Laminated article carrier and blank therefor

Abstract

To provide a carrier (90) for packaging one or more articles, a blank (10) for forming the carrier, and a method for forming the carrier.SOLUTION: Aspects of the present disclosure relate to the carrier (90) for packaging one or more articles, the blank (10) for forming the carrier, and a method for forming the carrier. In one aspect, an upper engaging article carrier is provided for packaging at least one article. The article carrier includes a main panel (12) including at least one upper engaging device having an upper receiving opening part. The main panel includes a laminated structure formed from two or more layers L1, L2 of a substrate (50) uniformly bonded together.SELECTED DRAWING: Figure 5E

Description

[Technical field]

[0001] The present invention relates to article carriers and blanks for forming the same, and more particularly, but not exclusively, to top-gripping or top-engaging style carriers having one or more apertures for receiving and retaining articles therein. [Background technology]

[0002] In the field of packaging, it is known to provide cartons for transporting multiple articles. Cartons are well known in the art and are useful for allowing consumers to transport, store, and access groups of articles for consumption. Cost and environmental considerations require such cartons or carriers to be formed from as little material as possible, necessitating as little waste as possible in the materials from which they are formed. An additional consideration is the strength of the carton and its suitability for holding and transporting large quantities of articles. It is desirable for the contents of the carton to be safe within the carton.

[0003] It is well known to provide top gripping article carriers where an aperture is formed in a panel of the carrier and a tab may be defined about said aperture, the tab being displaceable out of the plane of said panel, said tab engaging an article when the article is received in the aperture, typically around a flange or lip of the article. Summary of the Invention [Problem to be solved by the invention]

[0004] The present invention seeks to provide an improvement in the field of cartons, which are typically formed from paperboard or the like. [Means for solving the problem]

[0005] A first aspect of the invention is a method of forming an upper engaging article carrier, comprising the steps of: Providing a first paperboard substrate; Providing a second paperboard substrate; applying an adhesive treatment uniformly across a first surface of a first paperboard substrate; securing a surface of a second paperboard substrate to a first surface of the first paperboard substrate to form a laminated paperboard structure; cutting one or more blanks from the laminated paperboard structure; The present invention provides a method comprising:

[0006] Optionally, cutting one or more blanks from the laminated paperboard structure includes cutting one or more upper engagement devices from the laminated paperboard structure, each having an upper receiving opening.

[0007] Optionally, the method further comprises: applying the blank to one or more articles to form a package; engaging the one or more upper engagement devices with respective ones of the one or more articles; Includes.

[0008] Optionally, the one or more upper engagement devices each include at least one tooth, the at least one tooth comprising a uniformly bonded multi-ply laminate structure, and engaging the one or more upper engagement devices with a respective one of the one or more articles includes engaging an edge of the at least one tooth with a respective one flange of the one or more articles.

[0009] A second aspect of the present invention provides a top-engaging article carrier for packaging at least one article. The article carrier includes a main panel including at least one top-engaging device having a top receiving opening. The main panel includes a laminated structure formed from two or more layers of substrates uniformly bonded together.

[0010] Optionally, the upper engagement device includes one or more tines for engaging the article, the one or more tines including two or more layers of substrate uniformly bonded together.

[0011] Optionally, each of the two or more layers of the substrate includes at least one uncoated side.

[0012] Optionally, each of the two or more layers of the substrate includes a coated side, the coated side of a first layer being bonded to the coated side of a second layer.

[0013] Optionally, each of the two or more layers of the substrate includes an uncoated side opposite the coated side.

[0014] Optionally, each of the two or more layers of the substrate includes an uncoated side, and the uncoated side of a first layer is bonded to the uncoated side of a second layer.

[0015] Optionally, each of the two or more layers of the substrate includes a coated side opposite an uncoated side.

[0016] Optionally, each of the two or more layers of the substrate includes a second uncoated side opposite the first uncoated side.

[0017] Optionally, each of the two or more layers of the substrate includes an uncoated side, and the uncoated side of a first layer is bonded to the uncoated side of a second layer.

[0018] Optionally, the laminated structure comprises: a first layer having a coated side and an uncoated side opposite the coated side; a second layer having an uncoated side; Including, The uncoated side of the first layer is bonded to the uncoated side of the second layer.

[0019] Optionally, the substrate is a paperboard material.

[0020] A third aspect of the invention provides a blank for forming an upper-engaging article carrier, the blank including a main panel including at least one upper-engaging device having at least one upper receiving opening, the main panel including a laminated structure formed from two or more layers of substrate material uniformly bonded together.

[0021] A fourth aspect of the present invention provides an article carrier for packaging at least one article, the article carrier including a main panel including at least one article retaining device having at least one article receiving opening, the main panel including a laminated structure formed from two or more layers of paperboard material uniformly bonded together.

[0022] 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 including a second surface, the second surface being disposed adjacent to the first surface and uniformly bonded to the first surface.

[0023] It is contemplated or intended that within the scope of this application, the various aspects, embodiments, examples, features, and alternatives described in the preceding paragraphs, in the claims, and / or in the following description and drawings may be considered or interpreted independently or in any combination thereof.

[0024] A feature or element described in connection with or in relation to one embodiment is 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, and the feature or element extracted from said one embodiment may be included in addition to or instead of one or more features or elements of said other embodiments.

[0025] 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.

[0026] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief description of the drawings]

[0027] [Figure 1] FIG. 2 is a plan view from above of a plurality of connected blanks, each of which can form a carrier according to a first embodiment; [Diagram 2] FIG. 2 is a plan view from above of one of the blanks of FIG. 1. [Diagram 3] 3 is a top perspective view of a carrier formed from the blank of FIG. 2; FIG. [Figure 4] FIG. 2 is a plan view from above of a plurality of connected blanks, each of which can form a carrier according to a second embodiment; [Figure 5A]FIG. 1 is a schematic diagram of a multi-ply structure formed from a paperboard substrate according to various embodiments of the present disclosure. [Figure 5B] FIG. 1 is a schematic diagram of a multi-ply structure formed from a paperboard substrate according to various embodiments of the present disclosure. [Figure 5C] FIG. 1 is a schematic diagram of a multi-ply structure formed from a paperboard substrate according to various embodiments of the present disclosure. [Figure 5D] FIG. 1 is a schematic diagram of a multi-ply structure formed from a paperboard substrate according to various embodiments of the present disclosure. [Figure 5E] FIG. 1 is a schematic diagram of a multi-ply structure formed from a paperboard substrate according to various embodiments of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Detailed descriptions of specific embodiments of packages, blanks, and carriers are disclosed herein. It will be understood that the disclosed embodiments are merely examples of ways in which certain aspects of the present invention may be implemented, and do not represent an exhaustive list of all ways in which the present invention may be embodied. As used herein, the term "exemplary" is used broadly to refer to embodiments that serve as illustrations, samples, 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 specific components. Well-known components, materials, or methods have not necessarily been described in detail to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein should not be construed as limiting, but merely as a basis for the claims and as a representative basis for teaching those skilled in the art to use the present invention in various ways.

[0029] Referring to Figure 1, a plan view of a plurality of connected blanks 10A, 10B, 10C, 10D, 10D, 10E, 10F is shown. An individual blank 10 is shown in Figure 2, which may form a carton or carrier 90 (as shown in Figure 3) for containing and transporting a group of primary products such as, for example but not limited to, bottles or cans (hereafter referred to as item B), as shown in Figure 3. The blanks 10 form a secondary package for packaging at least one primary product container or package. An alternative blank 110 is shown in Figure 4.

[0030] In the embodiments detailed herein, the terms "carton" and "carrier" refer to a container for engaging and carrying articles, such as a primary product container, for non-limiting purposes of illustrating various features of the present invention. It is contemplated that the teachings of the present invention may be applied to a variety of product containers, which may or may not be tapered and / or cylindrical in shape. Exemplary containers include bottles (e.g., metal bottles, glass bottles, or plastic bottles), cans (e.g., aluminum cans), tin cans, pouches, packets, and the like.

[0031] The blanks 10, 110 are formed from sheets of a suitable substrate. As used herein, the term "suitable substrate" should be understood to include all types of foldable sheet material, such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be appreciated that one or other number of blanks may be used, where appropriate, for example, to provide a carrier structure, as described in more detail below.

[0032] The packaging structures or cartons described herein may be formed from sheet materials such as paperboard, which may be made from or coated with materials to increase its strength. An example of such a sheet material is the tear-resistant NATRALOCK® paperboard made by WestRock Company. It should be noted that tear-resistant materials may be provided by two or more layers to help improve the tear resistance of the package. Typically, one surface of the sheet material may have different properties than the other surface. For example, the surface of the sheet material facing outward from the finished package may be, among other things, smooth and may have a coating or other surface treatment, such as a clay coating, to provide good printability. On the other hand, the surface of the sheet material facing inward may be provided with a coating, layer, treatment, or otherwise prepared to provide properties such as one or more of tear resistance, good adhesion, heat sealability, or other desired functional properties.

[0033] In the illustrated embodiment, the blank 10 is configured to form a carton or carrier 90 for packaging an exemplary arrangement of exemplary items B. In the embodiment illustrated in Figures 1, 2, and 3, the arrangement is a 2x2 matrix or array. In the illustrated embodiment, two rows of two items are provided and item B is a beverage can. In the embodiment illustrated in Figure 4, the arrangement is a 3x2 matrix or array. In the illustrated embodiment, three rows of two items are provided and item B is a beverage can. Alternatively, the blanks 10, 110 may be configured to form carriers for packaging other types, numbers, and sizes of items and / or for packaging items in different arrangements or configurations.

[0034] 1, there is shown a plurality of connected blanks generally designated by reference character 1, specifically six blanks 10A, 10B, 10C, 10D, 10E, 10F arranged in a 3x2 matrix or array. Each blank 10A, 10B, 10C, 10D, 10E, 10F includes a main panel 12 for forming a top wall or mating 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.

[0035] The main panel 12 includes at least one item retaining structure RT1, RT2, RT3, RT4 (see FIG. 2). In the embodiment of FIG. 1 and FIG. 2, the main panel 12 includes a plurality of item retaining structures RT1, RT2, RT3, RT4, specifically, four item retaining structures RT1, RT2, RT3, RT4 arranged in a 2x2 matrix or array. Each of the item retaining structures RT1, RT2, RT3, RT4 includes an aperture A1, A2, A3, A4.

[0036] Each of the item retaining structures RT1, RT2, RT3, RT4 are substantially similar in construction and therefore will be described in detail with reference to the second item retaining structure RT2.

[0037] The second item retaining structure RT2 includes an item receiving opening defined in part by an aperture A2.

[0038] The second item retaining structure RT2 includes a first segment and a second segment, the first segment S1 defining a first circular arc S1 and the second segment defining a second circular arc S2.

[0039] The first segment S1 may be "toothed" and the second segment S2 may be "toothless". That is, the aperture A2 includes a plurality of teeth disposed about a first arc S1 in a peripheral region of the aperture A2 defined by the first segment S1. The peripheral region of the aperture A2 defined by the second segment (second arc S2) is toothless. In the embodiment illustrated in FIG. 2, the second segment includes an arcuate edge having a pair of spaced apart relief notches C8, C9.

[0040] The "toothed" region includes a plurality of teeth or tabs formed in the main panel 12 around the aperture A2.

[0041] Each tooth includes an engagement edge or tooth edge 31. Each tooth edge 31 may be linear or arcuate in shape. The tooth edge 31 may be defined by a portion of an arc or a circle. The aperture A2 includes a perimeter that may approximate or define a notional circle having a center.

[0042] The "toothed" area of ​​the main panel 12 surrounding the aperture A2 can include cutouts C1, C2, C3, C4, C5, C6, C7 in the form of recesses or notches. The cutouts C1, C2, C3, C4, C5, C6, C7 are substantially "U" shaped, although in other embodiments the cutouts C1, C2, C3, C4, C5, C6, C7 may be alternatively shaped, for example but not limited to, being "V" shaped. The cutouts C1, C2, C3, C4, C5, C6, C7 extend radially outward from a notional circle NC.

[0043] Each tooth or tab is at least partially defined by a pair of cutouts C1, C2, C3, C4, C5, C6, C7. The cutouts C1, C2, C3, C4, C5, C6, C7 may form relief elements extending radially away from a notional circular center.

[0044] The toothless or non-toothed region S2 of the main panel 12 surrounding the aperture A2 includes an engagement edge or free edge 37 (also referred to herein as a continuous support edge). The engagement edge 37 is curved or arcuate in shape.

[0045] The toothless or non-toothed region of the main panel 12 surrounding the aperture A2 may be defined within or occupy an arc subtending an angle of approximately 180°, although in other embodiments the angle may be less than 180°, such as, but not limited to, 170°.

[0046] Thus, substantially half of the perimeter of aperture A2 includes teeth or tabs.

[0047] The second article retaining structure RT2 includes two adjacently disposed relief elements C1, C7 with an engagement edge 37 defined therebetween. The engagement edge 37 may be interrupted by one or more relief elements C8, C9. In the illustrated embodiment, the engagement edge 37 is interrupted by two relief elements C8, C9.

[0048] The main panel 12 may optionally include a handle structure H. The handle structure H may include a handle opening. The handle opening is defined in the main panel 12 and positioned in an area centrally disposed between the first pair of item retaining structures RT1, RT2 and the second pair of item retaining 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 a fold line 15.

[0049] Optionally, the side edges of the main panel 12 may be arranged in a curved or undulating shape. In this manner, 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 that is less than twice the maximum width of any individual blank 10. This can have economic and environmental benefits by reducing the amount of substrate needed to produce a given number of blanks 10.

[0050] The main panel 12 includes at least a paperboard substrate. The material of the paperboard substrate may be selected from any conventional paperboard (e.g., in the range of about 10 pt. (0.010" / about 0.25 mm) up by weight, preferably in the range of about 16 pt. (0.016" / about 0.41 mm) to about 28 pt. (0.028" / about 0.7 mm)). The paperboard substrate may be 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.

[0051] Examples of such substrates are 28 point (pt.) SBS board (solid bleached sulfate paperboard coated on one side, trade name PrintKote®), unbleached uncoated Kraft board (UUK) or CNK® board (Coated Natural Kraft® - unbleached Kraft paperboard with a clay coating on one side, trade name CarrierKote™) manufactured by the WestRock® Company.

[0052] In the illustrated embodiment, the main panel 12 is formed from two layers of paperboard substrate that are bonded together to form a laminated paperboard material. An adhesive treatment or glue can form an adhesive layer between the two layers of paperboard substrate. Figures 5A-5E illustrate various embodiments of laminated paperboard materials for forming article carrier 90.

[0053] FIG. 5A illustrates an embodiment including a laminated paperboard structure, the laminated paperboard structure including a first ply L1 of paperboard having a coating 52 on one side of the fibrous 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 the fibrous layer 50. The uncoated side, or fibrous layer 50 of the first ply L1 is bonded to the uncoated side, or fibrous layer 50 of the second ply L2. An adhesive treatment or glue forms an adhesive layer or glue layer 54 therebetween. The laminated structure of FIG. 5A can be resistant to curling due to, for example, but not limited to, moisture absorption (absorption or adsorption) and / or desorption by the fibrous layer. The laminated paperboard structure includes coatings on opposing surfaces that can inhibit moisture absorption and / or desorption by the fibrous layer.

[0054] 5B shows an embodiment including a laminated paperboard structure including a first ply L1 of paperboard having a coating 52 on one side of a fibrous 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 fibrous layer 50. The coated side of the first ply L1 is bonded to the coated side of the second ply L2. An adhesive treatment or glue forms an adhesive layer or bond layer 54 therebetween.

[0055] 5C shows an embodiment including a laminated paperboard structure comprising a first ply L1 of paperboard having a coating 52 on one side of a fibrous 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 fibrous layer 50. The uncoated side, i.e., fibrous layer 50 of the first ply L1, is bonded to the coated side of the second ply L2. An adhesive treatment or glue forms an adhesive layer or bond layer 54 therebetween.

[0056] 5D shows an embodiment including a laminated paperboard structure comprising a first ply L1 of paperboard having a coating 52 on one side of a fibrous layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of uncoated paperboard having a fibrous layer 50. The uncoated side, i.e., fibrous layer 50 of the first ply L1, is bonded to one of the uncoated sides of the second ply L2. An adhesive treatment or glue forms an adhesive layer or bond 54 therebetween.

[0057] 5E shows an embodiment including a laminated paperboard structure including a first ply L1 of uncoated paperboard having a fibrous layer 50. The first ply L1 of paperboard is bonded to a second ply L2 of uncoated paperboard having a fibrous layer 50. One of the uncoated sides of the first ply L1 is bonded to one of the uncoated sides of the second ply L2. An adhesive treatment or glue forms an adhesive layer or bond layer 54 therebetween.

[0058] In one example, a first sheet of 28pt CBS or CNK board is bonded to a second sheet of 28pt CBS or CNK board. This creates a substrate having a thickness of about 0.056" (roughly 1.4 mm) with a coating on its opposing faces. The advantage of such a substrate is increased strength without the inclusion of polymeric or plastic materials, such substrates can provide environmental benefits, and can 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 an alternative embodiment, the coated side of one layer or sheet of material is bonded to the coated side of another layer or sheet of material.

[0059] It will be appreciated that the thickness or caliper (density or weight) of the paperboard substrates selected for bonding together can be of different thicknesses or weights. It will also be appreciated that the thickness or caliper (density or weight) of the selected paperboard substrates may be selected based on the weight or load that the article carrier is intended to support, e.g., an article carrier for packaging larger volume / heavier beverage cans or a greater number of beverage cans may be formed from a thicker (or heavier) paperboard substrate. Similarly, when the article carrier is intended to support a greater load, the article carrier may be formed from a greater number of layers or plies of paperboard substrates that are bonded together.

[0060] The adhesive layer may be formed from any adhesive that has good affinity for paperboard, such as, for example, a water-based adhesive (e.g., white craft glue, yellow wood glue, and polyvinyl acetate (PVA) adhesive).

[0061] Two or more sheets of paperboard can be laminated together into a laminated paperboard, and the laminated paperboard can then be die cut into a carrier blank 10, such as that of FIG.

[0062] In some embodiments, the blanks and article carriers are formed from two or more sheets or rolls of commercially available paperboard stock that are bonded together to form a laminated structure. It is contemplated that the laminated structure is formed from paperboard stock that has been dried at a paper mill and that the paperboard stock may also have been subjected to one or more dry end treatments, such as, but not limited to, calendaring and / or finishing with a coating, prior to being bonded together.

[0063] In some embodiments, the surface of a paperboard substrate that 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 with a partial cut depth.

[0064] The upper engaging carrier 90 includes uniformly bonded layers. In those embodiments in which the upper engaging carrier 90 includes engaging teeth, each tooth has a uniformly bonded paperboard layer. This is advantageous over article carriers having multiple paperboard layers with an unbonded structure and over article carriers having a post-bonded structure in which the paperboard layers are bonded together after each layer of paperboard is die-cut. In such post-bonded article carriers, since each layer has already been die-cut, the layers are bonded together by spot bonding, and therefore the carrier does not have uniformly bonded layers. If the carrier includes engaging teeth, the teeth may be formed from unbonded layers rather than including uniformly bonded layers.

[0065] In some embodiments, at least one tear-resistant layer may be disposed between a first layer and a second layer of a substrate, and such substrates may be formed by bonding two sheets of material, at least one of which includes a laminated tear-resistant layer, which can have the advantage of increasing the strength of the substrate.

[0066] The main panel 12 can include a tear-resistant layer laminated to the paperboard layer. Optionally, it includes an adhesive layer between the paperboard substrate and the tear-resistant layer. The tear-resistant layer can be disposed over the uncoated side of the paperboard substrate and can be formed of a polymeric material and secured to the substrate. The tear-resistant layer imparts toughness to the laminate structure. Suitable tear-resistant materials can include, but are not limited to, tear-resistant laminated sheet materials, such as NATRALOCK®, which can include layers of n-axially oriented films, such as MYLAR®, which are biaxially oriented polyester, oriented nylon, cross-laminated polyolefin, or high density polyolefin. The orientation of these materials and the cross-laminated structure contribute to the tear-resistant qualities. Tear resistance can also be attributed to the chemical nature of the tear resistant material, such as extruded metallocene catalyzed polyethylene (mPE).

[0067] Alternatively, the tear-resistant layer can 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.

[0068] The adhesive layer may be formed from a polyolefin material, such as low density polyethylene (LDPE), etc. The adhesive layer may be disposed between the substrate and the tear resistant layer to secure the tear resistant layer to the substrate.

[0069] 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 against the group of articles B. Each of the article retaining structures RT1, RT2, RT3, RT4 of the blank 10 is aligned with a respective article B in the group. A portion of article B passes through the main panel 12. The toothed areas of the main panel 12 around each of the article retaining structures RT1, RT2, RT3, RT4 may be folded out of the plane of the main panel 12.

[0070] Each toothed area of ​​the main panel 12 may be folded around one of the articles received in a respective one of the article retaining structures RT1, RT2, RT3, RT4. The blank 10 may be deformed around a shoulder portion of an article B, for example, but not limited to, an article B being a can, where the shoulder portion may be provided by a neck-in.

[0071] The engaging edges 31 of the teeth and the engaging edges 37 of the non-toothed areas of the main panel 12 engage under the protrusions. The protrusions may be located around the neck or chime of the item B (which may be provided with a flange). When the item B is a can, the protrusions may be provided by the end seams of the canner. In other embodiments, it may be provided by a ridge or undercut molding of the item B, or by an end closure of the item B, such as, but not limited to, a crown cork or closure. In this way, the engaging edges 31, 37 grip or hold the item B and prevent or inhibit the item B from unintentionally separating from the main panel 12. The assembled carrier 90 is shown in FIG. 3.

[0072] The teeth comprise two layers of substrate uniformly bonded together, which provides a secure engagement of article B.

[0073] Another optional feature of the carrier 90 is that the main panel 12 is defined by a perimeter to which other parts of the carrier 90 are not connected. That is, the carrier 90 has no connections to other panels, such as, but not limited to, side panels or end wall panels that extend around the sides of the article grouping. Thus, the perimeter of the main panel 12 is defined in its entirety by free, cut, or unhinged edges.

[0074] Another optional feature of the carrier 90 is that the main panel 12 is defined by a perimeter that includes a convexly curved edge and a concavely curved edge, where the radius of curvature of the convexly curved edge is substantially equal to the radius of curvature of the concavely curved edge, thus allowing two similar blanks 10 to be placed in a nested or tessellated arrangement.

[0075] In some embodiments, multiple blanks 1 are applied simultaneously to a first group of articles B. The first group of articles B is divisible into multiple second groups of articles B. Each second group of articles B is thus formed from a subset of the first group of articles B. In the embodiment illustrated in FIG. 1, the first group of articles B includes 24 articles arranged in a 4x6 matrix or array, with each individual blank 10A, 10B, 10C, 10D, 10E, 10F housing four articles in a 2x2 matrix or array.

[0076] The frangible connections 14 between the individual blanks 10A, 10B, 10C, 10D, 10E, 10F may be separated upon application of the plurality of blanks 1 to the first group of articles B. Alternatively, the frangible connections 14 may remain intact and the individual blanks 10A, 10B, 10C, 10D, 10E, 10F may be separated from one another at the point of sale or distribution.

[0077] Referring now to Figure 4, an additional embodiment of the present disclosure is shown. In the second illustrated embodiment, like numerals have been used where possible to indicate like parts, but 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 Figures 1 through 3 will be described in detail.

[0078] 4 illustrates a second embodiment, showing a plurality of connected blanks generally designated by reference character 101, specifically four blanks 110A, 110B, 110C, 110D arranged in a 2x2 matrix or array. Each blank 110A, 110B, 110C, 110D includes a main panel 112 for forming the top wall or mating panel of the carrier (not shown). Each blank 110A, 110B, 110C, 110D is connected to two adjacent blanks 110A, 110B, 110C, 110D by frangible connections 114.

[0079] The main panel 112 of each blank 110A, 110B, 110C, 110D includes at least one item retaining structure RT1, RT2, RT3, RT4, RT5, RT6. The main panel 112 includes a plurality of item retaining structures RT1, RT2, RT3, RT4, RT5, RT6, specifically, six item retaining structures RT1, RT2, RT3, RT4, RT5, RT6 arranged in a 3x2 matrix or array. Each of the item retaining structures RT1, RT2, RT3, RT4, RT5, RT6 includes an aperture A1, A2, A3, A4, A5, A6.

[0080] Each of the item retaining structures RT1, RT2, RT5, RT6 (also referred to as endmost item retaining structures RT1, RT2, RT5, RT6) is substantially similar in construction to the item retaining structures RT1, RT2, RT3, RT4 of the embodiment of Figures 1 and 2. These item retaining structures include six tines disposed around the perimeter of apertures A1, A2, A5, A6. The item retaining structures RT1, RT2, RT5, RT6 are disposed in corner or main panels 112.

[0081] The item retaining structures RT3, RT4 (also referred to as intermediate item retaining structures RT3, RT4) are disposed intermediately on the main panel 112 between the endmost item retaining structures RT1, RT2 of the first pair and the endmost item retaining structures RT5, RT6 of the second pair.

[0082] The intermediate article retaining structures RT3, RT4 include three teeth, each of which is defined in part by a pair of relief elements C. Each tooth includes an engagement edge 131, 132, 133. The engagement edges 131, 132, 133 of the teeth occupy a portion of the circumference of the aperture A3, A4. The portion defines a first arc of a notional circle having a center, and the angle subtended by the arc can be less than 120°, it can be greater than 60°, and can be approximately 90°. The first arc is defined between two relief elements.

[0083] The intermediate article retaining structures RT3, RT4 each include a toothless region. The toothless portion defines a second arc complementary to the first arc. The toothless region includes an engagement edge 137.

[0084] The main panel 112 may optionally include handle structures H1, H2. The handle structures H1, H2 may include a first opening at least partially formed by a first handle aperture. The first handle aperture is punched out of the main panel 112 and positioned in an area centrally disposed between the first pair of article retaining structures RT1, RT2 and the second pair of article retaining structures RT3, RT4. The first opening may be partially defined by a first cushioning tab hingedly connected to the main panel 112 by a fold line. The first handle aperture may be substantially crescent or "C" shaped. The handle structures H1, H2 may include a second opening at least partially formed by a second handle aperture. The second handle aperture is punched out of the main panel 112 and positioned in an area centrally disposed between the second pair of item retaining structures RT3, RT4 and the third pair of item retaining 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 disposed opposite one another such that the first and second cushioning flaps are hinged to the main panel 112 opposite one another.

[0085] The present disclosure provides a top-engaging type carrier having an article retaining structure or article top-engaging device formed from a laminated substrate formed from two or more layers of paperboard substrate uniformly bonded together, the laminated substrate being formed prior to die cutting a blank therefrom.

[0086] The laminated substrate may be formed from two or more sheets or rolls of paperboard, at least one of which is pre-printed with a graphic or other indicia. The two or more sheets or rolls are laminated after printing of one of the layers. Thus, a laminated substrate with a graphic or other indicia printed on at least one side is formed. The printed laminated substrate is then cut to form a carrier blank. In some embodiments where the laminated substrate is formed from a roll of paperboard, the laminated substrate may be cut into sheets prior to cutting the carrier blank. In other embodiments where the laminated substrate is formed from a roll of paperboard, it is not necessary to cut the laminated substrate into sheets, and the carrier blank may be cut directly from the laminated substrate using an in-line die cutting device.

[0087] A laminated substrate may be formed from bonding together two or more sheets or rolls of unprinted paperboard. Once the laminated substrate is formed, at least one side may be printed with a graphic or other indicia. Thus, a laminated substrate is formed with a graphic or other indicia printed on at least one side. The printed laminated substrate is then cut to form a carrier blank. In embodiments where the laminated substrate is formed from a roll of paperboard, the laminated substrate may be printed in-line or cut into sheets which are then printed.

[0088] It will be recognized that as used herein, directional references such as "top," "bottom," "base," "front," "back," "end," "side," "inside," "outside," "upper," and "lower," etc., do not necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.

[0089] As used herein, the terms "hinge connection" and "fold line" refer to all manner of lines that define hinge features of a blank that facilitate folding portions of the blank relative to one another or otherwise indicate optimal panel fold locations for the blank. References to a "hinge connection" should not necessarily be construed as referring to only a single fold line. In fact, a hinge connection may be formed from two or more fold lines, where each of the two or more fold lines can be either straight / linear or curved / curved in shape. When linear fold lines form a hinge connection, they may be disposed parallel to one another or slightly angled relative to one another. When curved fold lines form a hinge connection, they may cross one another and define a molded panel within the area enclosed by the curved fold line. A typical example of such a hinged connection may include a pair of arched or arcuate fold lines that intersect at two points such that they define an oval panel therebetween. A hinged connection may be formed from one or more linear fold lines and one or more curved fold lines. A typical example of such a hinged connection may include a combination of linear fold lines and arched or arcuate fold lines that intersect at two points such that they define a half-moon shaped panel therebetween.

[0090] As used herein, the term "fold line" may refer to one of the following: scored lines, embossed lines, debossed lines, perforation lines, short slit lines, half cut lines, single half cuts, interrupted cut lines, aligned slit lines, score lines, and any combination of the above options.

[0091] It should be understood that the hinged connections and fold lines can each include elements formed in the blank substrate including perforations, perforation lines, short slit lines, half cut lines, single half cuts, cut lines, interrupted cut lines, slits, scores, embossed lines, debossed lines, and any combination thereof. The elements can be sized and positioned to provide the desired functionality. For example, perforation lines can be sized or designed with a degree of weakness to define fold and / or cut lines. Perforation lines can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with greater effort, or to facilitate breaking with little effort.

[0092] The phrase "aligned with" as used herein refers to the alignment of two or more elements in an erected carton (e.g., an aperture formed in a first of two overlapping panels and a second aperture formed in a second of two overlapping panels). The elements that are aligned with one another may be aligned with one another in the thickness direction of the overlapping panels. For example, when an aperture in a first panel is "aligned 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 with the second aperture in the thickness direction of the first and second panels. [Explanation of symbols]

[0093] 1 Multiple connected blanks 10A, 10B, 10C, 10D, 10D, 10E, 10F Blank 12 Main Panel 14 Frangible connection 15 Folding lines 16 Cushioning tab 31, 32, 33, 34, 35, 36 Engagement edge or tooth edge 37 Engagement edge or free edge 50 fiber layers 52 Coating 54 Adhesive layer, adhesive layer 90 cartons, carriers 101 Multiple Connected Blanks 110A, 110B, 110C, 110D Blank 112 Main Panel 114 Frangible connection 131, 132, 133 Engagement edge 137 Engagement edge A1, A2, A3, A4, A5, A6 aperture B Goods C Relief element, center C1, C2, C3, C4, C5, C6, C7 cutouts C8, C9 relief elements H Handle Structure H1, H2 handle structure L1 First ply L2 Second Ply RT1, RT2, RT3, RT4, RT5, RT6 Article holding structure S1 First segment, first arc S2 Second segment, second arc

Claims

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

2. The upper engaging article carrier of claim 1 , wherein the upper engaging device includes one or more teeth for engaging an article, the one or more teeth including two or more layers of substrate uniformly bonded together.

3. The upper engaging article carrier of claim 1 , wherein each of the two or more layers of the substrate includes at least one uncoated side.

4. The upper engaging article carrier of claim 1 , wherein each of the two or more layers of the substrate includes a coated side, the coated side of a first layer being bonded to the coated side of a second layer.

5. The upper engaging article carrier of claim 4 , wherein each of the two or more layers of the substrate includes an uncoated side opposite the coated side.

6. 2. The upper engaging article carrier of claim 1, wherein each of the two or more layers of the substrate includes an uncoated side, the uncoated side of a first layer being bonded to the uncoated side of a second layer.

7. The upper engaging article carrier of claim 6 , wherein each of the two or more layers of the substrate includes a coated side opposite the uncoated side.

8. The upper engaging article carrier of claim 6 , wherein each of the two or more layers of substrate includes a second uncoated side opposite the first uncoated side.

9. 10. The upper engaging article carrier of claim 1, wherein each of the two or more layers of the substrate includes an uncoated side, the uncoated side of a first layer being bonded to the uncoated side of a second layer.

10. The laminated structure comprises: a first layer having a coated side and an uncoated side opposite the coated side; a second layer having an uncoated side; and Including, 10. The upper engaging article carrier of claim 1, wherein the uncoated side of the first layer is bonded to the uncoated side of the second layer.

11. The upper engaging article carrier of claim 1 , wherein the substrate is a paperboard material.

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

13. 1. A method of forming an upper engaging article carrier, comprising: Providing a first paperboard substrate; Providing a second paperboard substrate; applying an adhesive treatment uniformly across a first surface of the first paperboard substrate; 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; 23. A method of forming an upper engaging article carrier comprising:

14. 14. The method of forming an upper engaging article carrier as described in claim 13, wherein the step of cutting one or more blanks from the laminated paperboard structure includes the step of cutting one or more upper engaging devices from the laminated paperboard structure, each having an upper receiving opening.

15. applying the blank to one or more articles to form a package; engaging the one or more upper engagement devices with a respective one of the one or more articles; 15. A method of forming the upper engaging article carrier of claim 14, comprising:

16. 16. The method of forming an upper engaging article carrier as described in claim 15, wherein the one or more upper engaging devices each include at least one tooth, the at least one tooth comprising a uniformly bonded multi-ply laminate structure, and the step of engaging the one or more upper engaging devices with a respective one of the one or more articles includes the step of engaging an edge of the at least one tooth with a flange of a respective one of the one or more articles.

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

18. 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 including a second surface, the second surface being disposed adjacent to the first surface and uniformly bonded to the first surface.

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