Patent Application
20070051781
This invention relates to cartons, and more particularly to a carton for multiple articles having a dispenser.
Consumers often purchase beverages in disposable cartons to facilitate transporting and dispensing the beverages in various locations, such as parks and campgrounds. It is most convenient for the user to have the ability to dispose of the primary and secondary packaging when the beverages have been consumed, to avoid the need to transport empty containers back home. However, to keep the beverages cold pending consumption, the consumer must typically bring a separate cooler to ice the beverages down. Regardless of whether such coolers are disposable (e.g., STYROFOAM) or reusable, they create an extra expense and inconveniently must be discarded or transported home. Cartons have been developed that serve as containers, carriers, and coolers, but such cartons are typically expensive to manufacture because superfluous sheet material is required to accommodate the ice, and linings are needed to prevent leakage as the ice melts.
Therefore, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies. What is needed is a carton that is inexpensive to manufacture and that can be configured to serve as a leak resistant cooler for containing ice in order to keep the articles contained within the carton cold.
The various embodiments of the present invention overcome the shortcomings of the prior art by providing a carton or other container that can be configured to enclose articles, such as beverage cans, and then to be opened and reconfigured to form a retaining structure for retaining additional material, such as ice, above or around the articles that are enclosed within the carton. The leak resistant carton is advantageously manufactured as a unitary structure, without requiring substantial expenditures for additional sheet material.
Generally described, the retaining structure is formed from a wall of the carton which is divisible into retaining panels hingedly connected to opposing vertically disposed walls of the carton so as to be foldably raised into an upright position along the hinged connections, as well as from end flaps or panels that are slidable with respect to other opposed and vertically disposed walls of the carton. Together, the retaining panels and the slidable end flaps approximate a chimney-like structure that effectively extends the height of the peripheral walls of the carton so that additional material can be poured or otherwise placed on top of the articles.
In the exemplary embodiments, the retaining structure is formed from the top wall of a carton. In this respect, the phrase “top wall” simply refers to the wall that faces substantially upward when the carton is opened and the retaining structure is loaded with additional material, and does not limit the carton to any particular orientation when the carton is used in any other manner, such as during carrying or storage. The side and end edges of the top wall are hingedly connected to the peripheral walls of the carton, which typically include a pair of opposed side walls and a pair of opposed end walls, all interconnected to wrap around a group of articles that rest on a bottom wall that is also hingedly connected to the peripheral walls. The bottom wall generally opposes the top wall, although it is contemplated that the top wall may be vaulted, slanted, curved, gabled, or otherwise contoured. The top wall is divisible preferably by means of a first severable seam extending from one end of the top wall to an opposite end, and by additional second and third severable seams extending along the hinged connection between the top wall and the end walls. The first seam, which in the exemplary embodiments is formed from parallel severance lines to approximate a tear strip, is broken to define the centermost edges of a pair of retaining panels. The exemplary second and third seams, each formed from a severance line extending along the hinged connection, are broken to define the end edges of the retaining panels as well as the uppermost edges of a pair of slidable end flaps.
Each end wall is a composite structure that includes a bottom end flap that is fixedly connected to the bottom and side walls of the carton and a top end flap. It is this top end flap that is slidable with respect to the bottom end flap, which remains fixedly connected as the remnant of the end wall after the carton is opened and the retaining structure is formed. Breaking the second, and third seams frees each of the slidable top end flaps from connection to the remainder of the carton except for a pair of connecting strips that foldably connects each slidable top end flap to an end of each of the side walls and optionally to the retention panels. These connecting strips facilitate a telescoping sliding motion upward of the slidable top end flap with respect to the fixed bottom end flap, in which the top end flap moves from a face contacting arrangement toward a coplanar, edge to edge arrangement with respect to the bottom end flap. In this configuration, the free downward extending edge of the slidable top end flap is moved into closer proximity to, but may continue to partially overlap, the distal upward extending edge of the bottom end flap.
As mentioned above, to form the retention structure, the top wall is opened to liberate or to create opposing retention panels. These retention panels form opposite sides of the chimney-like retaining structure. The periphery of the retaining structure is completed by raising the slidable top end flaps to form opposing ends of the retaining structure. The connecting strips support the slidable top end flaps in the upright position. However, according to another aspect of certain embodiments, further support may be provided by a locking tab that is defined by an arcuate or otherwise suitably contoured severance line formed in each top end flap, which locking tab comes into registry with a notch formed in the corresponding bottom end flap. The locking tab is matingly received in the notch to further reinforce the desired position of the slidable top end flap.
With the retention flaps and top end flaps raised, a material such as ice can be poured on top of the articles still within the carton, and can be heaped up above the level of the uppermost ends of the articles, and retained by the retaining structure. As the ice melts, web panels that join the bottom end flaps to adjacent side end flaps prevent the liquid from leaking from the bottom corners of the carton. A convenient, disposable, and inexpensive cooler is thereby achieved, the cooler having leak resistant bottom corners.
It is contemplated that the carton can be usable in a variety of other applications as well, including where the initial contents of the carton are frozen and the material disposed on top heats the contents to form a liquid or slushy consistency that is retained by the walls of the carton.
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 various aspects of 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 exemplary embodiments of a carton for enclosing and dispensing articles. The carton can be reconfigured to serve as a cooler for articles enclosed within the carton, such as beverage cans. Specifically, the carton includes panels that can be raised to extend the height of the walls of the carton after it is opened, so that ice or other material can be retained above and around the articles.
End flaps are hingedly connected to opposite ends of each primary panel along fold lines that are substantially parallel to the longitudinal axis of the blank 100. The end flaps at opposite ends of each primary panel are substantially identical and therefore like references have been used, with “a” or “b” affixed to distinguish one end of the carton 200 from the other. As will be described below, a first end closure structure is formed from end flaps that are hingedly connected to what is shown in
Similarly, end flaps are hingedly connected to what is shown in
Web panels 140a, 142a connect the bottom end flap 120a to the adjacent side end flaps 124a, 136a such that the erected carton 200 can hold at least a certain amount of liquid, as described in further detail below. Specifically, web panel 140a is hingedly connected to side end flap 136a along fold line 144a, and is hingedly connected to bottom end flap 120a along fold line 146a. Similarly, web panel 142a is hingedly connected to bottom end flap 120a along fold line 148a, and is hingedly connected to side end flap 124a along fold line 150a. In the embodiment shown, the web panels 140a, 142a are triangular, although any suitable shape may be utilized, with additional fold lines subdividing each of the web panels as needed.
The blank 100 further includes connecting strips 152a, 154a that facilitate a telescoping end wall feature, which will be described in more detail below. As will be described in detail below, the connecting strips 152a, 154a function to connect the top end flap 128a to the side panel 106 and to the handle panel 114, respectively. Each connecting strip 152a, 154a is formed in part from top end flap 128a and in part from top panel 110. More specifically, connecting strip 152a is defined by a fold line 162a in the top end flap 128a that is offset from the fold line 130a, a portion of a side edge 156a of top end flap 128a that extends between the outermost ends of fold lines 130a, 162a, a severance line 158a that is offset from the side edge 156a and extends between the innermost end of fold line 130a and the innermost end of fold line 162a, a segment of the fold line 108, and a severance line 160a that extends diagonally from the intersection of fold line 130a and severance 158a to or toward fold line 108. Connecting strip 154a is similarly defined by side edge 164a, severance lines 166a, 168a, and fold lines 112, 170a.
Each connecting strip 152a, 154a may include a number of fold lines Fi, Fd that facilitate forming a support structure or a gusset style arrangement to maintain the top end flap 128a in an elevated position and facilitate a sliding or telescoping feature of the top end flap 128a, as described in further detail below. In the exemplary embodiment, an intermediate fold line Fi is disposed between and parallel to fold lines 130a, 162a. Further, diagonal fold lines Fd extend between each of the fold lines 162a, 130a and the intermediate fold line Fd. In the exemplary embodiment, the diagonal fold lines Fd are substantially parallel to the severance line 160a. The pattern of fold lines Fi, Fd that is disposed on each of the other connecting strips is substantially similar.
As used herein, the phrase “frangible line” or “severance line” includes, but is not limited to, perforations, a line of perforations, a printed “cut here” line, a line of short slits, a line of half cuts, a single half cut, any combination of perforations, slits, and half cuts, short score lines, or the equivalent.
The top and bottom end flaps 128a, 120a include features that are secured together to detachably connect the top and bottom end flaps 128a, 120a when an end closure structure is formed, as described in further detail below. A severance line 172a is disposed in the top end flap 128a near severance line S and is shaped to define a yieldable pull tab 182a. A severance line 174a is formed near an outer edge 176a of bottom end flap 120a and is shaped to define a severable reinforcing tab 184a. The placement of the severance lines 172a, 174a is selected to bring the pull tab 182a and the reinforcing tab 184a into registry when an end closure structure of the carton 200 is formed.
A tear strip T is substantially centered on the top panel 110 and extends across the top panel 110 between the top end flap 128a and the top end flap 128b. The tear strip T is defined by two substantially parallel severance lines 178, 180. In certain embodiments, a pull tab (not shown) may be disposed at one end of the tear strip T as a means for tear initiation. In other embodiments, one or both ends of the tear strip may be defined by a segment of the severance line S that extends between the severance lines 178, 180. In addition, in certain embodiments the severance lines 160a, 168a, and the severance line S extending therebetween, form a substantially continuous severance line that extends between the fold lines 108, 112. In other embodiments, the otherwise continuous severance line may be interrupted by one or more frangible connections between the adjacent sections of the blank. The tear strip T and the severance lines S, 160a, 168a define separable portions of the top panel 110, as described in further detail below. It should be understood that, in alternative embodiments, the tear strip T may be replaced by a single severance line, a cut line, or any other suitable means for controllably separating portions of the top panel 110 along an edge.
It is envisaged that, in any embodiment of the present invention, the carton can be formed from a blank by a series of sequential folding and gluing operations, which can be performed by a straight-line automatic packaging machine so that the carton is not required to be rotated or inverted to complete its construction. It is also envisaged that the series of sequential folding and gluing operations can be manually performed. The folding process is not limited to that described below and can be altered according to particular manufacturing or user requirements.
According to an exemplary method, the carton 200 can be partially constructed and preglued or otherwise secured as a tubular structure which may be collapsed for shipping or for loading into an automatic packaging machine. To do so, the side panel 116 is folded inwardly along fold line 118 such that the inside surface of the side panel 116 is in a face contacting arrangement with the inside surface of bottom panel 102. Glue, or other means for securing sheet material, is applied to the outside surface of the side panel 116 and to the outside surface of each of the side end flaps 136a, 136b such that, as the blank 100 is folded inwardly along fold line 108, the inside surface of handle panel 114 is brought into an at least partially overlapping face contacting arrangement with the outside surface of the side panel 116. Thereby, the side panel 116 and the handle panel 114 are secured to one another to form a composite side panel 114/116. Additionally, the inside surfaces of side end flaps 132a, 132b are also brought into an at least partially overlapping face contacting arrangement with the outside surfaces of side end flaps 136a, 136b, thereby forming composite side end flaps 132a/136a, 132b/136b. The sheet material of the blank 100 can be secured together by any known or yet to be developed means for securing sheet material including, but not limited to, glue or other adhesives, staples, tape, mechanical fasteners, Velcro®, and the like.
The partially erected carton 200 is now in a flattened tubular configuration suitable for storage, shipping, and loading either manually or by means of an automatic packaging machine (not shown). To erect the flattened carton into a tubular structure having walls defined by the primary panels, the primary panels are pulled apart. Accordingly, referring to
As best shown in
After the articles are grouped and loaded through either or both of the open ends of the carton 200 as it is arranged as a tubular structure, the end flaps are folded and secured together to form end closure structures at each open end of tubular structure and thereby define the end walls 204, 208. For clarity, the formation of only one of the end closure structures is described.
Referring to
It should be noted that the web panels 140a, 142a provide that the corners of the carton adjacent the bottom wall 202 of the carton are continuous or seamless such that the carton can retain a certain level of liquid. In other words, liquid is not allowed to escape between an end wall 204, 208 and an adjacent side wall 206, 214 at or near the bottom wall 202 of the carton 200.
An exemplary method for opening the carton and forming the retaining structure R of the carton 200 is now described. With reference to
The retaining structure R is further erected by pulling the top end flaps 128a, 128b such that they telescope upward with respect to the respective end wall 202, 208. To do so, composite tab 182b/184b is pressed inward (or outward) to break severance lines 174b and 172b, which are in registry. By doing so, reinforcing tab 184b, which is secured to pull tab 182b, is completely detached from bottom end flap 120b and pull tab 182b is partially detached from top end flap 128b. Then the pull tab 182b is pulled upward to break the severance lines 158b, 166b while urging the top end flap 128b to slidingly telescope upward with respect to the end wall 208 (shown in
Referring to
For example, in the embodiment shown, a locking tab 185a, 185b is defined by a severance line 190a, 190b (shown in
As another example, the retention panels 602, 604 and the top end flaps 128a, 128b can be interlocked to fortify the retaining structure R. It is contemplated that the side edges of each of these panels may be contoured to form complementary tabs and notches that matingly interlock to fix the position of each flap 602, 604, 128a, 128 relative to its neighboring flaps.
With retention panels 602, 604 and the top end flaps 128a, 128b disposed in a generally upright condition or otherwise extending to form a chimney-like retaining structure, the carton 200 can function as a disposable cooler, ice bucket, or ice pail in that the carton 200 is configured to receive, for example, ice or a similar coolant, which may be poured over the articles B. The retention panels 602, 604 and the top end flaps 128a, 128b function as retaining walls to keep the ice in the container or to otherwise increase the volumetric capacity of the carton 200. As previously described, as the ice melts, the web panels 140a, 140b, 142a, 142b disposed at the bottom four corners of the carton 200 create a barrier to prevent the water from flowing out through the corners. Further, in certain embodiments, the carton includes other means that increase the ability of the carton to withstand water soaking through the walls of the carton or that otherwise includes features that preserve the structural integrity of the walls. For example, inside surface of the blank for forming the carton may be treated with a water resistant coating. In other embodiments, the carton may include a film or liner for at least the interior of the carton. A film or liner can also provide or enhance the water retaining functionality that is described above with respect to the web panels.
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. For example, as used herein, directional references such as “top”, “base”, “bottom”, “end”, “side”, “inner”, “outer”, “upper”, “middle”, “lower”, “front” and “rear” do not limit the respective walls of the carton to such orientation, but merely serve to distinguish these walls from one another. Any reference to hinged connection should not be construed as necessarily referring to a junction including a single hinge only; indeed, it is envisaged that hinged connection can be formed from one or more potentially disparate means for hingedly connecting materials.
Those skilled in the art will also appreciate that the carton described represents only one example of the various sizes, shapes, types and carton configurations that will be suitable for implementation of the various embodiments of the invention, which is primarily directed to the end wall structure and opening feature that yields retaining walls for holding ice in contact with the articles within the carton.
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. Provisional Application No. 60/714,430, filed Sep. 6, 2005, the entirety of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60714430 | Sep 2005 | US |
