Blanks for forming article carriers

Abstract

A blank for forming an article carrier has a main panel with at least one article retention structure having an opening defined therein and one or more tabs formed on a periphery of the opening in the main panel, the one or more tabs being connected to the main panel such that when an article is received in the opening, the tabs yield and extend out of the plane of the main panel to press against the article. The main panel comprises a paperboard substrate and at least one polymer layer.

Description

[Technical Field]

[0001] The present invention relates to article carriers and blanks for forming them. More particularly, but without limitation, the present invention relates to top-gripping carriers having one or more openings for receiving and holding articles therein. [Background technology]

[0002] In the packaging art, it is known to provide article carriers or cartons for transporting multiple articles. Carriers are well known in the art and are useful in allowing consumers to transport, store, and access groups of articles for consumption. Cost and environmental considerations dictate that such carriers be formed from as little material as possible and minimize waste of the materials from which they are formed. A further consideration is the strength of the carton and whether it is suitable for holding and transporting heavy articles. It is desirable that the contents of the carrier be secure within the carrier.

[0003] It is well known to provide a top gripping article carrier in which an opening is formed in a panel of the carrier and a tab is cut from the opening, the tab being displaced out of the plane of the panel when an article is received within the opening, the tab typically engaging the article 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 improvements in the field of article carriers, which are typically formed from paperboard or the like. [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, a blank for forming an article carrier is provided. The blank includes a main panel having at least one article holding structure with an opening defined therein. The blank further includes one or more tabs formed around a periphery of the opening in the main panel. The one or more tabs are connected to the main panel such that when an article is received in the opening, the tabs yield and extend out of the plane of the main panel to press against the article. The main panel includes a paperboard substrate and at least one polymer layer.

[0006] Optionally, the paperboard substrate is formed from a foldable sheet material selected from the group consisting of paperboard, corrugated board, cardboard, and combinations thereof.

[0007] Optionally, at least one polymer layer comprises an n-axis oriented film, where "n" is a positive integer.

[0008] Optionally, the n-axis oriented film is formed from a material selected from the group consisting of biaxially oriented polyester, oriented nylon, cross-laminated polyolefin, metallocene-catalyzed polyethylene, and high density polyolefin.

[0009] Optionally, at least one polymer layer is tear resistant due to the chemical nature of the material from which it is formed.

[0010] Optionally, the material is extruded metallocene-catalyzed polyethylene.

[0011] Optionally, the main panel is defined by a perimeter to which no other portion of the carrier is connected.

[0012] Optionally, the major panel is defined by a perimeter including a convexly curved edge and a concavely curved edge, the radius of curvature of the convexly curved edge being substantially equal to the radius of curvature of the concavely curved edge.

[0013] Optionally, the carrier is configured to package articles having a maximum diameter D1 in an array having a first integer number Y of rows, and the main panels have a maximum length of less than or equal to Y×D1 when the main panels are applied to the articles.

[0014] Optionally, the array has a second integer number Z of columns, and the major panel has a maximum width less than or equal to Z x D1 when the engagement panel is applied to the article.

[0015] Optionally, the major panel has an opposing surface that has different properties than the other surface.

[0016] Optionally, one of the opposing surfaces is surface treated to provide good printability.

[0017] Optionally, a polymer layer is provided on the other surface of the major panel.

[0018] Optionally, the polymer layer is a tear resistant layer laminated to the paperboard substrate.

[0019] Optionally, the main panel includes a handle structure.

[0020] Optionally, the handle structure includes at least one handle opening formed in the main panel at a location spaced from the opening.

[0021] According to a second aspect of the present disclosure, a blank for forming an article carrier is provided, the blank comprising a main panel comprising at least one article holding structure having an opening defined therein, the main panel further comprising one or more tabs formed around a periphery of the opening in the main panel, the one or more tabs being connected to the main panel such that when an article is received within the opening, the tabs yield and extend out of the plane of the main panel to press against the article, the one or more tabs comprising a paperboard substrate and at least one polymer layer secured to the substrate.

[0022] According to a third aspect of the present disclosure, a blank for forming an article carrier is provided, the blank comprising a main panel, the main panel comprising at least one article holding structure having an opening defined therein, the main panel further comprising one or more tabs formed around a periphery of the opening in the main panel, the one or more tabs being connected to the main panel such that when an article is received within the opening, the tabs yield and extend out of the plane of the main panel to press against the article, the main panel comprising a paperboard substrate, the carrier configured to package articles having a maximum diameter D1 in an array having a first integer number Y of rows, the main panel having a maximum length less than or equal to Y×D1 when the main panel is applied to the article.

[0023] Optionally, the array has a second integer number Z of columns, and the major panel has a maximum width less than or equal to Z x D1 when the engagement panel is applied to the article.

[0024] According to a fourth aspect of the present disclosure, a combination is provided comprising two or more connected blanks each for forming an article carrier, each blank comprising a main panel comprising at least one article holding structure having an opening defined therein, each main panel being defined by a periphery including a convexly curved edge and a concavely curved edge, and the two or more connected blanks being connected together at the convexly curved edges.

[0025] Optionally, each of the two or more connected blanks is breakably connected to a next adjacent one of the two or more connected blanks by at least one breakable connection.

[0026] Optionally, the radius of curvature of the convexly curved edge is substantially equal to the radius of curvature of the concavely curved edge.

[0027] According to a fifth aspect of the present disclosure, a top-engagement carrier for packaging one or more articles is provided. The carrier includes a main panel having first and second adjacent openings, each configured to receive a portion of an article. The main panel further includes a series of annular tabs formed around each of the first and second openings. Each of the annular tabs is hingedly connected to the main panel such that, when an article is received in its respective opening, the tab yields and extends out of the plane of the main panel to press against the article. The annular tabs are spaced apart from one another by notches located between each tab and the next adjacent tab. Each notch has a curved end furthest from the center of its respective opening. Each of the annular tabs defines a respective notional circle, which is internally and tangentially bounded by the curved end of the notch disposed therein. The notional circles of the two annular series of tabs are spaced apart from one another by a first distance, and the distance between the curved end of any one of the notches in the first opening and the curved end of any one of the notches in the second opening is greater than the first distance.

[0028] Optionally, none of these tabs have a radial size greater than the radius of their respective notional circles.

[0029] Optionally, all of these tabs have a radial size that is less than the radius of their respective notional circles.

[0030] Optionally, the main panel is defined by a perimeter to which no other portion of the carrier is connected.

[0031] Optionally, the main panel is defined by a perimeter that has no connections to other panels.

[0032] Optionally, the major panel is defined by a perimeter generally defined by the cut edges.

[0033] Optionally, the major panel is defined by a perimeter including a convexly curved edge and a concavely curved edge, the radius of curvature of the convexly curved edge being substantially equal to the radius of curvature of the concavely curved edge.

[0034] Optionally, each tab is hinged to the main panel by a straight fold that tangentially contacts or intersects the curved end of the adjacent notch.

[0035] Optionally, the diameter of the notional circle is less than the maximum diameter of the article and greater than the diameter of the upper end of the article.

[0036] Optionally, the upper end of the article is defined by a feature selected from a chime, a cap, or a flange.

[0037] Optionally, each tab is hinged to the main panel by a straight fold that tangentially contacts or intersects the curved end of the adjacent notch.

[0038] Optionally, the diameter of the notional circle is less than the maximum diameter of the article and greater than the diameter of the upper end of the article.

[0039] Optionally, the upper end of the article is defined by a feature selected from a chime, a cap, or a flange.

[0040] Optionally, the carrier is arranged to package articles having a maximum diameter D1 in an array having a first integer number Y of rows and a second integer number Z of columns.

[0041] Optionally, the major panel has a maximum length less than or equal to Y×D1 when the major panel is applied to the article.

[0042] Optionally, the major panel has a maximum width of less than or equal to Z x D1 when the engagement panel is applied to the article.

[0043] Optionally, the curved end of each notch has a radius of curvature of 1 / 16" (1.6 mm) or greater.

[0044] According to a sixth aspect of the present disclosure, a blank for forming an article carrier is provided. The blank includes a main panel having first and second adjacent openings, each of which is configured to receive a portion of an article. The main panel further includes a series of annular tabs formed around each of the first and second openings. Each series of annular tabs is hingedly connected to the main panel so as to be yieldable out of the plane of the main panel when an article is received in its respective opening, and is configured to press against the received article. The series of annular tabs are spaced apart from one another by a notch disposed between each tab and the next adjacent tab, each notch having a curved end furthest from the center of its respective opening. Each of the series of annular tabs defines a respective notional circle, which is internally and tangentially bounded by the curved end of the notch disposed therein. The notional circles of the two series of annular tabs are spaced apart from one another by a first distance. The distance between the curved end of any one of the notches in the first opening and the curved end of any one of the notches in the second opening is greater than the first distance.

[0045] According to a seventh aspect of the present disclosure, a carrier for packaging one or more articles is provided, the carrier comprising a main panel having at least one article holding structure with an opening defined therein. The main panel further comprises a series of annular tabs formed around the opening, the series of annular tabs being hingedly connected to the main panel such that when an article is received in the opening, the tabs yield and extend out of the plane of the main panel to press against the article. The series of annular tabs are spaced apart from one another by notches located between each tab and the next adjacent tab, each notch being defined by a pair of opposing side edges and a curved end edge extending between the side edges. The curved ends are disposed furthest from the center of the respective opening, and the opposing side edges are arranged in a diverging manner with respect to one another.

[0046] Optionally, each of the annular series of tabs defines a notional circle that is internally and tangentially bounded by the curved end of the notch disposed therein, and the hinged connections of the annular series of tabs define a notional polygon having an integer number N of sides, with opposite side edges of the notch subtending an angle θ therebetween, the angle θ being greater than 0 degrees, with a maximum angle θ m Smaller,

[0047]

number

[0048] This becomes:

[0049] Optionally, each of the annular series of tabs defines a notional circle that is internally and tangentially bounded by the curved end of the notch disposed therein, with opposing side edges defining an angle θ therebetween, the angle θ being within one of the following ranges selected from the group of ranges: angle θ is greater than 0° and less than 45°, angle θ is greater than 0° and less than 30°, angle θ is in the range of 5° to 25°, angle θ is in the range of 10° to 20°, angle θ is in the range of 14° to 17°, or angle θ is in the range of 15° to 16°.

[0050] Optionally, each of the annular series of tabs defines a notional circle that is internally and tangentially bounded by the curved end of the notch disposed therein, with opposing side edges defining an angle θ therebetween, the angle θ being approximately 15.5°.

[0051] Optionally, each of the annular series of tabs defines a notional circle, the notional circle being internally and tangentially bounded by the curved end of the notch disposed therein. The hinged connections of the annular series of tabs define a notional polygon having an integer number N of sides, the opposing side edges of the notch subtending an angle θ therebetween, the angle θ being greater than 0 degrees, with a maximum angle θ mSmaller, θ m =(180(N-2)) / 2N.

[0052] According to an eighth aspect of the present disclosure, a blank for forming a carrier is provided. The blank includes a main panel having at least one item retention structure with an opening defined therein. The main panel further includes a series of annular tabs formed around the opening, the series of annular tabs being hingedly connected to the main panel so as to be yieldable out of the plane of the main panel when an item is received in the opening and configured to press against the item. The series of annular tabs are spaced apart from one another by notches located between each tab and the next adjacent tab, and each notch is defined by a pair of opposing side edges and a curved end edge extending between the side edges. The curved ends are disposed furthest from the center of the respective opening, and the opposing side edges are configured to diverge relative to one another.

[0053] According to a ninth aspect of the present disclosure, a blank for forming an article carrier is provided, the blank comprising a main panel comprising at least one article holding structure having an opening defined therein. The blank further comprises a series of annular tabs formed around the opening in the main panel. The series of annular tabs are hingedly connected to the main panel such that when an article is received in the opening, the tabs yield and extend out of the plane of the main panel to press against the article. The series of annular tabs are spaced apart from one another by notches disposed between each tab and the next adjacent tab. Each notch comprises a curved end furthest from the center of the opening. The main panel comprises a paperboard substrate and at least one polymeric tear-resistant layer laminated together.

[0054] Optionally, the paperboard substrate may be formed from a foldable sheet material selected from the group consisting of paperboard, corrugated board, cardboard, and combinations thereof.

[0055] Optionally, at least one polymeric tear resistant layer comprises an n-axis oriented film, where "n" is a positive integer.

[0056] According to a tenth aspect of the present disclosure, a blank for forming an article carrier is provided, the blank comprising a main panel, the main panel comprising at least one article holding structure having an opening defined therein, the blank further comprising a plurality of tabs formed around a periphery of the opening in the main panel, the plurality of tabs being connected to the main panel such that when an article is received within the opening, the tabs yield and extend out of the plane of the main panel to press against the article, the main panel comprising a paperboard substrate and at least one polymer layer.

[0057] Optionally, the plurality of tabs are formed as a ring-shaped series of tabs around the periphery of the opening in the main panel.

[0058] According to an eleventh aspect of the present disclosure, a blank is provided comprising two or more main panels each for forming an article carrier, each of the main panels comprising at least one article holding structure having an opening defined therein, each of the main panels being defined by an outer periphery including a convexly curved edge and a concavely curved edge, and the main panels being breakably connected together such that the blank can be applied to multiple groups of articles simultaneously.

[0059] Optionally, the blank is attachable as a single unit to a grouped arrangement of items, the grouped arrangement of items including two or more groups of items.

[0060] Optionally, each major panel comprises a matrix or array of item-retaining openings in a YxZ arrangement, where Y indicates the number of rows of items and Z indicates the number of columns of items.

[0061] Optionally, the width of the major panel is equal to Z times the maximum width of the article.

[0062] Optionally, the length of the major panel is equal to Y times the maximum width of the article.

[0063] It is contemplated and intended that within the scope of this application, the various aspects, embodiments, examples, features, and alternatives set forth in the preceding paragraphs, claims, and / or the following description and drawings may be taken independently or in any combination thereof. For example, a feature described in connection with one embodiment is applicable to all embodiments unless there is an incompatibility of the feature.

[0064] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0065] [Figure 1] 1 is a top plan view of a blank for forming an article carrier according to a first embodiment; FIG. [Figure 2] FIG. 2 is an enlarged plan view of the blank of FIG. 1. [Figure 3] FIG. 2 is a schematic diagram of a holding structure for the blank of FIG. 1. [Figure 4] FIG. 10 is a top plan view of a blank for forming an article carrier according to a second embodiment. [Figure 5] 1 is a perspective view of an item to be packaged. [Figure 6] 2 is a top perspective view of an article carrier formed from the blank of FIG. 1; FIG. [Figure 7] FIG. 1 is a top plan view of a plurality of blanks according to a first embodiment showing a nesting arrangement for cutting the blanks from a substrate sheet. DETAILED DESCRIPTION OF THE INVENTION

[0066] 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 some aspects of the present invention may be implemented and are not 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 can serve as an example, specimen, model, or pattern. Indeed, it will be understood that the packages, blanks, and carriers described herein can be embodied in a variety of alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials, or methods have not necessarily been described in detail in order to avoid obscuring the disclosure. Details regarding specific structure and function 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 employ the present invention in its various forms.

[0067] Referring to Figure 1, there is shown a plan view of a blank 10 from which a carton or carrier 90, as shown in Figure 6, can be formed for containing and transporting a group of primary products, such as, but not limited to, bottles or cans, hereafter referred to as Item B, as shown in Figure 5. The blank 10 forms a secondary package for packaging at least one primary product container or package.

[0068] Referring to Figure 4, there is shown a plan view of a blank 110 from which a carton or carrier can be formed for containing and transporting a group of primary products, such as, but not limited to, bottles or cans, hereafter referred to as Item B (as shown in Figure 5). Blank 110 forms a secondary package for packaging at least one primary product container or package.

[0069] In the embodiments detailed herein, the terms "carton" and "carrier" refer to a container for engaging and transporting articles, such as a primary product container, for purposes of illustrating various features of the present invention in a non-limiting manner. 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. Exemplary containers include bottles (e.g., metal, glass, or plastic bottles), cans (e.g., aluminum cans), tin cans, bags, packets, and the like.

[0070] The blanks 10, 110 are formed from sheets of suitable substrate. As used herein, it will be understood that the phrase "suitable substrate" includes any form of foldable sheet material, such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other number of blanks may be used, as appropriate, to achieve, for example, the carrier structure described in more detail below.

[0071] The packaging structures or carriers described herein may be formed from sheet materials, such as paperboard, which may be made from or coated with materials that enhance its strength. One example of such a sheet material is the tear-resistant NATRALOCK® paperboard made by WestRock. It should be noted that tear-resistant materials may be applied in multiple 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 particularly smooth and may have a coating, such as a clay coating, or other surface treatment that adds good printability. The surface of the sheet material facing inward, on the other hand, may be coated, layered, treated, or otherwise treated to add properties such as tear resistance, good adhesion, heat sealability, or one or more other desirable functional properties.

[0072] In the illustrated embodiment, the blanks 10, 110 are configured to form a carton or carrier 90 for packaging an exemplary arrangement of exemplary items B. In the embodiment illustrated in FIG. 1 , this arrangement is a 3×2 matrix or array, and in the illustrated embodiment, three rows of two items are provided, and items B are beverage cans. In the embodiment illustrated in FIG. 4 , this arrangement is a 6×4 matrix or array, and in the illustrated embodiment, six rows of four items are provided, and items B are beverage cans. In this illustrated embodiment, the blanks 110 may employ four blanks 10 in a 2×2 matrix or array, each frangibly connected to at least two other blanks 10. 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.

[0073] Referring to FIG. 1, blank 10 includes a main panel 12 for forming the top wall or mating panel of carrier 90 (see FIG. 6).

[0074] The main panel 12 includes at least one item retention structure R1, R2, R3, R4, R5, R6. In the embodiment of Figure 1, the main panel includes a plurality of item retention structures R1, R2, R3, R4, R5, R6, and specifically six item retention structures R1, R2, R3, R4, R5, R6 arranged in a 2x3 matrix or array.

[0075] Each of the item retaining structures R1, R2, R3, R4, R5, R6 are substantially similar in construction and therefore will be described in detail with respect to the first and fifth item retaining structures R1, R5.

[0076] The first item retaining structure R1 includes an opening A1. A plurality of item engaging tabs 16 are arranged around the periphery of the opening A1. Each tab 16 is hinged to the main panel 12 by a hinged connection, such as a fold 17. Each tab 16 is spaced from an adjacent element by a cutout or recess 18. In this manner, each tab 16 includes a first side edge 19 and a second side edge 21. Each tab 16 includes a free edge 23 opposite the hinged end edge 17. The free edge 23 forms an engaging edge for retaining an item B, or at least a portion thereof, within the opening A1. Each of the free edges 23 may be straight, as illustrated in FIGS. 1, 2, 4, and 7. However, each end edge 23 may optionally be curved either convexly or concavely when viewed from the center of the respective opening A1, A2, A3, A4, A5, or A6.

[0077] Each of the recesses 18 includes a curved portion 20. In the illustrated embodiment, the recesses 18 include rounded ends. That is, the curved portion 20 may be defined by a portion of a circumference. A portion of the recesses 18 may be defined by an arc of a circle. Further portions of the recesses 18 may be defined by trapezoids, which may be isosceles trapezoids. The trapezoids have tapered side edges 19, 21. Each tab 16 may be hinged to the main panel 12 by a straight fold 17 that tangentially contacts or intersects the rounded end 20 of an adjacent recess 18.

[0078] The curved portion 20 or rounded edge of the cutout 18 may reduce the likelihood of a tear propagating from the cutout 18 into the main panel 12 .

[0079] In the illustrated embodiment, the first item holding structure R1 includes ten tabs 16 arranged around the periphery of the opening A1. The item holding structure R1 defines a notional circle C1. The circle C1 is defined by the vertices of a first polygon P1 (see FIG. 3). The polygon P1 is defined by the folds 17 of the tabs 16 (see FIG. 3). In the illustrated embodiment, the first polygon P1 is a decagon, i.e., a polygon having ten sides; in other embodiments, other polygons having more or fewer sides may be used. Each of the sides of the first polygon P1 is of equal length.

[0080] The notional circle C1 has a diameter Dn and a radius Dn / 2.

[0081] The free edge 23 of the tab 16 defines a second polygon P2. The tab 16 has a height x defined between the free edge 23 and the hinged edge 17. In the illustrated embodiment, the first polygon P1 is a decagon, i.e., a polygon having ten sides, although other polygons having more or fewer sides may be used in other embodiments. The second polygon P2 has the same number of sides as the first polygon P1. Each of the sides of the second polygon P2 is of equal length.

[0082] The first side edge 19 of the first tab 16c and the second side edge 21 of the second tab 16b define an angle θ therebetween, i.e., the tapered side edges 19, 21 of the trapezoidal portion of the cutout 18 define an angle θ (see FIG. 2). The angle θ is greater than 0 degrees, and the maximum angle θ m Angle θ is smaller than angle θ m , the tab 16 has a substantially triangular shape, thus reducing the engagement edge to a point.

[0083] Angle θ m teeth,

[0084]

number

[0085] where: N = number of sides of polygon P1 d = half the length of one side of polygon P1 x = height of tab 16 and Arctan represents the inverse of the trigonometric tangent function.

[0086] Referring to Figure 3, θ max =2×Angle1 Angle1=Angle4-Angle2

[0087]

number

[0088]

number

[0089]

number

[0090]

number

[0091]

number

[0092] is.

[0093] The diameter Dn of the notional circle C1, C2 must be at least equal to the diameter D2 of the chime, cap, or flange 30 of the item B (see FIG. 5) so that the upper edge of the item B can pass through the main panel 12. Thus, the diameter of the flange 30 defines the minimum dimension of the diameter Dn of the notional circle C1.

[0094] The diameter Dn of notional circles C1, C2 must be less than or equal to the maximum diameter D1 of item B so that item B cannot entirely pass through main panel 12. Thus, the maximum diameter D1 of item B (see FIG. 5, where maximum diameter D1 is defined by body portion 34 of item B) defines the maximum dimension of diameter Dn of notional circle C1. Body portion 34 of item B is connected to chime 30 by a tapered or reduced diameter shoulder portion 32.

[0095] In some embodiments, the diameter Dn of the notional circle C1 may be substantially equal to the diameter of the chime, cap, or flange 30 of the item B (see FIG. 5).

[0096] The main panel 12 comprises a matrix or array of items B in a Y×Z arrangement, where Y indicates the number of rows of items B and Z indicates the number of columns of items B. The width W of the main panel 12 may be equal to Z times the maximum width D1 of the items B, i.e., W=Z×D1. The length L of the main panel 12 may be equal to Y times the maximum width D1 of the items B, i.e., L=Y×D1.

[0097] 1, items B are arranged in a 3×2 matrix. The width W of main panel 12 may be equal to two times the maximum width D1 of items B. The length L of main panel 12 may be equal to three times the maximum width D1 of items B.

[0098] The diameter Dn of the notional circle C1 may be smaller than the maximum diameter D1 of the item B and larger than the diameter D2 of the chime, cap, or flange of the item B.

[0099] In one example, item B may have a maximum diameter D1 of 2.6" (66 mm), chime or flange 30 may have a diameter of 2.1" (53.3 mm), and notional circles C1, C2 may have a diameter of 2.3" (58.4 mm). Tab 16 may have a height x of 3 / 16" (4.76 mm). Main panel 12 may have a width W of 5.3" (134.6 mm) and a length L of 7.8" (198.1 mm).

[0100] In another embodiment, angle θ is greater than 0° and less than 45°, and in yet another embodiment, angle θ is greater than 0° and less than 30°. Angle θ may be between 5° and 25°, or between 10° and 20°, or between 14° and 17°, or between 15° and 16°. In one embodiment, angle θ may be approximately 15.5°. In yet another embodiment, angle θ is greater than 0°,

[0101]

number

[0102] is smaller than (where N = the number of sides of polygon P1).

[0103] 3, the hinged edge 17 and the first side edge 19 of the tab 16 define an angle α therebetween, and the hinged edge 17 and the second side edge 21 of the tab 16 define an angle β therebetween. The angle α is

[0104]

number

[0105] (where N = the number of sides of polygon P1). The angle β is

[0106]

number

[0107] (where N = the number of sides of polygon P1).

[0108] In some embodiments, the maximum length L is less than or equal to Y×D1 when the main panel 12 is applied to the article B, and the maximum width W is less than or equal to Z×D1 when the main panel 12 is applied to the article B.

[0109] Each tab 16 is hinged to the main panel 12 by a straight or linear fold line 17 that tangentially contacts or intersects the rounded end of the adjacent cutout 18 .

[0110] The curved end 20 of each cutout 18 may be defined in part by a circle having a radius of curvature. In one embodiment, the radius of curvature of the rounded end 20 of each cutout 18 may be 1 / 16" (1.6 mm) or greater.

[0111] The main panel 12 may optionally include a handle structure. The handle structure may include a first handle opening A7 and a second handle opening A8. The first handle opening A7 is punched out of the main panel 12 and disposed in an area centrally disposed between the first pair of item holding structures R1, R2 and the second pair of item holding structures R3, R4. The second handle opening A8 is punched out of the main panel 12 and disposed in an area centrally disposed between the second pair of item holding structures R3, R4 and the third pair of item holding structures R5, R6. The first handle opening A7 may be defined in part by a shock-absorbing tab 14 hinged to the main panel 12 by a hinged connection, such as a fold line 15. The second handle opening A8 may be defined in part by a shock-absorbing tab 14 hinged to the main panel 12 by a fold line 15. Each of the first and second handle openings A7, A8 may be substantially crescent or "C" shaped.

[0112] The main panel 12 may optionally include one or more pull tabs T1, T2, T3, T4. The pull tabs T1, T2, T3, T4 may be located substantially at the corners of the main panel 12. The pull tabs T1, T2, T3, T4 may be substantially triangular in shape. The pull tabs T1, T2, T3, T4 may be arranged to extend the main panel 12 beyond the footprint of the group of items B to be packaged, thus allowing a user to more easily engage and disengage the carrier 90 from the items B.

[0113] Optionally, the side edges 13a, 13b of the major 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 (see FIG. 7). The undulating shape causes the first and second blanks 10 to together define a width that is less than twice the maximum width of any individual blank 10. This may have economic and environmental benefits by reducing the amount of substrate required to produce a given number of blanks 10.

[0114] The main panel 12 comprises at least a paperboard substrate and a polymeric tear-resistant layer laminated together. It optionally comprises an adhesive layer between the paperboard substrate and the tear-resistant layer. The paperboard substrate material may be selected from conventional paperboard, for example, from about 10 pt. weight and above, preferably in the range of about 11 pt. to about 14 pt. weight. One example of such a substrate is 12-point SBS cardboard or CNK cardboard manufactured by WestRock. The article carrier shown in FIG. 1 Blank forming 90 One example of a substrate that may be used with 10 is between about 24 pt. and about 32 pt., optionally about 28 pt. The paperboard substrate may be bleached or unbleached cardboard. The cardboard may be coated on at least one side, optionally the side opposite the lamination, with a conventional coating selected for compatibility with the printing method and cardboard composition.

[0115] The tear-resistant layer may be disposed on the uncoated side of the paperboard substrate and may be formed from a polymeric material and secured to the substrate. The tear-resistant layer provides toughness to the laminate structure. Suitable tear-resistant materials may include, but are not limited to, tear-resistant laminate sheet materials such as NATRALOCK®, which may 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 and cross-laminated structure of these materials contribute to their tear resistance. Tear resistance may also be due to the chemical properties of the tear-resistant material, such as extruded metallocene-catalyzed polyethylene (mPE).

[0116] Alternatively, the tear-resistant layer may be a layer of linear low density polyethylene (LLDPE). In embodiments where linear low density polyethylene (LLDPE) or mPE is used, it is not necessary to incorporate an adhesive layer. Other suitable materials with a high level of tear resistance may also be used.

[0117] The adhesive layer may be formed from a polyolefin material, such as low density polyethylene (LDPE). The adhesive layer may be disposed between the substrate and the tear-resistant layer to secure the tear-resistant layer to the substrate.

[0118] Referring to the steps for preparing the carrier 90 from the blank 10, the blank 10 may be applied to a group of items B. The blank 10 is lowered relative to the group of items B. Each of the item retention structures R1, R2, R3, R4, R5, and R6 of the blank 10 is aligned with each item B in the group. A portion of the items B passes through the main panel 12. The tabs 16 of each of the item retention structures R1, R2, R3, R4, R5, and R6 extend out from the plane of the main panel 12 and engage under the chime or flange 30 of the item B. In this manner, the tabs 16 grip or retain the items B, preventing or inhibiting the items B from inadvertently separating from the main panel 12. The assembled carrier 90 is shown in FIG. 6.

[0119] With particular reference to Figures 4 and 1, the blank 10 defines a top-engagement carrier 90 comprising a main panel 12 with first and second adjacent openings A1, A3, each configured and arranged side-by-side to receive a portion of an item B. The main panel 12 further includes a series of annular tabs 16 formed around each of the first and second openings A1, A3. Each series of annular tabs 16 is connected to the main panel 12 such that, when item B is received within the respective opening A1, A3, the tabs 16 yield and extend out of the plane of the main panel 12 to press against item B. The series of annular tabs 16 are spaced apart from one another by notches 18 located between each tab 16 and the next adjacent tab 16. Each notch 18 has a rounded edge 20 located furthest from the center of the respective opening A1, A3. Each annular series of tabs 16 defines a notional circle C1, C2 that internally contacts tangentially with the rounded ends 20 of at least some, and optionally all, of the notches 18. The notional circles C1, C2 of the two annular series of tabs 16 are spaced apart from each other by a first distance d2. The distance d1 between the rounded end 20 of any one of the notches 18 of the first opening A1 and the rounded end 20 of any one of the notches 18 of the second opening A3 is greater than the first distance d2.

[0120] Optionally, none of these tabs 16 have a radial size x greater than the radius Dn / 2 of the respective notional circle C1, C2. In other words, all of these tabs 16 have a radial size "x" that is less than the radius Dn / 2 of the respective notional circle C1, C2.

[0121] Another optional feature of carrier 90 is that major panel 12 is defined by a perimeter that is not connected to any other portion of carrier 90, i.e., carrier 90 is free from connection to other panels, such as, but not limited to, sidewall panels or endwall panels that extend around the sides of the group of articles. The perimeter of major panel 12 is thus defined as a whole by a free, cut, or unhinged edge.

[0122] Another optional feature of the carrier 90 is that the main panel 12 is defined by a periphery including a convexly curved edge and a concavely curved edge, the radius of curvature of the convexly curved edge being substantially equal to the radius of curvature of the concavely curved edge, thereby allowing two similar blanks 10 to be arranged in a nested or tessellated configuration.

[0123] Referring now to Figure 4, an additional embodiment of the present disclosure is shown. In the second illustrated embodiment, like numbers are used to represent like parts where possible, but the addition of the prefix "100" indicates that the feature belongs 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 1-3 and 5-7 will be described in detail.

[0124] The blank 110 comprises a plurality of main panels 112a, 112b, 112c, 112d for forming the top wall of the carrier. Each of the four main panels 112a, 112b, 112c, 112d illustrated in Figure 4 is breakably connected to two adjacent elements by breakable connections 22, 24.

[0125] The blank 110 may be applied to 24 articles arranged in a 6x4 matrix or array. In this manner, the blank 110 may be applied simultaneously to multiple groups of articles, each group including 6 articles arranged in a 3x2 matrix or array.

[0126] In some embodiments, the breakable connections are severed when the blank 110 is applied to item B. In some embodiments, item B may be disposed in a crate that is open-topped when the blank 110 is applied. In other embodiments, the breakable connections may remain intact after the blank 110 is applied to item B and may be severed by an operator or end user to detach one or more of the main panels 112a, 112b, 112c, 112d and their associated item group from the rest.

[0127] 4, there is shown a top plan view of a blank 110 forming a set of apex engaging clips 112a, 112b, 112c, 112d that are breakably connected by breakable connections 22, 24. The blank 110 is to be attached to a grouped arrangement of articles as a single unit. Each apex engaging clip 112a, 112b, 112c, 112d of the set is attached to an optional 2×3 arrangement of articles and is separated from the other apex engaging clips 112a, 112b, 112c, 112d to form four separate groups of arranged articles. Advantageously, in some arrangements, the device automatically breaks the breakable connections 22, 24 between the top engaging clips 112a, 112b, 112c, 112d of the set of breakably connected top engaging clips 112a, 112b, 112c, 112d, and the device applies a single blank 110 to the grouped arrangement of articles to form four smaller groups of articles each joined by a top engaging clip 112a, 112b, 112c, 112d.

[0128] In the illustrated embodiment, the blank 110 is configured to form a set of four clips 112a, 112b, 112c, 112d to group, join, or otherwise connect the exemplary arrangement of exemplary items "B." In the embodiment illustrated in FIG. 3, each of the four clips 112a, 112b, 112c, 112d together hold six items arranged in three rows of two items each in a grouped arrangement. The items "B" are beverage cans having a rim or chimed upper edge. Thus, the blank 110 is configured to be formed over a larger grouped arrangement of items 88. In the illustrated embodiment, the arrangement is a 6x4 matrix or array, and in the illustrated embodiment, four columns and six rows of items are provided for the grouped arrangement 88 of 24 cans "B." In this illustrated embodiment, blank 110 may employ four clips 112a, 112b, 112c, 112d in a 3x2 matrix or array, each breakably connected to at least two other blanks 112b, 112c, 112d, 112a using breakable connections 22, 24 to separate openings A9. Alternatively, blank 110 may be configured to form carriers for packaging other types, numbers, and sizes of articles and / or for packaging articles in different arrangements or configurations than those shown herein.

[0129] Referring to FIG. 4, blank 110 includes four top engaging clips 112a, 112b, 112c, 112d, each having a main panel or engaging panel for forming a top wall of clip 112a, 112b, 112c, 112d.

[0130] Each major panel includes at least one item holding structure, and in the embodiment of Figure 4, each major panel includes a plurality of item holding structures, specifically six item holding structures arranged in a 2x3 matrix or array.

[0131] Major panels 112a, 112b, 112c, 112d each include a matrix or array of item-retaining openings in a YxZ arrangement, where Y indicates the number of rows of item "B" and Z indicates the number of columns of item "B".

[0132] 4, item "B" is arranged in a 3x2 matrix. The width of major panels 112a, 112b, 112c, 112d may be equal to two times the maximum width of item "B." The length L of major panels 112a, 112b, 112c, 112d may be equal to three times the maximum width of item "B."

[0133] The diameter of the notional circle may be less than the maximum diameter of item "B" and greater than the (smaller) diameter of the chime, cap, or flange of item "B".

[0134] The main panels 112a, 112b, 112c, and 112d may optionally include a handle structure. The handle structure may include a first handle opening and a second handle opening. The first handle opening is punched out of the main panels 112a, 112b, 112c, and 112d and located in an area centrally disposed between the four item holding structures. The second handle opening is punched out of the main panels 112a, 112b, 112c, and 112d and located in an area centrally disposed between the four item holding structures. The first handle opening may be defined in part by a shock-absorbing tab hingedly connected to the main panels 112a, 112b, 112c, and 112d by a fold line. The second handle opening may have a similar structure.

[0135] The main panels 112a, 112b, 112c, 112d may optionally include one or more pull tabs T1. The pull tabs T1 may be located substantially at the corners of the main panels 112a, 112b, 112c, 112d. The pull tabs T1 may be substantially triangular in shape. The pull tabs T1 may be configured to extend the main panels 112a, 112b, 112c, 112d beyond the footprint of the group of items to be packaged, thus allowing a user to more easily engage and disengage the carrier or clip 112a, 112b, 112c, 112d from the group of items.

[0136] Another optional feature of the top engaging clips 112a, 112b, 112c, 112d is that each of the main panels 112a, 112b, 112c, 112d is defined by a perimeter that is not connected to any other portion of the top engaging clip 112a, 112b, 112c, 112d. That is, the top engaging clips 112a, 112b, 112c, 112d are free from connection to other panels, such as, but not limited to, sidewall panels or endwall panels that extend around the sides of a group of articles in another carrier. The perimeter of the main panels 112a, 112b, 112c, 112d is therefore generally defined by a free, cut, or unhinged edge. The periphery of the main panels 112a, 112b, 112c, 112d may be folded at an angle relative to the remainder of the main panels by folding the polygonal arrangement of tabs of the item retention structure and engaging under the chimes or flanges of item "B." Thus, the breakable connections 22, 24 are broken and the set of breakably coupled apex engaging clips 110 is automatically broken into four separate apex engaging clips 112a, 112b, 112c, 112d to form four separate groups of items.

[0137] It will be appreciated that, as used herein, directional references such as "top," "bottom," "base," "front," "back," "end," "side," "inside," "outside," "upper," and "lower" do not necessarily limit each panel to such orientation, but may serve only to distinguish these panels from one another.

[0138] As used herein, "hinge connection" and "fold line" refer to any manner of straight line that defines a hinge feature in a blank, facilitates folding of portions of the blank relative to one another, or otherwise directs optimal panel fold placement for the blank. References to a "hinge connection" should not be construed as necessarily referring to only a single fold line; indeed, a hinged connection may be formed from two or more fold lines, each of which may be either straight / linear or curved / curved in shape. When straight fold lines form a hinged connection, they may be disposed parallel to one another or slightly angled relative to one another. When curvilinear fold lines form a hinged connection, they may intersect one another to define a shaped panel within the area enclosed by the curvilinear fold lines. A typical example of such a hinged connection may include a pair of arched or arcuate fold lines that intersect at two points to define an elliptical panel therebetween. The hinged connection may be formed from one or more straight fold lines and one or more curved fold lines. A typical example of such a hinged connection may include a combination of a straight fold line and an arched or bowed fold line that intersect at two points to define a half-moon shaped panel therebetween.

[0139] As used herein, the term "crease" may refer to one of a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cut line, a line of aligned slits, a line of scores, and any combination of the foregoing selections.

[0140] It should be understood that the hinged connections and folds can each include elements formed in the substrate of the blank, including perforations, perforation lines, short slit lines, half-cut lines, single half-cuts, cut lines, dash lines, slits, score lines, any combination thereof, and the like. These elements can be sized and configured to provide a desired function. For example, perforation lines can be sized or designed to have a degree of weakness that defines the fold and / or cut line. Perforation lines can be designed to facilitate folding and resist tearing, to facilitate folding and facilitate tearing with greater force, or to facilitate tearing with little force.

[0141] The phrase "align with," as used herein, refers to the alignment of two or more elements in an upstanding carrier, such as an opening formed in a first of two overlapping panels and a second opening formed in a second of the two overlapping panels. The elements that are aligned with each other may be aligned with each other in the thickness direction of the overlapping panels. For example, when an opening in a first panel "aligns with" a second opening in a second panel that is in an overlapping arrangement with the first panel, the edge of the opening may extend along at least a portion of the edge of the second opening and may be aligned with the second opening in the thickness direction of the first and second panels. [Explanation of symbols]

[0142] A1, A2, A3, A4, A5, or A6 opening A7 First handle opening A8 Second handle opening A9 opening B Goods C1 Conceptual Circle C2 Conceptual Circle P1 First polygon P2 Second polygon R1, R2, R3, R4, R5, R6 Article holding structure T1, T2, T3, T4 pull tabs 10 blank 12 Main Panel 13a, 13b side edges 14 Buffer tab 15 folds 16 tabs 16b Second Tab 16c First Tab 17 crease 18 Cutouts or recesses 19 First side edge 20 Curved section 21 second side edge 22, 24 Breakable connection 23 Free edge 30 flange 32 Tapered or reduced diameter shoulder 34 Main body 88 Goods 90 cartons or carriers 110 Blank 112a, 112b, 112c, 112d Main Panels 112a, 112b, 112c, 112d Top Engagement Clip

Claims

1. a blank for forming an article carrier, the blank comprising a main panel, the main panel comprising at least two article retaining structures having openings defined therein; the blank further comprising one or more tabs formed around a periphery of the opening in the main panel, the tab or tabs each being hingedly connected to the main panel by a respective fold line such that when an article is received within the opening, the tab or tabs yield and extend out of the plane of the main panel to press against the article; the main panel comprising a paperboard substrate and at least one polymer layer; the main panel has an opposing surface having different properties than the other surface; The article carrier is configured to package a plurality of articles having a maximum diameter D1 in an array having a first integer number Y of rows, and when the main panels are applied to the articles, the distance between the short side edges of the main panels in a plane parallel to a plane in which the tops of the articles in the article carrying configuration extend is less than or equal to Y x D1.

2. 10. The blank of claim 1, wherein the paperboard substrate is formed from a foldable sheet material selected from the group consisting of paperboard, corrugated board, cardboard, and combinations thereof.

3. The blank of claim 1 , wherein the at least one polymer layer comprises an oriented film.

4. 4. The blank of claim 3, wherein the oriented film is formed from a material selected from the group consisting of biaxially oriented polyester, oriented nylon, cross-laminated polyolefin, metallocene-catalyzed polyethylene, and high density polyolefin.

5. 10. The blank of claim 1, wherein the at least one polymeric layer is tear resistant due to the chemistry of the material forming the at least one polymeric layer.

6. 6. The blank of claim 5, wherein the material is extruded metallocene-catalyzed polyethylene.

7. 10. The blank of claim 1, wherein the main panel is defined by a perimeter that is not connected to any other portion of the article carrier.

8. 10. The blank of claim 1, wherein the major panel is defined by a periphery including a convexly curved edge and a concavely curved edge, the radius of curvature of the convexly curved edge being substantially equal to the radius of curvature of the concavely curved edge.

9. 2. The blank of claim 1, wherein the array has a second integer number Z of rows, and when the engagement panels are applied to an article, the distance between the long side edges of the main panels in a plane parallel to the plane in which the top of the article extends is less than or equal to Z x D1.

10. The blank of claim 1 , wherein one of the opposing surfaces has a surface treatment that provides good printability.

11. The blank of claim 10 , wherein the polymer layer is disposed on the other surface of the major panel.

12. 10. The blank of claim 1, wherein the polymer layer is a tear-resistant layer laminated to the paperboard substrate.

13. the main panel includes a handle structure; 10. The blank of claim 1, wherein the handle structure comprises at least one handle opening formed in the main panel at a location spaced from the opening.

14. a blank for forming an article carrier, said blank comprising a main panel, said main panel comprising at least two article retaining structures having openings defined therein; the main panel being a single panel having an opening configured to receive an upper portion of an article; the main panel further comprising one or more tabs formed around a periphery of the opening in the main panel; the tab or tabs are each hingedly connected to the main panel by a respective fold line such that, when an article is received within the opening, the tabs yield and extend out of the plane of the main panel to press against the article in an article-carrying configuration in which the main panel is applied to two or more of the articles, the main panel comprising a paperboard substrate; In the article carrying configuration, the distance between the short side edges of the main panels in a plane parallel to the plane in which the top of the article extends is less than or equal to Y×D1; A blank, wherein D1 is the maximum diameter of two or more of said articles, and Y is the first integer number of rows in an array in which at least two of said article holding structures are arranged.

15. 15. The blank of claim 14, wherein the array has a second integer number of columns, Z, and the major panel has a maximum width in the article-carrying configuration that is less than or equal to Z*D1.

16. 16. A combination comprising two or more blanks according to claim 15, each connected to one another to form the article carrier, wherein each of the main panels is defined by a periphery including a convexly curved edge and a concavely curved edge, and wherein the two or more blanks according to claim 14 are connected to one another at their convexly curved edges.

17. 17. The combination of claim 16, wherein each of the two or more connected blanks of claim 14 is breakably connected to a next adjacent one of the two or more connected blanks of claim 14 by at least one breakable connection.

18. 17. The combination of claim 16, wherein the radius of curvature of the convexly curved edge is substantially equal to the radius of curvature of the concavely curved edge.

19. 15. The blank of claim 14, wherein two or more connected to each other each have the main panel to form the article carrier, the main panels being rupturably connected together so that the blank can be applied to multiple groups of articles simultaneously.

20. 20. The blank of claim 19, wherein the blank is attachable as a single unit to a grouped arrangement of items, the grouped arrangement of items including two or more groups of items.

21. 20. The blank of claim 19, wherein the major panels each comprise a matrix or array of item-retaining openings in a YxZ arrangement, where Y represents the number of rows of items and Z represents the number of columns of items.

22. 22. The blank of claim 21, wherein when the major panels are applied to an article, the distance between the long side edges of the major panels in a plane parallel to the plane in which the top of the article extends is equal to Z times the maximum width of the article.

23. 22. The blank of claim 21, wherein when the major panels are applied to an article, the distance between the short side edges of the major panels in a plane parallel to the plane in which the top of the article extends is equal to Y times the maximum width of the article.

24. The main panel (12) is defined in part by a pair of opposing long side edges each including a first concavely curved portion (13a, 13b), whereby the main panel (12) has a first length extending between the first concavely curved portions (13a, 13b); 15. The blank of claim 14, wherein the first length is less than the maximum distance (W) between the long side edges of the major panels (12).

25. A blank as described in Claim 24, wherein the main panel (12) has a handle structure (A7) arranged between the first concavely curved portions (13a, 13b).

26. The at least two item holding structures comprise a first pair of item holding structures (R1, R2) and a second pair of item holding structures (R3, R4); 26. The blank of claim 25, wherein the handle structure (A7) is disposed in an area located between the first pair of article holding structures (R1, R2) and the second pair of article holding structures (R3, R4).

27. A blank as described in claim 25, wherein the handle structure (A7) has a handle opening cut out from the main panel (12).

28. Each of the short side edges of the main panel (12) includes a second concavely curved portion, whereby the main panel (12) has a second length extending between the second concavely curved portions; 15. The blank of claim 14, wherein the second length is less than the maximum distance (L) between the short side edges of the major panels (12).

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