This invention relates generally to cartons, and more particularly, to an open-end wrap around style carton having a deflectable carry top.
Wrap around article cartons are well known in the art. An example of such a carton is disclosed in U.S. Pat. No. 3,424,368 in which a carton is illustrated having top, bottom, and side panels or walls which are foldably joined together to form a tubular structure with open ends. While such cartons are desirable because they provide the ability to display articles contained therein through the open ends, they typically provide little lateral support at the open ends due to the lack of large supporting walls which, if present, would obscure the contents of the carton. To assist in carrying such open-end cartons, it is known to provide finger holes at a top panel of the carton for the insertion of a user's fingers or to provide a handle attached to the top panel for grasping by a user.
While fit for the intended purpose, open-ended wrap around cartons having finger holes and handles for carrying have several disadvantages. For example, besides being aesthetically unappealing, the finger holes and handles weaken the top panel of the carton and interfere with graphics that may be placed on the top panel of the carton. Lifting cartons by top finger holes or handles also results in a large force concentrated in a few small areas on the carton's top panel, such as the finger holes or the handle's attachment points to the top panel, thereby leaving the top panel subject to ripping or tearing at these stress points. Furthermore, such finger holes and handles provide little or no lateral support to the contents of the carton, especially at the open ends, when the carton is lifted by a user. Also, finger holes and handles often have sharp edges which are uncomfortable when grasped by a user. Additionally, the handles typically require a user to use a closed grip, which may prove difficult for some persons such as those with arthritis.
What is needed is an open-ended carton that is comfortable and easy to carry. What is needed is an aesthetically pleasing open-ended type wrap-around carton that provides a generally uninterrupted top panel surface upon which graphics may be provided. What is further needed is an open-ended type carton that provides means of carrying the carton that does not weaken the top panel of the carton. What is further needed is an open-ended carton that secures the cartons contents and provides lateral support at the open ends when the carton is lifted. What is further needed is an open-ended type carton that minimizes the stress to the top panel of the carton when the carton is lifted by a user.
The present invention provides a carton having a generally uninterrupted top panel with deflectable end flaps attached thereto and a pair of side panels connected to the top panel and to base panels to form a tubular open-ended carton. The end flaps are located at the open ends of the carton and are inwardly deflectable to tighten the carton around articles held within the carton. The end flaps include finger receiving areas for grasping by a user. In an exemplary embodiment, the end flaps extend downwardly, and may extend outwardly from the top panel while at rest, and a portion of each end flap deflects inwardly when grasped by a user. The end flaps may include a plurality of panels hingedly connected to the top panel and a plurality of score lines to assist the inward deflection of the end flaps.
In an exemplary embodiment, the end flap deflects inward when grasped by a user such that a portion of the end flap contacts the top or upper portion of articles carried within the carton, thereby pushing the articles together and tightening them within the carton. Curved score lines may be provided to assist in deformation of the carton during lifting by the user including the upward curvature of the top panel and the inner curvature of the end flaps. Finger pressure by a user at the finger receiving areas deflect the end flaps and top panel, and snugs the articles held within the carton, thereby tightening the carton around the top or upper portion of each of the articles to better secure the articles. The deflectable top panel and end flaps with finger receiving portions eliminate the need for finger holes and handles, thereby allowing the top panel to be generally uninterrupted.
The exemplary carton is a tubular structure with at least one open end. The tubular structure includes a top panel, a first side panel hingedly connected to said top panel, a second side panel opposed to the first side panel and hingedly connected to said top panel, and at least one base panel hingedly connected to the first and second side panels. At least one end flap is hingedly connected to the top panel and extends partially over at least one of the open ends.
The end flap is defined at least in part by first and second fold lines. Each of the first and second fold lines extend from a corner of the end flap and are disposed at a first distance from the outermost edge of the end flap. The end flap is further defined by at least two arcuate relief slits that extend from one end from the first and second fold lines, respectively, as well as by a third fold line extending between the relief slits. The third fold line is disposed at a second distance from the outermost edge of the end flap wherein the second distance is greater than the first distance. Upper and lower medial panels are disposed between the third fold line and the outermost edge of the end flap and form a finger receiving area for receiving a finger of a user. The finger receiving area is disposed between the relief slits. Thus, the first and second fold lines may, in essence, be a continuous fold line interrupted by the arcuate relief slits and one or both of the medial panels. The third fold line may be parallel to the first and second fold lines, but is disposed further away from the outermost edge of the end flap. This offsetting of the first and second fold lines from the third fold line, in combination with the upwardly arching arcuate relief slits causes the top panel to bow upward when the carton is erected and/or lifted. Thereby, the end flaps are encouraged to deflect toward the interior of the carton. Each end flap may also include score lines provided on its surface to further facilitate the end flap deflecting inward when the carton is grasped by a user at the finger receiving area.
The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.
As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, 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 present invention.
Referring now to the drawings in which like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of an exemplary embodiment of a carton 700 (
The top panel 110 has end flaps 128, 130 hingedly connected to the top panel 110 which, when the carton 700 is formed, may be deflectable from an extended position to an interior position as described in more detail below. The top panel 110 is preferably uninterrupted by finger holes, handles, or other interruptions and thus provides a suitable surface for receiving graphics.
The end flaps 128 and 130 may each include upper and lower medial panels 136 and 134 located between left and right lateral panels 132, which are hingedly connected to top panel 110 by lateral fold lines 138. The upper medial panel 136 is hingedly connected to top panel 110 by upper medial fold line 140 and hingedly connected to lower medial panel 134 and lateral panels 132 by lower score line 142. In an exemplary embodiment, lateral and medial fold lines 138, 140 and relief slits 144 together form an upward arch so that the top panel 110 curves or bows upward when a user grasps the carton 700, as discussed in more detail below. Lower medial fold line 142 is also preferably arcuate to assist the inward deflection of the upper and lower medial panels 136, 134. Relief slits 144 may be formed at the location 106 where the top panel 110 joins end flaps 128 and 130. Each relief slit 144 extends between the adjacent fold line 138 and the respective upper medial fold line 140. The relief slits 144 may be curved to approximate a top portion of an article to be carried within the carton 700, such as a bottle cap of a bottle. It should be noted that the slits may be replaced by slots, apertures, openings, their combination, or the like.
Significantly, fold lines 138 and 140 are disposed in the plane of the blank 100 but are vertically offset from one another with respect to the uppermost and lowermost edges of the blank. In other words, the fold lines 138 may be parallel to fold lines 140, but not colinear. As can be seen in
Lower medial panel 134 may be hingedly connected to lateral panels 132 by fold lines 146. Upper and lower medial panels 136 and 134 define a finger receiving area 108 for receiving a user's finger when the user grasps and lifts the carton 700. Lateral panels 132 are hingedly connected to top panel 110 by fold lines 138, hingedly connected to lower medial panel 134 by fold lines 146, and hingedly connected to top gusset panels 152 by fold lines 158.
After construction is completed and the open-ended carton 700 formed, the end flaps 128, 130 extend downwardly from the top panel 110 at open ends of the carton 700. Fold lines 138 and 140 allow end flaps 128, 130 to move inward when the carton 700 is grasped by a user, as explained more fully below. Fold lines 142 may be curved and allow for lower medial panel 134 to move further inward into the interior portion of the erected carton 700. Preferably, top end flaps 128, 130 are sized such that when a user grasps the carton 700, and the end flaps 128, 130 deflect inward, a portion of each end flap 128, 130 contacts the side of an upper portion of at least one article, such as a bottle cap, within the carton and provides a lateral force that pushes the articles together, thereby providing support to the articles.
Side panels 112 and 114 are hingedly connected to top panel 110. Side panels 112, 114 have side flaps 196 hingedly coupled to the side panels 112, 114 by fold lines 150. Each side flap 196 may include a side end panel 148, a top gusset panel 152, a bottom major gusset panel 154, and a bottom minor gusset panel 156.
Side end panel 148 is hingedly connected to top gusset panel 152 by angled fold line 160, which is disposed between fold lines 158 and 150 and defines an acute angle with respect to either fold line 158 or 150. A relief aperture 162 is provided at the intersection of fold line 150 and angled fold line 160 defining an acute angle therebetween. Fold line 150 allows side end panel 148 to be folded inward on the inside surfaces of side panels 112 and 114. By inward, it is meant toward the interior of the blank. Top gusset panel 152 is hingedly connected to lateral panel 132 of front and rear end flaps 128, 130 by fold line 158. Top gusset panel 152 is hingedly connected to side end panel 148 at angled fold line 160.
Bottom major gusset panel 154 is hingedly connected to side end panel 148 at angled fold line 168, which is disposed between fold lines 150 and 172 and may define an acute angle with respect to either fold line 150 or 172. A relief slit 170 extends between one end of fold line 168 and the outer edge of side end panel 148. Bottom major gusset panel 154 may be hingedly connected to bottom minor gusset panel 156 along fold line 172. A relief aperture 174 is provided at the intersection of fold lines 150 and 168, interrupting fold line 168. Bottom minor gusset panel 156 is hingedly connected to bottom major gusset panel 154 by fold line 172 and base panel 120 by fold line 176. After construction of the carton 700 is completed, bottom major and minor gusset panels 154 and 156 define a web 164 that extends between side end panel 148 and base panels 120 and 122 and angles outward from the carton to provide article retaining means at the open end of the carton.
Outer and inner base panels 120, 122 include known tightening openings 188, 194. Known locking tabs 178, 182 are struck from outer base panel 120 for mating with known retaining tabs 190, 192, which are struck from inner base panel 122.
To erect the carton 700 illustrated in
As previously mentioned, the carton 700 is preferably a wrap-around style carton, that is, carton 700 is folded around a group of articles and the bottom is sealed by any suitable means, such as, but not limited to, hot melt glue or locking features, which are known. To erect the carton 700 and enclose the articles therein, the preferably completely flat blank shown in
The base panels 120 and 122 are moved further toward each other and interconnected to create a base closure structure. It should be noted that the base closure structure could alternatively be formed from a single one of the base panels 120, 122 interlocked with an edge flap (not shown), or from any other suitable arrangement known or yet to be developed. As shown in
As shown in
The movement of end flaps 128, 130 when grasped by a user is best shown in
The deflection of the end flaps 128, 130 also pulls the side panels 112, 114, which are connected to the end flaps 128, 130 by top gusset panel 152 and side end panel 148, inward to further secure the articles. Thus, the deflection of the end flaps 128, 130 and top panel 110 effectively tightens the carton around the articles by pushing the bottles 810 together in a front to back direction by the side panels 112, 114 and in a left to right direction by the end flaps 128, 130 and the web 164. This increases the contact points between the articles to better distribute the stresses.
It should be appreciated that as used herein, directional references such as “top”, “base”, “end”, “side”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. The orientation of the carton could be altered depending on, for example, the articles to be carried in the carton.
It should be still further appreciated that any reference to a fold line or hinged connection should not be construed as necessarily referring to a single fold line only: indeed it is envisaged that hinged connection can be formed from one or more of one of the following, a score line, a frangible line or a fold line, without departing from the scope of the invention.
The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.
This application claims priority to U.S. Application No. 60/673,214, filed Apr. 20, 2005, the entirety of which is incorporated herein by reference.
Number | Date | Country | |
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60673214 | Apr 2005 | US |