CONTAINER BLANKS AND CONTAINERS

Abstract

A carton blank (10) for forming a container, and comprising a row of body portion forming panels (P1-P5) arranged side-by-side, the boundaries between said panels (P1-P5) being defined by respective, substantially straight boundary lines of weakness (S1-S4) extending from top to bottom of said panels (P1-P5) substantially perpendicularly to said row, two adjacent boundary lines of weakness (S-S4) each having disposed at one side thereof a supplemental line of weakness (S11, S12, S21, S22, S31, S32, S31′, S32′, S41, S42), each supplemental line of weakness (S11, S12, S21, S22, S31, S32, S41, S42) being substantially the length of a panel (P1-P5).

Description

This invention relates to container blanks, containers formed from the blanks, and methods and apparatus for forming the same.

According to a first aspect of the present invention, there is provided a carton blank for forming a container, and comprising a row of body portion forming panels arranged side-by-side, the boundaries between said panels being defined by respective, substantially straight boundary lines of weakness extending from top to bottom of said panels substantially perpendicularly to said row, two adjacent boundary lines of weakness each having disposed at one side thereof a supplemental line of weakness, each supplemental line of weakness being substantially the length of a panel.

According to a second aspect of the present invention, there is provided a carton blank for forming a container, and comprising a row of body portion forming panels arranged side-by-side, the boundaries between said panels being defined by substantially straight boundary lines of weakness extending from top to bottom of said panels, two adjacent boundary lines of weakness each having disposed at respective opposite sides thereof supplemental lines of weakness, each supplemental line of weakness being at least half the length of a panel.

According to a third aspect of the present invention, there is provided a container comprising a loop of body portions, the boundaries between said portions being defined by respective, substantially straight boundary lines of weakness extending from top to bottom of said portions substantially perpendicularly to said loop, two adjacent boundary lines of weakness each having disposed at one side thereof a supplemental line of weakness, each supplemental line of weakness being substantially the length of a portion.

According to a fourth aspect of the present invention, there is provided a container comprising a loop of body portions, the boundaries between said portions being defined by substantially straight boundary lines of weakness extending from top to bottom of said portions, two adjacent boundary lines of weakness each having disposed at respective opposite sides thereof a supplemental line of weakness, each supplemental line of weakness being at least half the length of a portion.

According to a fifth aspect of the present invention, there is provided apparatus for handling partially formed containers comprising a conveying device including a plurality of receiving portions for receiving partially formed containers having a mid portion of predetermined cross-section, a filling device arranged to fill said partially formed containers, and a pressing device arranged to press on said mid portion so as to make said mid portion of rounder cross-section.

According to a sixth aspect of the present invention, there is provided a method for handling partially formed containers, comprising advancing a plurality of partially formed containers through a pressing device and a filling device, said partially formed containers having a mid portion of predetermined cross-section, pressing on said mid portion so as to make said mid portion of rounder cross-section, and filling said plurality of partially formed containers at the filling station.

Owing to these aspects of the invention, it is possible to provide a container solution which allows for substantial cost saving in the paper board converting process, uses less material per blank for the same liquid-product volume, improves the ergonomic properties of the container, and which works on mandrel-based container-forming technology. The provision of supplemental lines of weakness allows the container to bulge and provides an opportunity to lower the board-weight of the substrate within the packaging laminate. The system is suitable for the gable-top and flat-top configurations. The design of the container is such that it can be used with the existing machinery. The supplemental lines of weakness are provided on two adjacent vertical corner edges of the formed container. They could be provided on three of the edges, or on all four edges of a rectangular cross-section container. The supplemental lines of weakness in one embodiment can be provided as a pair of supplemental lines of weakness disposed at respective opposite sides of the boundary lines of weakness, each of the supplemental lines of weakness in the pair being at least half the height of a panel.

The invention provides the opportunity to save approximately 5 to 20 mm on the package height and at the same time be able to fill it with 1000 ml liquid, which is achieved by pressing the partially formed container on the substantially vertical corners after the bottom is formed on the mandrel, and before and/or during the content being filled. This de-forming can continue during the filling by activating the additional score lines on the substantially vertical corners. After filling, the container will take a new shape of its own accord, and the top can be sealed. The pressing can also take place after the container has been filled and sealed, which has the advantage of being able to carry out the pressing action outside of the forming, filling and sealing machine. The extent of bulging on the side walls will determine by how much lower the liquid level will become. Bulging is controlled by specially designed, functional supplemental lines of weakness (score lines), and will be recognized by the end user as an intentional design feature. The result will be a cheaper package with a new design appearance and excellent ergonomic properties.

To avoid the negative bulging de-forming effect at material handling and logistic levels (caused by the wider package), the container footprint can be resized to 65×65 mm. In this case, the container will be slimmer and will fit in the logistic system in the same way as the standard 70×70 mm 1 litre container. The container will be taller and more elegant appearance-wise. However, when the container footprint is reduced, the taller more elegant container may provide a logistical problem with fitting into existing forming, filling and sealing machinery. In such taller and elegant containers it is important to keep the container as aesthetically pleasing as possible, by reducing the intentional bulging to a minimum. With a single supplemental line of weakness disposed to one side of each of two adjacent boundary lines of weakness, so that, for example, the two supplemental lines of weakness are located on the front panel of the container, the intentional bulging is restricted to the front panel and the taller container retains its elegant appearance.

According to a seventh aspect of the present invention, there is provided a carton blank for a container including a quadrangular top obturating sub-panel, and disposed outwardly thereof, a top sealing sub-panel, a line of weakness separating said obturating sub-panel and said sealing sub-panel and bulging into said sealing sub-panel.

According to a eighth aspect of the present invention, there is provided a container including a top closure including a roof sub-panel and a top sealing sub-panel, said roof sub-panel bulging into said sealing sub-panel.

Owing to these aspects of the invention, it is possible to provide a sub-panel for mounting, for example, a pour spout fitment, that is larger than a corresponding sub-panel that does not bulge into the sealing sub-panel. This supports a larger pour spout fitment.

According to a ninth aspect of the invention, there is provided a blank for forming a container comprising a row of panels comprising first, second, third and fourth panels and a row of substantially rectangular end closure panels extending substantially parallely to said row of panels and comprised of first, second, third and fourth end closure panels, each of the first and third end closure panels have disposed outwardly thereof a respective end sealing panel extending across the width of the adjacent end closure panel, and each of the second and fourth end closure panels have disposed outwardly thereof a respective pair of tabs, each tab extending across less than half the width of the adjacent end closure panel.

According to an tenth aspect of the invention, there is provided a container comprising a loop of body portions comprising first, second, third and fourth body portions and an end enclosure comprising folded-in end closure portions and comprised of first, second, third and fourth end closure portions, each connected to a respective body portion, each of the first and third end closure portions being connected, at an opposite edge to the connection to a body portion, to a respective end sealing portion extending across the width of the adjacent end closure portion, and each of the second and fourth end closure portions being connected, at an opposite edge to the connection to a body portion, to a respective pair of tabs, each tab extending across less than half the width of the adjacent end closure portion, and a sealing fin comprised of the end sealing portions and the pairs of tabs.

Owing to these aspects of the invention, it is possible to provide an improved end closure, when the blank is formed into a container. The end closure is particularly suited for aseptic packaging applications, since there are no raw edges of paperboard material on the inside of the container nor are there any apex points on the inside of the finished container, as the folding process results in apexes being on the outside of the container.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a plan view of a carton blank,

FIG. 2 is a side view of a container formed from a blank similar to the blank of FIG. 1,

FIG. 3 is side view of a pair of containers, each shown in three views,

FIG. 4a is perspective view of an open top container, prior to activation,

FIG. 4b is perspective view of an open top container, following activation,

FIG. 5 is a plan view of a second embodiment of the carton blank,

FIG. 6a is a perspective view of two containers,

FIGS. 6b and 6c are respective perspective and top diagrammatic views of a container similar to that of the container on the right-hand side of FIG. 6a,

FIG. 7 is a plan view of a third embodiment of the carton blank,

FIGS. 8 to 21 show further embodiments of the blank,

FIG. 22 is a perspective view of a container formed from a blank similar to the blank of FIG. 21,

FIGS. 23 to 27 show further embodiments of the blank,

FIG. 28 is a perspective view of a container formed from the blank of FIG. 25,

FIG. 29 is a perspective view of a container formed from the blank of FIG. 24,

FIG. 30 is a plan view of the container of FIG. 29,

FIG. 31 is a side view and a front view of a plastics insert,

FIG. 32 is a plan view of a further carton blank,

FIG. 33 is a plan view of a yet further carton blank,

FIG. 34 is a perspective view of a container end closure at an intermediate stage of formation,

FIG. 35 is a perspective view of the container end closure of FIG. 34 at a completed stage of formation, and

FIG. 36 is a perspective view of the container end closure of FIG. 35 from within the container.

FIG. 1 shows a carton blank 10 for forming a container, and comprises a row of panels P1, P2, P3, P4 and P5 arranged side-by-side, the boundaries between the panels P1 to P5 being defined by respective boundary lines of weakness, being scorelines S1, S2, S3 and S4. The boundary lines of weakness S1 to S4 are substantially straight and extend from top to bottom of the panels P1 to P5. Each of the panels P1 to P4 will become a side of the ultimate container made from the blank 10, and the boundary lines of weakness S1 to S4 make up the corner edges of the container. The boundary lines of weakness S1 to S4 are each a straight continuous line starting at the top of a panel P1 to P5 and finishing at the bottom of the respective panel P1 to P5. The boundary lines of weakness S1 to S4 are each substantially perpendicular to the row of panels P1 to P5.

Each of the boundary lines of weakness S1 to S4 have disposed at respective opposite sides thereof supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42. Each supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 is at least half the height of the ultimate container, and have upper regions 12 and lower regions 14 proximal to a respective boundary line of weakness S1 to S4, and have a central region 16 further from the respective boundary line of weakness S1 to S4 than either the upper or lower regions 12 and 14.

The supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 are provided in the blank 10, so that when the blank 10 is ultimately formed into a container 18 (shown in FIG. 2), they are activated by squeezing in the central region of the container, to result in an intentional bulge in the container. This bulge allows the container 18 (once the lines of weakness are activated) to hold a greater volume of content (for example, a fluid such as milk) for a given height of container. This is because a circular cross-section has a greater area than the corresponding rectangular cross-section.

On the blank 10 each of the supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 of a pair of supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42, located either side of a boundary line of weakness S1-S4 define a sub-panel P6, P7, P8 and P9. Each of the supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 contact the respective boundary line of weakness S1 to S4 at the upper and lower regions 12 and 14.

To assist the formation of the bulge in the final container, the blank 10 further comprises transverse lines of weakness S13, S23, S33, S43 beginning at or near to a boundary line of weakness S1-S4 and extending towards a respective supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42. In the embodiment of FIG. 1, these transverse lines of weakness S13, S23, S33, S43 actually begin at a boundary line of weakness S1-S4 and terminate at a respective supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42. Each boundary line of weakness S1-S4 is provided with a plurality of the transverse lines of weakness S13, S23, S33, S43. The transverse lines of weakness S13, S23, S33, S43 provided on a boundary line of weakness S1-S4 are parallel.

The container 18 produced from the blank 10 helps to achieve low cost packaging by redesigning the existing carton configuration in a way that will allow for filling the same liquid volume in a carton of lesser height (with the identical footprint), which additionally means using less paperboard in the blank formation. For example, the blank will fill 1000 ml of liquid in a standard 1000 ml carton which is shorter by 5 to 20 mm. To achieve this goal, the blank 10 uses the fact that in bulged cartons the height level of liquids drops.

However, since the first association of a consumer with a bulging carton is that something is wrong with the content, this important issue must be solved. To overcome this problem, the blank 10 provides a design solution which leads to the re-shaping of the package walls in a way that clearly demonstrates to the consumer (via its appearance) the intention behind its unique design. The real “cost-saving” reason will not necessarily be visible to the end user, but at the same time the consumer will recognise the packaging shape as a novelty. To achieve this goal with design tools, the blank 10 is configured to actually control bulging with the additional scorelines, which are formed in a way that follows and allows this bulging effect. The scorelines must be placed in the right places to achieve the desired result.

To save approximately 5 to 20 mm on the package height and to be able to fill it with 1000 ml liquid, it is necessary to “squeeze” the package 18 on the corners after the bottom is formed on the mandrel and before/during/after filling. If the squeezing is to occur before/during filling, the de-forming can continue during the filling by activating the additional scorelines on all four walls (corners). After filling, the package 18 will take a new shape of its own accord, and the top can be sealed. The extent of bulging on the side walls will determine by how much lower the liquid level will become. Bulging will be controlled by specially designed, functional score lines, and will be recognized as an intentional design feature. The result will be a cheaper package with a new design appearance and excellent ergonomic properties.

FIG. 3 illustrates a comparison between the container 18 and a conventional container 20. The container 18a shows the container 18 filled with a fluid content, which has not yet had the corners activated. Container 18b shows the container 18a after activation of the supplemental lines of weakness. The activation is executed by pressing on the container 18 in the middle region, which changes the cross-section of the container 18 from the predetermined rectangular cross-section to a more rounded cross-section. The activation of the corners of the container 18 in FIG. 3 are shown as having been carried out on a filled and sealed container 18, but the process of activating the supplemental lines of weakness can occur before or during the filling process, prior to the top-sealing of the container 18.

Container 18c is a final configuration of the container 18 after having been filled, top-sealed, activated and is the end-product. The liquid level L as shown in containers 18b and 18c is lower than the liquid level L in the pre-activated container 18a. The containers 20 have the same footprint as the containers 18, yet the height of the containers 20 exceeds that of the containers 18, while containing the same volume of content. It can be seen that the liquid level L in container 20b is higher than the liquid level L in the corresponding container 18b.

An example of the activation of the container 18, prior to top sealing of the container 18, is shown in FIGS. 4a and 4b. The container 18a in FIG. 4a has been filled, but not yet activated. The FIGS. 4a and 4b show the liquid level L in 1000 ml container (which is 20 mm lower than a conventional container with the same footprint), filled with 1000 ml of water, before and after the vertical curved score lines on all four corners are activated and the container 18 squeezed. Depending upon the amount of squeezing force and the shape and configuration of the curved score-lines, the liquid level L will go down by between 5 to 25 mm.

The container 18 provides a low-cost packaging configuration. In order to use the existing mandrel carton forming technology, the container 18 is provided with four vertical corners that are needed for the carton forming on the mandrel, as well as the transportation through the filling machine and downstream equipment. The design of the container is such that standard logistic and material handling requirements are maintained. The reconfiguration of the packaging construction is used to achieve a new and attractive carton visual appearance. An additional result from the carton design is that the ergonomic properties of the container 18 are also improved.

FIG. 5 shows a second embodiment of the blank 10. This blank 10 is provided with a hole 22 for receiving a pour spout fitment, when the blank 10 is formed into a finished container. The blank 10 is provided with the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42, which will ultimately be used, when the container 18 is formed, to allow the cross-section of the container to become more rounded. In this embodiment, each supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 is substantially the height of the finished container, in length. Each supplemental line of weakness is substantially the length of a panel P1 to P5. Each supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 does not contact a respective boundary line of weakness S1 to S4.

FIG. 6a shows two examples of containers 18 that have been formed, filled and sealed, a gable-top container shown on the left-hand side and a flat-top container shown on the right-hand side. The provision of the lines of weakness at the corners of the containers 18 allows these containers to bulge outwards, when the scorelines are activated by the application of pressure (shown by the arrows in FIGS. 6b and 6c) at the middle portion 19 of the containers 18 where the sub-panels P6 to P9 are at their widest. The application of pressure at the middle portion 19 is advantageously directly on to the boundary lines of weakness S1 to S4 at an obtuse angle relative to the vertically orientated panels P1 to P4 (as shown in FIGS. 6b and 6c), the obtuse angle being preferably approximately 135°. The scorelines at the corners of the containers 18 can be used with square and rectangular flat-top and gable-top cartons.

A third embodiment of the blank 10 is shown in FIG. 7. The blank 10 is provided with the supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 and transverse lines of weakness S13, S23, S33, S43 (which stop before reaching the supplemental lines of weakness). Each pair of supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 around respective boundary lines of weakness S1 to S4 define sub-panels P6 to P9. As before, when this blank 10 is formed into a container 18 which would have a flat-top configuration rather than a gable-top configuration, the sub-panels P6 to P9 are pressed inwards to change the cross-section of the container 18, to make the container 18 more rounded.

The blank 10 shown in FIG. 7 is a so-called centre-seam design. The blanks 10 of FIGS. 1 and 5 show a corner-seam design. This refers to the ultimate location of the seam when the blank 10 is wrapped around a mandrel on the forming machine and sealed into a container sleeve. At the location of the seam, an overlap 24 of the blank (which is bounded by the dotted line 26) wraps under the other side of the blank 10. The design of FIG. 7 results in the overlap being present in the centre of a body portion rather than at the corner as in the blank of FIGS. 1 and 5. This means that the blank of FIG. 7, when formed into a container, does not have a double layer of material at one corner (which is the case with the blanks 10 of FIGS. 1 and 5). This means that all of the corners in the container 18 formed from the blank 10 of FIG. 7 require the same amount of pressure to press inwards.

The carton blank 10 of FIG. 7 includes a quadrangular top obturating sub-panel P10, and disposed outwardly thereof, a top sealing sub-panel P11, a line of weakness S50 separating the obturating sub-panel P10 from the sealing sub-panel P11 and bulging into the sealing sub-panel P11. The line of weakness S50 that is separating the obturating sub-panel P10 and the sealing sub-panel P11 is arcuate. The obturating sub-panel P10 includes a hole 22 for receiving a pour-spout fitment. The line of weakness S50 separating the obturating sub-panel P10 and the sealing sub-panel P11 is continuous along the boundary between the obturating sub-panel P10 and the sealing sub-panel P11. The blank 10 further comprises a second line of weakness S52 separating the obturating sub-panel P10 from a body sub-panel P3 and bulging into the body sub-panel P3. This second line of weakness S52 separating the obturating sub-panel P10 and said body sub-panel P11 is also arcuate. The shape of the lines of weakness S50 and S52 allow for a larger opturating sub-panel P10 and thus a larger hole 22 for a larger pour-spout fitment.

FIG. 8 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 1, but the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 terminate before they reach the boundary lines of weakness S1 to S4. In addition there is provided, between each pair of supplemental lines of weakness, a single transverse line of weakness S13, S23, S33, S43 which is provided at substantially the half way point in the blank 10, and is perpendicular to the respective boundary lines of weakness S1 to S4. Additional lines of weakness S54 are provided that run from the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 to the boundary lines of weakness S1 to S4. These additional lines of weakness S54 in the upper region 12 form a “V” shape, and in the lower portion 14, form in an inverted “V” shape.

FIG. 9 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 8, but has further oblique transverse line of weakness S13, S23, S33, S43 running from the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 to the boundary lines of weakness S1 to S4.

FIG. 10 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 5, but the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 are shaped differently. In FIG. 10, the central region 16 of the supplemental lines of weakness bulges further from the respective adjacent boundary line of weakness S1 to S4. There is a single transverse line of weakness S13, S23, S33, S43 between each pair of supplemental lines of weakness, which terminate before they reach the supplemental lines of weakness.

FIG. 11 shows a further embodiment of the blank 10. The supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 terminate before they reach the boundary lines of weakness S1 to S4. Each pair of the supplemental lines of weakness are provided with two oblique and crossing transverse line of weakness S13, S23, S33, S43 running from a supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42 through the boundary lines of weakness S1 to S4 to the other supplemental line of weakness of the pair. Each supplemental line of weakness is composed of three substantially straight portions rather than one or more curved portions.

FIG. 12 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 1, but the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 extend the entire length of the sub-panels that ultimately form the sides of the finished container 18.

FIG. 13 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 1, but has no transverse lines of weakness. FIG. 14 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 1, but has a pair of parallel transverse lines of weakness S13, S23, S33, S43 in-between each pair of supplemental lines of weakness, in the central region 16. FIG. 15 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 8, but the scorelines S54 are substantially perpendicular to the boundary lines of weakness S1 to S4.

FIG. 16 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 5, but the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 are shorter in length. FIG. 17 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 14, but the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 extend the entire length of the sub-panels that ultimately form the sides of the finished container 18.

FIG. 18 shows a further embodiment of the blank 10. In this blank 10, the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42 are formed by two substantially straight lines. Each pair of supplemental lines of weakness forms a respective diamond shape sub-panel P6 to P9. The blank 10 is also provided with a single straight transverse line of weakness S56, which is located at the central region 16 of the blank 10 and bisects each of the diamond shape sub-panels P6 to P9 at the widest point, and the panels P1 to P5. FIG. 19 shows a further embodiment of the blank 10. This blank 10 is similar to the blank 10 shown in FIG. 18, but the diamond-shaped sub-panel P6 to P9 include further transverse lines of weakness S13, S23, S33, S43, parallel to the transverse line of weakness S56.

FIG. 20 shows a further embodiment of the blank 10 in which two adjacent boundary lines of weakness S1 and S2 have respective pairs of supplemental lines of weakness S12, S21, S22 and S31 associated therewith. The blank 10 is provided with transverse lines of weakness, as described above with reference to other embodiments. The container that is formed from the blank 10 of FIG. 20, when the supplemental lines of weakness S12, S21, S22 and S31 have been activated, provides bulging of three of the four sides of the resulting container. The blank 10 is similar to the blank 10 of FIG. 7, in that it is provided with a line of weakness S50, which allows a larger obturating sub-panel P10. In addition, the blank 10 of FIG. 20 also includes a further line of weakness S51 on an opposing obturating sub-panel P20, which separates the sub-panel P20 from a top sealing sub-panel P21, and bulges into the obturating sub-panel P20. This line of weakness S51 is equal and opposite to the line of weakness S50, and when the container is formed from the blank 10, in a gable top configuration, then these complimentary two lines of weakness S50 and S51 ensure a satisfactory top fin.

FIG. 21 shows a further embodiment of the blank 10 for forming a container 18 (shown in FIG. 22), which has a reduced footprint size compared to a standard footprint, for example the container 18 formed from the blank of FIG. 21 has a footprint of 66 mm×66 mm compared to a standard 70 mm×70 mm for a 1 litre container. In this embodiment, two adjacent boundary lines of weakness S2 and S3 have respective single supplemental lines of weakness S31′ and S32′ associated therewith with both supplemental lines of weakness S21′ and S22′ being located on the front panel P3, the sub-panels P7 and P8 in this embodiment being defined and bounded by respective supplemental lines of weakness S31′ and S32′ and boundary lines of weakness S2 and S3. In this way, the intentional bulging of the panels, when the supplemental lines of weakness S31′ and S32′ have been activated, is restricted to the front panel P3. The blank 10 is also provided with transverse lines of weakness S23 and S33, as described above with reference to other embodiments.

FIG. 23 shows a yet further embodiment of the blank 10 which is substantially the same as the blank 10 shown in FIG. 21 except that the transverse lines of weakness S60 are longer and begin at a boundary line of weakness S1 and S4 and extend across a second boundary line of weakness S2 and S3 towards a supplemental line of weakness S31′ and S32′. This transverse line of weakness S60 divides into two lines of weakness after crossing the respective boundary line of weakness S2 or S3 and terminates before the supplemental line of weakness. The blank 10 could be provided with additional supplemental lines of weakness as described above on opposite sides of the second boundary line of weakness S2 and S3 and in this case the transverse lines of weakness S60 will cross the respective additional supplementary line of weakness.

When a container is formed from the blank 10 of FIG. 23 it is activated by pressing on the container in the middle region, to activate the supplemental score lines S31′ and S32′ and the transverse score lines S60. This results in a container with a more rounded cross-section in the middle region. The longer transverse lines of weakness S60, when compared to the shorter transverse lines of weakness S23 and S33 of FIG. 21, are less likely to crack the laminate material from which the blank is made, when they are activated. The extension of the transverse lines of weakness S60, along the whole side panels P2 and P4, is important for the activation of front sub-panels (in the activator) without producing cracks in paperboard on the side walls. The lines S60 guide the forces in the paper structure produced by squeezing, all the way along the extended score lines S60 without allowing cracks. At the same time, the score lines S60 are forming a grip area giving an ergonomic advantage.

A further embodiment of the elongate transverse lines of weakness S60 is shown in FIG. 24. A pair of transverse lines of weakness S60 are provided, which begin at the boundary line of weakness S1 and S4 and extend across the second boundary line of weakness S2 and S3 and terminate on the supplemental line of weakness S31′ and S32′. The pair of transverse lines of weakness S60 define a sub-panel P30. When a container is formed from the blank 10 of FIG. 24, the sub-panel P30 provides a target area for a user to hold when they are pouring the fluid contents from the container. FIGS. 25 to 27 show further embodiments of the blank 10 using the elongate transverse lines of weakness S60.

FIG. 28 shows a container 18 made from the blank 10 of FIG. 25. The transverse lines of weakness S60 can be seen, as can the supplemental lines of weakness S31′ and S32′. The cross-section of the container 18 in the middle region is more rounded, as the container 18 has been activated by pressing on this middle region to activate the various score lines. The activation of the lines of weakness S21′ and S31′ can take place before, after or during the filling of the container 18 with its fluid contents. FIG. 29 shows a container 18 as manufactured from the blank 10 of FIG. 24. The two transverse lines of weakness S60 define the sub-panel P30 which can be highlighted with printed material as the grip area for the user to hold the container 18, when they are pouring the fluid contents from the container.

The effect of the user's holding of the container 18, and the activation of the grip area P30 provide a functional improvement. During the pouring of the contents from the container 18, the back panel P1 remains the same shape, however, the front panel P3 collapses along the supplemental lines of weakness S31′, S32′ through the gripping of the user and the weight of the contents and has a width less than the back panel P3. This makes a very safe and pleasant cross-section for the user at the middle section of the container 18, where the grip sub-panel P30 is placed. Referring to FIG. 30, the cross-sectional profiles of the middle section of the container 18 are shown before activation (shown by the profile PF1) and after activation and gripping (shown by the profile PF2). When the container 18 has the profile PF2 at its mid-section then the back panel P1 remains the same width as in the profile PF1 whilst the front panel P3 collapses as aforesaid to a narrower width than as in the profile PF1 resulting in an intentional bulge at the front of the container 18 as pouring takes place.

FIG. 31 shows two views of a plastics insert 60. The insert 60 has a profile corresponding to the sub-panels P6 to P9 of FIGS. 1 and 2 and includes a vertical indent 62 running the entire length of the insert 60 which corresponds to the boundary lines of weakness S1 to S4 in the blank 10. The insert 60 also includes horizontal ribs 64, which likewise correspond to the transverse lines of weakness S13, S23, S33 and S43 of the blank 10. The shape and configuration of the insert 60 can be such that it matches any of the corresponding panels and lines of weakness of other embodiments of the blank 10. Instead of the horizontal ribs 64, the plastics insert 60 can have various suitable surface designs.

The insert 60 is formed of plastics material such as any polyolefin plastics or rubber material, and can be provided in any colour. The insert 60 is designed to be post-applied to the container 18 that is formed from the blank 10, at any or all of the vertical corners of that container 18. The length of the plastics insert 60 is preferably substantially equal to the length of an adjacent supplemental line of weakness S11, S12, S21, S22, S31, S32, S41, S42, and the same shape as a body sub-portion P6 to P9 to which the plastics insert 60 is attached. The insert 60 assists in providing an aesthetic container (for example through the use of different colours), provides better container stability through support of the container edges and improves the ergonomic properties of the container.

FIGS. 32 and 33 show two embodiments of a blank 10′, the blank 10′ being for forming a container. In both embodiments, the blank 10′ comprises a row of panels P1 to P4 comprising first, second, third and fourth panels P1 to P4. The blank 10′ also comprises a row of substantially rectangular end closure panels P12 to P15 extending substantially parallely to the row of panels P1 to P4 and comprised of first, second, third and fourth end closure panels P12 to P15. Each of the first and third end closure panels P12, P14 have disposed outwardly thereof a respective end sealing panel P17, P18 extending across the width of the adjacent end closure panel P12, P14. Each of the second and fourth end closure panels P13, P15 have disposed outwardly thereof a respective pair of tabs T1 to T4, each tab extending across less than half the width of the adjacent end closure panel P13, P15.

The blank 10′ also comprises a fifth panel P5 having disposed outwardly thereof a fifth end closure panel P16, the fifth end closure panel P16 having disposed outwardly thereof an end sealing panel P19 extending across the width of the fifth end closure panel P16. Each tab T1 to T4 is connected to an adjacent end sealing panel P17 to P19, and the width of each tab T1 to T4 is substantially equal. The tabs T1 to T4 are in pairs, and each tab T1 to T4 of a pair of tabs T1, T2 and T3, T4 are substantially equal and opposite in shape. The depth of each tab T1 to T4 is substantially equal to the depth of each sealing panel P17 to P19.

The design of the end closure panels P12 to P16, end sealing panels P17 to P19 and tabs T1 to T4 is to provide an improved end closure, when the blank 10′ is formed into a container. The end closure is particularly suited for aseptic packaging applications, since there are no raw edges of paperboard material on the inside of the container nor are there any apex points on the inside of the finished container, as the folding process (described in more detail below) means that the apexes are on the outside of the container. An apex point occurs when a panel is folded to form a triangular shaped sub-panel. An apex point is particularly susceptible to ingress of the fluid contents of the container, once that container has been filled. The blank 10′ can be folded on a mandrel, when the end closure is being formed.

The blanks 10′ of FIGS. 32 and 33 differ in that the blank 10′ of FIG. 32 is forming a container having a centre seam down the rear body panel, and the blank 10′ of FIG. 33 is for forming a container having a side seam extending along one corner edge of the container. When the blank 10′ is provided with the supplemental lines of weakness S11, S12, S21, S22, S31, S32, S41, S42, it is advantageous to have a centre seam on the finished container, otherwise the lines of weakness present at the corner where the container is sealed first panel P1 to fifth panel P5 discourage the activation of the supplemental lines of weakness at that corner. The end closure provided by the blank 10′ of FIGS. 32 and 33 is particularly suitable for use with a centre seamed container, such as that formed from the blank 10′ of FIG. 32. This is because many standard end closure configurations become sub-optimal, when used with a container that is designed to be centre seamed. For example, some standard end closure configurations will end up with the centre seam passing through the apex of a sub-panel in the bottom end closure, which increase in the likelihood of content leaking or content ingress into the paperboard substrate.

FIG. 34 shows the end closure 70 at a partial stage of formation. The second and fourth end closure panels P13 and P15 have first and second oblique lines of weakness which divide the respective end closure panels P13 and P15 into triangular sub-panels. As the end closure 70 is formed, end closure panel P14 and the combined end closure panel P12 and P16 which are opposite, are folded in towards each other. This results in the end closure panels P13 and P15 folding into their triangular sub-panels, as can be seen in FIG. 34. The tabs T1 to T4 and the sealing panels P17 to P19 are ultimately sealed face-to-face to form a sealing fin 72. This fin 72 is folded flat to the bottom of the container. The end closure 70 is completed by the apexes A1 and A2 being folded inwardly to be sealed flat to the bottom of the container, as can be seen in FIG. 35. The interior of the end closure 70 is shown in FIG. 36. The folding of the bottom closure 70 is such that no apexes are present within the interior of the container, nor are there any exposed raw edges of paperboard.

Claims

1-73. (canceled)

74. A carton blank for forming a container, and comprising a row of body portion forming panels arranged side-by-side, the boundaries between said panels being defined by respective, substantially straight boundary lines of weakness extending from top to bottom of said panels substantially perpendicularly to said row, two adjacent boundary lines of weakness each having disposed at one side thereof a supplemental line of weakness, each supplemental line of weakness being substantially the length of a panel.

75. A carton blank for forming a container, and comprising a row of body portion forming panels arranged side-by-side, the boundaries between said panels being defined by substantially straight boundary lines of weakness extending from top to bottom of said panels, two adjacent boundary lines of weakness each having disposed at respective opposite sides thereof supplemental lines of weakness, each supplemental line of weakness being at least half the length of a panel.

76. A blank according to claim 74, wherein each of each supplemental line of weakness is located on one of said row of panels.

77. A blank according to claim 74, and further comprising an additional supplemental line of weakness, wherein said adjacent boundary lines of weakness have disposed at respective opposite sides thereof a pair of supplemental lines of weakness.

78. A blank according to claim 74, wherein each supplemental line of weakness does not contact a respective boundary line of weakness.

79. A blank according to claim 74, and further comprising transverse lines of weakness beginning at or near to a boundary line of weakness and extending towards a respective supplemental line of weakness.

80. A blank according to claim 75, wherein each supplemental line of weakness is substantially the length of a panel.

81. A blank according to claim 74, and further comprising a transverse line of weakness beginning at or near to a boundary line of weakness and extending across a second boundary line of weakness towards a supplemental line of weakness.

82. A container comprising a loop of body portions, the boundaries between said portions being defined by respective, substantially straight boundary lines of weakness extending from top to bottom of said portions substantially perpendicularly to said loop, two adjacent boundary lines of weakness each having disposed at one side thereof a supplemental line of weakness, each supplemental line of weakness being substantially the length of a portion.

83. A container comprising a loop of body portions, the boundaries between said portions being defined by substantially straight boundary lines of weakness extending from top to bottom of said portions, two adjacent boundary lines of weakness each having disposed at respective opposite sides thereof a supplemental line of weakness, each supplemental line of weakness being at least half the length of a portion.

84. A container according to claim 82, wherein each supplemental line of weakness is located on one of said loop of body portions.

85. A container according to claim 82, and further comprising an additional supplemental line of weakness, wherein said adjacent boundary lines of weakness have disposed at respective opposite sides thereof a pair of supplemental lines of weakness.

86. A container according to claim 82, wherein each supplemental line of weakness does not contact a respective boundary line of weakness.

87. A container according to claim 82, and further comprising transverse lines of weakness beginning at or near to a boundary line of weakness and extending towards a respective supplemental line of weakness.

88. A container according to claim 83, wherein each supplemental line of weakness is substantially the height of the container, in length.

89. A container according to claim 82, and further comprising a transverse line of weakness beginning at or near to a boundary line of weakness and extending across a second boundary line of weakness towards a supplemental line of weakness.

90. A container according to claim 82, and further comprising a plastics insert attached to a boundary line of weakness.

91. A container according to claim 90, wherein the plastics insert is substantially the same shape as a body sub-portion to which said plastics insert is attached.

92. Apparatus for handling partially formed containers comprising

a conveying device including a plurality of receiving portions for receiving partially formed containers having a mid portion of predetermined cross-section,

a filling device arranged to fill said partially formed containers, and

a pressing device arranged to press on said mid portion so as to make said mid portion of rounder cross-section.

93. Apparatus according to claim 92, wherein each partially formed container comprising a loop of body portions, the boundaries between said portions being defined by boundary lines of weakness, two adjacent boundary lines of weakness having disposed at one side thereof a supplemental line of weakness, each supplemental line of weakness being at least half the height of the container, having upper and lower regions proximal to a respective boundary line of weakness and having a central region further from the respective boundary line of weakness than either the upper or lower region, and said pressing device is further arranged to activate the supplemental lines of weakness.

94. Apparatus according to claim 93, wherein said pressing device is arranged to activate the supplemental lines of weakness, prior to said filling station being arranged to fill said partially formed containers.

95. Apparatus according to claim 93, wherein said pressing device is arranged to activate the supplemental lines of weakness, during said filling station being arranged to fill said partially formed containers.

96. A method for handling partially formed containers, comprising

advancing a plurality of partially formed containers through a pressing device and a filling device, said partially formed containers having a mid portion of predetermined cross-section,

pressing on said mid portion so as to make said mid portion of rounder cross-section, and

filling said plurality of partially formed containers at the filling station.

97. A method according to claim 96, wherein each partially formed container comprising a loop of body portions, the boundaries between said portions being defined by boundary lines of weakness, two adjacent of said boundary lines of weakness having disposed at one side thereof a supplemental line of weakness, the supplemental line of weakness being at least half the height of the container, having upper and lower regions proximal to a respective boundary line of weakness and having a central region further from the respective boundary line of weakness than either the upper or lower region, and activating the supplemental lines of weakness at the pressing device.

98. A method according to claim 97, wherein said activating of the supplemental lines of weakness, occurs prior to the filling of said partially formed containers.

99. A method according to claim 97, wherein said activating of the supplemental lines of weakness, occurs during the filling of said partially formed containers.

100. A carton blank for a container including a quadrangular top obturating sub-panel, and disposed outwardly thereof, a top sealing sub-panel, a line of weakness separating said obturating sub-panel and said sealing sub-panel and bulging into said sealing sub-panel.

101. A blank according to claim 100, wherein said line of weakness separating said obturating sub-panel and said sealing sub-panel is arcuate.

102. A blank according to claim 100, wherein said line of weakness separating said obturating sub-panel and said sealing sub-panel is continuous along the boundary between said obturating sub-panel and said sealing sub-panel.

103. A blank according to claim 100, and further comprising a second line of weakness separating said obturating sub-panel from a body sub-panel and bulging into said body sub-panel.

104. A blank according to claim 100, and further comprising a second quadrangular top obturating sub-panel and disposed outwardly thereof, a second top sealing sub-panel, a third line of weakness separating said obturating sub-panel and said sealing sub-panel and bulging into said obturating sub-panel.

105. A blank according to claim 104, wherein said third line of weakness is substantially equal and opposite to the first line of weakness.

106. A container including a top closure including a roof sub-panel and a top sealing sub-panel, said roof sub-panel bulging into said sealing sub-panel.

107. A container according to claim 106, wherein said roof sub-panel bulging into said sealing sub-panel defines an arcuate line of weakness.

108. A container according to claim 107, wherein said line of weakness is continuous along the boundary between said roof sub-panel and said top sealing sub-panel.

109. A container according to claim 106, and further comprising, adjacent said roof sub-panel, a body portion, said roof sub-panel, bulging into said body portion.

110. A container according to claim 106, and further comprising a second roof sub-panel and a second top sealing sub-panel, a third line of weakness separating said second roof sub-panel and said second top sealing sub-panel and bulging into said roof sub-panel.

111. A container according to claim 110, wherein said third line of weakness is substantially equal and opposite to the first line of weakness.

112. A blank for forming a container comprising a row of panels comprising first, second, third and fourth panels and a row of substantially rectangular end closure panels extending substantially parallely to said row of panels and comprised of first, second, third and fourth end closure panels, each of the first and third end closure panels have disposed outwardly thereof a respective end sealing panel extending across the width of the adjacent end closure panel, and each of the second and fourth end closure panels have disposed outwardly thereof a respective pair of tabs, each tab extending across less than half the width of the adjacent end closure panel.

113. A blank according to claim 112, and further comprising a fifth panel having disposed outwardly thereof a fifth end closure panel, said fifth end closure panel having disposed outwardly thereof an end sealing panel extending across the width of the fifth end closure panel.

114. A blank according to claim 113, wherein each tab is connected to an adjacent end sealing panel.

115. A blank according to claim 112, wherein the width of each tab is substantially equal.

116. A blank according to claim 112, wherein each tab of a pair of tabs are substantially equal and opposite in shape.

117. A blank according to claim 112, wherein the depth of each tab is substantially equal to the depth of each sealing panel.

118. A container comprising a loop of body portions comprising first, second, third and fourth body portions and an end enclosure comprising

folded-in end closure portions and comprised of first, second, third and fourth end closure portions, each connected to a respective body portion, each of the first and third end closure portions being connected, at an opposite edge to the connection to a body portion, to a respective end sealing portion extending across the width of the adjacent end closure portion, and each of the second and fourth end closure portions being connected, at an opposite edge to the connection to a body portion, to a respective pair of tabs, each tab extending across less than half the width of the adjacent end closure portion, and

a sealing fin comprised of the end sealing portions and the pairs of tabs.

119. A container according to claim 118, and further comprising a fifth body portion being connected to a fifth end closure portion, said fifth end closure portion being connected, at an opposite edge to the connection to the body portion, to an end sealing portion extending across the width of the fifth end closure portion.

120. A container according to claim 119, wherein each tab is connected to an adjacent end sealing portion.

121. A container according to claim 118, wherein the width of each tab is substantially equal.

122. A container according to claim 118, wherein each tab of a pair of tabs are substantially equal and opposite in shape.

123. A container according to claim 118, wherein the depth of each tab is substantially equal to the depth of each sealing portion.