TECHNICAL FIELD

The present invention relates to a securing system and a method of securing two or more sheets, panels or layers of a packaging material together. More specifically, but not exclusively, the invention relates to securing two or more layers of paperboard material together. Aspects of the present invention relate to a securing system, a method of securing layers of material together, and to a carton or a package comprising the securing system.

BACKGROUND

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers. Such multi-packs are desirable for shipping and distribution purposes and for the display of promotional information.

For cost and environmental considerations, it is preferable if such cartons are formed from as little material as possible and cause as little wastage as possible in the materials from which they are formed. Another consideration is the strength of the packaging and its suitability for holding and transporting large weights of articles.

In the packaging industry, automatic, high-speed processing of the blanks that form the cartons, part-formed cartons and filled cartons, is required. In designing packaging, consideration needs to be given to automatic, high-speed processing and compatibility with existing automatic machinery.

It is often required to secure two or more panels, layers or plies of one or more carton blanks together in an overlapping relationship. It is desirable to provide a secure bond or fixing to prevent or inhibit separation of the panels or layers. Traditional gluing approaches to bonding two materials together rely on the z-directional strength of the glue-substrate bond in order for the material to remain secured together.

The present invention seeks to overcome or at least mitigate the problems of the prior art by providing an improved securing system.

SUMMARY

A first aspect of the invention provides a securing system for securing two or more plies of a sheet material together. The system comprises a first ply of sheet material having an inner surface and an outer surface and comprising at least one first cutaway; a second ply of sheet material having an inner surface and an outer surface, and a curable flowable bonding agent. A portion of the bonding agent is disposed in part between the inner surface of the first ply and the inner surface of the second ply. A portion of the bonding agent passes through the at least one first cutaway, so as to form a shaft extending through the first ply of sheet material, and terminates in a head proximate the outer surface of the first ply. The head is dimensioned greater than the at least one first cutaway.

Optionally, the securing system comprises at least one second cutaway in the second ply of sheet material. A portion of the bonding agent passes through the at least one second cutaway, so as to form a shaft extending through the second ply of sheet material, and terminates in a second head proximate the outer surface of the second ply. The second head is dimensioned greater than the at least one second cutaway.

Optionally, each at least one first cutaway is disposed, at least part, in vertical alignment with a respective one of the at least one second cutaway.

Optionally, each at least one first cutaway is in vertical alignment with a respective one of the at least one second cutaway.

Optionally, the at least one first cutaway defines an aperture in the first ply.

Optionally, the at least one second cutaway defines an aperture in the second ply.

Optionally, the first ply of sheet material is formed from paperboard.

Optionally, the second ply of sheet material is formed from paperboard.

Optionally, one of the first or second plies of sheet material comprises at least one void disposed between the inner surface and the outer surface. A portion of the bonding agent extends into the at least one void to form at least one arm.

Optionally, the inner surface of at least one of the first or second plies of sheet material is non- planar so as to define at least one void disposed between the inner surfaces of the first or second plies of sheet material. A portion of the bonding agent extends into the at least one void to form at least one arm. Optionally, said one of the first or second plies of sheet material is formed from corrugated board.

Optionally, the first ply comprises two cutaways. A portion of the bonding agent forming the head extends over the outer surface from a first cutaway to the second cutaway so as to be continuous therebetween.

A second aspect of the invention provides a method of securing two or more plies of a sheet material together. The method comprises providing a first ply of sheet material having a first surface and a second surface and comprising at least one first cutaway; providing a second ply of sheet material having a first surface and a second surface; applying a curable flowable bonding agent to the first surface of the second ply; bringing the first surface of the first ply and the first surface of the second ply into close proximity, and applying pressure to the first and second plies. A portion of the bonding agent flows through the at least one first cutaway so as to form a shaft extending through the first ply of sheet material and spreads over the second surface of the first ply so as to form a first head dimensioned greater than the at least one first cutaway. The method also comprises curing the curable flowable bonding agent.

Optionally, the second ply of sheet material comprises at least one second cutaway. Applying pressure to the first and second plies causes a portion of the bonding agent to flow through the at least one second cutaway so as to form a shaft extending through the second ply of sheet material and to spread over the second surface of the second ply so as to form a second head dimensioned greater than the at least one second cutaway.

Optionally, the method comprises aligning, at least partially, the at least one first cutaway with a respective one of the at least one second cutaway.

A third aspect of the invention provides a carton for packaging one or more articles. The carton comprises a first ply of sheet material having an inner surface and an outer surface and comprising at least one first cutaway; a second ply of sheet material having an inner surface and an outer surface, and a curable flowable bonding agent. A portion of the bonding agent is disposed in part between the inner surface of first ply and the inner surface of the second ply. A portion of the bonding agent passes through the at least one first cutaway, so as to form a shaft extending through the first ply of sheet material, and terminates in a head proximate the outer surface of the first ply. The head is dimensioned greater than the at least one first cutaway. Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

Figures 1 to 3 illustrate stages of forming a securing system or anchorage between two sheets of a packaging material according to a first embodiment of the invention;

Figure 4 is an enlarged perspective view of a stage of forming the anchorage according to the first embodiment of the invention;

Figure 5 is a perspective view of an anchorage shown in Figure 3 in which each of the sheets of packaging material are shown as transparent for illustrative purposes only;

Figures 6 to 8 illustrate stages of forming a securing system or anchorage between two sheets of a packaging material according to a second embodiment of the invention; and

Figures 9 and 10 illustrate a securing system or anchorage between two sheets of a packaging material according to a third embodiment of the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS Detailed descriptions of specific embodiments of the securing system, anchorage, package, blanks, cartons and method are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the securing system, anchorage, package, blanks, cartons and method described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention. Referring to Figure 1 there is shown a perspective view of a securing system 10 that can be employed in the construction of a carton (not shown), which carton is capable of accepting an input of primary products such as, but not limited to, bottles or cans, hereinafter referred to as articles (not shown). The carton may be formed from one or more blanks (not shown). The construction of the carton may require two separate carton blanks to be secured to each other, or a first portion of a carton blank to be secured to a second portion of a carton blank.

In the embodiments detailed herein, the terms “carton” and “carrier” refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging, carrying and/or dispensing articles, such as product containers. It is contemplated that the teachings of the invention can be applied to various product containers, which may or may not be tapered and/or cylindrical. Exemplary containers include bottles (for example metallic, glass or plastics bottles), cans (for example aluminium cans), tins, pouches, packets and the like.

The or each carton blank is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, Kraft board, corrugated board, cardboard, plastic, metal, combinations thereof, and the like. It should be recognised that one or other numbers of blanks may be employed, where suitable, for example, to provide the carton.

Referring to Figure 1 , it can be seen that a first sheet or panel 12 is disposed in an overlying relationship with a second sheet or panel 14. The first and second panels 12, 14 may form a wall of a carton. In the embodiment of Figures 1 to 5 the first and second panels 12, 14 are constructed from a corrugated fibreboard; this material comprises a fluted corrugated sheet F and two linerboards L1 , L2. In some embodiments one of the linerboards may be omitted. The structure comprises voids V1 , V2 between the fluted corrugated sheet and the respective linerboard. These voids may take the form of channels or troughs extending across the sheet material from one side to an opposing side.

The first panel 12 comprises a first cutaway such as an aperture A1 extending therethrough from a first, upper or outer, surface 9 to a second, lower or inner, surface 11 .

Optionally, the second panel 14 comprises a second cutaway such as an aperture (not shown) extending therethrough from a first, lower or outer, surface 15 to a second, upper or inner, surface 13. A bonding agent, which may take the form of adhesive, glue G or other flowable material, is applied to one of the inner surfaces 11 , 13. In the illustrated embodiment, glue G is applied to the inner surface 13 of the second panel 14. The bonding agent is curable; curing may be any process during which a chemical reaction (such as polymerisation) or physical action (such as evaporation) takes place, resulting in a harder, tougher, or more stable anchorage (such as an adhesive bond) or substance. Optionally, the curing process requires maintenance of a certain temperature and/or humidity level, other processes may require a certain pressure. The adhesive may require the application of, or treatment with, a hardening agent; the hardening agent may be a chemical element or compound, or may be electromagnetic radiation such as, but not limited to, ultraviolet radiation. Exposure to the hardening agent may trigger or accelerate curing of the adhesive. In other embodiments, the curing process may simply require the flowable material to be heated in order to allow it to flow. Upon cooling, the flowable material sets or hardens.

In some embodiments, the first or second panels 12, 14 may comprise a coating or outer film or layer which is treated, for example but not limited to heat treated, such that the coating becomes flowable.

The first and second panels 12, 14 are brought together such that the inner surfaces 11 , 13 are in face contacting relationship, or at least in close proximity as shown in Figure 2.

When the first and second panels 12, 14 are brought together (as indicated by direction arrows D1 , D2) force or pressure is applied to the glue G. The glue G is forced or flows into the orifice or bore of the first aperture A1 in the inner surface 11 of the first panel 12. When a second aperture is provided glue G is forced or flows into the orifice or bore of the second aperture in the inner surface 13 of the second panel 14.

The glue G forms an adhesive bond between the inner surfaces 11, 13 of the first and second panels 12, 14.

Some of the glue G flows through the first panel 12 and emerges from an orifice or opening in the outer surface 9 of the first panel 12. The glue G flows or is spread over the outer surface 9 of the first panel 12. The glue G forms a head 16. The head 16 is larger in dimension than the first aperture A1 . In this way, the head 16 forms a mechanical fixing, even if the adhesive bond formed by the glue G between the inner surfaces 11 , 13 of the first and second panels 12, 14, should fail. The glue G may also flow into or along one or more voids V1 , V2 in the first panel 12 when the first and second panels 12, 14 are brought together. This is best illustrated in Figure 5. Glue G has flowed along the void or channel C to form arms 30, 32 which further serve to secure the first and second panels 12, 14 together. This provides an additional mechanical fixing, as well as increasing the surface area of the adhesive bond the glue forms with the first or second panels 12, 14.

When a second aperture is provided in the second panel 14, some of the glue G flows through the second panel 14 and emerges from an orifice or opening in the outer surface 15 of the second panel 14. The glue G flows or is spread over the outer surface 15 of the second panel 14. The glue G forms a second head. The second head is larger in dimension than the second aperture. In this way, the head forms a mechanical fixing, even if the adhesive bond formed by the glue G between the inner surfaces 11 , 13 of the first and second panels 12, 14, should fail.

Referring now to Figures 6 to 8, there is shown an additional embodiment of the present disclosure. In the second illustrated embodiment like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “100” to indicate that these features belong to the second embodiment. The additional embodiment shares many common features with the first embodiment and therefore only the differences from the embodiment illustrated in Figures 1 to 5 will be described in detail.

There is shown a perspective view of a securing system 110. It can be seen that a first sheet or panel 112 is disposed in an overlying relationship with a second sheet or panel 114. The first and second panels 112, 114 may form a wall of a carton. In the embodiment of Figures 6 to 8 the first and second panels 112, 114 are constructed from a solid paperboard such as, but not limited to, Kraft board, Solid Bleached Board (SBB), Solid Bleached Sulphate (SBS), or Solid Unbleached Board (SUB). This material may be laminated or coated; however, the material lacks the voids V1 , V2 of the corrugated board of the embodiment of Figure 1 to 5.

The first panel 112 comprises a first aperture A1 extending therethrough from a first, upper or outer, surface 109 to a second, lower or inner, surface 111.

The second panel 114 comprises a second aperture A2 (see Figure 8) extending therethrough from a first, lower or outer, surface 115 to a second, upper or inner, surface 113. Adhesive, glue G or other flowable material is applied to one of the inner surfaces 111 , 113. In the illustrated embodiment glue G is applied to the inner surface 113 of the second panel 114.

The first and second panels 112, 114 are brought together such that the inner surfaces 111 , 113 are in face contacting relationship, or at least in close proximity as shown in Figure 7.

When the first and second panels 112, 114 are brought together (as indicated by direction arrows D3, D4) force or pressure is applied to the glue G. The glue G is forced or flows into the orifice or bore of the first aperture A1 in the inner surface 111 of the first panel 112. Glue G is forced or flows into the orifice or bore of the second aperture A2 in the inner surface 113 of the second panel 114.

The glue G forms an adhesive bond between the inner surfaces 111 , 113 of the first and second panels 112, 114.

Some of the glue G flows through the first panel 112 and emerges from an orifice or opening in the outer surface 109 of the first panel 112. The glue G flows or is spread over the outer surface 109 of the first panel 112. The glue G forms a first cap or head 116; the first head 116 is larger in dimension than the first aperture A1. In this way, the head 116 forms a mechanical fixing, even if the adhesive bond formed by the glue G between the inner surfaces 111 , 113 of the first and second panels 112, 114, should fail.

Some of the glue G flows through the second panel 114 and emerges from an orifice or opening in the outer surface 115 of the second panel 114. The glue G flows or is spread over the outer surface 115 of the second panel 114. The glue G forms a second cap or head 118, best illustrated in Figure 8. The second head 118 is larger in dimension than the second aperture A2. In this way, the head 118 forms a mechanical fixing, even if the adhesive bond formed by the glue G between the inner surfaces 111 , 113 of the first and second panels 112, 114, should fail.

The glue G forms a stalk or shaft extending through each of the first and second apertures A1 , A2. In this way, a continuous column extends between the first and second heads 116, 118. The glue G forms a “rivet” which provides a mechanical fixing securing the first and second panels 112, 114 together. Referring now to Figures 9 and 10, there is shown an additional embodiment of the present disclosure. In the third illustrated embodiment like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix “200” to indicate that these features belong to the third embodiment. The additional embodiment shares many common features with the previous embodiments and therefore only the differences from the embodiments illustrated in Figures 1 to 8 will be described in detail.

Figures 9 and 10 show perspective views of a securing system 210. It can be seen that a first sheet or panel 212 is disposed in an overlying relationship with a second sheet or panel 214. The first and second panels 212, 214 may form a wall of a carton.

The first panel 212 comprises a plurality of first apertures A1 extending therethrough from a first, upper or outer, surface 209 to a second, lower or inner, surface 211 .

The second panel 214 comprises a plurality of second apertures A2 extending therethrough from a first, lower or outer, surface 215 to a second, upper or inner, surface 213.

Adhesive, glue G or other flowable material is applied to one of the inner surfaces 211 , 213.

The first and second panels 212, 214 are brought together such that the inner surfaces 211 , 213 are in face contacting relationship, or at least in close proximity, as shown in Figure 10.

When the first and second panels 212, 214 are brought together force or pressure is applied to the glue G. The glue G is forced or flows into the orifices or bores of each of the first apertures A1 in the inner surface 211 . Glue G is forced or flows into the orifices or bores of each of the second apertures A2 in the inner surface 213.

The glue G forms an adhesive bond between the inner surfaces 211 , 213 of the first and second panels 212, 214.

Some of the glue G flows through the first panel 212 and emerges from orifices or openings in the outer surface 209 of the first panel 212. The glue G flows or is spread over the outer surface 209 of the first panel 212. The glue G forms first caps or heads 216A, 216B. The first heads 216A, 216B are larger in dimension than the respective ones of the first apertures A1. In this way, the heads 216A, 216B form a mechanical fixing, even if the adhesive bond formed by the glue G between the inner surfaces 211, 213 of the first and second panels 212, 214, should fail. The illustrated embodiment shows glue from a pair of adjacent first apertures A1 forming a single head 216B. In alternative embodiments glue from three or more first apertures A1 may flow or be spread to form a single head or a continuous head.

Some of the glue G may also flow through the second panel 214 and emerges from orifices or openings in the outer surface 215 of the second panel 214. The glue G flows or is spread overthe outer surface 215 of the second panel 214. The glue G forms second caps or heads (not shown); the second heads are larger in dimension than the respective ones of the second apertures.

In this way, the glue forms a mechanical fixing, even if the adhesive bond formed by the glue G between the inner surfaces 211 , 213 of the first and second panels 212, 214, should fail.

The glue G forms a stalk or shaft extending through each of the first and second pluralities of apertures A1 , A2. In this way, a continuous column extends between the first and second heads. The glue G forms a “rivet” which provides a mechanical fixing securing the first and second panels 212, 214 together.

The securing system 10, 110, 210 provides strength to packaging that previously had very little strength; that is, areas where z-directional glue failure takes place. Z-directional glue failure occurs when the bond between the inner surface 11 , 13; 111 , 113; 211 , 213 of one of the panels 12, 14; 112,114; 212, 214 and the glue G is broken. The z-direction is shown in Figures 1 , 6 and 10.

Cutting a hole or opening through a paperboard structure provides an avenue for glue (or other material) to flow. By strategically placing glue so that it traverses openings in several layers it can "rivet" the layers together. This shifts the failure mode from z-directional glue failure (glue tearing from paperboard) to actually having to shear the glue itself when glue is configured to extend continuously through the paperboard structure. This results in a stronger securement since the glue itself has greater resistance to shearing or otherwise mechanical failure.

One application of the securing system may be in construction of carrying handles, in particular, but not exclusively, when the carrying handle is configured to be held against the sides or walls of the package by the carton contents, proximate the region where the handle is glued. When the carton is partially full greater reliance is placed upon the z-directional adhesive glue strength in order for the carrying handle to remain functional or intact. The present disclosure provides a method to adhere layers together much more strongly than with the typical approach of gluing them together. By cutting an opening in a material (e.g. paperboard) and allowing glue to flow through the opening and spread on both sides of the board (or boards if traversing multiple layers), the glue acts like a rivet and secures the layers together.

This present disclosure provides a securing system in which the glue forms, or acts as, a structural member in addition to or alternatively to an adhesive bonding element. In order to separate two plies secured in the afore-described manner, the glue must be torn or broken rather than peeled away from the surface to which it is bonded. Once the “rivet” is formed the glue must be sheared through in order to fail. In pilot testing this has achieved a strength improvement of at least 8 times that of a typical glue bond.

This present disclosure also makes it possible to secure materials together that have poor glue adhesion, since this present disclosure may employ the glue as both an adhesive material and a structural member.

In another exemplary application, the technique disclosed herein may be applied to a single layer or panel. This could be utilised to prevent or reduce the likelihood of crack propagation, to alter or shift stress concentrations, and generally improve strength properties of substrates and more complex components or packaging.

It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape. In the foregoing embodiments, in which each layer of material being bonded comprises a cutaway, the cutaways are at least partially aligned “vertically”, that is to say, in the z-direction. In other embodiments, a cutaway in one layer may be partially or fully offset from a cutaway in an adjacent layer. The glue or other bonding agent may extend continuously (an unbroken connection) through the layers of material being secured together. In some embodiments, a cutaway in one layer may be dimensioned greater than that in an adjacent layer in order to facilitate at least partial alignment of the cutaways in the z-direction. The term “cutaway” as used herein refers to any cutaway area which include, but not limited to, an aperture, an opening, a hole, a cutaway, a cutout, a notch, a slot or the like which extends through the respective panel from a first surface of the panel to a second, opposed surface of the panel. It will be recognised that as used herein, directional references such as "top", "bottom", “base”, "front", "back", "end", "side", "inner", "outer", "upper" and "lower" do not necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.

The phrase “in registry with” as used herein refers to the alignment of two or more elements in an erected carton, such as an aperture formed in a first one of two overlapping panels and a second aperture formed in a second one of two overlapping panels. Those elements in registry with each other may be aligned with each other in the direction of the thickness of the overlapping panels. For example, when an aperture in a first panel is “in registry with” a second aperture in a second panel that is placed in an overlapping arrangement with the first panel, an edge of the aperture may extend along at least a portion of an edge of the second aperture and may be aligned, in the direction of the thickness of the first and second panels, with the second aperture.