The disclosure of U.S. Provisional Patent Application No. 61/455,181, which was filed on Oct. 15, 2010, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
The present disclosure generally relates to cartons for holding beverage containers or other types of articles. More specifically, the present disclosure relates to cartons having a reinforced top panel.
In general, one aspect of the disclosure is generally directed to a carton for holding a plurality of containers. The carton comprises a plurality of panels extending at least partially around an interior of the carton, the plurality of panels comprising a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, and a reinforcement panel foldably connected to the second side panel. The top panel can at least partially overlap the reinforcement panel. A reinforcement side flap can be foldably connected to the reinforcement panel, and an inner top reinforcement flap can be foldably connected to the reinforcement panel. The reinforcement panel can at least partially overlap the inner top reinforcement flap.
In another aspect, the disclosure is generally directed to a blank for forming a carton. The blank can comprise a plurality of panels comprising a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, and a reinforcement panel foldably connected to the second side panel. The top panel can at least partially overlap the reinforcement panel in the carton formed from the blank. A reinforcement side flap can be foldably connected to the reinforcement panel, and an inner top reinforcement flap can be foldably connected to the reinforcement panel. The reinforcement panel can at least partially overlap the inner top reinforcement flap when the carton is formed from the blank.
In another aspect, the disclosure is generally directed to a method of forming a carton. The method can comprise obtaining a blank comprising a plurality of panels comprising a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, and a reinforcement panel foldably connected to the second side panel. A reinforcement side flap can be foldably connected to the reinforcement panel, and an inner top reinforcement flap can be foldably connected to the reinforcement panel. The method further comprises positioning the inner top reinforcement flap so that the reinforcement panel at least partially overlaps the inner top reinforcement flap, positioning the reinforcement panel relative to the top panel so that the top panel at least partially overlaps the reinforcement panel, and forming an interior of the carton at least partially defined by the plurality of panels. The forming the interior of the carton comprising forming an open-ended sleeve.
Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims.
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. Further, 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 opening, dispensing, and handling features for 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, glass; aluminum and/or other metals; 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 blank 3 has a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiment, the blank 3 comprises a bottom panel 15 foldably connected to a first side panel 17 at a first lateral fold line 19, a top panel 23 foldably connected to the first side panel 17 at a second lateral fold line 25, and a second side panel 29 foldably connected to the bottom panel 15 at a third lateral fold line 31. A reinforcement panel 35 is foldably connected to the second side panel 29 at a fourth lateral fold line 37.
The bottom panel 15 is foldably connected to a first bottom end flap 43 and a second bottom end flap 45. The first side panel 17 is foldably connected to a first side end flap 47 and a second side end flap 49. The top panel 23 is foldably connected to a first top end flap 53 and a second top end flap 55. The second side panel 29 is foldably connected to a first side end flap 57 and a second side end flap 59. The reinforcement panel 35 is foldably connected to a first reinforcement end flap 63 and a second reinforcement end flap 65. When the carton 5 is erected, the end flaps 43, 47, 53, 57, 63 close a first end 72 of the carton, and the end flaps 45, 49, 55, 59, 65 close a second end 74 of the carton. In accordance with an alternative embodiment of the present disclosure, different flap arrangements can be used for closing the ends of the carton 5.
The end flaps 43, 47, 53, 57 extend along a first marginal area of the blank 1, and are foldably connected at a first longitudinal fold line 67 that extends along the length of the blank. The end flaps 45, 49, 55, 59 extend along a second marginal area of the blank 1, and are foldably connected at a second longitudinal fold line 69 that also extends along the length of the blank. The longitudinal fold lines 67, 69 may be, for example, substantially straight, or offset at one or more locations to account for blank thickness or for other factors. In the illustrated embodiment, the reinforcement end flaps 63, 65 are foldably connected to the reinforcement panel 35 at respective longitudinal fold lines 73, 75. In the illustrated embodiment, the fold lines 73, 75 comprise a plurality of spaced-apart longitudinal cut lines that create a plurality of distinct and spaced-apart areas of weakening that are wider than the longitudinal fold lines 67, 69, which can be single crease lines, for example. Alternatively, the fold lines 73, 75 could be a single crease line or other form of weakening without departing from the disclosure.
In the illustrated embodiment, the blank 3 includes two diamond-shaped corners, generally indicated at 81, at the first end 72 of the carton 5 and two diamond-shaped corners 83 at the second end 74 of the carton. The corners 81, 83 allow respective side panels 17, 29 and side end flaps 47, 57, 49, 59 to angle inwardly toward the interior of the carton 5. Each of the side end flaps 47, 49, 57, 59 can include a lower portion 85a, which can extend generally perpendicularly from the bottom panel 15 in the carton 5 (
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In the illustrated embodiment, a reinforcement side flap 127 can be foldably connected to the reinforcement panel 35 at a lateral fold line 39. The length of the reinforcement panel 35 between the longitudinal fold lines 67, 69 is generally similar to the length (D4) of the top panel 23 so that the longitudinal fold lines 67, 69 in the top panel 23 generally overlap the fold lines 73, 75 in the reinforcement panel 35 when the carton 5 is erected from the blank. The width (D1) of the reinforcement panel 35 between lateral fold lines 37 and 39 is generally smaller than the width (D2) of the top panel 23 between the lateral fold line 25 and the laterally-extending free edge 27 of the top panel 23 in the illustrated embodiment. In the assembled carton 5, the reinforcement side flap 127 can extend from the top panel 23 to the side panel 17 at an angle to provide a third taper in the interior of the carton 5 proximate the top panel 23 in addition to the tapered portions of the closed ends 72, 74. The reinforcement panel 35, the reinforcement end flaps 63, 65, the inner top reinforcement flaps 111, 113, and the reinforcing side flap 119 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.
An optional dispenser (not shown) can be included with one or more dispenser panels removably attached to the blank 3 at one or more tear lines extending in any of the panels or end flaps.
In accordance with the exemplary embodiment, the blank 3 can be erected into the carton 5 by folding the inner top reinforcement flaps 111, 113 along the respective longitudinal fold lines 67, 69 so that the inner top reinforcement flaps are in face-to-face contact with the inner surface of the reinforcement panel 35 and the handle cutouts 115 are generally aligned with the openings 105 (
When the top panel 23 overlaps the reinforcement panel 35, reinforcement end flaps 63, 65 are placed into face-to-face contact with a respective top end flap 53, 55. In the illustrated embodiment, the reinforcement end flaps 63, 65 are free to fold independently of the top end flaps 53, 55. In an alternative embodiment, the reinforcement end flaps 63, 65 and the respective top end flaps 53, 55 can be adhesively secured by an adhesive or they can be secured by other attachment mechanisms.
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In the illustrated embodiment, the first end 72 of the carton 5 is closed by respectively overlapping and adhering the end flaps 43, 47, 53, 57, 63 (
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The second end 74 of the carton 5 can be closed similarly to the first end 72 by respectively overlapping the end flaps 45, 49, 55, 59, 65 (
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In the illustrated embodiment, the tapered portion 132 of the first end 72, including the upper portions 85b of the side end flaps 47, 57, the top end flap 53, and the reinforcement end flap 63, angles inwardly from the lower portion of the first end 72 to the top panel 23 and the reinforcement panel 35 at the oblique segments 80, 84 of the longitudinal fold line 67. Similarly, the tapered portion 134 of the second end 74, including the upper portions 85b of the side end flaps 49, 59, the top end flap 55, and the reinforcement end flap 65, angles inwardly from the lower portion of the first end 74 to the top panel 23 and the reinforcement panel 35 at the oblique segments 82, 86 of the longitudinal fold line 69. The tapered portions 132, 134 of the first and second ends 72, 74 each contacts, or is closely adjacent, the upper portions N of the containers C in the rows respectively adjacent the first and second ends 72, 74. In addition, the diamond-shaped corners 81, 83 of the carton 5 can help allow the tapered portions 132, 134 of the ends 72, 74 to be angled inwardly so that the carton 5 is more narrow at the top than at the bottom at each end 72, 74. Accordingly, at least the tapered portions 132, 134 of the ends 72, 74 and the reinforcement side flap 127 form a narrowed upper interior portion 136 that helps restrain the upper portions N of the containers C above a wider lower interior portion 138 that helps restrain the bottom portions BP of the containers in the interior 130 of the carton 5.
The narrowing of the length of the carton 5 from the bottom to the top at the ends 72, 74 provides two points of contact of the ends with the containers to hold both the top portions N and the bottom portions BP of the containers C in a relatively fixed position to restrict movement of the containers in the carton. Accordingly, the carton 5 of the illustrated embodiment is tapered on two sides externally. Internally, the reinforcement side flap 127 provides a third side to the taper proximate the corner formed at the lateral fold line 25 connecting the top panel 23 to the first side panel 17. Accordingly, the carton 5 effectively is tapered on three sides internally.
Alternatively, the carton 5 of the present disclosure could be a three- or four-sided taper carton where the bottom panel 15 is both longer and wider in the directions L1, L2 than the top panel 23. A three-sided taper carton, for example, can have ends 72, 74 angling inwardly as described above and the upper portion of the second side panel 29 could be angled inwardly. Accordingly, the second side panel 29, the reinforcement side flap 127, and the closed ends 72, 74 would cooperate to form the upper interior portion 136 of the carton, and effectively provide a four-sided taper carton in the interior 130 of the carton 5.
An externally four-sided taper carton would have at least the upper portions of the ends 72, 74 and side panels 17, 29 angling inwardly to help restrain the upper portions N of the containers C. The reinforcement side flap 127 can cooperate with the angled side panels 17, 29 to further narrow the top of the interior of the carton 5. Alternatively, the reinforcement side flap 127 can be in face-to-face contact with the angled side panel 17, or the reinforcement side flap 127 could be omitted. Further, the carton 5 could alternatively be without any sides or ends that taper and all four of the ends 72, 74 and side panels 17, 29 could be substantially perpendicular to the bottom panel 15 without departing from the scope of the disclosure.
In a further alternative, the reinforcement panel 35 can include a second reinforcement side flap (not shown) foldably connected to the reinforcement panel at a lateral fold line proximate the second side panel 29. The second reinforcement side flap can extend at an angle from the reinforcement panel to abut the second side panel 29 similarly to the first reinforcement side flap 127 in relation to the first side panel 17. The second reinforcement side flap can be combined with variations of the carton 5 including where one or more of the side panels 17, 29 and closed ends 72, 74 taper inwardly, or where all of the sides and the ends are substantially perpendicular to the bottom panel 15.
In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blank may then be coated with a varnish to protect information printed on the blanks. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
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.
In accordance with the exemplary embodiments, 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 or depressed 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. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.
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 exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and 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. 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. 61/455,181, filed Oct. 15, 2010.
Number | Date | Country | |
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61455181 | Oct 2010 | US |