LAMINATED ARTICLE CARRIER AND BLANK THERFOR

Abstract

Aspects of the disclosure relate to a carrier (90) for packaging one or more articles B, a blank (10) for forming the carrier and a method of forming the carrier. In one aspect a top-engaging article carrier is provided for packaging at least one article. The article carrier comprises a main panel (12) including at least one a top engaging device having a top-receiving opening. The main panel comprises a laminated structure formed from two or more layers L1, L2 of a substrate (50) uniformly bonded together.

Description

TECHNICAL FIELD

The present invention relates to article carriers and to blanks for forming the same. More specifically, but not exclusively, the invention relates to a carrier of the top-gripping or top-engaging style having one or more apertures for receiving and retaining an article therein.

BACKGROUND

In the field of packaging it is known to provide cartons for carrying multiple articles. Cartons are well known in the art and are useful for enabling consumers to transport, store and access a group of articles for consumption. For cost and environmental considerations, such cartons or carriers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Further considerations are the strength of the carton and its suitability for holding and transporting large weights of articles. It is desirable that the contents of the carton are secure within the carton.

It is well known to provide top gripping article carriers in which an aperture is formed in a panel of the carrier, tabs may be defined about said aperture. The tabs are displaceable out of the plane of said panel. When an article is received in the aperture said tabs engage the article generally about a flange or lip of the article.

The present invention seeks to provide an improvement in the field of cartons, typically formed from paperboard or the like.

SUMMARY

A first aspect of the invention provides a method of forming a top-engaging article carrier comprising:

• • providing a first paperboard substrate;
  • providing a second paperboard substrate;
  • applying an adhesive treatment to a first surface of the first paperboard substrate uniformly thereacross;
  • securing a surface of the second paperboard substrate to the first surface of the first paperboard substrate to form a laminated paperboard structure;
  • cutting one or more blanks from the laminated paperboard structure.

Optionally, cutting one or more blanks from the laminated paperboard structure comprises cutting one or more top engaging devices each having a top-receiving opening from the laminated paperboard structure.

Optionally, the method comprises;

• • applying the blank to one or more articles to form a package;
  • engaging the one or more a top engaging devices with a respective one of the one or more articles.

Optionally, the one or more top engaging devices each the comprise at least one tooth, the at least one tooth comprising a uniformly bonded multiply laminate structure and wherein engaging the one or more a top engaging devices with a respective one of the one or more articles comprises;

• • engaging an edge of the at least one tooth with a flange of the respective one of the one or more articles.

A second aspect of the invention provides a top-engaging article carrier for packaging at least one article. The article carrier comprises a main panel including at least one a top engaging device having a top-receiving opening. The main panel comprises a laminated structure formed from two or more layers of a substrate uniformly bonded together.

Optionally, the top engaging device comprises one or more teeth for engaging an article, the one or more teeth comprising two or more layers of substrate which are uniformly bonded together.

Optionally, each of the two or more layers of substrate comprises at least one uncoated side.

Optionally, each of the two or more layers of substrate comprises a coated side and wherein the coated side of a first layer is bonded to the coated side of a second layer.

Optionally, each of the two or more layers of substrate comprises an uncoated side opposite the coated side.

Optionally, each of the two or more layers of substrate comprises an uncoated side and wherein the uncoated side of a first layer is bonded to the uncoated side of a second layer.

Optionally, each of the two or more layers of substrate comprises a coated side opposite the uncoated side.

Optionally, each of the two or more layers of substrate comprises a second uncoated side opposite a first uncoated side.

Optionally, each of the two or more layers of substrate comprises an uncoated side and wherein an uncoated side of a first layer is bonded to an uncoated side of a second layer.

Optionally, the laminated structure comprises;

• • a first layer having a coated side and an uncoated side opposite the coated side; and
  • a second layer having an uncoated side;
  • wherein an uncoated side of a first layer is bonded to an uncoated side of a second layer.

Optionally, the substrate is a paperboard material.

A third aspect of the invention provides a blank for forming a top-engaging article carrier. The blank comprises a main panel including at least one a top engaging device having at least one top-receiving opening. The main panel comprises a laminated structure formed from two or more layers of a substrate uniformly bonded together.

A fourth aspect of the invention provides an article carrier for packaging at least one article. The article carrier comprises a main panel including at least one an article retention device having at least one article-receiving opening. The main panel comprises a laminated structure formed from two or more layers of a paperboard material uniformly bonded together.

A fifth aspect of the invention provides a laminated paperboard structure for forming an article carrier comprising two or more layers of a paperboard substrate including a first layer having a first surface and a second layer comprising a second surface. The second surface is disposed adjacent to the first surface and is uniformly bonded thereto.

Within the scope of this application it is envisaged or intended 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 considered or taken independently or in any combination thereof.

Features or elements described in connection with, or relation to, one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into, or combined with, any of the other embodiments disclosed herein, said features or elements extracted from said one embodiment may be included in addition to, or in replacement of one or more features or elements of said other embodiment.

A feature, or combination of features, of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment. Alternatively, a feature, or combination of features, of an embodiment may be omitted from that embodiment.

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 plurality of connected blanks, each blank capable of forming a carrier according to a first embodiment;

FIG. 2 is a plan view from above of one of the blanks of FIG. 1;

FIG. 3 is a perspective view from above of a carrier formed from the blank of FIG. 2;

FIG. 4 is a plan view from above of a plurality of connected blanks, each blank capable of forming a carrier according to a second embodiment; and

FIGS. 5A to 5E are schematic illustrations of multiply structures formed from paperboard substrates according to various embodiments of present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the package, blanks and carriers 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 carriers described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimized 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 plurality of connected blanks 10A, 10B, 100, 10D, 10D, 10E, 10F; an individual blank 10 is shown in FIG. 2 which is capable of forming a carton or carrier 90, as shown in FIG. 3, for containing and carrying a group of primary products such as, but not limited to, bottles or cans, hereinafter referred to as articles B, as shown in FIG. 3. The blank 10 forms a secondary package for packaging at least one primary product container or package. An alternative blank 110 is shown in FIG. 4.

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 and carrying articles, such as primary 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 aluminum 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, 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 carrier structure described in more detail below.

The packaging structures or cartons described herein may be formed from a sheet material such as paperboard, which may be made of or coated with materials to increase its strength. An example of such a sheet material is tear-resistant NATRALOCK® paperboard made by WestRock Company. It should be noted that the tear resistant materials may be provided by more than one layer, to help improve the tear-resistance of the package. Typically, one surface of the sheet material may have different characteristics to the other surface. For example, the surface of the sheet material that faces outwardly from a finished package may be particularly smooth and may have a coating such as a clay coating or other surface treatment to provide good printability. The surface of the sheet material that faces inwardly may, on the other hand, be provided with a coating, a layer, a treatment or be otherwise prepared to provide properties such as one or more of tear-resistance, good glue-ability, heat sealability, or other desired functional properties.

In the illustrated embodiments, the blank 10 is configured to form a carton or carrier 90 for packaging an exemplary arrangement of exemplary articles B. In the embodiment illustrated in FIGS. 1, 2 and 3, the arrangement is a 2×2 matrix or array; in the illustrated embodiment two rows of two articles are provided, and the articles B are beverage cans. In the embodiments illustrated in FIG. 4, the arrangement is a 3×2 matrix or array; in the illustrated embodiments three rows of two articles are provided, and the articles B are beverage cans. Alternatively, the blanks 10, 110 can be configured to form a carrier for packaging other types, number and size of articles and/or for packaging articles in a different arrangement or configuration.

Referring to FIG. 1 there is shown a plurality of connected blanks referred to generally by reference sign 1, specifically there are six blanks 10A, 10B, 10C, 10D, 10E, 10F arranged in a 3×2 matrix or array. Each blank 10A, 10B, 10C, 10D, 10E, 10F comprises a main panel 12 for forming a top wall or engaging panel of a carrier 90 (see FIG. 3). Each blank 10A, 10B, 10C, 10D, 10E, 10F is connected to at least two adjacent blanks 10A, 10B, 10C, 10D, 10E, 10F by frangible connections 14.

The main panel 12 includes at least one article retention structure RT1, RT2, RT3, RT4, see FIG. 2. In the embodiment of FIGS. 1 and 2 the main panel 12 comprises a plurality of article retention structures RT1, RT2, RT3, RT4, specifically four article retention structures RT1, RT2, RT3, RT4 arranged in 2×2 matrix or array. Each of the article retention structures RT1, RT2, RT3, RT4 comprise an aperture A1, A2, A3, A4.

Each of the article retention structures RT1, RT2, RT3, RT4 is substantially similar in construction and will therefore be described in detail with reference to the second article retention structure RT2.

The second article retention structure RT2 comprises an article receiving opening defined in part by an aperture A2.

The second article retention structure RT2 comprises a first segment and a second segment. The first segment S1 defines a first arc S1 and the second segment defines a second arc S2.

The first segment may be ‘toothed’, the second segment may be ‘toothless’. That is to say the aperture A2 comprises a plurality of teeth disposed about the first arc S1, in a perimeter region of the aperture A2 defined by the first segment S1. A perimeter region, the second arc S2, of the aperture A2 defined by the second segment is free from teeth. In the embodiment illustrated in FIG. 2 the second segment comprises an arcuate edge having a pair of spaced apart relief notches C8, C9.

The ‘toothed’ region comprises a plurality of teeth or tabs formed in the main panel 12 about the aperture A2.

Each tooth comprises an engaging or tooth edge 31. Each tooth edge 31 may be linear in shape or may be arcuate. The tooth edges 31 may be defined by an arc or portion of a circle. The aperture A2 comprises a perimeter which may approximate, or define, a notional circle having a center.

The ‘toothed’ region of the main panel 12 surrounding the aperture A2 may comprise cutaways C1, C2, C3, C4, C5, C6, C7 in the form of recesses or notches. The cutaways C1, C2, C3, C4, C5, C6, C7 are substantially “U” shaped, in other embodiments the cutaways C1, C2, C3, C4, C5, C6, C7 may be alternatively shaped such as but not limited to “V” shaped. The cutaways C1, C2, C3, C4, C5, C6, C7 extend radially outward from the notional circle NC.

Each of the teeth or tabs is defined, at least in part, by a pair of cutaways C1, C2, C3, C4, C5, C6, C7. The cutaways C1, C2, C3, C4, C5, C6, C7 may form relief elements extending radially away from the center of the notional circle.

The toothless or tooth free region S2 of the main panel 12 surrounding the aperture A2 comprises an engaging or free edge 37 (also referred to herein as continuous supporting edge). The engaging edge 37 is curvilinear or arcuate in shape.

The toothless or tooth free region of the main panel 12 surrounding the aperture A2 may be defined in, or occupy, an arc subtending an angle of about 180°, in other embodiments the angle may be less than 180°, for example but not limited to 170°.

In this way substantially half of the perimeter of the aperture A2 comprises teeth or tabs.

The second article retention structure RT2 comprises two adjacently disposed relief elements C1, C7 between which the engaging edge 37 is defined. The engaging edge 37 may be interrupted by one or more relief elements C8, C9. In the illustrated embodiment, the engaging edge 37 is interrupted by two relief elements C8, C9.

The main panel 12 may optionally comprise a handle structure H. The handle structure H may comprise a handle opening. The handle opening is defined in the main panel 12 and is located in a region disposed centrally between a first pair of article retention structures RT1, RT2 and a second pair of article retention structures RT3, RT4. The handle opening may be defined at least in part by a cushioning tab 16 hinged to the main panel 12 by fold line 15.

Optionally, the side edges of the main panel 12 may be arranged in a curvilinear or undulating shape. In this way, a first blank 10 may be arranged in a nested arrangement with a second blank 10. The undulating shape provides that the first and second blanks 10 together define a width which is less than twice the maximum width of an individual blank 10. This may have economic and environmental benefit by reducing the amount of substrate required to produce a given number of blanks 10.

The main panel 12 includes at least a paperboard substrate. The material of the paperboard substrate may be selected from any conventional paperboard, for example, ranging in weight upwardly from about 10 pt. (0.010″/˜0.25 mm), preferably from about 16 pt. (0.016″/˜0.41 mm) to about 28 pt. (0.028″/˜0.7 mm). The paperboard substrate may be a bleached or unbleached board. The board may be coated on at least one side with a conventional coating selected for compatibility with the printing method and board composition.

An example of such a substrate is a 28 point (pt.) SBS board (solid bleached sulfate paperboard coated on one side, trade name PrintKote®), unbleached uncoated kraftboard (UUK) or CNK® board (Coated Natural Kraft®—an unbleached kraft paperboard having a clay coating on one side, trade name CarrierKote™) manufactured by WestRock® Company.

In the illustrated embodiment the main panel 12 is formed from two layers of a paperboard substrate bonded together to form a laminated paperboard material. An adhesive treatment or glue may form a glue layer between two layers of paperboard substrate. FIGS. 5A to 5E illustrate a various embodiments of a laminated paperboard material for forming the article carrier 90.

FIG. 5A shows an embodiment comprising a laminated paperboard structure comprising a first ply L1 of paperboard having a coating 52 on one side of a fibre layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of paperboard having a coating 52 on one side of a fibre layer 50. The uncoated side, the fibre layer 50 of the first layer L1 is bonded to the uncoated side, the fibre layer 50 of the second layer L2; an adhesive treatment or glue forms a glue or adhesive layer 54 therebetween. The laminated structure of FIG. 5A may be resistant to curling, due for example, but not limited to, to moisture sorption (absorption or adsorption) and/or desorption by the fibre layers. The laminated paperboard structure comprises coatings on opposed surfaces which may inhibit moisture sorption and/or desorption by the fibre layers.

FIG. 5B shows an embodiment comprising a laminated paperboard structure comprising a first ply L1 of paperboard having a coating 52 on one side of a fibre layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of paperboard having a coating 52 on one side of a fibre layer 50. The coated side of the first layer L1 is bonded to the coated side of the second layer L2; an adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

FIG. 5C shows an embodiment comprising a laminated paperboard structure comprising a first ply L1 of paperboard having a coating 52 on one side of a fibre layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of paperboard having a coating 52 on one side of a fibre layer 50. The uncoated side, the fibre layer 50 of the first layer L1 is bonded to the coated side of the second layer L2; an adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

FIG. 5D shows an embodiment comprising a laminated paperboard structure comprising a first ply L1 of paperboard having a coating 52 on one side of a fibre layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of uncoated paperboard having a fibre layer 50. The uncoated side, the fibre layer 50 of the first layer L1 is bonded to one of the uncoated sides of the second layer L2; an adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

FIG. 5E shows an embodiment comprising a laminated paperboard structure comprising a first ply L1 of uncoated paperboard having a fibre layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of uncoated paperboard having a fibre layer 50. One of the uncoated sides of the first layer L1 is bonded to one of the uncoated sides of the second layer L2; an adhesive treatment or glue forms a glue or adhesive layer 54 therebetween.

In one example a first sheet of a 28 pt CBS or CNK board is bonded to a second sheet a 28 pt CBS or CNK board. This produces a substrate having a thickness of about 0.056″ around 1.4 mm having a coating on opposing faces thereof. An advantage of such a substrate is increased strength without the inclusion of a polymeric material or plastics material, such substrates may provide environmental benefit and be more easily recycled. In other embodiments the coated side of one layer or sheet of material is bonded to the uncoated side of another layer or sheet of material. In alternative embodiments the coated side of one layer, or sheet, of material is bonded to the coated side of another layer, or sheet, of material.

It will be appreciated that the thickness or caliper (density or weight) of the paperboard substrates selected for bonding together may be of different thicknesses or weights. It will also be appreciated that the thickness or caliper (density or weight) of the paperboard substrates selected may be selected based upon the weight or load that the article carrier is intended to support, for example article carriers for packaging larger volume/heavier beverage cans or a greater number of beverage cans may be formed from thicker (or heavier weight) paperboards substrates. Similarly, when the article carrier is intended to support larger loads the article carriers may be formed from a greater number of layers or plies of paperboard substrate bonded together.

The glue layer may be formed of any adhesive having a good affinity to paperboard such as an aqueous glue (e.g., white craft glue, yellow wood glue and Polyvinyl acetate—PVA glue).

Two or more sheets of paperboard are laminated together into a laminated paperboard and then the laminated paperboard may be die-cut into carrier blanks 10 such as that of FIG. 1.

In some embodiments the blanks and article carriers are formed from two or more sheets or rolls of paperboard stock which are commercially available which sheets or rolls are bonded together to form a laminated structure. It is envisaged that the laminated structure is formed from paperboard stock which has been dried in a paper mill, the paperboard stock may also have been subject to one or more dry-end treatments such as, but not limited to, calendering and/or finishing with a coating prior to being bonded together.

In some embodiments a surface of the paperboard substrate which is to be bonded to another paperboard substrate may be treated or conditioned to improve cohesion, such as, but not limited to, by perforating or otherwise interrupting the surface for example with partial depth cuts.

The top-engaging carrier 90 comprises uniformly bonded layers. In those embodiments in which the top-engaging carrier 90 comprises engaging teeth, each tooth has uniformly bonded paperboard layers. This is advantageous over article carriers having multiple paperboard layers having an unglued structure and over article carriers having a post-glued structure in which the paperboard layers are adhered after each layer of paperboard was die-cut. In such post-glued article carriers because each layer is already die cut the layers are adhered together by spot gluing and therefore carrier does not have uniformly glued layers. Where the carrier comprises engaging teeth the teeth do not comprise uniformly glued layers and may be formed from unbonded layers.

In some embodiments at least one tear resistant layer may be disposed between the first and second layers of the substrate, such a substrate may be formed by bonding two sheets of material at least one of which comprises a tear resistant layer laminated thereto. This may have the advantage of increasing the strength of the substrate.

The main panel 12 may include a tear resistant layer laminated to the paperboard layer. It optionally includes an adhesive layer between the paperboard substrate and the tear resistant layer. The tear resistant layer may be disposed over the uncoated side of the paperboard substrate and may be formed of polymeric material and secured to the substrate. The tear resistant layer imparts toughness to the laminate structure. Suitable tear resistant materials may include, but not be limited to, tear resistant laminated sheet material, e.g., NATRALOCK®, which may include a layer of an n-axially oriented film, e.g. MYLAR®, which is a bi-axially oriented polyester, oriented nylon, cross-laminated polyolefin or high density polyolefin. The orientation and cross-laminated structure of these materials contribute to the tear resistant characteristic. Also, tear resistance may be attributed to the chemical nature of the tear resistant material such as extruded metallocene-catalyzed polyethylene (mPE).

Alternatively, the tear resistant layer may be a layer of linear low-density polyethylene (LLDPE). In embodiments where linear low-density polyethylene (LLDPE) or mPE is used, it is not necessary to incorporate an adhesive layer. Other suitable materials having a high level of tear resistance may also be used.

The adhesive layer may be formed of polyolefin material such as a low-density polyethylene (LDPE). The adhesive layer may be placed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

Turning to the construction of the carrier 90 from the blank 10, the blank 10 may be applied to a group of articles B. The blank 10 is lowered with respect to the group of articles B. Each of the article retention structures RT1, RT2, RT3, RT4 of the blank 10 are aligned with a respective article B in the group. Portions of the articles B pass through the main panel 12. The toothed regions of the main panel 12 about each of the article retention structures RT1, RT2, RT3, RT4 may be folded out of the plane of the main panel 12.

Each toothed region of the main panel 12 may be folded about one of the articles received in the respective one of the article retention structures RT1, RT2, RT3, RT4; the blank 10 may deform about the article B for example but not limited to a shoulder portion of the article B, where the article B is a can the shoulder portion may be provided by the neck-in.

The engaging edges 31 of the teeth and the engaging edge 37 of the tooth free region of the main panel 12 engage beneath a projection. The projection may be located about the neck or chime of the article B (which may provide a flange) of an article B. When the article B is a can the projection may be provided by a canner's end seam. In other embodiments it may be provided by a ridge or undercut shaping of the article B or by an end closure of the article B for example but not limited to a crown cork or closure. In this way, the engaging edges 31, 37 grip or hold the article B and prevent or inhibit the article B from unintentionally separating from the main panel 12. The assembled carrier 90 is shown in FIG. 3.

The teeth comprise two layers of substrate uniformly bonded together which provide secure engagement of the article B.

Another optional feature of the carrier 90 is that the main panel 12 is defined by a perimeter to which no other part of the carrier 90 is connected. That is to say, the carrier 90 is free of connection to other panels for example, but not limited to, side or end wall panels which extend about the sides of the article group. The perimeter of the main panel 12 is therefore defined in its entirety by free, cut or unhinged edges.

Another optional feature of the carrier 90 is that the main panel 12 is defined by a perimeter including convexly curved edges and concavely curved edges, wherein the radius of curvature of the convexly curved edges is substantially equal to the radius of curvature of the concavely curved edges, thus allowing two similar blanks 10 to be placed in a nested or tessellated arrangement.

In some embodiments the plurality of blanks 1 is applied simultaneously to a first group of articles B. The first group of articles B is divisible into a plurality of second groups of articles B. Each second group of articles B is thus formed from a subset of the first group of articles B. The embodiment illustrated in FIG. 1 the first group of articles B comprises twenty-four articles arranged in a 4×6 matrix or array, and each individual blank 10A, 10B, 10C, 10D, 10E, 10F accommodates four articles in a 2×2 matrix or array.

The frangible connections 14 between the individual blanks 10A, 10B, 10C, 10D, 10E, 10F may separate upon application of the plurality of blanks 1 to the first group of articles B. Alternatively, the frangible connections 14 may remain intact, individual blanks 10A, 10B, 10C, 10D, 10E, 10F may be separated from the others at a point of sale or distribution.

Referring now to FIG. 4, 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 first embodiment and therefore only the differences from the embodiment illustrated in FIGS. 1 to 3 will be described in detail.

FIG. 4 illustrates a second embodiment and shows a plurality of connected blanks referred to generally by reference sign 101 specifically there are four blanks 110A, 110B, 110C, 110D, arranged in a 2×2 matrix or array. Each blank 110A, 110B, 110C, 110D comprises a main panel 112 for forming a top wall or engaging panel of a carrier (not shown). Each blank 110A, 110B, 110C, 110D is connected to two adjacent blanks 110A, 110B, 110C, 110D, by frangible connections 114.

The main panel 112 of each blank 110A, 110B, 110C, 110D includes at least one article retention structure RT1, RT2, RT3, RT4, RT5, RT6. The main panel 112 comprises a plurality of article retention structures RT1, RT2, RT3, RT4, RT5, RT6, specifically six article retention structures RT1, RT2, RT3, RT4, RT5, RT6 arranged in 3×2 matrix or array. Each of the article retention structures RT1, RT2, RT3, RT4, RT5, RT6 comprise an aperture A1, A2, A3, A4, A5, A6.

Each of the article retention structures RT1, RT2, RT5, RT6, also referred to as endmost article retention structures RT1, RT2, RT5, RT6, is substantially similar in construction to the article retention structures RT1, RT2, RT3, RT4 of the embodiment of FIGS. 1 and 2. These article retention structures comprise six teeth disposed about the perimeter of the apertures A1, A2, A5, A6. The article retention structures RT1, RT2, RT5, RT6 are disposed in corners or the main panel 112.

The article retention structures RT3, RT4, also referred to as intermediate article retention structures RT3, RT4, are disposed medially on the main panel 112, between a first pair of end most article retention structures RT1, RT2 and a second pair of end most article retention structures RT5, RT6.

The intermediate article retention structures RT3, RT4 comprise three teeth each tooth is defined in part by a pair of relief elements C. Each tooth comprises an engaging edge 131, 132, 133. The engaging edges 131, 132, 133 of the teeth occupy a portion of the perimeter of the aperture A3, A4. The portion defines a first arc of a notional circle having a center, the angle subtended by the arc may be less than 120°, it may be greater than 60° and may be around 90°. The first arc is defined between two relief elements

The retention structures RT3, RT4 comprises a toothless or tooth free portion. The tooth free portion defines a second arc complimentary to the first arc. The tooth free region comprises an engaging edge 137.

The main panel 112 may optionally comprise a handle structure H1, H2. The handle structure H1, H2 may comprise a first opening formed at least in part by a first handle aperture. The first handle aperture is struck from the main panel 112 and is located in a region disposed centrally between a first pair of article retention structures RT1, RT2 and a second pair of article retention structures RT3, RT4. The first opening may be defined in part by a first cushioning tab hinged to the main panel 112 by a fold line. The first handle aperture may be substantially crescent or “C” shaped. The handle structure H1, H2 may comprise a second opening formed at least in part by a second handle aperture. The second handle aperture is struck from the main panel 112 and is located in a region disposed centrally between the second pair of article retention structures RT3, RT4 and a third pair of article retention structures RT5, RT6. The second opening may be defined in part by a second cushioning tab hinged to the main panel 112 by a fold line. The second handle aperture may be substantially crescent or “C” shaped. The first and second openings may be arranged in opposition to each other, such that the first and second cushioning flaps are hinged to the main panel 112 in opposition to each other.

The present disclosure provides a carrier of the top engaging type having article retention structures or article top engaging devices formed in a laminated substrate formed from two or more layers of a paperboard substrate uniformly bonded together. The laminated substrate is formed prior to die cutting a blank therefrom.

The laminated substrate may be formed from two or more sheets or rolls of paperboard at least one of which is preprinted with graphics or other indicia. The two or more sheets or rolls are laminated after printing of one of the layers. In this way a laminated substrate with printed graphics or other indicia on at least one side is formed. The printed laminated substrate is then cut to form carrier blanks. In some embodiments where the laminated substrate is formed from rolls of paperboard the laminated substrate may be cut into sheets prior to cutting the carrier blanks. In other embodiments where the laminated substrate is formed from rolls of paperboard it is not necessary to cut the laminated substrate into sheets, the carrier blanks may be cut directly from the laminated substrate using an inline die cutting device.

The laminated substrate may be formed from bonding two or more sheets or rolls of unprinted paperboard together. Once the laminated substrate is formed at least one side may be printed with graphics or other indicia. In this way a laminated substrate with printed graphics or other indicia on at least one side is formed. The printed laminated substrate is then cut to form carrier blanks. In embodiments where the laminated substrate is formed from rolls of paperboard the laminated substrate may be printed inline or may be cut into sheets which are then printed.

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 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 cutline, 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 cutline, an interrupted cutline, slits, scores, embossed lines, debossed lines, 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 top-engaging article carrier for packaging at least one article, the article carrier comprising a main panel including at least one a top engaging device having at least one top-receiving opening, the main panel comprising a laminated structure formed from two or more layers of a substrate uniformly bonded together.

2. A top-engaging article carrier to claim 1 wherein the top engaging device comprises one or more teeth for engaging an article, the one or more teeth comprising two or more layers of substrate which are uniformly bonded together.

3. A top-engaging article carrier to claim 1 wherein each of the two or more layers of substrate comprises at least one uncoated side.

4. A top-engaging article carrier to claim 1 wherein each of the two or more layers of substrate comprises a coated side and wherein the coated side of a first layer is bonded to the coated side of a second layer.

5. A top-engaging article carrier to claim 4 wherein each of the two or more layers of substrate comprises an uncoated side opposite the coated side.

6. A top-engaging article carrier to claim 1 wherein each of the two or more layers of substrate comprises an uncoated side and wherein the uncoated side of a first layer is bonded to the uncoated side of a second layer.

7. A top-engaging article carrier to claim 6 wherein each of the two or more layers of substrate comprises a coated side opposite the uncoated side.

8. A top-engaging article carrier to claim 6 wherein each of the two or more layers of substrate comprises a second uncoated side opposite a first uncoated side.

9. A top-engaging article carrier to claim 1 wherein each of the two or more layers of substrate comprises an uncoated side and wherein an uncoated side of a first layer is bonded to an uncoated side of a second layer.

10. A top-engaging article carrier to claim 1 wherein the laminated structure comprises;

a first layer having a coated side and an uncoated side opposite the coated side; and

a second layer having an uncoated side;

wherein an uncoated side of a first layer is bonded to an uncoated side of a second layer.

11. A top-engaging article carrier to claim 1 wherein the substrate is a paperboard material.

12. A blank for forming a top-engaging article carrier, the blank comprising a main panel including at least one a top engaging device having at least one top-receiving opening, the main panel comprising a laminated structure formed from two or more layers of a substrate uniformly bonded together.

13. A method of forming a top-engaging article carrier comprising:

providing a first paperboard substrate;

providing a second paperboard substrate;

applying an adhesive treatment to a first surface of the first paperboard substrate uniformly thereacross;

securing a surface of the second paperboard substrate to the first surface of the first paperboard substrate to form a laminated paperboard structure;

cutting one or more blanks from the laminated paperboard structure.

14. A method of forming a top-engaging article carrier according to claim 13 wherein cutting one or more blanks from the laminated paperboard structure comprises cutting one or more top engaging devices each having a top-receiving opening from the laminated paperboard structure.

15. A method of forming a top-engaging article carrier according to claim 14 comprising;

applying the blank to one or more articles to form a package;

engaging the one or more a top engaging devices with a respective one of the one or more articles.

16. A method of forming a top-engaging article carrier according to claim 15 wherein the one or more top engaging devices each the comprise at least one tooth, the at least one tooth comprising a uniformly bonded multiply laminate structure and wherein engaging the one or more a top engaging devices with a respective one of the one or more articles comprises;

engaging an edge of the at least one tooth with a flange of the respective one of the one or more articles.

17. An article carrier for packaging at least one article, the article carrier comprising a main panel including at least one an article retention device having at least one article-receiving opening, the main panel comprising a laminated structure formed from two or more layers of a paperboard material uniformly bonded together.

18. A laminated paperboard structure for forming an article carrier comprising two or more layers of a paperboard substrate comprising a first layer having a first surface and a second layer comprising a second surface, the second surface being disposed adjacent to the first surface and uniformly bonded thereto.