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 containing a plurality of articles. The carton comprises a plurality of panels that extend at least partially around an interior of the carton. The plurality of panels comprise a top panel, a first side panel, a second side panel, and a bottom panel. The carton also comprises a reinforcing insert comprising at least a first insert panel foldably connected to a second insert panel. The first insert panel is at least partially in face-to-face contact with at least the top panel and the second insert panel is at least partially in face-to-face contact with the first insert panel.
In general, another aspect of the disclosure is directed to the combination of a carton blank and an insert blank for forming a carton having reinforced features. The carton blank comprises a plurality of panels comprising a top panel, a first side panel, a second side panel, and a bottom panel. The insert blank comprises at least a first insert panel foldably connected to a second insert panel. The first insert panel is at least partially in face-to-face contact with at least the top panel and the second insert panel is at least partially in face-to-face contact with the first insert panel.
In general, another aspect of the disclosure is 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 first side panel, a second side panel, and a bottom panel. The method further comprises obtaining an insert blank comprising at least a first insert panel foldably connected to a second insert panel. The method further comprises positioning the first insert panel to be at least partially in face-to-face contact with at least the top panel, and positioning the second insert panel to be at least partially in face-to-face contact with at least the first insert panel.
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 103 has a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiment, the blank 103 comprises a top panel 110 foldably connected to a first side panel 120 at a first lateral fold line 121. A bottom panel 130 is foldably connected to the first side panel 120 at a second lateral fold line 131. A second side panel 140 is foldably connected to the top panel 110 at a third lateral fold line 141. In the illustrated embodiment, the blank 103 includes an adhesive flap 150 foldably connected to the bottom panel 130 at a fourth lateral fold line 152. The carton blank 103 may be otherwise configured to have multiple top panels and/or multiple bottom panels without departing from the scope of this disclosure.
In the illustrated embodiment, the top panel 110 is foldably connected to a first top end flap 112 and a second top end flap 114. The first side panel 120 is foldably connected to a first side flap 122 and a second side flap 124. The bottom panel 130 is foldably connected to a first bottom end flap 132 and a second bottom end flap 134. The second side panel 140 is foldably connected to a first side flap 142 and a second side flap 144. When the carton 105 is erected, the top and bottom end flaps 112 and 132 and side end flaps 122 and 142 close a first end 151 (
In one embodiment, the top and bottom end flaps 112 and 132 and side end flaps 122 and 142 extend along a first marginal area of the blank 103, and are foldably connected at a first longitudinal fold line 162 that extends along the length of the blank. The top and bottom end flaps 114 and 134 and side end flaps 124 and 144 extend along a second marginal area of the blank 103, and are foldably connected at a second longitudinal fold line 164 that also extends along the length of the blank. The longitudinal fold lines 162, 164 may be, for example, substantially straight, or offset at one or more locations to account for blank thickness, container shape, or for other factors.
In the illustrated embodiment, the longitudinal fold lines 162, 164 are angled to account for the bottom panel 130, which is larger than the top panel 110. Further, a fold line 125 extending across the first side panel 120 and the side end flaps 122, 124, and a fold line 145 extending across the second side panel 140 and the side end flaps 142, 144, provide creases to allow the side panels 120, 140 to taper inward towards the smaller top panel 110. Thus, the carton 105 follows the contours of containers C, such as long neck bottles. In accordance with an alternative embodiment of the present disclosure, tapers may be otherwise arranged or omitted without departing from the scope of this disclosure (e.g., the carton may be a four-crease carton with two tapered sides as opposed to a six-crease carton with four tapered sides).
As shown in
The first panel 206 comprises a pair of handle openings 270a, 272a and the second panel 208 comprises a pair of handle openings 270b, 272b. The handle openings 270a, 270b, 272a, 272b provide space for the handle flaps 170, 172 to be pushed into the carton 105 when the reinforced insert 205 is attached to the carton. A pair of hand guards 278 can be foldably attached to the first panel 206 at fold lines 271. A handle strip 276a is formed between the handle openings 270a, 272a, and a handle strip 276b is formed between the handle openings 270b, 272b. The handle openings and the other features of the insert blank 203 could be otherwise shaped and arranged without departing from this disclosure. Particularly, handle flaps may be foldably attached to the first panel 206 and/or the second panel 208 within one or more of the openings 270a, 272a, 270b, 272b to further cushion a user's hands when grasping the handle 111.
As shown in
As shown in
As illustrated in the figures, the first panel 206 and the second panel 208 of the insert blank 203 are shorter than the top panel 110 of the carton blank 103 in the lateral (L2) direction so that the longitudinal edges 209, 211 of the reinforcing insert 205 are spaced apart from the longitudinal fold lines 162, 164. In an alternative embodiment, at least one of the longitudinal edges 209, 211 of the reinforcing insert 205 can generally line up with the longitudinal fold lines 162 or 164. Also, the reinforcing insert 205 can overlap one or more of the end flaps 112, 114, 122, 124, 142, 144 without departing from the disclosure.
In accordance with the exemplary embodiment, the carton blank 103 with insert blank 203 attached thereto can be further erected into the carton 105 by folding along fold lines 145 and 125 (
In the illustrated embodiment once the blank 103 is formed into the sleeve 147 (
The handle 111 can be used to grasp the carton 105 by pressing against the elongate handle flaps 170, 172, folding them inward along respective fold lines 171, 173, to create a pair of handle openings in the top panel 110 of the carton 105 (
It is understood that the carton 105 may have an alternative number of handles or no handles or that the handle 111 can be otherwise shaped, arranged, and/or located without departing from the disclosure. Further, other opening arrangements for the handle 111 can be provided.
The reinforcing insert 205 provides extra layers of material for a three-ply top panel in the carton 105 surrounding the handle 111. The reinforcing insert 205 therefore reinforces the carton 105 by increasing the strength and rigidity of the carton to prevent tearing or other failure when the carton is lifted at the handle 111. Further, the first side flap 212 and the second side flap 214 restrict buckling in the respective side panels 140 and 120. The reinforcing insert 205 allows the carton 105 to carry heavier materials, have thinner walls, or both.
It is understood that the carton 105 can include a dispenser 180 (
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 of 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 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. 61/205,239, filed Jan. 16, 2009. U.S. Provisional Patent Application No. 61/205,239, which was filed on Jan. 16, 2009, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
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