BACKGROUND OF THE INVENTION
The present invention relates generally to cartons or containers and, more particularly, to improved containers having a three-piece, generally triangular prismatic construction. It is particularly advantageous for use in connection with objects having at least a portion which is generally in circular cross-sectional shape, such as cans, bottles, balls, rolls, tubes, and the like.
Traditionally, cartons or containers for multi-packs of beverage containers, such as six-pack or twelve-pack cartons for beer, soft drinks, and the like have been formed by folding and securing from one-piece blanks of paper board sheet material. Often, it is desired to employ a paper board sheet material that is laminated with a decorative plastic, foil, and/or printed layer to increase attractiveness to the consumer. Such laminates must be formed prior to forming the blank and add significantly to the cost of the sheet material, particularly where laminate includes a metallized or holographic layer. Thus, a drawback of using a one-piece carton is that the tops and bottoms of the carton are also, necessarily, formed of the expensive laminate sheet material. This adds to the cost of the carton, while adding little or no additional value to the carton since, generally, only the side of the carton is viewed by the purchaser, i.e., when it is stacked on a shelf or display, e.g., at a place of purchase.
Another drawback of the conventional one-piece carton designs is the large amount of waste typically generated when the blanks are stamped or die cut. This likewise adds to the cost of the carton, particularly when an expensive laminated paperboard sheet material is used, again, since any decorative laminates must be applied prior to cutting the blank.
The present invention provides a new and improved carton, blank, and method that overcome the above-referenced problems and others.
SUMMARY OF THE INVENTION
In one aspect, a carton for carrying a plurality of like objects having a generally circular cross-sectional shape includes a generally triangular first panel forming a base of the carton having first, second, and third sides and a generally triangular second panel coextensive with the base panel and opposing the base panel in aligned facing relation. A one-piece peripheral sidewall is secured to and extends between the first and second panels and has a cross-sectional shape coextensive with the first and second panels. The peripheral sidewall has three planar sides, each of which is connected to an adjacent planar side through a non-folded corner having a radius of curvature which is approximately equal to a radius of curvature of the objects to be carried.
In another aspect, a carton sidewall blank is formed of a sheet material being cut and scored and adapted to be assembled to define a tubular carton sidewall having generally triangular cross-sectional shape. The blank is further adapted to be combined with at least one separately formed, generally triangular end closure panel to define a generally triangular prismatic carton, the triangular prismatic carton being adapted to carry a plurality of like objects having a generally circular cross-sectional shape. The blank includes a generally rectangular main portion for forming the tubular sidewall and a first fold line parallel to a first edge of the main portion defining a first folding strip along the first edge. A second fold line runs parallel to a second edge of the main portion opposite the first edge and defines a second folding strip along the second edge. A plurality of score lines within the folding strips run perpendicular to the first and second fold lines and are arranged to facilitate bending the sidewall blank to form the tubular carton sidewall wherein the tubular carton sidewall has three planar sidewall surfaces wherein each planar sidewall surface is adjoined to an adjacent planar sidewall surface via a curved sidewall surface having a radius of curvature approximately equal to a radius of curvature of the objects to be carried.
In yet another aspect of the present invention, a method of forming a generally triangular prismatic carton adapted to carry a plurality of like objects having a generally circular cross-sectional shape is provided. The method comprises forming sidewall blank from a sheet of material comprising a generally rectangular main portion for forming the tubular sidewall and scoring a first fold line on the main portion parallel to a first edge of the main portion, the fold line defining a first folding strip along the first edge. A plurality of score lines are scored within the first folding strip running perpendicular to the first and second fold lines. The sidewall blank is bent to form a tubular carton sidewall having three planar sidewall surfaces wherein each planar sidewall surfaces is adjoined to an adjacent planar sidewall surface via a curved sidewall surface having a radius of curvature approximately equal to a radius of curvature of the objects to be carried, wherein the plurality of score lines arranged to facilitate the bending. An end of the tubular carton sidewall is closed by attaching a separately formed, generally triangular panel.
One advantage of the present invention resides in the provision of a triangular carton which uses less sheet material than the conventional rectangular cartons, thereby reducing its cost.
Another advantage of the present invention resides in the provision of a three-piece carton construction which does not require the base and top portion to be formed from the same sheet material as the sidewall portion. As such, the cost of the components is reduced even more since expensive printed and/or laminated materials such as a sheet material having lithographic, foil, or holographic laminate layers can be reserved for the sidewall, and wherein an inexpensive undecorated sheet material may be used for the base and/or cover portions.
Yet another advantage of the present invention resides in the fact that its manufacture may be adapted to existing assembly equipment.
Yet another advantage resides in a the provision of a prismatic carton system allowing cylindrical, spherical, or other objects having a generally circular cross-sectional shape to be packaged in less space, thereby reducing space requirements and/or storage costs for the packaged goods.
Still further benefits and advantages of the invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description may be best understood when read in reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of an exemplary carton in accordance with the present invention;
FIG. 2 is an exploded view of an exemplary carton of the invention, further including a cover, illustrating the three-piece construction;
FIG. 3 is a plan view of a blank for forming the side wall of the carton shown in FIG. 1;
FIG. 4 is a perspective view of a carton in accordance with a further embodiment of the invention;
FIG. 5 is a plan view of a blank for forming the side wall of the carton shown in FIG. 4;
FIG. 6 is an exploded view of a carton for beverage containers in accordance with yet another embodiment of the invention;
FIG. 7 is a plan view of an exemplary bottom blank for forming a carton base;
FIGS. 8A and 8B are fragmentary cross-sectional views taken along the lines 8—8 of FIG. 1, illustrating exemplary manners of securing the bottom blank to the side wall;
FIG. 9 is an exploded view of a carton according to yet another embodiment of the present invention;
FIGS. 10 and 11 depict alternative lid members for use with the embodiment of FIG. 9.
FIG. 12 is a perspective view of a carton according to still another embodiment of the present invention;
FIG. 13 is an exploded view of a carton for spherical objects, such as golf balls, in accordance with still another embodiment; and
FIGS. 14 and 15 illustrate multi-pack arrangements of the cartons as shown in FIG. 13.
FIG. 16 is an exploded view of a carton according to a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a generally triangular carton 10 includes a vertically raised peripheral sidewall 12 secured to a base 14 (see FIG. 2). The carton 10 is adapted to hold objects which are generally cylindrical or otherwise have a generally circular cross-sectional shape, such as beverage bottles 16 or cans. It will be recognized that the dimensions of the carton 10 may be adapted to hold other types of objects having a generally circular cross-sectional shape such as spherical objects such as balls, or elongate objects such as such cigars, cigarettes, rolls of sheet material such as aluminum foil, plastic wrap, paper products, and the like. The carton is particularly suited to hold the bottles 16 or other objects in a triangular configuration wherein each bottle is placed or interposed between two bottles of an adjacent row. Thus, the carton 10 of the present invention may hold, for example, three, six, ten, fifteen, twenty-one, twenty-eight, thirty-six objects, and so on.
The carton 10 preferably includes a structurally reinforced upper rim 18. This may be formed, for example, by folding or rolling the upper edge of the sidewall panel 12. In a preferred embodiment, the upper rim 18 is formed by folding the upper edge of the sidewall panel 12 toward the interior facing surface thereof. In another preferred embodiment, the upper rim 18 is formed by rolling the upper edge of the sidewall panel 12 toward the exterior facing surface thereof.
The carton 10 is depicted in FIG. 1 with an optional handle 20. Preferably, the handle 20 is integrally formed with the sidewall panel 12, although handles that are separately formed and attached to the container are also contemplated.
Referring now to FIG. 2, there is shown an exploded view of the container 10 shown in FIG. 1, further including a lid or cover 22. The lid 22 includes an upper portion or panel 24 and a peripheral base portion 26. In one embodiment, the lid 22 is a one-piece folded unit which is sized to engage the upper rim 18 in removable fashion, e.g., via a frictional fit, snap fit, etc., to cover an opening 23 in the carton 10.
Alternatively, the upper portion 24 of the lid 22 may be moveable with respect to or separable from the base portion 26. For example, the base portion 26 may attach to the rim 18 of the sidewall 12 with the upper portion 24 being removably and/or moveably mounted on the base portion 26 of the cover 22. For example, the base portion 26 may be secured to the rim 18, e.g., via an adhesive, mechanical fastener, or the like. The upper portion 24, in turn, is movably or removably secured to the base portion 26, e.g., via a frictional fit, snap fit, or other retention means. In an especially preferred embodiment, the upper portion 24 is secured to the base portion 26 via a hinge 28 (shown in phantom) wherein it may pivotally be opened to a position 29 (shown in phantom) and may be secured in the depicted closed position at the opposite corner via a fastener 30 (shown in phantom), e.g., a snap-fit type fastener or the like. For example, fastener 30 may be comprise a protrusion formed on one of the members 24 and 26 engaging a complimentary depression or receptacle formed on the other.
Referring now to FIG. 3, there appears a plan view of a carton sidewall blank 12 with integral handle 20. The sidewall blank 12 is formed of a sheet material such as a paperboard material, plastic, or a combination thereof, and preferably a paperboard and plastic laminate. The sidewall blank 12 can be cut, e.g., die cut, from a larger sheet of material, with the cutout regions 34 and, in some cases, the handle openings 36, forming the only waste. Furthermore, in some cases, handle openings 38 may be cut on three sides and scored along edges 38 for hingedly or swingably folding about the line 38 to reinforce the handle 20 when grasped.
Horizontal scoring lines 42 may be formed parallel to transversely extending edges 44 for folding therealong, e.g., toward an unprinted surface 40 of the sidewall 12. Alternatively, the upper edge may be reinforced by rolling, e.g., toward the printed side of the sidewall blank 12 opposite the unprinted side 40.
During construction of the carton 10, the optional handle portion 20 is folded along the line 32, toward the unprinted side 40. The folding of the handle 20 provides additional strength to prevent tearing. However, a non-folded, single-ply handle is also contemplated, e.g., wherein the sheet material forming the sidewall and handle is of sufficient strength to allow the unit to be carried without tearing.
The edges 44 may be folded or rolled as described above. The sidewall blank 12 is then bent or shaped about a mandrel, which may be facilitated by vertical scoring lines 46 preformed in the regions of the blank 12 corresponding to the rounded corners 48 (see FIG. 1) of the container 10. As stated above, the carton 10 in accordance with the present invention is particularly adapted to carry a plurality of like or like-sized objects wherein at least a portion of each object has a generally circular cross-sectional shape, such as a generally cylindrical objects, generally round or spherical objects, and so forth. Thus, the mandrel about which the vertical sidewall 12 is formed produces curved, non-folded corner regions 48 which preferably have a radius of curvature approximately equal to that of the objects 16 to be carried.
The blank 12 is sized so that the axially extending ends 49 (i.e., extending parallel to the axis of the formed tubular sidewall 12) form an axially extending overlap or seam 51 (see FIG. 1), e.g., of about 0.6 cm (0.25 in) to about 1.25 cm (0.5 in), and more preferably about 1.0 cm (0.375 in). The ends are joined via bonding, e.g., via an adhesive such as a hot-melt adhesive, thermosealing varnish, heat-sealable aqueous overcoat, or the like. Preferably, sidewall 12 is formed of plastic or a paperboard or other sheet material comprising a plastic layer or film, such a thermoplastic layer or film so as to render the material sealable via a conventional thermosealing process, wherein facing layers of plastic are joined by surface fusion upon the application of heat and pressure. The plastic film may be applied to the regions of overlapping surfaces to be joined, or, more preferably, over the entire surface of the sheet material forming the container 10. The plastic film may be, for example, acrylonitrilebutadiene-styrene (ABS), polyolefin such as high, medium, or low density polyethylene, polypropylene, methacrylene-butadiene-styrene (MBS), polystyrene, polyvinyl chloride, polyester, or like materials. The construction of the carton 10 of the may be performed manually or under automated or preprogrammed control.
In the depicted embodiments of FIGS. 1-3, the seam 51 is illustrated in a position along one of the generally planar sides 53 a side, i.e., disposed between two of the corners 48. However, it will be recognized that the seam 51 and optional handle 20 may also be placed at or near one of the corner regions 48, as depicted in FIG. 4.
Referring now to FIG. 4, a carton 110, which may be substantially as described above by way of reference to FIG. 1, includes a handle portion 120 which extends from an edge of a sidewall blank 112 forming a seam 51 at a corner 48 of the carton 110. Although the handle 120 will have an increased tendency to lie flat against the sidewall 112 when located between corners, the handle can be retained against the side wall, especially when placed on the corner, via spot gluing, e.g., by the application of adhesive tabs to secure the handle against the sidewall 112, which are releasable upon the grasping of the handle by the purchaser. The handle 120 may be folded as shown in FIG. 3, or may be a single ply handle as depicted in FIG. 5.
With reference now to FIG. 5, an exemplary sidewall blank 112 of FIG. 4 is substantially as described above by way of reference to FIG. 3, but includes a single ply handle 120 and vertical score lines 46 arranged so as to facilitate bending such that the seam 51 lies on a corner 48 (see FIG. 4).
With continued reference to FIG. 4, a lid 22 includes a rim 26 swingably attached to a lid panel 24 via hinge 28, e.g., of a type having rotating or flexible members. The lid panel 24 and rim 26 components of the lid 22 may be formed of the same or a different material, and may be plastic, paper, or a combination thereof. The rim 26 and closure panel 24 are preferably adapted so as to provide a positive retention of the panel 24 when the panel 24 is rotated into a closed position.
FIG. 6 illustrates an exemplary carton 210 according to yet another embodiment of the present invention which lacks a carrying handle. A preferred embodiment lid 222 includes a rim 226 and a swingably attached panel 24 via hinge members 28. The rim member 226 includes a peripheral wall 228 received within and conforming to the opening 29 in the tubular carton 210, and a peripheral flange member 230 engaging upper rim 18 thereof.
With reference to FIG. 7, a exemplary bottom blank 14 is cut or stamped oversized with respect to the opening 23 of the carton 10 (see FIG. 1). In construction of the bottom member 14 of the carton, the peripheral region 50 is folded about the line 52 such that the region 50 forms a downwardly extending peripheral wall 50 (see FIG. 2). The blank 14 may be scored for folding along the line 52, which conforms in size to the size of the opening 23.
Referring now to FIG. 8A, there appears a cross-sectional view of a preferred joint formed between the sidewall 12 and the base 14, taken along the lines 8—8 of FIG. 1. The base portion 14 includes a downwardly extending peripheral portion 50 which is received in the space or channel 52 defined by the sidewall 12 and folded edge 44. The portion 50 may be secured within the channel 52 of the sidewall 12 via bonding, e.g., with an adhesive. Preferably, the sheet material forming the sidewall 12 and base 14 comprises a plastic, such as paperboard with plastic coating or laminate, in which case the base and sidewall may be bonded by thermosealing as described above.
FIG. 8B illustrates an alternative joint between the sidewall 12 and a non-folded base member 14a, which is sized to conform to the size of the opening 23 (see FIG. 1) and is joined at its peripheral edge by an overlapping folded edge 44 of the sidewall 12. The overlapping edge 44 and the peripheral edge of the base 14 may be secured via adhesive bonding or, in the case of plastic or plastic laminated sheet material, via thermosealing as described above.
Referring now to FIG. 9, there appears an alternative generally triangular carton 60 including a vertically raised peripheral sidewall 62 secured to a base 14 as described above. The carton 60 is adapted to hold bottles 16 of a type having a narrow neck portion 64 adjoined to a wider base portion 66, e.g., via an intermediate shoulder portion 65. The sidewall 62 extends at least as high as the top of the base portions 66 of the bottles 16. The carton 60 preferably includes a structurally reinforced upper rim 68 formed, e.g., by folding or rolling the upper edge of the sidewall panel 62. The carton 60 is depicted with an optional handle 20 integrally formed with the sidewall panel 62.
A lid or cover 72 includes a plurality of apertures 74 arranged and adapted to receive the bottlenecks 64 when the lid 72 is placed on the sidewall 62 such that at least a portion of the bottleneck 64 protrudes therethrough, and preferably resting on the shoulders 65. A plurality of slits 76 are spaced about and extend radially from the apertures 74. The paperboard or other sheet material forming the lid 72 is sufficiently rigid or stiff so as to stabilize the bottles 16 within the container 60 and provide positive retention of the bottles 16 therein during transport, handling, and when the container 60 is carried by the handle 20.
Although the material forming the lid 72 has sufficient stiffness to retain the bottles, the material forming the lid 72 is also sufficiently flexible or
Although the material forming the lid 72 has sufficient stiffness to retain the bottles, the material forming the lid 72 is also sufficiently flexible or deformable such that the radial tabs 77 defined by the slits 76 and openings 74 will give way so to allow a bottle 16 to be removed from the carton when desired by grasping the protruding portion of the bottleneck 66 and pulling the bottle 16 upward and through the opening 74, without it being necessary to remove or detach the lid 72 from the carton 60. The slits 76 may be precut or, alternatively, may comprise perforated lines, partially cut lines, or otherwise weakened regions, which allows the slits 76 to be readily broken when a bottle 16 is removed from the container 60.
The lid 72 may be fastened to the upper rim 68 of the sidewall 62 via any number of methods. For example, a mechanical or adhesive type of fastener may be employed or, in the case a carton formed of a plastic or plastic laminate sheet material, the lid 72 may be bonded or fused to the sidewall 62 through the application of heat and pressure as described above. In the embodiment depicted, the peripheral edge 78 of the lid 72 is folded (both upwardly and downwardly folded edges are contemplated) to provide a vertically aligned surface for bonding or fastening to the rim 68 of the sidewall 62 (fastening to an interior or exterior facing surface of the sidewall 62 is contemplated). Alternatively the lid 72 may be fastened to the sidewall 62 through the use of clips, a snap-fit or interlocking engagement between the upper rim 68 of the sidewall 62 and the peripheral edge 78 of the lid 72, or other mechanical faster.
FIGS. 10 and 11 depict alternative lid members 172 and 272, respectively, for use in connection with the embodiment of FIG. 9. The lid 172 includes apertures 74 formed on a panel 124 bounded by a rim 178. The apertures 74 are sized and arranged to receive necks of beverage bottles or the like to be carried in the carton. Each aperture 74 includes a plurality of slits 76 (four in the depicted embodiment) radially extending from and spaced about the apertures and defining flexible, deformable, or deflectable tabs 77 therebetween. In the preferred arrangement shown, the arrangement of the radially slits 76 for each aperture 74 are rotationally offset with respect to the slits 76 of adjacent apertures 74 so as to avoid interference therebetween.
FIG. 11 shows an alternative lid 272 including apertures 74 for receiving bottlenecks of beverage bottles or the like to be carried in the carton formed on a lid panel 224. A series of perforated, partially cut, or otherwise weakened lines 276 defines a plurality of breakaway panels 277, with each breakaway panel including one of the apertures 74. The perforations or otherwise weakened lines 276 bounding each breakaway panel 277 allows each breakaway panel to be selectively removed from the lid panel 224 upon an upward pulling force by a user. Thus, a bottle to be removed from the carton without removing the lid 272 from the carton.
With reference to FIG. 12, an alternative carton embodiment 160 having protruding necks and which may be constructed as described above by way of reference to FIG. 9, but which includes a handle 120 extending from a seam 51 formed along a corner 48 of sidewall 162. A lid 178 is received on the sidewall 162 and includes a plurality of apertures 174 adapted to receive necks 64 of bottles 16 therethrough. The lid 178 may be removable from the carton 160 and/or may optionally include radial slits or breakaway panels as described above by way of reference to FIGS. 9-11.
Referring now to FIG. 13, a carton 80 adapted to hold three golf balls 90 or other balls such as tennis balls, baseballs, softballs, and the like, or other spherical objects, includes a sidewall 82, a base 84, and a lid 92 and may be constructed as described above. A first packaging array, namely, an 18-pack of the golf balls 90, comprising six cartons 80 in hexagonal arrangement is shown in FIG. 14. Alternatively, as shown in FIG. 15, any integral number of three-unit packages 80, preferably from 2 to 12, may be packaged in an outer triangular carton 180 having a length adapted to receive a desired number of the packages 80.
With reference to FIG. 16, there is shown a further embodiment carton 310 in accordance with the present invention which is adapted to carry elongate, e.g., generally cylindrical, objects 116. Although depicted with three objects, it will be recognized that the carton may be adapted to carry other numbers of objects, such as six, ten, fifteen, etc. Examples of elongate articles to be carried include, for example, cigars, cigarettes, rolls of sheet material such as aluminum foil, plastic sheet material, paper, and so forth. The carton construction 310 includes a sidewall 312, a base panel 314, and a lid 322, and may generally be constructed as described above. A handle, not shown, may optionally be provided.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. The forms hereinbefore described being merely explanatory and exemplary, it is intended that the invention be construed as including all such modifications and alterations.