BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill of the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures in which:
FIG. 1 shows a schematic perspective view of an embodiment of a carton carrier according to the present subject matter;
FIG. 2 shows a schematic vertical cross-sectional view of the embodiment of the carton carrier of FIG. 1 along lines I-I;
FIG. 3 shows a perspective view of an embodiment of a blank used to create a carton carrier according to the present subject matter;
FIG. 4 shows a schematic perspective view of the blank of FIG. 3 used to create a carton carrier according to the present subject matter;
FIG. 5 shows a perspective view of the blank of FIG. 3 folded to form at least a portion of a carton carrier according to the present subject matter;
FIG. 6 shows a schematic perspective view of an embodiment of a carton carrier used in a packaging system according to the present subject matter;
FIG. 7 shows a perspective view of an embodiment of a packaging system according to the present subject matter;
FIG. 8 shows a perspective view of the packaging system according to FIG. 7;
FIG. 9 shows a perspective view of the packaging system according to FIG. 7;
FIG. 10A shows a perspective view of the packaging system according to FIG. 7;
FIG. 10B shows a perspective view of the packaging system according to FIG. 7;
FIG. 11 shows a schematic side elevation view of an embodiment of a carton carrier according to the present subject matter;
FIG. 12A shows a schematic perspective view of an embodiment of a packaging system according to the present subject matter; and
FIG. 12B shows a schematic perspective view of the packaging system according FIG. 12A.
DETAILED DESCRIPTION
Reference will now be made in detail to presently preferred embodiments of the present subject matter, one or more examples of which are shown in the Figures. Each example is provided to explain the subject matter and not as a limitation. In fact, features illustrated or described as part of one embodiment can be used in another embodiment to yield still yet another embodiment. It is intended that the present subject matter covers such modifications and variations.
FIG. 1 illustrates a carton carrier, generally designated as 10, for use in transporting a tray, generally designated as 50, of plantlets. Carton carrier 10 has a bottom panel 12 on which tray 50 may reside. Carton carrier 10 includes end walls, generally designated as 20, on either end of carton carrier 10. Further, carton carrier 10 has supporting side walls, generally designated as 30, that extend upward from the sides of carton carrier 10. Supporting side walls 30 may permit the stacking of other carton carriers thereon. Each supporting side wall 30 may have an outer side panel 32, a top shelf panel 34 and an inner side wall panel 36. The top shelf panels 34 can create upper support surfaces, or shoulders, on which another carton carrier may be placed when the carton carriers are inserted into a transport box. Carton carrier 10 may be dimensioned such that tray 50 fits securely between supporting side walls 30 and end walls 20. For example, supporting side walls 30 and end walls 20 may abut against sides 52 and ends 54 of tray 50, respectively.
Carton carrier 10 may be made from any suitable material. For example, carton carrier 10 may be constructed from plastic, hardboard, fiberboard, or the like. For instance, carton carrier 10 can be made of a fiberboard, such as corrugated cardboard. Preferably, carton carrier 10 may be formed from the folding of a single blank as will be described below.
FIG. 2 illustrates a cross-sectional view of carton carrier 10 shown in FIG. 1 along the lines I-I. Supporting side walls 30 may have a triangular cross-sectional shape, such as an inverted triangular cross-section. However, the supporting walls 30 may also have other cross-sectional shapes, for example, rectangular, trapezoidal, or the like. Outer side wall panels 32 form the outside of supporting side walls 30. Top shelf panels 34 forming upper support surfaces that can extend substantially parallel to bottom panel 12 of carton carrier 10 to provide a surface on which another carton carrier 10 may be placed, thereby permitting carton carriers 10 to be stackable.
Supporting side walls 30 have a height D1 that provides sufficient space D2 above tray 50, which is placed on bottom panel 12. This space D2 permits the plantlets that reside in tray 50 to extend upward without damage by another carton carrier 10 that may be placed upon upper support surfaces of supporting side walls 30. Thus, the space D2 between a top 56 of tray 50 may be great enough for the stalk or stem of the plantlets to stand upright in its natural posture without any unnecessary or harmful bending. Therefore, depending on the type of plantlet being transported, height D1 of the supporting side walls 30 and the space D2 above the tray 50 may vary.
By having an inverted triangular cross-sectional shape with inner side wall panel 36 and outer side wall panel 32 converging at bottom panel 12 of carton carrier 10, supporting side walls 30 also help to secure tray 50 within carton carrier 10 when carton carrier 10 is placed within a transport box. By having inner side wall panels 36 of supporting side walls 30 extending upwardly and inwardly at an acute angle α from the base 12 when carton carrier 10 is within a box, inner side wall panels 36 can help to keep tray 50 secured in carton carrier 10 by abutting sides 52 of tray 50 about top 56 of tray 50 at an angle to hold tray 50 in place. In this manner, carton carrier 10 may help to prevent a jostling of tray 50 during transport of the box in which carton carrier 10 is placed. By minimizing movement of tray 50 in a vertical direction, supporting side walls 30 help to prevent damage to the plantlets placed in tray 50.
FIG. 3 illustrates a blank, generally designated as 60, that may be used to form a carton carrier 10. Blank 60 can be folded along its creases to form end walls 20 and supporting side walls 30 of a carton carrier 10 described above. Blank 60 may be made of material such as plastic, hardboard, fiberboard, or the like. For example, blank 60 may be formed out of cardboard. Such cardboard may be corrugated. The corrugations within the cardboard add strength to the different panels within blank 60 to create a sturdier carton carrier 10. Blank 60 includes bottom panel 12 formed between a first end crease 14, a second end crease 16, a first side wall crease 18 and a second side wall crease 19.
The first and second end creases 14 and 16 may define first and second ends of bottom panel 12. Further, first side wall crease 18 and second side wall crease 19 may define first and second sides, respectively, of bottom panel 12.
Blank 60 also includes end wall panels 22 on opposite sides of first end crease 14 and second end crease 16 from bottom panel 12. End wall panels 22 can be folded upward along first and second creases 14, 16 from bottom panel 12 to form end walls 20 of carton carrier 10. On the opposite sides of the first and second side wall creases 18, 19 from bottom panel 12, blank 60 includes outer side wall panels 32, top shelf panels 34 and inner side wall panels 36 used to form supporting side walls 30. Extending out from the sides of bottom panel 12, each outer side wall panel 32 follows the respective side wall creases 18, 19. Each of outer side wall panels 32 are followed by the respective top shelf panel 34 which is then followed by the respective inner side wall panel 36.
Each inner side wall panel 36 and top shelf panel 34 may be folded along supporting wall creases 38 as each outer side wall panel is folded along side wall creases 18, 19 to form supporting side wall 30. The inner side wall panels 36 may be secured on or about the bottom panel 12 in a variety of ways. For example, glue, glue strips, tape, staples, or the like may be used to hold inner side wall panels 36 to bottom panel 12.
Other mechanical means may also be used. For instance, on an outer edge 40 of inner side wall panel 36, one or more jags 42 may extend outward from blank 60. These jags 42 may fit into corresponding sleeves or slots 44 cut into blank 60 along each of the side wall creases 18, 19 when top shelf panels 34 and inner side wall panels 36 are folded inward along supporting wall creases 38 as outer side wall panels 32 are folded upward along side wall creases 18,19 to form support walls 30. Top shelf panel 34 may have finger apertures 46 cut into blank 60. These finger apertures 46 permit easy insertion and removal of carton carrier 10 from the transport box in which it will be placed and/or removed.
FIG. 4 illustrates a blank 60 with tray 50 of plantlets placed on bottom panel 12. Tray 50 may be placed on bottom panel 12 and outer side wall panels 32 may be folded up along side wall creases 18, 19 in directions A1. Top shelf panel 34 may be folded around supporting wall creases 38 in directions A2, while inner side wall panel 36 may be folded over around supporting wall creases 38 in directions A3 to form supporting side walls 30. Once the outer side wall panels 32, top shelf panels 34, and inner side wall panels 36 are folded around and jags 42 are inserted into sleeves 44 (see FIG. 3), the supporting side walls 30 of carton carrier 10 are formed. Similarly, the supporting side walls 30 may be formed before tray 50 is placed on bottom panel 12.
If the blank is made from corrugated cardboard as shown in FIG. 4, ribs 62 may run perpendicular to side wall creases 18, 19 and supporting side walls 30, while running parallel to end creases 14, 16 and end walls 20. These ribs 62 within the corrugation can also help stabilize carton carrier 10. Also, blank 60 can be different sizes depending on the size of tray 50 which is to be used. Similarly, bottom panel 12 can be different widths and lengths and the panels, which form end walls and side walls may be different heights depending on the size of the tray and the size of the plantlets being transported.
As shown in FIG. 5, once outer side wall panels 32 are folded along side wall creases 18, 19, and top shelf panel 34 and inner side wall panel 36 are folded over along supporting wall creases 38 to form supporting side walls 30, end panel 22 can be folded up to form end walls 20 to finish forming carton carrier 10. However, with carton carrier 10 outside the box, the support walls 30 do not necessarily have to reside up against tray 50. Further, end walls 20 will not necessarily have to reside against ends 54 of tray 50 even when carton carrier 10 is outside the transport box in which it will be inserted.
FIG. 6 illustrates a carton carrier 10 being placed into a transport box 70, once supporting side walls 30 are formed and tray 50 of plantlets are placed on bottom panel 12 of carton carrier 10. As can been seen from FIG. 6, end panels 22 which form end walls 20 now have to be folded into a standing position to fit into a transport box, generally designated as 70. Transport box 70 may have an interior 72 which is generally similar to the shape of the outer perimeter formed by supporting side walls 30 and end walls 20 of carton carrier 10 once carton carrier 10 is placed into transport box 70. End panels 22 do not have to be folded along first and second end creases 14, 16 (see FIG. 4) to form end walls 20 until carton carrier 10 is placed within transport box 70. As carton carrier 10 is lowered into the interior 72 in direction B, end walls 74 of transport box 70 fold end panels 22 in a direction C along first and second end creases 14, 16 to form end walls 20. Carton carrier 10 may be lowered into transport box 70 by using finger apertures 46 to lower carton carrier 10 into interior 72 of transport box 70. Once carton carrier 10 is lowered into transport box 70, transport box 70 may hold supporting side walls 30 and end walls 20 in an upright, or standing, position as shown in FIG. 1. At this point, carton carrier 10 is supported on four sides. End walls 20 help create a sturdier carton 10 by adding greater support in a direction perpendicular to supporting side walls 30 to prevent sagging of bottom panel 12.
FIG. 7 shows a carton carrier 10 being placed within a transport box 70. A tray 50 may be placed upon bottom panel 12 of carton carrier 10, and the panels that form supporting side walls 30 can be quickly folded to create the supporting side walls 30 in a timely manner. Top shelf panels 34 define finger apertures 46 therein to allow carton carrier 10 to be lowered into transport box 70. As carton carrier 10 is placed within transport box 70, end walls 74 of transport box 70 force end panels 22 upward to form end walls 20 of carton carrier 10. Carton carrier 10 is then pushed downward into transport box 70 to until it rests firmly against an upper support surface of another carton carrier or against the bottom of transport box 70.
FIG. 8 shows a carton 10 disposed within transport box 70. Carton carrier 10 has tray 50 disposed therein for carrying plantlets. Tray 50 resides on a bottom panel of the carton 10. Transport box 70 supports supporting side walls 30 and end walls 20 of carton carrier 10 in upright positions to provide the desired protection to the plantlets that may be disposed within tray 50. Side walls 76 of transport box 70 may help to support supporting side walls 30 of carton carrier 10 in an upright position and may push supporting side walls 30 against sides 52 of tray 50. End walls 74 of transport box 70 may help to support end walls 20 of carton carrier 10 in an upright position and may push end walls 20 against ends 54 of tray 50. Top shelf panels 34 provide upper support surfaces which allow for the stacking of a similar carton carrier within transport box 70 on top of upper support surfaces.
As stated above, height H (see FIG. 6) of transport box 70 may correspond to a height of a select number of carton carriers 10 that may fit within transport box 70. For example, as shown in FIG. 9, height H of box 70 may permit six carton carrier 10 to be stacked within interior 72 of box 70 with the last carton being flush with an outer edge 73 of the interior 72 of transport box 70. At this point, inner lids 78 and outer lids 79 may be closed onto the top carton carrier 10 to form a top wall of transport box 70. Since top carton carrier 10 is flush with outer edge 73 of interior 72 of transport box 70, this carton carrier 10 will also be flush with a top wall formed by inner lids 78 and outer lids 79 once these lids 78, 79 are folded into a closed position.
As shown in FIGS. 10A and 10B, inner lids 78 may be folded into a closed position with the outer lids 79 folded on top of the inner lids 78 and secured to form a top wall 80 of transport box 70. Similar inner and outer lids may be folded and secured in a closed position to form a bottom wall of transport box 70. The folding closed and securing of inner lids 78 and outer lids 79 further facilitate quick and easy shipment of the trays of plantlets. With the trays securely placed between the supporting side walls of the carton carrier and the carton carrier placed securely within transport box 70, movement of the trays within transport box 70 is minimized or prevented.
The inner and outer lids 78, 79 for both the top and the bottom of transport box 70 may have lengths and widths that permit full coverage of the opening of interior 72 of transport box 70 when each set of lids are folded into a closed position. For example, the edges 82 of inner lids 78 may abut against one another and the edges 84 of outer lids 79 may abut against one another. Alternatively, edges 82 of inner lids 78 may overlap one another when the inner lids 78 are folded in a closed position, while edges 84 of outer lids 79 may overlap one another when the inner lids 78 are folded in a closed position. By providing full coverage of the opening of interior 72 of transport box 70 with each set of lids 78, 79, the plantlets contained within transport box 70 are better insulated against outside temperatures. Also, with each carton carrier 10 (see FIG. 1) having end walls 20 and supporting walls 30, at least two layers of walls exist between the plantlets within the trays in carton carriers 10 and the outer environment surrounding transport box 70. Further, the strength in the width and length directions can be maximized.
FIG. 11 illustrates a side view of a carton carrier 10 having a tray 50 residing upon bottom panel 12 of carton carrier 10 as carton carrier 10 resides within a transport box. The weight of tray 50 creates a downward force F1 on the carton carrier 10. This created force F1 causes carton carrier 10 to want to bow inward in the directions E1 and E2 and thereby bend bottom panel 12 outward. By having end walls 20 folded upward and perpendicular to supporting side walls 30, end walls 20 counteract the tendency of carton carrier 10 to bow inward caused by force F1. End walls 20, which run perpendicular to supporting side walls 30, resist the bowing tendency by adding strength to carton carrier 10 in a width direction on either end of carton carrier 10. Even after carton carrier 10 is dampened through absorption of moisture from trays 50, end walls 20 still help to minimize any sagging of bottom panel 12 due to the added stability by end walls 20. In this manner, the sturdiness and stability of carton carrier 10 is greatly increased over carton carriers which have only two parallel side walls. At the same time, the amount of time needed to assemble cartons 10 is not increased, because no extra steps are needed to form end walls 20 within carton carrier 10. This is due to the fact that end walls 20 may be pushed into place by placement of carton carrier 10 within the transport box used to ship the plantlets to a desired location.
By having both end walls 20 and supporting side walls 30 within carton carrier 10, carton carrier 10 is made more stable and less likely to bend or collapse because end walls 20 and supporting side walls 30 add support in three different directions. As seen in FIG. 12A, supporting side walls 30 provide stability in a length direction Z with its inner side wall panel 36 and outer side wall panel 32 as well as top shelf panel 34. Further, these panels 32, 34, 36 of supporting side wall 30 also provide stability in carton carrier 10 in a height direction Y. Finally, by having end wall panels 22 that fold up to create end walls 20 of carton carrier 10, stability is created in a width direction X of carton carrier 10. By having added stability in carton carrier 10 in width direction X, height direction Y, and length direction Z, a more stable carton carrier is created for placement of a tray 50 thereon. The added stability by supporting side walls 30 and end walls 20 in the directions X, Y, and Z help to minimize sagging or bending of carton carrier 10 and thereby tray 50 which is placed thereon. Thus, damage to the plantlets within tray 50 due to the stability of carton carrier 10 can be minimized.
Transport box 70 with its end wall 74, side wall 76, inner lids 78 and outer lids 79 add stability in three directions as well. As shown in FIG. 12B, side walls 76 add stability in direction Y and direction Z. End walls 74 add stability in direction X and direction Y, while outer lids 79 add stability in direction Z and inner lids 78 add stability in direction X as shown in FIG. 12A.
Further, depending on the corrugation of the fiberboard used to create carton carrier 10, the ribs within the corrugation can also help stabilize carton carrier 10 in different directions. For example, the ribs of corrugation that run perpendicular to supporting side walls 30 may help to reinforce the stability of carton carrier 10 in both the height direction Y and the width direction X. Tray 50 placed within carton carrier 10 may also help to stabilize carton carrier 10 in both the width direction X and the length direction Z depending on the stability of tray 50. Similarly, transport box 70 may be made of a corrugated fiberboard such that the ribs of the corrugation help to reinforce the stability of transport box 70 for protection of the plantlets contained within the trays on carton carrier 10 within transport box 70. The ribs of the corrugation of the transport box 70 may reinforce transport box 70 in any or all of directions X, Y, and Z.
The packing systems and apparatuses disclosed above are designed to be efficient in loading and unloading of boxes, while creating greater strength in the box with minimal use of a carton. Such a system reduces the labor cost of packing and unloading of plantlets, thereby reducing the overall cost associated with the plantlets. The system is easy to understand and can increase efficiency of packing and shipping plantlets, even in high volume production environments including third world countries where education of the work force may be limited.
The embodiments of the present disclosure shown in the drawings and described above are exemplary of numerous embodiments that can be made within the scope of the appending claims. It is contemplated that the configurations for packaging trays of plantlets for transport can comprise numerous configurations other than those specifically disclosed. Thus, it is the applicant's intention that the scope of a patent issuing herefrom will only be limited by the scope of the appending claims.
Patent Application
20080053854
