U.S. patent application number 16/742206 was filed with the patent office on 2020-07-16 for product support.
The applicant listed for this patent is Multi Packaging Solutions UK Limited. Invention is credited to Kevin Topfer, David Yates.
Application Number | 20200223580 16/742206 |
Document ID | / |
Family ID | 65528162 |
Filed Date | 2020-07-16 |
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United States Patent
Application |
20200223580 |
Kind Code |
A1 |
Topfer; Kevin ; et
al. |
July 16, 2020 |
PRODUCT SUPPORT
Abstract
A machine erectable product support (1) comprises at least one
product support defining structure (3) including a top panel (5) a
bottom panel (7) and a longitudinal side wall panel (9). The
product support defining structure (3) defines, in the erected
product support (1), one or more product locating pockets (11). The
top panel (5) comprises cutlines and foldlines (15, 17) defining a
plurality of hinge panels (13) hingedly attaching a first portion
(6) of the top panel (5) to a second portion (8) of the top panel
(5) to enable the first portion (6) to be rotated relative to the
second portion (8) to erect the product support defining structure
(3) during erection of the product support (1). The bottom panel
(7) comprises one or more openings, each opening being registered
with a respective portion of the top panel (5) when the product
support defining structure (3) is in a flat configuration to
facilitate erection of the product support.
Inventors: |
Topfer; Kevin; (Bradford,
GB) ; Yates; David; (Bradford, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Multi Packaging Solutions UK Limited |
Nottingham |
|
GB |
|
|
Family ID: |
65528162 |
Appl. No.: |
16/742206 |
Filed: |
January 14, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/5059 20130101;
B65D 5/504 20130101; B65D 5/5052 20130101; B65D 5/5021 20130101;
B65D 71/72 20130101 |
International
Class: |
B65D 5/50 20060101
B65D005/50 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 15, 2019 |
GB |
1900565.1 |
Claims
1. A machine erectable product support made from cardboard,
paperboard or other lightweight foldable sheet material comprising:
at least one product support defining structure comprising: a top
panel comprising a first portion for providing an upper support
section of the product support defining structure in the erected
product support, and a second portion for providing a lower section
of the product support defining structure in the erected product
support; a bottom panel for providing a base of the product support
defining structure in the erected product support, wherein the
second portion of the top panel is secured to the bottom panel; and
a longitudinal side wall panel; wherein the product support
defining structure defines, in the erected product support, one or
more product locating pockets; wherein the top panel comprises
cutlines and foldlines defining a plurality of hinge panels
hingedly attaching the first portion of the top panel to the second
portion of the top panel to enable the first portion to be rotated
relative to the second portion to erect the product support
defining structure during erection of the product support; wherein
each hinge panel is connected at one end about a foldline to the
first portion of the top panel and at the other end about a
foldline to the second portion of the top panel; wherein the bottom
panel comprises one or more openings, each opening being registered
with a respective portion of the top panel when the product support
defining structure is in a flat configuration, whereby an erecting
pin of an erecting machine may be inserted from the underside of
the bottom panel through the opening to contact the top panel to
assist in rotating the first portion of the top panel relative to
the second portion of the top panel to erect the product support
defining structure during erection of the product support.
2. The product support of claim 1, wherein the second portion of
the top panel is adhesively secured to the bottom panel or wherein
the second portion of the top panel is secured to the bottom panel
using heat sealing.
3. The product support of claim 1 wherein the second portion of the
top panel extends into the or each product locating pocket.
4. The product support of claim 1 wherein the second portion
comprises a continuous longitudinal strip
5. The product support of claim 4 wherein the continuous
longitudinal strip is located adjacent, and extends to, an inner
edge of the top panel.
6. The product support of claim 1 wherein at least one opening is
provided registered with a respective hinge panel of the top
panel.
7. The product support of claim 1 wherein at least one opening is
provided registered with a portion of the first portion of the top
panel.
8. The product support of claim 1 wherein the first portion of the
top panel comprises a continuous longitudinal strip, wherein the
one or more openings includes one or more openings registered with
respective portions of the longitudinal strip.
9. The product support of claim 1 wherein the or each product
locating pocket further comprises a sidewall, the sidewall being
provided by one of the plurality of hinge panels of the product
support defining structure, wherein the sidewall is a longitudinal
sidewall.
10. The product support of claim 1 wherein the cutlines comprise a
plurality of cutlines, each defining an edge of one or more of the
hinge panels.
11. The product support of claim 10 wherein each one of at least
some of the plurality of cutlines further defines, in the erected
product support, an edge of one of the one or more product locating
pockets.
12. The product support of claim 1 wherein the product support is
configured such that, when erected, the product support defining
structure defines one or more product locating pockets along the
longitudinal direction of the product support, each product
locating pocket being defined between adjacent ones of the
plurality of hinge panels, and including product locating pocket
edges defined by cutlines of the product support defining
structure, which cutlines define the edges of the hinge panels on
either side of the product locating pocket.
13. The product support of claim 12 wherein, for each product
locating pocket, one edge of each of the hinge panels between which
the product locating pocket is defined is defined by a one of the
cutlines of the product support defining structure, and the opposed
edge of the hinge panel is defined by another one of the cutlines
of the product support defining structure or by an end edge of the
top panel.
14. The product support of claim 1 wherein the one or more product
locating pockets are defined between hinge panels of a first subset
of the plurality of hinge panels provided by the product support
defining structure, and wherein a sidewall of each product locating
pocket is provided by one of a second subset of the plurality of
hinge panels provided by the product support defining structure,
wherein an opening in the bottom panel is provided in respect of at
least some of the hinge panels of the first and/or second subsets
of hinge panels.
15. The product support of claim 14 wherein the product support
defining structure comprises a plurality of cutlines, which, in the
flat configuration of the product support defining structure, each
comprise a first portion defining an edge of one of the first
subset of hinge panels and a second portion defining an edge of one
of the second subset of hinge panels, wherein the second portion,
in the erected product support, defines at least a portion of the
edge of a product locating pocket.
16. The product support of claim 14 wherein the first portion of
the top panel, in the erected product support, comprises an outer
region and a plurality of fingers, each finger extending from the
outer region inward to a top of the second subset of hinge
panels.
17. The product support of claim 1 wherein the product support is
configured such that, when erected, the product support defining
structure defines a plurality of product locating pockets along the
longitudinal direction of the product support.
18. The product support of claim 1 wherein the one or more openings
of the bottom panel comprise a plurality of openings disposed in
one or more clusters, each cluster comprising a plurality of
openings, the openings within each cluster being registered with
portions of the top panel in a respective region of the top
panel.
19. The product support of claim 1 wherein the support is of a
single piece construction, for example wherein the product support
is formed from a single piece blank of sheet material.
20. A method of erecting the product support of claim 1 comprising
for at least some of the one or more openings in the bottom panel
of the or each product support defining structure, inserting a
respective erecting pin of an erecting machine from the underside
of the bottom panel therethrough to contact the portion of the top
panel associated with the opening, and using the pin to assist in
rotating the first portion of the top panel relative to the second
portion of the top panel to erect the product support defining
structure during erection of the product support.
Description
TECHNICAL FIELD
[0001] The present invention relates to a machine erectable product
support, made of cardboard, paperboard or other lightweight
foldable sheet material. The invention also extends to a method of
erecting the product support. The present invention is
particularly, although not exclusively, directed to a product
support which may be inserted into an outer package to locate one
or more products in a desired position relative to an outer package
in use.
BACKGROUND
[0002] It is often necessary to be able to locate certain products
in a desired position within an outer package. For example, this
may particularly important where multiple products are located
within a single package e.g. a multi-pack. It may be necessary to
locate product(s) within the package so as to enable them to be
viewable by a user from the exterior of the package e.g. such that
they are aligned with window(s) in the package. Various types of
product may be presented in this manner, including, but not limited
to, food item(s), such as confectionary, or cosmetic products. One
example of such a package would be a seasonal selection pack.
[0003] Some challenges may be involved in ensuring that product(s)
remain aligned relative to the package after assembly within the
package throughout shipping and until the product(s) are ultimately
removed from the package by a user.
[0004] Previously, products have been located in a desired position
within an outer package using a moulded plastic product support.
However, for environmental reasons, there is a growing need to
provide packaging which is more easily recyclable, and which may
avoid the use of plastic. In other arrangements, products have been
located within a package using a product support formed of
cardboard or paperboard, and integral with the outer package. Such
a product support may automatically erect itself when the outer
package is erected, or may require manual erection. The product is
then loaded into the product support with the product support
already within the outer package. It has been recognised that such
arrangements may not be suitable for high speed, high volume
machine erection.
[0005] The Applicant has realised that there is a need for a
machine erectable product support made of cardboard, paperboard or
other lightweight foldable sheet material.
SUMMARY
[0006] From a first aspect, the present invention provides a
machine erectable product support made from cardboard, paperboard
or other lightweight foldable sheet material comprising: [0007] at
least one product support defining structure comprising: [0008] a
top panel comprising a first portion for providing an upper support
section of the product support defining structure in the erected
product support, and a second portion for providing a lower section
of the product support defining structure in the erected product
support; [0009] a bottom panel for providing a base of the product
support defining structure in the erected product support, wherein
the second portion of the top panel is secured to the bottom panel;
[0010] and a longitudinal side wall panel; [0011] wherein the
product support defining structure defines, in the erected product
support, one or more product locating pockets; [0012] wherein the
top panel comprises cutlines and foldlines defining a plurality of
hinge panels hingedly attaching the first portion of the top panel
to the second portion of the top panel to enable the first portion
to be rotated relative to the second portion to erect the product
support defining structure during erection of the product support;
[0013] wherein each hinge panel is connected at one end about a
foldline to the first portion of the top panel and at the other end
about a foldline to the second portion of the top panel; [0014]
wherein the bottom panel comprises one or more openings, each
opening being registered with a respective portion of the top panel
when the product support defining structure is in a flat
configuration, whereby an erecting pin of an erecting machine may
be inserted from the underside of the bottom panel through the
opening to contact the portion of the top panel to assist in
rotating the first portion of the top panel relative to the second
portion of the top panel to erect the product support defining
structure during erection of the product support.
[0015] From a further aspect, the present invention provides a
method as set forth in claim 20.
[0016] In accordance with the invention, a product support is
provided, which may be readily erected by a machine. The product
support comprises at least one product support defining
structure.
[0017] The product support defining structure defines, in an
erected state of the product support, one or more product locating
pockets, and includes a top panel and a bottom panel. The top panel
includes a first portion which provides an upper support section of
the product support defining structure in the erected product
support and a second portion for providing a lower section of the
product support defining structure in the erected product support.
The top panel defines a plurality of hinge panels hingedly
attaching the first and second portions to one another.
[0018] The erectable product support is converted from an initial
flat configuration to an erected i.e. 3-dimensional configuration
during erection. The erection may take place as part of an overall
process in which the product support is filled with product and
assembled with an outer package.
[0019] Erection of the product support involves converting the or
each product support defining structure thereof from an initial
flat configuration to an erected i.e. 3-dimensional configuration
i.e. erecting the or each product support defining structure.
Erection of the product support may involve other steps e.g. the
erection of other components. In the erected product support, the
or each product support defining structure is erect. In a flat
configuration of the product support, the or each product support
defining structure is in a flat configuration. Where multiple
product support defining structures are provided, each will be
erected during erection of the product support. In the embodiments
illustrated herein, individual product support defining structures
are erected simultaneously. However, it will be appreciated that
this need not be the case provided that ultimately all product
support defining structures present are erected during erection of
the product support. For example, product support defining
structures may be erected sequentially, or in groups, wherein each
product support defining structure in a group is erected
simultaneously, with the groups of product support defining
structures being erected sequentially etc.
[0020] During erection of the product support, the hinge panels
enable the first portion of the top panel to be rotated relative to
the second portion to convert the product support defining
structure from a flat configuration to an erected configuration.
The bottom panel includes one or more openings, each registered
with a respective portion of the top panel. During erection of the
product support, an erecting pin of an erecting machine may be
inserted through the opening to contact the top panel to facilitate
rotation of the first portion relative to the second portion. Thus,
the one or more openings facilitate erection of the product support
defining structure and hence facilitate erection of the product
support. It will be appreciated that the pins need not be used
through the full extent of the rotation of the first portion of the
top panel involved in converting the product support defining
structure from a flat configuration to a final erected
configuration. For example, the pins may only be used over an
initial portion of the rotation of the first portion of the top
panel during erection of the product support defining structure in
some embodiments. Once rotation has commenced, and the hinge panels
have started to hinge about their respective foldlines, it may be
possible to complete the rotation without the assistance of the
pins. The pins may also be used to retain the product support in
its erected configuration during loading of product, for example,
where the sheet material is particularly flexible.
[0021] The product support defining structure includes a
longitudinal side wall panel which provides a longitudinal sidewall
of the erected product support. The longitudinal sidewall panel may
be connected to an outer edge of the top panel and an outer edge of
the bottom panel along respective foldlines. The longitudinal
sidewall panel extends along an outer side edge of the product
support in the erected product support. The longitudinal sidewall
panel may be straight or of another shape e.g. curved or
undulating.
[0022] The erectable product support comprises longitudinal ends
and longitudinal end edges. The longitudinal end edges are
separated by the longitudinal sidewall. The product support also
defines a transverse direction.
[0023] The second portion of the top panel may be secured to the
bottom panel in any suitable manner. The second portion of the top
panel is superposed on e.g. contacts the bottom panel. The second
portion may be attached to the bottom panel over at least a portion
of an area in which the top panel is superposed e.g. contacts the
bottom panel. The at least a portion of the area may be a single
region of attachment or may comprise a plurality of discrete
regions of attachment. The second portion of the top panel may be
attached to the bottom panel intermittently or continuously within
the or each region of attachment. For example, where an adhesive
attachment is used, adhesive may be provided using an intermittent
or continuous pattern within the or each region of attachment.
Thus, it will be appreciated that adhesive may be applied in any
suitable location(s) in order to provide a secure attachment
between the second portion of the top panel and the bottom panel.
Other forms of attachment may be used e.g. heat sealing. For
example, this may be achieved using a heat seal varnish or other
coating applied to surfaces of one or both of the top panel and
bottom panel.
[0024] The second portion of the top panel provides a lower section
of the product support defining structure in the erected product
support. The lower section is a lower section relative to the upper
section defined by the top panel which provides an upper support
section of the product support defining structure in the erected
product support. Thus the lower section may be seen as recessed
relative to the upper portion when the erected product support is
viewed from above. The lower section defines at least a part of the
interior of the product support.
[0025] The second portion of the top panel may be of any suitable
configuration. The second portion may extend into the or each
product locating pocket e.g. to form a bottom thereof. The second
portion may be continuous or discontinuous. The second portion
preferably comprises a section extending continuously in the
longitudinal direction of the product support e.g. a continuous
longitudinal strip. The section preferably extends to an inner edge
of the top panel. The section may be located adjacent the inner
edge of the top panel. In embodiments the section may be in the
form of a continuous longitudinal strip located adjacent, and
extending to, the inner edge of the top panel. This may facilitate
securing of the second portion to the bottom panel.
[0026] The cutlines and foldlines provided in the top panel may be
provided in any suitable configuration, depending upon the number,
configuration and arrangement of product(s) to be supported, and
hence the number, configuration and arrangement of product locating
pockets to be provided by the product support defining structure.
For example, a cutline may be curved, straight, or may include both
curved and straight sections. Combinations of different
configurations of cutline may be used in the plurality of cutlines.
Additional cutlines and/or foldlines may be present in the product
support and/or in a portion thereof providing the product support
defining structure.
[0027] In preferred embodiments the cutlines defining the plurality
of hinge panels comprise a plurality of cutlines, each defining an
edge of one or more of the hinge panels i.e. in both the flat and
erected configurations of the product support. A cutline may define
an edge of one or two of the hinge panels. Each edge extends
between the respective ends of the hinge panel i.e. the ends
connected by foldlines to the first and second portions of the top
panel respectively. In the erected product support, at least some,
and optionally each of the plurality of cutlines may also each
define an edge of a product locating pocket of the product support
defining structure. As discussed in more detail below, different
cutlines may define the edges of the same or different product
locating pockets where multiple pockets are provided. It will be
appreciated that the product support may or may not comprise
additional cutlines which do not define an edge of one or more of
the hinge panels and/or an edge of one or more of the product
locating pockets of a product support defining structure
thereof.
[0028] During erection of the product support, each hinge panel
hinges about the foldline connecting the hinge panel to the first
portion of the top panel to enable the first portion of the product
support defining structure to be rotated relative to the second
portion. Each hinge panel may hinge about the foldline connecting
the hinge panel to the first portion of the top panel into a
position in which the hinge panel is upstanding from the second
portion of the top panel. The sidewall panel may hinge about a
foldline connecting the sidewall panel to the bottom panel into a
position in which it is upstanding from the bottom panel. By
"upstanding" it is not required that a hinge panel necessarily is
perpendicular to the second portion. In the erected product
support, at least some of the hinge panels may be inclined. For
example, depending upon the desired appearance of the product
support and/or the type of product to be located, it may be
desirable for at least some of the walls of the pockets to be
inclined. Thus, a hinge panel forming a wall of a pocket may be
inclined in some embodiments.
[0029] During erection, the first portion of the product support
defining structure is rotated relative to the second portion to a
position in which it is located above the second portion. The hinge
panels may assist in maintaining the first portion located spaced
above the second portion in the erected product support. The first
portion may be rotated relative to the second portion from a first
position in which the first and second portions are substantially
co-planar i.e. in a flat configuration of the product support
defining structure (or product support) to a second position in
which the first portion is located above the second portion.
[0030] In embodiments in which a cutline additionally defines an
edge of one of the one or more product locating pockets, the edge
of the product locating pocket defined by the cutline may be of any
desired and suitable shape. For example, the edge may be straight
or curved. This may depend upon the configuration of the product to
be located. The shape of the edge of the product locating pocket
portion may correspond to a shape of an edge of a product with
which the product support is to be used. It will be appreciated
that, when product(s) are inserted in the product support, at least
at times, a product need not necessarily contact the edge of the
product locating pocket, or at least not along the entire length of
the edge of the product locating pocket e.g. if a straight edged
product is used with a curved product locating pocket edge, and/or,
where a pocket has inclined walls, depending upon a depth to which
a product is inserted in the product locating pocket etc. The
product locating pocket edge will still provide a stop to limit the
movement of the product relative to the product support and hence
act to locate the product.
[0031] In embodiments, the or each product locating pocket edge
forms part of an inner edge of the first portion of the top panel
which provides the upper support section of the product support
defining structure in the erected product support. Each hingeline
connecting a hinge panel to the first portion of the top panel may
also form part of the inner edge of the first portion of the top
panel. In embodiments the inner edge may consist of each product
locating pocket edge and the foldlines connecting the hinge panels
to the first portion of the top panel.
[0032] The bottom panel comprises one or more openings, each being
registered with a respective portion of the top panel when the
product support defining structure is in a flat configuration. Each
opening enables an erecting pin of an erecting machine to be
inserted from the underside of the bottom panel through the opening
to contact the portion of the top panel associated with the
opening.
[0033] It will be appreciated that the opening(s) may be of any
suitable shape or configuration, e.g. depending upon the portion of
the top panel to be engaged e.g. where this is a hinge panel, the
shape of the hinge panel, the number and arrangement of openings
provided, and/or the shape and configuration of the erecting pins
to be used.
[0034] The or each opening may be registered with any desired part
of the top panel to assist in rotation of the first portion thereof
relative to the second portion to erect the product support
defining structure during erection of the product support. By
"registered" with, it is meant that the opening is sufficiently
aligned with and underlies the portion of the top panel at least
when the product support in in a flat configuration to enable a pin
to be inserted through the opening from the underside of the bottom
panel to contact the portion and assist in rotation of the portion.
The opening will be registered with the portion of the top panel to
enable a pin inserted therethrough to contact the portion during at
least a part of the rotation of the portion involved in erecting
the product support defining structure, although may not be
registered with i.e. underlie the portion in the final erected
product support. For example, in embodiments described below in
which the portion is a hinge panel, the opening may no longer be
aligned with the hinge panel such that a pin extended therethrough
would contact the hinge panel, when the product support defining
structure is in the final erected state.
[0035] In preferred embodiments, a plurality of the openings is
provided. The openings may be regularly spaced. For example one or
more openings may be provided associated with each product locating
pocket, or with alternate pockets etc. In some embodiments, the
openings may comprise a plurality of openings disposed in one or
more clusters, each cluster comprising a plurality of openings, the
openings in the cluster being registered with portions of the top
panel in a respective region of the top panel. For example, a
plurality of such clusters may be provided, spaced along a
longitudinal direction of the bottom panel with the openings in the
respective clusters being registered with respective regions of the
top panel spaced along the longitudinal direction thereof. The most
appropriate arrangement of the openings (for example, in
embodiments, the number of openings in each cluster, and the number
and spacing of the clusters) may be selected as desired to provide
a suitable degree of assistance in erecting the product support
defining structure e.g. depending upon factors such as the position
of the pocket(s) of the product support defining structure e.g. the
relative dimension and/or spacing thereof, where applicable, the
sheet material used etc.
[0036] The or each portion of the top panel with which a respective
opening is registered may be any suitable and desired such portion.
The portion may be a hinge panel or a portion of the first portion
of the top panel. In embodiments, one or more openings is provided,
each being registered with a portion of the top panel, wherein at
least one opening is provided registered with a respective hinge
panel of the top panel and/or at least one opening is provided
registered with a portion of the first portion of the top panel.
Preferably a plurality of openings is provided in the or each such
location, each being registered with a respective portion of the
first portion of the top panel.
[0037] In some preferred embodiments the one or more openings of
the bottom panel comprise one or more openings (and preferably a
plurality thereof), each being registered with a respective one of
one of the hinge panels when the product support defining structure
is in a flat configuration, whereby an erecting pin of an erecting
machine may be inserted from the underside of the bottom panel
through the opening to contact the hinge panel to rotate the hinge
panel about the foldline connecting the hinge panel to the first
portion of the top panel to assist in rotating the first portion of
the top panel relative to the second portion of the top panel to
erect the product support defining structure during erection of the
product support. In these embodiments, additional openings may or
may not be provided associated with other portions of the top
panel.
[0038] In these embodiments it is not necessary that an opening
corresponds exactly in shape and size to the associated hinge panel
provided that it is sufficiently registered with the hinge panel to
allow contact to be made with the hinge panel, and to allow a
suitable configured erecting pin to extend through the opening to
rotate the hinge panel during at least a portion of the rotation of
the hinge panel involved in erection of the product support
defining structure.
[0039] In these embodiments the bottom panel may comprise an
opening in respect of each hinge panel, or in respect of only some
of the hinge panels. Preferably, whether or not an opening is
provided in respect of each hinge panel, the bottom panel comprises
a plurality of openings, each registered with a respective one of
the hinge panels. The openings in respect of different hinge panels
may be of the same or differing shapes and sizes. For example,
where the hinge panels vary in shape and size, the openings may
similarly vary in shape and size e.g. to approximately correspond
to the shape and size of the hinge panels.
[0040] Wherever the openings are provided, e.g. whether associated
with hinge panel(s) and/or the first portion of the top panel,
where multiple openings are provided, the openings may be
associated respective ones of the one or more pockets of the
product support, or otherwise. For example, openings may be
associated with hinge panels separating the pockets and/or defining
walls thereof, and/or may be associated with the first portion of
the top panel in a manner not specifically associated with
individual pocket(s) e.g. at the longitudinal ends thereof. Where
openings are provided associated with respective ones of the
pockets, they need not be provided associated with each pocket
present.
[0041] In any of the embodiments of the invention, an opening may
be completely surrounded by the material of the bottom panel i.e.
such that the bottom panel extends around the entire perimeter of
the opening. However, this need not be the case. For example, for
an opening located at a longitudinal end edge of the bottom panel,
the bottom panel may extend around only a portion of the perimeter
of the opening, with the opening being in the form of a notch in
the longitudinal end edge of the bottom panel.
[0042] In embodiments the product support is configured such that,
when erected, the product support defining structure defines one or
more product locating pockets along the longitudinal direction of
the product support. In embodiments in which the cutlines comprise
a plurality of cutlines, wherein each cutline of the plurality of
cutlines defines an edge of one or more of the hinge panels and
also defines an edge of a product locating pocket of the product
support defining structure, each product locating pocket may be
defined between adjacent ones of the plurality of hinge panels and
may include product locating pocket edges (i.e. first and second
product locating pocket edges) defined by the cutlines (i.e. first
and second cutlines) which define the edges of the hinge panels on
either side of the product locating pocket between which the
product locating pocket is defined.
[0043] Thus, in embodiments the support is configured such that,
when erected, the product support defining structure defines one or
more product locating pockets along the longitudinal direction of
the product support, each product locating pocket being defined
between adjacent ones of the plurality of hinge panels, and
including product locating pocket edges defined by cutlines of the
product support defining structure, which cutlines define the edges
of the hinge panels on either side of the product locating pocket
between which hinge panels the product locating pocket is
defined.
[0044] It will be appreciated that a pocket may be located with any
desired and suitable orientation, and may be of any desired size
and shape. Each product locating pocket may extend generally in a
transverse direction.
[0045] For each product locating pocket, one edge of each of the
(adjacent) hinge panels between which the product locating pocket
is defined, may be defined by one of the cutlines of the product
support defining structure. In embodiments the opposed edge of the
hinge panel may be defined by another one of the cutlines, or by a
(longitudinal) end edge of the top panel. For example, if the hinge
panel is located at an end of the product support, such that there
is a product locating pocket on only one side thereof, the edge of
the hinge panel on the opposite side thereof may be provided by an
end edge of the top panel. However, other arrangements may be
envisaged.
[0046] The or each product locating pocket may comprise a sidewall,
the sidewall being provided by one of the hinge panels. The
sidewall thus connects the first and second sections of the top
panel. The sidewall may be a longitudinal sidewall. Such a sidewall
may inhibit transverse movement of a product located in the pocket.
A longitudinal sidewall may extend generally in the longitudinal
direction of the product support, and may extend parallel to the
longitudinal sidewall of the product support defining structure, or
at any desired and suitable angle thereto. A given pocket may
comprise one or more sidewall provided by a hinge panel, and, in
some embodiments, includes only one such sidewall e.g. a
longitudinal sidewall. The most suitable sidewall configuration for
a pocket will depend upon factors such as; the type of product, the
desired arrangement of the product relative to the support, and the
depth at which the product is to be held etc. For example, an
inclined sidewall (whether or not a longitudinal sidewall) may be
used to control the point at which the bottom of a product will
contact the sidewall, and hence the depth at which the product will
be held within the pocket. It is envisaged that where multiple
products of differing configurations are to be held by the product
support, angling of the sidewalls of the pockets may enable
products of differing dimensions to be held at differing depths
within the pockets, so that the top surfaces of the products all
lie in the same level.
[0047] The one or more product locating pockets may be defined
between hinge panels of a set of one or more of the plurality of
hinge panels provided by the product support defining structure.
Thus, the set of the plurality of hinge panels may separate
adjacent product locating pockets from one another or separate end
pockets from an end of the product support. A product locating
pocket will be defined between (longitudinally) adjacent ones of
the hinge panels. Any given one of the set of hinge panels may
define a side of a product locating pocket on one or both sides
thereof, depending upon the number of pockets present. These hinge
panels may be referred to as "pocket defining hinge panels". This
set of hinge panels may be referred to as a "first" set to
distinguish them from any further set of hinge panels present. The
set of hinge panels may comprise a plurality of hinge panels. In
some embodiments, an opening in the bottom panel may be provided in
respect of at least some (i.e. one or more or a plurality of), and
optionally each hinge panel of this set of hinge panels. This set
of hinge panels may extend longitudinally along the product support
e.g. in a row. The foldlines connecting the hinge panels of this
set to the second portion of the top panel may optionally be
laterally aligned with one another. The hinge panels of this set
may, in the erected product support, optionally be laterally
aligned with one another.
[0048] Unless the context demands otherwise herein, a reference to
at least "some" of a set of objects e.g. openings encompasses one
or more or a plurality i.e. a single one, or a plurality of the
specified objects e.g. openings.
[0049] In embodiments in which the or each product locating pocket
comprises a (or one or more) sidewall, the (or each) sidewall of
each product locating pocket may be provided by one of a set of one
or more of the plurality of hinge panels. This set of hinge panels
may be referred to as a "second" set to distinguish them from any
further set of hinge panels present. The hinge panels of this set
may be referred to as "sidewall defining hinge panels". The set may
comprise a plurality of the hinge panels. An opening in the bottom
panel may be provided in respect of at least some, and optionally
each hinge panel of this set of hinge panels. The hinge panels of
this set may extend longitudinally along the product support e.g.
in a row. The foldlines connecting the hinge panels of this set to
the second portion of the top panel may optionally be laterally
offset relative to one another. The hinge panels of this set may
optionally, in the erected product support, be laterally offset
with respect to one another. This may enable products of differing
length to be accommodated. However, in other embodiments the
foldlines and hinge panels may be laterally aligned with each
other.
[0050] The first (pocket defining) or second (sidewall defining)
sets of hinge panels may, in embodiments, each be a subset of the
plurality of hinge panels provided by the product support defining
structure. There may or may not be additional hinge panels present
in the product support defining structure.
[0051] The bottom panel may comprise first and second rows of
openings, wherein the openings of the first row are associated with
the hinge panels of the first subset of hinge panels, and the
second row of openings is associated with the hinge panels of the
second subset of hinge panels.
[0052] Where first (pocket defining) and second (sidewall defining)
sets of hinge panels are provided, the first set of hinge panels
may be located inboard of the second set of hinge panels. Inboard
may refer to the hinge panels being located further from the edge
of the product support defined by the longitudinal side wall
panel.
[0053] In embodiments the one or more product locating pockets are
defined between hinge panels of a first subset of the plurality of
hinge panels provided by the product support defining structure,
and each product locating pocket comprises a sidewall provided by
one of a second subset of the plurality of hinge panels provided by
the products support defining structure. The first and second
subsets may thus be referred to as pocket defining and sidewall
defining subsets of hinge panels respectively. An opening in the
bottom panel may be provided in respect of at least some, or each
hinge panel of the first and/or second subsets of hinge panels.
[0054] The product support may be configured such that in the flat
(i.e. the flat configuration of the product support), the cutlines
of the product support includes a plurality of cutlines each
comprising a first portion defining an edge of one of the first
subset of hinge panels and a second portion defining an edge of one
of the second subset of hinge panels, wherein the second portion,
in the erected product support, defines at least a portion of the
edge of a product locating pocket. The first and second portions
define edges respectively of ones of the first and second subsets
of hinge panels associated with the product locating pocket having
an edge defined by the second portion. The cutline may include a
further portion providing a further portion of the edge of the
product locating pocket.
[0055] It will be appreciated that where both the first and second
subsets of the hinge panels are present, an opening in the bottom
panel may be provided in respect of one or more, (e.g. one or more
or a plurality of), or each hinge panel of either or both of the
first and second subsets of hinge panels. Depending upon the
configuration of the product support, strength of materials, type
of machine used etc., it may not be necessary to provide opening(s)
in respect of both subsets of hinge panels in order to facilitate
erection of the product support. Preferably an opening in the
bottom panel is provided at least in respect of at least some (e.g.
one or more or a plurality of) or each hinge panel of the second
subset of hinge panels. It will also be appreciated that is not
necessary for an opening to be provided in respect of each hinge
panel of the first or second subset of hinge panels, provided that
a sufficient number is provided to facilitate machine erection.
This may depend upon the configuration of the product support,
strength of materials, type of machine used etc.
[0056] It will be appreciated that the number and location of
openings provided associated with hinge panels of either of the
first or second subsets of hinge panels may vary, and may be
selected e.g. based upon the degree of assistance required during
erection of the support, the type of material used, the relative
positions and sizes of the pockets etc. Of course, even where hinge
panels corresponding to the first and/or second subsets of hinge
panels are present, it is not necessary that any opening is
provided registered with a hinge panel, and the opening(s) may
instead be registered with portion(s) of the first portion of the
top panel.
[0057] In some embodiments, an opening in the bottom panel is
provided in respect of each hinge panel of the plurality of hinge
panels of the product support defining structure.
[0058] Where openings are provided associated with at least some of
the first and/or second subsets of hinge panels, additional
opening(s) may or may not be provided registered with other
portion(s) of the top panel e.g. the first portion thereof.
[0059] In any of the embodiments of the invention, the first
portion of the top panel may, in the erected product support,
define a continuous longitudinal strip. Where the one or more
openings of the bottom panel comprises one or more openings
registered with the first portion of the top panel, the one or more
openings may include one or more openings registered with
respective portions of such a strip defined by the first portion of
the top panel. The openings may be disposed in clusters registered
with regions e.g. at each end of the strip and/or at locations
therebetween.
[0060] The respective foldline connecting each one of the set of
pocket defining hinge panels to the first portion of the top panel
may connect the hinge panel to a finger defined by the first
portion of the top panel.
[0061] The first portion of the top panel may, in the erected
product support, comprise an outer region and a plurality of
fingers, each finger extending from the outer region inward to a
top of a one of the pocket defining hinge panels i.e. one of the
second subset of hinge panels. The fingers may separate adjacent
pockets where multiple pockets are provided, or separate an end
pocket from an end edge of the product support. Each finger may be
defined between cutlines associated with the pockets on either side
thereof where present, or between a pocket and an end of the
product support.
[0062] In embodiments in which the first portion of the top panel
comprises an outer region and a plurality of fingers in the erected
product support, where the one or more openings of the bottom panel
comprises one or more openings registered with the first portion of
the top panel, the one or more openings may include one or more
openings registered with the outer region of the top panel. The
outer region may comprise a continuous longitudinal strip as
previously described.
[0063] In embodiments, where the second portion of the top panel
comprises a continuous longitudinal strip located adjacent, and
extending to, an inner edge of the top panel, the strip may be
located between the foldlines connecting the pocket defining hinge
panels to the second portion of the top panel and the inner edge of
the top panel, or, in the erected product support, between the
bottom of the or each pocket defining hinge panel and the inner
edge of the top panel. The strip may be located inboard of each of
the pocket defining hinge panels, and indeed, inboard of any hinge
panel of the product support defining structure.
[0064] In accordance with any of the embodiments, for each pocket,
there may be two cutlines defining an edge thereof. The edges
defined in this way may be separated by a foldline connecting a
hinge panel providing a sidewall of the pocket to the first portion
of the top panel.
[0065] Where multiple pockets are provided, the pockets may be of
regular or irregular size and shape. This may depend upon the
configuration of the products to be located therein. The side edge
of different pockets may be of the same or different lengths.
[0066] The product support defining structure may include
additional components. Furthermore, the pockets need not be
configured in the exemplary manners described above.
[0067] In some embodiments the cutlines in the top panel may
define, for one or more of the one or more product locating pockets
defined by the product support defining structure, one or more
panels, or optionally a net, for supporting the base of a product
inserted in the pocket. Such structure may be provided in addition
to other pocket defining structure described herein.
[0068] Preferably the product support is configured such that, when
erected, the product support defining structure defines a plurality
of product locating pockets along the longitudinal direction of the
product support.
[0069] The product support may comprise one or more of the product
support defining structures. In preferred embodiments, a pair of
the product support defining structures are provided, one on each
longitudinal side thereof. For example, they may be provided on
opposite sides of a longitudinal centreline of the product support.
However, such an arrangement is only exemplary, and multiple
product support defining structures may be arranged in any desired
manner e.g. end to end, offset or aligned with one another etc.
[0070] Where multiple product support defining structures, they may
be of the same or different construction, and each may include any
or all of the features described herein. The product support
defining structures may be described as first and second such
structures having first and second ones of any of the features
described herein. In some embodiments, a pair of product support
defining structures are provided which are mirror images of one
another about a longitudinal centreline.
[0071] The or each product locating pocket defined by the product
support defining structure on one side of the product support may
be (longitudinally) aligned with a corresponding product locating
pocket of the product support defining structure on the other side
of the product support for supporting opposed ends or sides of a
product extending (transversely) therebetween. However, such
arrangements are merely exemplary.
[0072] Where multiple product support defining structures are
provided, they may share components. For example, they may have a
common bottom panel. The bottom panel may then provide a base of
the product support. Where a product supporting structure e.g. net
or one or more panels is provided, such structure may extend across
the pockets associated with different product support defining
structures e.g. for supporting opposed ends or sides of a
product.
[0073] The product support may be of a single piece construction.
The erectable product support may be formed from a blank of sheet
material, preferably a single piece blank.
[0074] In embodiments the (first) product support defining
structure of the erectable product support is formed by folding a
blank having first, second and third panels, the third panel being
located between the first and second panels, wherein the first
panel is folded over and secured to the second panel, and wherein
the first panel provides the top panel, the second panel provides
the bottom panel and the third panel provides the longitudinal
sidewall panel of the product support defining structure in the
erectable product support.
[0075] Where the erectable product support comprises a further
product support defining structure, the blank may further comprise
fourth and fifth panels, the fourth panel being located between the
second and fifth panels, wherein the fifth panel is folded over and
secured to the second panel, and wherein the fifth panel provides
the top panel, the second panel provides the bottom panel and the
fourth panel provides the longitudinal sidewall panel of the
further product support defining structure in the erectable product
support. Thus first and second portions of the second panel may
provide the bottom panel of each of the product support defining
structures.
[0076] The second panel may provide a center portion of the blank
with the first and third, and fourth and fifth panels being side
portions of the blank.
[0077] However, it is not a requirement that the product support is
of a single piece construction. For example, the product support
could be formed from two pieces joined together e.g. one providing
the top panel, and one providing the bottom panel (with the
sidewall also being provided with one of the pieces). A seam
between multiple pieces may be located in any position.
Furthermore, where a single piece construction is used, with side
portions of a blank being folded over a centre portion, the side
portions need not be joined to the center portion such that their
side edges are on either side of, or coincident with a longitudinal
centerline thereof, but could be joined thereto along any line,
e.g. offset from a central longitudinal axis, or at differing
distances from the longitudinal axis. An asymmetric arrangement may
be used.
[0078] The present invention extends to a method of erecting the
product support in accordance with any of the embodiments
described.
[0079] The method comprises, for at least some, (and preferably the
or each) of the one or more openings in the bottom panel of the or
each product support defining structure, inserting a respective
erecting pin of an erecting machine from the underside of the
bottom panel therethrough to contact the portion of the top panel
associated with the opening, and using the pin to assist in
rotating the first portion of the top panel relative to the second
portion of the top panel to erect the product support defining
structure during erection of the product support. Where the portion
of the top panel is a hinge panel, the pin may rotate the hinge
panel associated with the opening about the foldline connecting the
hinge panel to the first portion of the top panel to assist in
rotating of the first portion of the top panel relative to the
second portion thereof to erect the product support defining
structure during erection of the product support.
[0080] One pin is used in respect of each opening of the bottom
panel used in the erection process. It is envisaged that only some,
but preferably all of the openings present in the bottom panel are
used in the erection process i.e. a pin is inserted
therethrough.
[0081] The pin(s) may be used during rotation of the first portion
(and, in embodiments hinge panel) over the full extent of rotation
involved in erecting the product support defining structure or only
over a portion e.g. an initial portion thereof. The pins are
preferably simultaneously inserted through each opening used (and
preferably each opening in the bottom panel of the or each product
support defining structure).
[0082] The pin(s) may be mounted on a forming element so as to be
upstanding therefrom. The pins may be mounted in a pattern
corresponding to the positions of the openings of a product support
with which they are to cooperate. For example, an array of pins may
be provided, including first and second rows of pins for
cooperating with first and second rows of the openings in the
bottom panel. The first and second rows of openings may be
associated with the first and second subsets of hinge panels, for a
given product support defining structure, in embodiments.
[0083] The step of inserting the pins through the openings may
comprise pressing the erectable product support onto a (or the
above mentioned) forming element having upstanding pins mounted
thereon. The pressing may be achieved in any suitable manner. In
embodiments the pressing is performed using a tool including one or
more portions for insertion into respective ones of the one or more
product locating pockets defined by the product support.
[0084] In embodiments the or each erection pin is a tapered pin.
The pin tapers toward its top. A tapered pin may define at least
one axially extending inclined surface. The pin may define such a
surface on one or more e.g. two opposed sides thereof. This may
facilitate insertion of the pin through an aperture. The pin may be
relatively easily inserted before more closely engaging a sidewall
of the aperture on one or both sides thereof. This may provide a
camming type action. The inclined surface(s) may ensure that the
pin continues to contact the portion of the top panel as the top
panel starts to rotate.
[0085] The method may further comprise locating one or more product
in the product support once erected. The product may be of any type
e.g. confectionary, cosmetics etc. Where more than one product is
inserted, the products may be of the same or different types and/or
configurations. The or each product may be located such that an end
or side of each respective product is located in a respective one
of the pockets of the product support defining structure. Where a
pair of product support defining structures are provided, the or
each product may extend between opposed pockets of the product
support defining structures, with opposed ends of the product
located in each of the pockets. Such arrangements are, however,
merely exemplary.
[0086] The method may further comprise supporting the erected
product support on the erection pin(s) during loading of the
product.
[0087] The method may further comprise inserting the loaded product
support into an outer package. Thus, the support is loaded with
product before being inserted in the package in contrast to
previous arrangements in which a support, integral with a package,
was erected at the same time as the package was erected, and then
loaded with product in situ. The present invention may facilitate
loading of product.
[0088] The product support may, for example, may be inserted into
the top end of an outer package.
[0089] The present invention extends to an erected product support
in accordance with any of the aspects or embodiments of the
invention having one or more products located therein, and/or
inserted in an outer package. Thus the invention extends to an
outer package having the product support, of any of the aspects or
embodiments of the invention described herein, inserted
therein.
[0090] References to an opening in the bottom panel being provided
in respect of a portion of the top panel e.g. hinge panel refer to
there being an opening registered with the respective portion of
the top panel e.g. hinge panel.
[0091] References herein to a longitudinal sidewall or direction of
the product support or product support defining structure should
not be construed as requiring the support or structure to be
elongate, although, in embodiments, the longitudinal direction
corresponds to a longer dimension of the support or structure.
[0092] References to top or upper, or bottom or lower, should not
be construed as providing any limitation regarding the intended
orientation of the product support or structure in use i.e. when
located in an outer package, although typically the top or upper
side will be the top or upper side when a product is loaded and the
support or structure inserted in an outer package in use.
[0093] The product support is made from a foldable sheet material
such as paperboard or cardboard, or even a plastics material. The
material may be chosen as desired. The arrangements described
herein may facilitate erection of a product support formed from a
lightweight foldable plastics material, avoiding the need to use
plastics forming tools. However, in some embodiments, the foldable
sheet material is preferably a non-plastics material. This may
provide a more environmentally friendly support.
[0094] A fold line as referred to herein refers to any line about
which components have been folded. The fold line may comprise a
line of weakness, crease line and/or perforations. If not
explicitly stated, and unless inconsistent therewith, any
connection described herein may be about a fold line.
[0095] The present invention in accordance with any of its further
aspects or embodiments may include any of the features described in
reference to other aspects or embodiments of the invention to the
extent it is not mutually inconsistent therewith.
[0096] Features of embodiments of the invention are set forth in
the dependent claims.
BRIEF DESCRIPTION OF DRAWINGS
[0097] Some preferred embodiments of the invention will now be
described by way of example only with reference to the accompanying
drawings, in which:
[0098] FIG. 1 illustrates an erected product support in accordance
with a first embodiment of the invention;
[0099] FIG. 2 illustrates a blank for providing an erectable
product support for providing the erected product support of FIG.
1;
[0100] FIG. 3 illustrates the erectable product support of FIG. 1
during erection;
[0101] FIG. 4 illustrates the product support of FIG. 1 from the
underside indicating the direction of movement of pins during
erection;
[0102] FIG. 5 illustrates an erected product support in accordance
with a second embodiment of the invention;
[0103] FIG. 6 illustrates a blank for providing an erectable
product support for providing the erected product support of FIG.
5;
[0104] FIG. 7 illustrates the product support of FIG. 5 from the
underside indicating the direction of movement of pins during
erection;
[0105] FIG. 8 illustrates the product support of FIG. 1 with
product loaded therein;
[0106] FIG. 9 illustrates the product support of FIG. 5 with
product located therein;
[0107] FIG. 10 schematically illustrates a process for erecting the
product support of FIG. 1;
[0108] FIG. 11 is a cross sectional view illustrating the
cooperation between the forming pins, the upper tool and the
support;
[0109] and FIG. 12 illustrates an alternative arrangement of the
openings in the bottom panel which may be used in embodiments of
the invention.
DETAILED DESCRIPTION
[0110] Some preferred embodiments of the invention will now be
described by way of example only.
[0111] With reference to FIGS. 1-5, a first embodiment of an
erectable product support in accordance with the invention will be
described.
[0112] FIG. 1 shows the erected product support 1. The product
support 1 is made from a foldable sheet material such as paperboard
or cardboard.
[0113] The product support is erected from a flat configuration.
FIG. 2 illustrates a blank for providing the flat erectable product
support and FIG. 3 illustrates the erectable product support once
assembled from the blank. FIG. 3 illustrates the erectable product
support in a configuration between its initial flat state and the
erected state in order to facilitate understanding of certain
features of the invention.
[0114] The product support 1 includes a first product support
defining structure 3 on one longitudinal side thereof, and a second
product support defining structure 3' on the other longitudinal
side thereof. In the illustrated embodiment the product support
defining structures 3, 3' are mirror images of one another about
the longitudinal centreline of the product support 1. However, it
will be appreciated that this need not be the case. Erecting the
product support involves erecting each of the product support
defining structures.
[0115] The features of the product support defining structure 3
will now be described. The product support defining structure 3' is
of identical construction. The corresponding features of the
product support defining structure 3' will be denoted using the
same reference numerals as those of the structure 3, annotated by a
"'" sign. Not all features are labelled in respect of both
structures, and some features are not visible in both structures as
shown in FIG. 1.
[0116] The product support defining structure 3 has a top panel 5
and a bottom panel 7 and a sidewall 9. In this embodiment the
bottom panel 7 is shared by the product support defining structures
3, 3'. The bottom panel 7 provides a base of the product
support.
[0117] The top panel 5 includes a first portion 6 defining an upper
support section of the product support and a second portion 8
providing a lower section of the product support. The second
portion of the top panel includes a continuous longitudinal strip
10 extending to an inner edge 12 of the top panel. The strip 10 is
shown as a hatched area for ease of illustration. This strip is
merely a notional part of the second portion.
[0118] The second portion of the top panel is adhesively secured to
the bottom panel 7. This is facilitated by the longitudinal strip
10. Any suitable adhesive pattern may be used, and the adhesive
need not extend over the entire area over which the second portion
extends. Other attachment mechanisms e.g. heat sealing may
alternatively be used.
[0119] The product support defining structure 3 defines a plurality
of product locating pockets 11 along the longitudinal direction
thereof. The pockets 11' of the product support defining structure
3' are aligned with those of the product support defining structure
3 for locating the opposed ends of a product extending transversely
therebetween. In this embodiment the second portion extends into
the base of each pocket 11.
[0120] It will be appreciated that the second portion of the top
panel need not be continuous along the length of the product
support as shown, and need not extend into the pockets. For
example, the second portion might be defined by tabs extending from
the base of each of the flaps 13, and may be absent in other areas
e.g. between the pockets and/or within the pockets.
[0121] A first subset of upstanding hinge panels 13 connect the
first portion 6 of the top panel to the second portion 8 of the top
panel 5. For ease of illustration, certain features will be
labelled only in relation to one of the hinge panels 13. Each hinge
panel 13 is connected at its top by a foldline 15 to the first
portion of the top panel and is connected at the bottom about a
foldline 17 to the second portion of the top panel. The pockets 11
are defined between side edges 19 of adjacent ones of the hinge
panels 13. Each hinge panel 13 is located at the end of a finger 23
extending from an outboard region of the first region 9 of the top
panel. The opposed edges of the fingers 23 provide side edges 35 of
the pockets 11.
[0122] A second subset of upstanding hinge panels 25 provide
(longitudinal) sidewalls for the pockets 11. Each of the hinge
panels 25 is connected along respective hingelines 27, 29 at the
top and bottom thereof to the first portion and the second portion
of the product support. An opening 31 is defined extending between
the sidewall provided by hinge panel 25 and the hinge panel 13 on
each side of a pocket.
[0123] The bottom panel includes an opening (not visible in FIG. 1)
associated with each hinge panel 13, which extends toward the outer
edge of the product support from the foldline 17 at the base of the
hinge panel 13. This is used in the erection of the product support
as described below. This opening underlies the finger 23 in the
erected product support.
[0124] While the hinge panels 25 are shown as perpendicular to the
base of the product support, this need not be the case. For
example, inclined hinge panels may provide inclined sidewalls for
the pockets. The sidewalls may be inclined so as to reduce the
length of the pocket (i.e. in the transverse direction of the
product support) with increasing depth. This may result in products
being support midway between the top and the bottom of the pocket,
depending upon the dimensions of the product. Such arrangements
could be used to enable products of differing dimensions to be
supported at differing depths, so that the tops of all products
were level.
[0125] The blank for providing the product support 1 will now be
described by reference to FIG. 2.
[0126] The blank includes a first panel 42 which provides the
bottom panel 7 of the erectable product support, a second panel 44
for providing the sidewall 9 and a third panel 46 for providing the
top panel 5 of the first product support defining structure 3.
Corresponding panels 44' and 46' are provided for the second
product support defining structure 3', with the bottom panel
provided by panel 42 being shared. The panels are connected to one
another along foldlines.
[0127] The panel 42 includes rows of openings 50, 50'.
[0128] The panel 46 includes a plurality of cutlines 52. A first
portion 53 of each cutline will define a side edge 19 of one of the
hinge panels 13. A second portion 54 of the cutline will define a
side edge 35 of one of the pockets 11. The first and second portion
53, 54 are defined on either side of the foldline 70.
[0129] The panel 46 also includes foldlines 59, 58. These foldlines
provide the foldlines 29, 27 at the bottom and top of the hinge
panels 25 respectively. Thus, the panels 60 between the foldlines
59, 58 will provide the hinge panels 25 corresponding to side walls
of the pockets.
[0130] At least a part of the second portion 54 also defines the
side edge of one of the hinge panels 60 which provide a side wall
25 of a pocket 11. For some of the deeper pockets, a longer cutline
is used, such that the second portion 54 may be subdivided into a
portion 55 which defines an edge of a hinge panel 60 and a
connecting portion 57 extending between the portion 55 and the
first portion 53.
[0131] The panel 46 also includes foldlines 70, 72 between which
panels 74 are defined. The foldlines 70, 72 provide the foldlines
15, 17 at the top and bottom of the hinge panels 19 of the product
support, which are provided by the panels 74.
[0132] It will be appreciated that the configuration and number of
foldlines and cutlines may vary depending upon the number and
configuration of pockets to be provided in the product support.
[0133] Panel 46' includes corresponding cutlines and foldlines.
[0134] In order to assemble the erectable product support, the
panel 46 is folded about foldline 82 over the panel 44 and the
panel 42 in the direction of the arrow. A longitudinal strip 84 at
the outboard edge of the panel 46 is adhesively attached to the
panel 42 inboard of the row of openings 50, between the openings
and a centreline of the blank 40. The strip 84 provides the strip
10 in the product support. Regions 86 of panel 46 which define a
base of the pockets in the product support may also be adhesively
attached to the panel 42.
[0135] The regions which are superposed on and secured to the panel
42, and which will provide the second portion 8 of the top panel 7
in the product support, are indicated with hashed lines. Adhesive
may be applied to any part of this region to provide an appropriate
securement. Of course, other forms of attachment may alternatively
be used e.g. heat sealing. In the case of heat sealing, a heat seal
varnish or other coating may be applied to the region denoted with
hashed lines to allow heat sealing to be achieved over this
region.
[0136] When the blank has been folded in this way, each one of the
openings 50 is registered with a one of the panels 74 which will
provide a hinge panel 13 of the product support to enable an
erecting pin to be inserted through the opening 50 from an
underside of the panel 42.
[0137] The panel 46' is similarly folded about foldline 82' and
secured to the panel 42 between the row of openings 50' and the
centreline. This will result in each one of the openings 50' being
registered with a one of the panels 74'.
[0138] FIG. 3 illustrates the erectable product support obtained,
with certain of the features of the product support labelled. In
order to erect the product support, an erecting pin of an erecting
machine is inserted from the underside of the bottom panel 7
through each respective one of the openings 50 so as to engage the
hinge panel 13 overlying the opening 50 and thus cause the hinge
panel to rotate into an upstanding position. This results in the
first portion 6 of the product support defining structure rotating
relative to the second portion 8. Simultaneously erecting pins will
be inserted through the openings 50' associated with the product
support defining structure 3' to cause rotation of the first
portion 6' relative to the second portion 8'. In this way the
erectable product support is converted from a flat configuration to
the erected configuration of FIG. 1.
[0139] FIG. 4 illustrates the erected product from the underside,
showing the openings 50 through which pins may be inserted in the
direction of the arrows.
[0140] A second embodiment of a product support in accordance with
the invention will be described by reference to FIGS. 5-7.
[0141] FIG. 5 shows the erected product support. The product
support 100 includes product support defining structures 103, 103'
on either side thereof. The product support and product support
defining structures are of the same general type as in the earlier
embodiment, and like components are given like reference numerals
incremented by 100. In this case, each product support defining
structure defines only two pockets 111 along the longitudinal
direction. The top panel 105 again defines a first portion 106
providing the upper section of the product support and a second
portion 107 providing a lower section thereof. First and second
sets of hinge panels 113, 125 are provided corresponding to the
panels 13 and 25 in the earlier embodiment. Openings 131, 131' are
defined along the sides of the pockets.
[0142] This embodiment differs from the earlier embodiment in the
number and shape of product locating pockets defined. The side
edges 135 of the pockets are curved in this embodiment.
[0143] FIG. 6 shows the blank from which the erectable product
support 100 is made. As in the earlier embodiment, the erectable
product support is provided by folding panel 146 over one side of
panel 144 and panel 142, and panel 146' over the other side of
panel 142 and panel 144'. Adhesive or heat sealing may be provided
in the hatched area as in the earlier embodiment.
[0144] FIG. 7 shows the erected product support from the underside.
As may be seen more clearly in FIGS. 6 and 7, a further difference
is that, in addition to the openings 150 which are registered with
the hinge panels 113 when the product support is in the flat, a
second set of openings 170 is provided registered with the hinge
panels 125. Thus, there are first and second rows of openings
including the openings 150 and 170 in respect of the hinge panels
113 and 125 respectively (and similarly 150' and 170' in respect of
the second product support defining structure).
[0145] FIG. 7 illustrates the erected product support of the second
embodiment showing the openings 150 and 170, and illustrating the
direction of insertion of the pins.
[0146] FIGS. 8 and 9 illustrate the erected product supports of
FIGS. 1 and 5 respectively with product 200, 300 located therein.
It will be seen that in the embodiment of FIG. 8, opposed ends 202,
204 of each product is located in the opposed pockets 111, 111'
defined by the product support defining structures 3, 3'.
[0147] The product may be any desired product, whether
confectionary or other food products, or cosmetics etc. The product
support may be used to locate products for insertion in a variety
pack or advent calendar, for example.
[0148] It will be appreciated that the embodiments shown in FIGS.
1-4 and 5-7 are merely exemplary. For example, a pocket may define
more than one sidewall. A net may be provided which may support a
product when located in the product support in use. For example,
this may extend between the opposed pockets of the first and second
product support defining structures of either embodiment. In either
embodiment, the sidewall(s) of a pocket may be inclined.
[0149] In the embodiments described, the inner edges of the top
panel of each product support defining means are located either on
the longitudinal centreline (first embodiment), or spaced laterally
therefrom by the same amount (second embodiment). Of course the
edges may be provided in any suitable position. It is not necessary
for multiple product support defining structures to be mirror
images of one another about the longitudinal centreline.
[0150] Furthermore, while the product supports are shown as being
formed from a single piece blank, this is not essential, and a
multi-piece arrangement may be used, including seam(s) in any
location. In embodiments using a single piece blank, folding need
not occur in the position shown.
[0151] It is not necessary for there to be a pair of product
support defining structures. For example, a single structure, or
more than two structures may be used, disposed in any desired
orientation and/or position relative to one another. Multiple
product support defining structures need not be of the same
appearance of construction.
[0152] A method of erecting the product support of the embodiment
of FIGS. 1-4 will now be described by reference to FIGS. 10 and 11.
A robotic arm 300, or any suitable mechanism, is used to pick up
the erectable product support 1 in its flat configuration from a
feeder 290 including a stack of the product supports in the flat
e.g. a magazine feeder or similar. FIG. 10 schematically shows the
top blank being removed from the pile and then held by the robotic
arm. The robotic arm includes a tool 301 at its distal end having
portions shaped to extend into the portions of the support which
will provide the when in the erect configuration. The robotic arm
300 locates the flat product support 1 on a forming plate 302
having a plurality of upstanding pins, arranged in two rows
(including pins 304 and 304' respectively). The forming plate is
one of a series of such plates which are conveyed along a machine
direction of the processing line.
[0153] The pins 304 are registered with the openings 50, and the
pins 304' with the openings 50'. The product support is pressed
down on to the forming element 302 by the tool 301 as shown in FIG.
10, urging the pins into the openings. The pins 304 engage the
hinge panels 13 through the openings 50 and cause the hinge panels
13 to rotate facilitating rotation of the first portion 6 of the
top panel relative to the second portion 8 of the product support
defining structure 3. Likewise, pins 304' engage the hinge panels
13' through the openings 50' and cause the panels 13' to rotate to
facilitate rotation of the first portion 6' of the second product
support defining structure 3' relative to the second portion 8'. In
this way, the product support is erected.
[0154] As may be more clearly seen in FIG. 11, which is a
transverse cross sectional view showing the product support being
pressed on to the forming plate, the pins are tapered, having an
outer inclined surface 305, 305'. This may facilitate insertion of
the pins, and helps maintain contact of the pins with the hinge
panels as the panels start to rotate. FIG. 11 shows the support
once fully erected on the pins, with the hinge panels 13,13'
upstanding.
[0155] Returning to FIG. 10, the tool 301 releases the product
support, and the product support travels along the production line
in the direction of the arrow, supported on the forming plate 302,
with the pins still located in the openings 50, 50'. The product is
loaded into the product support in the manner shown in FIG. 8, and
schematically illustrated in FIG. 10.
[0156] The product support loaded with product is then removed from
the forming plate 302 and inserted into an end of an outer package
308.
[0157] It is envisaged that in alternative embodiments, pins may be
used only to provide an initial part of the rotation of the
applicable hinge panels. Once movement about the applicable
foldlines has commenced, it may be possible to remove the pins, and
then complete erection without the pins being present. Thus,
loading of the product and insertion of the support into a product
may also be achieved without the product being supported on the
pins.
[0158] Erection of the product support in accordance with the
embodiment of FIGS. 5-7 proceeds in a similar manner. Here, the
pins on the forming plate will need to define a pattern
corresponding to the openings in the bottom panel, i.e. including
pins in the corresponding positions to openings 170 and 170' as
well as 150 and 150'. Pins will extend through openings 150, 150'
to engage the hinge panels 113 and 113' and the additional pins
will extend through openings 170, 170' to engage hinge panels 125
and 125' to rotate the panels and hence facilitate rotation of the
first portions 106, 106' of the first and second product support
defining structures relative to the second portion 108, 108'
thereof to erect the product support. Loading of the product
support and insertion into the package proceed as in the earlier
embodiment.
[0159] It will be appreciated that it is not necessary to provide
one opening for each hinge panel, for either the sets of hinge
panels for providing hinge panels 13, 13' (or 113, 113') or the set
of hinge panels for providing hinge panels 25, 25' (or 125, 125').
Openings may be provided for only a subset of either one or both of
the sets of hinge panels. The number of openings required will
depend upon factors such as the number and configuration of the
pockets, the material used for the product support etc., and the
amount of assistance required to erect the product support.
[0160] In addition to, or instead of providing openings registered
with hinge panels of the product support, one or more openings may
be provided at other openings. For example, the openings may be
provided in clusters registered with parts of the first portion 6,
6' or 116, 116' of the product support 1, 100.
[0161] FIG. 12 illustrates one such arrangement by reference to the
product support 1 earlier described. In addition to, or
alternatively to the openings 50, 50', another set of openings may
be provided in the bottom panel 7 to result in pins engaging
portions of the underside of the first section 6, 6' of the top
panel in each of the product support defining structures. For
example, the portions may result in the pins engaging portions 251
of the first portion as shown by the dots in FIG. 12 (for ease of
reference showing the locations only in respect of the second
product support defining structure 3'). The locations on the top
panel with which the openings are registered may define clusters
along the length of the product support section as illustrated. In
the illustrated embodiment, the openings are associated with an
outer portion of the first portion which defines a continuous
longitudinal strip i.e. outboard of the fingers 23, 23' denoted by
the hatched region. However, this need not be the case. There also
need not be more than one cluster, or indeed, more than one
pin/opening at each position along the length of the product. It
will be understood that the openings should be located
appropriately in the bottom panel such that they will engage
portions corresponding to those portions of the top panel indicated
in FIG. 12 when the product support in in the flat configuration.
Corresponding openings may be provided to enable pins to engage the
first product support defining structure in corresponding locations
(although not illustrated in FIG. 12).
[0162] Similarly, alternative or additional openings for providing
corresponding pin locations may be provided associated with the
first portion of the top panel in the embodiment of FIG. 5-7 or any
other embodiment.
[0163] In general, the openings of a product support defining
structure may be arranged to enable pins to contact the top panel,
whether a hinge panel or first section defined thereby, in any
locations to facilitate erection, which may generally be around
each, or a subset of the pockets defined by the product support
defining structure, but need not be e.g. may be at either end of
the first section etc.
LIST OF EXEMPLARY EMBODIMENTS
[0164] For the avoidance of doubt, the numbering of the embodiments
below refers to the numbering of the embodiments in this list of
embodiments.
Embodiment 1
[0165] A machine erectable product support made from cardboard,
paperboard or other lightweight foldable sheet material comprising:
[0166] at least one product support defining structure comprising:
[0167] a top panel comprising a first portion for providing an
upper support section of the product support defining structure in
the erected product support, and a second portion for providing a
lower section of the product support defining structure in the
erected product support; [0168] a bottom panel for providing a base
of the product support defining structure in the erected product
support, wherein the second portion of the top panel is secured to
the bottom panel; [0169] and a longitudinal side wall panel; [0170]
wherein the product support defining structure defines, in the
erected product support, one or more product locating pockets;
[0171] wherein the top panel comprises cutlines and foldlines
defining a plurality of hinge panels hingedly attaching the first
portion of the top panel to the second portion of the top panel to
enable the first portion to be rotated relative to the second
portion to erect the product support defining structure during
erection of the product support; [0172] wherein each hinge panel is
connected at one end about a foldline to the first portion of the
top panel and at the other end about a foldline to the second
portion of the top panel; [0173] wherein the bottom panel comprises
one or more openings, each opening being registered with a
respective portion of the top panel when the product support
defining structure is in a flat configuration, whereby an erecting
pin of an erecting machine may be inserted from the underside of
the bottom panel through the opening to contact the top panel to
assist in rotating the first portion of the top panel relative to
the second portion of the top panel to erect the product support
defining structure during erection of the product support.
Embodiment 2
[0174] The product support of embodiment 1 wherein the one or more
openings of the bottom panel comprise a plurality of openings
disposed in one or more clusters, each cluster comprising a
plurality of openings, the openings within each cluster being
registered with portions of the top panel in a respective region of
the top panel.
Embodiment 3
[0175] The product support of any one of the preceding embodiments
wherein at least one opening is provided registered with a
respective hinge panel of the top panel.
Embodiment 4
[0176] The product support of any one of the preceding embodiments
wherein at least one opening is provided registered with a portion
of the first portion of the top panel.
Embodiment 5
[0177] The product support of any one of the preceding embodiments
wherein the cutlines comprise a plurality of cutlines, each
defining an edge of one or more of the hinge panels.
Embodiment 6
[0178] The product support of embodiment 5 wherein each one of at
least some of the plurality of cutlines further defines, in the
erected product support, an edge of one of the one or more product
locating pockets.
Embodiment 7
[0179] The product support of any one of the preceding embodiments
wherein the product support is configured such that, when erected,
the product support defining structure defines one or more product
locating pockets along the longitudinal direction of the product
support, each product locating pocket being defined between
adjacent ones of the plurality of hinge panels, and including
product locating pocket edges defined by cutlines of the product
support defining structure, which cutlines define the edges of the
hinge panels on either side of the product locating pocket.
Embodiment 8
[0180] The product support of embodiment 7 wherein, for each
product locating pocket, one edge of each of the hinge panels
between which the product locating pocket is defined is defined by
a one of the cutlines of the product support defining structure,
and the opposed edge of the hinge panel is defined by another one
of the cutlines of the product support defining structure or by an
end edge of the top panel.
Embodiment 9
[0181] The product support of any one of the preceding embodiments
wherein the or each product locating pocket further comprises a
sidewall, the sidewall being provided by one of the plurality of
hinge panels of the product support defining structure, optionally
wherein the sidewall is a longitudinal sidewall.
Embodiment 10
[0182] The product support of any one of the preceding embodiments
wherein the one or more product locating pockets are defined
between hinge panels of a first subset of the plurality of hinge
panels provided by the product support defining structure, and
wherein a sidewall of each product locating pocket is provided by
one of a second subset of the plurality of hinge panels provided by
the product support defining structure, wherein an opening in the
bottom panel is provided in respect of at least some of the hinge
panels of the first and/or second subsets of hinge panels.
Embodiment 11
[0183] The product support of embodiment 10 wherein the product
support defining structure comprises a plurality of cutlines,
which, in the flat configuration of the product support defining
structure, each comprise a first portion defining an edge of one of
the first subset of hinge panels and a second portion defining an
edge of one of the second subset of hinge panels, wherein the
second portion, in the erected product support, defines at least a
portion of the edge of a product locating pocket.
Embodiment 12
[0184] The product support of embodiment 10 or embodiment 11
wherein the first portion of the top panel, in the erected product
support, comprises an outer region and a plurality of fingers, each
finger extending from the outer region inward to a top of the
second subset of hinge panels.
Embodiment 13
[0185] The product support of any one of the preceding embodiments
wherein the product support is configured such that, when erected,
the product support defining structure defines a plurality of
product locating pockets along the longitudinal direction of the
product support.
Embodiment 14
[0186] The product support of any one of the preceding embodiments
wherein the second portion comprises a continuous longitudinal
strip.
Embodiment 15
[0187] The product support of embodiment 14 wherein the continuous
longitudinal strip is located adjacent, and extends to, an inner
edge of the top panel.
Embodiment 16
[0188] The product support of any one of the preceding embodiments
wherein the first portion of the top panel comprises a continuous
longitudinal strip, wherein the one or more openings includes one
or more openings registered with respective portions of the
longitudinal strip.
Embodiment 17
[0189] The product support of any one of the preceding embodiments
wherein the erectable product support comprises a pair of said
product support defining structures, one on each longitudinal side
thereof.
Embodiment 18
[0190] The product support of embodiment 17 wherein the or each
product locating pocket defined by the product support defining
structure on one side of the product support is aligned with a
corresponding product locating pocket of the product support
defining structure on the other side of the product support for
supporting opposed ends or sides of a product extending
therebetween.
Embodiment 19
[0191] The product support of any one of the preceding embodiments
wherein the support is of a single piece construction.
Embodiment 20
[0192] The product support of any one of the preceding embodiments
wherein the erectable product support is formed from a blank of
sheet material, preferably a single piece blank.
Embodiment 21
[0193] A method of erecting the product support of any one of the
preceding embodiments comprising; [0194] for at least some of the
one or more openings in the bottom panel of the or each product
support defining structure, inserting a respective erecting pin of
an erecting machine from the underside of the bottom panel
therethrough to contact the portion of the top panel associated
with the opening, and using the pin to assist in rotating the first
portion of the top panel relative to the second portion of the top
panel to erect the product support defining structure during
erection of the product support.
Embodiment 22
[0195] The method of embodiment 21 further comprising locating one
or more product in the product support and then inserting the
product support in an outer package.
Embodiment 23
[0196] The method of embodiment 22 further comprising supporting
the product support on the erection pins during loading of the
product.
Embodiment 24
[0197] The method of any one of embodiments 21 to 23 wherein the
erection pins define at least one axially extending tapered
surface.
Embodiment 25
[0198] The method of any one of embodiments 21 to 24 wherein the
step of inserting the pins through the openings comprises pressing
the erectable product support onto a forming element having
upstanding pins mounted thereon.
Embodiment 26
[0199] The method of embodiment 25 wherein the pressing is
performed using a tool including one or more portions for insertion
into respective ones of the one or more product locating pockets
defined by the product support.
* * * * *