BACKGROUND
1. Technical Field
The present invention relates to cartons, and more particularly, to cartons for displaying articles therein.
2. Background Art
Products are occasionally inserted into a display carton or cartons when received by retailers and are positioned so that consumers may easily view, locate, and select products therefrom. Often, many cartons do not provide the visual access that is necessary to successfully market and sell a product. Certain carton designs have attempted to address this problem through the use of different sizes and shapes of cartons as well as one or more dividers disposed therein.
Graham et al. U.S. Pat. No. 3,687,278 discloses a shipping and display carton assembly. The assembly provides an open-topped tray portion containing two rows of upstanding articles. A resilient divider biases the rows of articles outwardly against sides of the tray portion and extends upwardly to tops of the articles.
Ellis U.S. Pat. No. 4,116,330 discloses a container for shipping of prepackaged foodstuffs. The container includes first, second, third, and fourth wall panels, a top portion, and a bottom portion in a closed configuration. The top portion includes first, second, and third side panels extending therefrom to cover the first, second, and third wall panels, respectively, when the container is in the closed configuration. A perforation line is disposed between the top portion and the fourth wall panel. The container is convertible into two display configurations. A first display configuration is obtained by detaching the first, second, and third side panels from the first, second, and third wall panels and removing the top portion along the perforation line. In this configuration, the second wall panel has a height that is less than a height of the fourth wall panel. The second display configuration is obtained by removing portions of the first, third, and fourth wall panels to create a display container wherein the heights of the first, second, third, and fourth wall panels are substantially the same.
Miller U.S. Pat. No. 5,167,324 discloses a shipping carton for tubes. The carton includes an upper portion, a lower portion, and tear strip portions. A divider is disposed in the carton wherein the divider includes upper and lower portions separated by a score line. The upper portion of the carton is separated from the lower portion thereof by removing the tear strip portions to form a display unit. After the upper and lower portions of the carton are separated from one another, the upper and lower portions of the divider may also be separated from one another.
O'Neill U.S. Pat. No. 5,505,371 discloses a shipping and display carton. The carton includes an outer container and an inner partition, wherein the partition includes a pair of primary divider panels each having a u-shaped cutout therein. The carton further includes a perforation line in a front wall that defines the same u-shaped cutout as the primary divider panels.
Heathcock U.S. Pat. No. 6,402,021 discloses a generally rectangular carton for holding and displaying a product. The carton includes a bottom, a first side, a second side, a front, a top, and a rear, all of which define an interior space of the carton. Lines of perforation are disposed around the carton whereby a user may grasp a front tear away section and pull the front tear away section upwardly and toward the rear so as to remove the front tear away section, the top, and optionally, a rear tear away section.
Auclair U.S. Patent Publication No. 2002/014887 A1 discloses a carton and carton blank for packaging one or more articles including an inner tray slidable within an outer sleeve. The carton may include end walls that form an acute angle with inner and outer base wall panels. Additionally, the carton is preferably provided with an access structure in the form of a reclosable tear flap hingedly connected to one panel of the carton, preferably the top panel.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a carton includes a base panel, first and second opposed wall panels extending transversely from the base panel, and third and fourth opposed wall panels extending between the first and second opposed wall panels. At least one of the first, second, third, or fourth wall panels extends at an angle other than 90° with respect to the base panel. The carton further includes a divider having fifth and sixth panels each having a top surface extending between either the first and second wall panels or the third and fourth wall panels.
According to another aspect of the present invention, a carton includes a base panel and first and second opposed wall panels extending from the base panel, wherein at least one of the first and second wall panels extend at an angle other than 90° with respect to the base panel. The carton further includes third and fourth opposed wall panels extending from the base panel, wherein one of the first, second, third, or fourth wall panels includes a cutout portion for viewing contents of the carton. Still further, the carton includes a divider having fifth and sixth panels each having a top surface extending between either the third and fourth opposed wall panels or the first and second opposed wall panels.
According to yet another aspect of the present invention, a carton includes a base panel and first and second opposed wall panels extending from the base panel, wherein at least one of the first and second wall panels extends at an angle other than 90° with respect to the base panel. The carton further includes third and fourth opposed wall panels extending perpendicularly from the base panel. Still further, the carton includes a divider having fifth and sixth panels each having a top surface extending between the third and fourth opposed wall panels, the divider defining first and second compartments between the fifth and sixth panels and the first and second opposed wall panels, respectively. An article is disposed in one of the first and second compartments, wherein a dimension of the article extends beyond an upper margin of the carton.
According to still another aspect of the present invention, a carton blank includes a base panel and first and second opposed wall panels connected to first and second opposite edges of the base panel, respectively, wherein the second wall panel includes a cutout portion therein for viewing of contents when erected. The carton blank further includes third and fourth opposed wall panels connected to third and fourth opposite edges of the base panel, respectively. Still further, the blank includes first and second side flaps extending from first and second opposite edges of the first wall panel and third and fourth side flaps extending from first and second opposite edges of the second wall panel.
According to another aspect of the present invention, a carton blank includes a base panel and first and second opposed wall panels connected to first and second opposite edges of the base panel, respectively, wherein the second wall panel includes a cutout portion therein for viewing of contents when erected. The blank also includes third and fourth opposed wall panels connected to third and fourth opposite edges of the base panel, respectively. Further, the blank includes a first connector flap extending between and connected to the first and third wall panels and a second connector flap extending between and connected to the second and third wall panels. Additionally, the blank includes a third connector flap extending between and connected to the first and fourth wall panels, and a fourth connector flap extending between and connected to the second and fourth wall panels.
Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is plan view of a first embodiment of a carton blank according to the present invention;
FIGS. 2-4 are isometric views of a first process of erecting the carton blank of FIG. 1;
FIGS. 5-7 are isometric views of a second process of erecting the carton blank of FIG. 1;
FIG. 8 is a plan view of a second embodiment of a carton blank according to the present invention;
FIGS. 9-11 are isometric views of a process of erecting the carton blank of FIG. 8;
FIG. 12 is an elevational view of a divider blank according to the present invention;
FIGS. 13 and 14 are isometric views of a process of erecting the divider blank of FIG. 12;
FIG. 15 is an isometric view of the carton of FIG. 4 with the divider of FIG. 14 inserted therein;
FIG. 16 is an isometric view of the carton of FIG. 11 with the divider of FIG. 14 inserted therein;
FIG. 17 is a cross-sectional view taken generally along the lines 17-17 of FIG. 15;
FIG. 18 is a cross-sectional view identical to that of FIG. 17 with a single item disposed in the carton of FIG. 15;
FIG. 19 is a cross-sectional view identical to that of FIG. 18 except with a plurality of items disposed in the carton of FIG. 15; and
FIG. 20 is a diagrammatic isometric view of the item of FIG. 18 or one of the items of FIG. 19.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
Referring to FIG. 1, a carton blank 20 includes sections of paperboard or other material connected by score lines. If desired, one or more of the score lines may have partially or fully cut-through portions. For example, a base panel 22 is joined at score lines 24, 26 to first and second opposed wall panels 28, 30, respectively. The base panel 22 is further joined at score lines 32, 34 to third and fourth opposed wall panels 36, 38, respectively. First and second side flaps 40, 42 are joined to opposite ends 44, 46 of the first wall panel 28 at score lines 48, 50, respectively. Third and fourth side flaps 52, 54 are joined to opposite ends 56, 58 of the second wall panel 30 at score lines 60, 62, respectively. A cutout portion 63 is preferably disposed in the second wall panel 30 whereby the cutout portion 63 allows a user to readily view the contents of the carton when the carton is fully erected. Optionally, the cutout portion 63 may be disposed in the first wall panel 28 or cutout portions may be disposed in both of the first and second wall panels 28, 30. Preferably, the score lines 24, 26, 32, and 34 include alternating fully cut-through portions that are a half inch in length and scores that are a half inch in length. Also preferably, the score lines 48, 50, 60, and 62 include alternating fully cut-through portions that are a quarter inch in length and scores that are a quarter inch in length.
The carton blank 20 of FIG. 1 is preferably erected by machinery (not shown) as seen and described with respect to FIGS. 2-4. Optionally, the carton blank 20 of FIG. 1 may be erected manually as described with respect to FIGS. 2-4. As seen in FIG. 2, the third and fourth opposed wall panels 36, 38 are folded upwardly and inwardly along the score lines 32, 34, respectively, toward the base panel 22. Thereafter, as seen in FIG. 3, the first and second wall panels 28, 30 are folded upwardly and inwardly along the score lines 24, 26, respectively, toward the base panel 22. An adhesive or other bonding agent is deposited on outer edges 64a, 64b of the third wall panel 36 and outside edges 65a, 65b of the fourth wall panel 38. The side flaps 40, 42 and 52, 54 are thereafter folded inwardly toward the third and fourth wall panels 36, 38, respectively. Simultaneously, the side flaps 40, 42 are pressed against the outer edges 64a, 64b, respectively, of the third wall panel 36 and the side flaps 52, 54 are pressed against the outer edges 65a, 65b, respectively, of the fourth wall panel 38 to form the carton of FIG. 4. The adhesive may be applied at any point during the erection process and may, alternatively or in addition, be applied to inner surfaces of the side flaps.
Optionally, the carton blank 20 of FIG. 1 may be erected by machinery (not shown) as seen and described with respect to FIGS. 5-7. Also optionally, the carton blank 20 of FIG. 1 may be erected manually as described with respect to FIGS. 5-7. As seen in FIG. 5, the second wall panel 30 is folded upwardly and inwardly along the score line 26 toward the base panel 22 and the third and fourth side flaps 52, 54 are folded inwardly along the score lines 60, 62, respectively, toward the base panel 22. As seen in FIG. 6, the first wall panel 28 is folded inwardly along the score line 24 toward the base panel 22 and the first and second side flaps 40, 42 are folded inwardly along the score lines 48, 50, respectively, toward the base panel 22. Thereafter, an adhesive or other bonding agent is deposited on inner surfaces 66, 68 of each of the third and fourth opposed wall panels 36, 38 and/or outer surfaces 70, 72, 74, 76 of the first, second, third, and fourth side flaps 40, 42, 52, and 54 respectively. The third and fourth opposed wall panels 36, 38 are then folded inwardly along the score lines 32, 34, respectively, and pressure is applied to the various panels 36, 38 and/or flaps 40, 42, 52, and 54 to form the carton 67 as seen in FIG. 7.
If desired, the foregoing steps may be undertaken in any suitable sequence other than the sequences described above. The order in which the first and second opposed wall panels 28, 30 are erected may be reversed. For example, the first wall panel 28 may be folded inwardly before the second wall panel 30. Also, the first and second wall panels 28, 30 may be folded inwardly before any of the side flaps 40, 42, 52, 54 are folded inwardly.
When erected, the first and second opposed walls 28, 30 form first and second angles A1 and A2 with respect to the base panel 22. In a preferred embodiment, each of the angles A1 and A2 is preferably between about 75 degrees and about 90 degrees, and more preferably between about 77.5 degrees and about 80.5 degrees, and most preferably about 79.38 degrees. The angles A1 and A2 are preferably equal, but need not necessarily be equal.
A second embodiment of a carton blank 120 according to the present invention is seen in FIG. 8 and is designed to be erected manually. The blank, 120 includes a base panel 122 joined at score lines 124, 126 to first and second opposed wall panels 128, 130, respectively. The base panel is also joined at score lines 132, 134 to third and fourth opposed wall panels 136, 138, respectively. A first connector flap 164 connects the first and third wall panels 128, 136 at score lines 166, 168, respectively, and a second connector flap 170 connects the second and fourth wall panels 130, 136 at score lines 172, 174, respectively. Further, a third connector flap 176 connects the first and fourth wall panels 128, 138 at score lines 178, 180, respectively, and a fourth connector flap 182 connects the second and fourth wall panels 130, 138 at score lines 184, 186, respectively.
First and second end flaps 188, 190 are joined at score lines 192, 194, respectively, to the third and fourth opposed wall panels 136, 138, respectively. The first end flap 188 includes first and second side tabs 196, 198. Similarly, the second end flap 190 includes third and fourth side tabs 200, 201. Similar to FIG. 1, the carton blank 120 of FIG. 8 includes a cutout portion 163 preferably disposed in the second wall panel 130 for facilitating viewing of contents of the carton when the carton is fully erected. Optionally, the cutout portion 163 may be disposed in the first wall panel 128 or cutout portions may be disposed in both of the first and second wall panels 128, 130. If desired, one or more of the score lines may have partially or fully cut-through portions. Preferably, the score lines 124, 126, 132, and 134 include alternating fully cut-through portions that are a half inch in length and creases that are a half inch in length. Also preferably, the score lines 166, 168, 172, 174, 178, 180, 184, and 186 include alternating fully cut-through portions that are a quarter inch in length and creases that are a quarter inch in length. Still preferably, the score lines 192, 194, and 203-206 have no cut-through portions.
The carton blank 120 of FIG. 8 is erected according to the process illustrated in FIGS. 9-11. The process of erecting the carton blank 120 includes a first step of folding the second wall panel 130 upwardly and inwardly along the score line 126 toward the base panel 122, as seen in FIG. 9. Simultaneously, the second connector flap 170 is folded inwardly along a diagonal score line 203 and the score lines 172, 174, and the fourth connector flap 182 is folded inwardly along a diagonal score line 204 and the score lines 184, 186, thereby forming gusseted regions in the second and fourth connector flaps 170, 182. Thereafter, as seen in FIG. 10, the first wall panel 128 is folded upwardly and inwardly along the score line 124 toward the base panel 122. Simultaneously, the first connector flap 164 is folded inwardly along a diagonal score line 205 and the score lines 166, 168, and the third connector flap 176 is folded inwardly along a diagonal score line 206 and the score lines 178, 180, thereby forming gusseted regions in the first and third connector flaps 164, 176.
The erection process further includes the step of simultaneously folding the third and fourth opposed wall panels 136, 138 inwardly along the score lines 132, 134, respectively, toward the base panel 122. As the third and fourth opposed wall panels 136, 138 are folded inwardly, the first and second end flaps 188, 190 are folded inwardly along the score lines 192, 194, respectively. The end flap 188 is then folded inwardly until the first and second side tabs 196, 198 are adjacent first and second slots 207, 208, respectively. The first and second side tabs 196, 198 are thereafter inserted into the first and second slots 207, 208 and are retained therein. Similarly, the end flap 190 is folded inwardly until the third and fourth side tabs 200, 201 are positioned adjacent third and fourth slots 209, 210, respectively, and the third and fourth side tabs 200, 201 are inserted into the first and second slots 200, 202 and are secured therein. When the carton blank 120 of FIG. 8 is fully erected, a carton 212 as seen in FIG. 11 is formed. Optionally, glue may be applied between the first and second connector flaps 164, 170, and the third opposed wall panel and/or between the third and fourth connector flaps 176, 182, and the fourth opposed wall panel 138 to secure the carton 212 in its erected form. Also optionally, glue may be applied between the first end flap 188 and the third opposed wall panel 136 and/or between the second end flap 190 and the fourth opposed wall panel 138 to secure the carton 212 in its erected form.
If desired, the foregoing steps may be undertaken in any suitable sequence. For example, the order in which the first and second wall panels 128, 130 are erected may be reversed, wherein the first wall panel 128 may be folded inwardly before the second wall panel 130.
Similar to the embodiment of FIGS. 2-4, the first and second opposed walls 128, 130 of the embodiment of FIGS. 8-11 form third and fourth angles A3 and A4 with respect to the base panel 122. In a preferred embodiment, each of the angles A3 and A4 is preferably between about 75 degrees and about 90 degrees, and more preferably between about 77.5 degrees and about 80.5 degrees, and most preferably about 79.38 degrees. The angles A3 and A4 are also preferably equal, but need not necessarily be so.
The carton 67 or 212 of the present invention may include a separate divider disposed therein that is erected from a divider blank 221. The divider blank 221, as seen in FIG. 12, includes fifth and sixth wall panels 223, 225 attached to one another at a score line 227. The divider blank 221 further includes first and second stabilizing flaps 229, 231 connected at score lines 233, 235, respectively, to the fifth wall panel 223. Still further, the divider blank 221 includes third and fourth stabilizing flaps 237, 239 connected at score lines 241, 243, respectively, to the sixth wall panel 225 and disposed adjacent the first and second stabilizing flaps 229, 231, respectively. If desired, one or more of the score lines of the divider may have partially or fully cut-through portions.
The divider blank 221 is erected by folding the fifth and sixth wall panels 223, 225 about the score line 227 as seen in FIG. 13 such that top surfaces 245, 247 of the fifth and sixth wall panels 223, 225, are disposed outwardly of the resulting v-shaped structure Thereafter, as seen in FIG. 14, the first and third stabilizing flaps 229, 237 are folded away from one another along the score lines 233, 241, respectively and the second and fourth stabilizing flaps 229, 237 are folded away from one another along the score lines 235, 243 respectively. At this point, the divider blank 221 as erected into a divider 249 is ready for insertion into the carton 67 or 212. The divider blank 221 for use in the carton 212 of FIG. 11 may be erected manually and the divider blank 221 for use in the carton 67 of FIGS. 4 and 7 is erected either manually or mechanically.
After the carton blank 20 or 120 of FIG. 1 or FIG. 8 and the divider blank 231 have been erected, the erected divider 249 may be inserted into the erected carton 67 or 212. For example, as seen in FIGS. 15-19 the divider 249 is inserted into the carton 67 or 212 by pressing the fifth and sixth wall panels 223, 225 of the divider 249 inwardly toward one another from the position shown in FIG. 14. Once surfaces 251, 253 of the fifth and sixth wall panels 223, 225, respectively, are in contact with each other, the divider 249 is inserted into the carton 67 or 212. When the divider 249 is fully inserted into the carton 67 or 212, the top surfaces 245, 247 of the fifth and sixth wall panels 223, 225, respectively, form first and second compartments 252, 254 with the first and second opposed wall panels 28, 30, or 128, 130 and portions of the base panel 22 or 122 as seen in FIGS. 15 and 16.
The divider 249 is inserted into the carton 67 or 212 such that first and second surfaces 255, 257 of the first and third stabilizing flaps 229, 237, respectively, are in contact with an inner surface 259 of the fourth opposed wall 38 or 138 and third and fourth surfaces 261, 263 of the second and fourth stabilizing flaps 231, 239, respectively, are in contact with an inner surface 265 of the third opposed wall 36 or 136. Also, the divider 249 is urged toward the base panel 22 or 122 of the carton 67 or 212 until the fifth and sixth wall panels 223, 225 and the first, second, third, and fourth stabilizing flaps 229, 231, 237, 239 are in contact with the base panel 22 or 122 as seen in FIGS. 15 and 16. When the divider 249 is fully inserted into the carton 67 or 212 (i.e., the fifth and sixth wall panels 223, 225 and the first, second, third, and fourth stabilizing flaps 229, 231, 237, 239 are in contact with the base panel 22 or 122), the fifth and sixth wall panels 223, 225 are preferably perpendicular to the base panel 22 or 122.
The stabilizing flaps 229, 231, 237, 239 of the divider 249 are preferably, although not necessarily, configured and sized such that the walls 223, 225 of the divider 249 are in contact with one another for an entire height thereof. Optionally, the walls 223, 225 of the divider 249 could taper toward one another at top portions thereof and away from one another at bottom portions thereof. As shown, the height H of the divider 249 when disposed in the carton 67 or 212 is less than a height of an upper margin 266 (FIGS. 16 and 17) of the carton. Optionally, the height H of the divider 240 when disposed in the carton 67 or 212 may be greater than or equal to the height of the upper margin 266 of the carton.
In other embodiments, any or all of the score and/or fold lines could be replaced with other lines of weakness in the corrugated cardboard or other paperboard material used in the carton black that enable the material to bend as described herein.
As previously noted, the cartons 67 and 212 of FIGS. 4, 7, and 11 are specifically designed for display purposes. Preferably, the carton 67 or 212 and the divider 249 are erected by the manufacturer, placed in a shipping container, and shipped to a retailer. The articles may be shipped to the retailer in a separate container, or may be shipped in the same container with the carton 67 or 212. When the retailer receives the shipping container, he/she removes the carton 67 or 212 from the shipping container and positions the articles 267 in the carton 67 or 212 as seen in FIGS. 18 and 19. Optionally, the carton blank 20 or 120 and the divider blank 221 may be shipped to the retailer and the retailer would thereafter erect the carton blank 20 or 120 and the divider blank 221. Still optionally, the erected carton 67 or 212 and the divider blank 221 may be shipped to the retailer, wherein only the divider blank 221 is erected by the retailer.
The carton of the present invention is preferably used to display at least one article 267 as seen in FIG. 20 having a length L, a width W, and a thickness T. Preferably, the width W and the length L of the article 267 are greater than the thickness T of the article 267 and the length L is greater than or equal to the width W of the article 267. Also preferably, but not necessarily, the articles 267 are placed in the carton (for example the carton 67 of FIGS. 4 and 7) such that a top surface 269 of each article 267 extends between the third and fourth opposed wall panels 36, 38. The articles 267 also preferably, although not necessarily, protrude beyond the upper margin 266 of the carton 67 as seen in FIGS. 18 and 19. When the articles 267 protrude beyond the upper margin 266 of the carton 67, graphics or advertising disposed on the articles 267 may be viewed beyond the upper margin 266 of the carton 67 and through the cutout portion 63 in the second wall panel 30. Optionally, the carton of the present invention may be used to display or hold any articles for which there is adequate room in the carton.
INDUSTRIAL APPLICABILITY
It should be apparent that the present invention provides a sturdy display carton for articles stacked therein. Specifically, the carton provides two compartments that tend to distribute weight in the carton evenly throughout the entire carton. The carton further provides the consumer with a clear view of the articles contained therein, as well as easy access to the articles therein.
Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.
Patent Application
20050258223
