CARTON, BLANK THEREFOR AND PACKAGE WITH COLLAPSIBLE POCKET

Abstract

Aspects of the invention relate to a carton (90) for packaging one or more articles and a blank (10) for forming the carton (90). The carton (90) has a plurality of panels defining walls (12, 14, 16, 18, 20) of a chamber for receiving at least one article (A), the plurality of panels comprising a first panel (12) and a second panel (20) disposed in an overlapping relationship to form a first wall (12/20) of the carton (90), the carton (90) comprising a collapsible pocket (P) comprising a plurality of pocket walls including a front wall (30), opposing side walls (32, 34), a base wall (36) and a rear wall (20), at least one of plurality of pocket walls (30) being coupled to one (12) of the first and second panels (12, 20) by a frangible connection (29a).

Description

TECHNICAL FIELD

The present invention relates to a consumer package comprising a collapsible pocket feature that enables the package to be expanded in order to increase the load space of the package.

BACKGROUND

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers. Such multi-packs are desirable for shipping and distribution purposes and for the display of promotional information.

For cost and environmental considerations, it is preferable if such cartons are formed from as little material as possible and cause as little wastage as possible in the materials from which they are formed. Another consideration is the strength of the packaging and its suitability for holding and transporting large weights of articles.

In the packaging industry automatic, high-speed processing of the blanks that form the cartons, part-formed cartons and filled cartons is required. In designing packages, consideration needs to be given to automatic, high-speed processing and compatibility with existing automatic machinery.

The present invention seeks to overcome or at least mitigate the problems of the prior art by providing a carton having a folded collapsible structure, which collapsible structure can be opened out and erected into a pocket to increase the load capacity of the carton.

SUMMARY

A first aspect of the invention provides a carton for packaging one or more articles, having a plurality of panels defining walls of a chamber for receiving at least one article. The plurality of panels comprises a first panel and a second panel disposed in an overlapping relationship to form a first wall of the carton. The carton comprises a collapsible pocket comprising a plurality of pocket walls including a front wall, opposing side walls, base wall and a rear wall. At least one of the plurality of pocket walls may be coupled to one of the first and second panels by a frangible connection.

Optionally, the frangible connection comprises a tear initiation point.

Optionally, the at least one of the pocket walls comprises the front wall of the pocket, the one of the first and second panels comprises the first panel, and the front wall is frangibly coupled to the first panel by the frangible connection.

Optionally, the at least one of the pocket walls comprises one of the opposing side walls of the pocket, the one of the first and second panels comprises the first panel, and the one of the opposing side walls is frangibly coupled to the first panel by the frangible connection.

Optionally, each of the opposing side walls of the pocket passes through an opening in the first wall of the carton and is moveable between a first stowed position within the chamber and a second deployed position where each of the opposing side walls at least partially is disposed outside the chamber.

Optionally, the front wall of the pocket is frangibly connected to the first panel.

Optionally, one of the opposing side walls of the pocket is frangibly connected to the first panel.

Optionally, each of the opposing side walls of the pocket passes through an opening in the first wall of the carton and is moveable between a first stowed position within the chamber and a second deployed position.

Optionally, each of the opposing side walls comprises at least one end stop for limiting travel thereof.

Optionally, each of the opposing side walls of the pocket comprises a securing flap hingedly connected thereto.

Optionally, each of the opposing side walls of the pocket comprises a securing flap frangibly connected to the second panel.

Optionally, the base wall comprises a first panel hingedly connected to an end edge of the front wall of the pocket and a base wall securing flap struck at least in part from the second panel of the first wall.

Optionally, the base wall securing flap comprises a fold line and is foldable about the fold line such that a first portion of the base wall securing flap is disposed in face to face contacting relationship with a second portion of the base wall securing flap when the pocket is in a deployed condition.

Optionally, the base wall of the pocket comprises a first base panel hingedly connected to a first one of the opposing side walls, a second base panel hingedly connected to the front wall, a first web panel hingedly connecting the first and second base panels, a third base panel hingedly connected to a second one of the opposing side walls and a second web panel hingedly connecting the second and third base panels.

Optionally, the second web panel is secured to the second base panel.

Optionally, one of the opposing side walls of the pocket is hingedly connected to the front wall along a first side edge of one of the opposing said side walls and is hingedly connected to a securing flap along a second, opposing, side edge of said side walls.

Optionally, the carton comprises a securing tab frangibly connected to the front wall.

Optionally, a securing tab is frangibly connected to the front wall along an end edge of the front wall disposed adjacent to the hinged connection between said one of the opposing side walls of the pocket and the front wall.

A second aspect of the invention provides a blank for forming a carton. The blank comprises a plurality of panels for defining walls of a chamber for receiving at least one article. The plurality of panels are arranged in a linear series hinged one to the next. The plurality of panels includes a first panel and a second panel for being disposed in an overlapping relationship to form a first wall of the carton. The blank comprises a collapsible pocket structure; the pocket structure comprises a plurality of pocket wall panels including a front wall panel, opposing side wall panels, a base wall panel and a rear wall panel. At least one of the plurality of pocket wall panels may be coupled to one of the first and second panels by a frangible connection.

A third aspect of the invention provides a carton comprising a collapsible pocket structure that is movable between a collapsed/stowed position and an expanded position, a first code placed in part on the pocket structure and in part on the other part of the carton such that the first code is readable when the pocket structure is in the collapsed/stowed position and such that the first code is unreadable, at least in part, when the pocket structure is in the expanded position, and a second code placed on either the pocket structure or the other part of the carton such that the second code is hidden from view when the pocket structure is in the collapsed/stowed position and such that the second bar code is exposed to view when the pocket structure is in the expanded position.

Optionally, the first and second codes are machine readable.

Optionally, the second code is obscured to prevent machine reading when the pocket structure is in the collapsed/stowed position and such that the second bar code is machine readable when the pocket structure is in the expanded position.

A fourth aspect of the invention provides a carton comprising a collapsible pocket structure that is movable between a collapsed/stowed position and an expanded position, a first code placed in part on the pocket structure and in part on the other part of the carton such that the first code is machine readable when the pocket structure is in the collapsed/stowed position and such that the first code is machine unreadable, at least in part, when the pocket structure is in the expanded position, and a second code placed on either the pocket structure or the other part of the carton such that the second code is machine unreadable when the pocket structure is in the collapsed/stowed position and such that the second bar code is machine readable when the pocket structure is in the expanded position.

A fifth aspect of the invention provides a carton comprising a collapsible pocket structure that is movable between a collapsed/stowed position and an expanded position, a first code provided at least in part on the pocket structure such that the first code is machine readable when the pocket structure is in the collapsed/stowed position and a second code placed at least in part on the pocket structure such that the second code is machine unreadable when the pocket structure is in the collapsed/stowed position and such that the second bar code is machine readable when the pocket structure is in the expanded position.

Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a plan view from above of a blank for forming a carton according to a first embodiment of the invention;

FIGS. 2 to 4 illustrate stages of construction of the blank of FIG. 1 into a flat collapsed structure;

FIG. 5 is a perspective view of a carton formed from the blank of FIG. 1;

FIG. 6 is a perspective view from above of the carton of FIG. 5, wherein the collapsible pocket feature has been deployed and loaded with additional articles;

FIG. 7 is a plan view from above of a blank for forming a carton according to a second embodiment of the invention;

FIGS. 8 to 11 illustrate stages of construction of the blank of FIG. 7 into a flat collapsed structure;

FIG. 12 is a perspective view of a carton formed from the blank of FIG. 7; and

FIG. 13 is a perspective view from above of the carton of FIG. 12, wherein the collapsible pocket feature has been deployed and loaded with additional articles.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Detailed descriptions of specific embodiments of the package, blanks and cartons are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packages, blanks and cartons described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Referring to FIG. 1 there is shown a plan view of a blank 10 that can be assembled into a carton 90 (see FIGS. 5 and 6) which is capable of accepting an input of primary products such as, but not limited to, bottles or cans, hereinafter referred to as articles A.

In the embodiments detailed herein, the terms “carton” and “carrier” refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging, carrying, and/or dispensing articles, such as product containers. It is contemplated that the teachings of the invention can be applied to various product containers, which may or may not be tapered and/or cylindrical. Exemplary containers include bottles (for example metallic, glass or plastics bottles), cans (for example aluminium cans), tins, pouches, packets and the like.

The blanks 10, 110 are formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, Kraft board, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, where suitable, for example, to provide the carton 90, 190 described in more detail below.

In the exemplary embodiment, the blank 10 is configured to form a carton 90 optionally of the fully enclosed type, for packaging an exemplary arrangement of exemplary articles. In a first illustrated exemplary embodiment, the carton 90 is configured to accept articles in a main compartment or chamber in a 2×3 matrix or array arrangement, and comprises a pocket expandable to accept 3 additional articles in a 1×3 matrix or array arrangement; and the articles are 25 cl aluminium cans. In a second illustrated exemplary embodiment, the carton 190 is configured to accept articles in a main compartment in a 2×3 matrix or array arrangement, and comprises a pocket expandable to accept 2 additional articles in a 1×2 matrix or array arrangement. The blanks 10, 110 can be alternatively configured to form a carrier for packaging other types, number and size of article and/or for packaging articles in a different arrangement or configuration.

Referring back to FIG. 1, it can be seen that the blank 10 comprises a plurality of main panels, optionally arranged in a linear series, that form enclosing walls of the carton 90. Optionally, the series of main panels includes: a first outer side panel 12, a top panel 14, a second side panel 16, a bottom panel 18 and a first inner side panel 20. The first outer panel 12, top panel 14, second side panel 16, bottom panel 18 and first inner side panel 20 are hinged together in series by fold lines 13, 15, 17 and 19 respectively. A pocket base panel 36 is hinged to the first outer side panel 12 by a fold line 35.

A first series of end flaps is provided at a first end of the blank 10. The first series of end flaps includes: a first end flap 22a, hinged by a fold line 21a to a first end of the first outer side panel 12; a second end flap 24a, hinged by a fold line 23a to a first end of the top panel 14; a third end flap 26a, hinged by a fold line 25a to a first end of the second side panel 16; and a fourth end flap 28a, hinged by a fold line 27a to a first end of the bottom panel 18. In use, the first, second, third and fourth end flaps 22a, 24a, 26a, 28a form a first end wall 22a/24a/26a/28a of the carton 90.

A second series of end flaps is provided at a second end of the blank 10. The second series of end flaps includes: a fifth end flap 22b, hinged by a fold line 21b to a second end of the first outer side panel 12; a sixth end flap 24b, hinged by a fold line 23b to a second end of the top panel 14; a seventh end flap 26b, hinged by a fold line 25b to a second end of the second side panel 16; and an eighth end flap 28b, hinged by a fold line 27b to a second end of the bottom panel 18. In use, the fifth, sixth, seventh and eighth end flaps 22b, 24b, 26b, 28b form a second end wall 22b/24b/26b/28b of the carton 90.

The blank 10 comprises a collapsible pocket feature P (see FIG. 6) which can be expanded to increase the load capacity of the carton 90.

The pocket feature P is formed in part in the first outer side panel 12 and in part in the first inner side panel 20.

The first outer side panel 12 comprises a front wall 30 of the pocket feature P. The front wall 30 is struck from the first outer side panel 12 and is defined in part by a first cutline 29e, a second cutline 29d, a third cutline 29c, a fourth cut line 29b and a weakened line of severance 29a. Weakened line of severance 29a comprises at least one frangible connection F; in the illustrated embodiment six frangible connections F are provided. The weakened line of severance 29a is interrupted by an aperture A1. The aperture A1 forms a tear initiation point for a user to sever the weakened line of severance 29a and deploy the pocket feature P.

The front wall 30 is substantially “T” shaped. The front wall 30 extends across the first outer side panel 12 from a first edge defined by fold line 21a to a second edge defined by fold line 21b. Third cutline 29c is collinear with fold line 21a and fourth cut line 29b is collinear with fold line 21b. The pocket base panel 36 is hinged to the front wall 30 by fold line 35. Optionally, the front wall 30 comprises a first fold line 31 and a second fold line 33. First fold line 31 defines in part an optional first bevel panel 32 and second fold line 33 defines in part an optional second bevel panel 34.

The first inner side panel 20 comprises a securing flap 40, configured to be secured to the pocket base panel 36. The securing flap 40 comprises a fold line 41 which defines in part a first portion 42 for being secured to the pocket base panel 36.

The first inner side panel 20 comprises a second securing flap 46a and a third securing flap 46b. The second securing flap 46a is hingedly connected to a first pocket side panel 44a by a fold line 43a. The second securing flap 46a is defined in part by severable line 47a defined in the first inner side panel 20, such that the second securing flap 46a and the first pocket side panel 44a are detachable from the first inner side panel 20. The third securing flap 46b is hingedly connected to a second pocket side panel 44b by a fold line 43b. The third securing flap 46b is defined in part by severable line 47b defined in the first inner side panel 20 such that the third securing flap 46b and the second pocket side panel 44b are detachable from the first inner side panel 20.

The first pocket side panel 44a comprises a pair of tabs 50a extending from opposing side edges. The tabs 50a are disposed proximate a free end edge of the first pocket side panel 44a. Each of the tabs 50a provides a shoulder each having an engagement edge 51a. The engagement edges 51a define end stops limiting the travel of the first and second pocket side panels 44a, 44b.

Optionally, the bottom panel 18 comprises an opening A2, which exposes to view a portion of one or more articles disposed therein.

The blank 10 in FIG. 1 is shown with an inside surface (sometimes with bleached paperboard, referred to as the “brown side”) facing outwards.

To form a part-assembled, flat-form structure as shown in FIG. 4, the bottom panel 18 and first inner side panel 20 are folded about fold line 17, as indicated by direction arrow D1 in FIG. 2, into face contacting relationship with the second side panel 16 and the top panel 14 respectively.

Glue G or other adhesive treatment is applied to the first, second and third securing flaps 40, 46a, 46b and to the first inner side panel 20.

The pocket base panel 36 is folded about fold line 35, as indicated by direction arrow D2 in FIG. 3, into face contacting relationship with the first outer side panel 12.

The blank 10 is then folded about fold line 13, as indicated by direction arrow D3 in FIG. 4, to bring the first outer side panel 12 into overlapping relationship with the first inner side panel 20. The first outer side panel 12 is secured to the first inner side panel 20. The pocket base panel 36 is brought into face contacting relationship with the first securing flap 40. The pocket base panel 36 is secured to the first securing flap 40.

The resulting structure is a part-assembled, flat-form carton as shown in FIG. 4. The part-assembled, flat-form carton can be readily shipped or distributed in its flat form.

As can be seen in FIG. 2, the weakened line of severance 29a maintains a temporary connection between the front wall 30 of the pocket feature P and the adjacent portion of the first outer side panel 12. In this way, the carton 90 is less likely to become caught up on parts of the machinery used in the processing and assembly of the blanks and the processing and filling of the cartons. This may beneficially mitigate against significant down-time of machinery which can otherwise be experienced when jutting out portions of blanks or part-assembled cartons become caught or jammed in the machinery.

When it is required to complete the construction of the carton 90, the part-assembled, flat-form carton can be opened out (optionally by pulling the first side panel 12/20 upwardly and away from the top panel 14).

The carton 90 is then erected to form a tubular structure open at both ends; the carton 90 can then be loaded with articles A through the one or both open ends.

To close the first open end, the first and third end flaps 22a, 26a, which form minor end flaps or dust flaps, are folded inwardly about fold lines 21a, 25a. The second end flap 24a is folded downwardly about fold line 23a. Glue or other adhesive treatment is applied to the second end flap 24a or to the fourth end flap 28a. The fourth end flap 28a is folded upwardly about fold line 27a and secured to the second end flap 24a.

Optionally, glue or other adhesive treatment is applied to the first and third end flaps 22a, 26a so as to secure them to one or both of the second and fourth end flaps 24a, 28a.

To close the second open end, the fifth and seventh end flaps 22b, 26b, which form minor end flaps or dust flaps, are folded inwardly about fold lines 21b, 25b. The sixth end flap 24b is folded downwardly about fold line 23b. Glue or other adhesive treatment is applied to the sixth end flap 24b or to the eighth end flap 28b. The eighth end flap 28b is folded upwardly about fold line 27b and secured to the sixth end flap 24b.

Optionally, glue or other adhesive treatment is applied to the fifth and seventh end flaps 22b, 26b so as to secure them to one or both of the sixth and eighth end flaps 24b, 28b.

The assembled carton 90 is shown in FIG. 5. The pocket feature P is stowed in a collapsed form in a first stowed position.

The pocket feature P can be deployed to an expanded condition as shown in FIG. 6. A user can engage the front wall panel 30 via the aperture A1 and pull the front wall panel 30 away from the first inner side wall 20, as indicated by direction arrow D4 in FIG. 6. The pocket feature P in the deployed condition can receive one or more articles A. In the illustrated embodiment the pocket feature P receives three additional articles A similar to those disposed within the main carton compartment.

When the pocket feature P is deployed the second and third securing flaps 46a, 46b are separated from the first inner side panel 20 by severing the weakened lines 47a, 47b. The first and second pocket side walls 44a, 44b are linearly translatable or moveable within respective openings O defined in the composite side wall 12/20; that is to say, the first and second pocket side walls 44a, 44b may be slid within the respective openings defined in the composite side wall 12/20. The composite side wall 12/20 is formed from the first inner and first outer side panels 12, 20. The openings are defined in part by a respective one of the cut lines 29c, 29b and in part by a respective one of the severable lines 47a, 47b. The tabs 50a/50b provide end stops preventing the first and second pocket side walls 44a, 44b being fully withdrawn through the respective one of the opening in the composite side wall 12/20. When the pocket feature P is in the second deployed position each of the opposing side walls is at least partially disposed outside the main carton compartment or chamber.

The base wall 36/40 is simultaneously erected as the first and second pocket side walls 44a, 44b are drawn through the respective one of the openings in the composite side wall 12/20.

The pocket base panel 36 is unfolded about fold line 35 so as to be substantially perpendicular to the front wall panel 30. The first securing flap 40 is unfolded about fold line 39, which is optionally collinear with fold line 19. The first securing flap 40 is folded about fold line 41 so as to bring an inner surface of the first portion 42 into face to face relationship with the other portion of the first securing flap 40.

The frangible connections F are destroyed when the pocket feature P is first deployed. However, it will be appreciated that the pocket feature P can be returned to the stowed condition if desired.

Optionally, the carton 90 may comprise a first indicia 92. The first indicia 92 is provided on the composite side wall 12/20. A first portion 98 of the first indicia 92 is provided on the at least one of the first bevel panel 32, front wall panel 30 and second bevel panel 34. In the embodiment illustrated in FIGS. 5 and 6 the first portion 98 of the first indicia 92 is provided in part on the front wall panel 30 and in part on the second bevel panel 34. A second portion 96 of the first indicia 92 is provided on a region of the first outer side panel 12 adjacent to the front wall panel 30 and in part on the second bevel panel 34. The first indicia 92 is therefore provided on both sides of the weakened line of severance 29a. The first indicia 92 is optionally provided on both sides of the fold line 33. In other embodiments, the first indicia 92 may be provided on both sides of fold line 31. In still other embodiments the first portion 98 of the first indicia 92 may be provided only on one of the first bevel panel 32, front wall panel 30 and second bevel panel 34.

The first indicia 92 may contain information characteristic of the package 90 when the pocket feature P is in the stowed condition. For example, but not limited to, the information may relate to the sales price of the package 90 the pocket feature P is in the stowed condition.

The information provided on the indicia may directly indicate the sales price or may contain a code which identifies the package 90. The code may be associated with pricing information in a point of sale system or computer. For example, the code may take the form of a barcode symbol such as Universal Product Code (UPC). Optionally, the code may be machine readable by for example, but not limited to, optical scanning such as a barcode, the barcode may be linear or one-dimensional in which data is represented by varying the width and spacing of parallel lines or may two-dimensional codes or matrix barcodes for example employing rectangles, dots, hexagons and/or other geometric patterns in two dimensions.

When the pocket feature P is deployed the first indicia 92 may be separated into two or more parts which are spaced apart from one another.

When the pocket feature P is in the deployed condition the first indicia 92 may be altered so as to indicate that the information provided is no longer applicable or to be used.

When the pocket feature P is in the deployed condition the first indicia 92 may be damaged or destroyed such that is becomes unusable or unreadable.

At least a portion of the first indicia 92 may be obscured from view when the pocket feature P is loaded with additional articles A.

In further alternative embodiments the first indicia 92 may be provided in alternative locations. A first alternative location 93 and a second alternative location 94 are shown in FIG. 5. In the first alternative location 93 the first indicia is provided in part on the first outer side panel 12 and in part on the first bevel panel 32 and in part on the front wall panel 30, however it will be appreciated that the first indicia may be disposed in part on the first outer side panel 12 and in part on only one of the first bevel panel 32 and the front wall panel 30.

In the second alternative location 94 the first indicia is provided in part on the first outer side panel 12 and in part on the second bevel panel 34 and in part on the front wall panel 30, however it will be appreciated that the first indicia may be disposed in part on the first outer side panel 12 and in part on only one of the second bevel panel 34 and the front wall panel 30.

The carton 90 may comprise a second indicia 99 as shown in FIG. 6. The second indicia 99 is visible when the pocket feature P is deployed. In the embodiment of FIG. 6 the second indicia is provided or located upon the first pocket side wall panel 44a. The second indicia 99 becomes exposed to view when the pocket feature is deployed. In the illustrated embodiment this is achieved when the first pocket side wall panel 44a is moved from a first position in which it is disposed internally of the main carton compartment to a second position in which a portion of the first pocket side wall panel 44a is disposed externally of the main carton compartment. In other embodiments the second indicia 99 may be provided additionally or alternatively upon a region of the second pocket side wall panel 44b which becomes disposed external to the main compartment of the carton 90 when the pocket feature P is deployed. In still other embodiments the second indicia 99 may be provided upon the base wall panel 40 or portion of the securing flap 40.

The second indicia 99 may contain information characteristic of the package 90 when the pocket feature P is in the deployed condition. For example, but not limited to, the information may relate to the sales price of the package 90 when the pocket feature P is in the deployed condition. The information provided on the second indicia 99 may directly indicate the sales price or may contain a code which identifies or is indicative of the pocket feature P as being in the deployed condition.

In this way the package 90 may comprise two different product or price codes such that a point of sale system determines the correct sale price and consequently the state (stowed or deployed) in which the package may be determined.

The first and second indicia 92, 99 may be printed directly upon the material substrate forming the carton 90 or may be provided on a separate label or other printed material. When a separate label is employed the label may be secured adhesively to the carton 90. In the case where a label is employed for providing the first indicia 92 the label may comprise a perforated line or be otherwise weakened such that it is divisible into at least two parts when the pocket features deployed. The label may be used in addition to, or as an alternative to, the weakened line of severance 29a and the frangible connections F for holding the pocket feature P in the stowed condition. The label may be applied to portion of the first outer side panel 12 and to a portion of at least one of the first bevel panel 32, the second bevel panel 34 and the front wall panel 30.

Referring now to FIGS. 7 to 13, there is shown an additional embodiment of the present disclosure. In the second illustrated embodiment like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “100” to indicate that these features belong to the second embodiment. The additional embodiment shares many common features with the previous embodiment and therefore only the differences from the embodiment illustrated in FIGS. 1 to 6 will be described in detail.

Referring to FIG. 7, it can be seen that the blank 110 comprises an optional linear series of main panels that form enclosing walls of the carton 190. Optionally, the series of main panels includes: a first outer side panel 112, a top panel 114, a second side panel 116, a bottom panel 118 and a first inner side panel 120. The first outer panel 112, top panel 114, second side panel 116, bottom panel 118 and first inner side panel 120 are hinged together in series by fold lines 113, 115, 117 and 119 respectively.

A first series of end flaps is provided at a first end of the blank 110. The first series of end flaps includes: a first end flap 122a, hinged by a fold line 121a to a first end of the first outer side panel 112; a second end flap 124a, hinged by a fold line 123a to a first end of the top panel 114; a third end flap 126a, hinged by a fold line 125a to a first end of the second side panel 116; and a fourth end flap 128a, hinged by a fold line 127a to a first end of the bottom panel 118. The first series of end flaps 122a, 124a, 126a, 128a includes an additional end flap. A first inner end flap 160a is hinged to a first end of the first inner side panel 120. A plurality of apertures A3 define a hinged connection between the first inner end flap 160a and the first inner side panel 120.

In use the first, second, third, fourth and first inner end flaps 122a, 124a, 126a, 128a, 160a form a first end wall 122a/124a/126a/128a/160a of the carton 190.

A second series of end flaps is provided at a second end of the blank 110. The second series of end flaps includes: a fifth end flap 122b, hinged by a fold line 121b to a second end of the first inner side panel 112; a sixth end flap 124b, hinged by a fold line 123b to a second end of the top panel 114; a seventh end flap 126b, hinged by a fold line 125b to a second end of the second side panel 116; and an eighth end flap 128b, hinged by a fold line 127b to a second end of the bottom panel 118. The second series of end flaps includes a further additional end flap. A fifth inner end flap 160b is hinged by a fold line 161b to a second end of the first inner side panel 120.

In use, the fifth, sixth, seventh, eighth and fifth inner end flaps 122b, 124b, 126b, 128b, 160b form a second end wall 122b/124b/126b/128b/160b of the carton 190.

The blank 110 comprises an alternative collapsible pocket feature P (see FIG. 13) which can be expanded to increase the load capacity of the carton 190.

The pocket feature P is formed in part from the first outer side panel 112 and in part from the first inner side panel 120.

The pocket feature P comprises a front wall panel 130 struck from the first outer side panel 112; a first pocket side wall 132 struck from the first outer side panel 112; and a second pocket side wall 134 struck from the fifth end closure flap 122b. The first pocket side wall 132 is hingedly connected to the front wall panel 130 by a fold line 131. The first pocket side wall 132 is hingedly connected to the blank 110 by a hinged connection, optionally to the first end closure flap 122a by a fold line 137. The second pocket side wall 134 is hingedly connected to the front wall panel 130 by a fold line 133. A securing flap 164 is hingedly connected to the second pocket side wall 134 by a fold line 165. Optionally, the fold line 165 is interrupted by a cut line 167.

The first pocket side wall 132 and the front wall panel 130 are severably connected to an upper portion of the first inner side panel 112 by a severable line 129a comprising a plurality of frangible connection points F. The severable line 129a may be interrupted by an aperture A1 so as to define a tear initiation point.

A pocket base panel structure 170, comprising a plurality of base panels 172, 174,176, 178, 182, is hinged in part to the first outer side panel 112 by fold lines 173,183 and in part to the sixth end flap 122b by fold line 187. The pocket base panel structure 170 comprises a first base panel 172 hinged to the first pocket side wall 132 by a hinged connection in the form of a fold line 173. A second base panel 174 is hinged to the first base panel 172 by a fold line 175. Fold line 175 is interrupted by an aperture A4 which partially separates the first and second base panels 172,174. A third base panel 176 is hinged to the front wall panel 130 by a fold line 183. The second base panel 174 is hinged to the third base panel 176 by a fold line 177. Fold line 177 is obliquely arranged with respect to fold line 183 and intersects the fold line 183 at a first end thereof. Third base panel 176 is hingedly connected to a fourth base panel 178 by a fold line 179. A fifth base panel 182 is hinged to the second pocket side wall 134 by a fold line 187. The fifth base panel 182 is hinged to the fourth base panel 178 by a fold line 181. Fold line 181 is obliquely arranged with respect to fold line 187. Optionally, fold line 181 is interrupted by a cutline 189. Cutline 189 may be substantially semi-circular in shape. Cutline 189 defines at least in part a securing tab T integrally formed with the fourth base panel 178 and struck from the fifth base panel 182.

The second and fourth base panels 174,178 form first and second web panels respectively. The first web panel hingedly connects the first base panel 172 to the third base panel 176. The second web panel hingedly connects the third base panel 176 to the fifth base panel 182.

Fold line 179 is interrupted by an aperture A5; aperture A5 separates, at least in part, the fourth and fifth base panels 178, 182 from third base panel 176.

A second securing tab 180 is frangibly connected to the front wall panel 130 by a severable line 185. The second securing tab 180 extends into the aperture A5, such that the aperture A5 defines a free end edge and a pair of opposing free side edges of the second securing tab 180.

Optionally, the blank 110 comprise a tab 162 defined in part by a nonlinear cutline 163; the cutline 163 may be “U” shaped. The cutline 163 is arranged such that the tab 162 interrupts the fold line 119 between the bottom panel 118 and the first inner side wall panel 120. The tab 162 may provide a catch or ledge for limiting travel of the pocket base panel structure 170 by engaging with one of the plurality of base panels 172, 174,176, 178, 182.

Turning to the construction of the carrier 190 from the blank 110, the carrier 190 may be formed by a series of sequential folding operations in a straight line machine so that the carrier 190 may not be required to be inverted to complete its construction.

To form a part-assembled, flat-form structure as shown in FIG. 11, the first, second, third, fourth and fifth base panels 172, 174, 176, 178 are folded about fold lines 173, 183, 187, as indicated by direction arrow D5 in FIG. 8, into face contacting relationship with the first pocket side wall panel 132, front wall panel 130 and second pocket side wall panel 134 respectively.

Glue G or other adhesive treatment is applied to the third base panel 176 or alternatively to the fourth base panel 178.

The blank 110 is folded about fold line 133, as indicated by direction arrow D6, such that the securing flap 164 is brought into overlying relationship with the second and third base panels 174, 176 and the second pocket side wall panel 134 is in overlying relationship with the third base panel 176 and the front wall panel 130. The fourth base panel 178 is brought into face contacting relationship with the third base panel 176 and is secured thereto as shown in FIG. 9.

The blank 110 is folded about fold line 117, as indicated by direction arrow D7, such that the first inner side panel 120 is brought into overlapping relationship with the top panel 114 and the base panel 118 is brought into overlapping relationship with the second side panel 116.

Glue G or other adhesive treatment is applied to the first inner side panel 120, to the first inner end flap 160a and to the fifth inner end closure flap 160b or alternatively to the fourth base panel 178 as shown in FIG. 10.

Glue G or other adhesive treatment is applied to the bottom panel 118.

The blank 110 is folded about fold line 113, as indicated by direction arrow D8, such that the first outer side panel 112 is brought into overlapping relationship with the first inner side panel 120 and the top panel 114. The first outer side panel 112 is brought into face to face contacting relationship with the first inner side panel 120 and is secured thereto.

The second securing tab 180 is secured to the bottom panel 118.

The resulting structure is a part-assembled, flat-form carton as shown in FIG. 11. The part-assembled, flat-form carton can be readily shipped or distributed in its flat form.

The carton 190 can be erected and loaded in similar manner to that described above in relation to the first embodiment of FIG. 1 so as to form the package illustrated in FIG. 12. The package comprises the erected carton 190 and one or more articles disposed therein.

The assembled carton 190 is shown in FIG. 12; the pocket feature P is stowed in a collapsed form.

The pocket feature P can be deployed to an expanded condition as shown in FIG. 13. A user can engage the front wall panel 130 via the aperture A1 and pull the front wall panel 130 away from the first inner side wall 120, as indicated by direction arrow D9 in FIG. 13. The pocket feature P when in the deployed condition can receive one or more articles A. In the illustrated embodiment the pocket feature receives two additional articles A similar to those disposed within the main compartment of the carton 190.

When the pocket feature P is deployed the first and second pocket side walls 132, 134 are brought into substantially perpendicular arrangement with the first inner side panel 120 by folding about fold lines 137 and 167 respectively.

The pocket base panel structure 170, comprising a plurality of base panels 172, 174, 176, 178, 182, is simultaneously erected as the front wall panel is separated from the first inner side panel 120.

The pocket base panel structure 170 is folded such that in the erected condition the second base panel 174 is disposed between the first and third base panels 172, 176. The fourth base panel 178 is disposed between the third and fifth base panels 176, 182. When the pocket feature P is deployed the blank 110 is folded about fold lines 175, 177, 179 and 181.

The frangible connections F and the severable line 185 are destroyed or severed when the pocket feature P is first deployed. However, it will be appreciated that the pocket feature P can be returned to the stowed condition if desired.

The first inner side wall panel 120 provides a rear wall of the pocket feature P.

Optionally, the carton 190 may comprise a first indicia 192, the first indicia 192 is provided on the composite side wall 112/120. A first portion 198 of the first indicia 192 is provided on at least one of the first pocket side wall 132 and the front wall panel 130. In the embodiment illustrated in FIGS. 12 and 13 the first portion 198 of the first indicia 192 is provided on first pocket side wall 132. A second portion 196 of the first indicia 192 is provided on a region of the first outer side panel 112 adjacent to the first pocket side wall 132. The first indicia 192 is therefore provided on both sides of the severable line 129a. The first portion 198 of the first indicia 192 is optionally provided on both the first pocket side wall 132 and the front wall panel 130 so as to be disposed on both sides of the fold line 131. In still other embodiments the first portion 198 of the first indicia 192 may be provided only on the front wall panel 130.

The first indicia 192 may contain information characteristic of the package 90 when the pocket feature P is in the stowed condition. For example, but not limited to, the information may be indicative of the sales price, it may be a first product code which can be employed to determine the sales price of the package 190 when the pocket feature P is in the stowed condition.

When the pocket feature P is deployed the first indicia 192 may be separated into two parts which are spaced apart from one another.

When the pocket feature P is in the deployed condition the first indicia 192 may be altered so as to indicate that the information provided is no longer applicable or to be used.

When the pocket feature P is in the deployed condition the first indicia 92 may be damaged or destroyed such that is becomes unusable or unreadable.

At least a portion of the first indicia 192 may be obscured from view when the pocket feature P is loaded with additional articles A.

The carton 190 may comprise a second indicia 199 as shown in FIG. 13. The second indicia 199 is visible when the pocket feature P is deployed. In the embodiment of FIG. 13 the second indicia 199 is provided or located upon the first inner side panel 120. The second indicia 199 becomes exposed to view when the pocket feature P is deployed. In the illustrated embodiment this is achieved when the second pocket side wall panel 134 is folded away from the first inner side panel 120. In other embodiments the second indicia 199 may be provided additionally or alternatively upon a region of the second pocket side wall panel 134 which becomes exposed to view when the pocket feature P is deployed. In still other embodiments the second indicia 99 may be provided upon one or more of the plurality of base panels 172, 174,176, 178, 182.

The second indicia 199 may contain information characteristic of the package 190 when the pocket feature P is in the deployed condition. For example, but not limited to, the information may be indicative of the sales price, it may be a second product code which can be employed to determine the sales price of the package 190 when the pocket feature P is in the deployed condition. The information provided on the second indicia 199 may directly indicate the sales price or may contain a code which identifies or is indicative of the fact that the pocket feature P is in the deployed condition.

In this way the package 190 may comprise two different product or price codes such that a point of sale system determines the correct sale price and consequently the state (stowed or deployed) in which the package may be determined.

The first and second indicia 192, 199 may be printed directly upon the material substrate forming the carton 190 or may be provided on a separate label or other printed material. When a separate label is employed the label may be secured adhesively to the carton 190. In the case where a label is employed for providing the first indicia 192 the label may comprise a perforated line or be otherwise weakened such that it is divisible into at least two parts when the pocket features deployed. The label may be used in addition to, or as an alternative to, the severable line 129a and the frangible connections F for holding the pocket feature P in the stowed condition. The label may be applied to portion of the first outer side panel 12 and to a portion of at least one of the first pocket side wall 32 and the front wall panel 30. The label may be applied to portion of the front wall panel 30 and to a portion of at least one end closure panels 160b, 128b, 124b, 122b, 126b for closing the second end of the carton 190.

The present disclosure provides a carton for packaging one or more articles having a plurality of panels defining the walls of a primary chamber for receiving at least one article. The plurality of panels may be arranged as a linear series hingedly connected one to the next. The plurality of panels includes a first panel and a second panel disposed in at least a partially overlapping relationship to form a first wall of the carton. The carton comprises a collapsible pocket defined by a plurality of pocket walls including a front wall and opposing side walls, base wall and a rear wall and defining a secondary chamber. At least one of the plurality of pocket walls is severably coupled to one of the first and second panels by a frangible connection. The pocket can be deployed and accessed without requiring access to the primary chamber. Articles can be loaded and removed from the secondary chamber without interaction with the primary chamber. The base wall of the pocket may be automatically formed when the pocket is deployed. Advantageously, the carton is formed from a single unitary blank. The pocket is formed from a pair of overlapping panels which form a composite wall of the primary chamber such that the number of gluing stages is reduced. The construction of the pocket can be carried out as part of the construction of a flat collapsed tubular structure, the flat collapsed tubular structure forming walls of the primary chamber.

The base wall of the pocket is disposed between the first and second panels when in a collapsed or stowed condition.

The carton can be readily assembled in a packaging machine. The pocket is held securely by the frangible connection such that the carton may be shipped in a flat collapsed form to a convertor plant in which the carton is erected and loaded. The pocket may remain in a flat collapsed form, the carton having one or more primary product containers in the primary chamber; the carton may be shipped in this form to a point of sale. A consumer or retailer may deploy the pocket and load the secondary chamber with additional primary product containers as desired.

The present disclosure provides a carton comprising a collapsible pocket structure that is movable between a collapsed/stowed position and an expanded position. A first code is placed in part on the pocket structure and in part on the other part of the carton such that the first code is machine readable when the pocket structure is in the collapsed/stowed position and such that the first code is machine unreadable, at least in part, when the pocket structure is in the expanded position. A second code is placed on either the pocket structure or the other part of the carton such that the second code is machine unreadable when the pocket structure is in the collapsed/stowed position and such that the second code is machine readable when the pocket structure is in the expanded position.

It will be appreciated that the first and second codes may be arranged such that the first code is only readable when in the stowed position and the second code is only readable when in the deployed position.

In some embodiments the first and second indicia may be provided by two layers disposed in overlapping relationship, an inner layer may be provided by the first inner side panel 20, 120 and an outer layer may be provided by the first outer side panel 12, 112.

The outermost layer of the first indicia may be translucent or transparent at least in part, when the inner most layer is disposed in close proximity to the outermost layer the first indicia displays a complete code or information which is readable by eye or by a machine.

The outermost layer of the second indicia may be translucent or transparent at least in part, when the inner most layer is spaced away from the outermost layer the second indicia displays a complete code or information which is readable by eye or by a machine. When the inner most layer is disposed in close proximity to the outermost layer the code or information provided on the second indicia is unreadable or otherwise unintelligible by eye or machine reading.

In still other embodiments the inner and outer layers (the outer layer being translucent or transparent at least in part) may be arranged such that when the inner most layer is disposed in close proximity to the outermost layer the indicia displays a first code or information set which is readable by eye or by a machine and when the inner most layer is spaced away from the outermost layer the indicia displays a second, different code or information set is readable by eye or by a machine. In this way the first and second indicia may be provided in registry with each other.

The first code or indicia may be defined by a superposition or combination of the inner and outer layers whereas the second code or indicia may be provided by the outer layer only.

In still other embodiments the pocket feature P may comprise a window or aperture in the front wall panel 30, 130 and/or in the first or second bevel panels 32, 34. The first indicia 92, 192 may be provided on a portion of the first inner side panel 20, 120 in registry with the window so as to be readable when the pocket feature is in the stowed position. In the deployed condition the first indicia 92, 192 may be obscured for example by articles A disposed within the pocket feature P.

It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape.

It will be recognized that as used herein, directional references such as “top”, “bottom”, “base”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.

As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed, a hinged connection can be formed from two or more fold lines wherein each of the two or more fold lines may be either straight/linear or curved/curvilinear in shape. When linear fold lines form a hinged connection, they may be disposed parallel with each other or be slightly angled with respect to each other. When curvilinear fold lines form a hinged connection, they may intersect each other to define a shaped panel within the area surrounded by the curvilinear fold lines. A typical example of such a hinged connection may comprise a pair of arched or arcuate fold lines intersecting at two points such that they define an elliptical panel therebetween. A hinged connection may be formed from one or more linear fold lines and one or more curvilinear fold lines. A typical example of such a hinged connection may comprise a combination of a linear fold line and an arched or arcuate fold line which intersect at two points such that they define a half moon-shaped panel therebetween.

As used herein, the terms “severance line”, “weakened line”, and “frangible line” refer to all manner of lines that facilitate separating portions of the substrate from one another or that indicate optimal separation locations. Severance lines may be frangible or otherwise weakened lines, tear lines, cut lines, or slits.

As used herein, the term “fold line” may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cut line, a line of aligned slits, a line of scores and any combination of the aforesaid options.

It should be understood that hinged connections and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

The phrase “in registry with” as used herein refers to the alignment of two or more elements in an erected carton, such as an aperture formed in a first of two overlapping panels and a second aperture formed in a second of two overlapping panels. Those elements in registry with each other may be aligned with each other in the direction of the thickness of the overlapping panels. For example, when an aperture in a first panel is “in registry with” a second aperture in a second panel that is placed in an overlapping arrangement with the first panel, an edge of the aperture may extend along at least a portion of an edge of the second aperture and may be aligned, in the direction of the thickness of the first and second panels, with the second aperture.

Claims

1. A carton for packaging one or more articles, having a plurality of panels defining walls of a chamber for receiving at least one article, the plurality of panels comprising a first panel and a second panel disposed in an overlapping relationship to form a first wall of the carton, the carton comprising a collapsible pocket comprising a plurality of pocket walls including a front wall, opposing side walls, a base wall and a rear wall, at least one of the pocket walls being coupled to one of the first and second panels by a frangible connection.

2. A carton according to claim 1 wherein the frangible connection comprises a tear initiation point.

3. A carton according to claim 1 wherein the at least one of the pocket walls comprises the front wall of the pocket, the one of the first and second panels comprises the first panel, and the front wall is frangibly coupled to the first panel by the frangible connection.

4. A carton according to claim 1 wherein the at least one of the pocket walls comprises one of the opposing side walls of the pocket, the one of the first and second panels comprises the first panel, and the one of the opposing side walls is frangibly coupled to the first panel by the frangible connection.

5. A carton according to claim 1 wherein each of the opposing side walls of the pocket passes through an opening in the first wall of the carton and is moveable between a first stowed position within the chamber and a second deployed position where the each of the opposing side walls at least partially is disposed outside the chamber.

6. A carton according to claim 5 wherein each of the opposing side walls comprises at least one end stop for limiting travel thereof.

7. A carton according to claim 5 wherein each of the opposing side walls of the pocket comprises a securing flap hingedly connected thereto.

8. A carton according to claim 5 wherein each of the opposing side walls of the pocket comprises a securing flap frangibly connected to the second panel.

9. A carton according to claim 1 wherein the base wall comprises a first panel hingedly connected to an end edge of the front wall of the pocket and a base wall securing flap struck at least in part from the second panel of the first wall.

10. A carton according to claim 9 wherein the base wall securing flap comprises a fold line and is foldable about the fold line such that a first portion of the base wall securing flap is disposed in face to face contacting relationship with a second portion of the base wall securing flap when the pocket is in a deployed condition.

11. A carton according to claim 1 wherein the base wall of the pocket comprises a first base panel hingedly connected to a first one of the opposing side walls, a second base panel hingedly connected to the front wall, a first web panel hingedly connecting the first and second base panels, a third base panel hingedly connected to a second one of the opposing side walls and a second web panel hingedly connecting the second and third base panels.

12. A carton according to claim 11 wherein the second web panel is secured to the second base panel.

13. A carton according to claim 1 wherein one of the opposing side walls of the pocket is hingedly connected to the front wall along a first side edge of said one of the opposing side walls and is hingedly connected to a securing flap along a second, opposing side edge of said one of the side walls.

14. A carton according to claim 1 comprising a securing tab frangibly connected to the front wall.

15. A carton according to claim 11 comprising a securing tab frangibly connected to the front wall along an end edge of the front wall disposed adjacent to the hinged connection between said one of the opposing side walls of the pocket and the front wall.

16. A blank for forming a carton, the blank comprising a plurality of panels for defining walls of a chamber for receiving at least one article, the plurality of panels arranged in a linear series hinged one to the next, the plurality of panels including a first panel and a second panel for being disposed in an overlapping relationship to form a first wall of the carton, the blank comprising a collapsible pocket structure, the pocket structure comprising a plurality of pocket wall panels including a front wall panel, opposing side wall panels, a base wall panel and a rear wall panel, at least one of the plurality of pocket wall panels being coupled to one of the first and second panels by a frangible connection.

17. A carton comprising a collapsible pocket structure that is movable between a collapsed/stowed position and an expanded position, a first code placed in part on the pocket structure and in part on the other part of the carton such that the first code is readable when the pocket structure is in the collapsed/stowed position and such that the first code is unreadable, at least in part, when the pocket structure is in the expanded position, and a second code placed on either the pocket structure or the other part of the carton such that the second code is hidden from view when the pocket structure is in the collapsed/stowed position and such that the second bar code is exposed to view when the pocket structure is in the expanded position.

18. A carton according to claim 17 wherein the first and second codes are machine readable.

19. A carton according to claim 17 wherein the second code is obscured to prevent machine reading when the pocket structure is in the collapsed/stowed position and such that the second bar code is machine readable when the pocket structure is in the expanded position.

20. (canceled)

21. (canceled)