Abstract:
A carton and blank for forming a carton for holding one or more articles, for example, flexible pouches, which carton comprises an article-retaining structure for preventing the dislodgment of the packaged articles through the open ends of the carton. The article-retaining structure comprises a retention panel which extends between the carton side walls intermediate the top and base walls of the carton to form a tubular structure in cooperation with the top wall. The retention panel is formed with at least one article receiving aperture, wherein tubular structure is provided with a brace for retaining the tubular structure in an erected form.

Description:
This is a continuation of international application No. PCT/US01/24554, filed Aug. 5, 2001, which is hereby incorporated by reference. 

   BACKGROUND OF THE INVENTION 
   This invention relates to a carton and a blank for forming a carton which is used for accommodating one or more articles, for example, flexible pouch packs or bottles. It also concerns the method of forming the carton from the blank and loading the same with one or more articles. More particularly, the invention relates to a wraparound carton incorporating a top-gripping structure which attaches to an upper portion of one or more articles thereby to secure the articles in an array. 
   Top-gripping cartons are well known, particularly in the field of multiple packaging of bottles. One example is illustrated in U.S. Pat. No. 3,168,963 which illustrates a wraparound carton having an article-retaining structure and a retention panel between the top and bottom walls formed with at least one article receiving aperture. 
   A problem associated with known top-gripping carriers is that the retention panel and/or tubular structure for retaining the article will tend to collapse which creates an unstable carrier. 
   SUMMARY OF THE INVENTION 
   The present invention seeks to overcome or at least mitigate the problems of the prior art. 
   One aspect of the invention provides a carton for holding one or more articles, for example, flexible pouches. The carton comprises a sleeve body and an article-retaining structure for preventing the dislodgment of the packaged articles through the open ends of the sleeve body. The sleeve body comprises top and base walls interconnected by a pair of side walls. The article-retaining structure comprises a retention panel extending between the side walls intermediate the top and base walls to form a tubular structure in cooperation with the top wall. The retention panel is formed with at least one article-receiving aperture. The tubular structure is provided with a brace for retaining the tubular structure in an erected form. 
   According to an optional feature of this aspect of the invention the brace may comprises a brace panel hingedly connected to the retention panel and folded into the tubular structure to engage the inner side surface of the tubular structure. Optionally, the brace panel is struck from the retention panel and defines the article-receiving aperture when folded into the tubular structure. 
   According to another optional feature of this aspect of the invention the brace panel may be provided with a friction tab hingedly connected to the brace panel, the friction tab being adapted to engage the upper portion of one of the carton side walls. Alternatively, the brace panel may be provided with a friction tab hingedly connected to the brace panel, the friction tab being adapted to be pressed against the inner side surface of the tubular structure to retain the tab in the folded position. 
   Preferably, friction tab is struck from the side wall of the tubular structure. 
   According to a further optional feature of this aspect of the invention the side wall may comprises an upper side panel hingedly interconnecting the top wall and the retention panel and the lower side wall panel connecting the base wall and attached to the upper side wall panel and wherein said friction tab is struck from the upper side wall panel. 
   Preferably, the lower side panel is attached to the outer surface of the upper side panel to cover the opening defined in the upper side panel by the friction tab. More preferably, a portion of the friction tabs is revealed in the opening defined in the upper side panel and wherein the friction tab is secured by glue to the lower side panel. 
   According to another optional feature of this aspect of the invention wherein at least one opening is formed in either the top wall or in the side wall of the article-retaining structure to allow the top portion of one of the articles to be exposed to view. 
   There may further comprise an end closure structure for closing the ends of the carton, which end closure structure comprising an enclosure panel and at least one glue flap hingedly connected to the end closure panel to be secured to one of the base or side wall panels of the carton. 
   A second aspect of the invention provides a blank for forming a carton for holding one or more articles, for example, flexible pouches, which blank comprises a plurality of panels for forming a carton including a first side wall panel, a base panel, a second side wall panel and a top panel hingedly connected one to the next, and an article-retaining structure extending from the top panel comprising a retention panel and securing means to connect the retention panel to the side walls panels to form a tubular structure in a set up carton, the retention panel is formed with at least one article receiving aperture and a brace for retaining the tubular structure in an erected form. 
   The brace may comprise a brace panel hingedly connected to the retention panel and adapted to be folded into the tubular structure to engage the inner side surface of the tubular structure. 
   According to an optional feature of the second aspect of the invention the brace panel is struck from the retention panel and defines the article-receiving aperture when folded into the tubular structure. 
   According to a further optional feature of the second aspect of the invention, the brace panel is provided with a friction tab hingedly connected to the brace panel. Optionally, the tab is struck from the side wall panel. 
   According to another optional feature of the second aspect of the invention the side wall panel may comprise an upper side panel hingedly interconnecting the top wall panel and a lower side wall panel connected to the base wall and wherein said friction tab is struck from the upper side wall panel. 
   There may further comprise at least one opening is formed in either the top wall panel or in the side wall panel of the article-retaining structure to allow the top portion of one of the articles to be exposed to view in the set up carton. 
   According to a still further optional feature of the second aspect of the invention there further comprises an end closure structure for closing the ends of the carton, which end closure structure comprising an enclosure panel and at least one glue flap hingedly connected to the end closure. 

   
     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: 
       FIG. 1  is a plan view of a blank of a first embodiment of the invention; 
       FIG. 2  is a plan view of a blank of a second embodiment of the invention; 
       FIG. 3  is a plan view of a blank of a third embodiment of the invention; 
       FIGS. 4 and 5  illustrate the first stages of construction of the first embodiment so that the carrier is in a flat collapsed condition ready to be supplied to an end user; 
       FIGS. 6 ,  7  and  8  illustrate the construction of the carrier from a flat collapsed condition illustrated in  FIG. 5 ; 
       FIG. 9  illustrates the carrier shown in  FIG. 5  in an erected and loaded condition; 
       FIG. 10  illustrates the carrier shown in  FIG. 5  in a set-up and completed condition; 
       FIGS. 11 and 12  illustrate the construction of the carrier according to the third embodiment of the blank shown in  FIG. 3 ; 
       FIG. 13  is a perspective view of the erected carton formed from the blank of  FIG. 3 ; and 
       FIG. 14  is a fragmentary plan view of a blank of a fourth embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring to the drawings, and in particular  FIG. 1 , there is shown a unitary blank  10  for forming an article carrier made from paperboard or similar foldable sheet material. In other embodiments, there may comprise a two-part blank, for example a blank for forming the wraparound carrier and a separate blank for forming the internal article-retaining structure. The blank  10  comprises a series of panels hingedly connected one to the next in series to define a top wall, opposed side walls and a base. Preferably, there comprises upper and lower side wall panels. Thus, the blank  10  comprises a plurality of panels for forming a wraparound carton, which in this embodiment comprises a first side wall panel  14 , a base panel  16 , second side wall panel  18 , an upper second side wall panel  20  and top wall panel  22  hingedly connected together in series along fold line  32 ,  34 ,  36  and  38  respectively. 
   In order to secure the first side wall panel  14  to the top panel  22 , suitable securing means is provided. In this embodiment, the securing means is provided by a securing flap  12  that is hingedly connected to the lateral edge of side panel  14  along fold line  30 . 
   There further comprises a plurality of panels for forming the article-retaining structure which are hingedly connected to the top panel  22  along fold line  40 . In this embodiment, the article-retaining structure is provided by a first spacer panel  24 , a retention panel  26  and a securing panel  28  hingedly connected together in series along fold lines  42  and  44  respectively. The spacer panel  24  spaces the retention panel  26  from the top panel  22 . 
   There may further comprise one or more display windows which are provided by apertures  46 ,  48  struck from upper second side wall panel  20  that extend into top panel  22 , shown in FIG.  1 . In use, the display apertures  46 ,  48  reveal a portion of the cap of the article retained within the carrier. 
   A brace is provided to prevent the article-retaining structure from collapsing. In  FIG. 1 , there comprises a brace panel  50  struck from and hingedly connected to retention panel  26  along fold line  54 . Preferably, there further comprises a friction tab  58  struck from the adjacent spacer panel  24  and hingedly connected to bracing panel  50  along fold line  62 . In use, the bracing panel  50  is folded out of alignment with retention panel  26  to reveal an article receiving aperture  90  (FIG.  7 ). A second bracing panel may be provided which, in this embodiment, is designated by a reference numeral  52  and is struck from retention panel  26  and hingedly connected thereto along fold line  56 . Similarly, a friction tab  60  is hingedly connected to bracing panel  52  along fold line  64 . 
   Turning to the second embodiment illustrated in  FIG. 2 , the blank  110  is substantially the same as the first embodiment and like features are designated by the same reference numerals with the prefix “1”. Therefore, only the differences shall be described in any further detail. 
   An end closure structure is provided to prevent the articles from inadvertently being removed, for example, before the product has been sold. The end closure structures are provided by opposing end panels  176   a  and  176   b  hingedly connected to opposing sides of side wall panel  118  along fold lines  175   a  and  175   b  respectively. Suitable securing means is provided to secure the end closure panels  176  in place, for example a locking tab and aperture arrangement could be used. 
   The construction of each end closure structure is the same, so like reference numerals have been used in  FIG. 2  with the addition of letter&#39;s ‘a’ and ‘b’ respectively. In this embodiment, glue flaps  178  and  180  are provided to be secured to the adjacent first side wall panel  114  and the base wall  116  respectively. It will be seen from  FIG. 2  that glue flap  178  is secured to a longitudinal edge of end closure panel  176  along fold line  182  and that glue flap  180  is secured to a lateral edge of end closure panel  176  along fold line  184 , which in this embodiment is an extension of fold line  134 . 
   Turning to the third embodiment illustrated in  FIG. 3 , it is similar to the first embodiment in its overall construction; and it is similar to the second embodiment in that there are provided end closure panels  276 . Like features of the first and second embodiments are designated by the same reference numeral with the prefix “2”. 
   Therefore, only those differences between the second and third embodiments are described in any further detail. 
   In the third embodiment, there further comprises an additional aperture  270  along the opposing part of top panel  220  which is aligned with the corresponding aperture  246 . Aperture  270  is struck from top panel  220  and extends into spacer panel  224 . In use, aperture  270  provides a second display window for the upper portion of the adjacent article A. Likewise, in those embodiments with two rows of articles, a second aperture  272  struck from top panel  220  and extending spacer panel  224  is provided to be substantially aligned with aperture  248 . 
   There are also corresponding recesses  286 ,  288  along the free edge of side panel  214 . In use, the recesses  286  and  288  are aligned with aperture  270  and  272  respectively to provide a display window. 
   In one class of embodiments, the friction tab  258  is not co-extensive with bracing panel  250  and terminates short, so that an aperture or notch  266  is provided. In use, the notch  266  functions to allow the tab  258  to protrude through the opening  270  to be engaged with an article. There is a similar notch  268  provided adjacent to bracing tab  260  that functions in the same way. 
   There may further comprise an aperture  274  struck from one of the side panels and a corresponding recess portion  289  in glue flap  228  to provide an additional display window to reveal part of the side wall of an article A. 
   Turning to the fourth embodiment illustrated in  FIG. 14 , it is virtually identical to the third embodiment in its overall construction except for the details of the friction tabs. Like features of the third embodiment are designated by the same reference numeral with the prefix “3”. Therefore, only those differences between the third and fourth embodiments are described in any further detail. 
   In the fourth embodiment, the friction tab  358 , again, is not co-extensive with bracing panel  350  and terminates short. However, an aperture or notch  366  is defined adjacent to the free end edge of the bracing panel  350  remote from fold line  354 . In use, the notch  366  functions to prevent the tab  358  from being exposed to view through opening  370 . In other words, the notch  366  is struck from the friction tab  358  to cooperate with the opening  370  to provide a window to reveal the top portion of one of the articles. There is a similar notch  368  provided adjacent to the free end edge of bracing panel  352 . The notch  368  functions to prevent friction tab  360  from being exposed to view through opening  372 . 
   Turning to the construction of the carton formed from one of the blanks illustrated in  FIGS. 1 ,  2 ,  3  or  14 , it is envisaged that 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 converted to complete its construction. The folding process is not limited to that described below and can be altered according to particular manufacturing requirements. 
   Turning now in particular to  FIG. 4 , the blank  10  of the first embodiment is folded in direction X along fold line  40  to form the internal article-retaining structure. Thus, spacer panel  24  and retention panel  26  are placed in face-contacting relationship with top panel  22  and upper second side wall panel  20  and are held in place by securing flap  28  to side wall panel  18  by glue G or other suitable securing means known in the art. The carrier is at an intermediate stage construction, shown in  FIG. 5 , whereby it is in flat collapsed condition ready to be supplied to a user, for example a bottler, to be loaded with articles, described below. 
   In order to construct and load the carrier, the retaining structure and brace are formed, whereby panels  20 ,  22 ,  24  and  26  forming the article-retaining structure are folded along fold lines  38 ,  40 ,  42  and  44  in direction Y so as to form a tubular structure T as shown in FIG.  6 . This folding action reveals friction tabs  58  and  60  that are ready to form the brace. Thereafter, the brace is formed by folding brace panels  50  and  52  in directions W and V respectively along fold lines  54  and  56  as shown in  FIG. 7  to take up a bracing position. The bracing panels  50 ,  52  act as braces by their free edges coming into contact with opposed spacer panels  24 ,  28  or, as the case may be, side walls. Additionally, or alternatively, the bracing tabs may abut the top wall to provide a brace between the top and retention panels  22 ,  26 . 
   In those embodiments with friction tabs  58  and  60  are folded along fold lines  62  and  64 , so as to come into face contacting relationship with spacer panel  24 . It is envisaged that in some embodiments the spacer panels are dispensed with, in which case the friction tabs come into face contacting relationship with the side walls. 
   Turning again to the embodiment shown in  FIG. 7 , the brace panels  50 ,  52  are held in place by the frictional engagement between the inner face of spacer panel  24  and the tabs  58  and  60  respectively, thereby to maintain the tubular structure in a set-up condition. Optionally, glue may be applied to friction tabs  58 ,  60  so that they are secured to spacer panel  24 . The tabs  58 ,  60  may be shaped so as to protrude in part  59 ,  61  (FIG.  9 ), through apertures  90 ,  92 . Beneficially, this allows tabs  58 ,  60  to be secured directly to an outer panel of the carrier, for example, securing tab  12  to provide a structure of improved rigidity. 
   In order to complete construction of the carton, the panels forming the wraparound carrier are formed, so that the base panel  16  and first side wall panel  14  are folded out of alignment with second side wall panel  18  along fold lines  34  and  32  respectively as shown in FIG.  8 . 
   Prior to constructing the wraparound carrier, the articles are applied to the carrier by relative movement between the article A and the tubular structure T, preferably during continuous forward movement. The articles are grouped in a two-by-two array although is anticipated that other groupings or even a single article could be packaged without departing from the scope of the invention. 
   As shown in  FIGS. 9 and 10  the articles pass through apertures  90  and  92  to be held in place within the tubular structure T. In some embodiments, suitable retention means engage the upper part of the article(s) to prevent any movement within the apertures  90 ,  92 . Thereafter, the side and base walls are folded as described above and the first side wall panel  14  is secured to the article-retaining structure by securing glue flap  12  to spacer panel  24  by glue or other suitable means known in the art. Thus, the carton is in set-up and loaded condition as shown in FIG.  10 . 
   It will be seen that the articles to be packaged, in this embodiment, are flexible foil pouches and so, in order to retain the articles in place, the panels forming the wraparound carrier are drawn in tightly by moving the securing flap  12  up along spacer panel  24  prior to being secured therewith so as to provide a stable and easy stacking package. 
   The construction of the second, third and fourth embodiments are substantially the same as the first embodiment described and illustrated in  FIGS. 4 ,  5 ,  6  and  7  and, therefore, only the construction of the end closure structure is described in any greater detail. The articles A are applied to the article-retaining structure by relative vertical movement during continuous forward feed, as shown in  FIGS. 11 and 12 , and before folding the base and side wall panels  216 ,  214 , the end closure structure is formed. This is achieved by folding end wall panel  276  inwardly along fold line  275 . In addition, glue flaps  278  and  280  are folded along fold lines  282  and  284  respectively around the articles A, as illustrated in FIG.  12 . Thereafter, the base and/or first side wall panel  214  may be secured to the glue flaps  278  and/or  280  respectively to retain the end closure panels  276  in place. Thus, the carton is in a set-up condition as shown in FIG.  13 . 
   In the embodiment shown in  FIG. 12 , the friction tabs  258  and  260  are engaged in apertures  270  and  272  respectively, to retain the brace panels  250  and  252  in a bracing position. 
   The present invention and its preferred embodiments relate to an arrangement for forming a brace in an article-retaining structure formed from material that also forms one or more article receiving apertures. However, it is anticipated that the invention can be applied to a variety of carriers and not limited to those of a wraparound type described above. 
   It will be recognized that as used herein, directional references such as “top”, “base”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. Any reference to “hinged connection” or fold line should not be constructed as necessarily referring to a single fold line only; indeed, it is envisaged that “hinged connection” can be formed from one or more the following, score line, a frangible line or a fold line, without departing from the scope of the invention. 
   It should be understood that various changes can be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of different size or shape, alternatively top and base closure structures may be used. The carton may accommodate more than one article in different arrays. In the illustrated embodiment, there comprise four articles arranged in two-by-two array although, of course, other arrays are envisaged.