FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
PROVISIONAL SPECIFICATION
(See section 10; rule 13)
1. Title of the invention. - MULTI FRAME CARTON AND PROCESS THEREFOR

2. Applicant(s)
(a)NAME :
(b) NATIONALITY
(c) ADDRESS:

ITC LIMITED
An Indian Company
37, J.L.Nehru Road, Kolkata- 700 071, State of West Bengal, India and also having a place of business at World Trade Centre, 18th Floor, Centre - 1, Cuff parade, Mumbai 400 005.

3. PREAMBLE TO THE DESCRIPTION
The following specification describes the invention

FIELD OF INVENTION
The present invention relates to multi-frame carton and process for making the same. More particularly it relates to a carton comprising an outer frame and an inner frame that substantially reinforces the outer frame across at least one frame surface wherein the inner frame and the outer frame are provided by folding a substantially planar carton layout along a plurality of creases.
BACKGROUND AND PRIOR ART
Cartons are generally understood to be packaging containers, commonly made from cardboard or paperboard. Sometimes, plastic may also be used. Cartons come in many different varieties but most cartons can be folded and assembled from a flat form, known as a carton blank.
The strength of a carton generally depends upon the strength of the paperboard from which it is made. Generally, high bulk paperboard, i. e. paperboard with a higher gram per square meter (gsm) specification, may be used to prepare stronger cartons. A stronger carton is generally understood as one that is able to bear a higher stacking load (or topload) when compared to another carton having the same dimensions.
However, by design, cartons also have flaps, creases and perforations designed to enable packaging of materials, efficient space utilization and ease of content display and removal. Cartons made from a higher gsm paperboard are hence limited in the folding flexibilities of a heavier paperboard and inconvenient creasing and perforation quality. Also enhanced, is the possibility of injury to a user during carton opening and the likelihood that the carton may not open along its designated perforation thereby damaging the carton and possibly, also damaging the contents.


Prior art in the development of reinforced cartons appears to focus on different mechanical structural modifications. US 4,546,914 teaches a carton with a handle formed on its top. The carton comprises top and bottom walls connected by a tubular body. The top wall has inner and outer panels extending from opposite sides of the tubular body and being overlapped and having portions secured together. An integral, reinforced, three-ply elongated handle panel is formed from a portion of the outer top panel twice bent back upon itself, and is substantially equally spaced from the tubular body opposite sides. A cut and perforated scoreline is formed in the outer top panel to define the handle panel, wherein the scoreline has a midsection partially parallel to a free end edge of the outer top panel and has flared end portions joined to the midsection for added strength at its joinder to the tubular body. The handle panel lies flat against the top wall of the carton while it is shipped and stored, and is readily accessible by lifting along the scoreline. An opening is also formed in the inner top wall panel to provide clearance for fingers to be positioned beneath the handle panel so the panel can be lifted to free the panel for use. A printed portion simulating a second opening can be provided on the outer top wall panel adjacent the handle panel opposite the finger opening to aid the user in positioning his fingers properly to grasp beneath and pull the handle panel to a use position.
US 4,681,252 teaches a can carton having interconnected top, bottom and side walls and end closure panels provided with a transverse flap formed in the top wall and including spaced parallel side edges and arcuate end slits interconnecting adjacent side edges of the flap, one of the side edges of the flap being defined by a perforated severance line and the other side edge of the flap being defined by a fold line together with stress relieving slits formed in the top and side walls which extend from each arcuate slit into the adjacent side wall. The point of intersection of the stress relieving slit in each side wall with the junction between each side and top wall is offset longitudinally from the severance line defining a side edge of the handle flap. According to a feature of the invention in one form each side edge of the handle flap may be defined by a perforated line which may function as a severance line or as a fold line.


US 5,219,089 teaches a non-corrugated box cardboard construction. The box has exterior panels, top and bottom flaps, and interior pads. An interior panel lies interior to and immediately adjacent each exterior panel, whereby the interior panels reinforce and support the exterior panels. The exterior panels, interior panels and flaps are joined by continuity to each other, having been cut from a single sheet. The fold lines between the interior panels include perforation lines along the fold lines.
US 5,506,046 teaches compositions, methods, and apparatus for manufacturing sheets having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form a sheet which has the desired performance criteria. The inorganically filled mixtures are formed into sheets by first extruding the mixtures and then passing the extruded materials between a set of rollers. The rolled sheets are dried in an accelerated manner to form a substantially hardened sheet, such as by heated rollers and/or a drying chamber. The inorganically filled sheets may have properties substantially similar to sheets presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. Such sheets can be cut, rolled, pressed, scored, perforated, folded, and glued to fashion articles from the sheets. They have especial utility in the mass production of containers, particularly food and beverage containers.
US 6,129,266 teaches a handle structure for a carton formed within a panel having a strap member extending between end edges of the panel. An elongated web extends diagonally from an intersection of side and end edges of the panel. The elongated web includes a perforated line and a score line intermediate the perforated line and the end edge of the panel. A connecting tab lies intermediate to the end region of the strap member and foldably interconnects the strap member with a region of the panel that lies between the strap member and one of the side edges of the panel. The perforated line and score line of the elongated web intersect at a point distal to the vertex of side and end edges.


US 6,390,290 teaches a soft-carton-type cigarette pack made from a one-piece blank of paper or the like. A base wall is reinforced by a double-layered design of base tabs and, in addition, is provided with a reinforcing strip which runs around the inside. An opening aid is provided, in interaction with a Z-fold, in the region of an end wall. An exposed grip tab can be gripped for the purpose of removing a tear-open flap, bounded by perforation lines, in the region of the end wall.
US 7,201,714 teaches a method of making reinforced cartons comprises the steps of advancing a length of carton material along a path and progressively laminating at least one ribbon of reinforcing material to the advancing length of carton material. The ribbon of reinforcing material generally has a width less than the width of the length of carton material and is applied with adhesive at selected location across the width of the length of carton material. The web and its laminated ribbon are cut into sheets of a predetermined size and the sheets are die-cut and scored with fold lines to form carton blanks. The fold lines may transition from non-reinforced to reinforced portions of the blank and a special transition zone is contemplated to accommodate the transition. The carton blanks are subsequently formed into cartons for receiving articles, the laminated reinforcing material providing reinforcement in selected portions of the cartons. Multiple ribbons and multiple layers of ribbons may be laminated to the web in respective selected locations to provide reinforcement in more than one portion of the cartons. Reinforcing ribbons may be deformed or altered to exhibit, for instance, corrugations or perforations prior to being adhered to the base sheet.
US 2007137771 Al teaches a method of making reinforced paperboard cartons comprises the steps of advancing a web of paperboard along a path and progressively laminating at least one ribbon of reinforcing material to the advancing web of paperboard. The ribbon of reinforcing material, which also may be paperboard, has a width less than the width of the web of paperboard and is applied with adhesive at a selected location across the width of the web. The web and its laminated ribbon are cut into sheets of a predetermined size and the sheets are die-cut and scored with fold lines to form carton blanks. The fold lines may


transition from non-reinforced to reinforced portions of the blank and a special transition zone is contemplated to accommodate the transition. The carton blanks are subsequently formed into cartons for receiving articles, the laminated reinforcing material providing reinforcement in selected portions of the cartons. Multiple ribbons and multiple layers of ribbons may be laminated to the web in respective selected locations to provide reinforcement in more than one portion of the cartons. Reinforcing ribbons may be deformed or altered to exhibit, for instance, corrugations or perforations prior to being adhered to the base sheet. Reinforced cartons and carton blanks made by the method also are provided.
From a scrutiny of prior art, it appears that there is presently an unmet need for a carton that combines the advantages of a reinforced material with the end usage flexibilities of a light paper. There is also a need for a carton that can bear a high stacking and transporting load and also offer the easy carton opening and 'precise opening along designated perforation' features of lightweight cartons. There is also a need for a process to manufacture such cartons.
OBJECTS OF THE INVENTION
Thus an object of the present invention is to meet the above mentioned needs and provide a carton.
Another object is to provide a carton comprising an outer frame and an inner frame that substantially reinforces the outer frame across at least one frame surface wherein the inner frame and the outer frame are provided by folding a substantially planar carton layout along a plurality of creases.
A further object is to provide a process for preparing a multiple frame carton


BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The foregoing and other advantages and features of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
Figure 1 illustrates one embodiment of the carton of the present invention.
Figure 2 illustrates another embodiment of the carton of the present invention.
Figure 3 illustrates one embodiment of the process of the present invention that provides the a multiple frame carton of the present invention.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
The process of forming the carton comprises the steps of providing a substantially planar carton layout, providing a plurality of creases on the substantially planar carton layout, folding the substantially planar carton layout along the plurality of creases to provide overlapping carton frames, and aligning the overlapping carton frames to provide the multiple frame carton of the present invention.
In the following description, like reference characters designate like or corresponding parts throughout the several illustrations shown in the figures. It is also understood that terms such as "top", "bottom", "outward", "inward", and the like are words of convenience and are not to be construed as limiting terms. Moreover, it will be understood that the illustrations are for the purpose of describing a particular exemplary embodiment of the invention and are not intended to limit the invention thereto.
Referring generally to Figures 1, 2 and 3, illustrative embodiments of the invention address the needs described above by providing a carton (100) and a process (400) for making the multiple frame carton of the present invention.


In one embodiment, the present invention provides a carton (100) comprising an outer frame (110) and an inner frame (120) that substantially reinforces (130) the outer frame (110) across at least one frame surface (140) wherein the inner frame (120) and the outer frame (110) are provided by folding (150) a substantially planar carton layout (160) along a plurality of creases (170).
The cartons of the present invention may be used in home and personal care applications and in industrial applications such as packaging, pharmaceuticals, nutraceuticals, medicinal, surgical, foods, and so on. It is generally understood that a carton is a packaging container, commonly made from cardboard or paperboard. Sometimes, polymer may also be used. Cartons come in many different varieties but most cartons can be folded and assembled from a flat form, known as a carton blank. Nowadays, carton blanks and planar carton layouts are designed using specialized computer programs and executed using specialized creasing, cutting and printing presses that operate to extremely close dimensional tolerances. Cartons of complex geometries may be envisioned using advanced design packages, visualized in a wide variety of colours, textures and visuals and prepared in a continuous assembly line of creasing, cutting and printing presses.
In one embodiment, the carton (100) of the present invention is formed from a single piece board. In another embodiment, the carton is formed using a plurality of boards. It is typically seen that the folding of a substantially planar carton layout along a plurality of creases aligns the outer frame and the inner frame. The aligning of the outer frame and the inner frame provides a carton with at least one of easy carton runnability, carton openability, perfect carton formation, and a combination thereof. The inner frame and the outer frame are glued at atleast one point. The frames are generally glued in alignment of the creases on the inner frame and the outer frame.
In one embodiment, the carton (100) of the present invention generally comprises at least one plurality of flaps (180) for closing the carton. The carton also comprises at least one plurality


of perforations (190) for opening the carton. Frequently, the at least one plurality of perforations (190) is supplemented with a plurality of creases (170) for opening carton (100) along a plurality of hinges (210). The carton is configured for subsequent use as a lidless container upon removal of the plurality of hinges (210).
Typically, the carton (100) comprises a material selected from the group consisting of paper, board, foil, plastic, and a combination thereof. The paper used in the making of the carton generally has a grams per square meter (gsm) specification between about 200 gsm to about 400 gsm. Often, the paper is coated with an anti-fungal coating.
Structurally, it is seen that the outer frame (110) and the inner frame (120) provide increased strength to the carton and generally, the folding of frames is substantially perpendicular. Such design offers increased robustness to the carton of the present invention and may provide the inventive step of the current invention. Sometimes, the inner frame (120) substantially reinforces the outer frame (110) across two frame surfaces.
The carton is printed on at least one surface and sometimes, the printing may also provide a texture to differentiate the contents of the carton or as a quality standard. Frequently, the texture also comprises a hologram.
Carton layouts prepared using computer programs may be executed using cutting and creases that are generally known to a person of ordinary skill in the art. The cutting of paperboard is generally accomplished using a precisely controlled blade. Creasing is known to practitioners of the art to refer to the making of a folding line using a blunt blade. The blunt blade is sometimes called a creasing ruler.
Generally occurring downstream to the cutting and creasing operations is a process of foil stamping wherein a layer of metallic foil may be deposited on carton paperboard (or any


other carton material) using heat and pressure. Sometimes, a holographic impression may also be created. Optional additional processes such as varnishing and stripping may also be performed, depending upon the carton layout and design specifications. Collectively, these are known as finishing operations and are followed by a gluing step that involves the application of an adhesive on a pre-designated glue joint or flap to form the carton from a flat die cut sheet. Generally, joints and flaps are pasted using synthetic glues.
A carton blank is formed by applying glue or an adhesive on certain areas of the carton. In one embodiment of the present invention, a position gluing (or spot gluing) between the inner frame and the outer frame provides proper alignment of the aforementioned frames. Such provision also ensures good runnability, openability and a perfect box formation. It also provides a clean, rectangular, uncrushed and unskewed appearance that is desirable to the customer and also facilitates a sharp-line carton geometry and enhanced aesthetics during formation from carton blanks. Positional gluing of flaps frequently ensures easy opening of the carton post formation.
Operational features in carton joints, flaps, folds and creases are typically related to a creasing stiffness value of the carton material at the crease line. The importance of this parameter is to ensure a proper runnability on the press. Typically, the cartons should form on the machine smoothly, without hindrance to the forming arms. In a preferred embodiment of the present invention, the cartons are formed at a speed of about 130 cartons per minute.
Within the scope of the present invention, runnability is generally understood to be the performance of the carton on the packing machine at a desired speed and operational level. Grain direction in a carton defines the orientation of its constituent paper fibres. In a preferred embodiment of the present invention, the grain direction is along the length of the carton.


The quality of carton perforation is generally understood as the ease with which a carton may be opened along the perforation without injury to the user or damage to the carton contents. Ideally, the carton should reach the consumer without the perforation opening in transit. In a preferred embodiment of the present invention that provides the aforementioned benefit, a 2x1 perforation appears to work particularly effectively. This nomenclature corresponds to a specification of cut and crease. In this instance, it relates to a 2 mm cut and a 1 mm crease.
Cartons may sometimes demonstrate processing defects. Ink flaking at the crease refers to small flake like formations on the crease by ink and varnish that occurs due to a breakage of the print layer. A disorientation and skew defect is caused by improper carton forming on the packing machine wherein the shape of the carton is distorted. The carton may form like a trapezoid. Many of the aforementioned defects may be minimized by a rigorous process and operations control measures known to a person of skill in the art.
In another embodiment of the present invention, illustrated in Figure 3, the invention provides a process (400) for preparing a multiple frame carton (125). The process comprises the steps of providing (410) a substantially planar carton layout (160), providing (420) a plurality of creases (170) on the substantially planar carton layout (160), folding (150) the substantially planar carton layout (160) along the plurality of creases (170) to provide overlapping carton frames (128), and aligning (430) the overlapping carton frames (128) to provide the multiple frame carton (125) of the present invention.
While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.


The following non limiting features describe the structure and process of forming the carton according to the present invention:
i. The carton comprises an outer frame and an inner frame that substantially
reinforces the outer frame across at least one frame surface wherein the inner
frame and the outer frame are provided by folding a substantially planar carton
layout along a plurality of creases,
ii. It may be formed from a single piece board or a plurality of boards,
iii. The folding is of a substantially planar carton layout along a plurality of creases
aligning the outer frame and the inner frame.
iv. The aligning of the outer frame and the inner frame provides a carton with at
least one of easy carton runnability, carton openability, perfect carton formation,
and a combination thereof.
v. The inner frame and the outer frame are glued at atleast one point which is in
alignment of the creases on the inner frame and the outer frame,
vi. The carton comprises at least one plurality of flaps for closing the carton. At least
one plurality of flaps is positionally glued,
vii. The carton comprises at least one plurality of perforations for opening the carton, viii. The plurality of perforations is supplemented with a plurality of creases for
opening the carton along a plurality of hinges,
ix. The carton is configured for use as a lidless container upon removal of the
plurality of hinges.
x. The carton comprises a material selected from the group consisting of paper,
board, foil, plastic, and a combination thereof,
xi. The carton comprising paper have a grams per square meter (gsm) specification
between about 200 gsm to about 400 gsm. and the paper is coated with an anti fungal coating,
xii. The carton is such that the outer frame and the inner frame provide increased
strength to the carton,
xiii. The folding of frames of the carton is substantially perpendicular, xiv. The carton is printed on at least one surface.


xv. The carton is printed to provide a texture. The texture may comprise hologram, xvi. The inner frame of the carton substantially reinforces the outer frame across two
frame surfaces,
xvii. The process for preparing a multiple frame carton, comprises:
(a) providing a substantially planar carton layout;
(b) providing a plurality of creases on the substantially planar carton layout;
(c) folding the substantially planar carton layout along the plurality of creases to provide overlapping carton frames; and
(d) aligning the overlapping carton frames to provide the multiple frame
carton.
xviii. The process for preparing a multiple frame carton is such that the multiple frame carton is formed from a single piece board or using a plurality of boards.
xix. In the process for preparing a multiple frame carton the folding the substantially planar carton layout along a plurality of creases aligns the outer frame and the inner frame.
xx. The process for preparing a multiple frame carton is such that the aligning of the outer frame and the inner frame provides a multiple frame carton with at least one of easy carton runnability, carton openability, perfect carton formation, and a combination thereof.
xxi. The process for preparing a multiple frame carton is such that the overlapping carton frames are glued at atleast one point and in alignment of the creases on the inner frame and the outer frame.
xxii. The process for preparing a multiple frame carton is such that the multiple frame carton formed comprises at least one plurality of flaps for closing the carton which is positionally glued.
xxiii. In the process for preparing a multiple frame carton the multiple frame carton comprises at least one plurality of perforations for opening the carton which may


be supplemented with a plurality of creases for opening the multiple frame carton along a plurality of hinges.
xxiv. The process for preparing a multiple frame carton is such that the multiple frame carton formed is configured for use as a lidless container upon removal of the plurality of hinges.
xxv. The process for preparing a multiple frame carton which comprises a material selected from the group consisting of paper, board, foil, plastic, and a combination thereof.
xxvi. The process for preparing a multiple frame carton such that the multiple frame carton comprises paper having a grams per square meter (gsm) specification between about 200 gsm to about 400 gsm.
xxvii. In the process for preparing a multiple frame carton the paper used is coated with an anti-fungal coating.
xxviii. The process for preparing a multiple frame carton is such that the multiple frames provide increased strength to the multiple frame carton.
xxix. The process for preparing a multiple frame carton is in a manner that the multiple frame carton is printed on at least one surface.
xxx. The process for preparing a multiple frame carton is such that the multiple frame carton is printed to provide a texture and the texture may comprise a hologram.
xxxi. The process for preparing a multiple frame carton is in a manner that the multiple frames substantially reinforce across two frame surfaces.
xxxii. In the process for preparing a multiple frame carton the folding of the substantially planar carton layout along the plurality of creases is substantially perpendicular.
LIST OF REFERENCE NUMERALS IN THE ACCOMPANYING DRAWINGS
100 carton
110 outer frame


120 inner frame
125 multiple frame carton
126 multiple frames
128 overlapping carton frames
130 substantial reinforcement
140 at least one frame surface
142 two frame surfaces
150 folding a surface
160 substantially planar carton layout
170 plurality of creases
180 plurality of flaps
190 plurality of perforations
210 plurality of hinges
220 anti-fungal coating
230 substantially perpendicular folding
240 printing on at least one surface
260 texture
270 hologram
400 process for preparing
410 providing a layout
420 providing a plurality of creases
430 aligning the carton frames
440 lidless container