Two-tier cup package with end closure-retaining panel

Abstract

 A carton which has top (32) and bottom panels (38, 40) interconnected by a pair of side panels (34, 42; 36, 50) to form a sleeve structure. It has end closure panels at each end of the sleeve structure for at least partially closing opposite ends of the structure. Each of the end closure panels comprises a connecting panel (62, 62a) foldably joined to an end edge (64, 64a) of the top panel and folded into face contacting relationship with an under-surface of the top panel, the connecting panel extending from one end edge of said top panel to an inner edge (68, 68a). An end panel (66, 66a) is foldably joined to the inner edge of the connecting panel and folded into a downwardly extended position so that the end panel at least partially closes one of the ends of the sleeve structure; and a pair of anchoring panels (84, 84a; 86, 86a) is foldably joined to each said side panel and disposed in a superposed relationship with the inside surfaces of the adjacent side panels, the anchoring panels interconnecting the end panel and the side panels so as to retain the end panel in its downwardly extended position.

Description

[0001] The present invention relates generally to packaging a group of articles such as cups, cans or the like, and more particularly to a package of articles arranged in two or more tiers within a sleeve, having divider panels disposed between the tiers of articles and end closure retaining panels at each end of the sleeve.

[0002] The carton of the present invention includes top and bottom panels interconnected by a pair of side panels to form a sleeve structure. The side panels of the carton are disposed alongside their respective side edges of the main panel. The carton has end retention means for engaging the shoulder of the divider means, when present, so as to prevent movement of the divider means along the axis of the sleeve structure. The retention means may be an end flap foldably joined to the end edge of one of the side panels adjacent to the shoulder of the divider means. The end flap is folded into a superposed relationship with one side panel and disposed such that a free edge of the end flap is located adjacent to or in engagement with the shoulder.

[0003] The package of the invention has a good integrity because, where a divider means is present, axial movement of the diver means is prohibited by the retention means. As a result, the divider means is locked in position without adhesive and thereby assists the package in obtaining improved article-retaining capability.

[0004] In a preferred embodiment, the divider means includes a side flap foldably joined to its one side edge along an interrupted fold line, and an engaging tab struck from the side flap and joined at its base to the divider panel along the interrupted portion of the interrupted fold line. In this embodiment, the engaging tab projects laterally from the one side edge of the divider panel to form the shoulder when the side flap is folded along the interrupted fold line.

[0005] One aspect of the invention provides a carton comprising top and bottom panels interconnected by a pair of side panels to form a sleeve structure, and end closure means at each end of said sleeve structure for at least partially closing opposite ends of said structure, each of said end closure means comprising a connecting panel foldably joined to an end edge of said top panel and folded into face contacting relationship with an under-surface of said top panel, said connecting panel extending from said one end edge of said top panel to an inner edge; characterized by an end panel foldably joined to said inner edge of said connecting panel and folded into a downwardly extended position wherein said end panel at least partially closes one of the ends of said sleeve structure; and by a pair of anchoring panels foldably joined to said side panels and disposed in a superposed relationship with the inside surfaces of the adjacent side panels. said anchoring panels interconnecting said end panel with said side panels so as to retain said end panel in its downwardly extended position.

[0006] According to a feature of this aspect of the embodiment of the invention, the end panel and each of the said anchoring panels may be interconnected by a gusset panel. Where gusset panels are provided, each gusset panel may be foldably joined to an adjacent anchoring panel along a first fold line and to an adjacent end panel along a second fold line, each gusset panel being disposed in a superposed relationship with its adjacent anchoring panel.

[0007] Preferably, each of the said gusset panels is defined in part by its first fold line and its second fold line, said first and second fold lines of each said gusset panel being disposed to converge at a corner of said connecting panel adjacent to said end panel.

[0008] According to another feature of this aspect of the invention, a corner of each of the said anchoring panels defined between the adjacent connecting panel and adjacent side panel may be severed by an aperture from adjacent portions of the carton.

[0009] According to yet another feature of this aspect of the invention, the end panel may extend downwardly from said inner edge of the connecting panel to a lower edge and has a cut-out open to said lower edge.

[0010] Another aspect of the invention provides a blank for forming a carton comprising, a top panel having side and end edges, a side panel foldably joined to each side edge of said top panel, a connecting panel having opposed parallel edges and foldably joined at one of said parallel edges thereof to said end edge of the top panel, characterised by an anchoring panel foldably joined to an end edge of an adjacent side panel adjacent to said connecting panel; by an end panel foldably joined to the other parallel edge of said connecting panel; and by a gusset panel foldably interconnecting adjacent ones of the anchoring and end panels.

[0011] According to a feature of this other aspect of the invention, each gusset panel may be foldably joined to an adjacent anchoring panel along a first fold line and to said end panel along a second fold line, said first and second fold lines being disposed to converge at said other parallel edge of said connecting panel. Preferably, a corner of each anchoring panel defined between said side and connecting panels is severed by an aperture from adjacent portions of said blank.

[0012] An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:-

Figure 1 is a plan view of a carton blank for forming a package according to the invention;

Figure 2 is a perspective view of the blank at a certain stage in the folding process;

Figure 3 is a perspective view of a package according to the invention, showing the package in an inverted condition and without the contents;

Figure 4 is a perspective view of the package according to the invention, showing the contents in chain-dotted lines;

Figure 5 is a cut-away view taken along the line 5-5 in Figure 4;

Figure 6 is a plan view of a divider panel in blank form;

Figure 7 is a fragmentary perspective view of the divider panel, showing a slot thereof receiving the flange of a cup; and

Figure 8 is a view taken along the line 8-8 in Figure 5.

[0013] The present invention is intended primarily for use with plastic cups of the type used in packaging foods or beverages such as yoghurt, puddings, mousses, jellies, fruit juice and the like. A typical example of a plastic cup includes a generally tubular tapered side wall with a closed bottom, a peripheral flange at the top end of the side wall and a lid, ordinarily in the form of a film or foil, attached to the flange to seal the open top of the side wall. A preferred type of such cups may be provided in a discrete or singular form wherein each cup is independent and separate from other cups. An example of such a cup is shown in Figures 5 and 7 wherein the side wall and the flange of the cups CU and CL are designated by the numerals 200 and 202, respectively. Alternatively, the invention may be used with cups having interconnected flanges.

[0014] In accordance with the invention, a package is provided wherein a plurality of cups are arranged in multiple tiers with a divider panel placed between adjacent tiers. An example of such a cup arrangement can be seen by reference to Figures 4 and 5 wherein two tiers of one discrete cup each are arranged to provide a package containing two cups CU and CL with a divider panel 12 therebetween. Of course, it will be recognised that the invention may be used with any arrangement or number of cups for each tier, and may also be used for cup arrangements having more than two tiers.

[0015] A divider panel useful in the invention may be formed from paperboard or similar foldable sheet material. An example of such a divider panel is shown in blank form in Figure 6 wherein the blank 12 includes a main panel 14 having an aperture 16 at the centre thereof. The aperture 16 may be used to receive the bottom of the lower tier cup CL as will be described later in more detail. A pair of side flaps 18 and 20 are foldably joined to the main panel 14 along interrupted fold lines 22 and 24, respectively. A pair of engaging tabs 26 and 28 are struck respectively from the side flaps 18 and 20. The tabs 26 and 28 are joined at their respective bases to the main panel 14 along the respective interrupted portions of the fold lines 22 and 24. As a result, each tab projects from the respective side edge of the main panel 14 and provides a pair of shoulders S1 and S2 at the opposite sides thereof.

[0016] A carton useful in the invention may also be formed from paperboard or similar foldable sheet material. An example of such a carton is shown in blank form in Figure 1. The blank 30 includes a rectangular top panel 32, a pair of side panels 35 and 36 and a pair of bottom flaps 38 and 40. Each side panel consists of upper and lower foldably interconnected portions. More particularly, the side panel 34 includes an upper portion 42 foldably joined to one of the opposite side edges of the top panel 32 along a fold line 44 and a lower portion 46 foldably joined to the upper portion 42 along a fold line 48 opposite the fold line 44. Likewise, the side panel 36 includes an upper portion 50 foldably joined to the other side edge of the top panel 32 along a fold line 52 and a lower portion 54 foldably joined to the upper portion 50 along a fold line 56 opposite the fold line 52.

[0017] The bottom flap 38 is foldably joined to the lower portion 46 along a fold line 58 at the edge opposite the fold line 48. Likewise the bottom flap 40 is foldably joined to the lower portion 36 along a fold line 60 at the edge opposite the fold line 56. These bottom flaps 38 and 40, when secured together, form a single composite bottom panel. The portion of the bottom flap 40 along the free edge thereof is designed to serve as a flue area for securing the flaps 38 and 40 together. However, locking tabs and cooperating locking slits may be provided respectively for the flaps 38 and 40 instead of the flue area. The details of one arrangement for such locking tabs and slits are described in US Patent No 4 600 140, assigned to the Mead Corporation, which is hereby incorporated by reference. It should, however, be readily understood that any other types of known panel securing/interconnecting means, including but not limited to other locking arrangements, may be used in place of the glue area according to the invention.

[0018] In order at least partially to close the ends of the carton when the carton is in its sleeve form, a set of end closure panels is provided along each of the straight longitudinal edges of the series of the primary panels 32, 34, 36, 38 and 40.

[0019] In one set of the end closure panels, a connecting panel 62 is foldably joined to the top panel 32 along a fold line 64. An upper end panel 66 is foldably joined to the connecting panel 62 along a fold line 68 that is parallel to the fold line 64. The upper end panel 66 is provided with a large cut-out 70 open to its free edge and thus it assumes a forked shape.

[0020] A pair of anchoring panels 72 and 74 are foldably joined to the upper portions 42 and 50 of the side panels 34 and 36 along fold lines 76 and 78 which are disposed in alignment with the fold line 64. These anchoring panels 72 and 74 are disposed adjacent to the connecting panel 62; however, there is no direct connection between the connecting panel 62 and the anchoring panels. In fact, the corner of the anchoring panel 72 defined between the upper portion 42 and the connecting panel 62 is bevelled and severed by an aperture 80 from the adjacent portions of the blank. Likewise, the corner of the anchoring panel 74 defined between the upper portion 50 and the connecting panel 62 is bevelled and severed by an aperture 82 from the adjacent portions of the blank.

[0021] The anchoring panels 72 and 74 are connected to the upper end panel 66 by a pair of triangular gusset panels 84 and 86. The gusset panel 84 is foldably joined to the anchoring panel 72 along a fold line 88 and to the upper end panel 66 along a fold line 90. The fold lines 88 and 90 form an acute angle therebetween and are disposed to converge at the corner of the connecting panel 62 defined between the upper end panel 66 and the aperture 80. In a like manner, the gusset panel 86 is foldably joined to the anchoring panel 74 along a fold line 92 and to the upper end panel 66 along a fold line 94. The fold lines 92 and 94 form an acute angle therebetween and converge at the corner of the connecting panel 62 defined between the upper end panel 66 and the aperture 82.

[0022] The length of the upper end panel 66 and the angles between the fold lines 88 and 90, and 92 and 94 may be varied depending on the desired function of the upper end panel. In the particular embodiment shown in Figure 1, the length of the upper end panel 66 is generally equal to or less than the width of the upper portions 42 and 50 along the fold lines 76 and 78 so that the upper end panel 66 serves, when the blank is set up, as a retainer for the upper tier cup only. However, the upper end panel 66 may be increased in length when desired to function also as a lower tier cup retainer or to fully close the associated end of the carton.

[0023] A pair of end flaps 96 and 98 are foldably joined respectively to the lower portions 46 and 54 of the side panels along fold lines 100 and 102 which are collinear with the fold lines 76 and 78. The end flaps 96 and 98 are also foldably joined to the anchoring panels 72 and 74 along fold lines 104 and 106 that are collinear with the fold lines 48 and 56 respectively. The distance between the fold line 100 and the free edge of the end flap 96 is less than the distance between the fold line 76 and the free edge of the anchoring panel 72. In other words, the dimension of the end flap 96 is such that the anchoring panel 72 extends beyond the free edge of the end flap 96. The same is true regarding the dimension of the end flap 98 as compared to that of the anchoring panel 74.

[0024] A pair of lower end panels 108 and 110 are foldably joined respectively to the bottom flaps 38 and 40 along fold lines 112 and 114 which are disposed in alignment with the fold lines 100 and 102. The lower end panels 108 and 110 are connected respectively to the end flaps 96 and 98 by triangular web panels 116 and 118. The web panel 116 is foldably joined to the end flap 96 along a fold line 120 and to the lower end panel 108 along a fold line 122. In like manner, the web panel 118 is foldably joined to the end flap 98 along a fold line 124 and to the lower end panel 110 along a fold line 126. Such lower end panels or masking panels are described in more details in U.S. Patent No. 5,060,792 assigned to the Mead Corporation, which is hereby incorporated by reference.

[0025] The opposite set of end closure panels foldably joined along the opposite longitudinal edge of the series of the primary panels of the blank is identical to the set of end closure panels described above, and accordingly like parts are designated by like reference numerals with the addition of the suffix "a".

[0026] To assemble the package shown in FIG. 4, a cup is first placed in an inverted condition to be a lower tier cup CL and then the divider panel 12 is placed on the bottom of the lower tier cup CL. The position of the panel 12 is adjusted so that the centre aperture 16 of the divider panel 12 is aligned with and thus receives the bottom of the lower tier cup CL. Then, an inverted upper tier cup CU is placed on the divider panel 12, and the side flaps 18 and 20 of the divider panel 12 are folded up along the fold lines 22 and 24 so as to be disposed at about a right angle with respect to the main panel 14 as best illustrated in FIG. 5. By this means, the diametrically opposed portions of the flange 202 of the upper tier cup CU is received in the slots 204 (only one shown in FIG. 7) which are defined in the divider panel 12 by the tabs 26 and 28. As a result, a two-tier cup arrangement is prepared. The cup arrangement thus prepared is wrapped with the carton blank 30 in the manner described below to provide a complete package.

[0027] The carton blank 30 is placed above the cup arrangement so that the top panel 32 overlies the bottom of the upper tier cup CU. Then, the end closure panels of the blank 30 are folded inwardly of the blank along the opposite longitudinal edges of the primary panels, and at the same time the upper end panels 66 and 66a and their associated gusset panels 84 and 86, and 84a and 86a are folded down along the fold lines 68, 88 and 92; and 68a, 88a and 92a. This condition is best illustrated in FIG. 2 wherein the cup arrangement is omitted. In the condition of FIG. 2, the connecting panels 62 and 62a are disposed in face contacting relationship with the inside surface of the top panel 32, and the anchoring panels 72, 74, 72a and 74a and the end flaps 96, 98, 96a and 98a are disposed in superposed relation with the adjacent inner surfaces of the side panels 34 and 36.

[0028] After the above steps, the side panels 34 and 36 as well as the bottom flaps 38 and 40 are folded down about the fold lines 44 and 52, and the side panels 34 and 36 are folded about the fold lines 48 and 56 so that the upper portions 42 and 50 of the side panels are disposed generally along the tapered side wall 200 of the upper tier cup CU as best shown in FIG. 5. By this means, the gusset panels 84, 86, 84a and 86a are folded into superposed relationship with the anchoring panels 72, 74, 72a and 74a respectively and are tucked together with the associated anchoring panels in the positions between the upper tier cup CU and the adjacent side panels 34 and 36. This allows the upper end panels 66 and 66a to be held in the downwardly folded position to partially close the ends of the partially assembled carton.

[0029] Meanwhile, the tab 26 of the divider panel 12 is brought into the position between the end flaps 98 and 98a, and the tab 28 is brought into position between the end flaps 96 and 96a as best shown in FIG. 8. In a preferred embodiment, the distance between the side edges of the main panel 14 is no more than the distance between the side panels 34 and 36 of the carton, whereas the distance between the free edges of the tabs 26 and 28 is no less than that between the side panels 34 and 36. Such an arrangement assures proper engagement between the tabs 26 and 28 and the associated end flaps 96, 98, 96a and 98a.

[0030] After the foregoing steps, the bottom flaps 38 and 40 are folded toward each other about the fold lines 58 and 60 and are glued together in an overlapping relationship as shown in FIG. 3 so that the package is completed. As the bottom flaps 38 and 40 are folded, the lower end panels 108, 110, 108a and 110a are folded back to be disposed at approximately a right angle with the respective bottom flaps 38 and 40 and envelop the flange 202 of the lower tier cup CL. Details regarding the folding of the lower end panels in conjunction with that of the web panels may be found by reference to the aforementioned U.S. patent No. 5,060,792. When interconnected, the bottom flaps 38 and 40 form a composite bottom panel which underlie the top of the lower tier cup.

[0031] FIG. 4 shows the completed package. This package has a good integrity in that axial movement of the divider panel 12 is prohibited by the end flaps 96, 98, 96a and 98a of the carton and thereby the divider panel 12 is prevented from being accidentally dislodged through the carton ends. As will be more readily understood by reference to FIG. 8, if the divider panel 12 moves in either direction along the sleeve axis of the carton, the tabs 26 and 28 are brought into abutment at their shoulders S1 and S2 upon either the end flaps 96 and 98 or the end flaps 96a and 98a. The divider panel 12 is retained in position due also to the arrangement wherein the side flaps 18 and 20 are positioned between the upper end panels 66 and 66a.

[0032] It will be recognized that many variations may be made to the foregoing within the scope of the present invention. For example, the carton design may be enhanced through the addition of a handle struck from the top panel, a tear opening feature provided for the carton walls and the like, using structures known and understood within the art.

[0033] It should be further recognized that it would be possible to omit the end flaps on one of the aforementioned side panels 34 and 36 as well as the associated engaging tab on the divider panel 12. Such an arrangement requires less carton material and may also simplify the package forming process.

[0034] It should be further recognized that when each tier constitutes one or more rows of cups, the tabs of each divider panel associated with the endmost cups of the respective tier serve to engage the end flaps of the carton. The cups in each tier may be disposed either upright with their tops up, or in an inverted condition. It should, however, be understood that the side flaps of the divider panel may be folded down when the package contains lower tier cups which are arranged upright. The number of the cups in each tier may be the same as, or different to that of the cups in the adjacent tier.

Claims

1. A carton comprising top (32) and bottom panels (38, 40) interconnected by a pair of side panels (34, 42; 36, 50) to form a sleeve structure, and end closure means at each end of said sleeve structure for at least partially closing opposite ends of said structure, each of said end closure means comprising a connecting panel (62, 62a) foldably joined to an end edge (64, 64a) of said top panel and folded into face contacting relationship with an under surface of said top panel, said connecting panel extending from said one end edge of said top panel to an inner edge (68, 68a); characterized by an end panel (66, 66a) foldably joined to said inner edge of said connecting panel and folded into a downwardly extended position wherein said end panel at least partially closes one of the ends of said sleeve structure; and by a pair of anchoring panels (84, 84a, 86, 86a) foldably joined to said side panels and disposed in superposed relationship with inside surfaces of adjacent side panels, said anchoring panels interconnecting said end panel with said side panels so as to retain said end panel in its downwardly extended position.

2. The carton according to claim 1, wherein said end panel and each of said anchoring panels are interconnected by a gusset panel (84, 84a; 86, 86a).

3. The carton according to claim 2 wherein each gusset panel is foldably joined to an adjacent anchoring panel along a first fold line and to an adjacent end panel along a second fold line, each gusset panel being disposed in superposed relationship with its adjacent anchoring panel.

4. The carton according to claim 3 wherein each of said gusset panels is defined in part by its first fold line and its second fold line, said first and second fold lines of each said gusset panel being disposed to converge at a corner of said connecting panel adjacent to said end panel.

5. The carton according to any of the preceding claims wherein a corner of each of said anchoring panels defined between the adjacent connecting panel and adjacent side panel is severed by an aperture (80, 80a, 82, 82a) from adjacent portions of the carton.

6. The carton according to any of the preceding claims wherein said end panel extends downwardly from said inner edge of the connecting panel to a lower edge and has a cut-out (70) open to said lower edge.

7. A blank (30) for forming a carton which blank comprises a top panel (32) having side (44, 52) and end edges (64, 64a), a side panel (34, 42; 36, 50) foldably joined to each side edge of said top panel, a connecting panel (62, 62a) having opposed parallel edges and foldably joined at one of said parallel edges thereof to said end edge of the top panel, characterized by an anchoring panel (84, 84a; 86, 86a) foldably joined to an end edge of an adjacent side panel adjacent to said connecting panel, and by an end panel (66, 66a) foldably joined to the other parallel edge of said connecting panel, and by a gusset panel (84, 84a; 86, 86a) foldably interconnecting adjacent ones of the anchoring and end panels.

8. The blank according to claim 7 wherein each gusset panel is foldably joined to an adjacent anchoring panel along a first fold line and to said end panel along a second fold line, said first and second fold lines being disposed to converge on said other parallel edge of said connecting panel.

9. The blank according to claim 7 or claim 8 wherein a corner of each anchoring panel defined between said side and connecting panels is severed by an aperture (80, 80a; 82, 82a) from adjacent portions of said blank.

10. A package comprising a carton as claimed in any of claims 1 to 6 and an array of articles contained in the carton.

Drawing