Patent Publication Number: US-9422093-B2

Title: Article carrier

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a National Phase application of PCT Application PCT/US2012/049689 filed Aug. 6, 2012, which claims the benefit of US Provisional Patent Application No. 61/515606, filed Aug. 5, 2011, each of which is incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to article carriers and blanks which are particularly useful for carrying articles, for example, cans or bottles. More particularly, the invention relates to an article carrier of the wrap-around type and is concerned with an improved article retention and carrier reinforcing feature which receive heel portions of cans or bottles accommodated in the carrier. 
     Bottle heel retention means in wraparound carriers are well known. 
     EP 0 171 229 B1 discloses a known bottle carrier of the wraparound type having top, bottom and side walls interconnected to form a tubular open-ended structure. A sloping heel panel interconnects each side wall along a fold line with an associated base lap panel. The bottom corners of the carton formed by the sloping heel panels comprise receiving apertures formed in each sloping heel panel which extend into the associated side wall and base lap panel. The receiving apertures form part of the bottle heel retaining feature which further comprises bottom engaging and carrier reinforcing flaps which are foldably joined along opposed peripheral edges of the bottle heel receiving apertures. In particular, EP 0 171 229 B1 discloses bottom engaging and carrier reinforcing flaps which extend across the associated sloping heel panel and into the associated side wall and base lap panel. The flaps comprise hinged portions so that in the formed bottle carrier, a portion of the bottle engaging and carrier reinforcing flap is substantially parallel with the inner surface of the associated base lap panel. In this construction, a portion of the heel of a bottle protrudes from the carrier without being protected. The tighter the package is made, the more is the tendency for the bottle heel to protrude further. Also, tears can be created in that area of the carton surrounding a receiving aperture due sometimes to an “over-tight” package and in part, at least, to any movement of a bottle acting directly against the edge of the receiving aperture. 
     Another type of bottle heel retaining structure is shown by WO 94/25367. This reference discloses a heel retaining flap extending primarily inwardly of the carton, although C shaped cuts provided cause a small portion of the flap to extend outwardly of the carton. The folding action of the retaining flaps is inward, i.e. the pivoting action is inward and not outward. The flaps are severed by a cut line from a sloping heel panel and the flaps are adapted to engage the heel of an article. 
     SUMMARY OF THE INVENTION 
     The present invention in one aspect provides an article carrier for packaging articles. The carrier comprises a pair of angularly related panels and an article retaining feature. The angularly related panels are hingedly connected together along a fold line. The retaining feature comprises a retaining aperture for receiving a portion of an article that is contained within the carrier. The aperture is defined in one of the angularly related panels and extends into the other of the angularly related panels. The retaining feature further comprises a tab portion protruding into the aperture. The tab portion is positioned such that the fold line between the angularly related panels extends across the tab portion and terminates at an apex of the tab portion. 
     In a preferred embodiment, the tab portion may have an outline that is substantially arcuate in shape, and the apex of the tab portion may be located along the outline. 
     In another preferred embodiment, the retaining feature may further comprise at least one flap hingedly connected to an edge of the aperture. The at least one flap may be folded inward of the carrier to abut the article in the aperture. The tab portion may be defined by a cut line in the at least one flap so that it is revealed as protruding substantially into the aperture when the at least one flap is folded inward of the carrier. 
     The fold line between the angularly related panels may intersect with the cut line at a substantially midpoint along the cut line. 
     The cut line may optionally be essentially arcuate in shape and may be curved convexly as viewed from a notional view point inside the aperture. 
     The at least one flap may optionally be hingedly connected to the angularly related panels along two separate fold lines, and the cut line may extend from one of the separate fold lines to the other of the separate fold lines. The separate fold lines and the cut line together may define an adjacent side edge of the at least one flap. The separate fold lines may extend divergently from the cut line toward the at least one flap. 
     The tab portion may optionally be shaped to conform to the profile of a diametrically reduced portion of the article received in the aperture. 
     In a further preferred embodiment, the tab portion may be formed in part from one of the angularly related panels and in part from the other of the angularly related panels. 
     In a still further preferred embodiment, the at least one flap comprises first and second flaps hingedly connected to opposed side edges of the aperture respectively, 
     In a still further preferred embodiment, the retaining feature may be provided at a position next to one of the opposite ends of the carrier, and the fold line between the angularly related panels may extend from the apex of the tab portion to the one of the opposite ends of the carrier. 
     In a still further embodiment, part of the perimeter of the aperture may be shaped to define the tab portion. 
     In a still further embodiment, one of the angularly related panels may include a side panel and a heel panel hingedly connected to a lower edge of the side panel, and the other of the angularly related panels may be a base panel hingedly connected at least in part to the lower edge of the heel panel. 
     The present invention in another aspect provides a blank for forming an article carrier. The blank comprises first and second panels which are to be angularly related when the blank is erected into a carrier. The first and second panels are hingedly connected together along a fold line. The blank further comprises an article retaining feature which comprises a retaining aperture for receiving a portion of an article. The aperture is defined in one of the first and second panels and extends into the other of the first and second panels. The retaining feature further comprises at least one flap hingedly connected to an edge of the aperture. The at least one flap is formed with a cut line that defines a tab portion protruding from the first and second panels into the at least one flap. The tab portion is positioned such that the fold line between the first and second panels extends across the tab portion and terminates at an apex of the tab portion. 
     In a preferred embodiment, the fold line between the first and second panel intersect with the cut line at a substantially midpoint along the cut line. 
     In another preferred embodiment, the cut line may be essentially arcuate in shape and may be curved convexly as viewed from a notional view point inside the aperture. 
     In another preferred embodiment, the at least one flap may be hingedly connected to the first and second panels along two separate fold lines, and the cut line may extend from one of the separate fold lines to the other of the separate fold lines. 
     In a further preferred embodiment, the tab portion may be formed in part from one of the first and second panels and in part from the other of the first and second panels. 
     In a still further preferred embodiment, the retaining feature may be provided at a position next to one of the opposite side edges of the blank. The fold line between the first and second panels may extends from the apex of the tab portion to the one of the opposite side edges of the blank. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An embodiment 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 for forming a carrier having bottom retaining features according to the present disclosure: 
         FIG. 2  is an enlarged plan view of one of the retaining features in  FIG. 1 ; 
         FIG. 3  is a perspective view of an erected carrier formed from the blank of  FIG. 1  with cans received in the carrier; 
         FIG. 4  is a bottom-side perspective view of the carrier of  FIG. 3 , showing the heels of the cans received in receiving apertures; 
         FIG. 5  is an enlarged perspective view of the carrier of  FIG. 3 , showing one of the inwardly-folded, engaging and reinforcing flaps that is in engagement with an end can; 
         FIG. 6  is a perspective view of the heel-retaining features viewed from the inside of the carrier; 
         FIG. 7  is an enlarged plan view of a conventional heel retaining feature, showing its initial flat condition in which the engaging and reinforcing flaps lay flat with the respective carrier blank; 
         FIG. 8  is an enlarged plan view of another conventional heel retaining feature showing its initial flat condition similar to  FIG. 7 ; 
         FIG. 9  is a diagram showing the result of a dropping test performed on substantially identical carrier samples each being similar to the carrier shown in  FIG. 1 ; 
         FIG. 10  is a diagram showing the result of a dropping test on carrier samples having the heel retaining features shown in  FIG. 7 ; and 
         FIG. 11  is a diagram showing the test result of a dropping test on carrier samples having the heel retaining features shown in  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 and 2 , there is shown a blank  10  for forming a wrap-around article carrier having heel retaining features  40  according to the present disclosure. The blank  10  comprises a plurality of primary panels that include a first base panel  12 , a first heel panel  22 , a first side panel  14 , a top panel  16 , a second side panel  18 , a second (or another) heel panel  22  and a second base panel  20 . These primary panels are hingedly connected one to the next by respective fold lines  26 ,  27 ,  28 ,  29 ,  27 ,  30  so that the primary panels are capable of forming a tubular structure that can wrap around a group of articles such as cans or bottles. The blank  10  further comprises a plurality of retaining features  40 . Each retaining feature  40  is formed in the respective base panel  12  or  20  and extends into the adjacent side wall comprising the first or second side panel  14  or  18  and its associated heel panel  22 . Each retaining feature  40  is not necessarily exclusively intended for the heel or lower portion of an article and may be used, for example, for an upper shoulder or upper portion of an article. In the embodiment wherein the retaining features are provided for the shoulder portions of the packaged articles, each of such retaining features may be formed in the respective top panel  16  and may extend into the adjacent side wall. The retaining feature  40  can be formed at the ends of the tubular structure of the article carrier, for example, to retain the end corner articles or alternatively, can be provided for only any one or more of the articles held in a carrier. The blank of  FIG. 1  is designed to package four cans of a 2×2 configuration. As such, all the four retaining features  40  serve to retain end corner cans when the blank  10  is erected into a carrier. Reference numerals “ 32 ” and “ 34 ” denote additional panels at the opposite ends of each of the first and second side panels  14 ,  18 . 
     Each retaining feature  40  comprises a retaining aperture  46  which in this example receives the heel of a can C, as shown in  FIGS. 3 and 4 . Each retaining feature  40  also comprises retaining flaps  42 ,  44  which in the erected carrier provide internal flaps which abut that part of the heel of the article C adjacent the respective heel panel  22 . The general form of flap is known and is described in detail, for example, in WO94/25363 which is hereby incorporated by reference. 
     Referring in particular to  FIG. 2 , each retaining feature  40  in this particular embodiment comprises a first flap  42  that is divided into upper, middle and lower flap portions by two fold lines  58 ,  60 . The upper portion is defined between the fold line  58  and the upper edge of the first flap  42  and is hinged to the side wall  14  along a fold line  48 . (The heel panel  22  is not provided at the respective carrier end since the fold line  27  extends between the two adjacent retaining features only and it does not further extend beyond the retaining features.) The middle portion is defined between the fold lines  58 ,  60  and is hinged to the upper portion along fold line  58  and to the lower portion along fold line  60 . The middle portion is partially defined by an arcuate cut line  50  and thus is not directly connected to either the adjacent side panel  14  or base panel  12 . The lower flap portion is defined between the fold line  60  and the lower edge of the flap  42  and is hinged to base panel  12  along a fold line  52 . The fold lines  48  and  52  are spaced from one another with the arcuate cut line  50  extending therebetween. These spaced fold lines  48 ,  52  are in a divergent relationship to define therebetween an obtuse angle. The fold lines  48 ,  52  extend from the arcuate cut line  50  divergently toward the first flap  42 . 
     Referring further to  FIG. 2 , the arcuate cut line  50  extends from fold line  48  to fold line  52  to define a tab portion  56  which is shaped to conform to the profile of a diametrically reduced portion “R” of the associated article that, in this embodiment, is a can “C”. Such a diametrically reduced portion “R” is shown in  FIG. 4  in which the diametrically reduced (or tapered) portion R is positioned in a substantial horizontal alignment with the fold line  26 . Articles, cans in particular, often include such a diametrically reduced portion of a standard size, which is typically about 1 cm in width. The fold line  26  between the side panel  14  and the base panel  12  extends from the end edge of the blank  10  and is interrupted by the arcuate cut line  50 . The point of the interruption is located at a substantially mid point along the arcuate cut line  50  and is spaced substantially from the opposite ends of the arcuate cut line  50 . Stated differently, the point of interruption is located at around the apex of the tab portion  56  wherein the apex is located midway along the arcuate outline of the tab portion  56  that is defined by the arcuate cut line  50 . This arrangement contributes to reinforcing or strengthening the area of the blank  10  between the aforementioned end edge of the blank and the aperture  46  in order to minimize development of tears in and around that area. 
     Returning to  FIG. 2 , it is envisaged that the shape of the cut line  50  can be altered according to the particular profile of the diametrically reduced portion of the associated article. The fold lines  48 ,  52  and cut line  50  together define the respective side edge of the first flap  42 . Apparent from  FIG. 2 , the first flap  42  is struck or formed from the primary panels (or side and base panels)  14 ,  12  and more particularly from the material of the blank  10  taken from the area of the aperture  46 . The first flap  42  is pivotal about the fold lines  48  and  52 . 
     Similarly, a second flap  44  comprises upper, middle and lower flap portions bounded by fold lines  62 ,  64 . In the illustrated embodiment, the second flap  44  has a width greater than that of the first flap  42  and separated from the first flap  42  along the central cut line  54 . It is anticipated that the two flaps  42 ,  44  need not necessarily be provided and indeed, only the first flap may be provided in a given retaining feature  40 . It is envisaged that where two flaps are provided, they need not abut along cut line  54  and indeed, a substantial gap could be provided between the flaps, for example. Reference numeral “ 66 ” denotes a line in the first side panel  14  located above the aperature  46 . 
     The upper portion of the second flap  44  is defined between its upper edge and the fold line  62  and is foldably connected to the heel panel  22  along a fold line  68 . The middle portion of the second flap  44  is defined between the fold lines  62 ,  64 . The lower portion of the second flap  44  is defined between the fold line  64  and the lower edge of the second flap  44  and is hingedly connected to base panel  12  along fold line  72 . An arcuate cut line  70  extends from fold line  68  to fold line  72 ; however, the orientation of the cut line  70  is opposite to that of the cut line  50  in the sense that the resultant tab portion remains attached to, or integral with, the respective flap  44  and protrudes outward of the receiving aperture  46  as opposed to the tab portion  56  which is integral with the primary panels  12 ,  14  and protrudes inward of the aperture  46 . However, the orientation of the cut line  70  may be altered such that the resultant tab portion is attached to the primary panels  12 ,  22  and protrudes inwardly of the aperture  46 . The fold lines  68 ,  72  and cut line  70  together define the respective side edge of the second flap  44 . The second flap  44  is struck or formed from the primary panels  12 ,  22 ,  14  and more particularly from the material of the blank  10  taken from the area of the aperture  46 . The second flap  44  is pivotal about fold lines  68 ,  72 . When both the flaps  42 ,  44  are co-planer, e.g., when the carrier is in blank form illustrated in  FIGS. 1 and 2 , the aperture  46  is closed at least in part. 
     In the illustrated embodiment, the carrier is formed to package two rows of two cans. The blank  10  shown in  FIG. 1  comprises retaining features  40  (for one of the two rows of cans) formed from side panel  14 , the heel panel  22  and the base panel  12 . The blank  10  further comprises retaining features  40  (for the other row of cans) formed from the side panel  18 , the heel panel  22  and the base panel  20 . The retaining features  40  for the other row are substantially the same as the retaining features  40  and therefore are not described in any greater detail. 
     In order to erect a wraparound carrier from the blank  10 , the top panel  16  of the carrier blank  10  is applied to the tops of a group of articles C to be packaged in the carrier, and the side walls  14 ,  18  are folded downwardly to be disposed in flanking relationship along the side walls of the articles. During and/or before the side wall folding process, the flaps  42 ,  44  are displaced inwardly toward the article group by suitable means which may be similar, at least in function, to those known, for example, from WO 94/25363. Displacement of the flaps  42 ,  44  thus causes the flaps  42 ,  44  to be disposed internally of the carrier to reveal tab portion  56 . The heel portion of an article C is thereby received in the aperture  46  as well as by the flaps  42 ,  44  of the respective retaining feature  40 . The tab portion  56  engages the diametrically reduced portion R of the associated article C as shown in  FIG. 4 . The tab portion  56  can be pressed against the article to provide a tighter carrier and can engage the diametrically reduced portion R to restrict movement of the article C along the cylindrical axis such as the can axis. The respective base panel  20  can then be folded inwardly and upwardly into engagement with the base portions of the articles C. A similar operation on the other side of the group of articles is also performed, and the base panel  12  is placed in an overlapping relationship with the base panel  20 . These base panels  12 ,  20  are secured together by means known in the art, e.g., gluing or mechanical locks such as shown in  FIG. 1  at  36 ,  38 . By securing the base panels together, the wraparound carrier can be completed as shown in  FIG. 4  in which the top panel  16  and either side walls are angularly related while each side wall and the adjacent base panel  12  or  20  are also angularly related. In the application the term “angularly related” refers to a relationship between two panels which are disposed to define therebetween any angle other than 0 and 180 degrees and preferably an angle about 90 degrees. 
     After the base panels  12 ,  20  have been secured together, the carrier is in an erected condition and the retaining features  40  are such that the internal engaging and reinforcing flaps  42 ,  44  are provided to engage the heels of the articles C. Further, the protruding tab portions  56  engage the diametrically reduced portions R of the cans C. Thus, the engaging flaps  42 ,  44  and protruding tab portions  56  are particularly able to conform to the bottom or heel portions of the articles. The tab portions  56  in particular are positioned such that the adjacent fold line  26  between the adjacent base panel  12  or  20  and the adjacent side wall  14 ,  22 ; or  18 ,  22  intersects with the respective cut line  50  at the substantially mid point along the cut line  50 . The “mid point” in this application refers to a position spaced substantially from the opposite ends of the respective cut line  50  which is curved convexly as viewed from a notional view point inside the aperture  46 . The tab portion  56  defined by such a cut line  50  protrudes into the first flap  42  as viewed in  FIG. 2  and projects substantially into the aperture  46  when the first flap  42  is folded inwardly of the carrier (see  FIGS. 3-6 .) Stated differently, the fold line  26  extends across the tab portion  56  and terminates at the apex of the protruding tab portion  56 . 
     Drop Impact Test 
     Twelve carrier samples (or test specimens) I each identical in the size and structure to the carrier of  FIGS. 1-6  are prepared. Twelve conventional carrier samples (or control specimens) II and twelve conventional carrier samples (or control specimens) III are prepared. Conventional carrier samples II each has the retaining feature  140  shown in  FIG. 7  while carrier samples III each has the retaining feature  240  shown in  FIG. 8 . The size and structures of each of the carrier samples II and III are substantially the same as the carrier shown in  FIGS. 1-6  except their respective retaining features. The reference numerals used in  FIGS. 7 and 8  are similar to those used in  FIG. 2  in that they designate corresponding portions of the retaining feature  40  respectively. The reference numerals in  FIGS. 7 and 8  differ from those in  FIG. 2  in that they are preceded by the prefix “1” and by the prefix “2”, respectively. Except for the function of the cut line  50  and tab portion  56 , the functions of the denoted portions in  FIG. 2  are similar to that of those denoted in  FIGS. 7 and 8 . Therefore, further description of  FIGS. 7 and 8  are omitted. The test and control carrier samples I, II and III are each tested to determine:
         The resistance to impact applied to the respective carrier sample when the samples are dropped from a certain elevation.       

     The test carrier samples I are formed from paperboard material having a thickness of about 350 gsm (gram per square meter). The control carrier samples sample II are formed from the paperboard material having a thickness of about 380 gsm while the control carrier samples III are formed from paperboard material of a thickness of about 350 gsm. The paperboard material used for all the carrier samples I, II and II are coated natural craft board identified as “CNK” which is a trademark of MeadWestvaco Corporation. 
     All tests were carried out after applying each carrier sample to a group of four cans of a 2×2 configuration and thereby making a loaded packaging and by dropping the package from the elevation of 50 cm measured from a flat surface on which the package is dropped. Each can used for the tests has a capacity of 47 cl and identified as “202” can and has been loaded with the corresponding amount of beer. 
     The test results are presented in the diagrams shown in  FIGS. 9-11 . As described earlier, twelve carrier samples were tested for each type of sample (I-III). The sample numbers 1-12 are shown along the abscissa in each of  FIGS. 9-11 . The number of the times each package was dropped was counted till one or more tears extended from at least one of the receiving apertures all the way through the adjacent carrier edge or till any can in the package exits from the package. The numbers of times the carrier samples are dropped are given along the ordinate in each of  FIGS. 9-11 .  FIG. 9  shows the drop test results for carrier samples I,  FIG. 10  shows those for carrier samples II and  FIG. 11  shows those for carrier samples III. The minimum, maximum and average of the number of the times the carrier samples are dropped are given in the following table. 
     
       
         
           
               
               
               
               
             
               
                   
                   
               
               
                   
                 Min. 
                 Max. 
                 Average 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
            
               
                   
                 Samples I 
                 12 
                 More than 22 
                 19.58 
               
               
                   
                 Samples II 
                 2 
                 8 
                 4.67 
               
               
                   
                 Samples III 
                 0 
                 2 
                 1.17 
               
               
                   
                   
               
            
           
         
       
     
     The results demonstrate that the carrier of the present disclosure can increase the impact resistance of a carrier formed from the same material. The carrier of the present disclosure can even provide a superior impact resistance than a conventional carrier formed from a thicker material. 
     It can be appreciated that various changes may be made within the scope of the present disclosure, for example, the present disclosure is not limited in its application to paperboard, but may be envisaged that the present disclosure may usefully be employed with other types of foldable sheet material including paper, cardboard and plastics materials. 
     It is apparent that the improved conformity of the carrier provided by the present disclosure enables a relatively strong package tightening whilst minimizing the risk of tearing. 
     Further, the present disclosure is not limited to a configuration as described above, and it is envisaged, it would be possible to provide a retaining feature according to the present disclosure comprising one or more hinged connections per engaging and reinforcing flap in order to enable the protruding tab portion to be provided in the assembled carrier. 
     The present disclosure and its preferred embodiment relate to an article carrier which is shaped to provide satisfactory strength to hold the articles securely but with a degree of flexibility so that the load transferred to the retaining features is absorbed by the carrier. The carrier can be applied to an array of bottles by hand or automatic machinery.