U.S. patent application number 12/736890 was filed with the patent office on 2011-05-19 for container blanks and containers.
This patent application is currently assigned to ELOPAK SYSTEMS AG. Invention is credited to Ivica Franic.
Application Number | 20110113733 12/736890 |
Document ID | / |
Family ID | 39596143 |
Filed Date | 2011-05-19 |
United States Patent
Application |
20110113733 |
Kind Code |
A1 |
Franic; Ivica |
May 19, 2011 |
CONTAINER BLANKS AND CONTAINERS
Abstract
A carton blank (10) for forming a container, and comprising a
row of body portion forming panels (P1-P5) arranged side-by-side,
the boundaries between said panels (P1-P5) being defined by
respective, substantially straight boundary lines of weakness
(S1-S4) extending from top to bottom of said panels (P1-P5)
substantially perpendicularly to said row, two adjacent boundary
lines of weakness (S-S4) each having disposed at one side thereof a
supplemental line of weakness (S11, S12, S21, S22, S31, S32, S31',
S32', S41, S42), each supplemental line of weakness (S11, S12, S21,
S22, S31, S32, S41, S42) being substantially the length of a panel
(P1-P5).
Inventors: |
Franic; Ivica; (Vienna,
AT) |
Assignee: |
ELOPAK SYSTEMS AG
Glattbrugg
CH
|
Family ID: |
39596143 |
Appl. No.: |
12/736890 |
Filed: |
May 20, 2009 |
PCT Filed: |
May 20, 2009 |
PCT NO: |
PCT/EP2009/056159 |
371 Date: |
January 31, 2011 |
Current U.S.
Class: |
53/452 ; 220/62;
220/677; 53/167 |
Current CPC
Class: |
B65D 5/029 20130101;
B65D 5/4266 20130101; B65D 5/067 20130101 |
Class at
Publication: |
53/452 ; 220/62;
220/677; 53/167 |
International
Class: |
B65B 3/02 20060101
B65B003/02; B65D 25/00 20060101 B65D025/00; B65D 6/00 20060101
B65D006/00; B65B 65/08 20060101 B65B065/08 |
Foreign Application Data
Date |
Code |
Application Number |
May 20, 2008 |
GB |
0809082.1 |
Claims
1-73. (canceled)
74. A carton blank for forming a container, and comprising a row of
body portion forming panels arranged side-by-side, the boundaries
between said panels being defined by respective, substantially
straight boundary lines of weakness extending from top to bottom of
said panels substantially perpendicularly to said row, two adjacent
boundary lines of weakness each having disposed at one side thereof
a supplemental line of weakness, each supplemental line of weakness
being substantially the length of a panel.
75. A carton blank for forming a container, and comprising a row of
body portion forming panels arranged side-by-side, the boundaries
between said panels being defined by substantially straight
boundary lines of weakness extending from top to bottom of said
panels, two adjacent boundary lines of weakness each having
disposed at respective opposite sides thereof supplemental lines of
weakness, each supplemental line of weakness being at least half
the length of a panel.
76. A blank according to claim 74, wherein each of each
supplemental line of weakness is located on one of said row of
panels.
77. A blank according to claim 74, and further comprising an
additional supplemental line of weakness, wherein said adjacent
boundary lines of weakness have disposed at respective opposite
sides thereof a pair of supplemental lines of weakness.
78. A blank according to claim 74, wherein each supplemental line
of weakness does not contact a respective boundary line of
weakness.
79. A blank according to claim 74, and further comprising
transverse lines of weakness beginning at or near to a boundary
line of weakness and extending towards a respective supplemental
line of weakness.
80. A blank according to claim 75, wherein each supplemental line
of weakness is substantially the length of a panel.
81. A blank according to claim 74, and further comprising a
transverse line of weakness beginning at or near to a boundary line
of weakness and extending across a second boundary line of weakness
towards a supplemental line of weakness.
82. A container comprising a loop of body portions, the boundaries
between said portions being defined by respective, substantially
straight boundary lines of weakness extending from top to bottom of
said portions substantially perpendicularly to said loop, two
adjacent boundary lines of weakness each having disposed at one
side thereof a supplemental line of weakness, each supplemental
line of weakness being substantially the length of a portion.
83. A container comprising a loop of body portions, the boundaries
between said portions being defined by substantially straight
boundary lines of weakness extending from top to bottom of said
portions, two adjacent boundary lines of weakness each having
disposed at respective opposite sides thereof a supplemental line
of weakness, each supplemental line of weakness being at least half
the length of a portion.
84. A container according to claim 82, wherein each supplemental
line of weakness is located on one of said loop of body
portions.
85. A container according to claim 82, and further comprising an
additional supplemental line of weakness, wherein said adjacent
boundary lines of weakness have disposed at respective opposite
sides thereof a pair of supplemental lines of weakness.
86. A container according to claim 82, wherein each supplemental
line of weakness does not contact a respective boundary line of
weakness.
87. A container according to claim 82, and further comprising
transverse lines of weakness beginning at or near to a boundary
line of weakness and extending towards a respective supplemental
line of weakness.
88. A container according to claim 83, wherein each supplemental
line of weakness is substantially the height of the container, in
length.
89. A container according to claim 82, and further comprising a
transverse line of weakness beginning at or near to a boundary line
of weakness and extending across a second boundary line of weakness
towards a supplemental line of weakness.
90. A container according to claim 82, and further comprising a
plastics insert attached to a boundary line of weakness.
91. A container according to claim 90, wherein the plastics insert
is substantially the same shape as a body sub-portion to which said
plastics insert is attached.
92. Apparatus for handling partially formed containers comprising a
conveying device including a plurality of receiving portions for
receiving partially formed containers having a mid portion of
predetermined cross-section, a filling device arranged to fill said
partially formed containers, and a pressing device arranged to
press on said mid portion so as to make said mid portion of rounder
cross-section.
93. Apparatus according to claim 92, wherein each partially formed
container comprising a loop of body portions, the boundaries
between said portions being defined by boundary lines of weakness,
two adjacent boundary lines of weakness having disposed at one side
thereof a supplemental line of weakness, each supplemental line of
weakness being at least half the height of the container, having
upper and lower regions proximal to a respective boundary line of
weakness and having a central region further from the respective
boundary line of weakness than either the upper or lower region,
and said pressing device is further arranged to activate the
supplemental lines of weakness.
94. Apparatus according to claim 93, wherein said pressing device
is arranged to activate the supplemental lines of weakness, prior
to said filling station being arranged to fill said partially
formed containers.
95. Apparatus according to claim 93, wherein said pressing device
is arranged to activate the supplemental lines of weakness, during
said filling station being arranged to fill said partially formed
containers.
96. A method for handling partially formed containers, comprising
advancing a plurality of partially formed containers through a
pressing device and a filling device, said partially formed
containers having a mid portion of predetermined cross-section,
pressing on said mid portion so as to make said mid portion of
rounder cross-section, and filling said plurality of partially
formed containers at the filling station.
97. A method according to claim 96, wherein each partially formed
container comprising a loop of body portions, the boundaries
between said portions being defined by boundary lines of weakness,
two adjacent of said boundary lines of weakness having disposed at
one side thereof a supplemental line of weakness, the supplemental
line of weakness being at least half the height of the container,
having upper and lower regions proximal to a respective boundary
line of weakness and having a central region further from the
respective boundary line of weakness than either the upper or lower
region, and activating the supplemental lines of weakness at the
pressing device.
98. A method according to claim 97, wherein said activating of the
supplemental lines of weakness, occurs prior to the filling of said
partially formed containers.
99. A method according to claim 97, wherein said activating of the
supplemental lines of weakness, occurs during the filling of said
partially formed containers.
100. A carton blank for a container including a quadrangular top
obturating sub-panel, and disposed outwardly thereof, a top sealing
sub-panel, a line of weakness separating said obturating sub-panel
and said sealing sub-panel and bulging into said sealing
sub-panel.
101. A blank according to claim 100, wherein said line of weakness
separating said obturating sub-panel and said sealing sub-panel is
arcuate.
102. A blank according to claim 100, wherein said line of weakness
separating said obturating sub-panel and said sealing sub-panel is
continuous along the boundary between said obturating sub-panel and
said sealing sub-panel.
103. A blank according to claim 100, and further comprising a
second line of weakness separating said obturating sub-panel from a
body sub-panel and bulging into said body sub-panel.
104. A blank according to claim 100, and further comprising a
second quadrangular top obturating sub-panel and disposed outwardly
thereof, a second top sealing sub-panel, a third line of weakness
separating said obturating sub-panel and said sealing sub-panel and
bulging into said obturating sub-panel.
105. A blank according to claim 104, wherein said third line of
weakness is substantially equal and opposite to the first line of
weakness.
106. A container including a top closure including a roof sub-panel
and a top sealing sub-panel, said roof sub-panel bulging into said
sealing sub-panel.
107. A container according to claim 106, wherein said roof
sub-panel bulging into said sealing sub-panel defines an arcuate
line of weakness.
108. A container according to claim 107, wherein said line of
weakness is continuous along the boundary between said roof
sub-panel and said top sealing sub-panel.
109. A container according to claim 106, and further comprising,
adjacent said roof sub-panel, a body portion, said roof sub-panel,
bulging into said body portion.
110. A container according to claim 106, and further comprising a
second roof sub-panel and a second top sealing sub-panel, a third
line of weakness separating said second roof sub-panel and said
second top sealing sub-panel and bulging into said roof
sub-panel.
111. A container according to claim 110, wherein said third line of
weakness is substantially equal and opposite to the first line of
weakness.
112. A blank for forming a container comprising a row of panels
comprising first, second, third and fourth panels and a row of
substantially rectangular end closure panels extending
substantially parallely to said row of panels and comprised of
first, second, third and fourth end closure panels, each of the
first and third end closure panels have disposed outwardly thereof
a respective end sealing panel extending across the width of the
adjacent end closure panel, and each of the second and fourth end
closure panels have disposed outwardly thereof a respective pair of
tabs, each tab extending across less than half the width of the
adjacent end closure panel.
113. A blank according to claim 112, and further comprising a fifth
panel having disposed outwardly thereof a fifth end closure panel,
said fifth end closure panel having disposed outwardly thereof an
end sealing panel extending across the width of the fifth end
closure panel.
114. A blank according to claim 113, wherein each tab is connected
to an adjacent end sealing panel.
115. A blank according to claim 112, wherein the width of each tab
is substantially equal.
116. A blank according to claim 112, wherein each tab of a pair of
tabs are substantially equal and opposite in shape.
117. A blank according to claim 112, wherein the depth of each tab
is substantially equal to the depth of each sealing panel.
118. A container comprising a loop of body portions comprising
first, second, third and fourth body portions and an end enclosure
comprising folded-in end closure portions and comprised of first,
second, third and fourth end closure portions, each connected to a
respective body portion, each of the first and third end closure
portions being connected, at an opposite edge to the connection to
a body portion, to a respective end sealing portion extending
across the width of the adjacent end closure portion, and each of
the second and fourth end closure portions being connected, at an
opposite edge to the connection to a body portion, to a respective
pair of tabs, each tab extending across less than half the width of
the adjacent end closure portion, and a sealing fin comprised of
the end sealing portions and the pairs of tabs.
119. A container according to claim 118, and further comprising a
fifth body portion being connected to a fifth end closure portion,
said fifth end closure portion being connected, at an opposite edge
to the connection to the body portion, to an end sealing portion
extending across the width of the fifth end closure portion.
120. A container according to claim 119, wherein each tab is
connected to an adjacent end sealing portion.
121. A container according to claim 118, wherein the width of each
tab is substantially equal.
122. A container according to claim 118, wherein each tab of a pair
of tabs are substantially equal and opposite in shape.
123. A container according to claim 118, wherein the depth of each
tab is substantially equal to the depth of each sealing portion.
Description
[0001] This invention relates to container blanks, containers
formed from the blanks, and methods and apparatus for forming the
same.
[0002] According to a first aspect of the present invention, there
is provided a carton blank for forming a container, and comprising
a row of body portion forming panels arranged side-by-side, the
boundaries between said panels being defined by respective,
substantially straight boundary lines of weakness extending from
top to bottom of said panels substantially perpendicularly to said
row, two adjacent boundary lines of weakness each having disposed
at one side thereof a supplemental line of weakness, each
supplemental line of weakness being substantially the length of a
panel.
[0003] According to a second aspect of the present invention, there
is provided a carton blank for forming a container, and comprising
a row of body portion forming panels arranged side-by-side, the
boundaries between said panels being defined by substantially
straight boundary lines of weakness extending from top to bottom of
said panels, two adjacent boundary lines of weakness each having
disposed at respective opposite sides thereof supplemental lines of
weakness, each supplemental line of weakness being at least half
the length of a panel.
[0004] According to a third aspect of the present invention, there
is provided a container comprising a loop of body portions, the
boundaries between said portions being defined by respective,
substantially straight boundary lines of weakness extending from
top to bottom of said portions substantially perpendicularly to
said loop, two adjacent boundary lines of weakness each having
disposed at one side thereof a supplemental line of weakness, each
supplemental line of weakness being substantially the length of a
portion.
[0005] According to a fourth aspect of the present invention, there
is provided a container comprising a loop of body portions, the
boundaries between said portions being defined by substantially
straight boundary lines of weakness extending from top to bottom of
said portions, two adjacent boundary lines of weakness each having
disposed at respective opposite sides thereof a supplemental line
of weakness, each supplemental line of weakness being at least half
the length of a portion.
[0006] According to a fifth aspect of the present invention, there
is provided apparatus for handling partially formed containers
comprising a conveying device including a plurality of receiving
portions for receiving partially formed containers having a mid
portion of predetermined cross-section, a filling device arranged
to fill said partially formed containers, and a pressing device
arranged to press on said mid portion so as to make said mid
portion of rounder cross-section.
[0007] According to a sixth aspect of the present invention, there
is provided a method for handling partially formed containers,
comprising advancing a plurality of partially formed containers
through a pressing device and a filling device, said partially
formed containers having a mid portion of predetermined
cross-section, pressing on said mid portion so as to make said mid
portion of rounder cross-section, and filling said plurality of
partially formed containers at the filling station.
[0008] Owing to these aspects of the invention, it is possible to
provide a container solution which allows for substantial cost
saving in the paper board converting process, uses less material
per blank for the same liquid-product volume, improves the
ergonomic properties of the container, and which works on
mandrel-based container-forming technology. The provision of
supplemental lines of weakness allows the container to bulge and
provides an opportunity to lower the board-weight of the substrate
within the packaging laminate. The system is suitable for the
gable-top and flat-top configurations. The design of the container
is such that it can be used with the existing machinery. The
supplemental lines of weakness are provided on two adjacent
vertical corner edges of the formed container. They could be
provided on three of the edges, or on all four edges of a
rectangular cross-section container. The supplemental lines of
weakness in one embodiment can be provided as a pair of
supplemental lines of weakness disposed at respective opposite
sides of the boundary lines of weakness, each of the supplemental
lines of weakness in the pair being at least half the height of a
panel.
[0009] The invention provides the opportunity to save approximately
5 to 20 mm on the package height and at the same time be able to
fill it with 1000 ml liquid, which is achieved by pressing the
partially formed container on the substantially vertical corners
after the bottom is formed on the mandrel, and before and/or during
the content being filled. This de-forming can continue during the
filling by activating the additional score lines on the
substantially vertical corners. After filling, the container will
take a new shape of its own accord, and the top can be sealed. The
pressing can also take place after the container has been filled
and sealed, which has the advantage of being able to carry out the
pressing action outside of the forming, filling and sealing
machine. The extent of bulging on the side walls will determine by
how much lower the liquid level will become. Bulging is controlled
by specially designed, functional supplemental lines of weakness
(score lines), and will be recognized by the end user as an
intentional design feature. The result will be a cheaper package
with a new design appearance and excellent ergonomic
properties.
[0010] To avoid the negative bulging de-forming effect at material
handling and logistic levels (caused by the wider package), the
container footprint can be resized to 65.times.65 mm. In this case,
the container will be slimmer and will fit in the logistic system
in the same way as the standard 70.times.70 mm 1 litre container.
The container will be taller and more elegant appearance-wise.
However, when the container footprint is reduced, the taller more
elegant container may provide a logistical problem with fitting
into existing forming, filling and sealing machinery. In such
taller and elegant containers it is important to keep the container
as aesthetically pleasing as possible, by reducing the intentional
bulging to a minimum. With a single supplemental line of weakness
disposed to one side of each of two adjacent boundary lines of
weakness, so that, for example, the two supplemental lines of
weakness are located on the front panel of the container, the
intentional bulging is restricted to the front panel and the taller
container retains its elegant appearance.
[0011] According to a seventh aspect of the present invention,
there is provided a carton blank for a container including a
quadrangular top obturating sub-panel, and disposed outwardly
thereof, a top sealing sub-panel, a line of weakness separating
said obturating sub-panel and said sealing sub-panel and bulging
into said sealing sub-panel.
[0012] According to a eighth aspect of the present invention, there
is provided a container including a top closure including a roof
sub-panel and a top sealing sub-panel, said roof sub-panel bulging
into said sealing sub-panel.
[0013] Owing to these aspects of the invention, it is possible to
provide a sub-panel for mounting, for example, a pour spout
fitment, that is larger than a corresponding sub-panel that does
not bulge into the sealing sub-panel. This supports a larger pour
spout fitment.
[0014] According to a ninth aspect of the invention, there is
provided a blank for forming a container comprising a row of panels
comprising first, second, third and fourth panels and a row of
substantially rectangular end closure panels extending
substantially parallely to said row of panels and comprised of
first, second, third and fourth end closure panels, each of the
first and third end closure panels have disposed outwardly thereof
a respective end sealing panel extending across the width of the
adjacent end closure panel, and each of the second and fourth end
closure panels have disposed outwardly thereof a respective pair of
tabs, each tab extending across less than half the width of the
adjacent end closure panel.
[0015] According to an tenth aspect of the invention, there is
provided a container comprising a loop of body portions comprising
first, second, third and fourth body portions and an end enclosure
comprising folded-in end closure portions and comprised of first,
second, third and fourth end closure portions, each connected to a
respective body portion, each of the first and third end closure
portions being connected, at an opposite edge to the connection to
a body portion, to a respective end sealing portion extending
across the width of the adjacent end closure portion, and each of
the second and fourth end closure portions being connected, at an
opposite edge to the connection to a body portion, to a respective
pair of tabs, each tab extending across less than half the width of
the adjacent end closure portion, and a sealing fin comprised of
the end sealing portions and the pairs of tabs.
[0016] Owing to these aspects of the invention, it is possible to
provide an improved end closure, when the blank is formed into a
container. The end closure is particularly suited for aseptic
packaging applications, since there are no raw edges of paperboard
material on the inside of the container nor are there any apex
points on the inside of the finished container, as the folding
process results in apexes being on the outside of the
container.
[0017] Embodiments of the present invention will now be described,
by way of example only, with reference to the accompanying
drawings, in which:
[0018] FIG. 1 is a plan view of a carton blank,
[0019] FIG. 2 is a side view of a container formed from a blank
similar to the blank of FIG. 1,
[0020] FIG. 3 is side view of a pair of containers, each shown in
three views,
[0021] FIG. 4a is perspective view of an open top container, prior
to activation,
[0022] FIG. 4b is perspective view of an open top container,
following activation,
[0023] FIG. 5 is a plan view of a second embodiment of the carton
blank,
[0024] FIG. 6a is a perspective view of two containers,
[0025] FIGS. 6b and 6c are respective perspective and top
diagrammatic views of a container similar to that of the container
on the right-hand side of FIG. 6a,
[0026] FIG. 7 is a plan view of a third embodiment of the carton
blank,
[0027] FIGS. 8 to 21 show further embodiments of the blank,
[0028] FIG. 22 is a perspective view of a container formed from a
blank similar to the blank of FIG. 21,
[0029] FIGS. 23 to 27 show further embodiments of the blank,
[0030] FIG. 28 is a perspective view of a container formed from the
blank of FIG. 25,
[0031] FIG. 29 is a perspective view of a container formed from the
blank of FIG. 24,
[0032] FIG. 30 is a plan view of the container of FIG. 29,
[0033] FIG. 31 is a side view and a front view of a plastics
insert,
[0034] FIG. 32 is a plan view of a further carton blank,
[0035] FIG. 33 is a plan view of a yet further carton blank,
[0036] FIG. 34 is a perspective view of a container end closure at
an intermediate stage of formation,
[0037] FIG. 35 is a perspective view of the container end closure
of FIG. 34 at a completed stage of formation, and
[0038] FIG. 36 is a perspective view of the container end closure
of FIG. 35 from within the container.
[0039] FIG. 1 shows a carton blank 10 for forming a container, and
comprises a row of panels P1, P2, P3, P4 and P5 arranged
side-by-side, the boundaries between the panels P1 to P5 being
defined by respective boundary lines of weakness, being scorelines
S1, S2, S3 and S4. The boundary lines of weakness S1 to S4 are
substantially straight and extend from top to bottom of the panels
P1 to P5. Each of the panels P1 to P4 will become a side of the
ultimate container made from the blank 10, and the boundary lines
of weakness S1 to S4 make up the corner edges of the container. The
boundary lines of weakness S1 to S4 are each a straight continuous
line starting at the top of a panel P1 to P5 and finishing at the
bottom of the respective panel P1 to P5. The boundary lines of
weakness S1 to S4 are each substantially perpendicular to the row
of panels P1 to P5.
[0040] Each of the boundary lines of weakness S1 to S4 have
disposed at respective opposite sides thereof supplemental lines of
weakness S11, S12, S21, S22, S31, S32, S41, S42. Each supplemental
line of weakness S11, S12, S21, S22, S31, S32, S41, S42 is at least
half the height of the ultimate container, and have upper regions
12 and lower regions 14 proximal to a respective boundary line of
weakness S1 to S4, and have a central region 16 further from the
respective boundary line of weakness S1 to S4 than either the upper
or lower regions 12 and 14.
[0041] The supplemental line of weakness S11, S12, S21, S22, S31,
S32, S41, S42 are provided in the blank 10, so that when the blank
10 is ultimately formed into a container 18 (shown in FIG. 2), they
are activated by squeezing in the central region of the container,
to result in an intentional bulge in the container. This bulge
allows the container 18 (once the lines of weakness are activated)
to hold a greater volume of content (for example, a fluid such as
milk) for a given height of container. This is because a circular
cross-section has a greater area than the corresponding rectangular
cross-section.
[0042] On the blank 10 each of the supplemental line of weakness
S11, S12, S21, S22, S31, S32, S41, S42 of a pair of supplemental
lines of weakness S11, S12, S21, S22, S31, S32, S41, S42, located
either side of a boundary line of weakness S1-S4 define a sub-panel
P6, P7, P8 and P9. Each of the supplemental line of weakness S11,
S12, S21, S22, S31, S32, S41, S42 contact the respective boundary
line of weakness S1 to S4 at the upper and lower regions 12 and
14.
[0043] To assist the formation of the bulge in the final container,
the blank 10 further comprises transverse lines of weakness S13,
S23, S33, S43 beginning at or near to a boundary line of weakness
S1-S4 and extending towards a respective supplemental line of
weakness S11, S12, S21, S22, S31, S32, S41, S42. In the embodiment
of FIG. 1, these transverse lines of weakness S13, S23, S33, S43
actually begin at a boundary line of weakness S1-S4 and terminate
at a respective supplemental line of weakness S11, S12, S21, S22,
S31, S32, S41, S42. Each boundary line of weakness S1-S4 is
provided with a plurality of the transverse lines of weakness S13,
S23, S33, S43. The transverse lines of weakness S13, S23, S33, S43
provided on a boundary line of weakness S1-S4 are parallel.
[0044] The container 18 produced from the blank 10 helps to achieve
low cost packaging by redesigning the existing carton configuration
in a way that will allow for filling the same liquid volume in a
carton of lesser height (with the identical footprint), which
additionally means using less paperboard in the blank formation.
For example, the blank will fill 1000 ml of liquid in a standard
1000 ml carton which is shorter by 5 to 20 mm. To achieve this
goal, the blank 10 uses the fact that in bulged cartons the height
level of liquids drops.
[0045] However, since the first association of a consumer with a
bulging carton is that something is wrong with the content, this
important issue must be solved. To overcome this problem, the blank
10 provides a design solution which leads to the re-shaping of the
package walls in a way that clearly demonstrates to the consumer
(via its appearance) the intention behind its unique design. The
real "cost-saving" reason will not necessarily be visible to the
end user, but at the same time the consumer will recognise the
packaging shape as a novelty. To achieve this goal with design
tools, the blank 10 is configured to actually control bulging with
the additional scorelines, which are formed in a way that follows
and allows this bulging effect. The scorelines must be placed in
the right places to achieve the desired result.
[0046] To save approximately 5 to 20 mm on the package height and
to be able to fill it with 1000 ml liquid, it is necessary to
"squeeze" the package 18 on the corners after the bottom is formed
on the mandrel and before/during/after filling. If the squeezing is
to occur before/during filling, the de-forming can continue during
the filling by activating the additional scorelines on all four
walls (corners). After filling, the package 18 will take a new
shape of its own accord, and the top can be sealed. The extent of
bulging on the side walls will determine by how much lower the
liquid level will become. Bulging will be controlled by specially
designed, functional score lines, and will be recognized as an
intentional design feature. The result will be a cheaper package
with a new design appearance and excellent ergonomic
properties.
[0047] FIG. 3 illustrates a comparison between the container 18 and
a conventional container 20. The container 18a shows the container
18 filled with a fluid content, which has not yet had the corners
activated. Container 18b shows the container 18a after activation
of the supplemental lines of weakness. The activation is executed
by pressing on the container 18 in the middle region, which changes
the cross-section of the container 18 from the predetermined
rectangular cross-section to a more rounded cross-section. The
activation of the corners of the container 18 in FIG. 3 are shown
as having been carried out on a filled and sealed container 18, but
the process of activating the supplemental lines of weakness can
occur before or during the filling process, prior to the
top-sealing of the container 18.
[0048] Container 18c is a final configuration of the container 18
after having been filled, top-sealed, activated and is the
end-product. The liquid level L as shown in containers 18b and 18c
is lower than the liquid level L in the pre-activated container
18a. The containers 20 have the same footprint as the containers
18, yet the height of the containers 20 exceeds that of the
containers 18, while containing the same volume of content. It can
be seen that the liquid level L in container 20b is higher than the
liquid level L in the corresponding container 18b.
[0049] An example of the activation of the container 18, prior to
top sealing of the container 18, is shown in FIGS. 4a and 4b. The
container 18a in FIG. 4a has been filled, but not yet activated.
The FIGS. 4a and 4b show the liquid level L in 1000 ml container
(which is 20 mm lower than a conventional container with the same
footprint), filled with 1000 ml of water, before and after the
vertical curved score lines on all four corners are activated and
the container 18 squeezed. Depending upon the amount of squeezing
force and the shape and configuration of the curved score-lines,
the liquid level L will go down by between 5 to 25 mm.
[0050] The container 18 provides a low-cost packaging
configuration. In order to use the existing mandrel carton forming
technology, the container 18 is provided with four vertical corners
that are needed for the carton forming on the mandrel, as well as
the transportation through the filling machine and downstream
equipment. The design of the container is such that standard
logistic and material handling requirements are maintained. The
reconfiguration of the packaging construction is used to achieve a
new and attractive carton visual appearance. An additional result
from the carton design is that the ergonomic properties of the
container 18 are also improved.
[0051] FIG. 5 shows a second embodiment of the blank 10. This blank
10 is provided with a hole 22 for receiving a pour spout fitment,
when the blank 10 is formed into a finished container. The blank 10
is provided with the supplemental lines of weakness S11, S12, S21,
S22, S31, S32, S41, S42, which will ultimately be used, when the
container 18 is formed, to allow the cross-section of the container
to become more rounded. In this embodiment, each supplemental line
of weakness S11, S12, S21, S22, S31, S32, S41, S42 is substantially
the height of the finished container, in length. Each supplemental
line of weakness is substantially the length of a panel P1 to P5.
Each supplemental line of weakness S11, S12, S21, S22, S31, S32,
S41, S42 does not contact a respective boundary line of weakness S1
to S4.
[0052] FIG. 6a shows two examples of containers 18 that have been
formed, filled and sealed, a gable-top container shown on the
left-hand side and a flat-top container shown on the right-hand
side. The provision of the lines of weakness at the corners of the
containers 18 allows these containers to bulge outwards, when the
scorelines are activated by the application of pressure (shown by
the arrows in FIGS. 6b and 6c) at the middle portion 19 of the
containers 18 where the sub-panels P6 to P9 are at their widest.
The application of pressure at the middle portion 19 is
advantageously directly on to the boundary lines of weakness S1 to
S4 at an obtuse angle relative to the vertically orientated panels
P1 to P4 (as shown in FIGS. 6b and 6c), the obtuse angle being
preferably approximately 135.degree.. The scorelines at the corners
of the containers 18 can be used with square and rectangular
flat-top and gable-top cartons.
[0053] A third embodiment of the blank 10 is shown in FIG. 7. The
blank 10 is provided with the supplemental line of weakness S11,
S12, S21, S22, S31, S32, S41, S42 and transverse lines of weakness
S13, S23, S33, S43 (which stop before reaching the supplemental
lines of weakness). Each pair of supplemental lines of weakness
S11, S12, S21, S22, S31, S32, S41, S42 around respective boundary
lines of weakness S1 to S4 define sub-panels P6 to P9. As before,
when this blank 10 is formed into a container 18 which would have a
flat-top configuration rather than a gable-top configuration, the
sub-panels P6 to P9 are pressed inwards to change the cross-section
of the container 18, to make the container 18 more rounded.
[0054] The blank 10 shown in FIG. 7 is a so-called centre-seam
design. The blanks 10 of FIGS. 1 and 5 show a corner-seam design.
This refers to the ultimate location of the seam when the blank 10
is wrapped around a mandrel on the forming machine and sealed into
a container sleeve. At the location of the seam, an overlap 24 of
the blank (which is bounded by the dotted line 26) wraps under the
other side of the blank 10. The design of FIG. 7 results in the
overlap being present in the centre of a body portion rather than
at the corner as in the blank of FIGS. 1 and 5. This means that the
blank of FIG. 7, when formed into a container, does not have a
double layer of material at one corner (which is the case with the
blanks 10 of FIGS. 1 and 5). This means that all of the corners in
the container 18 formed from the blank 10 of FIG. 7 require the
same amount of pressure to press inwards.
[0055] The carton blank 10 of FIG. 7 includes a quadrangular top
obturating sub-panel P10, and disposed outwardly thereof, a top
sealing sub-panel P11, a line of weakness S50 separating the
obturating sub-panel P10 from the sealing sub-panel P11 and bulging
into the sealing sub-panel P11. The line of weakness S50 that is
separating the obturating sub-panel P10 and the sealing sub-panel
P11 is arcuate. The obturating sub-panel P10 includes a hole 22 for
receiving a pour-spout fitment. The line of weakness S50 separating
the obturating sub-panel P10 and the sealing sub-panel P11 is
continuous along the boundary between the obturating sub-panel P10
and the sealing sub-panel P11. The blank 10 further comprises a
second line of weakness S52 separating the obturating sub-panel P10
from a body sub-panel P3 and bulging into the body sub-panel P3.
This second line of weakness S52 separating the obturating
sub-panel P10 and said body sub-panel P11 is also arcuate. The
shape of the lines of weakness S50 and S52 allow for a larger
opturating sub-panel P10 and thus a larger hole 22 for a larger
pour-spout fitment.
[0056] FIG. 8 shows a further embodiment of the blank 10. This
blank 10 is similar to the blank 10 shown in FIG. 1, but the
supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41,
S42 terminate before they reach the boundary lines of weakness S1
to S4. In addition there is provided, between each pair of
supplemental lines of weakness, a single transverse line of
weakness S13, S23, S33, S43 which is provided at substantially the
half way point in the blank 10, and is perpendicular to the
respective boundary lines of weakness S1 to S4. Additional lines of
weakness S54 are provided that run from the supplemental lines of
weakness S11, S12, S21, S22, S31, S32, S41, S42 to the boundary
lines of weakness S1 to S4. These additional lines of weakness S54
in the upper region 12 form a "V" shape, and in the lower portion
14, form in an inverted "V" shape.
[0057] FIG. 9 shows a further embodiment of the blank 10. This
blank 10 is similar to the blank 10 shown in FIG. 8, but has
further oblique transverse line of weakness S13, S23, S33, S43
running from the supplemental lines of weakness S11, S12, S21, S22,
S31, S32, S41, S42 to the boundary lines of weakness S1 to S4.
[0058] FIG. 10 shows a further embodiment of the blank 10. This
blank 10 is similar to the blank 10 shown in FIG. 5, but the
supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41,
S42 are shaped differently. In FIG. 10, the central region 16 of
the supplemental lines of weakness bulges further from the
respective adjacent boundary line of weakness S1 to S4. There is a
single transverse line of weakness S13, S23, S33, S43 between each
pair of supplemental lines of weakness, which terminate before they
reach the supplemental lines of weakness.
[0059] FIG. 11 shows a further embodiment of the blank 10. The
supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41,
S42 terminate before they reach the boundary lines of weakness S1
to S4. Each pair of the supplemental lines of weakness are provided
with two oblique and crossing transverse line of weakness S13, S23,
S33, S43 running from a supplemental line of weakness S11, S12,
S21, S22, S31, S32, S41, S42 through the boundary lines of weakness
S1 to S4 to the other supplemental line of weakness of the pair.
Each supplemental line of weakness is composed of three
substantially straight portions rather than one or more curved
portions.
[0060] FIG. 12 shows a further embodiment of the blank 10. This
blank 10 is similar to the blank 10 shown in FIG. 1, but the
supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41,
S42 extend the entire length of the sub-panels that ultimately form
the sides of the finished container 18.
[0061] FIG. 13 shows a further embodiment of the blank 10. This
blank 10 is similar to the blank 10 shown in FIG. 1, but has no
transverse lines of weakness. FIG. 14 shows a further embodiment of
the blank 10. This blank 10 is similar to the blank 10 shown in
FIG. 1, but has a pair of parallel transverse lines of weakness
S13, S23, S33, S43 in-between each pair of supplemental lines of
weakness, in the central region 16. FIG. 15 shows a further
embodiment of the blank 10. This blank 10 is similar to the blank
10 shown in FIG. 8, but the scorelines S54 are substantially
perpendicular to the boundary lines of weakness S1 to S4.
[0062] FIG. 16 shows a further embodiment of the blank 10. This
blank 10 is similar to the blank 10 shown in FIG. 5, but the
supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41,
S42 are shorter in length. FIG. 17 shows a further embodiment of
the blank 10. This blank 10 is similar to the blank 10 shown in
FIG. 14, but the supplemental lines of weakness S11, S12, S21, S22,
S31, S32, S41, S42 extend the entire length of the sub-panels that
ultimately form the sides of the finished container 18.
[0063] FIG. 18 shows a further embodiment of the blank 10. In this
blank 10, the supplemental lines of weakness S11, S12, S21, S22,
S31, S32, S41, S42 are formed by two substantially straight lines.
Each pair of supplemental lines of weakness forms a respective
diamond shape sub-panel P6 to P9. The blank 10 is also provided
with a single straight transverse line of weakness S56, which is
located at the central region 16 of the blank 10 and bisects each
of the diamond shape sub-panels P6 to P9 at the widest point, and
the panels P1 to P5. FIG. 19 shows a further embodiment of the
blank 10. This blank 10 is similar to the blank 10 shown in FIG.
18, but the diamond-shaped sub-panel P6 to P9 include further
transverse lines of weakness S13, S23, S33, S43, parallel to the
transverse line of weakness S56.
[0064] FIG. 20 shows a further embodiment of the blank 10 in which
two adjacent boundary lines of weakness S1 and S2 have respective
pairs of supplemental lines of weakness S12, S21, S22 and S31
associated therewith. The blank 10 is provided with transverse
lines of weakness, as described above with reference to other
embodiments. The container that is formed from the blank 10 of FIG.
20, when the supplemental lines of weakness S12, S21, S22 and S31
have been activated, provides bulging of three of the four sides of
the resulting container. The blank 10 is similar to the blank 10 of
FIG. 7, in that it is provided with a line of weakness S50, which
allows a larger obturating sub-panel P10. In addition, the blank 10
of FIG. 20 also includes a further line of weakness S51 on an
opposing obturating sub-panel P20, which separates the sub-panel
P20 from a top sealing sub-panel P21, and bulges into the
obturating sub-panel P20. This line of weakness S51 is equal and
opposite to the line of weakness S50, and when the container is
formed from the blank 10, in a gable top configuration, then these
complimentary two lines of weakness S50 and S51 ensure a
satisfactory top fin.
[0065] FIG. 21 shows a further embodiment of the blank 10 for
forming a container 18 (shown in FIG. 22), which has a reduced
footprint size compared to a standard footprint, for example the
container 18 formed from the blank of FIG. 21 has a footprint of 66
mm.times.66 mm compared to a standard 70 mm.times.70 mm for a 1
litre container. In this embodiment, two adjacent boundary lines of
weakness S2 and S3 have respective single supplemental lines of
weakness S31' and S32' associated therewith with both supplemental
lines of weakness S21' and S22' being located on the front panel
P3, the sub-panels P7 and P8 in this embodiment being defined and
bounded by respective supplemental lines of weakness S31' and S32'
and boundary lines of weakness S2 and S3. In this way, the
intentional bulging of the panels, when the supplemental lines of
weakness S31' and S32' have been activated, is restricted to the
front panel P3. The blank 10 is also provided with transverse lines
of weakness S23 and S33, as described above with reference to other
embodiments.
[0066] FIG. 23 shows a yet further embodiment of the blank 10 which
is substantially the same as the blank 10 shown in FIG. 21 except
that the transverse lines of weakness S60 are longer and begin at a
boundary line of weakness S1 and S4 and extend across a second
boundary line of weakness S2 and S3 towards a supplemental line of
weakness S31' and S32'. This transverse line of weakness S60
divides into two lines of weakness after crossing the respective
boundary line of weakness S2 or S3 and terminates before the
supplemental line of weakness. The blank 10 could be provided with
additional supplemental lines of weakness as described above on
opposite sides of the second boundary line of weakness S2 and S3
and in this case the transverse lines of weakness S60 will cross
the respective additional supplementary line of weakness.
[0067] When a container is formed from the blank 10 of FIG. 23 it
is activated by pressing on the container in the middle region, to
activate the supplemental score lines S31' and S32' and the
transverse score lines S60. This results in a container with a more
rounded cross-section in the middle region. The longer transverse
lines of weakness S60, when compared to the shorter transverse
lines of weakness S23 and S33 of FIG. 21, are less likely to crack
the laminate material from which the blank is made, when they are
activated. The extension of the transverse lines of weakness S60,
along the whole side panels P2 and P4, is important for the
activation of front sub-panels (in the activator) without producing
cracks in paperboard on the side walls. The lines S60 guide the
forces in the paper structure produced by squeezing, all the way
along the extended score lines S60 without allowing cracks. At the
same time, the score lines S60 are forming a grip area giving an
ergonomic advantage.
[0068] A further embodiment of the elongate transverse lines of
weakness S60 is shown in FIG. 24. A pair of transverse lines of
weakness S60 are provided, which begin at the boundary line of
weakness S1 and S4 and extend across the second boundary line of
weakness S2 and S3 and terminate on the supplemental line of
weakness S31' and S32'. The pair of transverse lines of weakness
S60 define a sub-panel P30. When a container is formed from the
blank 10 of FIG. 24, the sub-panel P30 provides a target area for a
user to hold when they are pouring the fluid contents from the
container. FIGS. 25 to 27 show further embodiments of the blank 10
using the elongate transverse lines of weakness S60.
[0069] FIG. 28 shows a container 18 made from the blank 10 of FIG.
25. The transverse lines of weakness S60 can be seen, as can the
supplemental lines of weakness S31' and S32'. The cross-section of
the container 18 in the middle region is more rounded, as the
container 18 has been activated by pressing on this middle region
to activate the various score lines. The activation of the lines of
weakness S21' and S31' can take place before, after or during the
filling of the container 18 with its fluid contents. FIG. 29 shows
a container 18 as manufactured from the blank 10 of FIG. 24. The
two transverse lines of weakness S60 define the sub-panel P30 which
can be highlighted with printed material as the grip area for the
user to hold the container 18, when they are pouring the fluid
contents from the container.
[0070] The effect of the user's holding of the container 18, and
the activation of the grip area P30 provide a functional
improvement. During the pouring of the contents from the container
18, the back panel P1 remains the same shape, however, the front
panel P3 collapses along the supplemental lines of weakness S31',
S32' through the gripping of the user and the weight of the
contents and has a width less than the back panel P3. This makes a
very safe and pleasant cross-section for the user at the middle
section of the container 18, where the grip sub-panel P30 is
placed. Referring to FIG. 30, the cross-sectional profiles of the
middle section of the container 18 are shown before activation
(shown by the profile PF1) and after activation and gripping (shown
by the profile PF2). When the container 18 has the profile PF2 at
its mid-section then the back panel P1 remains the same width as in
the profile PF1 whilst the front panel P3 collapses as aforesaid to
a narrower width than as in the profile PF1 resulting in an
intentional bulge at the front of the container 18 as pouring takes
place.
[0071] FIG. 31 shows two views of a plastics insert 60. The insert
60 has a profile corresponding to the sub-panels P6 to P9 of FIGS.
1 and 2 and includes a vertical indent 62 running the entire length
of the insert 60 which corresponds to the boundary lines of
weakness S1 to S4 in the blank 10. The insert 60 also includes
horizontal ribs 64, which likewise correspond to the transverse
lines of weakness S13, S23, S33 and S43 of the blank 10. The shape
and configuration of the insert 60 can be such that it matches any
of the corresponding panels and lines of weakness of other
embodiments of the blank 10. Instead of the horizontal ribs 64, the
plastics insert 60 can have various suitable surface designs.
[0072] The insert 60 is formed of plastics material such as any
polyolefin plastics or rubber material, and can be provided in any
colour. The insert 60 is designed to be post-applied to the
container 18 that is formed from the blank 10, at any or all of the
vertical corners of that container 18. The length of the plastics
insert 60 is preferably substantially equal to the length of an
adjacent supplemental line of weakness S11, S12, S21, S22, S31,
S32, S41, S42, and the same shape as a body sub-portion P6 to P9 to
which the plastics insert 60 is attached. The insert 60 assists in
providing an aesthetic container (for example through the use of
different colours), provides better container stability through
support of the container edges and improves the ergonomic
properties of the container.
[0073] FIGS. 32 and 33 show two embodiments of a blank 10', the
blank 10' being for forming a container. In both embodiments, the
blank 10' comprises a row of panels P1 to P4 comprising first,
second, third and fourth panels P1 to P4. The blank 10' also
comprises a row of substantially rectangular end closure panels P12
to P15 extending substantially parallely to the row of panels P1 to
P4 and comprised of first, second, third and fourth end closure
panels P12 to P15. Each of the first and third end closure panels
P12, P14 have disposed outwardly thereof a respective end sealing
panel P17, P18 extending across the width of the adjacent end
closure panel P12, P14. Each of the second and fourth end closure
panels P13, P15 have disposed outwardly thereof a respective pair
of tabs T1 to T4, each tab extending across less than half the
width of the adjacent end closure panel P13, P15.
[0074] The blank 10' also comprises a fifth panel P5 having
disposed outwardly thereof a fifth end closure panel P16, the fifth
end closure panel P16 having disposed outwardly thereof an end
sealing panel P19 extending across the width of the fifth end
closure panel P16. Each tab T1 to T4 is connected to an adjacent
end sealing panel P17 to P19, and the width of each tab T1 to T4 is
substantially equal. The tabs T1 to T4 are in pairs, and each tab
T1 to T4 of a pair of tabs T1, T2 and T3, T4 are substantially
equal and opposite in shape. The depth of each tab T1 to T4 is
substantially equal to the depth of each sealing panel P17 to
P19.
[0075] The design of the end closure panels P12 to P16, end sealing
panels P17 to P19 and tabs T1 to T4 is to provide an improved end
closure, when the blank 10' is formed into a container. The end
closure is particularly suited for aseptic packaging applications,
since there are no raw edges of paperboard material on the inside
of the container nor are there any apex points on the inside of the
finished container, as the folding process (described in more
detail below) means that the apexes are on the outside of the
container. An apex point occurs when a panel is folded to form a
triangular shaped sub-panel. An apex point is particularly
susceptible to ingress of the fluid contents of the container, once
that container has been filled. The blank 10' can be folded on a
mandrel, when the end closure is being formed.
[0076] The blanks 10' of FIGS. 32 and 33 differ in that the blank
10' of FIG. 32 is forming a container having a centre seam down the
rear body panel, and the blank 10' of FIG. 33 is for forming a
container having a side seam extending along one corner edge of the
container. When the blank 10' is provided with the supplemental
lines of weakness S11, S12, S21, S22, S31, S32, S41, S42, it is
advantageous to have a centre seam on the finished container,
otherwise the lines of weakness present at the corner where the
container is sealed first panel P1 to fifth panel P5 discourage the
activation of the supplemental lines of weakness at that corner.
The end closure provided by the blank 10' of FIGS. 32 and 33 is
particularly suitable for use with a centre seamed container, such
as that formed from the blank 10' of FIG. 32. This is because many
standard end closure configurations become sub-optimal, when used
with a container that is designed to be centre seamed. For example,
some standard end closure configurations will end up with the
centre seam passing through the apex of a sub-panel in the bottom
end closure, which increase in the likelihood of content leaking or
content ingress into the paperboard substrate.
[0077] FIG. 34 shows the end closure 70 at a partial stage of
formation. The second and fourth end closure panels P13 and P15
have first and second oblique lines of weakness which divide the
respective end closure panels P13 and P15 into triangular
sub-panels. As the end closure 70 is formed, end closure panel P14
and the combined end closure panel P12 and P16 which are opposite,
are folded in towards each other. This results in the end closure
panels P13 and P15 folding into their triangular sub-panels, as can
be seen in FIG. 34. The tabs T1 to T4 and the sealing panels P17 to
P19 are ultimately sealed face-to-face to form a sealing fin 72.
This fin 72 is folded flat to the bottom of the container. The end
closure 70 is completed by the apexes A1 and A2 being folded
inwardly to be sealed flat to the bottom of the container, as can
be seen in FIG. 35. The interior of the end closure 70 is shown in
FIG. 36. The folding of the bottom closure 70 is such that no
apexes are present within the interior of the container, nor are
there any exposed raw edges of paperboard.
* * * * *