GB2493403A

GB2493403A - A U shaped carton whose walls are supported by strapping

Info

Publication number: GB2493403A
Application number: GB1119205.1A
Authority: GB
Inventors: Joyce Dempsey
Original assignee: FINSBURY FOOD GROUP PLC
Current assignee: FINSBURY FOOD GROUP PLC
Priority date: 2011-11-07
Filing date: 2011-11-07
Publication date: 2013-02-06
Also published as: GB201119205D0

Abstract

A U shaped carton 1 has a base 3, opposing sides 4 and an annular band 10 encircling the base and the sides to support them. Ideally there is no other support means extending between the side walls. The band may be polypropylene and able to support 5kg. The band may be formed by heat sealing or gluing an elongate strip, this joint constituting a point of weakness. One of the ends of the band my protrude from the join forming a release tab. There may be top flaps 5 and end flaps 6 extending from the sides 4. The base may include a slot 8 to receive a tuck 7 connecting the end flaps and the base.

Description

Packaging The present invention relaics toa carton or box used for packaging ul the kind having at least a base and ap&r of facing side walls extending from the base, :5 The packaging industry ises a great variety of different cartons and boxes for many lifferent purposes. The most common font of box orcarton packaging isthe regular slotted container having four side walls, a base and top, the base and the top each being formed by a pair olmajor flaps on opposing sides, and a pair of minor flaps on the other pair of opposing sides. While a regular slotted container offers very good protection for the contents, it does use a large amount of material, normally cardboard, fibrehoartI corrugated tibreboard. corrugated cardboard, card stock or the Iike Additionally, unpacking such a lxix is lime corisunhing because the flaps are normally taped down, and the tape must be cut or removed in order to open the box. Quick IS opetãng of the box often require% a tool such as a box cutter or knife, which is inconvenitni Additionally., the contents of such boxes tend to be tightly packed making It difficult to extract the contents quickly. Many retailers are now demanding that loadIng of paekagIng take the shortest possible amount of time, preferably no more than five seconds to open a box, remove its contents and place the contents on a shelL This is difficult to achieve with a regular slotted container.

Other types of i.arton are also available, including the tray style carton which has a base and four low side walls, biat no top. The contents of the tray are held in place by a film or wrap around the tray and the contents. While this kind af package rcduces the amount of material used in the packaging substantially, removal of the film wrap is time c<nmning, and the tray tends only to be suitable for more robust goods. The film also contributes significantly to the waste left over after unpacking.

The present invention aiths to reduce the amount of packaging but also to permit the coz*ents of' the package to be unloaded very quickly. Of course, the contents must also be protected.

According to a first aspect of the present invention, a carton comprises a base defining a base plane; a pair of facing side walls extending from the base; a band extending around the base and thesi do walls to support the side walls so that they extend outwardly from the base plane, there being no. other support structure between the side walls above the base plane. It will be appreciated that the base and sIde wails define the. space within the canon.. Removal ohM band, permits the side waul to be pushed outwardly very easily to give the pemon unloading the carton very easy and very quick access to the contents, Additionally, since the carton is not 1Mm. wrapped, but includes the band. the band xnity be used ai a handle to lift the carton, thus making handling of the carton that much easier. It means, for instance, that a person handling the carton does not need to bend so far that they can reach the base of the' carton, but just so far as to reach the band as it passes across the top of the carton.

Ptetbrably, the band is mAde of a plastics materiai which may be polypropyiene The band prefWably has a tensile strength in excess otfive kilograms to petmit the carton to be lifttd by the band. More. preferably, the tensile strength of the band H in excess of ten kilograms.

It is also preferred that the band includes a point of' weakness at which it can, be 2(1 broken. That point of weakness might be a joint between two ends of' the band, and might typically be a heat joint or adhesive joint. One end of the band nay extend beyond the joint to tbrm a tab which can be grasped by the fingers of a person handling the carton in order to separate one end of the band front the other to break it Pretèrably. the action of breaking the band is very easy and can be done with one hand sitbout supporting the; carton. i.e., the weight o the carton and the eontçnts gve sulticent opposing force to the pulling of the end Qf the band that point of weabwss will break. The pulling of the end of the band M generally perpeodicuhu-to the joint between the two ent of the band, which allows the band to be broken qult( etsily.

On the other hand, it is preferred that the tensile straigth of the joint is much stronger sothat the carton and its contents can be lifted by the band.

The joint between the ends of the band might be a heat joint or an adhesive joint, or any other suitable type of joint. One end of the band may extend beyond the joint to form a tab which gives a penon purchase on the end of the band in order to break. it.

Preferably, the tab is formed on the outside of the band pointing downwards so that lifting or pulling the tab allows a person to break. thc joint.

It is preIbrred that each side wall carries a top flap which defines the top of the cartoa the position of the top flaps being unsupporud by the side walls, but supported iii position by the band. The top flaps give some protection to the top of the contents of the carton. Advantageously, the top flaps, when supported by the band. are spaced apart to font a finger space by which the hand can be used as a handje. fri this way, it IC) is easy for a ixmon tojpsert a finger or flngers into the finger space because the band does not tie flush agaInst the top of the carton. As a consequence, this facilitates the use of the band as a handle.

it is also prefernsd that the side walls each carry an end flap to further protect the contents ci' the carton. The end flaps are preferably connected to the base by a tuck flap which moves into a iblded p4sidon against the base in which the end flap is held generally perpendicular to the side wall. The base may include a tuck slot into which the tuck flap can be insetS in the folded position.

According to a second aspect of the present invention., a carton comprises a base defining a base plane; a pair of facing sIde waIls extending from the base; a band extending around the base and the side walls to stport the sIde walls so that they extend outwardly from the base plan; the baud including a point of weakness at whidi the band can be brokeit Ibe second aspect: of the invention permits easy opening of the carton thrnply by breaking the band at the pSi of weakness, hut stilt kflows the hand to he used at; a handle to lilt the carton, anáfbcilitates a reduction in material used in the carton when compared with a regular slotted contaIner.

According to a third aspect of the present inveation a carton comprises a base defining a base plane; a. pair of facing side walls euending from the base; a pair of top flaps carried by respective side wails and which define the top @1 the carton, the top flps being unsupported by the side walls; and a band extending around the base, the side walls and the top flaps to support the side walls so that they extend outwardly from the base plane, and to support the top flaps so that they extcnd across the top of the carton, Without the presence of the band, the top flap would not properly lay across thetop of the varton. The band pe'mits the cartop to be opened quickly and easily sp that the contents can be removed in a very short period of time. Preferably the top flaps, when supported by the band, are spaced apart to form a.finger space by which the hand can I') be used as a handle.

K will be appreciated that The carton can be a transit carton which, once it reaches a retailer, is emptied of its contents, or a retail-ready carton Winch, once it reaches the retailer, is placed directly on the shelf with the contents still inside. A shopper actual ty removes the contents from the carton. The top part of the varton may be rentoved when the carton is placed on the shelf to giw better access to the carton's contents.

According to a fourth aspect of the present invention a method of forming a carton comprises: (1) folding a pair of facing side walls from a base which lies in a base plane to define a load space within the carton; (2) placing a band around the base and side walls of the carton to support the side walls so that they extend outwardly from the base plane, there being:no other support structure between the side walls above the base plane.

According to a filTh aspect of the present inventioti a method of unloading a carton compzt,s( I) breakIng a hand which surrounds the base sid side nIls oldie cafton; (2) epai1ting the side walLs & the carton; and () rertmvirtg the contents of the carton.

AccOrding to a sixth aspect of the inventlon a method of moving a carton conipSes: (1) inserting one or more fingers into a finger space between a pair of top flaps of the carton; and (2) raising the or each linger to engage the underside of a band which is positioned around the base, side wall and top flaps ofthe carton so as to lift the carton.

The preferred embodiment of the present invention will now be described by way of example only with reference to the drawings in which: Figure:1 shows a blank which can be ibkled intt a carton according to the embodiment; Figure 2 is a perspective view of the carton aeeordingto the embodiment; Figure 3 is a partial view of a band in the embodiment; and Figure 4 is an end perspective view of the carton of Figure 2.

JO Referring first to Figure 1, a blank 1 is shown which can be fokied into a carton of the present invention, The blank 1 has a number of areas separated by lines of weakness in the fhnn of slots cut in U. The blank I is made of a suitable inaLerial, such as cardboard, corrugated fibreboard, fibreboard, papeEboard, card stock and the øke F he blank 1 includes a base 3, a pair of side walls 4 which can be bern so as to be positioned perpendkular to the base 3 and a, pair of top flapt S respectiwly carried by theskie walls 4. Each side walI4 also carries a pair of end walls 6 which may he bent so as to be perpendiculartc the side walls 4. Adjacent end waIls 6 are joined by stuck flap 1. The base 3 includes a pair of tuck slots 8 into which the tuck flaps tan be inserted, and this will be'descrihcd in more detail with respect to Figure 4. A pair of tear-lines 20 are included which permit part of the carton to be torn away fto.m the rest, fbr use in retail-ready cartons.

Referring now to Figure 2, an erected carton 2 is shown in which the side waIts 4 have been bent so as to be perpendicular to the plane of the base 3. The two top (laps 5 have been bent so as to be generally perpendicular to the' side walls 4 such that they are directed towards each other and, together with the side walls 4 define a load space 9 within thc carton 2. The end flaps 6 arc bent perpendic War to the side walls 4 such that thcy an directed towards each other and defIne the ends of the load space 9.

3Q A band lOis disposed around the outside of the base 3, side walls 4 arid top flaps 5 so as'to support the side walls 4 in their position perpendicular to the plane of the base 3, and to support the top flaps 5 in their position perpendicular to the side walls 4. It will be understood that the position of the side walls 4 perpendicular to the plane of the

S

base 3 is not very securely supported by the folding of the blank 1 because there is no support structure between the side walls 4 above the plane of the base 3. except for the band 10. This is visible more clearly in Figure 4 which is described below. In fact, in view of the band U), ft. is not essential to Ixive any other support tbr holding thø side S walls 4 in their position perpeudicular to the plane of the base-3.

The band is made' of a plastics material, most preferably polypropylene. It is very thin and between one: and 6 cm wide. En the preferred embodiment, the band is 28 mm wide. The size of the hand gives it sufficient strength to properly support the side: walls 4 so that they are not pushed apart. It is also strong enough that, if a person inserts one or more fingers beneath the band, the person can lift the carton using the band 10 as a handle. Thus, the band 10 must be sufficiently strong to be able to support the weight of the canon and its contents. In this embodiment, the hand can süpportn carton weighing up. to 10 kg. However; in other embodiments, the band 10 IS may be capable of supporting carton of low weight, as little as 2 kg4 or a higher weight of as much as 25 kg. It is not,just the strength that is itnpurbnfl, hut thefaot that the band 1(1 must net stretch significantly wken tiftinE the carton. It must sulantially retain its length during lilting.

The band lOis also transparent so that it gives an unobstructed view of the eonient of the cation 2, and an unobstructed view of any labelling or printed matter on the external surface of the carton 2.

While the band 10 has a higher tensile strength to permit its use as a handle. it must also he easy to remove. In this regard, the band 10 is Ibrmed of a single piece having two ends which are joined to form a joint. This is shown more clearly in, Figure 3 wltcrc the two ends of the band l0vcrlap and have ajoint. 12 located"on that c.wcrlap.

in Figure 3, the end descending from above lies over the top of the end canting up from underneath. The end descending from above also extends beyond the joint' 12. so as to form a tab. 13 which can be grasped by a peason wishing to break the hand 10.

Lifting the tab 13 causes the joint 12 between the ends of the band 10 to be broken because the force applied to the joint 12 applies a tearing or peeling force on that joint to which there is less resistance than a wnM le foze such as is applie4 during the Ii lUng of a carton by the band 10. The action of breakiag the hand is very easy. ad can be done with one hand without supporting the earten. ibis means that the weight of the carton and its contents gives sufficient opposing force to the pulling of the end of the band U) that the john 12 will break. The puiJing of the tab 13 may be perpendicular to thejoint which allows the band to be broken quite easily.

The John 1.2 between' the cmii of the band 10 may be tbnned by heating: the band at the point at which the joint 12 j$ to be funned, in whidh ease the jointing is a heat joint, or it may be loaned by adhesive betwten the two ends. Further ways of joining I 0 the two ends of the hand might also be possible.

Additionally, it will be noted that the two top flaps 5 do not meet when tha carton is assembled, a finger space 11 existing between them. This is significant because a person lifting the carton is much more easily able to slip his or her fingers beneath the 15' band 10 itt the finger space than if the top flaps 5 were to theet Even when The carton is lit!!, the finger space ii gives a few mIllimetres of ekamnee between the underside of the band 10 and the top of the contents within the load space 9 to aid insertion of a handler's fingers. The finger space I! must be sufficiently wide to allow a handler to insert one or more iinger beneath the hand., In the preferred embodiment, the finger space U is 6 cm, although a smaller finger space 11 of as little as 2 cm nut)' he

acceptable.

One of the tear-lines 20 is visible in Figure 2 by whIch the top part can be torn away from the lower part of the carton so that the carton is retail-ready. Rather than the tontents of the carton being removed from the carton and placed on the shelyes of a shop, the top part of the carton can be torn oft and the lower part of the carton placed directly onto the shelf in a shop as a tray with the contents still inside. When a shopper approaches the shelf he or she removes the contents directly from the carton, the bottom part of the carton effectively thrming' a tray. C)f course, betbit the top part of the carton is torn away, the band is removed, By having tear lines 20 onthe carton, the retailer has a choice as to whether they will use the bottom pan of the carton as a tray on their shelf, or simply remove all the contents of the canon and stack them directly on the shelves.

S R.efernng now to Figure 4. one end of the carton is shown partially erected. The side walls 4 have been beutso as to be perpendIcular to thopktne of the base 3. and the top flaps 5 have been bent so as to be perpendicular to the side walls 4. The end flaps have been bent so that. they are perpendicular to the side walls 4, and this causes ttck flap 7 to be formed with two trIangular pieces 14 which are bent double over the re'n of the I 0 tuck flap 7. ibis doubling up causes the bottom of the end flaps to be held in position perpendIcular to the side walls 4. The tuck flap 7 is simply folded underneath the base 3 of the carton in the direction of arrow 15 and inserted into the tuck slot 8. Not only does this give some support to the end flap 6, bat also give some twpport to the side Walls 4. although this is limited th view of the fact that the support is all at or below the love! o the base 3. It does not take very much force on the top cf the side walls 4 to push them apart; and in many circumstances, this does not gisc sufficient strength to the carton. Thus, the band 10 (not shown in Figure 4) is required to support the side walls 4 It will be appreciated, however, that, umoval of the tuck flaps and tuck slots is possible thrice th Mdc walls 4. are supported by the hand 10. 2()

In, the present embodiment, the carton is an outer carton, that is to say it is secondary packaging. If the contents of the carton are to be birthday cakes, eath cake is individually packaged within a primary carton or box, and a number of the primary cartons or boxes are loaded into the load space 9 of the carton 2 fbi shipping to a retail store. In this embodiment, six boxes of cakes will be inserted into the load space 9, and the carton 2 is then placed on a pallet together wIth many other cartons 2 and wrapped in film to h&d all of thc canons on the pallet The, use of the carton will now be described.

Firstly we describe the loading of the carton. A blank 1 is taken and either in its unfolded position or in its partially erected position, six boxes are placed on the base 3. The carton is then fully' erected around the six boxes by raising the side walls 4, by folding over the top flaps S and by inserting the tack flaps 7 into the tuck slots 8. A band 10 is then secured around the carton 2. En this way, the carton is lAaded. ftc carton is then placed on a. pallet with many other cartons, wrapped in flint and shipped to a retail store. In loading the carton, a signIficant saving in materiat i aehicved by The lid that the load space 9 is not fully enclosed by the eaton, and neither the top flaps nor the end flaps overlap. This results. in a saving of material of in. excess of 23%/Packaging iS aS reduced by the absenee of adhesive tape, adhesives or stapits holding the carton together. Packaging is further reduced by the absence of a film around the carton which must later be disposed of l0 Once the pallet of cartoas reaches the retail store, handlers must unload the cartons 1mm the pallet and load the contents ot' the carton otno the shelt The cartons are very easy to handle because the handkr simply needs to s11p his or her fingers into the finger space Ii beneath the band 10 using the band 10. has a handle. This reduces the bending re4uired by the handler since he or she only needs to reach doi as far as the top o: the carton with one hand, and does not need to reach down to the base of the carton with two hands. Once the carton has reached the location of the shelf, the handler can grasp the tab 13 and easily break the band, thereby releasing the support holding the side wails 4 in position. The side walls 4 can then be pushed apart and. the boxes within it pLaced on the shelf. Not only does the band JO function as a handle, it also has a quick release function by which the band can be easily btt'ken. l'he band uses very little material, itducing the amount of waste when the carton is finished with. The packaging permits the very efficient stacking of shelves since It takes the handler an extremely small amount of time to move the carton to the location of the shelf, open the carton and extract the contents onto. the shelf In the paragraph above, unloading of the cartons S described. An altsrnative is that, once the band is removed, tint top part of the ctrton is removed by tearing along the tear-Jüies 20 converting the carton into a tray whith can be placed directly onto a retailer's shelf with the contents still inside. Customers wishing to take the contents simply remove the contents from within the lower part of the carton. This saves the time of unloading the cartot.

The specific description above refers to the carton containing six boxes of cakes. Of course, all manner of goods could be held within the carton. For example, the carton could contain a singLe item, or many items. flit items contained can vaty &catlY and include boxes of cakes, ready-made meals, packets of cheese, bottles of detergent and the like. if) to

Claims

<claim-text>Claims A carton comprising: a base defining a base plane; S a pair of facing side walls extending from the base; a band extending around the base and the Mdc walls La support the side walls so that they. extend outwardly (mm the. base plane, there being no other snpport suuetute between the side walls above the base plane.</claim-text> <claim-text>2. The carton of claim 1, wherein the' band is of a plastics material.</claim-text> <claim-text>3. The carton of claim 2. wherein the plastics material is polypropyLene.</claim-text> <claim-text>4. The carton of claim 2 or 3, wherein the band has a tensile strength in iS exCess <4' 5. The carton of any one of daims 2 t1 4. wherein the band includes a point of weakness at which the band can be broken.6. The carton' of claim S. wherein the point of weakness of the hand i ajoint hdween two ends of the band.7.. The carton of claim 6. wherein the joint isa beat joint 8. The carton according to claim 6, wherein the joint is an adhesivejoInt The carton according to any one of claims 6 to. g, wherein one end of the band extends beyond the joint to (cnn a tab.ilL The carton according' to any one o. the pcedin2 daima, wherein each side wall carries a top flap wthich defines the top of the carton, the top flaps being unsupported by the side walls, but supported in position by the band.U11. The carton accordinE to claim JO, wherein the top flaps, when supported by the band, are spaced apart: to form a linger space by which the hand can beused as a handle S 12. The carton according to any one oldie prcccding claims, wherein the side walin each carry tnt end flpp 13. The carton according to claim 12, whcrein the end flap is connected to the base by a tuck flap which moves into a (bided position against the base in which the end flap is held generally perpendicular to the side wall.14. The carton according to claim 13, wherein the base includes a tuck slot into which the tuck flap can be inserted in the Ihided positiott B I & A carton comprising; a base defining a base platte; a pair of thcinside walls vxtcnding furn, the base; a band extending around the base and the side walls to support the si:de walls so that they extend outwardly from the base piane, the band inchidinga point of weakness at which the band can be broken.16. A carton comprisIng: a base defining 3 base plane; a pair ni'facing side walls extending from the base; a pair oftop flaps earned by respective side walls and which define the top of the cation, the top flaps being unsupported by the side walls; and a band extending around the base,, the side walls and the top 0eps to suppott the side waLls so that they extend outwardly from the base plane. and to stpport the top flaps so that they extend across the top of We carton.17. The cation according to claim 1, wherein the top flaps, when supported by the band, are spaced apart to form a finger space by which the band can be used as a handle, IX. A method of forming a carton, comprising; (1) fblding a pair of (acing side walls from a base which lies in a base plant to define a kvttd space within the carton; (2) placing a band around the base and skk w&ls of the carton to support the side walls so that the)r extend outwardly from the base plane, there being no other support structure between the side wails above the kie plane 19. A method of unloading a carton, comprising: (l breaking a band which surrounds the base and side walls of' the carton; (2) separating the side walls of the carton; and (3) removing the contents of the carton.The method of' cLaim 19, wherein breaking the band includes the step of jc separating the two ends of the band.21. The method of claim 20, wherein the two ends of the band are separated by one end behig pealed away from, the other end..22. A method of tnving a carton comprising: (I) inserting one or more lIngers into a finger space between a pair of top flaps of the carton; and (2) raising the o each finger to engage the underside of a band which is positioned around the base, side wall and top tiaps of (Itt carton so at to lift the: carton.23. A carton constructed, and arranged substantiAlly as described with refrrence to Figures 2,3 arid 4.24. A rnethoa otiTorming a carton substantiAlly as described in tin description.2S. A method of moving a carton using the band substantially as described inthe description.Amendments to the claims have been made as follows: Claims 1. A carton comprising: a base defining a base plane; a pair of facing side walls extending from the base; a band surrounding the base and the side walls to support the side walls so that they extend outwardly from the base plane, there being no other support structure between the side walls above the base plane.
2. The carton of claim 1, wherein the band is of a plastics material.
3. The carton of claim 2, wherein the plastics material is polypropylene.
4. The carton of claim 2 or 3, wherein the band has a tensile strength in excess of 5kg. LC)O
5. The carton of any one of claims 2 to 4, wherein the band includes a point of weakness at which the band can be broken.
6. The canon of claim 5, wherein the point of weakness of the band is a joint betwecn two ends of the band.
7. The carton of claim 6, wherein the joint is a heat joint.
8. The carton according to claim 6, wherein the joint is an adhesive joint.
9. The carton according to any one of claims 6 to 8, wherein one end of the band extends beyond the joint to form a tab.
10. The carton according to any one of the preceding claims, wherein each side wall carries a top flap which defines thc top of the carton, the top flaps being unsupported by the side walls, but supported in position by the band.
11, The carton according to claim 10. wherein the top flaps, when supported by the band, are spaced apart to form a finger space by which the band can be used as a handle.
12. The carton according to any one of the preceding claims, wherein the side walls each carry an end flap.
13. The carton according to claim 12, wherein the end flap is connected to the base by a tuck flap which moves into a folded position against the base in which the end flap is held generally perpendicular to the side wall.
14. The carton according to claim 13, wherein the base includes a tuck slot into which the tuck flap can be inserted in the folded position.
15. A carton comprising: a base defining a base plane; o a pair of facing side walls extending from the base; a band surrounding the base and the side walls to support the side walls so o that they extend outwardly from the base plane, the band including a point of weakness at which the band can be broken.
16. A carton comprising: a base defining a base plane; a pair of facing side walls extending from the base; a pair of iop flaps carried by respective side walls and which define the top of the carton, the top flaps being unsupported by the side walls; and a band surrounding the base, the side. walls and the top flaps to support the side walls so that they extend outwardly from the base plane, and to support the top flaps so that they extend across the top of the carton.
1 7. The carton according to claim 16, wherein the top flaps, when supported by the band, are spaced apart to form a finger space by which the band can be used as a handle.
18. A method of forming a carton, comprising: (I) folding a pair of facing side walls from a base which lies in a base plane to define a load space within the carton; (2) placing a band around the base and side walls of the carton to support the side walls so that they extend outwardly from the base plane, there being no other support structure between the side walls above the base plane
19. A method of unloading a carton, comprising: (1) breaking a band which surrounds the base and side walls of the carton; (2) separating the side walls of the carton; and (3) removing the contents of the carton.
20. The method of claim 19, wherein breaking the band includes the step of separating the two ends of the band. ro
21. The method or claim 20, wherein the two ends of the band are separated by one end being pealed away from the other end.
22. A method of moving a carton comprising: (1) inserting one or more fingers into a finger space between a pair of top liaps of the carton; and (2) raising the or each finger to engage the underside of a band which is positioned surrounding the base, side wall and iop flaps of the carton so as to lift the carton.
23. A carton constructed and aranged substantially as dcscribed with reference to Figures 2, 3 and 4.
24. A method of forming a carton substantially as described in the description.
25. A method of moving a carton using the band substantially as described inthe description.</claim-text>