U.S. patent application Ser. No. 14/095,136, which was filed on Dec. 3, 2013, U.S. application Ser. No. 11/549,355, which was filed on Oct. 13, 2006, U.S. Provisional Application No. 60/726,408, which was filed on Oct. 13, 2005, U.S. application Ser. No. 11/524,574, which was filed on Sep. 21, 2006, and U.S. Provisional Application No. 60/719,309, which was filed on Sep. 21, 2005, are hereby incorporated by reference for all purposes as if presented herein in their entirety.
Cartons are typically shipped in bulk quantities. During shipping, the cartons may be vertically stacked upon each other in order to maximize the amount of product shipped in a particular vessel. The amount of product shipped may depend, however, on the load-bearing capacity of the stacked cartons. It is therefore desirable to produce cartons having high rigidity and/or strength in compression for shipping, and for other purposes such as the protection of the carton contents in general.
A conventional method for increasing the strength of a carton is to produce the carton from a blank of a different, stronger board material, or to produce the blank from the same carton material but of greater thickness. Such methods typically increase the costs associated with manufacturing the carton, with the material costs of manufacture generally increasing according to the cost of increasing the strength and/or thickness of the entire blank. Some sections of the blank, however, may not be load-bearing, and the additional costs associated with increasing the strength of non-load bearing sections of the blank are wasted.
In general, one aspect of the disclosure is generally directed to a carton for holding a plurality of articles. The carton comprises a plurality of panels that extends around an interior of the carton. The plurality of panels comprises a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel. The bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line. A plurality of end flaps are respectively foldably connected to a respective panel of the plurality of panels and are at least partially overlapped to close an end of the carton. The plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The first distal side end flap is in face-to-face contact with the second distal side end flap, the first bottom end flap is in face-to-face contact with the first proximal side end flap, and the second bottom end flap is in face-to-face contact with the second proximal side end flap.
In another aspect, the disclosure is generally directed to a blank for forming a carton.
The blank comprises a plurality of panels comprising a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel. The bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line. A plurality of end flaps are respectively foldably connected to a respective panel of the plurality of panels and are for being at least partially overlapped to close an end of the carton formed from the blank. The plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The first distal side end flap is positionable to be in face-to-face contact with the second distal side end flap, the first bottom end flap is in face-to-face contact with the first proximal side end flap, and the second bottom end flap is in face-to-face contact with the second proximal side end flap.
In another aspect, the disclosure is generally directed to a method of forming a carton for containing a plurality of articles. The method comprises obtaining a blank comprising a plurality of panels comprising a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel. The bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line. The blank comprises a plurality of end flaps respectively foldably connected to a respective panel of the plurality of panels. The plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The method comprises positioning the plurality of panels to form an interior of the carton and positioning the plurality of end flaps to at least partially close an end of the carton. The positioning the plurality of end flaps comprises positioning the first distal side end flap to be in face-to-face contact with the second distal side end flap, positioning the first bottom end flap to be in face-to-face contact with the first proximal side end flap, and positioning the second bottom end flap to be in face-to-face contact with the second proximal side end flap.
The foregoing and other features, aspects, and advantages of the invention will become more apparent upon review of the detailed description of the preferred embodiments set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.
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 invention.
Briefly described, the present invention is directed to cartons having enhanced strength and rigidity. The cartons are formed from primary blanks reinforced with one or more reinforcing blanks adhered to the primary blanks. In this specification, the terms “bottom,” “side,” and “top” are used to indicate orientations determined in relation to fully erected cartons placed in upright configurations, and are not intended to limit the scope of the invention.
Referring to
The first side panel 20 is foldably connected at each end to a first proximal side end flap 22, which is connected to a first distal side end flap 24. The bottom panel 30 is foldably connected at each end to two bottom end flaps 32. The bottom end flaps 32 are separated by transversely extending cuts 34. The second side panel 40 is foldably connected at each end to a second proximal side end flap 42, which is connected to a second distal side end flap 44. The first top panel 50 is foldably connected at each end to a first top end flap 52. The second top panel 60 is foldably connected at each end to a second top end flap 62. Handle apertures or knockouts 54 may be formed in one or both of the first and third top panels 50, 70. The end flaps 22, 24, 32, 42, 44, 52, 62 extend along a first and a second marginal area of the blank 6, and may be connected at first and second longitudinally extending fold lines 65, 66. The longitudinal fold lines 65, 66 may be straight, or they may be offset at one or more locations to account for, for example, blank thickness. The first side end flaps 22, 24 are foldably connected at longitudinal fold lines 25, and the second side end flaps 42, 44 are foldably connected at longitudinal fold lines 45.
The first reinforcing blank 8 has a perimeter that may be in part generally complementary to a part of the first marginal area of the primary blank 6. The first reinforcing blank 8 is meant to overlie a part of the first marginal area of the primary blank 6 in order to reinforce the blank 6. The first reinforcing blank 8 includes a strip 80 of sequentially arranged rectangular reinforcing panels 81, 82, 83, 84, 85, 86, 87, and foldably attached reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′. During erection, the blank 8 is placed over the primary blank 6 so that the reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′ of the first reinforcing blank 8 overlie and generally conform in shape to corresponding end flaps 62, 22, 32, 32, 42, 52, respectively, of the primary blank 6. The sequentially arranged reinforcing panels 81, 82, 83, 84, 85, 86, 87 are aligned with respective panels 60, 20, 30, 40, 50, 70 of the primary blank 6 so that the reinforcing blank 9 folds along the transverse fold lines 61, 31, 35, 41, 51, 71 in the primary blank 6.
Similarly, the second reinforcing blank 9 has a shape that may be in part generally complementary to a part of the second marginal area of the primary blank 6, and is meant to overlie and reinforce a second part of the first blank 6. The second reinforcing blank 9 includes a strip 90 of sequentially arranged rectangular reinforcing panels 91, 92, 93, 94, 95, 96, 97, and reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′. During erection, the second reinforcing blank 9 is placed over the primary blank 6 so that the reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′ of the reinforcing blank 9 overlie and generally conform in shape to the end flaps 62, 22, 32, 32, 42, 52 of the primary blank 6. The reinforcing panels 91, 92, 93, 94, 95, 96, 97 are aligned with respective panels 60, 20, 30, 40, 50, 70 of the primary blank 6 so that the second reinforcing blank 9 folds along the transverse fold lines 61, 31, 35, 41, 51, 71 of the primary blank 6. Portions of the second reinforcing blank 9 may be, for example, a mirror image of the first reinforcing blank 8, and certain common reference numerals are therefore used in the reinforcing blanks 8 and 9.
The third reinforcing blank 407 is designed to overlie and reinforce a central section of primary blank 406. The third reinforcing blank 407 comprises a series of sequentially arranged reinforcing panels 471, 472, 473, 474, 475, 476, 477. During erection, the third reinforcing blank 407 is placed over the primary blank 406 so that the reinforcing panels 471, 472, 473, 474, 475, 476, 477 overlie and are adhered to the panels 460, 420, 430, 440, 450, 470 of the primary blank 460. The resultant multi-ply blank 410 formed from the blanks 406, 407, 408, 409 is shown in
Referring to
Referring to
According to the above embodiments, a primary blank can be reinforced at selected locations by reinforcing blanks. The carton formed from the resulting multi-ply blank can accordingly have enhanced strength and rigidity at selected sections of the carton. According to the present invention, selected reinforcement of specific areas of the primary blank can produce a high strength carton while using relatively small amounts of board.
One or more of the reinforcing blanks discussed above may be omitted in the above embodiments, for example, if a lesser amount of reinforcement is sufficient for a particular application.
In accordance with the exemplary embodiments, the cartons may be constructed of paperboard, for example. The blanks, and thus the cartons, can also be constructed of other materials, such as cardboard, solid unbleached sulfate (SUS) board, or any other material having properties suitable for enabling the carton to function at least generally as described above.
In one exemplary embodiment, the primary and reinforcing blanks are formed from SUS board. The primary blank has a caliper in the range of about 14-30 point, which may be more specifically in the range of about 18-26 point. The caliper of the reinforcing blanks can be slightly less than the primary blank, and can be in the range of about 14-20 point.
The blanks can also be laminated to or coated with one or more additional sheet-like materials at selected panels or panel sections. One or more panels of the blanks discussed above can be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product, advertising, and other information or images. The blanks may also be coated to protect any information printed on the blanks. The blanks may be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.
In accordance with the above-described embodiments of the present invention, a fold line can be any substantially linear, although not necessarily straight, line of disruption or other form of weakening that facilitates folding therealong.
In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” 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 carton panels in place.
The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected embodiments of the invention, but it is to be understood that the invention 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.
This application is a continuation application of U.S. application Ser. No. 14/095,136, filed Dec. 3, 2013, which is a divisional of U.S. application Ser. No. 11/549,355, filed Oct. 13, 2006, which claims the benefit of U.S. Provisional Application No. 60/726,408, filed Oct. 13, 2005, and U.S. application Ser. No. 11/549,355 is a continuation-in-part of application Ser. No. 11/524,574, filed Sep. 21, 2006, which claims the benefit of U.S. Application Ser. No. 60/719,309, filed Sep. 21, 2005.
Number | Name | Date | Kind |
---|---|---|---|
499655 | Clark | Jun 1893 | A |
642121 | Hildreth | Jan 1900 | A |
1503161 | Hornecker | Jul 1924 | A |
1634073 | Labombarde | Jun 1927 | A |
1656919 | Marsh | Jan 1928 | A |
1762704 | Smith | Jun 1930 | A |
1901483 | Ware, Jr. | Mar 1933 | A |
1912698 | Forsman | Jun 1933 | A |
1925102 | Levkoff | Sep 1933 | A |
1951408 | Haven | Mar 1934 | A |
1971863 | Lupton | Aug 1934 | A |
2027079 | Weiss | Jan 1936 | A |
2141743 | Ethridge | Dec 1938 | A |
2145430 | New | Jan 1939 | A |
2152079 | Mott | Mar 1939 | A |
2196243 | Bensel | Apr 1940 | A |
2290971 | King | Jul 1942 | A |
2330294 | Leavitt et al. | Sep 1943 | A |
2383853 | Guyer | Aug 1945 | A |
2407802 | Stotter | Sep 1946 | A |
2416332 | Lehman | Feb 1947 | A |
2619276 | Gibbons | Nov 1952 | A |
2643589 | Weiss | Jun 1953 | A |
2679349 | Mullinix | May 1954 | A |
2710134 | Schroeder et al. | Jun 1955 | A |
2791362 | Nute | May 1957 | A |
2852177 | Frasch | Sep 1958 | A |
2875938 | Bramhill | Mar 1959 | A |
2887389 | Linville | May 1959 | A |
2909312 | Conerty | Oct 1959 | A |
2933228 | Reynolds | Apr 1960 | A |
2954913 | Rossman | Oct 1960 | A |
2967610 | Ebert et al. | Jan 1961 | A |
2990992 | Ellis | Jul 1961 | A |
3002613 | Merkel et al. | Oct 1961 | A |
3090483 | Altree et al. | May 1963 | A |
3092301 | Selle | Jun 1963 | A |
3094266 | Hoff | Jun 1963 | A |
3157342 | Grady | Nov 1964 | A |
3158312 | Daniel | Nov 1964 | A |
3164316 | Wurster et al. | Jan 1965 | A |
3199763 | Anderson | Aug 1965 | A |
3265283 | Farquhar | Aug 1966 | A |
3276665 | Rasmussen | Oct 1966 | A |
3280968 | Craine | Oct 1966 | A |
3434648 | Du Barry, Jr. | Mar 1969 | A |
3653495 | Gray | Apr 1972 | A |
3677458 | Gosling | Jul 1972 | A |
3698548 | Stenzel et al. | Oct 1972 | A |
3759378 | Werth | Sep 1973 | A |
3786914 | Beutler | Jan 1974 | A |
3884348 | Ross | May 1975 | A |
4008849 | Baber | Feb 1977 | A |
4059220 | Lorenz | Nov 1977 | A |
4113100 | Soja et al. | Sep 1978 | A |
4267959 | Gilbert | May 1981 | A |
4519538 | Omichi | May 1985 | A |
4558785 | Gordon | Dec 1985 | A |
4586643 | Halabisky et al. | May 1986 | A |
4742917 | Bornwasser | May 1988 | A |
4760952 | Wachter et al. | Aug 1988 | A |
4773541 | Riddell | Sep 1988 | A |
4778057 | Allen et al. | Oct 1988 | A |
4815609 | Kiedaisch | Mar 1989 | A |
4865187 | Zulauf et al. | Sep 1989 | A |
4886160 | Kligerman | Dec 1989 | A |
4919269 | Wright et al. | Apr 1990 | A |
5012929 | Roosa | May 1991 | A |
5181650 | Hollander et al. | Jan 1993 | A |
5222660 | Koss | Jun 1993 | A |
5328091 | Koss | Jul 1994 | A |
5505372 | Edson et al. | Apr 1996 | A |
5699957 | Blin et al. | Dec 1997 | A |
5783030 | Walsh | Jul 1998 | A |
5842576 | Snow | Dec 1998 | A |
5857570 | Brown | Jan 1999 | A |
5881884 | Podosek | Mar 1999 | A |
D412114 | Hansen | Jul 1999 | S |
5921398 | Carroll | Jul 1999 | A |
5927498 | Saam | Jul 1999 | A |
5979749 | Bozich | Nov 1999 | A |
D419440 | Hansen | Jan 2000 | S |
6015084 | Mathieu et al. | Jan 2000 | A |
6027017 | Kuhn et al. | Feb 2000 | A |
6129211 | Prakken et al. | Oct 2000 | A |
6135289 | Miller | Oct 2000 | A |
6158579 | Rosenbaum | Dec 2000 | A |
6386369 | Yuhas et al. | May 2002 | B2 |
6419152 | Tokarski | Jul 2002 | B1 |
6435351 | Gibb | Aug 2002 | B1 |
6478159 | Taylor et al. | Nov 2002 | B1 |
6510982 | White | Jan 2003 | B2 |
6523692 | Gregory | Feb 2003 | B2 |
6729475 | Yuhas et al. | May 2004 | B2 |
6854639 | Walsh | Feb 2005 | B2 |
6869009 | Sutherland et al. | Mar 2005 | B2 |
6905027 | Galter | Jun 2005 | B2 |
6913189 | Oliff et al. | Jul 2005 | B2 |
6918487 | Harrelson | Jul 2005 | B2 |
6935557 | Aubry et al. | Aug 2005 | B2 |
7021468 | Cargile, Jr. | Apr 2006 | B2 |
7201714 | Zoeckler et al. | Apr 2007 | B2 |
8025209 | Garner | Sep 2011 | B2 |
8196805 | Brand et al. | Jun 2012 | B2 |
8622280 | Colitr-Johnson et al. | Jan 2014 | B2 |
8827144 | Gomes et al. | Sep 2014 | B2 |
9260215 | Coltri-Johnson | Feb 2016 | B2 |
20010048022 | Zoeckler | Dec 2001 | A1 |
20020170845 | Oliff | Nov 2002 | A1 |
20030226879 | Auclair et al. | Dec 2003 | A1 |
20050092649 | Ford et al. | May 2005 | A1 |
20050167291 | Sutherland | Aug 2005 | A1 |
20050218203 | Harrelson | Oct 2005 | A1 |
20060255106 | Green | Nov 2006 | A1 |
20060266815 | Coltri-Johnson et al. | Nov 2006 | A1 |
Number | Date | Country |
---|---|---|
2 320 190 | Nov 1973 | DE |
36 27 019 | Feb 1988 | DE |
298 17 195 | Nov 1998 | DE |
202 16 854 | Jan 2003 | DE |
0 133 595 | Feb 1985 | EP |
0 704 386 | Apr 1996 | EP |
1.379.931 | Dec 1963 | FR |
2 882 032 | Aug 2006 | FR |
1 218 016 | Jan 1971 | GB |
WO 9831593 | Jul 1998 | WO |
WO 03082686 | Oct 2003 | WO |
WO 2004063031 | Jul 2004 | WO |
Entry |
---|
European Search Report for EP 08 01 0412 dated Oct. 22, 2008. |
International Search Report and Written Opinion for PCT/US06/039865 dated Feb. 25, 2008. |
Annex to Form PCT/ISA/266 Communication Relating to the Results of the Partial International Search for PCT/US06/039865 dated Mar. 8, 2007. |
International Search Report for PCT/US06/036818 dated Feb. 5, 2007. |
Preliminary Amendment for U.S. Appl. No. 11/549,355 dated Jun. 3, 2008. |
Office Action for U.S. Appl. No. 11/549,355 dated Oct. 1, 2009. |
Response to Election of Species Requirement for U.S. Appl. No. 11/549,355 dated Nov. 2, 2009. |
Office Action for U.S. Appl. No. 11/549,355 dated Feb. 18, 2010. |
Amendment A and Response to Office Action for U.S. Appl. No. 11/549,355 dated May 18, 2010. |
Office Action for U.S. Appl. No. 11/549,355 dated Aug. 11, 2010. |
Request for Continued Examination (RCE) Transmittal for U.S. Appl. No. 11/549,355 dated Nov. 10, 2010. |
Amendment B and Response to Office Action for U.S. Appl. No. 11/549,355 dated Nov. 10, 2010. |
Office Action for U.S. Appl. No. 11/549,355 dated May 14, 2013. |
Amendment C and Response to Office Action for U.S. Appl. No. 11/549,355 dated Jul. 30, 2013. |
Notice of Allowance and Fee(s) Due for U.S. Appl. No. 11/549,355 dated Sep. 3, 2013. |
Part B—Fee(s) Transmittal for U.S. Appl. No. 11/549,355 dated Dec. 3, 2013. |
Issue Notification for U.S. Appl. No. 11/549,355 dated Dec. 18, 2013. |
Office Action for U.S. Appl. No. 14/095,136 dated Apr. 16, 2015. |
Response to Election of Species for U.S. Appl. No. 14/095,136 dated May 15, 2015. |
Office Action for U.S. Appl. No. 14/095,136 dated Jun. 4, 2015. |
Amendment A and Response to Office Action for U.S. Appl. No. 14/095,136 dated Aug. 27, 2015. |
Notice of Allowance and Fee(s) Due for U.S. Appl. No. 14/095,136 dated Oct. 8, 2015. |
Part B—Fee(s) Transmittal for U.S. Appl. No. 14/095,136 dated Jan. 7, 2016. |
Issue Notification for U.S. Appl. No. 14/095,136 dated Jan. 27, 2016. |
Number | Date | Country | |
---|---|---|---|
20160114930 A1 | Apr 2016 | US |
Number | Date | Country | |
---|---|---|---|
60726408 | Oct 2005 | US | |
60719309 | Sep 2005 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 11549355 | Oct 2006 | US |
Child | 14095136 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 14095136 | Dec 2013 | US |
Child | 14990373 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 11524574 | Sep 2006 | US |
Child | 11549355 | US |