GB2487765A

GB2487765A - Take-Away Food Container and Lid

Info

Publication number: GB2487765A
Application number: GB1101895.9A
Authority: GB
Inventors: Neal Andrew Whipp
Original assignee: Carton Edge Ltd
Current assignee: Carton Edge Ltd
Priority date: 2011-02-03
Filing date: 2011-02-03
Publication date: 2012-08-08
Also published as: GB201101895D0

Abstract

A carton for take-away food comprises a container having an open top and tapered side walls 26-32 extending from a base, a tray-shaped lid having tapered side walls 90-96 extending from a base 80, the lid nesting in the container to close the container, hinged to the container by attaching lid side wall 90 with container side wall 26. Web portions 44-50 join side walls 26-32 having two differently sized panels. Tabs 130-134 extend from the upper edges of side walls 28-32, tab flaps 142-146 extending from tabs 130-134. The edges of tabs and flaps adjacent to the lid in the erected container have straight edges 160, 162 and semi-circular protrusions 163 engaging apertures 119 in webs 110, 116 between adjacent side walls of the lid. The edges of the other tabs and flaps 150-158 are tapered. When the container is closed tabs 130-134 may lie against side walls 92-96 of the lid and flaps 142-146 lie against base 80 of the lid. Protrusions 164 may be grasped by a user to unfold the tabs.

Description

A Carton and a Blank for forming a Carton The present invention relates to a carton and a blank for forming a carton. In particular, the present invention relates to a carton suitable for containing takeaway food and a blank for forming such a carton.

it is known to use plastic containers with lids to contain takeaway food.

However, production of plastics material is not particularly environmentally friendly, and it would be preferable to use a more environmentally friendly, natural material, such as carton board.

According to a first aspect of the present invention there is provided a carton comprising an open topped container with an attached lid, the lid being tray shaped and arranged to nest in the container to close the container.

The carton of the present invention is more environnientally friendly in comparison to conventional takeaway containers made from plastics material.

Further, the fact that the lid is attached to the container allows easy use of the carton once assembled, as once the container is filled with food, the user does not have to look for a lid, as the lid is already attached. In addition, the fact that the lid is tray shaped and arranged to nest in the container allows the lid to be easily located to close the container, and helps to ensure a reasonable fit within the container.

The container may comprise at least one wall which tapers inwards away from the opening, the lid comprising a base, and sides extending upwardly from the base, the or each side of the base which corresponds to the or each tapered wall of the container preferably being tapered outwardly away from the base, the taper angle of the or each wall of the container being substantially the same as the taper angle of the or each corresponding side of the lid. Corresponding angles of taper on the container wall and the lid side helps to ensure correct location of the lid at an optimum depth in the container, as, if it is attempted to push the lid further than the optimum depth, the relative taper of the at least one wall and the at least one side will prevent this.

Further, use of corresponding tapers also helps to ensure good fit between the wall and the side.

The outer edge of a side of the lid may be attached to the outer edge of a wall of the container. in one embodiment the wall of the container opposite the side to which the lid is attached is tapered. In another embodiment two opposed walls of the container may be tapered, each wall being adjacent to the wall to which the lid is attached. Preferably all of the walls of the container and sides of the lid are tapered.

According to a second aspect of the present invention a carton is provided which comprises an open topped container and a tray-shaped lid, the container comprising at least two opposed walls which taper inwards away from the opening, the lid comprising a base and sides extending from the base, the or each side which corresponds with a tapered wall of the container tapering outwardly away from the base, the taper angle of the or each wall of the container being substantially the same as the taper angle of the or each corresponding side of the lid, such that the lid can nest in the container to close the container.

in the second aspect of the present invention, a carton is provided, therefore, which is more environmentally friendly than a container of plastics material. Further, the fact that at least two opposed walls taper inwards and these correspond with tapered sides of the lid, aids correct location of the lid within the container, without the need for the lid to be attached to the container, and also limits how far the lid can be inserted into the container.

The lid may be attached to the container. This has the advantage that the user does not have to look for a lid once the container has been filled, and the lid is already there and in the correct orientation. Preferably an outer edge of a side of the lid is attached to the outer edge of a wall of the container. Preferably the wall to which the lid is attached is located between two tapered sides.

The lid and container may be integral. Preferably, a single blank can be erected into the lid and the container.

The container and lid may be rectangular, having two opposed short edges and two opposed long edges, and the lid and container may be attached along tong edges.

Attachment of the lid and container along long edges helps ensure better location of the lid than if they were attached along a short edge.

The container may further include a tab extending in a hinged manner from an outer edge of a wall of the container, the tab being arranged such that when the lid is nested in the container, the tab can be moved about the hinge such that it is folded over the lid.

Preferably the container includes at least two tabs, each tab extending in a hinged manner from the outer edge of adjacent walls of the container, each tab being arranged such that when the lid is nested in the container, the tab can be moved about the hinge such that it is folded over the lid so that the tabs engage with each other such that the tabs are retained in their folded over positions, and the tabs retain the lid in a closed position. This is a simple method of retaining the lid within the container, without the use of elements which are separate from the container or lid.

Preferably the tabs engage with each other along a side edge such that each tab creates a force which opposes movement of the other tab out of the folded, lid retaining position. Therefore, the tab design is simple and a closed carton with the tabs engaged to retain the lid is easy for the user to assemble.

Preferably, where the lid is attached to the container, a tab extends from each wall apart from the wall to which the lid is attached. Preferably, where the lid is not attached to the container, a tab extends from each wall. Therefore, the number of tabs is maximiscd and the retention effect on the lid is also maximised.

Preferably each tab has side edges which taper inwards along at least part of their length in the direction away from the wall. This prevents the tabs on adjacent walls interfering with each other or with an adjacent side too much on folding into the container.

Preferably each tab is hinged to comprise a first tab panel attached to the outer edge of a wall which overlies the side of the lid when the tab is folded into the container, and an end tab flap which is arranged to overlie the base of the lid when the tab is folded into the container. This aids retention. Preferably each tab extends the full length of the other edge of the wall to which it is attached. Therefore, a seal is provided against the sides of the lid and also against the portion of the base of the lid which is next to the sides of the lid. Preferably, at least the sides of the first tab panels are tapered.

Preferably, the container and lid are arranged such that, when the lid is nested in the container, the portion of the wall of the container which protrudes above the level of the base of the lid is substantially the same as the depth of the or each first tab panel. This makes it easy for the tab to be folded over the top of the wall and the side of the lid.

Preferably, on the sides of tabs which lie adjacent another wall with a tab, the side of the end tab flap adjacent said other wall is tapered. Preferably, the angle of taper of the side edges of the end tab flap is greater than the angle of taper of the side edges of the first tab panel. Thus, the side edges of the end tab flap do not interfere with the contact of the side edges of the first tab panels with each other. Where the lid is joined to the container, the sides of the end tab flaps of tab panels on walls adjacent to the wall to which the lid is attached are not tapered. Therefore, on folding of the tabs, the non-tapered sides abut the lid side to produce an interference fit.

Preferably, the angle of taper of the sides of the first tab panels, or where the tabs do not comprise first tab panels and end tab flaps, the tapered side portion adjacent the wall to which the tab is attached, is within 5°, more preferably within 2°, and most preferably is substantially the same as the angle of taper of the wall to which the tab is attached.

The end tab flap may be narrower than the first tab panel.

The carton is preferably erected from a flat blank. Such flat blanks can be easily transported, and therefore, it is simple and cost efficient for the blanks to be made at a different location to the location at which the cartons are erected into containers and lids, at least. Preferably, the walls of the container are connected by creased webs on the blank. The blank may be coated with plastics material, such that the walls of the container can be connected by heat welding. The blank may be coated with material which can act as an adhesive on the application of heat, such that the walls of the container can be connected by heat welding. The sides of the lid may be connected by folded webs in the blank. The blank may be coated with plastics material, such that the sides of the lid can be connected by heat welding. The blank may be coated with material which can act as an adhesive on the application of heat, such that the sides of the lid can be connected by heat welding. Heat welding in assembly of the container and the lid ensures high dimensional tolerance, so that the lid can seal the container as closely as possible. The blank may be coated with polyethylene.

According to a third aspect of the present invention there is provided a blank for a carton according to either of the previous aspects of the present invention.

An embodiment of the invention will now be described with reference to the drawings, in which: Figure 1 shows a perspective view of the carton of the present invention with the lid open; Figure 2 is a perspective view of the carton of Figure 1, with the lid folded into the container; Figure 3 is a perspective view of the carton of Figure 1 with the lid folded into the container, and the tabs folded over into the container to retain the lid; Figure 4 is a plan view of the carton of Figure 3; Figure 5 is a perspective close-up view of a corner of the carton of Figure 3; Figure 6 is a plan view of the blank from which the carton of Figures 1 to 5 is assembled; and Figure 7 is a perspective view of a corner of the container of the carton of Figure 1 being folded, prior to heat welding, without the tabs shown.

A carton 10 comprises a container 12 and a lid 14, as shown in Fig. 1.

The container 12 comprises a rectangular base 16. The base 16 has four edges 18, 20, 22, 24, as shown in Fig. 6. A wall 26, 28, 30, 32 extends from each of the edges 18, 20, 22, 24 of the base, respectively. The walls 26, 28 are joined at a corner 34, the walls 28, 30 are joined at a corner 36, the walls 30, 32 are joined at a corner 38, and the walls 32, 26 are joined at a corner 40. The container 12 is formed from a blank 42, as shown in Fig. 6. In the blank 42, the sides 26, 28 are connected by a web portion 44, the sides 28, 30 are connected by a web portion 46, the sides 30, 32 are connected by a web portion 48, and the sides 32, 26 are connected by a web portion 50. Each web portion 44, 46, 48, 50 comprises two triangular web panels, a first web panel 52 and a second web panel 54. The first web panels 52 are connected to the longer walls 26, 30 of the container 12 and extend from the whole of the side edges 56 of the longer walls 26, 30. The second web panels 54 extend from the side edges 56 of the shorter walls 28, 32 of the container 12. The second web panels 54 are shorter than the first web panels 52 and thus do not extend from the whole of the side edges 56 or the walls 28, 32, but, rather, stop short of the top edges 58 of the walls 28, 32 of the container 12.

The side 60 of the blank 42, which includes the inner surfaces of the walls 26, 28, 30, 32 and the base 16 of the container 12, does not have a polyethylene layer.

The side 62 of the blank 42 which forms the outside surfaces of the walls 26, 28, 30, 32 and the base 16 of the container 12 is also covered in a thin layer, 63 of polyethylene. in order to assemble the blank 42 into the container 12, the web portions 44, 46, 48, 50 are folded along the join 64 between the first web panel 52 and the second web panel 54 so that the surfaces of the web panels 52, 54 which are on the side 60 of the blank 42 are in contact with each other, and further so that the portion 66 of the first web panel 52 which extends above the second web panel 54 is in contact with the outer surface 68 of a small wall 28, 32 of the container 12. The web portions 44, 46, 48, 50 and the shorter walls 28, 32 have heat and pressure applied so that the layer 63 of polyethylene bonds to the outer surface 62 to hold web portions 44, 46, 48, 50 in the folded arrangement described, to form corners 34, 36, 38, 40 of the container 12. Use of heat welding in this way allows an accurately dimensioned container 12 to be produced.

The lid 14 is tray shaped and comprises a rectangular base 80 with edges 82, 84, 86, 88. A side 90, 92, 94, 96 extends from each edge 82, 84, 86, 88, respectively.

The sides 90, 92 are joined at corner 98, the sides 92, 94 are joined at corner 100, the sides 94, 96 are joined at corner 102, and the sides 96, 90 are joined at corner 104.

The lid 14 is attached to the container 12 along the top edge 58 of the long wall 26 of the container 12 and the outside edge 106 of the side 90 of the lid 14.

The lid 14 is assembled from a blank 108, which is attached to the blank 42 for the container 12. The layer of polyethylene which is on side 60 of the blank 42 for the container 12 also extends over the side 60 of the blank 108 for the lid 14. As for the container 12, the side 62 of the lid 14 does not have a layer of polyethylene. A triangular web portion 110, 112, 114, 116 extends from each side edge 118 of the shorter sides 92, 96 of the lid 14. To assemble the lid 14, the web portions 110, 112, 114, 116 are positioned so that they lie against the outer surface 121 of the long sides 90, 94 of the lid 14, and are heat welded in place in the same manner as for the corners 34, 36, 38, 40 of the container 12 to produce the corners 98, 100, 102, 104.

The side edges 56 of the walls 26, 28, 30, 32 of the container 12 are tapered outwardly away from the base 16 so that the length of the walls 26, 28, 30, 32 increases away from the base 16. In the same manner, the sides 90, 92, 94, 96 of the lid 14 are tapered outwardly away from the base 80 of the lid 14, so that length of the sides 90, 92, 94, 96 increases away from the base 80 of the lid 14. Therefore, when the container 12 and lid 14 are assembled the walls 26, 28, 30, 32 and the sides 90, 92, 94, 96 taper outwardly from the respective bases 16, 80 of the container 12 and lid 14.

An aperture 119 is provided along the join 120 between each side edge 118 and web portions 110, 116. The aperture 119 is sized such that the excess cartonboard will drop out, without needing to be pushed.

In use, when the container 12 and lid 14 are assembled, the join 107 between the container 12 and the lid 14 can be folded such that the lid 14 is positioned inside the container 12. The fact that the lid 14 is attached to the container 12 along the join 107 obviously prevents the lid 14 from extending too far into the container 12.

However, the angle of taper of the sides 90, 92, 94, 96 corresponds to the angle of the taper of the corresponding walls 26, 28, 30, 32 of the container such that movement of the lid 14 beyond a certain depth within the container 12 would be limited in any case.

The lid 14 therefore nests within the container 12.

The container 12 further includes tabs 130, 132, 134 which extend from the top edges 58 of the walls 28, 30, 32, respectively. Each tab 130, 132, 134 comprises a first tab panel 136, 138, 140 which extends from the whole of the top edge 58 of the respective wall 28, 30, 32 of the container. Each tab 130, 132, 134 further includes an end tab flap 142, 144, 146 which extends from the edge 148 of the first tab panel 136, 138, 140. The sides 150 of the first tab panels 136, 138, 140 are tapered inwardly away from the wall 28, 30, 32. The sides 152, 154 of end tab flaps 144, 146 are tapered at a greater angle than the sides 150 of the first tab panel 136, 138, 140. The side 156 of end tab flap 142, and the sides 158 of end tab flap 146 are tapered in a similar manner to sides 152, 154. Thus, all the sides 152, 154, 156, 158 of end tab flaps 142, 144, 146 which have an adjacent side of another panel are tapered inwardly away from the wall 28, 30, 32 to which they are attached. The sides 160, 162 of the end tab flaps 142, 146 which are adjacent the wall 26 to which the lid 14 is attached are not tapered, but rather are straight. Each of the sides 150 which lie adjacent the wall 26 to which the lid 14 is attached has a small semicircular protrusion 163, sized such that it will fit inside an aperture 119 of the lid 14. Each of the end tab flaps 142, 146 has a large semicircular protrusion 164.

In use, once the lid 14 has been nested in the container 12, the tabs 130, 132, 134 can be folded over into the container 12 such that the first tab panels 136, 138, lie against the sides 92, 94, 96, respectively, of the lid 14, and the end tab flaps 142, 144, 146 lie against the base 80 of the lid 14. The fact that sides 150 of the first tab panels 136, 138, 140 are tapered such that when the tabs 130, 132, 134 are folded inwards so that the first tab panel 136, 138, 140 lies facing the respective wall 28, 30, 32 of the container 12, the taper of the first tab panel 136, 138, 140 is the same as that of the corner 34, 36, 38, 40 against which it lies. The edges 148 of the first tab panels 136, 138, 140 which are adjacent other first tab panels contact the adjacent sides of the adjacent tab panel. The fact that the sides 152, 154 of end tab flaps 142, 144, 146 are tapered at a greater angle than sides 150 of first tab panels 136, 138, 140 prevents the end tab flaps 142, 144, 146 interfering in folding of the tabs 130, 132, 134 into the container 12. The straight sides 160, 162 of end tab flaps 142, 146 ensure that when the tab is folded in, the side 160, 162 is in contact with the side 90 of the lid 14. in order for each adjacent tab to be unfolded out of the edge 148 of the first tab panel 136, 138, 140 must be moved in a direction towards the edge 148 of the adjacent tab panel. Therefore, each tab creates a force which opposes the movement of the other tab out of the folded, lid-retaining position. This allows the lid 14 to be retained in the container 12, thus keeping the container 12 closed. The protrusions 163 can be located in the apertures 119 of the lid, so then the sides 150 which lie adjacent the wall 26 to which the lid 14 is attached are retained in position. To facilitate unfolding of the tabs 130, 134 a user can pull the tabs 130, 134 via the semicircular protrusions 164.

In the above embodiment, the container and lid both have a rectangular configuration.

however, it will be apparent to the skilled man that a square configuration could be used. Alternatively, the container and lid may have only three walls or sides, respectively, or more than four wall or sides, respectively, as long as the number of sides, and their dimensions, corresponds between the container and the lid to ensure the lid can nest within the container.

Heat welding has been used in the above embodiment, and is the preferred method of erecting the container and lid, as it allows high dimensional tolerance of the container and lid, ensuring a good fit when nesting. However, other joining methods could be used, for example gluing, although using such methods it will be more difficult to obtain such accurately dimensioned containers and lids.

In an alternative embodiment, the web portions may be arranged in the opposite sense, i.e. so that the shorter web portion is attached to the longer side, and, therefore, when the web portion is folded to produce a corner, the web portions lie against, and are heat welded to, the outer surface of a longer side.

Further, whichever web portion is outermost when the corner is folded, need not be longer, but need only be shaped such that it overlaps the other web portion when a corner is formed, so that it can contact the outside of the wall of the container. For example, along the outer edge, the innermost web portion may be the same length as the outermost web portion, but at the edge which joins to the other web portion, the innermost web portion may be shorter. It will further be apparent to the skilled man that the overlapping portion need not be at the outermost edge of the web portion.

Alternatively, if the corner is to be assembled by gluing, rather than heat sealing, the web portions can be the same size and shape. If no heat sealing is used, the container need not have a polyethylene layer, although this is beneficial inside the container for barrier properties.

If a polyethylene layer is not required for barrier properties, a polyethylene layer could just be provided at areas at which it is required for heat sealing.

A polyethylene layer could be applied to both sides of the blank. It will be apparent to the skilled man that, although in the embodiment a polyethylene layer is used, a layer of any material which acts as an adhesive on the application of heat, will be suitable, so that the container can be heat welded. If such a layer is applied to both sides of the blank, heat welding can be used to form corners, without any overlapping web portions.

The skilled man will appreciate that the corners of the lid do not need to be sealed in order to correctly locate the lid when closed, as the tapered edges of the sides will contact the walls of the container. Alternatively, if the lid is attached to the container and the corners of the lid are sealed to maintain the angle between the base and the sides, the sides of the lid and the walls of the container need not be tapered to ensure correct depth location of the lid in the container.

The blanks are coated in the above embodiment with polyethylene. however, the blanks may be coated with any suitable material which will melt on the application of heat to allow the surfaces to be joined. further, it is not necessary for the whole of the surface of the blank to be covered in such a material. Rather, such a material may be applied, instead, only on the areas which must be joined to each other.

In the above embodiment, all wall/side pairs of the container/lid are tapered. It will be apparent to the skilled man that other wall/side pairs may be tapered instead. For example, if only the two wall/side pairs adjacent the lid/container joint are tapered, in addition to the lid being attached to the container, this will be sufficient to prevent the lid rotating relative to the container. Alternatively, only the wall/side pair opposite the lid/container joint may be tapered. As a further alternative, all three side/wall pairs apart from the lid/container joint may be tapered.

Further, none of the sides may be tapered, as lid will be held in position by the lid/container joint, and as long as there is an interference fit between the lid sides and the container walls, the lid can be held at a desired depth and orientation within the container.

Alternatively, the lid may not be joined to the container, but at least two opposed sides may be tapered to ensure the lid is held at the desired depth and orientation when nesting in the container.

Claims

Claims 1. A carton comprising an open-topped container with an attached lid, the lid being tray shaped and arranged to nest in the container to close the container.
2. A carton according to claim 1, the container comprising at least one wall which tapers inwards away from the opening, the lid comprising a base, and sides extending upwardly from the base, the or each side of the base which corresponds to the or each tapered wall of the container being tapered outwardly away from the base, the taper angle of the or each wall of the container being substantially the same as the taper angle of the or each corresponding side of the lid.
3. A carton according to claim 2, wherein the outer edge of a side of the lid is attached to the outer edge of a wall of the container.
4. A carton according to claim 2 or claim 3, wherein the wall of the container opposite the side to which the lid is attached is tapered.
5. A carton according to claim 2, 3 or 4, wherein two opposed walls of the container are tapered, each wall being adjacent the wall to which the lid is attached.
6. A carton comprising an open-topped container and a tray-shaped lid, the container comprising at least two opposed walls which taper inwards away from the opening, the lid comprising a base and sides extending from the base, the or each side which corresponds with a tapered wall of the container tapering outwardly away from the base, the taper angle of the or each wall of the container being substantially the same as the taper angle of the or each corresponding side of the lid, such that the lid can nest in the container to close the container.
7. A carton according to claim 6, wherein the lid is attached to the container.
8. A carton according to claim 7, wherein the outer edge of a side of the lid is attached to the outer edge of a wall of the container.
9. A carton according to cLaim 8, wherein the wall to which the lid is attached is located between two tapered sides.
10. A carton according to any of claims 2 to 9, wherein all the walls of the container and sides of the lid are tapered.
11. A carton according to any of preceding claim, wherein the lid and container are integral.
12. A carton according to any preceding claim, wherein the container and lid are rectangular, having two opposed short edges and two opposed long edges, and the lid and container are attached along long edges.
13. A carton according to any preceding claim, wherein the container further includes a tab extending in a hinged manner from an outer edge of a wall of the container, the tab being arranged such that when the lid is nested in the container, the tab can be moved about the hinge such that it is folded over the lid.
14. A carton according to claim 13, wherein the container includes at least two tabs, each tab extending in a hinged maimer from the outer edge of adjacent walls of the container, each tab being arranged such that when the lid is nested in the container, the tab can be moved about the hinge such that it is folded over the lid so that the tabs engage with each other such that the tabs are retained in their folded over positions, and the tabs retain the lid in the closed position.
15. A carton according to claim 14, wherein the tabs engage with each other along a side edge such that each tab creates a force which opposes movement of the other tab out of the folded, lid-retaining position.
16. A carton according to claim 14 or claim 15, wherein, where the lid is attached to the container, a tab extends from each wall apart from the wall to which the lid is attached.
17. A carton according to any of claims 14 to 16, wherein each tab has side edges which taper inwards along at least part of its length in the direction away from the wall.
18. A carton according to any of claims 14 to 17, wherein the or each tab is hinged to comprise a first tab panel attached to the outer edge of a wall and which overlies the side of the lid when the tab is folded into the container, and an end tab flap which is arranged to overlie the base of the lid when the tab is folded into the container.
19. A carton according to claim 18, wherein the container and lid are arranged such that, when the Lid is nested in the container, the portion of wall of the container which protrudes above the level of the base of the lid is substantially the same as the depth of the or each first tab panel.
20. A carton according to claim 18 or claim 19, wherein, where the or each tab has side edges which taper, the angle of taper of the side edges of the end tab flap is greater than the angle of taper of the side edges of the first tab panel.
21. A carton according to claim 18, claim 19 or claim 20, wherein the end tab flap is narrower than the first tab panel.
22. A carton according to any preceding claim, wherein the carton is erected from a flat blank.
23. A carton according to claim 22, wherein the walls of the container are connected by creased webs in the blank.
24. A carton according to claim 23, wherein at least the creased webs of the blank are coated with plastics material, such that the walls of the container can be connected by heat welding.
25. A carton according to claim 23, wherein at least the creased webs of the blank are coated with material which can act as an adhesive on the application of heat, such that the walls of the container can be connected by heat welding.
26. A carton according to any of claims 22 to 25, wherein the sides of the lid are connected by creased webs in the blank.
27. A carton according to claim 26, wherein at least the creased webs of the lid of the blank are coated with plastics material, such that the sides of the lid can be connected by heat welding.
28. A carton according to claim 26, wherein at least the creased webs of the lid of the blank are coated with material which can act as an adhesive on the application of heat, such that the sides of the lid can be connected by heat welding.
29. A carton according to any of claims 22 to 28, wherein the blank is coated with polyethylene.
30. A carton substantially as described herein and with reference to Figs. 1 to 5 and 7.
31. A flat blank for erection into a carton according to any preceding claim.
32. A blank substantially as described herein and with reference to Fig. 6.