Note: Descriptions are shown in the official language in which they were submitted.
CA 02308583 2004-04-29
ELEVATED BOTTOM CARTON
The present invention relates to a carton having an elevated bottom.
Specifically, the present invention relates to a carton having the edge
portions of
the bottom elevated to protect the raw paperboard edges from damage and
absorption of moisture.
Cartons fabricated from a carton blank on a form, fill and seal packaging
machine risk absorption of moisture into the raw paperboard edges of the
bottom
of the carton. This absorption is accelerated if the raw paperboard edges are
damaged and the carton is continuously exposed to moisture. The
transportation,
loading and storage of the carton from the conveyance between the packaging
machinelpacker unit and the retailer display are all sources for damage and
moisture absorption.
The raw paper edges are a by-product of the composition of the carton
blank. Generally, the carton blank is cut and scored from a sheet of coated
fiberboard material. The coated fiberboard material is usually composed of
three
layers, and may have a barrier layer juxtaposed between fiberboard layers. The
exposed surfaces of this sheet are coated with a polymer material such as
polyethylene. However, the coating does not extend to the edges which are thus
left uncoated, and partially unprotected at least to moisture and sensitive to
damage. When the carton is erected and partially formed, these raw paper edges
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2
are most prevalent at the bottom of the carton. If moisture is absorbed into
the
raw paper edges, the water may be absorbed throughout the fiberboard interior
layer, which due to its cellulose-like nature, has a strong affinity for
liquids.
This absorption of moisture may compromise the integrity of the carton thereby
.
rendering it defective.
This problem has yet to be directly addressed by the packaging industry.
However, inventions directed to resolving the stability of cartons have been
disclosed in the prior art. Mills et al, U.S. Patent Nos. 5,482,204, and
5.588,943.
respectively for a Carton Bottom Sealer and Carton Bottom Sealing Dies
disclose
cartons having an embossed inverse pyramidal bottom which is directed to
providing greater stability to the filled carton and to reduce bulging of the
carton.
It should be noted, as shown in FIGS. 8 and 9 of the Mills et al Patents, that
the
end portions of the exposed raw paper edges of the bottom of the carton are
not
embossed, and therefore are susceptible to moisture absorption.
Fujikawa et al, U.S. Patent No. 5,222.667, for a Container Made Of Paper-
Base Laminate, similarly discloses a carton having an inverted V-shaped bottom
to provide greater stability to the carton. As shown in FIG. 6 of the Fujikawa
et
al Patent, the raw paper edge of panel 27 is not inverted and is susceptible
to
moisture absorption since the V-shaped inversion begins at the raw paper edge
and
since the inversion must be centered to provide stability to the carton.
CA 02308583 2004-04-29
The present invention mitigates the problem of absorption of moisture through
raw paper edges by providing a carton having the raw paper edges elevated in
order to
protect the raw paperboard edges and reduce the susceptibility of moisture
absorption.
The present invention is able to accomplish this without adversely affecting
the carton.
Therefore, an object of the present invention is to provide a carton having
elevated raw paper edges on the bottom of the carton to prevent moisture
absorption.
Another object of the present invention is to provide a carton having all raw
paper
edges on the bottom of the carton elevated in order to prevent moisture
absorption.
One feature of the present invention is the provision of a carton having
bottom
panels sealed together to form a sealed bottom with the edge of one bottom
panel
exposed wherein a region surrounding the edge is elevated to prevent moisture
absorption.
Another feature of the present invention is the provision of a carton having
bottom panels sealed together to form a sealed bottom with a plurality of raw
paper edges
exposed wherein all of the raw paper edges are elevated to prevent moisture
absorption.
Therefore, in one aspect the invention provides a carton having a plurality of
side
panels, the plurality of side panels including at least a first pair of
opposing side panels
and a second pair of opposing side panels generally perpendicular to the first
pair of
opposing side panels, and a plurality of bottom panels, each bottom panel
corresponding
to an adjacent side panel, the plurality of bottom panels being folded and
sealed together
to form a sealed carton bottom, a last folded and sealed bottom panel having
an exposed
edge traversing the bottom of the carton. The carton comprises: a primary
elevated
portion extending along a length of the exposed edge between the first pair of
opposing
side panels and generally parallel to the second pair of opposing side panels,
the primary
elevated portion being inverted into the carton and having an elevation; a
first
substantially planar portion defined by one side of the primary elevated
portion, the first
pair of opposing side panels and one of the second pair of opposing side
panels; a second
substantially planar portion defined by another side of the elevated portion,
the first pair
of opposing side panels and another of the second pair of side panels; and a
secondary
elevated portion disposed within the primary elevated portion, the secondary
elevated
portion having an elevation above the elevation of the primary elevated
portion.
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3a
In another embodiment the invention provides a carton having a plurality of
side
panels, the plurality of side panels including at least a first pair of
opposing side panels
and a second pair of opposing side panels generally perpendicular to the first
pair of
opposing side panels, and a plurality of bottom panels, each bottom panel
corresponding
to an adjacent side panel, the plurality of bottom panels being folded and
sealed together
to form a sealed carton bottom, a last folded and sealed bottom panel having a
first
exposed edge traversing the bottom of the carton and a second exposed edge
substantially
perpendicular to the first exposed edge. The carton comprises: a primary
elevated
portion extending along a length of the first exposed edge between the first
pair of
opposing side panels and generally parallel to the second pair of opposing
side panels,
the primary elevated portion being inverted into the carton and having an
elevation; a
side elevated portion extending along a length of the second exposed edge, the
side
elevated portion being inverted into the carton and having an elevation; a
first
substantially planar portion defined by one side of the primary elevated
portion, the first
pair of opposing side panels and one of the second pair of opposing side
panels; a second
substantially planar portion defined by another side of the primary elevated
portion, the
first pair of opposing side panels and another of the second pair of opposing
side panels;
and secondary elevated portion disposed within the primary elevated portion,
the
secondary elevated portion having an elevation above the elevation of the
primary
elevated portion.
In another aspect a carton according to the invention can have a plurality of
side
panels, the plurality of side panels including at least a first pair of
opposing side panels
and a second pair of opposing side panels generally perpendicular to the first
pair of
opposing side panels, and a plurality of bottom panels, each bottom panel
corresponding
to an adjacent side panel, the plurality of bottom panels being folded and
sealed together
to form a sealed carton bottom, a last folded and sealed bottom panel having a
plurality
of exposed edges; the carton comprising: a plurality of primary elevated
portions, each of
the plurality of primary elevated portions corresponding to an associated one
of the
exposed edges, each of the primary elevated portions having an elevation; and
a
secondary elevated portion disposed within one of the plurality of primary
elevated
portions, the secondary elevated portion having an elevation above the
elevation of the
primary elevated portion within which it is disposed.
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3b
In a specific embodiment according to the invention a carton for a liquid food
product has first, second, third and fourth side panels, each side panel
ending at a
corresponding bottom panel, first and third opposing bottom panels folded
under second
and fourth opposing bottom panels, the fourth bottom panel having a first
exposed edge
of paperboard or paper transversing the bottom of the carton from the end of
the first side
panel to the end of the third side panel and a second exposed edge of
paperboard or paper
substantially perpendicular to the first exposed edge. The carton further
comprises: a
first elevated portion extending along the length of the first exposed edge
from the end of
the first side panel to the end of the third side panel, the first elevated
portion being
inverted into the carton thereby inverting the first exposed edge, the first
exposed edge
lying on a first horizontal plane; a second elevated portion extending along
the entire
length of the second exposed edge, the second elevated portion being inverted
into the
carton thereby inverting the second exposed edge, the second exposed edge
lying on the
first horizontal plane; a first substantially planar portion defined by one
side of the
elevated portion and the ends of the fourth side panel and portions of the
first and third
side panels, the first substantially planar portion being substantially
perpendicular to the
corresponding side panels and lying on a second horizontal plane; and a second
substantially planar portion defined by an opposing side of the elevated
portion and the
ends of the second side panel and portions of the first and third side panels,
the second
substantially planar portion being substantially perpendicular to the
corresponding side
panels and lying on the second horizontal plane. The first substantially
planar portion
and the second substantially planar portion define an area on the bottom of
the carton
larger than the first and second elevated portions and whereby the first
horizontal plane
lies above the second horizontal plane.
In yet another aspect, the invention contemplates a carton having a plurality
of
side panels and a plurality of bottom panels corresponding thereto, the
plurality of bottom
panels folded and sealed together to form a sealed bottom, the carton having a
first
exposed edge traversing the bottom of the carton and a second exposed edge
substantially
perpendicular to the first exposed edge. The carton comprises: a primary
elevated
portion extending along a length of the first exposed edge, the elevated
portion being
inverted into the carton; a first substantially planar portion defined by one
side of the
elevated portion and the ends of side panels corresponding thereto, the first
substantially
CA 02308583 2004-04-29
3c
planar portion being substantially perpendicular to the corresponding side
panels; a
second substantially planar portion defined by another side of the elevated
portion and
the ends of side panels corresponding thereto, the second substantially planar
portion
being substantially perpendicular to the corresponding side panels; and a side
angled
portion extending along the length of the second exposed edge, the side angled
portion
being inverted into the carton forming an obtuse angle with one of said first
and second
substantially planar portions.
In accordance with an alternative embodiment a carton has a plurality of side
panels and a plurality of bottom panels corresponding thereto, the plurality
of bottom
panels folded and sealed together to form a sealed bottom, a last folded and
sealed
bottom panel having a first exposed edge traversing the bottom of the carton
and a
penultimate folded and sealed bottom panel having a second exposed edge
substantially
perpendicular to the first exposed edge. This carton comprises: a primary
elevated
portion extending along the length of the first exposed edge, the primary
elevated portion
being inverted into the carton; a side elevated portion extending along the
length of the
second exposed edge, the side elevated portion being inverted into the carton;
a first
substantially planar portion defined by one side of the primary elevated
portion and the
ends of side panels corresponding thereto, the first substantially planar
portion being
substantially perpendicular to the corresponding side panels; a second
substantially
planar portion defined by another side of the primary elevated portion and the
ends of
side panels corresponding thereto, the second substantially planar portion
being
substantially perpendicular to the corresponding side panels, the previously-
mentioned
side elevated portion forming an obtuse angle with one of said first and
second
substantially planar portions; and a first secondary elevated portion disposed
within the
primary elevated portion, the secondary elevated portion being inverted into
the carton a
depth greater than a depth of the primary elevated portion.
A yet additional aspect provides a carton having a plurality of side panels
and a
plurality of bottom panels corresponding thereto, the plurality of bottom
panels folded
and sealed together to form a sealed bottom, a last folded and sealed bottom
panel having
a first exposed edge traversing the bottom of the carton and a penultimate
folded and
sealed bottom panel having a second exposed edge substantially perpendicular
to the first
exposed edge. This carton comprises: a primary elevated portion extending
along a
CA 02308583 2004-04-29
3d
length of the first exposed edge, the primary elevated portion being inverted
into the
carton; a side elevated portion extending along a length of the second exposed
edge, the
side elevated portion being inverted into the carton; a first substantially
planar portion
defined by one side of the primary elevated portion and the ends of side
panels
corresponding thereto, the first substantially planar portion being
substantially
perpendicular to the corresponding side panels; a second substantially planar
portion
defined by another side of the primary elevated portion and the ends of side
panels
corresponding thereto, the second substantially planar portion being
substantially
perpendicular to the corresponding side panels, the above-mentioned side
elevated
portion forming an obtuse angle with one of said first and second
substantially planar
portions; a first secondary elevated portion disposed within the primary
elevated portion,
the first secondary elevated portion being inverted into the carton a depth
that is greater
than a depth of the primary elevated portion; and a second secondary elevated
portion
disposed within the primary elevated portion and opposite the first secondary
elevated
portion, the second secondary elevated portion being inverted into the carton
a depth that
is greater than a depth of the primary elevated portion.
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4
Brief Description of the Drawings
Several features of the present invention are further described in
connection with the accompanying drawings in which:
There is illustrated in FIG. 1 a perspective view of one embodiment of a
carton of the present invention.
There is illustrated in FIG. 2 a plan view of a blank for the carton of FIG.
1.
There is illustrated in FIG. 3 bottom perspective view of one embodiment
of a carton of the present invention.
There is illustrated in FIG. 4 bottom perspective view of another
embodiment of a carton of the present invention.
There is illustrated in FIG. 5 bottom perspective view of a preferred
embodiment of a carton of the present invention.
There is illustrated in FIG. 6 a perspective view of another embodiment of
a carton of the present invention.
There is illustrated in FIG. 7 a plan view of a blank for the carton of FIG.
6.
There is illustrated in FIG. 8 bottom perspective view of one embodiment
of a carton of the present invention.
There is illustrated in FIG. 9 bottom perspective view of another
embodiment of a carton of the present invention.
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There is illustrated in FIG. 1 a carton 10 embodying the present invention.
The carton 10 has a plurality of side panels 12a and 12b, a top panel 14, a
top fin
5 16, bottom score lines 18a and 18b defining the bottom from the side panels
12a
and 12b, and an elevated portion 20. The side panel 12b is actually folded
over
and sealed to a sealing panel 22. The folding and sealing of the carton
creates a
raw paper edge which extends from the top 16 to the bottom of the carton 10
along
this intersection of the sealing panel 22 and side panel 12b, top panel 14,
top fin
16 and the bottom panel corresponding to side panel 12b.
FIG. 2 illustrates a blank 30 of the carton 10 of FIG. 1. The side panels
~12a-d are separated from bottom panels 32a-d by bottom horizontal score lines
34
and each of the side panels 12a-d and bottom panels 32a-d are separated from
each
other by vertical score lines 36. The side panels 12a-d are separated from top
panels 14 and 14b-d by top horizontal score lines 38. The top fin panels 16
and
16b-d are separated from top panels 14 and 14b-d by upper horizontal score
line
39. The sealing panel 22 is separated from side panel 12a by a vertical score
line
36. A top sealing panel 22b and a bottom sealing panel 22c further define
sealing
panel 22. The raw paper edge 40 extends along top fin 16, top panel 14, side
panel 12b and bottom panel 32b.
FIG. 3 shows an embodiment of the present invention. The bottom of the
carton 10 has the elevated portion 20 bounded by substantially planar portions
60
and 62. The planar portions 60 and 62 are substantially perpendicular to side
panels 12a, 12b and 12c and 12d, not shown. The planar portions 60 and 62
c~ contact a conveyor belt while elevated portion 20 is elevated above the
belt
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6
and any moisture thereon. The same applies during distribution whether in a
crate or a shelf at a store.
The elevated portion 20 is further defined by angled portions 64 and 66
and elevated planar portion 70. The elevated planar portion 70 is further
defined
as elevated planar portion 70a and elevated planar portion 70b. The elevated
planar portion 70a substantially includes a portion of panel 32b while
elevated
planar portion 70b includes a portion of panel 32d. The exposed raw paper edge
40a traverses the bottom of the carton 10, extending from the end of panel 12
a to
the end of panel 12c, not shown. Likewise, the elevated portion 20 traverses
the
bottom of the carton 10. Preferably, elevated portion 20 is centered on the
bottom
of the carton 10 with planar portions 60 and 62 being equal in area to each
other.
However, those skilled in the pertinent art will recognize that planar
portions 60
and 62 may be unequal and elevated portion 20 may be uncentered without
departing from the scope and spirit of the present invention.
It is readily apparent that elevated portion 70a. angled portion 64 and
planar portion 60 all are part of bottom panel 32b. Also. elevated portion
70b,
angled portion 66 and planar portion 62 all are part of bottom panel 32d.
FIG. 4 shows an alternate embodiment of the present invention. FIG. 4 is
similar to FIG. 3 except that all exposed raw paper edges 40a and 40b are
elevated. The exposed edge 40b is substantially perpendicular to exposed edge
40a. A second elevated portion 20a elevates this exposed edge 40b thereby
preventing moisture absorption as with exposed edge 40a. The second elevated
portion 20a has an angled portion 70 that engages planar portion 60, side
panel
12a, and angled portion 64. Those skilled in the art will recognize that the
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7
exposed raw edges may be elevated in a similar fashion without departing from
the scope and content of the present invention.
A preferred embodiment of the present invention is illustrated in FIG. 5.
As shown in FIG. 5, the exposed edge 40b is substantially perpendicular to
exposed edge 40a. A side elevated portion 20a elevates this exposed edge 40b
thereby preventing moisture absorption as with exposed edge 40a. The side
elevated portion 20a has an angled portion 72 which engages planar portion 60,
side panel 12a, and angled portion 64. Those skilled in the art will recognize
that
the exposed raw edges may be elevated in a similar fashion without departing
from the scope and content of the present invention.
Approximately in the center of the elevated portion 20 is a secondary
elevated portion 100. The secondary elevated portion 100 prevents loss of
elevation in the center of the bottom of the carton 10 during transportation
from a
packaging machine to the retailer/wholesaler to the consumer. As is apparent,
the
center of the bottom of the carton 10 is most susceptible to deelevation from
the
weight of the product. The weight of the product in the carton 10 is focused
on
the center of the bottom of the carton 10, and thus it is necessary to provide
greater elevation in this area. This greater elevation is provided by the
seconday
elevated portion 100 which compensates for gravitational forces exerted by the
product on the center of the bottom of the carton 10.
In a preferred embodiment, the secondary elevated portion 100 is
triangular in shape with its apex 1 O1 near the exact center of the bottom of
the
carton 10. The secondary elevated portion 100 is substantially contained
within
elevated planar portions 70a and 70b. However, there is a transition to angled
portion 66. Alternatively, the triangular shaped embodiment of the secondary
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8
elevated portion 100 may be rotated any degree from 1-360 degrees, about apex
101 while not departing from the scope and spirit of the present invention.
Thus.
the secondary elevated portion 100 may lie entirely within elevated planar
portion
70a.
In the preferred embodiment, the secondary elevated portion 100 is
partially defined by secondary angled portions 102, 104, 106 and 108. The
secondary angled portions 102 and 104 form a transition from the secondary
elevated portion 100 to elevated planar portion 70a whereas the secondary
angled
portions 106 and 108 form a transition from the secondary elevated portion 100
to
elevated planar portion 70b.
The bottom of the carton 10 is usually formed on a mandrel of a form, fill
and seal packaging machine, not shown. The carton blanks 30 are fed from a
magazine, not shown, to a bottom forming station of the machine, not shown.
During the transfer from magazine to bottom forming station, the carton blank
is
erected. On the bottom forming station, the bottom panels are pretreated if
necessary, and then heat-sealed together to form the bottom. This is
accomplished
by pressing against the bottom panels as they lie on the mandrel. In order to
achieve the elevated bottom of the present invention, one may have a special
press
and mandrel that allows for the elevated bottom of the present invention.
There is illustrated in FIG. 6 a carton 210 another embodiment of the
present invention. The carton 210 has a plurality of side panels 212a and
212b, a
top panel 214, a top fin 216, bottom score lines 218a and 218b defining the
bottom
from the side panels 212a and 212b, and an elevated portion 220. A sealing
panel
222, partially shown in FIG. 6, is connected to the side panel 212a and is
folded
over and sealed to the side panel 212b, not shown. The folding and sealing of
the
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9
carton creates a raw paperboard edge which extends from the top 216 to the
bottom of the carton 210 along this intersection of the sealing panel 222 and
side
panel 212b, top panel 214, top fin 216 and the bottom panel corresponding to
side
panel 212d.
FIG. 7 illustrates a blank 230 of the carton 210 of FIG. 6. The side panels
212a-d are separated from bottom panels 232a-d by bottom horizontal score
lines
234 and each of the side panels 212a-d and bottom panels 232a-d are separated
from each other by vertical score lines 236. The side panels 212a-d are
separated
from top panels 214a-d by top horizontal score lines 238. The top fin panels
216a-d are separated from top panels 214a-d by upper horizontal score line
239.
The sealing panel 222 is separated from side panel 212a by a vertical score
line
236. A top sealing panel 222b and a bottom sealing panel 222c further define
sealing panel 222. The raw paperboard edge 240 extends along the entire
perimeter of the carton blank 230. However, for purposes of this invention,
the
most important portions of the raw paperboard edge 240 are portions 240a and
240b which lie on the bottom of the carton. All other portions of the raw
paperboard edge 240 are either covered by a coated panel, or are elevated
above
the surface when the blank 230 is formed into a carton 210. Thus, moisture
absorption by these portions of the raw paperboard edge 240 is highly
unlikely.
FIG. 8 shows another embodiment of the elevated bottom of the present
invention. The bottom of the carton 210 has the elevated portion 220 bounded
by
substantially planar portions 260 and 262. The planar portions 260 and 262 are
substantially perpendicular to side panels 212a, 212b and 212c and 212d, not
shown. The planar portions 260 and 262 contact a surface such as a conveyor
belt
on a packaging machine while the elevated portion 220 is elevated above the
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surface and any moisture thereon. The same applies during distribution of the
carton whether in a crate or on a shelf at a store.
The elevated portion 220 is further defined by angled portions 264 and 266
and elevated planar portion 270. The elevated planar portion 270 is further
5 defined as elevated planar portion 270a and elevated planar portion 270b.
The
elevated planar portion 270a substantially includes a portion of panel 232b
while
elevated planar portion 270b includes a portion of panel 232d. The exposed raw
paperboard edge 240b traverses the bottom of the carton 210, extending from
the
end of panel 212a to the end of panel 212c, not shown. Likewise, the elevated
10 portion 220 traverses the bottom of the carton 210. Preferably, the
elevated
portion 220 is centered on the bottom of the carton 210 with planar portions
260
and 262 being equal in area to each other. However, those skilled in the
pertinent
art will recognize that planar portions 260 and 262 may be unequal and
elevated
portion 220 may be uncentered without departing from the scope and spirit of
the
present invention.
It is readily apparent that elevated portion 270a_ angled portion 264 and
planar portion 260 all are part of bottom panel 232b. Also, elevated portion
270b,
angled portion 266 and planar portion 262 all are part of bottom panel 232d.
The exposed edge 240a is substantially perpendicular to exposed edge
240b. A side elevated/angled portion 220a elevates this exposed edge 240a
thereby preventing moisture absorption as with exposed edge 240b. The side
elevated/angled portion 220a has an angled portion 272 which engages planar
portion 260, side panel 212a, and angled portion 264. Those skilled in the art
will
recognize that the exposed raw edges may be elevated in a similar fashion
without -
departing from the scope and content of the present invention.
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11
Another embodiment of the elevated bottom of the carton of the present
invention is shown in FIG. 9. The carton 210 of FIG. 9 is similar to the
carton
210 of FIG. 8 except that approximately in the center of the elevated portion
220
are secondary elevated portions 300 and 301. The secondary elevated portions
300 and 301 prevent loss of elevation in the center of the bottom of the
carton 210
during transportation from a packaging machine to the retailer/wholesaler to
the
consumer. As is apparent, the center of the bottom of the carton 210 is most
susceptible to deelevation from the weight of the product. The weight of the
product in the carton 210 is focused on the center of the bottom of the carton
210.
and thus it is necessary to provide greater elevation in this area. This
greater
elevation is provided by the secondary elevated portions 300 and 301 which
compensate for gravitational forces exerted by the product on the center of
the
bottom of the carton 210.
In an exemplary embodiment, the secondary elevated portions 300 and 301
are triangular in shape with apices 302a-b facing the center of the bottom of
the
carton 210. The secondary elevated portions 300 and 301 are substantially
contained within elevated planar portions 270a and 270b. However, there is a
transition for each secondary elevated portions 300 and 301 to angled portions
266
and 264, respectively. Alternatively, the triangular shaped embodiment of the
secondary elevated portions 300 and 301 may be rotated any degree from 1-360
degrees, about apices 302a-b while not departing from the scope and spirit of
the
present invention. Thus, the secondary elevated portions 300 and 301 may lie
entirely within elevated planar portion 270b and 270a, respectively.
In this embodiment, the secondary elevated portions 300 and 301 are
partially defined by secondary angled portions 304a-d. The secondary angled
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12
portions 304a-d form a transition from the secondary elevated portions 300 and
301 to the elevated planar portions 270b and 270a.
In an alternative embodiment not shown, the canon 210 of FIG. 9 may
only have one secondary elevated portion 300 or 301 which may be disposed on
either of planar portion 270a or 270b.
The bottom of the carton 210 is usually formed on a mandrel of a form, fi 11
and seal packaging machine, not shown. The carton blanks 230 are fed from a
magazine, not shown, to a bottom forming station of the machine, not shown.
During the transfer from magazine to bottom forming station, the carton blank
is
erected. On the bottom forming station, the bottom panels are pretreated if
necessary, and then heat sealed together to form the bottom. This is
accomplished
by pressing against the bottom panels as they lie on the mandrel. In order to
achieve the elevated bottom of the present invention, one may have a special
sealing plate and mandrel which allows for the elevated bottom of the present
invention.
