the bottles. The end wall panels 38, 38a; 40, 40a of the second blank 34 are then folded downwardly out of alignment with the top panel 36, such that lower end panel 40 comes into overlapping relationship with the side end flaps 22, 26, and base end flap 30 of the first blank and is secured thereto by using glue or other suitable securing means known in the art. At the same time, gusset panels are caused to be folded inwardly into overlapping relationship with the next adjacent gusset panel to form the comer structure. Using the example of the comer structure described above, gusset panels 42 and 44 are folded inwardly in direction Z about fold lines 150 and 142 to cause the gusset panels 42 and 44 to be folded into overlapping relationship about fold line 144. This results in fold line 150 abutting fold line 142, as shown in Figure 6. In a particularly preferred embodiment, fold line 150 is substantially co-extensive with fold line 142. This relationship between gusset panels 42 and 44 is subsequently maintained by the sandwiching effect between the end wall and the guide tab 24, and may be augmented by gluing or otherwise securing the gusset panel 42 to the upper side panel 40a. In the preferred embodiment, a similar folding operation takes place to secure the end panel 38 to the side and end flaps 22a, 26a; 30a. In the preferred embodiment, each end wall is divided into two panels 38, 38a; 40, 40a, such that the upper end panel 38 a, 40a may taper inwards towards the top of the carton so as to conform with the tapered shape of the bottles B contained within. In alternative embodiments, a single panel may be provided on each side wall if non-tapering articles are to be contained within the carton. Thus, the carton is at a set up position shown in Figure 6. The carton is now preferably rotated through substantially 90° in order to move on the next stage of the carton erection process, which is shown in Figure 7. Promotional literature or other articles 52 may be introduced into the partially erected carton by opening the access panel 17 and placing the article 52 into opening 50. Thereafter, suitable securing means can be applied to secure the access panel 17 in a closed position once the article(s) have been introduced. Alternatively, side access panel 17 could be made recloseable by the use of detachable securing means known in the art, for example a locking tab and aperture. In prior art processes, where such articles 52 are introduced into the carton in a partially erected state, it is, for example, necessary to leave an end flap or side panel open to defining an article receiving aperture. The flap/panel is free to move whilst the partially erected carton progresses through the production line, and therefore when the stage is reached when the flap/panel is to be closed once the article has been introduced, it is often difficult for the flap/panel to be located and guided with any degree of accuracy. The carton of the present invention incorporates an access structure to overcome the aforementioned problem. More particularly, the access structure is provided by one of the carton panels to provide temporary access to the interior of the carton during and /or after the erection of the carton by creating an opening in said panel. The access structure comprises a hinged flap 17 which can be hinged from a closed position to an open position to create an opening. A flap or panel limiter is provided to restrict hinging of the flap to prevent it from opening beyond a predetermined position. As mentioned above, the guide tabs and complementary engagement tabs provide the panel limiter in this embodiment. Referring now to Figures 7 and 8, the end wall serves to maintain the guide tabs 24, 28 in their desired position so that the access panel 17 functions as desired. The access panels 17, 19 are prevented from opening past a certain angle, or predetermined position by one or more protruding portions 25 (or limit stops) extending from the or each guide tab 24, 28; 24a, 28a. The protruding portions are sized to engage with the downturned engagement flaps 45, 46 on the second blank 34. In this embodiment, there comprises a protruding portion extending from each guide tab, although it is anticipated that only one protrading portion need be required for each access panel 17, 19. By incorporating an access structure as described above, the access panel can be moved between open and closed positions shown in Figures 7 and 8 respectively. The open position is a known position by virtue of the protruding portion 25 defining a limit stop at a certain distance from the access panel. Therefore, when packaging the carton, the access structure can easily be guided into a closed position using, for example, a guide bar arranged substantially parallel with the direction of movement of the carton, thereby reducing the complexity of folding devices in a packaging machine. Figure 8 also illustrates a handle 54, in this preferred embodiment, which is secured to the end panels 38a, 40a of the second blank so as to form a handle strap. In alternative embodiments, a handle may be provided by, for example, forming an opening in the upper panel 36 of the second blank 34 as is well known. The carton is then in its fully erected and loaded state and is illustrated in Figure 8. The side access panels may be re-opened at a later point by, for example, the purchaser of the contents of the carton in order to gain access to the promotional or other material 52, or the contents of the carton B. It will be recognised 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 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. It will be understood that various changes may be made within the scope of this invention. For example, a single side access panel may be provided, with the opposing side being configured as on a standard carton, the carton may be used to hold a single article rather than a group of articles, and/or the carton may be re-orientated such that the hinged flaps form downwardly facing apertures when opened.

Claims: CLAIMS 1. A carton for accommodating a plurality of articles, for example bottles which carton comprises a top, a base, opposed side panels and end panels wherein an access structure is provided by one of the carton panels to provide temporary access to the interior of the carton during and /or after the erection of the carton by creating an opening in said panel, the access structure comprising a hinged flap which can be hinged from a closed position to an open position to create said opening, a flap limiter being provided to restrict hinging of the flap to prevent it from opening beyond a predetermined position. 2. A carton according to claim 1 wherein the flap limiter comprises guide tab which engages with a complementary engagement flap hingedly connected to an adjacent panel of the carton. 3. A carton according to claim 2 wherein at least one gusset panel hingedly connects the engagement flap to the end panels and is so folded as to maintain the engagement flap in a downturned position. 4. A carton according to any preceding claim wherein securing means is provided along the engagement flap to secure the or each access stracture when closed. 5. A carton according to any preceding claim wherein the carton is constructed from a two part blank. 6. A carton according to any preceding claim wherein one access stracture is provided on each side wall. 7. A blank for forming a carton for accommodating articles, for example bottles, the blank comprising an interconnected series of panels including a base panel, side panels, and an access structure, wherein the access structure comprises a hingable access panel, and a flap limiter which when the blank is erected to form a carton prevents the panel opening beyond a pre-determined angle. 8. A blank according to claim 7 wherein the flap limiter comprises a guide tab hingedly connected to the access panel which tab is adapted to engage with a complementary engagement flap hingedly connected to an adjacent panel of the carton. 9. A blank according to claim 8 wherein the blank further comprises an interconnected series of panels including end panels, a top panel and the engagement flap. 10. A blank according to claim 8 wherein a second blank is provided, which blank comprises an interconnected series of panels including the end panels, the top panel and the engaging flap. 11. A method of forming a carton for accommodating a plurality of articles, for example, bottles, having at least one access structure which method comprises the steps of: i) folding side panels out of alignment with a base panel to form a substantially 'U' shaped piece; ii) introducing a grouping of articles into the carton; iii) folding at least one end tab out of alignment with at least one access panel; iv) folding downwardly at least one side engagement flap hingedly attached to a top panel and at least one retaining flap hingedly connected to a side panel of the carton; v) folding the carton so as to place the top panel in a position substantially covering the tops of the articles; vi) inserting the article; vii) closing the access structure;

Inventors: LEBRAS PHILIPPE, LEBRAS, PHILIPPE
Applicants: LEBRAS PHILIPPE, MEAD CORP, LEBRAS, PHILIPPE, THE MEAD CORPORATION
Application year: 2000
Main classification: B65D5
IPC codes: B65D5, B65D71