INCORPORATION BY REFERENCE
The disclosures of U.S. Provisional Patent Application No. 63/541,446, filed Sep. 29, 2023, U.S. Provisional Patent Application No. 63/533,393, filed Aug. 18, 2023, U.S. patent application Ser. No. 16/037,425, filed Jul. 17, 2018, U.S. patent application Ser. No. 15/654,814, filed Jul. 20, 2017, and U.S. patent application Ser. No. 12/992,131, filed Feb. 11, 2011, are hereby incorporated by reference for all purposes as if presented herein in their entirety.
BACKGROUND OF THE DISCLOSURE
The present disclosure relates to blanks, containers, trays, constructs, and various features and methods for forming a container from a blank. More specifically, the disclosure is generally directed to a container having a liner.
SUMMARY OF THE DISCLOSURE
In general, one aspect of the disclosure is generally directed to a container for holding one or more articles. The container can comprise a base comprising one or more bottom panels and one or more divider panels and a crown comprising a flange panel. A bottom wall can comprise at least the one or more bottom panels and a sidewall can comprise at least a portion of the base and at least a portion of the crown. The sidewall and the bottom wall can extend along an interior of the container. A flange can comprise the flange panel, and the flange can extend outwardly from the sidewall. A divider can comprise the one or more divider panels, and the divider can extend upwardly from the bottom wall into the interior of the container.
In another aspect, the disclosure is generally directed to, in combination, a base blank and a crown blank for forming a container for holding one or more articles. The base blank can comprise one or more bottom panels and one or more divider panels. The one or more bottom panels can be for at least partially forming a bottom wall of the container formed from the base blank and the crown blank, and the one or more divider panels can be for at least partially forming a divider of the container formed from the base blank and the crown blank. The one or more divider panels can be for extending upwardly from one or more bottom panels when the container is formed from the base blank and the crown blank. The crown blank can comprise at least a flange panel for at least partially forming a flange of the container formed from the base blank and the crown blank. At least a portion of the base blank and at least a portion of the crown blank can be for at least partially forming a sidewall of the container formed from the base blank and the crown blank.
In another aspect, the disclosure is generally directed to a method of forming a container for holding one or more articles. The method can comprise obtaining a base blank and a crown blank. The base blank can comprise one or more bottom panels and one or more divider panels, and the crown blank can comprise at least a flange panel. The method further can comprise forming the base blank into a base comprising positioning the one or more bottom panels to at least partially form a bottom wall extending along an interior of the container and forming the crown blank into a crown at least partially overlapping the base. Portions of the crown and the base can cooperate to at least partially form a sidewall extending at least partially around the interior of the container, and the flange panel can at least partially form a flange extending outwardly from the sidewall. The method also can comprise forming a divider comprising positioning the one or more divider panels to extend at least upwardly from the bottom wall.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
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.
FIGS. 1 and 2 are plan views of a respective first blank and second blank used for forming a container according to exemplary embodiments of the disclosure.
FIG. 3 is a perspective view of the container formed from the blanks of FIGS. 1 and 2 according to exemplary embodiments of the disclosure.
FIG. 4 is a perspective top view of the container of FIG. 3.
FIG. 5 is a perspective bottom view of the container of FIGS. 3 and 4.
FIGS. 6 and 7 are plan views of a respective first blank and second blank used for forming a container according to further exemplary embodiments of the disclosure.
FIGS. 8 and 9 are perspective views of the container formed from the blanks of FIGS. 6 and 7 according to exemplary embodiments of the disclosure.
FIG. 10 is a perspective bottom view of the container of FIGS. 8 and 9.
FIG. 11 is a perspective schematic cross-sectional view of the container of FIGS. 8-10.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
The present disclosure relates generally to various aspects of containers, constructs, trays, materials, packages, elements, and articles, and methods of making such containers, constructs, trays, materials, packages, elements, and articles. Although several different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations thereof, and modifications of the various aspects, implementations, and embodiments are contemplated hereby. In one illustrated embodiment, the present disclosure relates to forming a container or tray for holding food items or various other articles. However, in other embodiments, the container or tray can be used to form other non-food containing articles or may be used for heating or cooking. In this specification, the terms “inner,” “interior,” “outer,” “exterior,” “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright packages. As described herein, constructs can be formed from blanks with multiple panels, portions, tabs, and/or flaps, which may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or nonsequential reference, without departing from the disclosure.
FIGS. 1 and 2 illustrate a first or bottom or base blank 103 and a second or top or crown blank 104, respectively, that are used to form a respective base 101 and crown 102, which cooperate to form a container 105 (FIGS. 3-5) having a base layer 107 and a liner 109 (FIG. 3) according to embodiments of the disclosure. In exemplary embodiments, the blanks 103, 104 and the base layer 107 comprise paperboard (e.g., solid bleached sulphate folding boxboard), or other suitable material that can be recyclable, and the liner comprises a plastic layer such as polyethylene, PET material, or any other thermoplastic material, or a bioplastic, such as vegetable oil or starch-based plastics. The container 105 can be suitable for holding and/or displaying one or more articles (e.g., food products) for sale, transportation, storage, etc. and/or for heating a food product in an oven such as a convection or conventional heating oven or microwave oven. In the illustrated embodiment, the liner can be adhered to the base layer 107 (e.g., along at least a portion of the base 101 and at least a portion of the crown 102) and can be in contact with the food product held in the container 105. After use of the container 105, the base layer 107 and the liner can be separated to allow both the base layer 107 and the liner to be placed in separate waste streams (e.g., for recycling, composting, incineration, land fill, etc.).
As shown in FIG. 1, the base blank 103 has a longitudinal direction L1 and a lateral direction L2. In the illustrated embodiment, the base blank 103 has a first bottom panel 111 and a second bottom panel 113 connected by a divider structure 115. As shown in FIG. 1, the divider structure 115 can include a first divider panel 117 and a second divider panel 119, wherein the first divider panel is foldably connected to the first bottom panel 111 along a lateral fold line 121 and the second divider panel 119 is foldably connected to the second bottom panel 113 along a lateral fold line 123. The first divider panel 117 and the second divider panel 119 can be foldably connected along a lateral fold line 125. The base blank 103 further can include a first end panel 127 and a second end panel 129 foldably connected to the first bottom panel 111 along respective fold lines 131, 133 (e.g., oblique fold lines 131, 133) and a third end panel 135 and a fourth end panel 137 foldably connected to the second bottom panel along respective fold lines 139, 141 (e.g., oblique fold lines 139, 141). As shown in FIG. 1, a first side panel 143 and an opposing second side panel 145 can be foldably connected to the first bottom panel 111 along respective longitudinal fold lines 147, 149, and a third side panel 151 and an opposing fourth side panel 153 can be foldably connected to the second bottom panel 113 along respective longitudinal fold lines 155, 157.
In the illustrated embodiment, the base blank 103 can include corner panels 159, 161 respectively foldably connected to the first bottom panel 111 along respective oblique fold lines 163, 165 and corner panels 167, 169 respectively foldably connected to the second bottom panel 113 along respective oblique fold lines 171, 173. As shown in FIG. 1, the corner panel 159 is disposed between the first end panel 127 and the first side panel 143, the corner panel 161 is disposed between the second end panel 129 and the second side panel 145, the corner panel 167 is disposed between the third end panel 135 and the third side panel 151, and the corner panel 169 is disposed between the fourth end panel 137 and the fourth side panel 153.
In the illustrated embodiments, each of the end panels 127, 129, 135, 137, side panels 143, 145, 151, 153, and corner panels 159, 161, 167, 169 can be foldably connected to a respective flange portion 175a, 175b, 175c, 175d, 177a, 177b, 177c, 177d, 179a, 179b, 179c, 179d along respective fold lines 181a, 181b, 181c, 181d, 183a, 183b, 183c, 183d, 185a, 185b, 185c, 185d (e.g., the flange portions can be portions of the respective end panels, side panels. and corner panels at least partially defined by the respective fold lines). As shown in FIG. 1, the first bottom panel 111, the first side panel 143, and the second side panel 145 can be spaced apart from the second bottom panel 113, the third side panel 151, and the fourth side panel 153 in the blank 103, and overlap tabs 187 can extend from the second bottom panel 113, the third side panel 151, and the fourth side panel 153 toward the first bottom panel 111, the first side panel 143, and the second side panel 145. When the container 105 is formed, the overlap tabs 187 at least partially overlap the first bottom panel 111, the first side panel 143, and the second side panel 145.
The base blank 103 can be otherwise shaped, arranged, and/or configured without departing from the disclosure. In addition, any of the bottom panels 111, 113, the end panels 127, 129, 135, 137, the side panels 143, 145, 151, 153, the corner panels 159, 161, 167, 169, and/or the flange portions 175a, 175b, 175c, 175d, 177a, 177b, 177c, 177d, 179a, 179b, 179c, 179d could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, the base blank 103 could have any suitable number of panels and any suitable shape for the perimeter around the bottom panel 111.
As shown in FIG. 2, the crown blank 104 has a longitudinal direction L1 and a lateral direction L2 and includes a flange panel 206 extending around a perimeter of the crown blank 104 (e.g., continuously around the crown blank 104 for forming a smooth, continuous upper surface of the flange of the container 105 for attaching the liner and/or a lid film). In the illustrated embodiments, the crown blank 104 can include a central opening 208 (e.g., at least partially defined by an inner edge of the flange panel 206. A first end flap 210, a second end flap 212, a third end flap 214, and a fourth end flap 216 can be foldably connected to the flange panel 206 along the central opening 208 along respective oblique fold lines 218, 220, 222, 224. As shown in FIG. 2, the blank 104 can include a first side flap 226, a second side flap 228, a third side flap 230, and a fourth side flap 232 foldably connected to the flange panel 206 along respective longitudinal fold lines 234, 236, 238, 240. In the illustrated embodiments, corner flaps 242, 244, 246, 248 can be foldably connected to the flange panel 206 along respective oblique fold lines 250, 252, 254, 256. In embodiments, the first side flap 226, and the second side flap 228 can include respective cutouts 258 for accommodating the overlap tabs 187 extending from the respective third side panel 151 and fourth side panel 153 and overlapping the respective first side panel 143 and second side panel 145 when the container 105 is formed from the base blank 103 and the crown blank 104 (FIGS. 3 and 4).
The crown blank 104 can be otherwise shaped, arranged, and/or configured without departing from the disclosure. In addition, any of the flange panel 206, the end flaps 210, 212, 214, 216, the side flaps 226, 228, 230, 232, and/or the corner flaps 242, 244, 246, 248, could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, the crown blank 104 could have any suitable number of panels and any suitable shape for the perimeter around the central opening 208.
When the container 105 is formed from the base blank 103 and the crown blank 104 (e.g., manually or by a forming tool), the base blank 103 can be formed into the base 101 and the crown blank 104 can be formed into the crown 102. For example, the bottom panels 111, 113 are moved closer together so that the overlap tabs 187 extending from the second bottom panel 113 at least partially overlap the first bottom panel 111 to form a bottom wall 260 (FIGS. 3 and 4). As the bottom panels 111, 113 are moved together, the divider panels 117, 119 are folded upwardly along the lateral fold lines 121, 123 and fold relative to one another along the lateral fold line 125 to form a divider 262 extending upwardly from the bottom wall 260 (FIGS. 3 and 4). The panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 can be folded upwardly relative to the bottom panels 111, 113 along their respective fold lines, and the flange portions 175a, 175b, 175c, 175d, 177a, 177b, 177c, 177d, 179a, 179b, 179c, 179d can be folded outwardly relative to the respective panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169. In the illustrated embodiment, the overlap tabs 187 extending from the side panels 151, 153 can overlap the side panels 143, 145 (FIGS. 3 and 4). The panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 and the flange portions 175a, 175b, 175c, 175d, 177a, 177b, 177c, 177d, 179a, 179b, 179c, 179d can be positioned before, after, or during the forming of the bottom wall 260 and the divider 262.
The container 105 further can be formed by placing the flange panel 206 of the crown blank 104 over the flange portions 175a, 175b, 175c, 175d, 177a, 177b, 177c, 177d, 179a, 179b, 179c, 179d of the base 101 so that the flange portions and the flange panel are in face-to-face contact (e.g., the flange portions are in face-to-face contact with the bottom surface of the flange panel). The flaps 210, 212, 214, 216, 226, 228, 230, 232, 242, 244, 246, 248 can be downwardly folded along their respective fold lines so that the flaps 210, 212, 214, 216, 226, 228, 230, 232, 242, 244, 246, 248 overlap the respective panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 (FIGS. 3 and 4). In embodiments, the flaps 210, 212, 214, 216, 226, 228, 230, 232, 242, 244, 246, 248 and the panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 cooperate to form a sidewall 264 of the container 105. Similarly, the flange portions 175a, 175b, 175c, 175d, 177a, 177b, 177c, 177d, 179a, 179b, 179c, 179d and the flange panel 206 can cooperate to form a flange 266 of the container 105, with the flange panel 206 providing a smooth, continuous upper surface of the flange 266. Accordingly, in embodiments, the crown 102 at least partially overlaps the base 101 when the base layer 107 of the container 105 is formed.
In embodiments, a liner material (not shown) can be applied over at least the sidewall 264, the bottom wall 260, and the divider 262 so that the liner material can form a liner 109 adhered to at least the overlapped flaps and panels of the sidewall 264, to the bottom panels 111, 113 of the bottom wall 260, and to the divider panels 117, 119 of the divider 262 along an interior 268 of the container 105. In embodiments, the liner 109 can be attached along at least a portion of the flange panel 206. In exemplary embodiments, the liner 109 can be adhered to the base layer 107 by a heat seal layer, adhesive, and/or other suitable features. In the illustrated embodiments, the attachment of the liner 109 to the base layer 107 can attach the flaps 210, 212, 214, 216, 226, 228, 230, 232, 242, 244, 246, 248 to the respective panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 and can attach the overlap tabs 187 to the respective first bottom panel 111, first side panel 143, and second side panel 145. As shown in FIGS. 3 and 4, the flaps 210, 212, 214, 216, 226, 228, 230, 232, 242, 244, 246, 248 are smaller than the respective panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 so that portions of each of the flaps and panels are in contact with the liner 109. In embodiments, the liner 109 can at least partially hold the crown 102 and the base 101 of the base layer 107 together and maintain the shape of the container 105. Alternatively, or in addition, one or more aspects of the base layer 107 can be attached by thermo-mechanical sealing, adhesive, etc.
As shown in FIGS. 3-5, the sidewall 264 and the bottom wall 260 extend around and at least partially define the interior 268 of the container 105, and the divider 262 extends upwardly into the interior 268 to at least partially form two interior portions of the container 105 for at least partially separating products held in the container 105. In the illustrated embodiments, the divider 262 can have a draft angle (e.g., the divider panels 117, 119 can extend obliquely from the respective lateral fold lines 121, 123 to the common lateral fold line 125). The draft angle of the divider 262 can facilitate stacking of the containers 105. For example, the divider 262 can at least partially define an opening 282 in the bottom wall 260 (FIG. 5) that can at least partially receive the divider 262 of a lower container 105 when the containers are stacked. In embodiments, the overlapping of the tabs 187 with the first bottom panel 111 and the side panels 143, 145 and/or the overlapping of the flaps 210, 212, 214, 216, 226, 228, 230, 232, 242, 244, 246, 248 with the respective panels 127, 129, 135, 137, 143, 145, 151, 153, 159, 161, 167, 169 can help increase the rigidity of the sidewall 264 and the bottom wall 260 of the container 105.
FIGS. 6 and 7 are plan views of a respective first or bottom or base blank 303 and second or top or crown blank 304 for forming a respective base 301 and crown 302, which cooperate to form a container 305 (FIGS. 10-16B) of a second embodiment of the disclosure (e.g., a container including a crown or crown component formed from the crown blank 304 and a bottom construct or component formed from the base blank 303, wherein the crown and the bottom construct can be secured together by at least a liner 309 to form a base layer 307). The second embodiment is generally similar to the prior embodiments, except for variations noted and variations that will be apparent to one of ordinary skill in the art. Accordingly, similar or identical features of the embodiments have been given like or similar reference numbers. As shown in FIG. 6, the base blank 303 is similar to the base blank 103 of the first embodiment except that the base blank 303 includes one end panel 327 foldably connected to the first bottom panel 311 along a lateral fold line 331 and one end panel 335 foldably connected to the second bottom panel 313 along a lateral fold line 339 (e.g., the second and fourth end panels 129, 137 of the base blank 103 are omitted in the base blank 303). As shown in FIG. 6, flange portions 375a, 375b are foldably connected to the respective first end panel 327 and second end panel 335 along respective lateral fold lines 381a, 381b. In the illustrated embodiments, the side panels 343, 345, 351, 353 of the base blank 303 have different shapes than the side panels 143, 145, 151, 153 of the base blank 103. For example, the tabs 187 are omitted in the base blank 303, and the side panels 343, 345, 351, 353 each have an oblique edge extending from the respective bottom panel 311, 313 to a respective notch 380 defined along the respective side panels 343, 345, 351, 353 and the respective flange portions 377a, 377b, 377c, 377d. Any of the bottom panels 311, 313, the end panels 327, 335, the side panels 343, 345, 351, 353, the corner panels 159, 161, 167, 169, and/or the flange portions 375a, 375b, 377a, 377b, 377c, 377d, 179a, 179b, 179c, 179d could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.
As shown in FIG. 6, the base blank 303 has a first divider structure 315 (e.g., a lower divider structure) for cooperating with a second divider structure 415 (e.g., an upper divider structure) in the crown blank 304 (FIG. 7) to form a divider 462 (FIGS. 8-11) as described in more detail below. In the illustrated embodiments, the first divider structure 315 can include a first divider panel 317 (e.g., a first lower divider panel) foldably connected to the first bottom panel 311 along a lateral fold line 321 and a second divider panel 319 (e.g., a second lower divider panel) foldably connected to the second bottom panel 313 along a lateral fold line 323. In embodiments, the first divider panel 317 is foldably connected to central panels 324 along lateral fold lines 325a, and the second divider panel 319 is foldably connected to the central panels 324 along lateral fold lines 325b. As shown in FIG. 8, the divider panels 317, 319 can have oblique outer edges that extend from the respective bottom panels 311, 313 to the central panels 324, wherein tabs 389 (e.g., rectangular tabs) can extend outwardly from the central panels 324 (e.g., the tabs 389 can be continuous with the central panels 324). In embodiments, the tabs 389 can cooperate with the flange portions of the base blank 303 when the flange 466 is formed as described in more detail below. As shown in FIG. 6, a divider opening 391 can extend in the divider structure 315 with an edge 393 extending along each of the divider panels 317, 319, and the central panels 324. In the illustrated embodiment, a central divider flap 395 is foldably connected to the first divider panel 317 along a lateral fold line 397 so that the central divider flap 395 extends along the divider opening 391. Any portion of the divider structure 315 could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, the divider flap 395 could be foldably connected to the second divider panel 319.
As shown in FIG. 7, the flange panel 406 of the crown blank 304 is a different shape than the flange panel 206 of the crown blank 104 of the first embodiment. In the illustrated embodiments, the crown blank 304 has two end flaps 410, 414 foldably connected to the flange panel 406 along respective lateral fold lines 418, 422 and has a first side flap 426, a second side flap 428, a third side flap 430, and a fourth side flap 432 foldably connected to the flange panel 406 along respective longitudinal fold lines 434, 436, 438, 440. As shown in FIG. 7, corner flaps 442, 444, 446, 448 can be foldably connected to the flange panel 406 along respective oblique fold lines 450, 452, 454, 456. In embodiments, each of the flaps 410, 414, 426, 428, 430, 432, 442, 444, 446, 448 can be separable from the respectively adjacent flaps along respective tear or cut lines extending therebetween. Any of the flange panel 406, the end flaps 410, 414, the side flaps 426, 428, 430, 432, and/or the corner flaps 442, 444, 446, 448, could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.
In the illustrated embodiments, the second divider structure 415 of the crown blank 304 can include a third divider panel 417 (e.g., a first upper divider panel) and a fourth divider panel 419 (e.g., a second upper divider panel) each foldably connected to two extensions 470 of the flange panel 406 along respective lateral fold lines 425a, 425b. In embodiments, the extensions 470 can extend inwardly from the remainder of the flange panel 406 in the lateral direction L2. As shown in FIG. 7, the second divider structure 415 can include a divider opening 491 extending along the divider panels 417, 419. In the illustrated embodiments, the second divider structure 415 further can include two side divider flaps 472, 474 foldably connected to the respective extensions 470 along respective longitudinal fold lines 476, 479.
As shown in FIG. 7, the second divider structure 415 can extend across a central portion of the crown blank 304 with an opening 408 on either side of the second divider structure 425. In exemplary embodiments, the first opening 408 can extend along respective edges of the end flap 410, the side flaps 426, 428, the corner flaps 442, 444, and the third divider panel 417, and the second opening 408 can extend along respective edges of the end flap 414, the side flaps 430, 432, the corner flaps 446, 448, and the fourth divider panel 419. The crown blank 304 can be otherwise shaped, arranged, and/or configured without departing from the disclosure. In addition, any of the flange panel 406, the end flaps 410, 414, the side flaps 426, 428, 430, 432, the corner flaps 442, 444, 446, 448, and/or the second divider structure 415 could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.
When the container 305 is formed from the base blank 303 and the crown blank 304 (e.g., manually or by a forming tool), the bottom panels 311, 313 are moved closer together so that the divider panels 317, 319 are folded upwardly relative to the bottom panels 311, 313 along the lateral fold lines 321, 323, moving the central panels 324 upwardly while folding along the lateral fold lines 325a, 325b. In embodiments, the central panels 324 can remain parallel (e.g., generally and/or substantially parallel) with the bottom panels 311, 313. When the lower divider panels 317, 319 are in position (e.g., extending at least upwardly; e.g., upwardly at an oblique angle toward the central panels 324), the central divider flap 395 can be folded along the lateral fold line 397 so that the distal edge of the central divider flap 395 abuts the laterally extending edge of the divider panel 319 opposite to the lateral fold line 397.
The base construct 101 can be formed by folding the panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169 upwardly relative to the bottom panels 311, 313 along their respective fold lines and folding the flange portions 375a, 375b, 377a, 377b, 377c, 377d, 179a, 179b, 179c, 179d outwardly relative to the respective panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169. In the illustrated embodiments, the central panels 324 can be coplanar (e.g., generally and/or approximately coplanar) with the outwardly folded flange portions 375a, 375b, 377a, 377b, 377c, 377d, 179a, 179b, 179c, 179d, and the tabs 389 can be located in the notches 380 (e.g., as shown in FIG. 10) in the base construct. In embodiments, the panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169 can extend at least upwardly (e.g., upwardly and outwardly) from the bottom panels 311, 313, and the adjacent edges of the panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169 can abut one another (FIGS. 8-11). Further, the adjacent edges of the flange portions 375a, 375b, 377a, 377b, 377c, 377d, 179a, 179b, 179c, 179d can abut one another with the edges of the tabs 389 abutting the edges of the flange portions 377a, 377b, 377c, 377d (FIG. 14).
The container 305 further can be formed by placing the flange panel 406 of the crown blank 304 over the flange portions 375a, 375b, 377a, 377b, 377c, 377d, 179a, 179b, 179c, 179d so that the flange portions and the flange panel are in face-to-face contact (e.g., the flange portions are in face-to-face contact with the bottom surface of the flange panel). The flaps 410, 414, 426, 428, 430, 432, 442, 444, 446, 448 can be downwardly folded along their respective fold lines to form the crown and so that the flaps 410, 414, 426, 428, 430, 432, 442, 444, 446, 448 overlap the respective panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169 (FIGS. 10-13, 15, and 16A). In embodiments, the flaps 410, 414, 426, 428, 430, 432, 442, 444, 446, 448 and the panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169 cooperate to form a sidewall 464 of the container 305. Similarly, the flange portions 375a, 375b, 377a, 377b, 377c, 377d, 179a, 179b, 179c, 179d and the flange panel 406 can cooperate to form a flange 466 of the container 305, with the flange panel 406 providing a smooth, continuous upper surface of the flange 466.
As shown in FIGS. 8-11, the divider 462 can be formed in the container 305 when the crown blank 304 is placed over the bottom construct and the upper divider panels 417, 419 are folded downwardly along the respective lateral fold lines 425a, 425b to at least partially overlap the respective lower divider panels 317, 319. Further, the side divider flaps 472, 474 can be folded downwardly along the respective longitudinal fold lines 476, 478 so that the distal edges of the side divider flaps 472, 474 abut the respective longitudinally extending edges of the central divider flap 395 and the side edges of the side divider flaps 472, 474 abut the adjacent edges of the upper divider panels 417, 419 (FIGS. 8-11). Accordingly, in embodiments, the divider flaps 395, 472, 474 can at least partially close the at least partially aligned divider openings 391, 491 when the container 305 is formed.
In embodiments, a liner material (not shown) can be applied over at least the sidewall 464, the bottom wall 460, and the divider 462 so that the liner material can form a liner 309 (FIG. 8) adhered to at least the overlapped flaps and panels of the sidewall 464, to the bottom panels 311, 313 of the bottom wall 460, and to the divider panels 317, 319, 417, 419 and the divider flaps 395, 472, 474 of the divider 462 along an interior 468 of the container 305. In embodiments, the liner 309 can be attached along at least a portion of the flange panel 406. In exemplary embodiments, the liner 309 can be adhered to the base layer 307 by a heat seal layer, adhesive, and/or other suitable features. In the illustrated embodiments, the attachment of the liner 309 to the base layer 307 can attach the flaps 410, 414, 426, 428, 430, 432, 442, 444, 446, 448 to the respective panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169, can attach the upper divider panels 417, 419 to the respective lower divider panels 317, 319, and can help secure the divider flaps 395, 472, 474 in place in the divider 462. As shown in FIGS. 8-11, the flaps 410, 414, 426, 428, 430, 432, 442, 444, 446, 448 are smaller than the respective panels 327, 335, 343, 345, 351, 353, 159, 161, 167, 169 so that portions of each of the flaps and panels are in contact with the liner. In embodiments, the liner 309 can at least partially hold the portions of the base layer 307 together and maintain the shape of the container 305. Alternatively, or in addition, one or more aspects of the base layer 307 can be attached by thermo-mechanical sealing, adhesive, etc.
As shown in FIGS. 8-11, the sidewall 464 and the bottom wall 460 extend around and at least partially define the interior 468 of the container 305, and the divider 462 extends upwardly into the interior 468 to at least partially form two interior portions (e.g., two receiving spaces) of the container 305 for at least partially separating products held in the container 305. As shown in FIGS. 8, 10, and 11, the divider 462 can at least partially define a recess 482 between the two bottom panels 311, 313 for at least partially receiving a divider 462 of a lower container 305 when the containers are stacked.
In embodiments, the container 305 with the integrated divider 462 can be formed in a single process, and the shape of the divider 462 can help maintain the rigidity and/or the integrity of the container 305 without intruding into the sealing area of the container 305. The container 305 can provide a paper-based tray wherein the divider 462 facilitates the separation of products contained in the tray and wherein the container 305 can replace plastic trays.
All dimensional information presented herein is intended to be illustrative of certain aspects, features, etc., of various embodiments of the disclosure, and is not intended to limit the scope of the disclosure. The dimensions of the blanks, containers, forming tools, features, or any other dimension, can be more or less than what is shown and described in this disclosure without departing from the scope of this disclosure and can be within the listed ranges of dimensions for each feature or outside the listed ranges of dimensions for each feature without departing from the scope of this disclosure.
The blanks according to the present invention 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 blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.
In general, the blanks 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 blanks 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 blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
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 illustrates and describes various embodiments of the present disclosure. 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, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and are 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 without departing from the scope of the disclosure.
Patent Application
20250058928
