Patent Grant
8087570
This invention relates to cartons or sleeves used to store or carry products. The cartons or sleeves are formed from blanks and generally surround or hold at least a portion of the product or articles placed therein.
The entire disclosures of International Application No. PCT/US2008/071307 and U.S. Provisional Application No. 60/962,244 are hereby incorporated by reference in their entirety as though fully set forth herein.
Cartons are typically shipped in bulk quantities. During shipping, the cartons may be vertically stacked upon each other in order to maximize the amount of product shipped in a particular vessel. The amount of product shipped may depend, however, on the load-bearing capacity of the stacked cartons. It is therefore desirable to produce cartons having high rigidity and/or strength in compression for shipping, and for other purposes such as the protection of the carton contents in general.
In order to increase the strength of a carton some conventional cartons provide blank of a different, stronger board material (such as corrugated material) or produce the blank from the a greater thickness carton material. These conventional cartons suffer from typically increased costs associated with manufacturing the carton, since the material costs of manufacture generally increase according to the cost of increasing the strength and/or thickness of the entire blank. Since, however, some sections of the blank, however, may not be load-bearing, the additional costs associated with increasing the strength of non-load-bearing sections of the blank are wasted.
According to a first aspect of the invention, a carton is formed from a multi-ply blank. The multi-ply blank includes a primary blank and one or more reinforcing blanks overlying the primary blank. The reinforcing blanks can be adhered and/or otherwise attached to selected locations on the primary blank in order to increase desirable properties such as, for example, strength and rigidity in the resultant or combination carton. The size and location of the applied reinforcing blanks can be selected, for example, to minimize board use while providing a desired level of increased strength and/or rigidity.
According to another aspect of the invention, angled or beveled corner features can be formed at one or more intersections of side and end panels of the carton. The corner features provide additional strength to the carton.
According to yet another aspect of the invention, a dispenser feature can be formed in the carton to facilitate removal of articles from the carton.
According to yet another aspect of the invention, an aperture can be provided in the carton such that articles accommodated in the carton are visible from the carton exterior. The aperture can serve as a starting point for accessing the dispenser of the carton.
In another aspect, the invention includes a multi-ply blank for forming a carton, with the multi-ply blank including at least a primary blank and a first reinforcing blank. The primary blank includes a first panel connected to a second panel along a first fold line, the second panel is connected to a third panel along a second fold line, and the third panel is connected to a fourth panel along a third fold line. A first top end flap is connected to the first panel along a first traverse fold line, which is transverse to the first fold line. A first corner feature is disposed along the first transverse fold line between the first panel and the first end flap. The first reinforcing blank is attached to the primary blank. Alternatively, a separable portion is formed at least partially in the second panel of the primary blank. The separable portion can be defined at least partially by a tear line that extends from the second panel into the third panel across the second fold line. The tear line generally is substantially continuous and separated at its perimeter by an opening feature, which can be formed in the third panel and which can be covered by a finger flap. Further, at least a second end flap can be connected to the second panel along the first transverse fold line, and a third end flap can be connected to the third panel along the transverse fold line. A second corner feature can be disposed along the first transverse fold line between the third panel and the third end flap. Further still, at least one handle feature can be disposed in either the first panel or the fourth panel, and an adhesive flap can be attached to the fourth panel along a fourth fold line. Alternatively still, a second reinforcing blank can be attached to the primary blank. In such arrangement, the first reinforcing blank can be disposed along the first transverse fold line, and the second reinforcing blank can be disposed along a second transverse fold line, with the second transverse fold line disposed on an opposite side of the first panel parallel the first transverse fold line. Further still, at least a first bottom end flap can be to the first panel along the second transverse fold line, a second bottom end flap can be connected to the second panel along the second transverse fold line, a third bottom end flap can be connected to the third panel along the second transverse fold line, and a fourth bottom end flap can be connected to the fourth panel along the second transverse fold line. Even further still, at least a second corner feature can be disposed along the second transverse fold line between the first panel and the first bottom end flap, a third corner feature can be disposed along the second transverse fold line between the third panel and the third bottom end flap, and a fourth corner feature can be disposed along the second transverse fold line between the fourth panel and the fourth bottom end flap.
In another aspect, the invention includes a carton formed of a multi-ply blank that includes a primary blank and a first reinforcing blank. The primary blank including a first panel connected to a second panel along a first fold line. The second panel is connected to a third panel along a second fold line and the third panel is connected to a fourth panel along a third fold line. A first top end flap is connected to the first panel along a first transverse fold line, which is transverse to the first fold line. A first corner feature is provided along the first transverse fold line between the first panel and the first end flap. The first reinforcing blank is attached to the primary blank. The first corner feature has a beveled shape and strengthens the carton. Optionally, the carton includes a separable portion is formed at least partially in the second panel of the primary blank. Further, the separable portion can be defined at least partially by a tear line, which can extend from the second panel into the third panel across the second fold line. The tear line can be substantially continuous and separated at its perimeter by an opening feature, the opening feature capable of being utilized as a starting point for separating the separable portion along the tear line. The opening feature can be an opening formed in the third panel. The opening feature can be covered by a finger flap. The carton can also include at least a second end flap connected to the second panel along the first transverse fold line, a third end flap connected to the third panel along the transverse fold line, and a second corner feature is disposed along the first transverse fold line and disposed between the third panel and the third end flap. The carton can also include at least one handle feature in either the first panel or the fourth panel. The carton can also include an adhesive flap attached to the fourth panel along a fourth fold line. Optionally still, the carton can include a second reinforcing blank attached to the primary blank, with the first reinforcing blank along the first transverse fold line and with the second reinforcing blank along a second transverse fold line. The second transverse fold line on an opposite side of the first panel, parallel the first transverse fold line. The carton can also include at least a first bottom end flap connected to the first panel along the second transverse fold line, a second bottom end flap connected to the second panel along the second transverse fold line, a third bottom end flap connected to the third panel along the second transverse fold line, and a fourth bottom end flap connected to the fourth panel along the second transverse fold line. The carton can also include at least a second corner feature along the second transverse fold line between the first panel and the first bottom end flap. The carton can also include a third corner feature along the second transverse fold line between the third panel and the third bottom end flap, and a fourth corner feature along the second transverse fold line between the fourth panel and the fourth bottom end flap. The carton can also include a separable portion formed at least partially in the second panel of the primary blank between the first reinforcing panel and the second reinforcing panel.
In yet another aspect, the invention includes a method of dispensing from a carton formed of a multi-ply blank formed of a primary blank and a first reinforcing blank. The primary blank including a first panel connected to a second panel along a first fold line. The second panel is connected to a third panel along a second fold line. The third panel is connected to a fourth panel along a third fold line. A first top end flap is connected to the first panel along a first transverse fold line, which is transverse to the first fold line. A first corner feature is provided along the first transverse fold line between the first panel and the first end flap. The first reinforcing blank is attached to the primary blank. The method including the steps of forming the multi-ply blank into the carton for receiving articles and separating a separable portion along a tear line, with the separable portion being located at least partially in the second panel of the primary blank. Optionally, the method can provide a second reinforcing blank attached to the primary blank and the separable portion can be defined in the primary blank between the first reinforcing blank and the second reinforcing blank.
The foregoing and other features, aspects, and advantages of the invention will become more apparent upon review of the detailed description of the embodiments set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.
According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.
Briefly described, the present invention is directed to cartons having enhanced strength and rigidity. The cartons are formed from primary blanks reinforced with one or more reinforcing blanks adhered to the primary blanks. In this specification, the terms “side,” and “end” are used for ease of description are not intended to limit the scope of the invention or to imply relative sizes or orientations of panels or flaps.
As discussed in further detail below, the reinforcing blanks 6 can have plan areas or “footprints” that are complementary to and overlap with portions of the footprint of the primary blank 5. One or more sections of the perimeter edges of the reinforcing blanks 6 can also coincide with portions of the perimeter edge of the primary blank 5. The blank 8 is “multi-ply” in that the primary and reinforcing blank plies 5, 6 comprising the blank 8 include substantial overlapping portions. The terms “two-ply” and “multi-ply” are not intended to indicate that all sections of the blank 8 are formed from two or more plies. For example, the reinforcing blanks 6 may have slightly different footprints than the primary blank 5, and need not overlap the primary blank 5 at all points.
Referring to
In the primary blank 5, the first side panel 10 is foldably connected at each end to a first side end flap 12. The second side panel 20 is foldably connected at each end to a second side end flap 22. The third side panel 30 is foldably connected at each end to a third side end flap 32. The fourth side panel 40 is foldably connected at each end to a fourth side end flap 42. The end flaps 12, 22, 32, 42 extend along a first and a second marginal area of the primary blank 5, and may be connected at first and second longitudinally extending fold lines 56. As shown in
According to an aspect of the present invention, a corner feature 60 is located at each end of the second side panel 20 and at each end of the fourth side panel 40 of the primary blank 5. Each corner feature 60 is defined at its periphery by opposed V-shaped lines of disruption 62 that connect spaced, parallel longitudinal lines of disruption 64. Transverse lines of disruption 66 extend from ends of the spaced longitudinal lines of disruption 64. The lines of disruption 64, 66 define a rectangular corner panel 70 between the side panels 20, 40 and their associated end flaps 22, 42. A triangular panel 74 is foldably connected at each end of the corner panel 70 at the transverse lines of disruption 66. Additional corner features 60 may be formed in the blank 8, such as at the ends at the side panels 10, 30.
According to another aspect of the present invention, the primary blank 5 includes a dispenser pattern 80. In the exemplary embodiment, the dispenser pattern 80 is formed in the second and third side panels 20, 30. The dispenser pattern 80 includes a breachable line 84 of disruption extending through the second and third side panels 20, 30 and defining a removable dispenser section 90. An aperture 94 can be formed in the second side panel 20 adjacent to the dispenser section 90. Handle features 98 can be formed in one or more of the side panels 10, 20, 30, 40.
According to yet another aspect of the present invention, each reinforcing blank 6 has a perimeter edge and/or footprint that may be wholly or in part complementary to the perimeter edge and/or footprint the primary blank 5. In one embodiment of the invention, as illustrated in
With continuing reference to
The lines of disruption 21, 31, 41, 51, 56, 62, 64, 66, 84, 121, 131, 141, 151, 156, 162, 164, 166 may be, for example, score lines, cut-space lines, cut-crease lines, cuts, overlapping and/or sequential combinations thereof, or other lines of disruption that facilitate folding, bending and/or erection of the multi-ply blank 8. In the illustrated exemplary embodiment, the lines of disruption 21, 31, 41, 51, 66, 121, 131, 141, 151, 166 are creases, the lines of disruption 56, 62, 64, 156, 162, 164 are cut-creases, and the breachable line of disruption 84 is a tear line. The cutout section struck from the primary blank 5 and forming the aperture 94 may alternatively be formed from a knockout section that is removed, for example, before or during erection of the blank 8.
According to one exemplary method of assembling the multi-ply blank 8, the reinforcing blanks 6 are placed over their respective locations at the first and second marginal areas of the primary blank 5 so that the reinforcing end flaps 112, 122, 132, 142 of the reinforcing blanks 6 overlie and generally conform in shape to corresponding end flaps 12, 22, 32, 42, respectively, of the primary blank 5. The edges of the reinforcing blanks 6 may also be aligned with the edges of the primary blank 5 at the marginal areas of the blank 5. The sequentially arranged reinforcing panels 110, 120, 130, 140, 150 of the reinforcing blanks 6 are aligned with respective panels 10, 20, 30, 40, 50 of the primary blank 5 so that the transverse fold lines 121, 131, 141, 151 of the reinforcing blanks 6 can be folded along with the transverse fold lines 21, 31, 41, 51, respectively, in the primary blank 5. The reinforcing blanks 6 are then glued, laminated, adhered or otherwise joined to the primary blank 5.
Referring to
Referring to
For exemplary purposes only, the carton can be formed from a blank into a substantially equal sided cube shape, such as if the blank is provided with dimensions including an overall example length of panels 10, 20, 30, 40, and 50 of at least approximately 24 19/32 inches with panel 50 having a length of at least approximately ⅝-inch, panels 10, 20, and 30 having lengths of at least approximately 6-inches, and panel 40 having a length of at least approximately 5 31/32 inch. The blank 5 can have an example width of at least approximately 12½ inch with at least approximately a 6-inch width between longitudinal fold lines 156, dispenser section 90 having a width of at least approximately 2.769-inch, and blanks 6 having widths of at least approximately 4¾ inch. The blanks can be formed of any caliper, including for example a caliper of 0.018. All dimensional information presented herein is intended to be illustrative of typical embodiments of the disclosure and is not intended to be limiting. Further, the various features of the blanks 5 and 6 and the carton formed therefrom can have dimensions other than listed herein, without departing from the scope of this disclosure.
According to the above embodiment, the reinforcing blanks 6 generally provide additional strength and rigidity to the carton 200. For example, when the carton 200 is supported on any of the side panels, the reinforcing blanks 6 provide significant strength against vertical axial compression of the carton. This feature allows the multiple cartons to be stacked in relatively high numbers. The corner features 60 provide additional strength and rigidity to the carton, particularly in compression.
The primary blank 5 can be selectively reinforced at any specified locations by one or more reinforcing blanks. Cartons formed from the resulting multi-ply blanks can accordingly have enhanced strength and rigidity at selected sections of the carton. Selected reinforcement of specific areas of a primary blank can produce high strength cartons while using relatively small amounts of reinforcing blank.
One or more of the reinforcing blanks discussed above may be omitted in the above embodiments, for example, if a lesser amount of reinforcement is sufficient for a particular application.
In accordance with the exemplary embodiments, the cartons may be constructed of paperboard, for example. The blanks, and thus the cartons, can also be constructed of other materials, such as cardboard, solid unbleached sulfate (SUS) board, or any other material having properties suitable for enabling the carton to function at least generally as described above.
The blanks can also be laminated to or coated with one or more additional sheet-like materials at selected panels or panel sections. One or more panels of the blanks discussed above can be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product, advertising, and other information or images. The blanks may also be coated to protect information printed on the blanks. The blanks may be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.
For purposes of the description presented herein, the term “line of disruption” or “line of weakening” can be used to generally refer to cuts, tear lines, creases, scores, and fold lines (or overlapping and/or sequential combinations of at least one cut, crease, score, tear line, or fold line). A “breachable line of disruption” is a line of disruption that is intended to be breached during ordinary use of the carton, such as when placing the carton in a dispensing configuration. An example of a breachable line of disruption is a tear line.
In accordance with the exemplary embodiments of the present invention, a fold line can be any substantially linear, although not necessarily straight, form of disruption or weakening in a blank that facilitates folding, pivoting or bending therealong.
In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections.
The above embodiments may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.
It will be understood by those skilled in the art that while the present invention has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention. For example, embodiments of the invention have been described as having several features included in combination, whereas each of these features may be included in a carton in isolation and in various combinations.
This application is a continuation of International Application No. PCT/US2008/071307, filed Jul. 28, 2008, entitled “Carton With Dispenser, Display Features and/or Corner Features,” which designates the United States of America and which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/962,244, filed Jul. 27, 2007.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2152079 | Mott | Mar 1939 | A |
| 2710134 | Schroeder et al. | Jun 1955 | A |
| 2755984 | Reifers | Jul 1956 | A |
| 3098599 | Hagan | Jul 1963 | A |
| 3186545 | Conrades | Jun 1965 | A |
| 4058250 | Akkerman | Nov 1977 | A |
| 4059220 | Lorenz | Nov 1977 | A |
| 4373929 | Smith | Feb 1983 | A |
| 4566593 | Muller | Jan 1986 | A |
| 4577799 | Oliff | Mar 1986 | A |
| 4946093 | Moorman | Aug 1990 | A |
| 5386937 | Crawford | Feb 1995 | A |
| 5447270 | McNown | Sep 1995 | A |
| 5505372 | Edson et al. | Apr 1996 | A |
| 6227367 | Harrelson et al. | May 2001 | B1 |
| 6968992 | Schuster | Nov 2005 | B2 |
| 6997316 | Sutherland | Feb 2006 | B2 |
| 7416109 | Sutherland | Aug 2008 | B2 |
| 7699215 | Spivey, Sr. | Apr 2010 | B2 |
| 7703666 | Hand et al. | Apr 2010 | B2 |
| 7762394 | Bradford et al. | Jul 2010 | B2 |
| 20020134698 | Rhodes et al. | Sep 2002 | A1 |
| 20040188508 | Holley et al. | Sep 2004 | A1 |
| 20060231604 | DeBusk et al. | Oct 2006 | A1 |
| 20060266815 | Coltri-Johnson et al. | Nov 2006 | A1 |
| 20070080199 | Sutherland | Apr 2007 | A1 |
| 20070131749 | Coltri-Johnson et al. | Jun 2007 | A1 |
| 20070267466 | Brand et al. | Nov 2007 | A1 |
| 20110011924 | Spivey, Sr. et al. | Jan 2011 | A1 |
| 20110030321 | Brand | Feb 2011 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20100140336 A1 | Jun 2010 | US |
| Number | Date | Country | |
|---|---|---|---|
| 60962244 | Jul 2007 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2008/071307 | Jul 2008 | US |
| Child | 12652249 | US |
