U.S. Provisional Patent Application No. 61/275,403, which was filed on Aug. 28, 2009, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
The present disclosure generally relates to cartons for holding and dispensing beverage containers or other types of articles. More specifically, the present disclosure relates to cartons having a reinforcing insert.
In general, one aspect of the disclosure is directed to a carton for holding a plurality of containers. The carton comprises a plurality of panels that extends at least partially around an interior of the carton. The plurality of panels comprises a top panel, a bottom panel, a first side panel, and a second side panel. At least two end flaps are respectively foldably attached to respective panels of the plurality of panels. The end flaps are overlapped with respect to one another and thereby at least partially form a closed end of the carton. A reinforcing insert comprises a central panel at least partially in face-to-face contact with the top panel, at least one reinforcing end flap at least partially in face-to-face contact with at least one of the at least two end flaps, and at least one reinforcing side flap foldably connected to the central panel. The carton comprises a dispenser for allowing access to the articles in the carton. The dispenser comprises at least a portion of the top panel and at least a portion of the central panel.
In another aspect, the disclosure is generally directed to the combination of a carton blank and a reinforcing insert for forming a carton for holding a plurality of containers. The carton blank comprises a plurality of panels comprising a top panel, a bottom panel, a first side panel, and a second side panel. At least two end flaps are respectively foldably attached to respective panels of the plurality of panels for overlapping to at least partially close an end of a carton formed from the carton blank. The reinforcing insert comprises a central panel at least partially in face-to-face contact with the top panel, at least one reinforcing end flap at least partially in face-to-face contact with at least one of the at least two end flaps, and at least one reinforcing side flap foldably connected to the central panel. Dispenser features comprise at least a portion of the top panel and at least a portion of the central panel.
In another aspect, the disclosure is generally directed to a method of forming a carton. The method comprises obtaining a carton blank comprising a plurality of panels comprising a top panel, a bottom panel, a first side panel, and a second side panel, at least two end flaps respectively foldably attached to respective panels of the plurality of panels. Dispenser features comprises at least a portion of the top panel. The method further comprises obtaining an insert blank comprising a central panel, at least one reinforcing end flap, and at least one reinforcing side flap foldably connected to the central panel. The dispenser features comprise at least a portion of the central panel. The method further comprises positioning the insert blank relative to the carton blank so that the central panel overlaps at least a portion of the top panel and the reinforcing end flap overlaps at least a portion of at least one flap of the at least two end flaps, and forming an interior of the carton at least partially defined by the plurality of panels. The forming the interior of the carton comprises forming an open-ended sleeve. The method further comprises positioning the at least two end flaps and the at least one reinforcing end flap to at least partially close an end of the open-ended sleeve.
In another aspect, the disclosure is generally directed to carton for holding a plurality of containers. The carton comprises a plurality of panels that extends at least partially around an interior of the carton. The plurality of panels comprises a top panel, a bottom panel, a first side panel, and a second side panel. At least two end flaps are respectively foldably attached to respective panels of the plurality of panels. The end flaps are overlapped with respect to one another to thereby at least partially form a closed end of the carton. The end flaps comprise at least a top end flap and at least one side end flap. The carton further comprises a reinforcing insert comprising a reinforcing end flap at least partially in face-to-face contact with an exterior surface of the at least one side end flap and at least partially in face-to-face contact with an interior surface of the top end flap.
Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.
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 disclosure.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
The present disclosure generally relates to cartons that contain articles such as containers, bottles, cans, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, aluminum and/or other metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof.
Cartons according to the present disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes beverage containers (e.g., glass beverage bottles) as disposed within the carton embodiments. In this specification, the terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected and upright cartons.
The carton blank 5 has a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiment, the blank 5 comprises a top panel 10 foldably connected to a first side panel 20 at a first lateral fold line 21. A bottom panel 30 is foldably connected to the first side panel 20 at a second lateral fold line 31. A second side panel 40 is foldably connected to the bottom panel 30 at a third lateral fold line 41. In the illustrated embodiment, the blank 5 includes an adhesive flap 50 foldably connected to the top panel 10 at a fourth lateral fold line 51.
The top panel 10 is foldably connected along fold line 18 to a first top end flap 12 and along fold line 16 to a second top end flap 14. The first side panel 20 is foldably connected along fold line 28 to a first side end flap 22 and along fold line 26 to a second side end flap 24. The bottom panel 30 is foldably connected along fold line 38 to a first bottom end flap 32 and along fold line 36 to a second bottom end flap 34. The second side panel 40 is foldably connected along fold line 48 to a first side end flap 42 and along fold line 46 to a second side end flap 44. When the carton 600 is erected, the top and bottom end flaps 12 and 32 and side end flaps 22 and 42 close a first end 52 of the carton (
The top and bottom end flaps 12 and 32 and side end flaps 22 and 42 extend along a first marginal area 8 of the blank 5, and are foldably connected along a first longitudinal fold line 68 that extends along the length of the blank and includes fold line segments 18, 28, 38, 48. The top and bottom end flaps 14 and 34 and side end flaps 24 and 44 extend along a second marginal area 6 of the blank 5, and are foldably connected along a second longitudinal fold line 66 that also extends along the length of the blank and includes fold line segments 16, 26, 36, 46. The fold line segments 16, 18, 26, 28, 36, 38, 46, 48, or the longitudinal fold lines 66, 68, may be, for example, substantially straight, or offset at one or more locations to account for blank thickness or for other factors. The end flaps 22, 24, 42, 44 also can include upper flaps 25, 45, 125, 145 defined respectively by cuts 23, 43, 123, 143 and fold lines 27, 47, 127, 147. The upper flaps 24, 45, 125, 145 can fold into the interior of the carton 600 to help secure the containers C therewithin.
As shown in
The outer dispenser 70 can include an outer access panel or finger panel 80 in the top panel 10 separable from the carton at an oval-shaped tear line 79, for example. As shown in
As shown in
As shown in
The features that form handle 115 include an elongate handle flap 113 formed in the top end flap 14 and foldably attached to the top end flap at a handle fold line 111 and separable from the top end flap 14 at a tear line 119. Alternatively, tear line 119 can be a series of cut lines. In the illustrated embodiment, the features of handle 115 include two oblique fold lines 107, 109 extending from the fold line 111 and a longitudinal fold line 117 for allowing deformation of the handle flap 113 when activating the handle 115. The features of the handle 115 include respective curved cutouts 129, 149 below the upper portions in the side end flaps 24, 44 that allow the elongate handle flap 113 to fold inwardly when the handle is activated to form a handle opening in the carton. The elongate handle flap 113 can be shaped and positioned in the blank 5 so that the handle 115 is activated by pressing on the handle flap and folding the handle flap inwardly into the curved cutouts 129, 149 to form a handle opening in the carton 600. The opening is shaped for insertion of a user's fingers during grasping of the carton 600. The handle 115 may be otherwise shaped and located in the carton 600 without departing from the scope of this disclosure. Handles 15 and 115 could have different features from one another without departing from the disclosure. Further, either handle 15 or 115 can be omitted without departing from the disclosure.
As shown in
As shown in
The features of handle 315 includes an elongate handle flap 313 formed in reinforcing end flap 214 and foldably attached to the reinforcing end flap at a handle fold line 311 and separable from the reinforcing end flap 214 at a tear line 319. Alternatively, tear line 319 can be a series of cut lines. In the illustrated embodiment, the features of handle 315 include two oblique fold lines 307, 309 extending from the fold line 311 and a longitudinal fold line 317 for allowing deformation of the handle flap 313 when activating the handle 315. When the insert 200 is positioned onto blank 5, the elongate handle flap 313 is shaped and positioned so that the handle 315 is activated by pressing on the handle flap and folding the handle flap inwardly into the curved cutouts 29, 49 or 129, 149 to form the handle opening at one end in the carton 600. In one embodiment, the handle flap 313 is generally aligned with the handle flap 113 of the top end flap 14 when the carton 600 is erected and closed, and pressing on handle flap 113 activates handle flap 313.
The opening formed by handles 215 and 315 are shaped for insertion of a user's fingers during grasping of the carton 600. The handles 215 and 315 may be otherwise shaped and located in the carton 600 without departing from the scope of this disclosure. For example, the handle flaps 213, 313 can be omitted and handles 215, 315 can be handle openings. Handles 215 and 315 could have different features from one another without departing from the disclosure. Further, either handles 215 and 315 can be omitted without departing from the disclosure.
In the illustrated embodiment, the inner dispenser 270 is formed in the central panel 210 and in side flaps 250, 260 and generally corresponds to the outer dispenser 70 of blank 5. The inner dispenser 270 includes a first inner dispenser panel 282 and a second inner dispenser panel 284. The first dispenser panel 282 is separable from the carton 600 along an inner tear line 289 to further form the dispenser opening 500 (
The central panel 210 can include an inner access panel or finger panel 280 at the center of the central panel 210. The inner finger panel 280 generally corresponds to outer finger panel 80 in carton blank 5. A tear line 279 is provided in central panel 210 that generally corresponds with the tear line 79 of the top panel 10. The center panel 210 also includes remainder portions 286 and 288 that extend between dispenser 270 and fold lines 295 and 293, respectively. The features of the insert blank 200 could be otherwise shaped and arranged without departing from this disclosure.
As shown in
The tear line segments 275 of the inner tear line 289 extend beyond where the tear line segments 75, 175 intersect with the tear line segments 73, 173 of the outer tear line 89, under the upper remainder portions 86, 88 (
In accordance with the exemplary embodiment, the carton blank 5 with insert blank 200 adhered thereto can be erected into carton 600 by folding along fold lines 21, 31, 41, and 51 and adhering the adhesive flap 50 to the second side panel 40 to form a sleeve 300 (
As shown in
As shown in
In the illustrated embodiment, the first end 52 has similar features as the second end 53 and can be closed in substantially the same manner as the second end 53. The closed first end 52 is shown in
Inside the erected and closed carton 600, the tent structure, including the angled corners formed between the top panel 10 and the side panels 40, 20 by the reinforcing side flaps 250, 260 and the angled corners formed between the top panel 10 and the ends 52, 53 by the reinforcing end flaps 212, 214, defines interior corners that are chamfered or angled rather than square. This, in turn, helps to hold the bottles in place and prevents them from jostling around excessively.
The top end flaps 12, 14, the upper portions of side end flaps 24 and 44, and the reinforcing end flaps 212, 214 provide three layers of material above each handle 15, 115 with the reinforcing end flaps 212, 214 in face-to-face contact with an interior surface of the respective top end flaps 12, 14, and in face-to-face contact with an exterior surface of the side end flaps 22, 42 and side end flaps 24, 44.
Once the blank 5 is formed into the sleeve 300, the containers C may be loaded in the carton 600 from the first end 52 and then the first end 52 may be closed by overlapping and gluing the side end flaps 42, 44 and top and bottom end flaps 14, 34, and then the second end 53 may be closed by overlapping and gluing the side end flaps 22, 42 and top and bottom end flaps 12, 32. The assembled carton 600 is shown in
The handle 15 can be used to grasp the carton 600 by pressing against the elongate handle flap 13, which contacts the aligned handle flap 213 to pivot the handle flaps 13, 213 inwardly to create a handle opening in the closed first end 52 of the carton 600. Similarly, the handle 115 can be used to grasp the carton 600 at the closed second end 53. The reinforcing end flaps 212, 214 of the reinforcing insert provide an extra layer of material above each handle 15, 115 to reinforce the carton 600 by increasing the strength and rigidity of the carton to prevent tearing or other failure when the carton is lifted at the handles. It is understood that the carton 600 may have one handle or no handles or that the handles 15, 115 can be otherwise shaped, arranged, and/or located without departing from the disclosure. When the carton 600 is closed and the handle 15 or 115 is activated for grasping of the carton, the handle flap 13, 113 can be folded inward along fold line 11, 111 to pivot the respective handle flaps 213, 313 inwardly to be in opposing face-to-face relation with the interior surface of the upper portions of the respective side end flaps 22, 42 or 24, 44. Other opening arrangements for the handles 15, 115 can be provided without departing from the scope of this disclosure.
As shown in
In the illustrated embodiment, the dispenser 7 can be closed by downwardly folding the first dispenser panels 82, 282 adjacent the retention tabs 501, 502 in a downwardly folded position. Further, retaining portions 285 of the inner dispenser panels 282, 284 are generally wider than the outer dispenser panels 82, 84 where the tear line segments 275 extend under the outer remainder portions 86, 88. The retaining portions 285 can interfere with the outer remainder portions 86, 88 to retain the dispenser panels in a closed position. The dispenser 7 thus resists reopening. Other closing arrangements and retention mechanisms for the dispenser 7 can be provided without departing from the scope of this disclosure.
As shown in
Handle 515 includes an elongate handle flap 513 formed in the reinforcing end flap 414 and foldably attached to the reinforcing end flap at a handle fold line 511 and separable from the reinforcing end flap 414 at a tear line 519. Alternatively, tear line 519 can be a series of cut lines. In the illustrated embodiment, the features of handle 515 include two oblique fold lines 507, 509 extending from the fold line 511 and a longitudinal fold line 517 for allowing deformation of the handle flap 513 when activating the handle 515. When the insert 400 is positioned onto blank 5, the elongate handle flap 513 is shaped and positioned so that the handle 515 is activated by pressing on the handle flap and folding the handle flap inwardly into the curved cutouts 29, 49 or 129, 149 to form the handle opening at one end in the carton 600.
The opening formed by handles 415 and 515 are shaped for insertion of a user's fingers during grasping of the carton 600. The handles 415 and 515 may be otherwise shaped and located in the carton 600 without departing from the scope of this disclosure. Handles 415 and 515 could have different features from one another without departing from the disclosure. Further, either handles 415 and 515 can be omitted without departing from the disclosure.
The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.
In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.
As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.
The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.
The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments that are within the scope of the claims. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 61/275,403, filed Aug. 28, 2009.
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Number | Date | Country | |
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61275403 | Aug 2009 | US |