GB2344339A - Collapsible carton - Google Patents

Abstract

A carton formed from one or more blanks has a base panel 111, side panels 112,114, and end wall panels 118,119 attached to opposite side panels 114,112 by tabs 165,166. Base extension panels 115,116 overlie the end wall panels 119,118 when erect. With the extension panels 115,116 overlying the base panel, the carton may be collapsed by folding at crease lines 141 - 148. In the erect condition, handle flaps 156,157 with resilient tabs 161,163 may engage in handle cut-outs 151,152 in the extension panels 115,116. Lid panels 121 - 127 preferably with lid retention tabs 128,129 to cooperate with slots 171,172 may be provided.

Description

Quick-Erect/Collapse Carton This invention relates to cartons, and is particularly, but not exclusively, concerned with'quick-erect'and Iquick-collapse' (folding) carton structures.

Terminology-Carton The term'carton'is employed herein to embrace any (partially or completely enfolded) volumetric enclosure-and as such may be expressed in diverse configurations, whether, say, a box, bin or bag form.

Cartons are widely used for transport and storage and are typically configured either to bespoke or dedicated forms, or are of a general purpose nature-requiring the user to exercise some judgement upon suitable uses and storage or load carrying capacity.

Cartons are commonly of a pre-fabricated construction from thin-walled material, such as cardboard or plastics sheet.

Thin sheet is vulnerable to bulging, buckling or bending under localised loading.

An erected carton configuration must compensate for this, for example by the provision of supplementary localise stiffening or reinforcement.

Stiffening which consumes more sheet material, either in increased sheet thickness, or by relying upon multiple overlaid layers or plies, can prove costly in material ingredient.

Thus, contriving cost-effective carton stiffening, only where justified, represents an engineering challenge.

Carton handling-ie lifting and re-positioning-is facilitated by the provision of localise pick-up or handling points.

Thus, for example, it is known to have integrated handles, or handle cut-outs in carton side walls.

However, handles are themselves a potential point of structural weakness, and attendant vulnerability to initiating tears in the sheet fabric, absent special reinforcement or bracing.

Scaling-Single vs Multiple Carton Blank Pieces Generally, cartons are fabricated from a carton blank- (initially) in the form of a flat sheet of bespoke profile, sub-divided into a matrix array of panels, by an intersecting grid of cuts, folds and cut-outs, deployed in a prescribed sequence, to achieve a prescribed erected three-dimensional carton form.

A single-piece carton blank is ultimately constrained in size to that of stock sheet material production widths and runs, and conversion machinery handling capacity limitations.

This in turn restricts the overall carton size derivable from a single-piece carton blank.

A multi-piece carton blank, according to one aspect of the invention, allows assembly of a larger carton blank-and thus larger overall carton size-by co-operative relative disposition of multiple individual carton blank pieces, or elements.

The elements can be secured to one another, by, say, mechanical fastening, such as staples, adhesive bonding, or localise (heat or induction) welding patches, and are of complementary, inter-fitting, profile.

In this way,'isolating'overall carton size and configuration, from that of individual constituent carton blank elements, more effective and economical usage of costly sheet material ingredient can be contrived.

Moreover, alternative sub-assemblies could be constructed from individual carton blank elements, or less than a full set of such elements.

Such sub-assemblies could represent intermediate forms, with an independent individual ancillary role, or purpose.

Alternatively, final carton assembly could be from pre-assembled, such subassemblies.

Another aspect of the present invention envisages making further constructive use of a multi-piece carton blank, by adopting different colours, (surface) patterns or textures and/or materials, for a more varied overall effect-such as a patchwork, or harlequin appearance.

In that regard, it is envisaged that a user could select different combinations, in a'mixand-match'style of carton design regime.

Overall carton size and shape, whether fabricated from individual or multi-piece carton blanks, admits of considerable variation.

Alternative Forms-per Fold Sequence Generally, erection and collapse are selectively reversible, or interchangeable, states or conditions.

Moreover, alternative erected and/or collapsed forms may be admitted, by adopting a different folding sequence and/or orientation, and (re-) deploying folds from a common (master) set, embodied in the carton blank from the outset-but not all of which need necessarily be employed in any given folding sequence.

Indeed, the Applicants have themselves devised various carton configurations, such as those the subject of pending UK national patent application no: 9825929.4, together with PCT International patent application no PCT/GB97102195, and follow on UK application no: 9903517.2.

Certain of these represent somewhat more elaborate structures than envisaged in at least the simpler variants of the present case.

Thus, for example, past elaborations included the provision of selective stiffening or reinforcement through multiple overlaid walls-by repeated over-folding of panels from an outer edge of a carton blank.

By such means a substantial, robust peripheral carton edge can be achieved, making the carton suitable for heavy duty applications-such as archive file storage, where an overloading propensity is not uncommon.

However, the nature and degree of over-folding in those earlier cases, is not necessarily economic for some applications.

That said, a certain limited edge rim stiffening, by re-deployment of optional entrained lid panels, configured as side wall extension panels, can be achieved according to one aspect of the present invention.

However, the more fabric employed, the greater the attendant material ingredient and fabrication costs.

Integrated Lid (Panel) Option Other optional supplementary features of the Applicant's previous carton configurations include integrated-and selectively deployable-folding lid closures.

Some have embodied an (inter) locking handle feature, in which a handle cut-out and complementary in-fill tab are deployed to entrain and positively interlock multiple overlapping layers of an erect carton form-thereby bracing and preserving erected carton integrity.

Another feature is the extension of a base area into opposed side flaps, which are turned upwards in the erected carton and overlaid with other side flap extensions of side walls, with a common overlaid handle cut-out and locking flap.

By this means, when the carton is carried by its integrated handles, suspension loads are transferred more directly between base and supporting handle.

The entire base periphery is in turn supported by upstanding side and end walls, which are themselves bound together through overlapping end wall flaps and respective aligned handle cut-outs, penetrated by handle tabs with lateral locking ears.

Again such elaborate,'material-hungry', forms are not appropriate to some applications-hence the need for a simpler approach.

A particular application requiring economy of manufacture is in dedicated or bespoke cartons to serve as shopping carrier bags, in retail situations, with a quick-erect and quick-collapse construction.

Adoption of edge-sealed corrugated plastics sheeting is known for this purpose, in the interests of hygiene-le by obviating crevices for entrapment of food debris or dirt.

Aspects of the present invention are concerned with structural simplification of carton construction-yet allowing a self-supporting or braced, open-top, erect carton form.

Where durability is the prime consideration, the preferred material is corrugated plastics, multi-layer sheet, (such as twin-walled CORREX or CORRIBOARD-Trade Marks).

Such sheet has facing layers on opposite surfaces, separated by an intervening layer of convolutions or corrugations, imparting inherent bracing stiffness, load spreading and impact cushioning.

This exhibits a compliance to cutting and creasing, yet resilience to folding, along with moisture-resistance; which lends it to repeated use, without undue degradation.

Where a lower cost, less durable solution is acceptable, use of corrugated cardboard would be feasible.

Statement of Invention Variant Without Integral Lid According'to one aspect of the invention, a carton comprises: a base panel, a plurality of peripheral [side and end] wall panels, deployable as an upstanding, contiguous boundary, in an erected carton condition, the panels incorporating handle cut-outs, mutually overlaid and aligned when erected, with a locking tab, insertable through the respective handle cut-outs, of multiple overlaid panels, collectively forming opposed end walls, to facilitate their mutual entrainment.

In such a carton configuration, reliance is placed upon a base platform which is supported directly by opposed end flaps.

Indirect support is through opposed side flaps.

In a particular construction, longitudinal side wall extension end panels are in-turned, to overlie the base platform end flaps.

Such extension panels may themselves carry supplementary tabs, which are turned to wrap around an associated comer of an erected carton, and secured-say by adhesive or heat fusion bonding-to an opposite longitudinal side wall.

Once such comer tabs are secured, the carton cannot revert to the original flat sheet carton blank form-but an alternative, or substitute, compact'wallet'folded configuration is admitted, through (re-) deployment of ancillary folds for collapsing end and base panels, as described later.

In a particular construction of dual layer end wall construction, the overlapping panel flaps are mutually entrained, by displacement of a handle tab, from a cut-out in an outer side wall, through a cut-out in an inner base end flap.

Such a handle tab carries lateral ears, which resiliently deform, to allow such insertion through the aligned cut-out in the base end flap-and which spring back to impede withdrawal of the handle tab and thus entraining the two end panels together.

Although this variant has no integrated lid, a discrete lid-optionally of otherwise conventional construction-may be fitted to the erected carton form.

Statement of Invention tntegrat Lid Variant According to one aspect of the invention, a carton, is configured from a carton blank, with a base panel, surmounted by upstanding walls ; multi-layered end wall panels, with aligned cut-outs, for mutual entrainment, using a locking handle tab; lid panels on side walls, and side wall extension (end) panels ; the erect carton being collapsible, using supplementary intermediate folds, into a (relatively compact) wallet configuration.

In a particular construction, such a carton comprises a carton blank, sub-divided by a matrix array of co-operatively disposed, intersecting cuts, creases and folds, to form selectively foldable panels and flaps.

The erect carton configuration comprises a base panel, with upstanding side and end panels; the end wall being multi-layered, with mutually overlaid and aligned handle cut-outs.

An outside end wall has a handle flap, to penetrate respective handle cut-outs, and thereby mutually to entrain the end wall panels.

An integral lid assembly comprises opposed lid panels, extending from side wall panels, and altemating with opposed lid panels, extending from end wall panels, themselves being extensions of intervening side wall panels.

Desirably, upon lid closure, lid flaps, at opposing ends of opposed lid panels, are disposed to penetrate complementary profile slots in the edge fold between side walls and side wall lid panels.

Supplementary creases in the carton blank facilitate collapse of an erect carton, with open lid flaps, into a (relatively compact) wallet configuration.

In an erected carton form, upon lid closure, the integrated lid flaps collectively internest with one another and the carton sides.

This contributes additional strength, rigidity and structural integrity to the carton, aside from affording overall protection for goods within the carton.

In a particular constructional aspect, in order to provide additional load bearing strength, a lateral upstanding extension of the base panel forms part of the end wall, thereby distributing the load weight between the handle and the base.

Conveniently, the side wall extension, which forms an end panel, has a supplementary lateral jointing tab.

This jointing tab'wraps'around an adjacent side wall in the erected carton, where it is secured-by, for example, adhesive or heat fusion bonding.

Once that wrapped jointing tab is so secured, the carton cannot, upon collapse, revert to the flat sheet carton blank, but utilises supplementary intermediate folds, to collapse into a relatively compact wallet form.

Multi-layer end walls have aligned cut-outs, which enable them to be mutually entrained, by inserting a handle flap on the outside wall (with resilient lateral tabs) through the cut-outs.

Statement of Invention In-Tumed Integrated Lid Panels-Stiffened Rim Variant According to another aspect of the invention, a carton with integral lid, [deployable in alternative dispositions,] is configured from a carton blank, with a base panel, surmounted by upstanding walls ; multi-layered end wall panels, with aligned cut-outs, for mutual entrainment, using a locking handle tab; lid panels on side walls, and side wall extension (end) panels ; lid panels on side wall extension (end) panels, with aligned handle cuts outs, facilitating entrainment of in-turned lid panels by a locking handle tab; the erect, open, carton being collapsible, using supplementary intermediate folds, into a (relatively compact) wallet configuration.

In a particular construction, aligned handle cut-outs are included in the side wall extension (end) panel lid panels.

The handle cut-outs allow, in the erect carton, the in-turning of the lid panels and the entrainment of end wall extension lid panels, to the end wall panels, by the handle tab.

Such lid panel in-folding creates a reinforced peripheral rim around the carton, for additional carton rigidity and strength.

Maintenance of the cut-out through all layers allows easy carriage of the carton even when the lid panels are in-tumed.

Statement of Invention Multi-Element Carton Blank Variant According to another aspect of the invention, a carton, is configured from a multi-element carton blank, to form a carton, with a base panel, surmounted by upstanding walls ; multi-layered end wall panels, with aligned cut-outs, for mutual entrainment, using a locking handle tab; selectively deployable lid panels on side wails, and side wall extension (end) panels ; the erect carton being collapsible, using supplementary intermediate folds, into a (relatively compact) wallet configuration.

In such a carton configuration the carton blank is fabricated from more than one individual piece, portion or element of carton (sheet) material.

Thus, for example, a triple-element carton blank could be contrived-and is the version described in a supporting embodiment.

Each carton blank constituent element retains a matrix array of co-operatively disposed, intersecting cuts, creases and folds, necessary to allow selectively foldable panels and flaps to be created.

Overall carton erection reflects that described for single-element carton blanks, subject either to: pre-assembly of a carton blank from multiple individual elements-whose profile contributes collectively to the overall profile ; or joining part-assembled, part-erected, contributory elements together during overall carton erection.

It is envisaged that the individual constituent parts of a multi-element blank could be joined by bonding/welding extension tabs on one element to an overlap region on another element.

In order to achieve a more robust carton format, it is anticipated that the tabs could wrap around what, in the erect carton, becomes a corner edge.

Multi-element carton construction also allows for the construction of a variety of different carton configurations from a set of carton blank elements.

Moreover, by using only a'sub-set'of such'contributory'elements, an open-sided carton may be constructed, such as for merchandising, point-of-sale display.

Alternative constructions from a given set of a carton blank elements could be contrived. Thus, for example, one set of carton blanks may be used together to create a large carton, or used separately to make several of smaller cartons.

Embodiments There now follows a description of some particular embodiments of the invention, by way of example only, with reference to the accompanying diagrammatic and schematic drawings, in which: Variant Without (Integral) Lid Figures 1 A through 1 F show successive stages of progressive carton erection, from an initial carton blank, into a self-contained, unitary, (part-enclosed or open-top box configuration) three-dimensional form.

Figures 2A though 2C show locking of an erected carton through the deployment of locking handle tabs.

Figures 3A through 3C show progressive collapse of an erected carton, into a compact wallet carton form.

Thus more specifically: Figure 1A shows a perspective view of a laid flat sheet carton blank of bespoke outer profile or contour, sub-divided into a matrix array of panels, by a rectangular intersecting grid of crease or fold lines ; Figure 1 B shows a base extension end flap initially in-turned, to facilitate erection of a peripheral upstanding wall around a base panel ; Figure 1C shows a longitudinal side wall panel, upturned, from a base panel of the blank of Figure 1A, about a central base panel edge, with the in-turned base extension end flap temporarily overlying the base; Figure 1 D shows an opposite longitudinal side wall also in-turned from the base panel, to form an open-ended U-section trough; Figure 1 E shows a preliminary step in end wall formation between upturned longitudinal side wall panels-by initially in-turning an extension end flap of the upturned longitudinal side wall of Figure 1 C, leaving a protruding tab; Figure 1 F shows the protruding tab of the up-tumed longitudinal side wall of Figure 1C folded around a corner edge, to overlie a portion of the opposite up-tumed longitudinal side wall of Figure 1 D; Figure 2A shows a near-completed erect carton, with an opposite end wall constructed by the corresponding steps of Figures 1 E and 1 F, but with interlocking handle flaps not yet deployed; Figure 2B show out-tuming of the initially in-tumed base extension end flap (s), as inner layers to the end walls of the erected carton; Figure 2C shows handle flap deployment of the erected carton of Figure 2A, by insertion, from an outer end wall flap, through an overlaid inner end (wall) flap, and resilient reversion of lateral ears to inhibit flap withdrawal; Figures 3A through 3C show successive stages in progressive collapse of an erected carton, such as that of Figure 2C, into a compact flat-pack folded wallet form, by deploying supplementary intermediate crease or fold lines in the base and end wall panels; Thus, more specifically : Figure 3A shows a base extension end flap returned away from an associated side wall end flap, to overlay a portion of the base itself (the associated locking handle flap having been disengaged)-this being repeated for the corresponding opposite end flap; Figure 3B shows the opposite base end flap also retumed, and the base (along with retumed end flaps) itself initially (concertina) folded about a central longitudinal crease, along with partially in turned (concertina) folding, about central creases, of the residual end wall flaps originally integrated with a longitudinal side wall and entrained by bonding of end tab to the longitudinal side walls ; and Figure 3C shows complete collapse of the base and opposed end walls by concertina folding.

Intearal Lid Variant Figure 4A through 4H show successive stages of progressive carton erection-from an initial, flat-sheet, carton blank, into an erected three-dimensional carton, with open lid ; Figures 5A and 5B show the deployment of locking handle tabs, mutually to entrain overlapping end wall panels; Figures 6A through 6D show progressive stages of lid closure upon an erect carton; and Figure 7A through 7C show progressive collapse of an erected carton into a relatively compact wallet form.

More specifically : Figure 4A shows a flat-sheet carton blank, sub-divided into a matrix array of panels, by an intersecting grid of cuts, creases or fold lines ; Figure 4B shows the first stage of carton erection, an extension of a base panel to form an end wall is upturned, before being folded down flat overlaying the base panel, as shown in Figure 4C; Figure 4C shows a longitudinal side wall, upturned from the base, and the base end wall extension folded back over the base proper; Figure 4D shows an opposite longitudinal side wall, from that in Figure 4C, also upturned from the base panel, to form an open-ended U-section trough; Figure 4E shows a preliminary stage of end wall formation, in which a side wall extension, forming an outer end wall panel, has been in-turned, leaving a tab on the end wall panel to protrude beyond the side wall ; Figure 4F shows the protruding tab folded over and secured to the opposite side wall ; Figure 4G shows an erect carton with both outer end wall panels secured; Figure 4H shows the base panel extension end wall being raised from the base and brought to an upright position to produce a multi-layered end wall, with handle cutouts in the end panels mutually aligned; Figure 5A shows an erected carton with open lid and multi-layered end walls ; Figure 5B depicts a handle tab, with resilient lateral ears, penetrating aligned handle cut outs, entraining the end panels ; Figures 6A through 6D show successive stages in lid closure, with each lid panel being deployed in turn; thus: Figure 6A shows a lid panel, as a longitudinal side wall extension, folded over, to reach some one half way across the carton span; Figure 6B shows an opposite lid panel folded marginal to overlie the other lid panel at mid-span of the carton; Figure 6C shows closure of an end wall lid panel, and insertion of opposed retention tabs into slots on edge boundary folds between side walls and respective lid panels ; Figure 6D shows an erect carton with lid fully closed.

Figure 7A through 7C show successive stages in progressive collapse of an erected carton with open lid, as shown in Figure 5B, to a collapsed wallet configuration, as shown in Figure 7C; thus more specifically: Figure 7A shows, in an open carton, disengagement of a locking handle tab, to allow dis-entrainment of a base panel extension from an end wall, and its folding down onto the carton base; Figure 7B shows initial stages of carton collapse. With opposed end walls and associated lid panels (concertina) folded inwards about intermediate creases and base and overlaid end panels displaced outwardly from the carton about respective intermediate creases ;.

Figure 7C shows a completely collapsed carton in a relatively compact wallet configuration.

In-tumed Lid-Stiffened Rim Variant Embodiments Figure 8 shows a carton blank for an integrated lid carton variant, with a lid panel adaptation to allow optional alternative in-folding, as a stiffened peripheral rim, whilst preserving side handle functionality; Figures 9A and 9B show progressive stages of lid closure upon an erect carton; Figure 10 shows an erect carton with lid panels in-turned; More specifically ; Figure 8 shows a flat sheet carton blank for a carton with integrated lid, illustrating handle cut-outs in each of the end wall extension lid panels ; Figure 9A shows initial stages of lid closure on a carton erected from the carton blank of Figure 8.

Longitudinal side wall extension panels are folded over, to reach some half way across the carton span, closure of one end wall extension panel is depicted, with insertion of opposed retention tabs into slots on edge boundary folds between side walls and respective lid panels.

Figure 9B shows an erect carton with closed lid, following closure of the second end wall lid extension panel.

Figure 10 shows an erect carton, as in Figure 9B, with lid open, and lid panels inturned.

A handle flap, with resilient tabs, is depicted as penetrating and entraining aligned handle cut-outs in end wall panels and an overlaid in-turned lid panel. Thus handle functionality is preserved.

Lid panel retention tabs, on the end wall lid extension panel, are shown to entrain the opposed in-turned side wall lid panels.

Corrugated Sheet Material Although cartons according to the invention may be fabricated from diverse (sheet) materials, corrugated sheet material offers certain advantages.

Thus, the orientation of corrugations or flutes can be deployed constructively, in order to bolster (bending) stiffness of individual panels and the overall torsional stiffness of the assembly.

In the following embodiment, corrugations or flutes are depicted, by striated in-fill shading, in order to convey their orientation and relative disposition-which contributes to form stiffness and rigidity.

Thus a structural'box-girder'constructional form, of intersecting, mutually-braced (thin-wall) planes, may be contrived.

Multi-Element Carton Blank Variant Figures 11 A through 13C depict the stages of construction, erection and collapse of a carton variant, from a multi-element carton (in this case three elements) carton blank, and with an (albeit optional) integrated lid.

[Optional] handle cut-outs, on the end wall (extension) lid panels, to facilitate inturning of the lid, are depicted.

Differential, contrasting, carton shading reflects the preferred orientation of the corrugated flutes in a carton constructed from say multiple corrugated plastics elements.

Figures 11A through 11 F show successive stage of progressive carton erection from an initial carton blank-constituted from three distinct, co-operatively profiled carton blank elements-into an erected three-dimensional carton with open lid ; Figures 12A through 12B show progressive stages of lid closure upon an erect carton; and Figures 13A through 13C show progressive stages of collapse of an erected carton into a relatively compact wallet form.

More specifically: Figure 11A shows three discrete, initially flat, carton blank elements, configured for co-operative inter-fitting in an overall carton assembly, and variously subdivided individually into a matrix array of subsidiary base, side wall, end wall and (albeit optional) lid panels, by an intersecting grid of cuts, crease or fold lines ; Figure 11 B shows one alternative first stage of carton erection, a side wall and end panel are upturned from an extension panel-which will later be bonded to the base panel; Figure 11C shows the end panel of Figure 11B in-turned to a position at right angles to the side wall ; Figure 11 D shows the addition of the base panel, with upturned end panels-to form a U shaped trough-to the side wall and end panel of Figure 11 C ; The extension panel depicted in Figure 11A will be bonded to the base panel, shown in Figure 11D ; Figure 11 E shows the addition of the third carton element-the opposite side and end panel to that in Figure 11B-protruding tabs on the end wall remain to be secured to the side walls ; Figure 11 F shows the erect three element carton, with protruding end wall extension tabs secured to the longitudinal side walls, and a handle tab, with resilient lateral ears, penetrating aligned handle cut outs, entraining the end panels ; Figures 12A through 12B show successive stages in lid closure; Figure 12A shows longitudinal side wall extension panels, folded over, to reach some half way across the carton span, and the closure of one end wall extension panel by insertion of opposed retention tabs into slots on edge boundary folds between side walls and respective lid panels ; Figure 12B shows closure of a second lid extension panel, to depict an erect carton with fully closed lid.

Figures 13A through 13C show successive stages in the progressive collapse of erected carton with open lid, as shown in Figure 11 F.

Figure 13A shows initial stages in carton collapse, disengagement of the handle tabs, allowing the base panel extension end walls to fold back onto the base.

Figure 13B shows (concertina) infolding of the end wall panels, about creases, and outward displacement of the base panel and overlaid end panels about a centre line crease.

Figure 13C shows a collapsed carton, of compact wallet like configuration.

Referring to the drawings, an erect carton form 30 is fabricated from a preparatory flat sheet carton blank 10, as depicted in Figure 1A, of resiliently deformable corrugated plastics sheet, sub-divided into a matrix array of panels, by a rectangular grid of multiple intersecting cut, crease or fold lines.

Thus a generally rectangular base area 11 is bounded by a rectangular grid of intersecting creases 31,33,35,37 and entrained opposed longitudinal side wall panels 12,14 and interposed end wall panels 15,16.

As described in more detail later, supplementary creases 41,43,45 subdivide the base panel 11 and end wall panels 15,16,17,19, to allow selective collapse of an erected carton 30 into a wallet form 40, as depicted in Figure 3C.

The longitudinal side walls 12,14 themselves carry lateral extension panels 17,19, which also serve as end wall panels in the erected carton 30.

More specifically, the erected carton end walls comprise multiple- (in fact dual in this example)-overlaid layers, 15,17 and 16,19 respectively.

The formative end panel (outer layers) 17,19 incorporate respective handle cut-outs or apertures 22,24 and entrained handle flaps 27,29, with (locking) side tabs or ears 51,53.

Similarly, the end panels 15,16, entrained direct as extensions of the base 11, have respective handle cut-outs or apertures 21,23.

In an erected carton 30, with the end panels 15,16 overlaid respectively by outer layers 17,19, the handle cut-outs 21,23 align respectively with the corresponding cut-outs or apertures 22,24.

The associated handle flaps 27,29, are displaced inwardly through the cut-outs 21, 23, by resilient deflection of the side tabs or ears 51,53.

The base extension end panels 15,16 correspond in area to that of an end wall in the erected carton, but the longitudinal side wall end panels 17,19 are of marginally greater width, in order to create protruding corner tabs 47,49.

These corner tabs 47,49 are available to fold around the associated corner 57,59 of the erect carton 30 and bond (adhesively or by fusion welding) to the opposite longitudinal side wall 12,14, as depicted in Figure 1 F.

The end wall panels 17,19 incorporate supplementary intermediate creases 43,45 respectively, generally at their mid-span (disregarding the respective end tabs 47, 49). A continuous crease 41 also longitudinally divides the base panel 11 and end flaps 15, 16.

The creases, 41,43,45 allow the end wall panels 17,19 of the assembled carton 30 to be folded inwardly, as depicted in Figure 3B, whilst the base 11 and associated inturned and overlying end panels 15,16 are folded outwardly.

The final collapsed'wallet style'carton form 40 is shown in Figure 3C, and represents a convenient overall size and proportions to allow carriage, say under the arm.

Erection from this collapsed wallet form 40 is readily achieved, by a reversal of the collapse. That is the longitudinal sides 12,14 are pulled apart, as the folded base 11 and opposed end wall panels 17,19 are restored to their former flat selves.

The (base panel extension) end panels 15,16 are finally re-erected and entrained to the panels 17,19 by the interlocking handle flaps 27,29 penetrating mutually aligned handle cut-outs 21,22 and 23,24 respectively.

Overall, the carton 10,30,40 allows ready erection and collapse, yet provides more robust and generous storage than, say, merely a re-interpretation of a conventional plastics or paper carrier bag, with side handles. integrated Lid Variant Referring to Figures 4A through 7C of the drawings, an erect carton form 120, as shown in Figure 5B, is fabricated from a flat sheet carton blank 110, as depicted in Figure 4A.

The carton blank 110 generally comprises a rectangular base area 111, bounded by a rectangular grid of intersecting creases 131,133,135, and 137 and longitudinal side wall panels 112,114 and end wall panels 115,116.

The longitudinal side wall panels 112,114 carry respective longitudinal lid panels 126, 127, together with lateral extension panels 118,119, which form end wall panels in the erect carton 120.

The lateral extension panels 118,119 themselves carry lid panels 121, 122.

Lid panels 121,122 carry opposed retention tabs 123,124 and 128,129 respectively.

When the carton is erected and the lid closed, the retention flaps 123,124 penetrate slots 171,172 respectively, in boundary edge folds between longitudinal sidewalls and associated lid panels.

In an erected carton 120, end wall panels 115,116 are overlaid by panels 119,118 respectively.-whereupon handle cut-outs or apertures 151,152 are aligned with apertures 153,154 respectively.

Handle flaps 156,157 are displaced inwardly, through apertures 151 and 152 respectively.

Resilient side tabs 161,163 entrain the end panels 115,116, when the carton is erect.

The respective lateral extension end wall panels 118,119 of the longitudinal side walls 112,114 are marginally wider than the base 111 and base extension end flaps 115,116, creating tabs 165,166 The tabs 165,166 fold around adjacent longitudinal side walls, 114,112 respectively, and are adhered, welded or bonded thereto, as depicted in Figures 4E and 4F.

Supplementary intermediate creases, 141,142,143,144,145,147,148 subdivide the base panel 111, end panels 115,116,118,119 and lid panel 121,122, to allow selective collapse of the erect carton into a wallet form, as depicted in Figure 7C.

In-turned Lid-Stiffened Rim Variant Whilst in the variant embodiment of Figures 4A through 7C, integrated lid panels have been depicted configured for outward deployment as over-folding closures to the otherwise open mouth of a rectangular carton enclosure, they may be re-deployed in an alternative configuration, as shown in Figures 8 through 10.

Provision is made for preserving handle functionality when the lid panels are so inturned.

More specifically, by inward-folding of the lid panels 121,122,126,127 about their associated side wall panel (upper) entrainment edge, an in-turned peripheral stiffening rim can be achieved-as depicted in Figure 10.

In order to avoid the in-turned lid panels 121,122 obstructing the handle aperture 151,152 in the respective side wall, additional handle cut-outs 174,175 may be incorporated in the lid panels 121,122, and disposed to align with the handle apertures 151,153 and 152 154 respectively when folded inwards.

A through handle aperture is thus preserved through the entire multiple ply side walls.

The splayed retaining handle flap 156,157 provision may be retained.

That is, the handle flaps entrained with opposed side wall handle apertures may be displaced through the overlying side wall extension lid panel.

The lateral (flap) retaining tabs 161,163 would be displaced temporarily to allow thus, and revert to their outer splayed condition, once the flap emerges through the inturned lid panel, thus restraining or locking the lid panel alongside the associated side wall panel.

Retention tabs, 123,124 and 128,129 on lid panels 122 ad 122, respectively, entrain the side wall lid panels 126 and 127.

Multi-Element Carton Blank Variant Referring to Figures 11A through 13C of the drawings, an erect carton form 220-with integral lid, as shown in Figure 11 F, is fabricated from three discrete flat sheet carton blank elements, 270,280,290, as depicted in Figure 11 A.

In this particular embodiment, the three constituent elements 270,280 and 290 are joined together during erection of the carton 220.

The carton blank elements, 270 and 290, which form the longitudinal side walls 214, 212 and outer end panels, 219,218 of the carton, carry; longitudinal lid panels 227,226, extensions of longitudinal side panels 214, 212; lid panels 222,221, extensions of the end wall panels, 219,218; lateral extension tabs 266,265 which, during carton erection, fold around adjacent longitudinal side walls 212,214 respectively, and are bonded or welded thereto; and longitudinal extension tabs 234,232, at the base of longitudinal side panels 214,212 which are bonded or welded to base panel 211, of carton blank 280, during erection of the carton 220.

The third carton blank element 280, comprises base panel 211 with lateral end wall panels 215,216.

The lid panels 222,221 carry opposed retention tabs 223,224 (referenced for only lid panel 221), which in the erect carton, with closed lid, penetrate slots 271 and 272 respectively.

Optional handle cut-outs 275,274 on lid panels 222,221 preserve the handle through-aperture, upon in-turning of the lid panels.

Once erected, the multi-element carton 220 behaves as previously discussed single element carton 120, using an array of supplementary intermediate creases, 241,242, 243,244,245,247,248, which subdivide the three carton elements, to revert between an erect structure 220 and a compact collapsed wallet structure 230.

An alternative discrete, lid may be employed, on both single and multi-element erect cartons.

This lid may incorporate upstanding corner pieces, for location and stacking.

Overall the above embodiments describe [a family of related] carton structures: of simple fabrication from a flat sheet carton blank (single or multi-element) with an array of folds, creases, cuts and cut-outs ; which once erected can be quickly collapsed-to a wallet configuration-and erected again; *may incorporate an integrated lid structure, composed of panel extensions which can be in-turned and entrained if required.

Component List Variant Without Lid 10 carton blank 11 base panel 12 longitudinal side wall panel 14 longitudinal side wall panel 15 end wall panel 16 end wall panel 17 extension panel 19 extension panel 21 handle cut-out 22 handle cut-out 23 handle cut-out 24 handle cut-out 27 handle flap 29 handle flap 30 (erected) carton 31 crease/fold 33 crease/fold 35 crease/fold 36 (intermediate) crease 37 crease/fold 38 (intermediate) crease 40 collapsed wallet carton 41 (intermediate) crease 43 (intermediate) crease 45 (intermediate) crease 47 end tab 49 end tab 51 side tab 53 side tab 57 corner 59 corner ntrated Lid Variant 110 carton blank 111 base panel 112 longitudinal side wall (panei) 114 longitudinal side wall (panei) 115 base extension, end wall panel 116 base extension, end wall panel 118 side wall extension, end wall panel 119 side wall extension, end wall panel 120 erected carton 121 lid panel 122 lid panel 123 lid panel retention tab 124 lid panel retention tab 126 lid panel 127 lid panel 128 lid panel retention tabs 129 lid panel retention tabs 130 collapsed wallet carton 131 crease/fold 133 crease/fold 135 crease/fold 137 crease/fold 141 (intermediate) crease 142 (intermediate) crease 143 (intermediate) crease 144 (intermediate) crease 145 (intermediate) crease 147 (intermediate) crease 148 (intermediate) crease 151 handle cut-out 152 handle cut-out 153 handle cut-out 154 handle cut-out 156 handle flap 157 handle flap 161 resilient tab 163 resilient tab 165 tab 166 tab 171 slot 172 slot 174 handle cut-out 175 handle cut-out Multi-element variant 211 base panel 212 longitudinal side wall (panel) 214 longitudinal side wall (panel) 215 base extension, end wall panel 216 base extension, end wall panel 218 side wall extension, end wall panel 219 side wall extension, end wall panel 220 erect carton form 221 lid panel 222 lid panel 223 lid panel retention tab 224 lid panel retention tab 226 lid panel 227 lid panel 230 collapsed wallet carton 231 crease/fold 232 tab 233 crease/fold 234 tab 235 crease/fold 236 crease/fold 237 crease/fold 238 crease/fold 241 (intermediate) crease 242 (intermediate) crease 243 (intermediate) crease 244 (intermediate) crease 245 (intermediate) crease 247 (intermediate) crease 248 (intermediate) crease 251 handle cut-out 252 handle cut-out 253 handle cut-out 254 handle cut-out 256 handle flap 257 handle flap 261 resilient tab 263 resilient tab 265 tab 266 tab 270 carton blank 271 slot 272 slot 274 (optional) handle cut-out 275 (optional) handle cut-out 280 carton blank 290 carton blank

Claims (14)

1. Claims 1. {collapsible} A carton configured from a carton blank (10) of sheet material, incorporating an array of creases, or folds, (41,43,45), variously deployable to allow an erected, assembled, form (30), and an alternative, compact, collapsed form (40), preserving the assembly integrity.
2. 2. {variant without lid} A carton, as claimed in Claim 1, configured from a carton blank (10), comprising, in an erect form, a base panel (11), surmounted by peripheral upstanding end walls (15,16,17,19) and intervening side walls (12,14), opposed end panels (15,16), configured as a direct extension of the base panel (11), opposed, multi-layer, end walls (15,17 and 16,19) incorporating mutually aligned handle cut-outs (21,22 and 23,24) mutually entrained by locking handle tabs (51,53), of a handle flap (27,29).
3. 3. {integral lid variant} A carton (120), as claimed in either of the preceding claims, with entrained lid panels (121,122,126,127), on longitudinal side walls (112,114), and side wall extension (end) panels (118,119), to form an integral lid structure in the erect carton.
4. 4. {lid flaps/tabs/ears} A carton, as claimed in any of the preceding claims, with lid flaps upon end wall lid panels, selectively locatable in slots in boundary edge folds, between the side walls and side wall lid panels, to hold the lid panels closed.
5. 5.

   A carton, as claimed in any of the preceding claims, with lid flaps upon end wall lid panels, deployable to entrain the side wall lid panels, when the lid panels are in-turned.
6. 6. {lid panel handle cut-outs} A carton, as claimed in any of the preceding claims, including end wall lid panels, with handle cut-outs, aligned upon carton assembly, to facilitate entrainment of in-turned lid panels, by a handle tab, of a handle flap.
7. 7. {multi-element carton blank} A carton (220), as claimed in any of preceding claims constructed from co-operatively configured, multiple, discrete, carton blank elements (270,280,290).
8. 8.

   A carton, as claims in any of the preceding claims, constructed from a triple element carton blank (270,280,290), two elements (270,290) defining respective side walls (214,212) and an entrained end wall (219,218); a third element (280), defining a base (211) and entrained end wall panels (215,216).
9. 9.

   A carton, as claims in any of the preceding claims, constructed from a triple element carton blank, two elements (270, 290) defining respective side wall (214,212) an end wall (219,218) and entrained lid panels (221,222,226,227); a third element (280), defining a base (211) and end wall panels (215,216).
10. 10.

    A carton, as claimed in any of the preceding claims, comprising multiple individual carton blank elements, of different outline form, and/or surface feature, such as texture, pattern, ornament or colour.
11. 11.

    A carton, as claimed in any of the preceding claims, comprising multiple individual carton blank elements, individually configured for selective (re) combination, into various different carton configurations.
12. 12.

    A carton, as claimed in any of the preceding claims constructed from corrugated or fluted sheet material, the relative orientation and disposition of corrugations or flutes, upon individual panels in juxta-position, being contrived to contribute to individual panel (bending) stiffness and overall (torsional) stiffness of an assembled carton,
13. 13.

    A carton, substantially as hereinbefore described, with reference to, and as shown in, the accompanying drawings.
14. 14.

    A collapsible carton, substantially as hereinbefore described, with reference to, and as shown in, the accompanying drawings.

    14. {variant without integral lid} A carton (10,30,40) comprising a base panel (11), surmounted a peripheral upstanding wall (12,14,15,16,17,19), in an erect condition (30), with opposed end walls (15,17 and 16,19), incorporating mutually-aligned handle cut-outs (21,22 and 23,24), in successive overlaid layers (15,17 and 16,19), and mutually entrained, by locking handle tabs (51,53), of handle flaps (27,29) protruding therethrough, an end wall panel (15,16) at each end, being a direct extension of the base panel (11), so that the handle flaps directly support the base panel.

    15. {collapsible variant-without integral lid} A carton (10,30,40) comprising a (rectangular) base panel (11), a pair of longitudinal side wall panels (12,14), on opposite sides of the base, and entrained therewith, through intervening creases or fold lines (31,33); a pair of opposed end wall panels (15, 16), as base extensions, alternating with the longitudinal side wall panels ; the longitudinal side walls carrying lateral end flap extensions (17,19); in an erected carton form (30), the base extension panels (15,16) and side wall panels (17,19) being overlaid at respective ends of the base, to form a dual-layer end walls (61), and the overlaid end wall panels (15,16) being mutually entrained, by handle flap (27,29) tab (51,53) intrusion, from side wall extension panels (17, 19), through handle apertures (21,23), in base extension end panels (15,16), so that loads upon the base (11) are braced by supporting handles (21,23), which also preserve integrity of the surrounding side walls (12,14,15,16,17,19); the base and end wall panels (15,16,17,19) each incorporating creases (41,43,45), to allow in-folding and collapse from overall erect carton, into a compact (wallet) form (40).

    16. {collapsible variant-with integral lid} A carton (120), configured from a carton blank (110), with a base panel (11) surmounted, in an erect condition, by upstanding walls (112,114,115,116); multi-layered end wall panels (115,119,116,118), with aligned cut-outs (151-154), for mutual entrainment, using a locking handle flap (156,157) with tabs (161,163); lid panels (121, 122,126,127) on longitudinal side walls (112,114), and side wall extension (end) panels (118,119); the erect carton being collapsible, using supplementary intermediate folds (141-148), into a (relatively compact) [wallet] configuration (130).

    17. {multi-element carton blank variant} A carton (220), configured from a carton blank, of multi-piece (270,280,290) configuration, with a base panel (211), surmounted by upstanding walls (212,214,215,216,218,219); multi-layered end wall panels (215,219 and 216,218), with aligned cut-outs (252,254 and 251,253), for mutual entrainment, using a locking handle flap (256,257) with tabs (261,263); selectively deployable lid panels (227,226,222,221), upon side walls (214,212) and side wall extension (end) panels (219,218); the erect carton being collapsible, using supplementary intermediate folds (241-248), into a (relatively compact) wallet configuration (230).

    Amendments to the claims have been filed as follows Claims 1. {collapsible, flute orientation} A collapsible carton, configured from a carton blank (10), of corrugated, or fluted, sheet material, incorporating a matrix of creases, or folds, (41,43,45), sub-dividing the blank, into an array of juxtaposed panels (15, 16,17,19), and selectively deployable into an erect assembly (30), from a flat form; and, post-assembly, into an alternative collapsed form (40); the relative orientation and disposition of corrugations or flutes, upon individual panels in juxta-position, being contrived to contribute to individual panel (bending) stiffness and overall (torsional) stiffness of an assembled carton.

    2. {intermediate creases-carton collapse} A collapsible carton, as claimed in Claim 1, incorporating intermediate folds, or creases, subdividing panel faces, and deployable post-assembly, for carton collapse into an alternative configuration.

    3. {flute orientation in side and end wall panels} A collapsible carton, as claimed in either of the preceding claims, with laterally orientated flutes or corrugations, of side and outer end wall panels, whilst flutes of a pair of inner opposed end walls, juxtaposed within respective adjacent outer wall panels, are orientated orthogonally, in relation to the outer wall fluting, in an erect carton assembly.

    4. {handles} A collapsible carton, as claimed in any of the preceding claims, incorporating handles, in certain panels, the handles being deployable mutually to entrain successive overlaid panels, thereby promoting overall assembly integrity and rigidity, and inhibiting inadvertent collapse ; re-deployment of the handles, releasing overlaid panels, to allow post-assembly, carton collapse.

    5. {location of handle flaps, cuts outs and flute orientation} A collapsible carton, as claimed in Claim 4, with elongate handle cut-outs, the handle cut-outs in outermost panels being somewhat larger in outline than those in inner panels, and having appended elongate handle flaps, with opposed lateral locking tabs, the flap elongation being aligned, with the flutes, or corrugations, of the associated panel, the flaps and tabs penetrating corresponding aligned handle cut-outs, on other, inwardly disposed, panels; the handle flaps emerging at innermost panels, with the locking tabs helping mutually entrain overlaid panels, and thereby preserving an erect carton assembly; disengagement of handle flaps and associated locking tabs, releasing intervening wall panels, to allow carton collapse.

    6. {integral lid variant, with lid flaps) A collapsible carton (120), as claimed in any of the preceding claims, with entrained lid panels (121,122,126,127), on longitudinal side walls (112,114), and side wall extension (end) panels (118,119), configured to form an integral lid structure in the erect carton; resilient lid flaps (123,124,128,129) upon end wall lid panels (121,122), selectively locatable in slots (171,172) in boundary edge folds, between the side walls (112,114) and side wall lid panels (126,127), to hold the lid panels closed.

    7. {lid flaps and in-turned lid panels} A collapsible carton, as claimed in Claim 6, with lid flaps upon end wall lid panels, deployable to entrain side wall lid panels, when the lid panels are in-turned.

    8. {lid panel handle cut-outs} A collapsible carton, as claimed in Claim 6 or 7, including end wall lid panels, with handle cut-outs, aligned upon carton assembly, to facilitate entrainment of in-turned lid panels, by a handle tab, of a handle flap.

    9. {multi-element carton blank} A collapsible carton (220), as claimed in any of preceding claims constructed from co-operatively configured, multiple, discrete, carton blank elements (270,280,290).

    10. {triple-element carton blank} A collapsible carton, as claimed in any of the preceding claims, constructed from a triple element carton blank (270,280,290), two elements (270, 290) defining respective side walls (214,212) and an entrained end wall (219,218); a third element (280), defining a base (211) and entrained end wall panels (215,216).

    11. {triple-element carton blank with entrained lid} A collapsible carton, as claimed in any of the preceding claims, constructed from a triple element carton blank, two elements (270,290) defining respective side wall (214,212) an end wall (219,218) and entrained lid panels (221,222,226,227); a third element (280), defining a base (211) and end wall panels (215,216).

    12.

    A collapsible carton, as claimed in any of the preceding claims, comprising multiple individual carton blank elements, of different outline form, and/or surface feature, such as texture, pattern, ornament or colour.

    13.

    A collapsible carton, as claimed in any of the preceding claims, comprising multiple individual carton blank elements, individually configured for selective (re) combination, into various different carton configurations.