TECHNICAL FIELD

The present invention relates to a carton. More particularly, the present invention is directed towards a carton that is easily opened and re-closed by a consumer.

BACKGROUND

Cartons formed from a paperboard blank or multiple paperboard blanks, are already known. For example, WO 2009/106535 (Unilever) describes a re-closable carton which maintains its integrity when it is opened by a user and is designed to be easily opened without tearing unwanted areas of the carton. Nonetheless there is a continuing need for improved cartons. In particular there is a need for a carton that requires only a small amount of storage space (e.g. in a cupboard or on a shelf), and yet maximises access to the contents of the carton.

SUMMARY OF THE INVENTION

In a first aspect the invention relates to a carton comprising an outer container and at least one inner container wherein the outer container receives the inner container(s);

the outer container comprising a lid, a bottom wall, a rear wall, two side walls, a substantially open front section and a closure means;

each inner container comprising a bottom panel, a top panel, two side panels, a front panel and a rear panel; a section of the rear panel being openable, preferably removable, so as to provide the inner container with an opening;

wherein the inner container(s) are hingedly attached to the outer container so that each inner container can pivot from a closed position wherein the inner container is located inside the outer container to an open position wherein the inner container is located substantially adjacent to the outer container.

We have found that such a carton requires only a small amount of storage space (e.g. in a cupboard or on a shelf), and yet maximises access to the contents of the carton (e.g. tea bags). DETAILED DESCRIPTION

Certain embodiments of the invention are illustrated by the drawings, in which:

Figure 1 a is a perspective side view of an outer container according to an embodiment of the invention;

Figure 1 b is a perspective front view of the outer container illustrated in Figure 1 a;

Figures 2a to 2c are a series of perspective front views of an inner container according to an embodiment of the invention and show the inner container being opened.

Figure 3a is a perspective front view of a carton according to an embodiment of the invention in an open position;

Figure 3b is a perspective front view the carton of Figure 3a in a closed position;

Figures 4a to 4c are a series of sectional views showing the operation of a carton according to an embodiment of the invention;

Figure 5a is a perspective rear view showing a first possible embodiment of the hinge attachment between the inner and outer containers;

Figure 5b is a perspective front view showing a second possible embodiment of the hinge attachment between the inner and outer containers;

Figure 5c is a cut-away perspective rear view showing a third possible embodiment of the hinge attachment between the inner and outer containers;

Figure 6 shows a plan view of a blank for an outer container according to an embodiment of the invention; and

Figure 7 shows a plan view of a blank for an inner container according to an embodiment of the invention; and

Figure 8 is a perspective front view of a carton according to an embodiment of the invention wherein the carton has two inner containers.

Unless otherwise specified, terms such as top, bottom, front, rear, side, upper etc. refer to the carton in the orientation in which it will usually be stored - as illustrated, for example, in Figure 3b.

Figures 1 a and 1 b show two different perspective views of an outer container 1 according to an embodiment of the invention. The outer container comprises a lid 2, a bottom wall 3, a rear wall 4, two side walls 5, 6 and a substantially open front section. The lid 2 of the outer container is in a partially open position. The lid comprises a lid panel 7 and a closure means. In the embodiment shown in Figures 1 a and 1 b, the lid comprises a skirted section 8 which acts as the closure means and the lid panel 7 is hingedly attached via a crease line 9 such that the lid can pivot thereby allowing the outer container to be easily opened and closed.

Figure 2 shows a series of perspective views of an example of an inner container 10 according to the present invention wherein the inner container comprises a bottom panel 11 , a top panel 12, two side panels 13, 14 a front panel 15 (not visible in Figure 2 since it is on the underside in the orientation shown) and a rear panel 16. A section of the rear panel 16 is openable so as to provide the inner container 10 with an opening. The openable section may optionally comprise one or more tabs 18. The tab(s) 18 can be part of the bottom panel 11 , top panel 12 and or side panels 13, 14. The openable section is not necessarily removable, although in a preferred embodiment it is. In alternative embodiments, the openable section may be re-closable (e.g. by being hingedly attached to the bottom panel 11 , top panel 12 or one of the side panels 13, 14).

In the embodiment shown in Figure 2, the rear panel 16 comprises a removable section 17. Figure 2a shows the inner container 10 with the removable section 17 in situ. The removable section 17 is shown comprising a tab 18. The tab 18 is formed from a section of the top panel 12 and is attached to the removable section 17 along part of an edge shared by the rear panel 16 and the top panel 12. The tab 18 may be defined by a tear line, preferably a perforated tear line. A tab may additionally or alternatively be formed from a section of the bottom panel 11 and or one or more of the side panels 13, 14.

Figure 2b shows the rear panel 16 being opened, wherein the removable section 17 is partially attached to the inner container 10. The tab 18 allows the consumer to conveniently grip the removable section 17 so as to tear and/or peel it away from the inner container 10. In order to facilitate its removal, the removable section 17 is preferably defined by a tear line. Figure 2c shows the inner container 10 wherein the removable section 17 is no longer attached to the inner container 10, and wherein in place of the removable section 17 there is an opening thereby permitting access to items contained within the inner container. The opening should be of a sufficient size to allow the contents of the inner container to be viewed and removed easily, since this allows the consumer to select an individual item. It is envisaged that the inner container may contain a selection of similar items (e.g. different types of tea bags) and it is desirable that the inner container facilitates selection of an appropriate item by a consumer when it is in its open position. In order to avoid unwanted spillage of the contents of the inner container, in certain embodiments the opening may comprise a lip 19 extending partially or wholly around the perimeter of the opening. Such a lip 19 helps to keep the contents within the inner container, especially when the inner container is in transition between its open and closed positions.

Figure 3a shows a perspective view of a carton 20 according to an embodiment of the present invention. The carton 20 comprises an outer container 1 and an inner container 10 hingedly attached to one another. The carton 20 is shown in an open position wherein the inner container 10 is located substantially adjacent to the outer container 1 and wherein the lid 2 of the outer container is in a partially open position.

Figure 3b shows a perspective view of the carton Figure 3a in a closed position wherein the inner container 10 is located inside the outer container 1. The front panel 15 of the inner container 10 constitutes the front face of the carton, thereby closing the carton 20. The lid 2 of the outer container is shown in a closed position such that the skirted section 8 of the lid 2 overlays an upper section of each of the side walls 5, 6 of the outer container and an upper section of the front panel 15 of the inner container. Thus, the skirted section 8 of the lid 2 acts as a closure means preventing the inner container 10 from pivoting to its open position.

It should be noted that other closure means may be used. For example, in an alternative embodiment (not shown) the lid may comprise a tab or flap attached to the lid panel and adapted so as to be able to engage a locking slit situated on the front panel of the inner container. Similarly, such a tab or flap could be included in addition to the skirted portion, either attached to the lid panel or attached to the skirted portion itself. Figures 4a to 4c are a series of sectional views showing the operation of a carton according to an embodiment of the invention. In Figure 4a the carton 20 is shown in a closed position wherein the inner container 10 is located inside the outer container 1 (but with the lid 2 shown in an open position). The inner container 10 preferably fits closely inside the outer container 1 , with the rear panel 16 of the inner container 10 abutting the rear wall 4 of the outer container 1 and the side panels 13, 14 of the inner container 10 abutting the side walls 5, 6 of the outer container 1. This arrangement is particularly advantageous where the openable section of the rear panel 16 is a removable section 17, since the opening of the inner container will abut the rear wall 4 of the outer container 1 and hence any items contained within the inner container 10 will be securely enclosed once the inner container 10 is in its closed position.

The inner container 10 is hingedly attached to the outer container 1 so that it can pivot from a closed position to an open position. The inner container preferably pivots through an angle of 90° in going from its closed position to its open position. Thus when the inner container 10 is in its open position, the front panel 15 of the inner container 10 and the bottom wall 3 of the outer container 1 are substantially coplanar.

The bottom panel 11 of the inner container 10 is hinged to the bottom wall 3 of the outer container 1 such that they can pivot relative to each other about a common axis extending between the two side walls 5, 6 of the outer container 1. In this preferred embodiment, the common axis extends along the front edge of the bottom wall 3 of the outer container 1.

Figure 4b shows the inner container in transition between its open and closed positions, wherein the inner container 10 is pivoting around a hinge 21. This pivoting action is preferably initiated by a user gripping the inner container and applying a force thereto. Thus, at least one and preferably both of the side walls 5, 6 of the outer container 1 may optionally comprise a cut-away section 22. Each cut-away section 22 is positioned such that a vertex of the inner container 10 is accessible to the user when the inner container 10 is in its closed position (see, for example, Figure 4a).

Figure 4c shows the inner container in its open position, wherein the inner container 10 is located substantially adjacent to the outer container 1. The front panel 15 of the inner container 10 and the bottom wall 3 of the outer container 1 are substantially coplanar.

The hinge 21 may be a separate section. However, for ease of manufacture it is preferred that the hinge 21 is integrally formed as part of the outer container 1 or the inner container 10.

For example, Figure 5a shows an embodiment wherein a hinge tab 23 is formed from a section of the bottom panel 11 of the inner container 10. The hinge tab 23 is attached (e.g. by gluing) to the bottom wall 3 of the outer container 1 (for clarity, the only part of the outer container shown is a portion the bottom wall 3). Thus the inner container 10 can pivot between its open and closed positions around the hinge 21.

An alternative embodiment is shown in Figure 5b, wherein there is a hinge flap 24 extending from the bottom wall 3 of the outer container 1. The hinge flap 24 is attached (e.g. by gluing) to the outside of the front panel 15 of the inner container 10 (for clarity, the only part of the inner container shown is a portion of the front panel 15). Thus the inner container 10 can pivot between its open and closed positions around the hinge 21.

Figure 5c is a cut-away rear perspective view of a further possible embodiment wherein a hinge tab 25 is formed from a section of the bottom wall 3 of the outer container 1. The hinge tab 25 is attached (e.g. by gluing) to the bottom panel 11 of the inner container 10, thus the inner container 10 can pivot between its open and closed positions around the hinge 21. The inner container is pivotable between an open and a closed position once the closure means has been released, with the substantially open front section of the outer container 1 facilitating this transition. In the embodiment shown in Figure 4, the lid 2 comprises a skirted section 8 which acts as the closure means. When the lid 2 is closed (not shown) the front panel 15 of the inner container abuts against the skirted section 8 of the lid 2, and thus the skirted section 8 holds the inner container 10 in its closed position (i.e. inside the outer container). Once the closure means has been released (e.g. by opening the lid), the inner container 10 is no longer held in its closed position and is hence able to pivot to its open position.

The lid 2 may be integrally formed as part of the outer container 1 , or may be formed as a separate part. Where the lid is formed as a separate part, it may optionally be attached to the outer container 1 (e.g. by gluing). It is preferred that the lid panel 7 is hingedly attached to the outer container 1 via a crease line 9 such that the lid can pivot thereby opening the outer container 1.

Figure 6 shows a plan view of a blank 101 for an outer container according to an embodiment of the invention. The blank 101 can be stamped or cut from any suitably rigid material, but is preferably paperboard.

The blank 101 shown in Figure 6 is for an embodiment of the outer container 1 in which the lid 2 is integrally formed as part of the outer container 1 and wherein the lid panel 7 is hingedly attached to the rear wall 4 of the outer container 1 via a crease line 9. It should be noted that in an alternative embodiment (not shown), the lid panel may be hingedly attached to one of the side walls 5, 6 of the outer container 1 instead of to the rear wall 4.

In Figure 6 the rear wall 4 is delimited from each of the side walls 5, 6 by crease lines 26, 27. Similarly, the rear wall 4 is delimited from the bottom wall 3 by a crease line 28. Two flaps 29, 30 extend from the bottom wall 3, wherein said flaps 29, 30 are delimited from the bottom wall 3 by crease lines 31 , 32. When the outer container 1 is assembled, these flaps 29, 30 are attached to the lower portions of the side walls 5, 6 (e.g. by gluing). Of course, in alternative embodiments (not shown), one or both of the flaps 29, 30 could extend from the side walls 5, 6 and be attached to the bottom wall 3 on assembly of the outer container 1. In the embodiment shown, each of the side walls 5, 6 of the outer container 1 comprises a cut-away section 22. As mentioned above, the lid 2 may comprise a skirted section 8 which can serve as the closure means. Preferably the skirted section comprises three end flaps, with each end flap extending partially or wholly along an edge of the lid panel 7. Of course, if the lid 2 is formed as a separate part, it may comprise four end flaps, with the fourth end flap optionally being used to attach the lid 2 to a wall 4, 5, 6 of the outer container 1.

The blank 101 shown in Figure 6 corresponds to an embodiment of the outer container 1 that has a lid 2 with a skirted section 8. The skirted portion 8 of the lid 2 is preferably formed from end flaps 33, 34, 35 which are connected to the lid panel 7 via crease lines 36, 37, 38.

Two skirt tabs 39, 40 extend from the end flaps 33, 35 and are delimited from them by crease lines 41 , 42. When the lid 2 is assembled, these skirt tabs 39, 40 are attached (e.g. glued) to the end flap 34. Thus the end flaps 33, 34, 35 form the skirted portion 8 of the lid 2. Alternative embodiments (not shown) can be envisaged in which one or both of the skirt tabs 39, 40 extend from the end flap 34 and, on assembly of the lid 2, are attached (e.g. glued) to the end flaps 33, 35. The skirted portion 8 of the lid 2 is preferably adapted such that, when the lid 2 is fully closed, the end flaps 33, 34, 35 overlay a portion of the side walls 5, 6 and the substantially open front section of the outer container 1.

In order to ensure that the carton does not open during transport and or storage prior to reaching a consumer, it is preferred that the carton 20 is manufactured with the lid 2 secured closed. However, it is also desirable that the carton 20 can be easily opened by a consumer. In embodiments wherein the lid 2 comprises a skirted section 8 this can be achieved by including one or more tear-off sections 43, 44 which are attached to the outer container 1 (e.g. by gluing) and are separable from the skirt portion 8 by severance lines 45, 46. Preferably, each tear-off section 43, 44 is secured to the respective side wall 5, 6 of the outer container 1. Figure 7 shows a plan view of a blank 110 for an inner container according to an embodiment of the invention. The blank 110 can be stamped or cut from any suitably rigid material, but is preferably paperboard. The blank 110 shown in Figure 7 is for an embodiment of the inner container 10 in which a hinge tab 23 is formed from a section of the bottom panel 11 of the inner container 10 (e.g. as shown in Figure 5a). The removable section 17 is shown in situ, where it is delimited from the rear panel 16 by a tear line 47. The rear panel 16 is delimited from the top panel 12, the bottom panel 11 , and each of the side panels 13, 14 by crease lines 48, 49, 50, 51. Similarly, the front panel 15 is delimited from the side panel 13 by a crease line 52. A flap 53 extends from the side panel 13 and is delimited from it by a crease line 54. When the inner container is assembled, the flap 53 is attached (e.g. glued) to the front panel 15.

The blank 110 shown in Figure 7 corresponds to an embodiment wherein the removable section 17 has two tabs 18. One tab 18 is formed from a section of the top panel 12 and is attached to the removable section 17 along part of the crease line 48. The other tab 18 is formed from a section of the bottom panel 11 and is attached to the removable section 17 along part of the crease line 49. Both tabs are defined by a portion of the tear line 47. The top panel 12 comprises a front flap 55 and two side flaps 56, 57. The flaps are connected to the top panel 12 by crease lines 58, 59, 60. When the inner container is assembled, the front flap 55 is attached (e.g. glued) to the front panel 15 and the side flaps 56, 57 are attached (e.g. glued) to the side panels 14, 13. The bottom panel 11 similarly comprises a front flap 61 and two side flaps 62, 63. The flaps are delimited from the bottom panel 11 by crease lines 64, 65, 66. In this embodiment the hinge 21 consists of part of the crease line 64. When the inner container is assembled, the front flap 61 is attached to the front panel 15 and the side flaps 62, 63 are attached to the side panels 14, 13. Figure 8 is a perspective front view of a carton 20 according to an embodiment of the invention wherein the carton 20 has two inner containers 10a, 10b which are both hingedly attached to the outer container 1. In the embodiment shown, each of the inner containers 10a, 10b can pivot from a closed position an open position independently of the other inner container. In Figure 8, a first inner container 10a is shown in its closed position wherein the inner container 10a is located substantially inside the outer container 1. A second inner container 10b is shown in its open position wherein the second inner container 10b is located substantially adjacent to the outer container 1 and wherein the front panel 15 of the second inner container 10b and the bottom wall 3 of the outer container 1 are substantially coplanar. The lid 2 of the outer container is shown in a partially open position.

An alternative embodiment (not shown) wherein the two inner containers 10a, 10b cannot pivot independently of one another is also a possibility.

The carton of the invention can be used for packaging various different products. In a preferred embodiment, the carton contains tea bags.