Relating to container carriers

Abstract

A clip type carrier for packaging articles of the type having a rim, bead, chime, undercut, waist or the like. The carrier comprises a first layer having a plurality of generally circular apertures and a second layer having a plurality of respective locking apertures. The locking apertures are provided with a plurality of locking tabs for engaging under an article rim in use. An aggregate effective aperture diameter, being approximately the generally circular aperture minus twice the thickness of the locking tabs, is greater than the diameter of the container rim, causing formation of a reinforcing rim at the periphery of the generally circular aperture once applied.

Claims

1. A clip-type carrier for packaging articles of the type having a rim, chime, waist, undercut or the like, the clip-type carrier comprising a first layer having a plurality of generally circular apertures and a second layer having a plurality of respective locking apertures, the locking apertures are provided with a plurality locking tabs which fold through the generally circular apertures and engage an article rim or the like in use, wherein an interior periphery of the circular apertures of the first layer is formed with or configured to provide a reinforcing rim which supports the locking tabs so as to resist deformation thereof, the reinforcing rim having an inner edge offset in a vertical direction relative to the rest of the first layer so as to be located closer to an inner end of each of the plurality of locking apertures in the vertical direction compared to the rest of the first layer.

2. The carrier of claim 1, wherein the reinforcing rim is formed as the carrier is applied.

3. The carrier of claim 1, wherein a subtractive aperture diameter (D1) minus twice the thickness of the locking tabs is less than a diameter of the article rim.

4. The carrier of claim 1, wherein D12T<D2, where D1 is an upper aperture diameter, D2 is a diameter of the article rim and T is a thickness of the second layer locking tabs.

5. The carrier of claim 1, wherein a diameter D1 of the circular apertures are dimensioned according to a formula D1<D2at least 2*T, where D2 is a diameter of the article rim and T is a thickness of the locking tabs of the second layer.

6. The carrier of claim 5, wherein D1=D2(4*T).

7. The carrier of claim 1, wherein the first and second layers are formed separately and are secured or are securable together.

8. The carrier of claim 1, wherein the first and second layers are adhered, bonded or glued together in advance of application or at the time of application.

9. The carrier of claim 6, wherein the layers are secured together using re-pulpable adhesive.

10. The carrier of claim 1, wherein each locking tab is a foldable flap.

11. The carrier of claim 1, wherein the apertures in the first layer provide a fold point for the locking tabs.

12. The carrier of claim 1, wherein apertures of the second layer are castellated to provide the locking tabs.

13. The carrier of claim 1, wherein the first and/or second layers are formed from cardboard material.

14. The carrier of claim 1, wherein the first and second layers are generally rectangular or generally square sheets.

15. The carrier of claim 1, further comprising one or more marketing panels formed along one or more sides of the first and/or second layers.

16. The carrier of claim 1, further comprising a handle.

17. The carrier of claim 1, further comprising a cover film for covering the first layer.

18. The carrier of claim 1, wherein the first and/or second layers include one or more folds that form panels or flaps, and in which the fold includes tension means for causing tension therein in a folded condition.

19. The carrier of claim 1 in combination with one or more packaging articles.

Description

(1) Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combination other than those explicitly set out in the claims. Each aspect can be carried out independently of the other aspects or in combination with one or more of the other aspects.

(2) The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings.

(3) The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternative forms and should not be construed as limited to the examples set forth herein.

(4) Accordingly, while embodiments can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

(5) Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art. It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealised or overly formal sense unless expressly so defined herein.

(6) In the following description, all orientational terms, such as upper, lower, radially and axially, are used in relation to the drawings and should not be interpreted as limiting on the invention.

(7) FIG. 1 shows a clip-type carrier generally indicated 10.

(8) As shown in FIGS. 2 and 3 the carrier is formed from first, upper layer 20 and a second, lower layer 15. The layers 15, 20 have approximately the same generally rectangular outline shape.

(9) The lower layer 15 is formed with six (in this embodiment) retaining apertures 25a-f, provided in two parallel rows of three. Each of the apertures 25a-f is generally circular and at their periphery have a plurality of radially extending slits 30 which define a plurality of retaining lugs 35.

(10) Along the centre of the layer 15 are two generally circular holes 40, 42, used both as finger holes and also to manipulate the carrier during application. It will be noted that at the ends of the carrier there are semi-circular holes 44, 46 because in this embodiment the carrier is formed in a continuous strip with other such carriers, so the holes at either end are bisected.

(11) The upper layer 20 is formed with six apertures 50a-f, provided in two parallel rows of three and corresponding to respective apertures 25a-f of the first layer.

(12) Referring also to FIG. 4, in this embodiment each of the apertures (on 50a is shown) is generally elliptical. The major axis Y of the apertures is shown and runs parallel to the axis of carrier application X shown in FIG. 1. To aid understanding a notional circular aperture is shown in dotted lines.

(13) Again corresponding to the first layer, along the centre of the layer 20 are two generally circular holes 55, 57 and the ends of the carrier also have semi-circular holes 59, 61.

(14) The layers/sheets 15, 20 are formed separately and secured together, in this embodiment by gluing. The sheets cannot therefore move relative to each other.

(15) The length of the slits in the apertures 25a-f means that they extend at least to the edge of the apertures 50a-f, as can be seen in FIG. 1.

(16) FIG. 5 shows a carrier 110 of the general type described in relation to FIG. 1 to 4 and applied to six standard sized beverage cans 170.

(17) It will be seen that the lugs 135 are deflected upwards and engage under the can end chimes 175. The lugs 135 are prevented from deformation by the presence of the apertures in the second layer, which effectively act like a collar.

(18) FIG. 6 illustrates a close-up of an aperture 250d with lugs 235 deflected upwards.

(19) FIG. 7A shows first and second layers 320, 315 of a carrier formed according to a further embodiment. This embodiment is designed for sleek cans or slim cans, having a smaller diameter than a standard can.

(20) Unlike standard cans, sleek and slim cans typically do not include a pronounced frusto-conical upper portion below a chime (meaning that the diameter of the end is very similar to the diameter of the body; typically only slightly larger). As a result, with the cans fitted into a carrier and sitting close to each other, there is very little carrier material between them. In addition, it is often preferable to have no or only a very small overhang at the edges of the carrier or else they cannot be stacked together efficiently. The result is that there would be very little carrier material around the cans, which would increase the risk of the material tearing.

(21) To address this potential problem, the embodiment of FIG. 7A provides additional material flaps 321a-d along each edge of the upper layer 320.

(22) The principle of the carrier 310 formed from layers 320, 315 is generally the same as that for the carrier 110 described in relation to FIG. 5, for example. A carrier 310 of this type is shown applied to six sleek beverage cans 370 in FIG. 7B. The flaps 321 are folded down (by approximately 90 degrees) so that that lie generally flat against the side of the cans. In this embodiment the flaps are folded during application; in other embodiments the flaps may be pre-folded.

(23) In this embodiment the apertures 350 in the upper layer 320 are generally circular.

(24) FIG. 8 shows a carrier 410 formed in accordance with the present invention and applied to six slim can 470. The carrier 410 is similar to the carrier 310, with extra material flaps 421 provided along each edge.

(25) FIG. 9 shows a carrier 510 formed according to a further embodiment. The carrier 510 is similar to the carrier 410 and is shown applied to slim cans 570.

(26) The folds which form the flaps are provided with tensioning means. In this embodiment, for example, the fold line 522 along which the upper layer is folded to form the flap includes two elongated elliptical shaped panels (reminiscent of a marquise shape) 523a, 523b. When the flap is folded the panels introduce tension into the fold line, which holds the flaps in position (i.e. prevents it from rising up/unfolding) and means that the flap is held alongside the cans.

(27) FIGS. 10A to 10C illustrate a fold formed in accordance with the present invention. The fold line 622 includes an elongated elliptical panel 623. This places the fold line under tension and provides a stable folded configuration.

(28) FIGS. 11A to 11C show carriers 710, 810, 910 formed according to further embodiments. The carrier 710 is generally rectangular and the flaps along the longer sides each have two spaced elliptical tensioning panels. The carrier 810 has a single elliptical panel along the fold line of each longer side flap. The carrier 910 has a single elliptical panel along the fold line of each longer side flap and a single elliptical panel forming part of the fold of each shorter side.

(29) FIG. 12A shows a carrier 1010 formed according to a further embodiment. The carrier 1010 is similar to the carriers 10 and 110. In this embodiment the longer sides of the bottom layer are extended to form panels 1080a, 1080b, which could be used, for example, as a merchandising/advertising space. The carrier 1010 is folded along lines 1085a, 1085b to form the panels 1080a, 1080b.

(30) The carrier 1110 of FIG. 12B is similar to the carrier 1010 of FIG. 12A, except that only one panel 1180 is provided.

(31) FIG. 13 shows part of a carrier 1210 formed according to a further embodiment, with lugs 1235 located under a can chime 1275.

(32) FIGS. 14A to 14D illustrate a carrier 1310 formed according to a further embodiment and shown unitising a plurality of cans 1370.

(33) FIG. 15 shows a carrier 1410 formed according to a further embodiment. The carrier 1410 is similar to the carrier 10, 110. In this embodiment a peelable film 1482 is provided and extends across the layer 1420. This means that when the carrier is applied (see FIG. 16) the tops of the cans 1470 are protected. Because the film 1482 is peelable it can easily be removed from the cardboard carrier before recycling.

(34) FIG. 17 illustrates a method of applying clip-type carriers. The carriers 1510 are provided as a continuous strip 1590, which approach and move onto a rotary drum 1595. The drum may, for example, include posts which engage manipulation holes.

(35) The drum 1595 causes the carriers to be rolled onto waiting sets of containers (as opposed, for example to pushing them down vertically from above).

(36) To achieve the closest possible fit of the first layer in relation to the second layer in a roll-on system, elliptical apertures (with ellipticity in the application direction) may be used to facilitate close fitting whilst allowing clearance for the aperture to pass over the trailing edge of the container as it is applied.

(37) The strip may, for example include perforations, embossed lines or the like to allow separation before, during or after application.

(38) FIGS. 18 and 19 show a carrier formed according to a further aspect of the present invention. The carrier is formed from a lower layer 1615 and an upper layer 1620.

(39) The lower layer 1615 is formed with six (in this embodiment) retaining apertures 1625, provided in two parallel rows of three. Each of the apertures 1625 is generally circular and at their periphery have a plurality of radially extending slits 1630 which define a plurality of retaining lugs 1635.

(40) The upper layer 1620 is formed with apertures 1650 corresponding to respective apertures 1625 of the lower layer 1615.

(41) The circular apertures 1650 are dimensioned using formula: D1<D2-2T to result in formation of a ridge/crease/fillet 1665 when applied, which significantly improves retention.

(42) The lugs 1635 are shown located under a can chime 1675.

(43) Drop tests were carried out on the smaller diameter aperture in top layer of carrier. The drop tests were carried out on 6500 ml cans at a drop distance of approximately 1.

(44) These tests were performed on the standard 55 mm diameter, smaller 54 mm diameter and the 53.5 mm diameter aperture carriers i.e. D1+2T>D2; D1+2T=D2; and D1+2T<D2. For this test the top of the cans is approximately 54 mm diameter and the board thickness of a single layer is 0.35 mm.

(45) The reduction in the aperture diameter, 53.5 mm combined with the board thickness of 20.35 mm creates an aggregated aperture of only 52.8 mm. This is an interference fit over the top of the cans and may require a precise method of application to prevent the non-stretchy cardboard from tearing (e.g. see FIGS. 23 and 24).

(46) TABLE-US-00004 Aperture Average diameter number (mm) of drops 55 7 54 9 53.5 25+

(47) The results show a marked improvement in can retention. This is because how the pack works is fundamentally different.

(48) On the designs of FIGS. 1 to 16, for example, the top layer diameter supports the fingers of the lower diameter, helping to prevent them from bending and the pack failing. By reducing the diameter further, it has been found that the amount the fingers extend through the top aperture is reduced (for example approximately 1.9 mm vs 2.75 mm) as a result of the smaller diameter not sitting further down on the conical top of the can. It also creates a reinforcing bead around the fingers. These shorter fingers are less prone to deformation. The difference is in the interference fit of the carrier over the rim of the can. Once the finger deformation becomes critical they can no longer support the cans and pack failure results. On the smaller diameter undersized aperture version, due to the interference fit, the deforming fingers prevent the rim of the cans from passing through the carrier aperture. Therefore, in order for the pack to fail the carrier would need to tear. In effect, the revised design achieves a two-stage method of (can) retention.

(49) The perception was that reducing the size of the apertures even further over the initial design, would have a detrimental effect to the pack itself. As there is no stretch available in the cartonboard material, it was suspected that the pack would split as had seen in previous tests. However, surprisingly the deformation and resultant bead that is created has improved pack performance as noted above.

(50) FIG. 20A shows a plan view of an upper layer aperture 1725. Also shown are retaining flaps 1735 folded up and through the aperture 1725 (as they are in use) and having a thickness T. This forms an aggregate container receiving aperture diameter represented as D12T in FIG. 20B.

(51) FIG. 20C shows a container (in this embodiment being a metal can) with a chime 1775 having a diameter represented as D2. The aggregate diameter D12T is less than D2, so that as the carrier is initially applied onto the container the flaps 1735 are bent up and through the aperture 1725 and continued application causes formation of the bent rim 1765, as shown in FIG. 21.

(52) FIGS. 22A and 22B show a comparison of two scenarios: i) D2 is less than or equal to D12T, in which case no bent rim is formed; and ii) D2 is greater than D12T, in which case a reinforcing rim is formed.

(53) FIGS. 23 and 24: in order to apply the modified carrier of some embodiments effectively it has been found that a close-fitting pusher plate 1800 is required. Further, in order to prevent the corners of the carrier 1810 deforming during application retaining strips 1860 within the tool hold the carrier, which improves application.

(54) These strips take the form of articulated clamps mounted along each edge of the application head/pusher plate 1800. Prior to picking up the carrier the clamps are in a retracted position. As the individual carrier is picked up from a pre-application stack by the pusher plate, the clamps move and grip the edges of the carrier against the underside of the plate. This provides extra support which acts against the forces created during application, preventing flexing and deformation of the carrier, resulting in a more secure pack. These strips may be profiled to avoid contact with the containers during application. Once applied the retaining strips retract, releasing the applied carrier and allowing the next carrier to be picked up and engaged within the application head; the process is then repeated.

(55) FIG. 25 shows a set of containers 1905. Each container 1905 includes a transfer bead 1906, a conical portion 1907 and a waist 1908 formed in a sidewall 1909.

(56) A carrier formed in accordance with the present invention could, for example, be configured to fit under the bead 1906, in which case the diameter of the bead 1906 would be D2. Alternatively a carrier could be configured to fit into the waist 1908, in which case the diameter of the sidewall 1909 would be D2 (the overdimension that causes formation of the aperture bent rim).

(57) Although illustrative embodiments of the invention have been disclosed in detail herein, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention.