Gusseted Carton Having Upper and Lower Storage Compartments

Abstract

Cartons, carton blanks, and methods for manufacturing cartons are described herein. In one implementation, a carton formed from a carton blank includes a lower storage compartment having at least one panel. The carton also includes a lid connected to a first panel of the lower storage compartment, where the lid is configured to be pivotable with respect to the lower storage compartment. The carton further includes an upper storage compartment that is formed within the lid. The lid comprises a lower lid panel that separates the lower storage compartment from the upper storage compartment.

Description

BRIEF DESCRIPTION OF THE 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 present disclosure.

FIG. 1 is a plan view of a carton blank used to form a carton according to a first embodiment of the present disclosure.

FIG. 2 is a perspective view of an open end of the carton blank of FIG. 1 in a partially erected state.

FIG. 3 is a front perspective view a carton erected from the carton blank of FIG. 1 in accordance with a first embodiment.

FIG. 4 is a perspective view of the back of the carton.

FIG. 5 is a perspective view of the front of the carton with a lid of the carton opened.

FIG. 6 is a perspective view of an end of the carton with the lid opened.

FIG. 7 is a perspective view of the back of the carton with the lid opened.

FIG. 8 is a perspective view of the carton with the lid opened and containers accommodated within the carton.

DETAILED DESCRIPTION

The first embodiment of the present disclosure generally relates to a carton suitable for storing and dispensing articles such as, for example, beverage containers. The carton is also suitable for storing and dispensing articles of a second type, such as dry snacks, in a separate compartment. In accordance with the first embodiment, the carton includes a bottom receptacle suitable for accommodating, for example, liquids, ice, or other coolants in the carton bottom. In one exemplary embodiment, ice can be added to the opened carton to cool articles held within the carton. As the ice melts, all or a part of the resultant runoff water may be at least temporarily held within the bottom receptacle.

Articles accommodated in a bottom portion of the carton can include containers such as, for example, petaloid bottle containers, beverage cans, glass or plastic bottles, or other containers such as, for example, those used in packaging foodstuffs. For the purposes of illustration and not for the purpose of limiting the scope of the present disclosure, the following detailed description describes beverage containers as disposed within the carton embodiments. In this specification, the terms “lower,” “upper,” “bottom,” “front” and “back” indicate orientations determined in relation to fully erected, upright cartons.

FIG. 1 is a plan view of a blank 8 used to form the carton 190 (illustrated in FIGS. 3 and 4) according to the first embodiment of the present disclosure. The blank 8 can be cut from a single planar sheet having a material that is suitable for the construction of a carton. As shown in FIG. 1, the blank 8 may be symmetric or nearly symmetric about a longitudinal centerline CL. Therefore, certain elements in the drawing figures may have identical or similar reference numerals in order to reflect partial or complete longitudinal symmetry in the blank.

The blank 8 comprises a lower lid panel 10 adjacent to a front panel 40, a bottom panel 50 foldably connected to the front panel 40 at a transverse fold line 51, a back panel 60 foldably connected to the bottom panel 50 at a transverse fold line 61, an upper lid panel 70 foldably connected to the back panel 60 at a transverse fold line 76, and a front adhesive panel 90.

First gussets 45 are disposed at either end of the front panel 40. The first gussets 45 comprise a pair of gusset panels 42, 46 foldably connected to one another at an oblique fold line 44. Each gusset panel 42 is foldably connected to the front panel 40 at a longitudinal fold line 106, and each gusset panel 46 is foldably connected to a bottom end panel 52 at the transverse fold line 51. An adhesive flap 54 is foldably connected to each bottom end panel 52 at a longitudinal fold line 56.

Second gussets 65 are disposed at either end of the back panel 60. The second gussets 65 comprise a pair of gusset panels 62, 66 foldably connected at an oblique fold line 64. Each gusset panel 62 is foldably connected to the back panel 60 at the longitudinal fold line 106, and each gusset panel 66 is foldably connected to a bottom end panel 52 at the transverse fold line 61.

The periphery of the lower lid panel 10 is defined at one end of the blank 8 by a separation pattern, which includes, for example, spaced longitudinal cuts 20, oblique cuts 22, and a transverse cut 24 connecting the oblique cuts 22. More generally, as in one example, the periphery of the lower lid panel 10 is defined by one or more tear lines, slits, or any combination thereof. The lower lid panel 10 can be retained in place in the blank 8 by nicks around the periphery of the lower lid panel 10. The nicks, for example, are “bridging” pieces of the blank 8 located between slits in the blank 8. An adhesive panel 12 is in part defined at one end of the panel 10 by a transverse fold line 14, and an adhesive panel 16 is in part defined at the other end of the lower lid panel 10 by a transverse fold line 18. The middle section of the lower lid panel 10 is intermediate between adhesive panels 12 and 16. Longitudinal panels 28 extend along each side of the lower lid panel 10 and are foldably connected to the front panel 40 at transverse fold lines 41.

The periphery of the upper lid panel 70 is defined by a transverse fold line 74, spaced longitudinal tear lines 80, oblique tear lines 92, and a tear line 94 connecting the oblique tear lines 92. The tear lines 80, 92, and 94 allow the upper lid panel 70 to remain in place with respect to the adjoining panels. However, the tear lines 80, 92, and 94 can be torn by a user without special cutting tools to separate the upper lid panel from longitudinal panels 78 and the front adhesive panel 90. After the tear lines are torn, the upper lid panel 70 can be pivoted as explained in more detail below. A pivot panel 72 is defined at one end of the upper lid panel 70 in part by a transverse fold line 76. A spacer panel 84 is defined in the other end of the upper lid panel 70 in part by transverse fold lines 83, 86. An adhesive panel 88 is foldably connected to the spacer panel 84 at the transverse fold line 86. The longitudinal panels 78 extend along each side of the upper lid panel 70 and are foldably connected to the back panel 60 at transverse fold lines 63. The front adhesive panel 90 extends from the end of the blank 8 and is foldably connected to the longitudinal panels 78 at transverse fold lines 91.

Inner handle panels 30 are foldably connected to the longitudinal panels 28 at the fold lines 106. Apertures 34 can be formed along the fold lines 106 to facilitate folding of the handle panels 30. Cut-out 32, which in some embodiments form racetrack-shaped handles, are formed in the handle panels 30. Outer handle panels 100 are foldably connected to the longitudinal panels 78 at the fold lines 106. The outer handle panels 100 include handles 102 that are arranged to align with the cut-outs 32, e.g., handles, in the erected carton 190.

According to one exemplary aspect of the present disclosure, the gussets 45, 65, the front panel 40, the back panel 60, the bottom end panels 52, and bottom panel 50 form a wholly or partially liquid-tight bottom receptacle 175 (illustrated in FIGS. 6 and 7) in the erected carton 190. The panels 30, 42, 46, 52, 62, 66, 100 generally extend both along a first marginal area (the upper region or area in FIG. 1) of the blank 8, and also along a second marginal area (the lower region or area in FIG. 1) of the blank 8. The longitudinal fold lines 106 can be, for example, straight or generally straight lines, or may be offset to account for blank thickness or for other factors.

An exemplary method of erection of the blank 8 into the carton 190 will now be discussed with reference to FIGS. 1 and 2. FIG. 2 illustrates the blank 8 glued and folded into a generally tubular configuration with both ends of the tube open to form a partially erected carton. The lower lid panel 10 is folded at the transverse fold lines 14, 18 so that the adhesive panel 12 is brought into contact with the pivot panel 72 and is adhered thereto by adhesive material therebetween. Also, the adhesive panel 16 is brought into contact with the adhesive panel 88 of spacer panel 84 and adhered thereto by adhesive material therebetween. It should be noted that the adhesive material is typically not applied to the adhesive panels 12, 16, 88 and pivot panel 72 until the time of carton erection. The adhesive material, in this case, can be applied to portions of one or both of the respective adjoining adhesive panels. When the adhesive panels 12, 16 are adequately adhered to the pivot panel 72 and adhesive panel 88, respectively, folding along fold lines can automatically strike, i.e. separate, the lower lid panel 10 from the prior position of the lower lid panel 10 in the blank 8.

The exterior sides of the longitudinal panels 28 are typically adhered to the interior or undersides of the longitudinal panels 78, and the exterior sides of the handle panels 30 are typically adhered to the interior sides of the handle panels 100 so that the handles 32, 102 align. The interior side or underside of the front adhesive panel 90 is adhered to the exterior side of the front panel 40. The ends of the partially erected carton may now be closed by the first and second gussets 45, 65 and the bottom end panels 52. The discussion below describes closing of one end of the partially erected blank. The opposite end may be closed in a similar manner.

Still referring to FIG. 2, the overlapped inner and outer handle panels 30, 100 are initially folded inwardly about the longitudinal fold lines 106, and the first and second gussets 45, 65 and the bottom end panels 52 are subsequently folded inwardly about the longitudinal fold lines 106. As the gussets 45, 65 and the bottom end panels 52 are folded inwardly, the first gussets 45 fold inwardly about the oblique fold lines 44 and the second gussets 65 fold inwardly about the oblique fold lines 64. The bottom end panels 52 may be folded over the inwardly folded gussets 45, 65 and may, for example, be adhered to the interior sides of the gusset panels 46, 66. In other embodiments, the end panels 52 may be folded such that the interior sides of the gusset panels 42, 62 of gussets 45, 65 can be adhered to the interior sides of the front panel 40 and back panel 60, respectively. The exterior surfaces of the gusset panels 42 may be adhered to exterior surfaces of the gusset panels 46. The exterior surfaces of gusset panels 62, 66 may also be adhered together. The first and second gussets 45, 65 and the bottom end panels 52 are folded over the overlapped handle panels 30, 100 and the interior side of each adhesive panel 54 is adhered to the exterior side of a handle panel 100. Alternatively, the handle panels 30, 100 may overlap the bottom end panels 52. The erected carton 190 may be loaded with containers C and/or additional articles, for example, at any time before closing both ends of the carton. In accordance with an alternative embodiment, the gussets 45, 65 are omitted and the bottom end panels 52 are closed with connectional end flaps.

FIG. 3 illustrates the front of the erected carton 190. To continue to erect the carton 190, the front adhesive panel 90 is folded about the fold lines 91 and is adhered to a front surface of the front panel 40. The adhesive panel 88 of the upper lid panel 70 is adhered to the adhesive panel 16 (shown in FIG. 1) of the lower lid panel 10. The spacer panel 84 extends across the front face of the carton 190 and separates the upper and lower lid panels 10, 70. The upper and lower lid panels 10, 70 define a lid 150 in the top portion of the carton 190.

FIG. 4 illustrates the back of the carton 190. The pivot panel 72 is foldably connected to the back panel 60 at the fold line 74. When the lid 150 is in a closed position (as illustrated), the pivot panel 72 extends substantially flush across the back face of the carton 190.

FIG. 5 illustrates the front of the carton 190 with the lid 150 in an opened position. Referring also to FIG. 3, the lid 150 may be opened by tearing along the tear lines 80, 92, 94 and pulling up on the lid 150. As the lid 150 pivots upwardly, the connection of the adhesive panel 88 to the adhesive panel 16 causes the lower lid panel 10 to also move upwardly. Along with the adhesively connected panels 12, 72, the spacer panel 84 provides a spacing between the upper and lower lid panels 70, 10. The volume between the upper and lower lid panels 70, 10 comprises an upper storage compartment 160 in the lid 150. The upper and lower lid panels 70, 10 and the upper storage compartment 160, in alternative embodiments, can be formed in a variety of different shapes. A lower storage compartment 170 is defined in the bottom portion of the carton 190, and a bottom receptacle 175 is further defined in the lower storage compartment 170. The upper storage compartment 160 in the lid 150 is at least partially isolated from the lower storage compartment 170 by the lower lid panel 10. In the opened position, as illustrated in FIG. 5, items can be respectively stored within or removed from the upper storage compartment 160 and lower storage compartment 170.

Referring also to FIG. 6, as the pivotable lid 150 is opened, the lower lid panel 10 pivots about the fold line 14, with the adhesive panel 12 being adhesively secured to the pivot panel 72. The carton 190 can be designed such that friction between the edges of the lower lid panel 10 of the lid 150 and the edges of the open section of the carton 190 can help maintain the lid 150 in an open position. That is, the lower lid panel 10 may be the as or a little wider than, or a little offset with respect to, the upper lid panel 70. FIG. 7 illustrates the back of the opened carton 190. As the lid 150 is pivoted open, the pivot panel 72 pivots away from the back panel 60 about the fold line 74. FIG. 8 illustrates the carton 190 with containers C accommodated within the carton 190.

Referring again to FIG. 6, the bottom receptacle 175, which is defined by portions of the first and second gussets 45, 65, the bottom end panels 52, and the panels 40, 50, 60, may be at least partially liquid-tight. The top edge or border of the bottom receptacle 175 is indicated by the dashed perimeter line 177 in FIGS. 3-5. The top edge of the bottom receptacle 175 represents a portion of the bottom of the carton 190 below which typically no glued seals or seams are formed through which water or other liquid might leak from the carton 190. That is, in accordance with the first embodiment, no adhesive seal or other joinder of material where liquid or particulate matter might escape the carton 190 is located in the carton at a position below the top perimeter line 177 of the bottom receptacle 175. Referring also to FIG. 1, the bottom receptacle 175 may therefore be formed from a continuous section of folded material of the blank 8. The height of the liquid-tight portion of the bottom receptacle 175 below which there are no glued seams is generally indicated as a height H_R in FIG. 6, which generally corresponds to the height at which the fold lines 56 are located. Referring to FIG. 1, the height H_R may generally coincide with an uppermost point 48 where the gusset panels 42, 46 of the first gussets 45 are foldably connected to one another, and the uppermost point 68 where the gusset panels 62, 66 of the second gussets 65 are connected.

According to another aspect of the present disclosure, the height H_R may be, for example, defined as a function of a height of the carton 190. For example, referring to FIG. 6, the bottom receptacle 175 may define a liquid-tight portion having a height H_R that is at least about 10% of the height H_C of the carton 190. Higher bottom receptacle heights, such as a height H_R that is at least 20% of carton height H_C, are also possible. In the illustrated embodiment, the height H_C is about 8 inches and the height H_R is about 3.9 inches, which is about 49% of the carton height H_C. The height H_R may be increased, for example, to accommodate larger anticipated liquid volumes in the carton 190.

According to one aspect of the present disclosure, the upper storage compartment 160 in the lid 150 may be used to store items separate from items accommodated in the lower storage compartment 170. For example, the upper storage compartment 160 may be a “dry” compartment used to accommodate items such as packaged foods. The lower storage compartment 170 can be a “wet” compartment used to accommodate beverage containers C, and, if desired, ice or other coolant substances.

If desired, additional articles may be placed in the carton 190 after opening. For example, if the containers C are beverage containers, ice may be placed over the containers C and held within the lower storage compartment 170 to cool the containers C. As the ice melts, the bottom receptacle 175 of the carton 190 serves to retain all or a portion of the water runoff as the ice melts. The receptacle 175 may also serve, for example, to house fine particulate matter that might otherwise escape through a glued seam. If one or more containers C is damaged during shipping or storage of the carton 190, the bottom receptacle 175 can serve to retain all or a portion of the contents of the broken container.

The blank 8 can, for example, be constructed of water resistant material to any degree desired so that liquid in the bottom of the carton 190 remains in the bottom receptacle 175 for a selected amount of time. The carton 190 can therefore be constructed so that liquid retained in the bottom receptacle 175 initially remains in the carton 190 at least until it reached the height H_R.

Cartons constructed according to the principles of the present disclosure may be formed from materials such as paperboard. Therefore, if exposed to water or other liquids for extended periods of time, the carton may allow for the passage of liquid through the wetted carton surfaces due to partial permeability of the carton material. In this specification, the term “liquid-tight” is generally used to define a section of a carton that is formed from a continuous section of material or of a section without any glued seams through which liquid or fine particulate matter might leak, and the term “liquid-tight” therefore encompasses cartons that may become partially water permeable over time.

In order to reduce the permeability of cartons to liquid, blanks according to the present disclosure may be coated with, for example, a moisture barrier layer, on either or both sides of a blank. Blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. For example, the interior surfaces of the blank 8 may include a water-resistant or water-tight film such as, for example, polyethylene, polyester, or polypropylene films. Coatings of the same materials may also be applied to the blank 8. Accordingly, the sheet from which the blank 8 is cut may have multiple plys.

In the above embodiments, the carton 190 is illustrated as accommodating eight containers C in a 2×4 configuration. Other arrangements of containers, packages, articles, and other items, however, can be accommodated within a carton according to the principles of the present disclosure. For example, a carton constructed according to the principles of the present disclosure would also work satisfactorily if the carton were sized and shaped to hold articles in other configurations, such as 3×4, 4×3, 3×6, 2×4, 2×5, etc. The dimensions of the blank 8 may also be altered, for example, to accommodate various container forms. For example, 16-ounce petaloid bottles may be accommodated within a carton constructed according to the principles of the present disclosure.

In the exemplary embodiments discussed above, the exemplary blank 8 may be formed from, for example, clay coated newsprint (CCN), solid unbleached sulfate board (SUS), and/or other materials. In general, the blank may be constructed from paperboard having a caliper of at least about 14, for example, 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/or other information or images. The blank may then be coated with a varnish to protect information printed on the blank.

In the present specification, a “panel” need not be flat or otherwise planar. A “panel” can, for example, comprise a plurality of interconnected generally flat or planar sections.

The above embodiments may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place.

The term “line” as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines.

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.

In the illustrated embodiments, selected fold lines may be shown as including spaced cuts to facilitate folding along the lines. If the cuts are below or adjacent to the bottom receptacle 175 portion of the carton, less than 100% cuts, e.g., cuts that do not extend all the way through the blank, may be used to prevent leakage along the fold lines. Alternatively, cuts or scores may be omitted within or near the bottom receptacle 175.

The term “tear line” as used herein can be any fold, cut, puncture, slice, slit, perforation, etc., or any combinations thereof, which allows the blank 8 to be folded along an intended line. When the tear lines contains slits, for example, the slits are typically aligned nearly end-to-end including bridges between them, wherein the bridges can be ripped. The tear lines can also be formed using a kiss cut that cuts through one surface of the blank 8, but does not extend all the way through it.

The foregoing description of the present disclosure illustrates and describes selected embodiments. However, it is to be understood that the present disclosure is not limited by the exemplary embodiments, but can include other modifications and changes within the spirit and scope of the descriptions expressed herein. Such modifications known to one of ordinary skill in the art are intended to be included within the present disclosure and limited only by the following claims.

Claims

1. A carton formed from a carton blank, the carton comprising: a lower storage compartment having at least one panel;a lid connected to a first panel of the lower storage compartment, the lid configured to be pivotable with respect to the lower storage compartment; andan upper storage compartment formed within the lid;wherein the lid comprises a lower lid panel that separates the lower storage compartment from the upper storage compartment.

2. The carton of claim 1, wherein the lower storage compartment comprises a substantially water-tight receptacle.

3. The carton of claim 2, wherein the water-tight receptacle allows the lower storage compartment to be substantially water tight up to a first height.

4. The carton of claim 3, wherein the first height is greater than about 20% of the height of the carton.

5. The carton of claim 1, wherein the lid is pivotable between a closed position and an opened position.

6. The carton of claim 5, wherein, in the closed position, items stored in the upper storage compartment are at least partially separated from items in the lower storage compartment by the lower lid panel.

7. The carton of claim 5, wherein, in the opened position, the upper storage compartment and lower storage compartment are accessible for storing or removing items.

8. The carton of claim 1, further comprising a first handle and a second handle, wherein the first handle and second handle are positioned at substantially opposite ends of the carton.

9. A carton blank comprising: a plurality of adjoining panels connected together by a plurality of fold lines, the plurality of adjoining panels capable of being formed into a lower storage compartment of a carton;a lower lid panel having a first panel, a second panel, and an intermediate panel, the first panel foldably connected to a first end of the intermediate panel, the second panel foldably connected to a second end of the intermediate panel; andan upper lid panel having a pivot panel and a spacer panel;wherein the pivot panel is positioned for overlapping the first panel of the lower lid in response to predetermined folding along at least a first fold line of the plurality of fold lines; andwherein the spacer panel includes a portion thereof positioned for overlapping the second panel of the lower lid in response to predetermined folding along at least a second fold line of the plurality of fold lines.

10. The carton blank of claim 9, wherein the plurality of adjoining panels comprises: a bottom panel;a front panel foldably connected to the bottom panel;a back panel foldably connected to the bottom panel;first and second end panels foldably connected to the bottom panel;a first gusset foldably connected to the first end panel and the front panel;a second gusset foldably connected to the front panel and the second end panel;a third gusset foldably connected to the second end panel and the back panel; anda fourth gusset foldably connected to the back panel and the first end panel.

11. The carton blank of claim 10, further comprising a fold line between the pivot panel and the back panel.

12. The carton blank of claim 9, further comprising: first and second longitudinal panels foldably connected to the back panel in a longitudinal direction; andthird and fourth longitudinal panels foldably connected to the front panel in a longitudinal direction.

13. The carton blank of claim 12, further comprising: first and second outer handle panels foldably connected to the first and second longitudinal panels, respectively; andfirst and second inner handle panels foldably connected to the third and fourth longitudinal panels, respectively.

14. The carton blank of claim 9, wherein the lower lid panel is cut and removed from the single planar sheet with no fold lines connecting the lower lid panel to adjoining panels.

15. A method of manufacturing a carton, the method comprising: cutting a carton blank from a sheet of material, the carton blank comprising a plurality of adjoining panels, an upper lid panel, and a lower lid panel;attaching the lower lid panel to the upper lid panel to at least partially form an upper storage compartment of the carton; andfolding the plurality of adjoining panels along respective fold lines to form a lower storage compartment of the carton.

16. The method of claim 15, wherein the lower lid panel is at least partially struck from at least one of the plurality of panels and the upper storage compartment is at least partially further formed in response to the folding step.

17. The method of claim 15, wherein the carton blank further comprises outer handle panels and inner handle panels, the method further comprising: adhering the inner handle panels to first portions of the outer handle panels.

18. The method of claim 17, wherein the plurality of adjoining panels includes end panels, the method further comprising: adhering second portions of the outer handle panels to portions of the end panels.

19. The method of claim 15, further comprising: forming a fold line along a first edge of the upper lid panel; andforming tear lines along other edges of the upper lid panel.

20. The method of claim 19, further comprising: tearing the tear lines along the other edges of the upper lid panel to thereby allow the upper lid panel to be pivoted along the fold line along the first edge.