Note: Descriptions are shown in the official language in which they were submitted.
CA 02541617 2011-05-20
SHIPPING CONTAINERS WITH STACKING SUPPORT STRUCTURES
BACKGROUND OF THE INVENTION
[0001] The present invention relates to shipping containers, in particular
shipping
containers that are fabricated at least in part from paper, paperboard and/or
corrugated
paperboard material.
[0002] Shipping container designs are known which are tray/wrap structures,
having
an inside minor flap which is divided, and shared with an outside full depth
flap, to
provide four additional corners in the same amount of material as other
shipping
containers.
[0003] However, issues arise when the depth of the shipping container is
greater than
its width, as it may cause the internal and external flaps to interfere with
each other
when machine erected unless material is removed from those flaps.
[0004] In extreme instances, the size of the slot of removed material can be
severe,
creating potential weakness in the flat blank in unit load building and
handling prior to
erecting, not to mention the removal of material which could benefit the
customer by
further contributing stacking support.
[0005] In addition, as paperboard structures derive their supportive stacking
strength
from vertical support structures, increasing the number of corners can help to
increase
the overall stacking strength without increasing the material consumption.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The present invention comprises, in part, a carton, fabricated from a
blank
formed from at least one of paper, paperboard and corrugated paperboard,
comprising
a bottom panel; two side panels emanating from opposing side edges of the
bottom
panel; and two end panels emanating from opposing end edges of the bottom
panel,
the opposing end edges of the bottom panel extending substantially
perpendicular to
the opposing side edges of the bottom panel. At least one connection panel
emanates
from a top edge region of at least one of the two side panels, with a foldable
line of
weakness disposed between each side panel and its respective at least one
connection
panel. At least one outer support panel emanates from an end edge of at least
one
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connection panel, with a foldable line of weakness disposed between each
connection
panel and its corresponding at least one outer support panel, the outer
support panel
being affixed to an outer surface of an adjacent one of the end panels. At
least one
first inner support panel emanates from an end edge of at least one of the two
end
panels, with a line of foldable weakness disposed between the first inner
support panel,
and its respective end panel. At least one second inner support panel emanates
from
an edge of the at least one first inner support panel, with a line of foldable
weakness
disposed between each second inner support panel and its corresponding first
inner
support panel. At least one third inner support panel emanates from an edge of
the at
least one second inner support panel, with a line of foldable weakness
disposed
between each third inner support panel and its corresponding second inner
support
panel. The at least one third inner support panel is affixed to an inner
surface of its
respective associated end panel, to form, with the first and second inner
support
panels, at least one vertically extending stacking support structure, upon
articulation of
the blank into the carton.
[0007] In a preferred embodiment of the invention, the at least one vertically
extending stacking support structure is L-shaped in cross-section. In this
alternative
preferred embodiment of the invention, the at least one second inner support
panel has
a width that is less than a width of the respective at least one first inner
support panel.
In an alternative embodiment, the at least one vertically extending stacking
support
structure is triangular in cross-section. In this embodiment, the at least one
second
inner support panels has a width that is greater than a width of its
respective first inner
support panel.
[0008] The carton may further comprise at least one second outer support
panel,
emanating from each at least one first outer support panel, along a foldable
line of
weakness disposed therebetween, the at least one second outer support panel
being
affixed to an outside surface of the respective side panel with which the at
least one
second outer support panel is associated.
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[0009] The carton may further comprise at least one lid panel, emanating from
a top
edge of one of the side panels. The at least one lid panel may comprises two
lid
panels, emanating from top edges of the two side panels.
[0010] The carton may further comprise at least one closure flap, emanating
from an
end edge of the at least one lid panel, and affixable to an outside surface of
an adjacent
end panel. The at least one closure flap may comprise two closure flaps,
emanating
from opposing end edges of the at least one lid panel, and affixable to
outside surfaces
of adjacent end panels.
[0011] The carton may further comprise at least one closure flap, emanating
from an
end edge of each of the two lid panels, and affixable to an outside surface of
an
adjacent end panel. The at least one closure flap may comprise two closure
flaps,
emanating from opposing end edges of each of the lid panels, and affixable to
outside
surfaces of adjacent end panels.
[0012] The carton may further comprise at least one closure flap, emanating
from an
end edge of each of the two lid panels, and affixable to an outside surface of
an
adjacent end panel. The at least one closure flap may comprise two closure
flaps,
emanating from opposing end edges of each of the lid panels, and affixable to
outside
surfaces of adjacent end panels.
[0013] The at least one outer support panel may have a width which is
substantially
the same as the end panel adjacent to which it is positioned, in which case
the carton
may further comprise two second outer support panels, emanating from opposing
end
edges of the at least one outer support panel, and affixed to outer surfaces
of each of
the side panels.
[0014] The present invention also comprises in part, a blank for a carton,
formed
from at least one of paper, paperboard and corrugated paperboard. The blank
may
comprise a bottom panel; two side panels emanating from opposing side edges of
the
bottom panel; and two end panels emanating from opposing end edges of the
bottom
panel, the opposing end edges of the bottom panel extending substantially
perpendicular to the opposing side edges of the bottom panel. At least one
connection
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panel emanates from a top edge region of at least one of the two side panels,
with a
foldable line of weakness disposed between each side panel and its respective
at least
one connection panel. At least one outer support panel emanates from an end
edge of
at least one connection panel, with a foldable line of weakness disposed
between each
connection panel and its corresponding at least one outer support panel. At
least one
first inner support panel emanates from an end edge of at least one of the two
end
panels, with a line of foldable weakness disposed between the first inner
support panel,
and its respective end panel. At least one second inner support panel emanates
from
an edge of the at least one first inner support panel, with a line of foldable
weakness
disposed between each second inner support panel and its corresponding first
inner
support panel. At least one third inner support panel emanates from an edge of
the at
least one second inner support panel, with a line of foldable weakness
disposed
between each third inner support panel and its corresponding second inner
support
panel.
[0015] In a preferred embodiment of the invention, the at least one second
inner
support panel has a width that is less than a width of the respective at least
one first
inner support panel. In an alternative embodiment, the at least one second
inner
support panel has a width that is greater than a width of its respective first
inner
support panel.
[0016] The blank may further comprise at least one second outer support panel,
emanating from each at least one first outer support panel, along a foldable
line of
weakness disposed therebetween.
[0017] The blank may further comprise at least one lid panel, emanating from a
top
edge of one of the side panels. The at least one lid panel may comprise two
lid panels,
emanating from top edges of the two side panels.
[0018] The blank may further comprise at least one closure flap, emanating
from an
end edge of the at least one lid panel. The at least one closure flap may
comprise two
closure flaps, emanating from opposing end edges of the at least one lid
panel.
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[0019] The blank may further comprise at least one closure flap, emanating
from an
end edge of each of the two lid panels. The at least one closure flap may
comprise two
closure flaps, emanating from opposing end edges of each of the lid panels.
[0020] In an embodiment in which the at least one outer support panel has a
width
which is substantially the same as the end panel adjacent to which it is
positioned, the
blank may further comprise two second outer support panels, emanating from
opposing end edges of the at least one outer support panel.
[0021] The present invention also comprises in part, a method for forming a
carton,
fabricated from a blank formed from at least one of paper, paperboard and
corrugated
paperboard, the method comprising the steps of: providing a bottom panel;
providing
two side panels emanating from opposing side edges of the bottom panel;
providing
two end panels emanating from opposing end edges of the bottom panel, the
opposing
end edges of the bottom panel extending substantially perpendicular to the
opposing
side edges of the bottom panel; providing at least one connection panel,
emanating
from a top edge region of at least one of the two side panels, with a foldable
line of
weakness disposed between each side panel and its respective at least one
connection
panel; providing at least one outer support panel, emanating from an end edge
of at
least one connection panel, with a foldable line of weakness disposed between
each
connection panel and its corresponding at least one outer support panel; at
least one
first inner support panel, emanating from an end edge of at least one of the
two end
panels, with a line of foldable weakness disposed between the first inner
support panel,
and its respective end panel; providing at least one second inner support
panel,
emanating from an edge of the at least one first inner support panel, with a
line of
foldable weakness disposed between each second inner support panel and its
corresponding first inner support panel; and providing at least one third
inner support
panel, emanating from an edge of the at least one second inner support panel,
with a
line of foldable weakness disposed between each third inner support panel and
its
corresponding second inner support panel.
[0022] The method may comprise the steps of: folding the at least one first
inner
support panel inwardly to a position substantially perpendicular to its
corresponding
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end panel; folding the at least one second inner support panel inwardly to a
position
substantially parallel to and overlying an inwardly facing surface of the at
least one
first inner support panel; folding the at least one third inner support panel
outwardly to
a position substantially perpendicular to the at least one second inner
support panel,
and substantially parallel to an inside surface of an end panel from which the
first,
second, and third inner support panels emanate, so that the first, second and
third inner
support panels form an L-shaped cross-section; affixing the at least one inner
support
panel to the inside surface of the end panel; folding the two end panels to
positions
substantially perpendicular to the bottom panel; folding the two side panels
up to
positions substantially perpendicular to the bottom panel; affixing at least
one of the
side panels to an outside surface of the at least one inner support panel;
folding the at
least one connection panel inwardly to a position substantially parallel to
the bottom
panel; folding the at least one outer support panel downwardly to a position
substantially parallel to and overlying at least a portion of an adjacent end
panel.
[0023] The method may comprise the steps of: folding the at least one first
inner
support panel inwardly to a position substantially perpendicular to its
corresponding
end panel; folding the at least one second inner support panel inwardly to a
position
oblique to the at least one first inner support panel; folding the at least
one third inner
support panel outwardly to a position oblique to the at least one second inner
support
panel, and substantially parallel to an inside surface of an end panel from
which the
first, second, and third inner support panels emanate, so that the first and
second inner
support panels and the adjacent end panel form a triangular cross-section;
affixing the
at least one inner support panel to the inside surface of the end panel;
folding the two
end panels to positions substantially perpendicular to the bottom panel;
folding the two
side panels up to positions substantially perpendicular to the bottom panel;
affixing at
least one of the side panels to an outside surface of the at least one inner
support panel;
folding the at least one connection panel inwardly to a position substantially
parallel to
the bottom panel; folding the at least one outer support panel downwardly to a
position
substantially parallel to and overlying at least a portion of an adjacent end
panel.
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[0024] The method may comprise the step of: affixing the at least one outer
support
panel to the adjacent end panel.
[0025] The method may comprise the step of: affixing the at least one outer
support
panel to the adjacent end panel.
[0026] The method may comprise the steps of: providing at least one second
outer
support panel, emanating from an edge of the at least one outer support panel;
and
folding the at least one second outer support panel to a position
substantially
perpendicular to the at least one outer support panel; affixing the at least
one second
outer support panel to an outer surface of a side panel.
[0027] The method may comprise the step of: providing at least one top panel,
emanating from a top edge of a side panel.
[0028] The method may comprise the step of: providing two top panels,
emanating
from top edges of the side panels.
[0029] The method may comprise the steps of: providing at least one closure
panel,
emanating from an end edge of the at least one lid panel.
[0030] The method may comprise the steps of: filling the carton with articles;
folding the at least one lid panel to a position substantially parallel to the
bottom panel;
folding the at least one closure panel to a position substantially
perpendicular to the at
least one lid panel; and affixing the at least one lid panel to an outer
surface of an end
panel.
[0031] The method may comprise the steps of: providing at least one closure
panel,
emanating from end edges of each of the lid panels.
[0032] The method may comprise the steps of: filling the carton with articles;
folding the lid panels to positions substantially parallel to the bottom
panel; folding the
closure panels to positions substantially perpendicular to the at least one
lid panel; and
affixing the lid panels to outer surfaces of at least one end panel.
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[0033] The method may comprise the step of: providing the at least one second
inner
support panel with a width less than a width of the at least one first inner
support
panel.
[0034] The method may comprise the step of: providing the at least one second
inner
support panel with a width less than a width of the at least one first inner
support
panel.
[0035] The method may comprise the step of: providing the at least one second
inner
support panel with a width greater than a width of the at least one first
inner support
panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Fig. 1 is a perspective view of a quadcomer tray wrapper container
according
to one embodiment, shown in an open configuration, atop other containers of
the same
configuration.
[0037] Fig. 2 is a plan view of a blank for forming the tray wrapper container
according to the embodiment of Fig. 1.
[0038] Fig. 3 is a perspective view of the blank of Fig. 2, at an early stage
in the
process of being articulated into a container, with the goods to be packaged
being
omitted from the illustration.
[0039] Fig. 4 is a perspective view of the blank of Fig. 2, at a later stage
in the
process of being articulated into a container, with the goods to be packaged
being
omitted from the illustration.
[0040] Fig. 5 is a perspective view of the container of Fig. 1, near the end
of the
process of articulation into a completed container, prior to closure of the
container,
with the goods to be packaged being omitted from the illustration.
[0041] Fig. 6 is a perspective view of the container of Fig. 5, as the top
panel is
being brought into closure position, the major (outside) end flaps are being
folded
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down, and the minor (reinforcing) flaps are being folded around to provide the
final
closure of the container.
[0042] Fig. 7 is a perspective view of the container of Figs. 1 - 6, in fully
articulated,
closed configuration.
[0043] Fig. 8 is a perspective "transparent" view of the container of Fig. 7.
[0044] Fig. 9 is a further view of the blank of Fig. 2.
[0045] Fig. 10A is a perspective view of a container according to another
embodiment, shown partially articulated.
[0046] Fig. 10B is a perspective view of the container according to Fig. 10A,
shown
in a further stage of articulation.
[0047] Fig. 10C is a perspective view of the container according to Fig. 10A,
shown
in a further stage of articulation.
[0048] Fig. 10D is a perspective view of the container of Fig. 10A shown fully
articulated.
[0049] Fig. 11 is a plan view of a blank for the container of Figs. 10A - 10D.
[0050] Fig. 12 is a plan view of a blank for a container according to another
embodiment.
[0051] Fig. 13A is a perspective view of a container according to the
embodiment of
Fig. 12, shown partially articulated.
[0052] Fig. 13B is a perspective view of the container according to Fig. 13A,
shown
in a further stage of articulation.
[0053] Fig. 13C is a perspective view of the container according to Fig. 13A,
shown
in a further stage of articulation.
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[0054] Fig. 13D is a perspective view of the container of Fig. 13A, shown
fully
articulated.
[0055] Fig. 14 is a perspective view of a container according to another
embodiment,
showing two different articulation "paths" for two different possible
container loading
"paths".
[0056] Fig. 15 is a plan view of a container according to another embodiment,
similar to the container of Figs. 1 - 9, but resulting in a container having a
frusto-
pyramidal configuration.
[0057] Fig. 16 is a plan view of a container according to another embodiment,
similar to the container of Figs. 13A - 13D and 14.
[0058] Fig. 17A is a perspective view of a container according to another
embodiment, with the container substantially fully articulated except for
final closure,
wherein the container further includes removable portions for display
conversion.
[0059] Fig. 17B is a perspective view of a container according to the
embodiment of
Fig. 17A, in its fully articulated configuration.
[0060] Fig. 18A is a plan view of the blank for the container of Figs. 17A and
17B.
[0061] Fig. 18B is a perspective view of the container of Figs. 17A - 18A.
[0062] Fig. 19A is a perspective view of the container of Fig. 17A , shown
partially
articulated.
[0063] Fig. 19B is a perspective view of the container of Fig. 19A, shown
further
along in the articulation process.
[0064] Fig. 19C is a perspective view of the container of Fig. 17A, shown
partially
articulated, via a different sequence of articulation steps.
[0065] Fig. 19D is a perspective view of the container of Fig. 19C, shown
further
along the articulation process.
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[0066] Fig. 19E is a perspective view of the container of Fig. 19D, shown
further
along the articulation process.
[0067] Fig. 19F is a perspective view of the container of Fig. 19E, shown
fully
articulated.
[0068] Fig. 20 is a plan view of a blank for a container according to another
embodiment.
[0069] Fig. 21A is a rear perspective view of the container formed from the
blank of
Fig. 20.
[0070] Fig. 21B is a front perspective view of a plurality of stacked
containers
according to Figs. 20 and 21A.
[0071] Fig. 22 is a perspective view of a container according to the
embodiment of
Figs. 20, 21A-B, shown partially articulated.
[0072] Fig. 23 is a perspective view of a container according to the
embodiment of
Fig. 22, shown further along the process of articulation.
[0073] Fig. 24 is a perspective view of the container of Fig. 23, shown
further
articulated toward closure.
[0074] Fig. 25 is a plan view of a blank for a container according to another
embodiment, in which the container has "slotless" gusseted comers.
[0075] Fig. 26A is a perspective view of a container according to the blank of
Fig.
25, shown partially articulated.
[0076] Fig. 26B is a perspective view of the container of Fig. 26A, shown
further
along the articulation process.
[0077] Fig. 26C is a perspective view of the container of Figs. 26A and 26B,
shown
fully articulated.
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[0078] Fig. 27 is a plan view of a blank for a container according to another
embodiment, in which the container as a reinforced transverse closure seal.
[0079] Fig. 28A is a perspective view of a container according to the blank of
Fig.
27.
[0080] Fig. 28B is a perspective view of the container of Fig. 27, further
along the
articulation process.
[0081] Fig. 28C is an enlarged cross-sectional view of a portion of the
container of
Fig. 27, showing the reinforced transverse closure seal that is formed upon
full
articulation of the container blank.
[0082] Fig. 29 is a plan view of a blank of a carton with integrated lid
according to a
preferred embodiment.
[0083] Fig. 30 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 29, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0084] Fig. 31. is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[0085] Fig. 32 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 31, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0086] Fig. 33 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[0087] Fig. 34 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 33, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0088] Fig. 35 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
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[0089] Fig. 36 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 35, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0090] Fig. 37 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[0091] Fig. 38 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 37, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0092] Fig. 39 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[0093] Fig. 40 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 39, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0094] Fig. 41 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[0095] Fig. 42 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 41, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0096] Fig. 43 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[0097] Fig. 44 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 43, shown in its erected configuration,
with the
top open prior to loading and sealing.
[0098] Fig. 45 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
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[0099] Fig. 46 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 45, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00100] Fig. 47 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00101] Fig. 48 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 47, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00102] Fig. 49 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00103] Fig. 50 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 49, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00104] Fig. 51 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00105] Fig. 52 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 51, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00106] Fig. 53 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00107] Fig. 54 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 53, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00108] Fig. 55 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
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[00109] Fig. 56 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 55, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00110] Fig. 57 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00111] Fig. 58 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 57, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00112] Fig. 59 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00113] Fig. 60 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 59, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00114] Fig. 61 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00115] Fig. 62 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 61, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00116] Fig. 63 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00117] Fig. 64 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 63, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00118] Fig. 65 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
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[00119] Fig. 66 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 65, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00120] Fig. 67 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00121] Fig. 68 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 67, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00122] Fig. 69 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00123] Fig. 70 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 69, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00124] Fig. 71 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00125] Fig. 72 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 71, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00126] Fig. 73 is a plan view of a blank of a carton with integrated lid
according to
another preferred embodiment.
[00127] Fig. 74 is a simplified perspective view of a carton with integrated
lid
according to the embodiment of Fig. 73, shown in its erected configuration,
with the
top open prior to loading and sealing.
[00128] Fig. 75 illustrates the first several steps in a method for forming a
package,
using the carton blank from Figs. 29 - 30.
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[00129] Fig. 76 illustrates the remaining steps in a method for forming a
package,
using the carton blank from Figs. 29 - 30
[00130] Fig. 77 illustrates the first several steps in a method for forming a
package,
using the carton blank from Figs. 49 - 50.
[00131] Fig. 78 illustrates the remaining steps in a method for forming a
package,
using the carton blank from Figs. 49 - 50.
[00132] Fig. 79 is a plan view for a blank for an open-topped carton, having
stacking
support structures, according to a preferred embodiment of the invention.
[00133] Figs. 79A - 79F illustrate various stages in the articulation of the
blank of
Fig. 79.
[00134] Fig. 80 is a plan view for a blank for an open-topped carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
[00135] Figs. 80A - 80F illustrate various stages in the articulation of the
blank of
Fig. 80.
[00136] Fig. 81 is a plan view of a blank for a double-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
[00137] Figs. 81A - 81H illustrate various stages of the articulation of the
blank of
Fig. 81.
[00138] Fig. 82 is a plan view of a blank for a double-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
[00139] Figs. 82A - 82H illustrated various stages in the articulation of the
blank of
Fig. 82.
[00140] Fig. 83 is a plan view of a blank for a single-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
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CA 02541617 2011-05-20
[00141] Figs. 83A - 83H illustrate various stages in the articulation of the
blank of
Fig. 83.
[00142] Fig. 84 is a plan view of a blank for a single-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
[00143] Figs. 84A - 84H illustrate various stages in the articulation of the
blank of
Fig. 84.
DETAILED DESCRIPTION OF THE INVENTION
[00144] While this invention is susceptible of embodiment in many different
forms,
there are shown in the drawings and will be described in detail, several
specific
embodiments, with the understanding that the present disclosure is to be
considered as
an exemplification of the principles of the invention and is not intended to
limit the
invention to the embodiments illustrated.
[00145] When referring to the plan illustrations of the blanks, the usual
drawing
conventions are applied. That is, unless otherwise noted, broken lines
indicate fold
lines; scalloped lines indicate lines of weakness forming a tear strip or
similar
structure; and interior solid lines indicate through-cuts.
[00146] In preferred embodiments, the blanks are fabricated from corrugated
paperboard material, although other materials having similar suitable
performance
characteristics may be employed if desired.
[00147] The basic premise underlying the quadcorrier tray wrapper designs of
Figs 1
- 28, is that of providing a wrapper type blank construction, in which the
blank
comprises four panels, consecutively arranged on the blank: top panel; rear
(side)
panel; bottom panel; and front (side) panel, contiguously connected along
interpanel
fold lines. Major flaps (end panels) emanate from the end edges of the top and
bottom
panels, each of which major flaps (end panels) are sized to cover the ends of
the
articulated carton. Minor flaps emanate from the leading and trailing edges of
the
major flaps. A closure tab emanates from a free edge of either the top or the
front (i.e.,
the leading or trailing edges of the blank).
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=
CA 02541617 2011-05-20
[00148] Upon articulation, the minor flaps emanating from the major (end)
flaps of
the bottom panel are folded to the inside of the front and rear panels, and
form vertical
supports for the container. The described minor flaps may or may not be
adhered to
the stated front and rear panels. If adhered, improved stacking strength can
result.
The interior folded (and adhered) minor flaps form vertical supports for the
container.
The front and rear (side) panels are then folded up perpendicular to the
bottom panel.
Within this phase of container articulation, adhesive can be dispensed to
adhere the
minor flaps juxtaposed to the front and rear panels. The top panel is then
folded down
parallel to the bottom panel and the extension from the top panel (closure tab
or glue
lap) is further folded down and adhered over the front panel and parallel to
the front
and rear panels. The major flaps (external end panels) emanating from the top
panel
are folded down over the major flaps (internal end panels) of the bottom panel
and
once juxtaposed are adhered to each other. The minor reinforcing flaps of the
major
flaps (external end panels) emanating from the top panel are folded and
adhered to the
outside of the front and rear panels. This creates a laminated and adhered
triple
thickness of container material along the end edge regions of the front and
rear panels,
as well as a laminated and adhered double thickness of material on the ends of
the
carton.
[00149] In a first variation of the general design (Figs. 1 - 9), the width of
the carton
is considerably greater than the depth or height. The minor flaps are all each
substantially less than one-half the width of the carton, so that there is a
substantial
gap between facing free edges of the minor flaps on the interior and exterior
faces of
the front and rear walls, thus creating "corner post" reinforcement
structures, rather
than complete end or side walls. The closure tab emanates from the free edge
of the
top panel, and is folded to be juxtaposed and adhesively affixed to the front
panel.
[00150] Container 10 is formed from blank 11 (Fig. 2). Blank 11 includes
bottom
panel 12, front (side) panel 14, rear (side) panel 16, top panel 18 and
closure flap 20;
as well as fold lines 13, 15, 17 and 19. Blank 11 also includes inner end
panels 22, 24
(emanating along fold lines 21, 23, respectively) from which interior minor
flaps 26,
28, 30, 32 emanate along fold lines 25, 27, 29 and 31, respectively. Outer end
panels
-19-
CA 02541617 2011-05-20
34, 36 emanate from top panel 18 along fold lines 33, 35, respectively.
Reinforcing
flanges 38, 40, 42, 44 emanate from outer end panels 34, 36, along fold lines
37, 39,
41 and 43, respectively. The end edges of panels 14 and 16 may be vertical.
Alternatively, the end edges of rear panel 16 preferably may be concavely
bowed and
the end edges of front panel 14 preferably may be inwardly inclined from
bottom to
top (both as illustrated), because this style of slot configuration may permit
ease of
removing and ease of stripping the waste material from the designated and
created
aperture in the blank sheet. As an alternative, rather than the described
designated
slot, a singular cut including offsets as required may be implemented thereby
eliminating a need to remove waste material.
[00151] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 11, which will be laid flat on a packaging apparatus. Flaps
30, 32
will be folded perpendicular to panel 24, and flaps 26, 28 will be folded
perpendicular
to panel 22. Panels 22, 24 will be folded upwardly perpendicularly to bottom
panel
12. Rear (side) panel 16 and front (side) panel 14 will then be folded
upwardly
perpendicular to bottom panel 12, as shown sequentially in Figs. 3 - 5. Top
panel 18 is
then folded down, toward and parallel to bottom panel 12; and outer end panels
34, 36
are folded over inner end panels 22, 24, respectively and adhered to end
panels 22, 24.
Finally, reinforcing flanges (minor flaps) 38, 40, 42, 44 are folded
perpendicular to
outer end panels 34, 36, and adhesively adhered to the outer surfaces of front
and rear
(side) panels 14, 16. When top panel 18 is folded down, closure flap 20 is
preferably
folded to the outside of front panel 14, and adhesively affixed to the outer
surface 15
thereof (Fig. 6).
[00152] In an alternative sequence, which is described in detail with respect
to the
embodiment of Fig. 14, but which is understood to be applicable to all of the
embodiments described and/or illustrated herein, the goods to be packaged are
not
placed on the bottom panel prior to any articulation. Instead, the front inner
minor
flaps and the front panel may not be folded with respect to the inner end
panels and the
bottom panel, respectively, at the same time that the rear inner minor flaps
and the rear
panel are folded and adhered with respect to the inner end panels and the
bottom
-20-
CA 02541617 2011-05-20
panel, respectively. This would result in a partially erected container,
having an open
frontal area, into which the goods to be packaged would be thrust, relying
upon the
inner surfaces of the rear inner minor flaps to provide stacking or other
alignment
structures. Upon insertion of the goods, the remaining panels and flaps are
articulated
and glued substantially as previously described.
[00153] The first variation of the general design of Figs. 1 - 9 may be
addressed in
an alternative manner. The width of the carton is still considerably greater
than the
depth or height. The minor flaps are all each substantially less than one-half
the width
of the carton, so that there is a substantial gap between facing free edges of
the minor
flaps on the interior and exterior faces of the front and rear walls, thus
creating "corner
post" reinforcement structures, rather than complete end or side walls. The
closure tab
emanates from the free edge of the top panel, and is folded to be juxtaposed
and
adhesively affixed to the front panel.
[00154] Container 10 will be formed from blank 11 (Fig. 2). Blank 11 includes
bottom panel 12, front (side) panel 14, rear (side) panel 16, top panel 18 and
closure
flap 20; as well as fold lines 13, 15, 17 and 19. Blank 11 also includes inner
end
panels 22, 24 (emanating along fold lines 21, 23, respectively) from which
interior
minor flaps 26, 28, 30, 32 emanate along fold lines 25, 27, 29 and 31,
respectively.
Outer end panels 34, 36 emanate from top panel 18 along fold lines 33, 35,
respectively. Reinforcing flanges 38, 40, 42, 44 emanate from outer end panels
34, 36,
along fold lines 37, 39, 41 and 43, respectively. The end edges of panels 14
and 16
may be vertical. Alternatively, the end edges of rear panel 16 preferably may
be
concavely bowed and the end edges of front panel 14 preferably may be inwardly
inclined from bottom to top (both as illustrated), because this style of slot
configuration may permit ease of removing and ease of stripping the waste
material
from the designated and created aperture in the blank sheet. As an
alternative, rather
than the described designated slot, a singular cut including offsets as
required may be
implemented thereby eliminating a need to remove waste material.
[00155] In a typical alternative articulation procedure, first the blank 11 is
formed
into a tray-like container as per Fig. 10 whereby inner minor panels 26, 28,
30 and 32
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CA 02541617 2011-05-20
are folded along folds 25, 27, 29 and 31, respectively, perpendicular to inner
end
panels 22 and 24. End panels 22 and 24 are then folded along folds 21 and 23,
respectively, perpendicular to bottom panel 12. Inner minor panels 26, 28, 30
and 32
are adhesively adhered to front (side) panel 14 and rear (side) panel 16.
Product to be
contained will be drop packed into the formed cavity whose perimeter can
consist of
inner minor flaps 26, 28, 30 and 32, front (side) panel 14 and rear (side)
panel 16,
inner end panels 22 and 24 along with bottom panel 12 of blank 16 and as shown
sequentially in Figs. 3 - 5. Top panel 18 is then folded down, toward and
parallel to
bottom panel 12; and outer end panels 34, 36 are folded over inner end panels
22, 24,
respectively and adhered to end panels 22, 24. Finally, reinforcing flanges
(minor
flaps) 38, 40, 42 and 44 are folded perpendicular to outer end panels 34, 36
and
adhesively adhered to the outer surfaces of front and rear (side) panels 14,
16. When
top panel 18 is folded down, closure flap 20 is preferably folded to the
outside of front
panel 14, and adhesively affixed to the outer surface thereof (Fig. 6).
[00156] In an alternative sequence, which is described in detail with respect
to the
embodiment of Fig. 14, but which is understood to be applicable to all of the
embodiments described and/or illustrated herein, the goods to be packaged are
not
placed on the bottom panel prior to any articulation. The product will be drop
packed
into the described walled cavity whose perimeter is formed from inner minor
flaps
226, 228, 230 and 232 along with inner end panels 222 and 224 and bottom panel
212.
Depending upon proportions, the rear perimeter will be formed by the addition
of rear
(side) panel 216. The front (side) panel of the tray may only be a portion of
the front
perimeter panel and would be completed by the top panel 220. The front inner
minor
flaps and the partial front panel may be folded with respect to the inner end
panels and
the bottom panel, respectively, at the same time that the rear inner minor
flaps and the
rear panel are folded and adhered with respect to the inner end panels and the
bottom
panel, respectively. This would result in an erected tray container, having a
partially
open frontal area, into which the goods to be packaged would be drop packed,
relying
upon the inner surfaces of the rear inner minor flaps, the inner end panels,
the front
minor flaps, and potentially, a partial front (side) panel as well as a rear
(side) panel to
provide stacking or other alignment structures. Upon insertion of the goods,
the =
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CA 02541617 2011-05-20
remaining panels and flaps are articulated and glued substantially as
previously
described.
[00157] A second variation of the design (Figs. 10A - 10D and 11) is
substantially
the same as that of Figs. 1 - 9, except that the closure tab 20' is
trapezoidal.
Accordingly, the blank forming container 10' is substantially identical to
blank 11
forming container 10 of Figs. 1 - 9, and the method of articulation of the
blank
forming container 10' is substantially identical to the method of articulation
of blank
11.
[00158] Therefore, the panels and fold lines forming blank 11' which are
similar or
identical to corresponding panels and fold lines of blank 11 are provided with
like
reference numerals, augmented by a prime (`). The process of articulation of
blank 11'
is illustrated in Figs. 10A - 10D.
[00159] Container 10' is formed from blank 11' (Fig. 11). Blank 11' includes
bottom panel 12', front (side) panel 14', rear (side) panel 16', top panel 18'
and
closure flap 20'; as well as fold lines 13', 15', 17' and 19'. Blank 11' also
includes
inner end panels 22', 24' (emanating along fold lines 21', 23', respectively)
from
which interior minor flaps 26', 28', 30', 32' emanate along fold lines 25',
27', 29' and
31', respectively. Outer end panels 34', 36' emanate from top panel 18' along
fold
lines 33', 35', respectively. Reinforcing flanges 38', 40', 42', 44' emanate
from outer
end panels 34', 36', along fold lines 37', 39', 41' and 43', respectively. The
end edges
of panel 14' and 16' may be vertical. Alternatively, the end edges of both
rear panel
16' and front panel 14' preferably may be concavely bowed or notched (as
illustrated),
because this style of slot configuration may permit ease of removing and ease
of
stripping the waste material from the designated and created aperture in the
blank
sheet. As an alternative, rather than the designated and created slot, a
singular cut
including offsets as required may be implemented thereby eliminating a need to
remove waste material.
[00160] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 11', which will be laid flat on a packaging apparatus. Flaps
30',
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CA 02541617 2011-05-20
32' will be folded perpendicular to panel 24', and flaps 26', 28' will be
folded
perpendicular to panel 22'. Panels 22', 24' will be folded upwardly
perpendicularly to
bottom panel 12'. Rear (side) panel 16' and front (side) panel 14' will then
be folded
upwardly perpendicular to bottom panel 12', as shown sequentially in Figs. 10A
-
10D. Top panel 18' is then folded down, toward and parallel to bottom panel
12'; and
outer end panels 34', 36' are folded over and adhered to inner end panels 22',
24',
respectively. Finally, reinforcing flanges (minor flaps) 38', 40', 42' and 44'
are folded
perpendicular along folds 37', 39', 41' and 42', respectively to outer end
panels 34',
36', and adhesively adhered to the outer surfaces of front and rear (side)
panels 14',
16'. When top panel 18' is folded down, closure flap 20' is preferably folded
to the
outside of front panel 14', and adhesively affixed to the outer surface
thereof (Figs.
10C and 10D).
[00161] A third variation of the design (Figs. 12 and 13) is similar to the
variations
of Figs. 1 - 9 and 10 - 11, except that the closure tab emanates from the free
edge of
the front panel 114, and is trapezoidal.
[00162] Container 110 is formed from blank 111 (Fig. 12). Blank 111 includes
bottom panel 112, front (side) panel 114, rear (side) panel 116, top panel 118
and
closure flap 120; as well as fold lines 113, 115, 117 and 119. Blank 111 also
includes
inner end panels 122, 124 (emanating along fold lines 121, 123, respectively)
from
which interior minor flaps 126, 128, 130, 132 emanate along fold lines 125,
127, 129
and 131, respectively. Outer end panels 134, 136 emanate from top panel 118
along
fold lines 133, 135, respectively. Reinforcing flanges 138, 140, 142, 144
emanate
from outer end panels 134, 136, along fold lines 137, 139, 141 and 143,
respectively.
The end edges of panels 114 and 116 may be vertical. Alternatively, the end
edges of
both rear panel 116 and front panel 114 preferably may be concavely bowed or
notched (as illustrated), because this style of slot configuration may permit
ease of
removing and ease of stripping the waste material from the designated and
created
aperture in the blank sheet. As an alternative, rather than the described
designated
slot, a singular cut including offsets as required may be implemented, thereby
eliminating a need to remove waste material.
-24-
CA 02541617 2011-05-20
[00163] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 111, which will be laid flat on a packaging apparatus. Flaps
130,
132 will be folded perpendicular to panel 124, and flaps 126, 128 will be
folded
perpendicular to panel 122. Panels 122, 124 will be folded upwardly
perpendicularly
to bottom panel 112. Rear (side) panel 116 and front (side) panel 114 will
then be
folded upwardly perpendicular to bottom panel 112, as shown in Figs. 13A -
13D.
Top panel 118 is then folded down, toward and parallel to bottom panel 112;
and outer
end panels 134, 136 are folded over and adhesively affixed to inner end panels
122,
124, respectively. Finally, reinforcing flanges (minor flaps) 138, 140, 142
and 144 are
folded perpendicular to outer end panels 134, 136, and adhesively adhered to
the outer
surfaces of front and rear (side) panels 114, 116. When top panel 118 is
folded down,
closure flap 120 is preferably folded to the inside of top panel 118, and
adhesively
affixed to the inside surface thereof.
[00164] In a fourth variation of the design (Fig. 14), which is generally
similar to the
embodiment of Figs. 1 - 9, the ratio of the width of the carton to the depth
of the carton
is still greater than one, but substantially less than in the variations of
Figs.1 - 9; 10 -
11; or 12 - 13. As such, the widths of the "minor" flaps equals one-half the
width of
the carton, so that the minor-flap-facing free edges meet or nearly meet,
along the side-
to-side midpoint of the carton, along the inside and outside surfaces of the
front and
rear panels.
[00165] Container 210 is formed from blank 211 (Fig. 14). Blank 211 includes
bottom panel 212, front (side) panel 214, rear (side) panel 216, top panel 218
and
closure flap 220; as well as fold lines positioned similarly to fold lines 13,
15, 17 and
19 of Fig. 2. Blank 211 also includes inner end panels 222, 224 (emanating
along fold
lines positioned similarly to fold lines 21, 23, of Fig. 2, respectively) from
which
interior minor flaps 226, 228, 230, 232 emanate along fold lines positioned
similarly to
fold lines 25, 27, 29 and 31 of Fig. 2, respectively. Outer end panels 234,
236 emanate
from top panel 218 along fold lines positioned similarly to fold lines 33, 35
of Fig. 2.
Reinforcing flanges 238, 240, 242, 244 emanate from outer end panels 234, 236,
along
fold lines positioned similarly to fold lines 37, 39, 41 and 43 of Fig. 2,
respectively.
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CA 02541617 2011-05-20
The end edges of rear panel 216 and front panel 214 may be concavely bowed or
notched, or inwardly inclined from bottom to top, or vertical, as disclosed in
previously described embodiments, if so desired or deemed necessary in
accordance
with the requirements of any particular application.
[00166] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 211, which will be laid flat on a packaging apparatus. Flaps
230,
232 will be folded perpendicular to panel 224, and flaps 226, 228 will be
folded
perpendicular to panel 222. Panels 222, 224 will be folded upwardly
perpendicularly
to bottom panel 212. Rear (side) panel 216 and front (side) panel 214 will
then be
folded upwardly perpendicular to bottom panel 212, as shown in Path A of Fig.
14.
Top panel 218 is then folded down, toward and parallel to bottom panel 212;
and outer
end panels 234, 236 are folded over and adhesively affixed to inner end panels
222,
224, respectively. Finally, reinforcing flanges (minor flaps) 238, 240, 242,
244 are
folded along folds 237, 239, 241 and 243, respectively, perpendicular to outer
end
panels 234, 236, and adhesively adhered to the outer surfaces of front and
rear (side)
panels 214, 216 and 220. When top panel 218 is folded down, closure flap 220
is
preferably folded to the outside of front minor flaps 228 and 234, and
adhesively
affixed to the outer surface thereof, but to the inside of reinforcing flanges
242, 238,
due to the breadth of those flanges.
[00167] In an alternative embodiment of the method for forming the package,
shown
in Path B, front panel 214 is not raised at the same time as rear panel 216,
and minor
flaps 232 and 228 are likewise not folded inwardly, at the same time as flaps
230, 226.
This provides for a "tray-like" function, in that instead of placing the
product on
bottom panel 212, prior to any articulation, positioning of the product may be
delayed
until the configuration that is the first step (as reflected by the arrow) in
Path B is
attained. In this configuration, because there is a "back wall" formed by
minor flaps
230, 226, the container can serve as a straightening or alignment structure,
for more or
less loosely collected, stacked or otherwise aligned, products.
[00168] Regardless of the path taken, the structure and configuration of the
container
according to Fig. 14 will be the same, as shown in the right-hand side of that
figure.
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CA 02541617 2011-05-20
[00169] A fifth variation of the design (Fig. 15) is similar to the design of
Figs. 1 -9,
except that, upon articulation, the sides of the carton are all inclined, so
that the
resultant container is frusto-pyramidal in configuration.
[00170] The frusto-pyramidal container is formed from blank 311 (Fig. 15).
Blank
311 includes bottom panel 312, front (side) panel 314, rear (side) panel 316,
top panel
318 and closure flap 320; as well as fold lines 313, 315, 317 and 319. Blank
311 also
includes inner end panels 322, 324 (emanating along fold lines 321, 323,
respectively)
from which interior minor flaps 326, 328, 330, 332 emanate along fold lines
325, 327,
329 and 331, respectively. Outer end panels 334, 336 emanate from top panel
318
along fold lines 333, 335, respectively. Reinforcing flanges 338, 340, 342,
344
emanate from outer end panels 334, 336, along fold lines 337, 339, 341 and
343,
respectively. The end edges of rear panel 316 may be concavely bowed (as
illustrated), notched, inclined or vertical, while the end edges of front
panel 314 may
be vertical (as illustrated), inwardly inclined from bottom to top, or
concave, because
this style of slot configuration may permit ease of removing and ease of
stripping the
waste material from the designated and created aperture in the blank sheet. As
an
alternative, rather than the described designated slot, a singular cut
including offsets as
required may be implemented thereby eliminating a need to remove waste
material.
[00171] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 311, which will be laid flat on a packaging apparatus. Flaps
330,
332 will be folded perpendicular to panel 324, and flaps 326, 328 will be
folded
perpendicular to panel 322. Panels 322, 324 will be folded upwardly
perpendicularly
to bottom panel 312. Rear (side) panel 316 and front (side) panel 314 will
then be
folded upwardly perpendicular to bottom panel 312. Top panel 318 is then
folded
down, toward and parallel to bottom panel 312; and outer end panels 334, 336
are
folded over inner end panels 322, 324, respectively. Finally, reinforcing
flanges
(minor flaps) 338, 340, 342 and 344 are folded along folds 337, 339, 341 and
343
perpendicular to outer end panels 334, 336, and adhesively adhered to front
and rear
(side) panels 314, 316. When top panel 318 is folded down, closure flap 320 is
-27-
CA 02541617 2011-05-20
preferably folded to the outside of front panel 314, and adhesively affixed to
the outer
surface thereof.
[00172] Fold lines 329, 331, 325, and 327 are all at non-perpendicular angles
with
respect to fold lines 323, 321, respectively. Similarly, fold lines 341, 343,
337 and 339
are all at non-perpendicular angles with respect to fold lines 335 and 333,
respectively.
In addition, panels 342, 344, 330, 332, 338, 340, 326, 328 are all non-
rectangular.
Further, bottom panel 312 is deeper, from front to back, than top panel 318.
Thus,
upon articulation, the resultant container has inwardly inclined front, rear,
and end
regions, to create a frusto-pyramidal container.
[00173] A sixth variation of the design (Fig. 16) is similar to the design of
Figs. 12-
13, except that, upon articulation, the sides of the carton are all inclined,
so that the
resultant carton is frusto-pyramidal in configuration.
[00174] The container is formed from blank 411 (Fig. 16). Blank 411 includes
bottom panel 412, front (side) panel 414, rear (side) panel 416, top panel 418
and
closure flap 420; as well as fold lines 413, 415, 417 and 419. Blank 411 also
includes
inner end panels 422, 424 (emanating along fold lines 421, 423, respectively)
from
which interior minor flaps 426, 428, 430, 432 emanate along fold lines 425,
427, 429
and 431, respectively. Outer end panels 434, 436 emanate from top panel 418
along
fold lines 433, 435, respectively. Reinforcing flanges 438, 440, 442, 444
emanate
from outer end panels 434, 436, along fold lines 437, 439, 441 and 443,
respectively.
The end edges of panels 414 and 416 may be vertical. Alternatively, the end
edges of
both rear panel 416 and front panel 414 preferably may be concavely bowed or
notched (as illustrated), because this style of slot configuration may permit
ease of
removing and ease of stripping the waste material from the designated and
created
aperture in the blank sheet. As an alternative, rather than the described
designated
slot, a singular cut including offsets as required may be implemented thereby
eliminating a need to remove waste material.
[00175] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 411, which will be laid flat on a packaging apparatus. Flaps
430,
-28-
CA 02541617 2011-05-20
432 will be folded perpendicular to panel 424, and flaps 426, 428 will be
folded
perpendicular to panel 422. Panels 422, 424 will be folded upwardly
perpendicularly
to bottom panel 412. Rear (side) panel 416 and front (side) panel 414 will
then be
folded upwardly perpendicular to bottom panel 412. Top panel 418 is then
folded
down, toward and parallel to bottom panel 412; and outer end panels 434, 436
are
folded over inner end panels 422, 424, respectively. Finally, reinforcing
flanges
(minor flaps) 438, 440, 442 and 444 are folded perpendicular to outer end
panels 434,
436, and adhesively adhered to the outer surfaces of front and rear (side)
panels 414,
416. When top panel 418 is folded down, closure flap 420 is preferably folded
to the
inside of top panel 418, and adhesively affixed to the inside surface thereof.
[00176] Fold lines 429, 431, 425, and 427 are all at non-perpendicular angles
with
respect to fold lines 423, 421, respectively. Similarly, fold lines 441, 443,
437 and 439
are all at non-perpendicular angles with respect to fold lines 435 and 433,
respectively.
In addition, panels 442, 444, 430, 432, 438, 440, 426, 428 are all non-
rectangular.
Further, bottom panel 412 is deeper, from front to back, than top panel 418.
Thus,
upon articulation, the resultant container has inwardly inclined front, rear,
and end
regions, to create a frusto-pyramidal container.
[00177] The seventh variation (Figs. 17A - 19F) of the design are similar to
the basic
design of Figs. 1 - 9; except that the front panel is substantially shorter
than the rear
panel, to create an open display region, and lines of weakness are provided in
the
closure tab, along the middle portions of the front, rear, and side edges of
the top panel
and along diagonals at the corners of the top panel. This permits the bulk of
the top
panel to be removed, leaving triangular-shaped top panel sections remaining,
for
strength, stability and stacking ability.
[00178] Container 510 is formed from blank 511. Blank 511 includes bottom
panel
512, front (side) panel 514, rear (side) panel 516, top center panel 518a with
top corner
panels 518b - 518e, and closure flap 520a; as well as fold lines 513, 515,
517a and
517d and 519a and 519d. Blank 511 also includes inner end panels 522, 524
(emanating along fold lines 521, 523, respectively) from which interior minor
flaps
526, 528, 530, 532 emanate along fold lines 525, 527, 529 and 531,
respectively.
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CA 02541617 2011-05-20
Outer end panels 534, 536 emanate from top center panel 518a and its
respective
comer panels, along fold lines 533b - c, 535b - c, and perforations 533a,
535a,
respectively. Reinforcing flanges 538, 540, 542, 544 emanate from outer end
panels
534, 536, along fold lines 537, 539, 541 and 543, respectively. Blank 511 also
includes perforation lines 517b, 517c, 518g - j, 519b and 519c, as well as
apertures
518f and 520d.
[00179] The end edges of panels 514 and 516 may be vertical. Alternatively,
the
end edges of rear panel 516 preferably may be concavely bowed and the end
edges of
front panel 514 preferably may be inwardly inclined from bottom to top (both
as
illustrated), because this style of slot configuration may permit ease of
removing and
ease of stripping the waste material from the designated and created aperture
in the
blank sheet. As an alternative, rather than the described designated slot, a
singular cut
including offsets as required may be implemented thereby eliminating a need to
remove waste material.
[00180] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 511, which will be laid flat on a packaging apparatus. Flaps
530,
532 will be folded perpendicular to panel 524, and flaps 526, 528 will be
folded
perpendicular to panel 522. Panels 522, 524 will be folded upwardly
perpendicularly
to bottom panel 512. Rear (side) panel 516 and front (side) panel 514 will
then be
folded upwardly perpendicular to bottom panel 512, as shown sequentially in
Figs.
17A and 19A - 19F. Top panel 518 is then folded down, toward and parallel to
bottom
panel 512; and outer end panels 534, 536 are folded over and adhesively
adhered to
the outer surfaces of inner end panels 522, 524, respectively. Finally,
reinforcing
flanges (minor flaps) 538, 540, 542 and 544 are folded perpendicular to outer
end
panels 534, 536, and adhesively adhered to the outer surface of rear (side)
panel 516,
outer surface of front (side) panel 514 and outer surfaces of closure flap
520a,
specifically outer surfaces of top closure front panels 520c and 520b. When
top panel
518 is folded down, closure flap 520a is preferably folded to the outside
surfaces of
interior minor flaps 532 and 528 and adhesively affixed to the outer surface
thereof.
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CA 02541617 2011-05-20
[00181] Instead of ripping or cutting the container apart, as in other
wraparound
container constructions, access to the interior of container 510 is achieved,
via removal
of top center panel 518a, tearing along perforation lines 533a, 518h, 517b,
517c, 518j,
535a, 518i, 519c, 519b and 518g, leaving behind a display tray having four
corner
posts, with triangular top corner panels for still enabling stacking of the
opened tray.
Figs. 19A - 19F show different ways in which articulation of blank 511 may be
accomplished, to arrive at the fully articulated configuration of Fig. 19F.
[00182] In the eighth variation of the design (Figs. 20 - 24), there is no
closure tab
along either of the leading or trailing edges of the blank. Instead, there are
trapezoidal
areas of both the top and front panels that are die cut out, to leave an open
area along
the top and front panels, for display and dispensing purposes, without removal
of
material from the carton.
[00183] Container 610 is formed from blank 611 (Fig. 20). Blank 611 includes
bottom panel 612, front (side) panel 614, rear (side) panel 616, and top panel
618; as
well as fold lines 613, 615, and 617. Blank 611 also includes inner end panels
622,
624 (emanating along fold lines 621, 623, respectively) from which interior
minor
flaps 626, 628, 630, 632 emanate along fold lines 625, 627, 629 and 631,
respectively.
Outer end panels 634, 636 emanate from top panel 618 along fold lines 633,
635,
respectively. Reinforcing flanges 638, 640, 642, 644 emanate from outer end
panels
634, 636, along fold lines 637, 639, 641 and 643, respectively. The end edges
of rear
panel 616 may be concavely bowed (as illustrated), notched, inclined or
vertical, while
the end edges of front panel 614 may be vertical (as illustrated), inwardly
inclined
from bottom to top, or concave, because this style of slot configuration may
permit
ease of removing and ease of stripping the waste material from the designated
and
created aperture in the blank sheet. As an alternative, rather than the
described
designated slot, a singular cut including offsets as required may be
implemented
thereby eliminating a need to remove waste material.
[00184] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 611, which will be laid flat on a packaging apparatus.
Interior
minor flaps 630, 632 will be folded perpendicular to end panel 624, and
interior minor
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CA 02541617 2011-05-20
flaps 626, 628 will be folded perpendicular to end panel 622. End panels 622,
624 will
be folded upwardly perpendicularly to bottom panel 612. Rear (side) panel 616
and
front (side) panel 614 will then be folded upwardly perpendicular to bottom
panel 612
and be adhesively affixed to exterior surfaces of interior minor flaps 626,
628, 630 and
632. Top panel 618 is then folded down, toward and parallel to bottom panel
612; and
outer end panels 634, 636 are folded over and adhesively affixed to exterior
surfaces
of inner end panels 622, 624, respectively. Finally, reinforcing flanges
(minor flaps)
638, 640, 642 and 644 are folded along folds 637, 639, 641 and 643
perpendicular to
outer end panels 634, 636, and adhesively adhered to the outer surfaces of
front and
rear (side) panels 614, 616.
[00185] In a ninth variation (Figs. 25 and 26A - C), the container is provided
with
gusseted corner panel structures, instead of 'minor flaps emanating from the
inner end
panel side edges, to create a so-called "slotless" container.
[00186] Container 710 is formed from blank 711 (Fig. 25). Blank 711 includes
bottom panel 712, front (side) panel 714, rear (side) panel 716, top panel 718
and
closure flap 720; as well as fold lines 713, 715, 717 and 719. Blank 711 also
includes
inner end panels 722, 724 (emanating along fold lines 721, 723, respectively)
from
which interior minor flaps 726, 728, 730, 732 emanate along fold lines 725,
727, 729
and 731, respectively. Outer end panels 734, 736 emanate from top panel 718
along
fold lines 733, 735, respectively. Reinforcing flanges 738, 740, 742, 744
emanate
from outer end panels 734, 736, along fold lines 737, 739, 741 and 743,
respectively.
In addition, blank 711 includes gusset panels 726a, 726b, 730a, 730b, 728a,
728b,
732a and 732b; gusset fold lines 726c, 730c, 728c and 732c; and gusset notches
726d,
730d, 728d and 732d. Blank 711 also includes clearance diecuts 716c, 716d.
[00187] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 711, which will be laid flat on a packaging apparatus.
Interior end
panels 722, 724 will be folded upwardly perpendicularly to bottom panel 712,
while
rear (side) panel 716 and front (side) panel 714 are drawn by the comer gusset
structures to be folded upwardly perpendicular to bottom panel 712, as shown
in Figs.
26A - 26C. At each corner, the respective gusset panel pairs are folded
inwardly, so
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CA 02541617 2011-05-20
that panels 730b, 726b are brought parallel to the inside surface of panel
716,
capturing and adhesively affixing panels 730a, 726b between them,
respectively; and
panels 728b, 732b are brought parallel to the inside surface of panel 714,
capturing
and adhesively affixing panels 728a, 732a between them, respectively.
[00188] Top panel 718 is then folded down, toward and parallel to bottom panel
712; and outer end panels 734, 736 are folded over inner end panels 722, 724,
respectively. Finally, reinforcing flanges (minor flaps) 738, 740, 742 and 744
are
folded along fold lines 737, 739, 741 and 743, respectively, perpendicular to
outer end
panels 734, 736, and adhesively adhered to the outer surfaces of front and
rear (side)
panels 714, 716. When top panel 718 is folded down, closure flap 720 is
preferably
folded to the outside of front panel 714, and adhesively affixed to the outer
surface
thereof (Fig. 26C). The resultant container 710 is thus a "slotless"
container, suitable
for the prevention of leakage of liquids (if suitably coated on the inside
surfaces
thereof), and otherwise suitable for the prevention of leakage of granular or
particulate
dry materials.
[00189] In a tenth variation (Figs. 27 and 28A - C), a container similar to
that of the
embodiment of Figs. 1 - 9 is provided with a second closure flap, so that the
two
closure flaps from the top and front panels overlap to form a reinforced "bar"
across
the front of the container, at what would otherwise be the weakest corner
region,
depending upon the proportions, of the sealed container.
[00190] Container 810 is formed from blank 811 (Fig. 27). Blank 811 includes
bottom panel 812, front (side) panel 814, rear (side) panel 816, top panel 818
and top
closure flap 820 and front closure flap 852; as well as fold lines 813, 815,
817, 819
and 850. Blank 811 also includes inner end panels 822, 824 (emanating along
fold
lines 821, 823, respectively) from which interior minor flaps 826, 828, 830,
832
emanate along fold lines 825, 827, 829 and 831, respectively. Outer end panels
834,
836 emanate from top panel 818 along fold lines 833, 835, respectively.
Reinforcing
flanges 838, 840, 842, 844 emanate from outer end panels 834, 836, along fold
lines
837, 839, 841 and 843, respectively. The end edges of panels 814 and 816 may
be
vertical. Alternatively, the end edges of the rear panel 816 and front panel
814
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CA 02541617 2011-05-20
preferably may be concavely bowed or notched (as illustrated) or inwardly
inclined
from bottom to top because this style of slot configuration may permit ease of
removing and ease of stripping the waste material from the designated and
created
aperture in the blank sheet. As an alternative, rather than the described
designated
slot, a singular cut including offsets as required may be implemented thereby
eliminating a need to remove waste material.
[00191] In a typical articulation procedure, first, the product to be
contained will be
pushed onto blank 811, which will be laid flat on a packaging apparatus. Flaps
830,
832 will be folded perpendicular to panel 824, and flaps 826, 828 will be
folded
perpendicular to panel 822. Panels 822, 824 will be folded upwardly
perpendicularly
to bottom panel 812. Rear (side) panel 816 and front (side) panel 814 will
then be
folded upwardly perpendicular to bottom panel 812, as shown in Figs. 28A -
28C.
Top panel 818 is then folded down, toward and parallel to bottom panel 812;
and outer
end panels 834, 836 are folded over inner end panels 822, 824, respectively.
Finally,
reinforcing flanges (minor flaps) 838, 840, 842 and 844 are folded along fold
lines
837, 839, 841 and 843 perpendicular to outer end panels 834, 836, and
adhesively
adhere to the outer surfaces of front and rear (side) panels 814, 816. When
top panel
818 is folded down, closure flap 820 is preferably folded to the outside of
front panel
814, and adhesively affixed to the outer surface thereof, while front closure
panel 852
is folded inwardly, and affixed to the underside surface of top panel 818,
both as
shown in Fig. 28C.
[00192] The cartons of Figs. 29-78 are preferably fabricated from paper,
paperboard
and/or corrugated paperboard, although other materials having similar
performance
characteristics may be employed, as desired or dictated by the requirements of
a
particular application.
[00193] When referring to the plan illustrations of the blanks, the usual
drawing
conventions for illustration of carton blanks fabricated from paper,
paperboard and/or
corrugated paperboard, as are customarily employed in the art, are applied.
That is,
unless otherwise noted, broken lines indicate scores, fold lines or other
lines of
weakness such as perforations; scalloped lines indicate lines of weakness
forming a
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CA 02541617 2011-05-20
tear strip or similar structure; and solid lines within the interior of, or
extending to the
edge of, a blank, indicate through-cuts.
[00194] A first embodiment is illustrated in Figs. 29 and 30, which features a
single
top panel. Carton 10' (Fig. 30) is formed from blank 11', which is preferably
fabricated from corrugated paperboard, although similarly performing
alternative
materials may be employed. If corrugated paperboard is employed, the preferred
direction of the flutes is indicated by the double-headed arrow in Fig. 29.
Blank 11'
includes bottom panel 12'; side panels 13', 14'; fold lines 15', 16'; minor
flaps 17' -
20'; fold lines 21' - 24'; (front) end panel 25'; (rear) end panel 26'; fold
lines 27', 28';
top panel 29'; top side closure flaps 30', 31'; top front closure flap 32';
top corner
panels 33', 34'; fold lines 35' - 38'; first overlap panels 39', 40'; second
overlap
panels 41' -44'; and fold lines 45' -48'.
[00195] Inner side panels 13', 14' include hand-holes 49', 50', which are
preferably
formed by oval perforations 51', 52', to enable the centers 49A, 50A to be
pushed out,
as desired. Outer side panels 39', 40' include upper edge cutouts 53', 54'. In
this
embodiment, front panel 25' Is slightly trapezoidal (although it could be
rectangular in
alternative embodiments). Rear panel 26' has an hourglass shape, though it
too, could
be rectangular in alternative embodiments. Blank 11' also includes fold lines
55', 56'
and perforations 57', 58', 59', 60'.
[00196] In order to erect carton 10', side panels 13' and 14' have been folded
up
perpendicular to bottom panel 12'. Minor flaps 17' - 20' have been folded
perpendicular to side panels 13', 14' and may be, if desired, adhered to the
inside
surfaces of (front) end panel 25' and (rear) end panel 26'. First overlap
panels 39', 40'
have been positioned to the outside of and adhered to side panels 13', 14'.
First
overlap panels 41'- 44' have been folded perpendicular to first overlap panels
39', 40'
and adhered to the outwardly facing surfaces of (front) end panel 25' and
(rear) end
panel 26'.
[00197] Because of perforations 57', 58', 59', 60' are maintained intact when
the
overlap panels are positioned and glued, top panel 29' is initially positioned
over the
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CA 02541617 2011-05-20
carton opening, parallel to bottom panel 12', but top side closure flaps 30',
31' and top
front closure flap 32' are not glued. To place product in carton 10' (if blank
11' was
not, in fact formed around a load of product), a worker (or machine) pulls up
on top
panel 29', breaking perforations 57', 58'.
[00198] After product has been placed in carton 10', which placement may occur
early in the carton erecting process while the carton is wrapped around the
load in the
usual manner of wrapper type container blanks, top panel 29' is then folded
over
parallel to bottom panel 12' and then top side closure flaps 30', 31' are
folded down
and adhered to outwardly facing surfaces of inner side panels 13', 14' and top
front
closure flap 32' is folded down perpendicular to top panel 29' and adhered to
an
outwardly facing surface of (front) end panel 25'.
[00199] Figs. 75 - 76 illustrate the steps in a method for setting up a
carton, such as
may be fabricated from the blank of Figs. 29 - 30. These methods may be
performed
using suitably modified carton forming machinery such as are known in the art,
and
such modifications may be readily accomplished by one of ordinary skill in the
art,
having the present disclosure before them. The steps are as follows:
[00200] I. A flat blank is indexed into a forming station from the top of a
stack of
blanks.
[00201] II. The blank is then indexed laterally as adhesive is applied to the
inside
surfaces of the blank, such as on panels 25', 26', 39', 40', 41', 42', 43',
44'.
[00202] III. A mandrel then pushes the blank down through a forming chamber in
the forming station into a compression station.
[00203] IV. At a secondary forming station, the top and side panels are folded
while
the overlap panels are articulated and glued.
[00204] V. As a new carton is received in the forming chamber, the just-formed
carton is discharged from the compression section onto a powered take-away
conveyor.
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CA 02541617 2011-05-20
[00205] VI. Formed cartons are pushed down a chute from a case-erecting room
located on an upper floor to a production floor of a production facility.
[00206] VII. Cartons are moved laterally, e.g., at shoulder height, on a
powered belt
conveyor, past manual packing stations.
[00207] VIII. A worker selects an empty carton from the belt conveyor, and
positions the carton at the worker's pack station, e.g., at waist or thigh
height.
[00208] IX. The top front closure flap is pulled up to open the carton for
packing.
[00209] X. Product, such as 1"1 CryovacTM wrapped meat cuts are packed into
the
open carton.
[00210] XI. The filled carton is pushed forward onto a take-away conveyor to a
sealing device, such as an Elliott Top & Side Sealer, a Pearson side flange
sealer or a
Smurfit-Stone Container Corporation side flange sealer.
[00211] XII. The top panel is plowed down and the top front closure flap is
sealed
with hot melt adhesive.
[00212] XIII. The carton is then rotated 90 and the top side closure flaps
are sealed
with hot melt adhesive.
[00213] XIV. Sealed cartons are then transported, e.g., by roller conveyor to
a
manual palletizing area. Pallet Loads are built, transferred by lift trucks to
temporary
storage, and then shipped to customers as required.
[00214] Figs. 21 - 32 illustrate an embodiment which features a two panel top.
Carton 100' is formed from a blank 101', which is preferably symmetrical about
longitudinal axis L and transverse axis T. Again, for a corrugated paperboard
blank,
the preferred direction of the flutes is indicated by the double arrow in Fig.
31. Blank
101' includes bottom panel 102'; side panels 103', 104'; fold lines 105',
106', which
are interrupted by cutouts 107', 108' and 109', 110', respectively; end panel
111'; fold
line 112' interrupted by cutouts 113', 114'; end panel 115'; fold line 116'
interrupted
-37-
CA 02541617 2011-05-20
by cutouts 117', 118'; gusset panels 119' - 122'; minor flaps 123' - 126';
fold lines
127' -134'; first top panels 135', 136'; second top panels 137', 137A; top
corner
panels 138' -141'; fold line 142', interrupted by vent hole 143' and die-cut
tabs 144',
145'; fold line 146', interrupted by vent hole 147' and die-cut tabs 148',
149'; fold
lines 150', 151'; first overlap panels 152' - 155'; second overlap panels 156'
- 159';
fold lines 160' - 167'. Blank 102' also includes slots 168' - 171', which are
configured to receive or fit over hooked tabs 172' - 175', as shown in Fig.
28. Side
panels 103', 104' also may include hand holes 176', 177'. Separation lines
180' -
183', between top corner panels 138' -141' and first top panels 135', 136' may
be
perforations or through-cuts. If perforations, upon gluing and folding down of
first
overlap panels 152' - 155' and second overlap panels 156' - 159', first top
panels 135',
136' will be in a "closed" position, and will have to be pulled up (in the
manner
described relative to the embodiment of Figs. 29 - 30) to permit loading of
the carton,
if carton 100' were not already formed around a load.
[00215] In forming carton 100', side panels 103' and 104' have been folded
perpendicular to bottom panel 102' as have end panel 111' and end panel 115'.
Minor
flaps 124' and 125' have been adhered to the inside surface of end panel 115'
while
minor flaps 123' and 126' have been adhered to an inner surface of end panel
111' so
that gusset panels 119' - 122' extend diagonally across the corners of the
interior of
the carton, acting as stacking support structures. (See gusset panel 120' in
Fig. 32). In
an embodiment in which this carton 100' is wrapped around a load, after the
load has
been placed and the front rear and side panels have been folded up, the first
and
second top panels 135' - 137A may be folded over. In particular, corner panels
138' -
141' are folded over to positions parallel to bottom wall 102'. Then first
overlap
panels 152' - 155' are folded down to positions parallel to and the outside
surfaces of
side panels 103', 104'. Second
overlap panels 156' - 159' are then folded
perpendicular to first overlap panels 152' - 155' and adhered to outwardly
facing
surfaces of end panel 111' and end panel 115'. Carton 100' is a self-locking
carton, in
that stacking tabs 172' - 175' are provided with notches which engage end edge
regions of slots 168' - 171' of second top panels 137' and 137A.
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CA 02541617 2011-05-20
[00216] Figs. 33 - 34 illustrate an embodiment which features a two panel top.
Carton 200' is formed from a blank 201', which is preferably bilaterally
symmetrical,
in the manner of the embodiment of Figs. 31 and 32. Again, for a corrugated
paperboard blank, the preferred direction of the flutes is indicated by the
double arrow
in Fig. 36. Blank 201' includes bottom panel 202'; side panels 203', 204';
fold lines
205', 206', which are interrupted by cutouts 207', 208' and 209', 210',
respectively;
end panel 211'; fold line 212' interrupted by cutouts 213', 214'; end panel
215'; fold
line 216' interrupted by cutouts 217', 218'; gusset panels 219' - 222'; minor
flaps 223'
- 226'; fold lines 227' - 234'; first top panels 235', 236'; second top panels
237',
237A; top corner panels 238' - 241'; fold line 242', interrupted by vent hole
243' and
die-cut tabs 244', 245'; fold line 246', interrupted by vent hole 247' and die-
cut tabs
248', 249'; fold lines 250', 251'; overlap panels 252' - 255'; fold lines 260'
- 263'.
Blank 202' also includes slots 268' - 271', which are configured to receive or
fit over
hooked tabs 272' - 275', as shown in Fig. 37. Side panels 203', 204' also may
include
hand holes 276', 277', and separation lines 280' - 283', which as in the
embodiment of
Figs. 33 - 32, may be perforations or through-cuts, with the corresponding
modes of
operation as discussed in that embodiment.
[00217] Carton 200' of Figs. 33 - 34 is erected and affixed to itself in
substantially
the same manner as the carton of Figs. 31 - 32, except that since there are
only overlap
panels 252' - 255', they must be adhered to outer facing surfaces of side
panels 203',
204', to be held in place there. The closure of the top panels is accomplished
in the
same manner as in the embodiment of Figs. 31 - 32.
[00218] Figs. 35 - 36 illustrate a covered tray with integral lid structure.
Again, for a
corrugated paperboard blank, the preferred direction of the flutes is
indicated by the
double arrow in Fig. 35. Tray 300' is formed from blank 301' (preferably
bilaterally
symmetrical), which includes bottom panel 302'; outer side panels 303', 304';
fold
line 305' interrupted by die-cut slots 306', 307'; fold line 308' interrupted
by die-cut
slots 309', 310'; end panels 311', 312'; fold line 313' interrupted by vent
hole 314';
fold line 315' interrupted by vent hole 316'; inner side panels 317', 318';
web fold
lines 319' - 322'; minor flaps 322A - 325'; fold lines 326' - 329'; gusset
panels 330' -
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CA 02541617 2011-05-20
333'; inner side panel minor flaps 334' - 337'; fold lines 338' - 345'; top
corner panels
346' - 349'; first overlap panels 350' - 353'; second overlap panels 354' -
357'; fold
lines 358' - 361'; fold lines 362' - 365'; top panels 366', 367'; notches 368'
- 371';
vent holes 372' - 379'; and fold lines 380' - 381'. In addition, blank 301'
includes
separation lines 390' - 393', which may be perforations or through-cuts, as in
the
embodiment of Figs. 29 - 30, with similar modes of operation as discussed.
When the
inner side panels are folded in, the webs that connect the inner side panels
and the
outer side panels form stacking tabs, the top edges of which are defined by
the fold
lines 319' -322'.
[00219] Covered tray 300' is formed by folding up outer side panels 303', 304'
perpendicular to bottom panel 302' while folding up end panels 311', 312'
perpendicular to bottom 302'. Inner side panel minor flaps 322A - 325' are
adhered to
inside surfaces of end panels 311' and 312', while panels 334' - 337' are
adhered to
inside surfaces of minor flaps 322A - 325', so that gusset panels 330' - 333'
are
positioned spanning the corners of the interior of the carton. Triangular top
panels
346' - 349' are folded to positions over the corners of the carton parallel to
bottom
panel 302' to enable first overlap panels 350' - 353' to be folded down over
the
outside surfaces of and adhered to, if desired, to outer side panels 303',
304'. Second
overlap panels 354' - 357' are folded perpendicular to first overlap panels
350' - 353'
and adhered to outer surfaces of end panels 311', 312'. Top panels 366', 367'
are then
folded down parallel to bottom panel 302' so that notches 368' - 371' fit
along the
inside surfaces of the stacking tabs formed by the webs connecting outer side
panels
303', 304' with their respective inner side panels 317', 318'. Panels 317',
318' are
folded over 180 degrees to be located parallel and to the inside of panels
303' and
304', so that the two sets of inner and outer minor flaps overlap one another,
with the
inner minor flaps not contacting the outer walls of the container.
[00220] Figs. 37 - 38 illustrate a covered tray with integral lid structure.
For a
corrugated paperboard blank, the preferred direction of the flutes is
indicated by the
double arrow in Fig. 37. Tray 400' is formed from blank 401' (preferably
bilaterally
symmetrical), which includes bottom panel 402'; outer side panels 403', 404';
fold
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CA 02541617 2011-05-20
line 405' interrupted by die-cut slots 406', 407'; fold line 408' interrupted
by die-cut
slots 409', 410'; end panels 411', 412'; fold line 413' interrupted by vent
hole 414';
fold line 415' interrupted by vent hole 416'; inner side panels 417', 418';
web fold
lines 419' - 422'; minor flaps 422A - 425'; fold lines 426' - 429'; gusset
panels 430' -
433'; inner side panel minor flaps 434' - 437'; fold lines 438' - 445'; top
corner panels
446' - 449'; first overlap panels 450' - 453'; second overlap panels 454' -
457'; fold
lines 458' - 461'; fold lines 462' - 465'; top panels 466', 467' with
extensions 466A,
467A; notches 468' - 471'; vent holes 472' - 479'; top side closure flaps 480'
- 483';
fold lines 484' - 487'; and fold lines 488', 489'. When the inner side panels
are folded
in, the webs that connect the inner side panels and the outer side panels form
stacking
tabs, the top edges of which are defined by the fold lines 419' - 422'.
[00221] Blank 401' further includes separation lines 490', 491' which are
preferably
continuous perforations. To load carton 400' (if not formed around a load),
top panels
466', 467' are pulled up, breaking the perforations of separation lines 490',
491', up to
(but preferably not beyond) fold lines 488', 489'. After filling, top panels
466', 467'
are folded down, and top side closure flaps 480' - 483' will be glued and
folded down.
Removal of top panels 466', 467' are accomplished, in part, by tearing along
the
remaining unbroken perforated portions of separation lines 490', 491'.
[00222] Carton 400' is formed in substantially the same manner as carton 300'
except that for carton 400', blank 401' is provided with additional closure
flaps 480' -
483', which are adhered to outside surfaces of outer side panels 403', 404'.
In
addition, top panels 466', 467' terminate in extensions 466A and 467A, which
are
defined by perforations 494', 495'. Extensions 466A and 467A can be used to
open
the container, and permit removal of the lid portion.
[00223] Figs. 39 - 40 illustrate a covered tray, similar to tray 400'. Tray
500' is
formed from blank 501' (preferably bilaterally symmetrical), which includes
bottom
panel 502'; outer side panels 503', 504'; fold line 505' interrupted by die-
cut slots
506', 507'; fold line 508' interrupted by die-cut slots 509', 510'; end panels
511',
512'; fold line 513' interrupted by vent hole 514'; fold line 515' interrupted
by vent
hole 516; inner side panels 517', 518'; web fold lines 519' - 522'; minor
flaps 522A -
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CA 02541617 2011-05-20
525; fold lines 526'- 529'; gusset panels 530' - 533'; inner side panel minor
flaps 534'
- 537'; fold lines 538' - 545'; top corner panels 546' - 549'; first overlap
panels 550'-
553'; second overlap panels 554' - 557'; fold lines 558' - 561'; fold lines
562' - 565';
top panels 566', 567' with extensions 566A, 567A; top side closure flaps 596' -
599'
(which when folded, form or expose slots, for fitting over the stacking tabs
formed
when the inner side panels are folded in against the outer side panels) and
fold lines
588A, 588B, 589A, 589B. For a corrugated paperboard blank, the preferred
direction
of the flutes is indicated by the double arrow in Fig. 39. When the inner side
panels
are folded in, the webs that connect the inner side panels and the outer side
panels
form stacking tabs, the top edges of which are defined by the fold lines 519' -
522'.
Separation lines 590', 592', 593' and 595' are preferably through-cuts, while
separation lines 591', 594' are preferably perforation lines.
[00224] Figs. 41 - 42 illustrate a covered tray with integral lid, and having
stacking
tabs. For a corrugated paperboard blank, the preferred direction of the flutes
is
indicated by the double arrow in Fig. 41. Covered tray 600' is formed from
blank
601' (preferably bilaterally symmetrical), which includes bottom panel 602',
end
panels 603', 604'; fold lines 605', 606'; outer side panels 607', 608'; fold
line 609',
interrupted by vent holes 610', 611'; fold line 612', interrupted by vent
holes 613',
614'; inner side panels 615', 616'; double fold line 617', interrupted by T-
tab
structures 620', 621' including offset tab fold lines 618', 619 '; double fold
line 622',
interrupted by T-tab structures 625', 626' including offset tab fold lines
623', 624';
outer side panel minor flaps 627' - 630'; fold lines 631' - 634'; inner side
panel minor
flaps 635' - 638'; fold lines 639' - 642'; inner side panel notches 643' -
646'; top
panels 647', 648'; fold lines 649', 650'; top corner panels 651' - 654'; first
overlap
panels 655' - 658'; fold lines 659' - 662'; second overlap panels 663' - 666';
fold lines
667' - 670'; top panel notches 671' - 674'. Blank 601' also includes through-
cuts
674" - 676' (which may be substituted by perforations, with the corresponding
modes
of operation as discussed herein).
[00225] In carton 600', when inner side panel 615', 616' are folded over their
respective double fold lines to positions parallel to and overlying the inside
surfaces of
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CA 02541617 2011-05-20
outer side panels 607', 608', the offset fold line 618', 619', 623' and 624'
cause the
upside down t-shaped tab 620', 621', 625', 626' to separate from the
surrounding
portions of the inner side panels 615', 616', as shown in Fig. 42. Inner side
panel
minor flaps 635' - 638' are adhered to the inside surfaces of minor flaps 627'
- 630'.
Outer side panel minor flaps 627' - 630' are adhered to the inside surfaces of
side
panels 603', 604'. First overlap panels 655' - 658' have been folded down to
positions
overlying the outside surfaces of outer side panels 607', 608' with second
overlap
panels 663' - 666' folded perpendicular thereto and adhered to outside
surfaces of end
panels 603', 604'. The closure of carton 600' is an indicated in Fig. 42.
[00226] Figs. 43 - 44 illustrate a carton with integral lid according to
another
embodiment of the invention. For a corrugated paperboard blank, the preferred
direction of the flutes is indicated by the double arrow in Fig. 43. Carton
700' is
formed from blank 701' (preferably bilaterally symmetrical), which includes
bottom
panel 702'; end panels 703', 704'; fold lines 705', 706'; side panels 707',
708'; fold
lines 707A, 708A; side panel minor flaps 709' - 712'; fold lines 713' - 716';
top panels
717', 718'; fold lines 719', 720'; top corner panels 721' - 724'; perforations
725' -
728'; top flaps 729' - 732'; fold lines 733' - 736'; contoured cuts 737' -
740'; overlap
741' - 744'; and fold lines 745' - 748'. Blank 701' also includes knock-outs
750',
751', formed by perforations 752', 753'.
[00227] In carton 700', side panel minor flaps 709' - 712' have been adhered
to the
inside surfaces the end panels 703', 704' and overlap panels 741' - 744' have
been
preferably adhered to outside surfaces of side panels 707', 708'. Upon closure
of top
panel 717', 718' the inner facing edges of these two panels may overlap and
top flap
729' - 732' are folded down and adhered to outer surfaces of end panels 707',
708'
where they are exposed by the contoured cuts 737' - 740'.
[00228] Figs. 45 - 46 illustrate a carton with integral lid, including
diagonal corner
support panels. For a corrugated paperboard blank, the preferred direction of
the flutes
is indicated by the double arrow in Fig. 45. Carton 800' is formed from blank
801'
(preferably bilaterally symmetrical), and includes bottom panel 802'; end
panels 803',
804'; fold lines 805', 806'; side panels 807', 808'; fold lines 809', 810';
gusset panels
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CA 02541617 2011-05-20
811' - 814'; fold lines 815' - 818'; side panel minor flaps 819' - 822'; fold
lines 823' -
826'; top panels 827', 828'; fold lines 829', 830'; top panel flaps 833' -
836'; fold
lines 837' - 840'; top corner panels 841' - 844'; countered cuts 845' - 848';
overlap
panels 849' - 852'; fold lines 853' - 856'; knockouts 857', 858', formed by
perforations 859', 860'. Blank 801' also includes cuts 861' - 864' (which may
be
substituted with perforations, if desired, with the corresponding modes of
operation as
discussed herein).
[00229] Carton 800' is formed in a substantially similar manner as carton
700',
except that blank 801' for 800' includes gusset panels 811' - 814'.
[00230] In a further alternative embodiment of the carton of Figs. 45 - 46,
gusset
panels 811' - 814' may be omitted, by eliminating fold lines 815' - 818'. Such
an
alternative construction is illustrated in Figs. 47 - 48, by carton 800",
formed by blank
801" (preferably bilaterally symmetrical), which has all the other panels,
fold lines and
other features of blank 800' of Figs. 45 - 46. For a corrugated paperboard
blank, the
preferred direction of the flutes is indicated by the double arrow in Fig. 47.
[00231] In another alternative embodiment, shown in Figs. 49 - 50, a covered
carton
with two top panels, and with outer corner support panels, is shown. For a
corrugated
paperboard blank, the preferred direction of the flutes is indicated by the
double arrow
in Fig. 49. Carton 900'
is formed from blank 901' (preferably bilaterally
symmetrical), which includes bottom panel 902'; end panels 903', 904'; fold
lines
905', 906'; side panels 907', 908'; fold lines 909', 910'; minor flaps 911' -
914'; fold
lines 915' - 918'; top panels 919', 920'; fold lines 921', 922'; top corner
panels 923' -
926'; perforations 927' - 930' (which may be replaced by straight cuts); top
side
closure flaps 931' - 934'; fold lines 935' - 938'; first overlap panels 940' -
943'; fold
lines 944' - 947'; second overlap panels 948' - 951'; fold lines 952' - 955';
and knock-
outs 956', 957', formed by perforations 958', 959'.
[00232] Carton 900' is substantially similar to carton 700', but for the
addition of
second overlap panels 948' - 951', which are adhered to the outside surfaces
of side
panels 907', 908'.
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CA 02541617 2011-05-20
[00233] Figs. 77 - 78 illustrate the steps in a method for setting up a
carton, such as
may be fabricated from the blank of Figs. 49 - 50. These methods may be
performed
using suitably modified carton forming machinery such as are known in the art,
and
such modifications may be readily accomplished by one of ordinary skill in the
art,
having the present disclosure before them. The steps are as follows:
[00234] 1. A flat blank is indexed into a forming station from the top of a
stack of
blanks.
[00235] II. The blank is indexed laterally as adhesive is applied to the
inside surfaces
of panels '903', 904', 948' - 951' and 940' - 943', particularly in a series
of parallel
glue lines, extending in a direction parallel to the direction of the flutes
(as shown by
the double arrow). In panels 903', 904', the glue lines may be placed near the
top and
bottom of those panels (as observed in Fig. 49), but not along the mid-regions
of those
panels, if desired.
[00236] III. A mandrel pushes the blank down through a forming chamber into a
compression section.
[00237] IV. At a secondary forming station, the top panels and first overlap
panels
are folded down while the second overlap panels are articulated and glued.
[00238] V. As a new carton is received in the forming chamber, the just formed
carton is discharged from the compression section onto a powered take-away
conveyor.
[00239] VI. Formed cartons are pushed down a chute from a case erecting room
located on an upper floor to a production floor of a production facility.
[00240] VII. Cartons are moved laterally, e.g., at shoulder height, on a
powered belt
conveyor, past manual packing stations.
[00241] VIII. A worker selects an empty carton from the belt conveyor, and
positions the carton at the worker's pack station, e.g., at waist or thigh
height.
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CA 02541617 2011-05-20
[00242] IX. The top panels are pulled up (breaking perforations as necessary)
to
open the carton for packing.
[00243] X. Product, such as CryovacTM wrapped meat cuts are packed into the
open
carton.
[00244] XI. The filled carton is pushed forward onto a take-away conveyor to a
sealing device, such as an Elliott Top & Side Sealer, a Pearson side flange
sealer or a
Smurfit-Stone Container Corporation side flange sealer.
[00245] XII. The top panels are plowed down and the top side closure flaps are
sealed with hot melt adhesive.
[00246] XIII. Sealed cartons are then transported, e.g., by roller conveyor to
a
manual palletizing area. Pallet Loads are built, transferred by lift trucks to
temporary
storage, and then shipped to customers as required.
[00247] In the embodiment of Figs. 51 - 52, carton 1000' is formed by blank
1001',
to create a single top panel carton. For a corrugated paperboard blank, the
preferred
direction of the flutes is indicated by the double arrow in Fig. 51. Blank
1001'
includes bottom panel 1002'; (front) end panel 1003'; (rear) end panel 1004';
fold
lines 1005', 1006'; side panels 1007', 1008'; fold lines 1009', 1010'; gusset
panels
1011' - 1014'; fold lines 1015' - 1018'; minor flaps 1019' - 1022'; fold lines
1024' -
1027'; top panel 1028'; fold line 1029'; top side closure flaps 1030', 1031';
fold lines
(or perforation lines) 1032', 1033'; cutouts 1034', 1035'; top corner panels
1036',
1037'; perforations or through cuts 1038', 1039'; first overlap panels 1040',
1041';
fold lines 1059', 1060'; perforations 1042', 1043'; top front closure flap
1044'; fold
line 1045'; second overlap panels 1046' - 1049'; fold lines 1050' - 1053';
hand holes
1054', 1056'; and vent apertures 1057', 1058'.
[00248] Carton 1000' is formed by placing side panels 1007', 1008'
perpendicular to
bottom panel 1002'. Minor flaps 1019' - 1022' are affixed to inside surfaces
of (front)
end panel 1003' and (rear) end panel 1004'. Closure of carton 1000' is
accomplished
by folding top panel 1028' to a position parallel to bottom panel 1002'. At
this point,
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CA 02541617 2011-05-20
top panel 1028' is still attached along perforations 1042' and 1043' to first
overlap
panels 1040', 1041'. First overlap panels 1040', 1041' are affixed to outside
surfaces
of side panels 1007', 1008' with second overlap panels 1046' - 1049' being
affixed to
outside surfaces of (front) end panel 1003' and (rear) end panel 1004'. Top
front
closure flap 1044' is affixed to an outer surface of (front) end panel 1003'.
In
addition, top side closure panels 1030' and 1031' are adhered to outside
surfaces of
side panels 1007' and 1008'. Opening of carton 1000' is accomplished by
peeling
back top front closure panel 1044', and top side closure panels 1030' and
1031' (or
tearing along their respective fold lines/perforations), and tearing along
perforations
1042' and 1043'.
[00249] The embodiment of Figs. 53 - 54 is a carton 1100' provided with a two-
panel top, and is formed from blank 1101' (preferably bilaterally
symmetrical). For a
corrugated paperboard blank, the preferred direction of the flutes is
indicated by the
double arrow in Fig. 53. Blank 1101' includes bottom panel 1102', end panels
1103',
1104'; fold lines 1105', 1106'; side panels 1107', 1108'; fold lines 1109',
1110';
gusset panels 1111'- 1114'; fold lines 1115'- 1118'; minor panels 1119'-
1122'; fold
lines 1123' - 1126'; top panels 1127', 1128'; fold lines 1129', 1130'; first
overlap
panels 1131' - 1134'; perforations 1135'- 1138'; top side closure flaps 1139' -
1142';
cuts 1143'- 1146'; fold lines 1147'- 1150'; second overlap panels 1151'-
1154'; and
hand holes 1155', 1156'.
[00250] In carton 1100', minor panels 1119' - 1122' are adhered to inside
surfaces
of side panels 1103', 1104', so that gusset panels 1111' - 1114' extend
diagonally
across the corners of the interior of carton 1100' to provide vertical
stacking strength.
First overlap panels 1131' - 1134' are adhered to outside surfaces of side
panels 1107',
1108'. Top panels 1128', 1127' are pulled up, tearing perforations 1135' -
1138'
where the top panels are joined to first overlap panels 1131' - 1134', to
permit the top
panels to be raised for loading. After loading, top side closure flaps 1139' -
1142' are
folded down and glued in place, later to be separated from the top panels
along the
perforations to enable access to the interior of carton 1100'.
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CA 02541617 2011-05-20
[00251] Carton 1200' of Figs. 55 - 56 is formed from blank 1201'. For a
corrugated
paperboard blank, the preferred direction of the flutes is indicated by the
double arrow
in Fig. 55. Blank 1201' includes bottom panel 1202'; (front) end panel 1203';
(rear)
end panel 1204'; fold lines 1205', 1206'; side panels 1207', 1208'; fold lines
1209',
1210'; gusset panels 1211' - 1214'; fold lines 1215' - 1218'; minor flaps
1219' -
1222'; fold lines 1223' - 1226'; top panel 1227'; fold line 1228'; top side
closure flaps
1229', 1230'; fold lines 1231', 1232'; top front closure flap 1233'; fold line
1234';
first overlap panels 1235', 1236'; perforations 1237' - 1240'; second overlap
panels
flaps 1241' - 1244'; fold lines 1245' - 1248'; hand holes 1249', 1250'; and
vent holes
1251', 1252'.
[00252] Carton 1200' is formed from a blank 1201', which is similar to carton
1000'
previously described, the primary difference being that the blank of carton
1200' is not
provided with the top corner panels along the rear panel of the blank as in
the
embodiment of carton 1000'.
[00253] Carton 1300' of Figs. 57 - 58 is formed from blank 1301'. For a
corrugated
paperboard blank, the preferred direction of the flutes is indicated by the
double arrow
in Fig. 57. Blank 1301' includes bottom panel 1302'; end panels 1303', 1304';
fold
lines 1305', 1306'; top panels 1307', 1308'; fold line 1309' interrupted by
die-cut
stacking tabs 1311', 1312'; fold line 1310' interrupted by die-cut stacking
tabs 1313',
1314'; top side closure flaps 1315' - 1318'; fold lines 1319' - 1322'; top
corner panels
1323' - 1326'; through-cuts 1327' - 1330' (which could be replaced by
perforations);
fold lines 1331' - 1334'; first overlap panels 1333' - 1336'; second overlap
panels
1337' - 1340'; fold lines 1341' - 1344'; outer side panels 1345', 1346'; fold
lines
1347' - 1348'; double fold lines 1349', 1350'; inner side panels 1351', 1352';
outer
side panel minor flaps 1353' - 1356'; fold lines 1357' - 1360'; V-shaped
gusset panels
1361' - 1364'; fold lines 1365' - 1372'; inner side panel minor flaps 1373' -
1376';
vent openings 1377', 1379'; die-cut stacking slots 1380' - 1383'.
[00254] Carton 1300', shown in Figs. 57 - 58, is, except for the proportions,
substantially similar in the structure and mode of operation to carton 300'.
In addition,
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CA 02541617 2011-05-20
top side closure flaps 1315' - 1318' extend from end edges of the top panels
and are
adhered to outside surfaces of side panels 1345', 1346'.
[00255] Carton 1400', shown in Figs. 59 - 60, is a two top panel carton, but
based on
an asymmetrical blank 1401'. For a corrugated paperboard blank, the preferred
direction of the flutes is indicated by the double arrow in Fig. 59. Blank
1401'
includes bottom panel 1402'; end panels 1403', 1404'; fold lines 1405', 1406';
side
panels 1407', 1408'; fold lines 1409', 1410'; gusset panels 1411' - 1414';
fold lines
1415' - 1418'; minor flaps 1419' - 1422'; fold lines 1423' - 1426'; top panels
1427',
1428'; fold lines 1429', 1430'; top corner panels 1431' - 1434'; through-cuts
1435' -
1438' (which could be replaced by perforations); first overlap panels 1439' -
1442';
fold lines 1443' -1446'; second overlap panels 1447' - 1450'; fold lines 1451'
- 1454';
top side closure flaps 1455', 1456'; fold lines 1457', 1458'; locking flaps
1459',
1460'; fold lines 1461', 1462'; tabs 1463', 1464'; hand holes 1465', 1466'.
[00256] In the embodiment shown in Figs. 59 - 60, tabs 1463', 1464' are set
off by
separate score lines 1467' - 1470' that extend perpendicular to fold lines
1471', 1472'
that extend across locking flaps 1459', 1460'. In an alternative embodiment of
the
invention, score lines 1467' - 1470' may be omitted.
[00257] In carton 1400', minor flaps 1419' - 1422' are adhered to inside
surfaces of
end panels 1403', 1404'. First overlap panels 1439' - 1442' are adhered to
outside
surfaces of side panels 1407', 1408' and/or second overlap panels 1447' -
1450' are
adhered to outside surfaces of end panels 1403', 1402'. To maintain closure
panel
1427' in place over bottom panel 1402', closure flaps 1455', 1456' are folded
down
over the outer surfaces of side panels 1407', 1408', while tabs 1464', 1463'
or locking
flaps 1459', 1460' are inserted and received through hand holes 1465', 1466',
locking
the top flaps 1427', 1428' down in place.
[00258] Figs. 61 - 62 illustrate a covered carton with self-locking top
panels. For a
corrugated paperboard blank, the preferred direction of the flutes is
indicated by the
double arrow in Fig. 61. Carton 1500' is formed from blank 1501', which
includes
bottom panel 1502'; outer side panels 1503', 1504'; fold line 1505',
interrupted by
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CA 02541617 2011-05-20
stacking notches 1506', 1507'; fold line 1508' interrupted by stacking notches
1509',
1510'; end panels 1511', 1512'; fold lines 1513', 1514'; top panels 1516',
1517'; fold
lines 1518', 1519'; top corner panels 1520' - 1523'; through-cuts 1524' 1527'
(which
may be replaced by perforations); locking tabs 1528' - 1531'; first overlap
panels
1532' - 1535'; fold lines 1536' - 1539'; second overlap panels 1540' - 1543';
inner
side panels 1544', 1545'; web fold lines 1546' - 1549'; outer side panel
stacking tabs
1550' - 1553'; inner side panel stacking tabs 1554' - 1557'; minor flaps 1560'
- 1563';
fold lines 1563" - 1566'; minor flaps 1567' - 1570'; fold lines 1571' - 1574';
and
stacking notches 1575' -1578'.
[00259] In the carton 1500', minor flaps 1560' - 1563' are affixed to inside
surfaces
of end panels 1511', 1512' and minor flaps 1567' - 1570' are affixed to inside
surfaces
of minor flaps 1560' - 1563'. In addition, second overlap panels 1540' - 1543'
are
affixed to outside surfaces of end panels 1511', 1512'. The stacking tab
structures
1554' - 1557' also serve to help keep the lid closed or re-closeable by being
provided
with notches that receive locking tabs 1528', 1531' as indicated in Fig. 62.
[00260] Carton 1600' of Figs. 63 - 64 is formed from blank 1601', and has
bottom
panel 1602'; outer side panels 1603', 1604'; fold line 1605', interrupted by
stacking
openings 1606', 1607'; fold line 1608', interrupted by stacking openings
1609', 1610';
end panels 1611', 1612'; fold lines 1613', 1614'; top panels 1615', 1616';
fold lines
1617', 1618'; top corner panels 1619' - 1622'; through-cuts 1623' - 1626'
(which may
be replaced by perforations); locking tabs 1627' - 1630'; first overlap panels
1631' -
1634'; fold lines 1635' - 1638'; second overlap panels 1639' - 1642'; inner
side panels
1643', 1644'; web double fold lines 1645' - 1648'; outer side panel stacking
tabs
1649' - 1652'; notched inner side panel stacking tabs 1653' - 1656'; minor
flaps 1658'
- 1661'; fold lines 1662' - 1664"; minor flaps 1665' - 1668'; double fold
lines 1669' -
1672'; and stacking notches 1673' - 1680'. For a corrugated paperboard blank,
the
preferred direction of the flutes is indicated by the double arrow in Fig. 63.
[00261] In carton 1600', the structure mode of operation and manner of
affixation of
certain panels to other panels is substantially similar to that of the
embodiment of
carton 1500', except that the panels emanating from the ends of the inner side
panels
-50-
CA 02541617 2011-05-20
are elongated so as to be folded back upon outwardly facing surfaces of the
inner side
panels. Thus, panels 1665', 1666' are captured between panels 1603' and 1643',
and
panels 1667' and 1668' are captured between panels 1604' and 1664'. This
sandwiching so of panels is evidenced in Fig. 64, particularly on the left end
of the
carton where outer side panel 1603' and inner side panel 1643' capture between
them
panels 1665' and 1666'.
[00262] Carton 1700' is illustrated in Figs. 65 - 66. For a corrugated
paperboard
blank, the preferred direction of the flutes is indicated by the double arrow
in Fig. 65.
Blank 1701' includes bottom panel 1702'; outer side panels 1703', 1704'; fold
line
1705' interrupted by stacking openings 1706', 1707'; fold line 1708'
interrupted by
stacking openings 1709', 1710'; end panels 1711', 1712'; fold lines 1713',
1714'; top
panels 1715', 1716'; fold lines 1717', 1718'; top corner panels 1719' - 1722';
through-
cuts 1786' - 1789'; first overlap panels 1723' - 1726'; fold lines 1727' -
1730'; second
overlap panels 1731' - 1734'; fold lines 1735' - 1738'; minor flaps 1739' -
1742'; fold
lines 1743' - 1746'; web fold lines 1747' - 1750'; outer side panel stacking
tabs 1751'
- 1754'; inner side panel stacking tabs 1755' - 1758'; inner side panels
1759', 1760';
minor flaps 1761' - 1764'; gusset panels 1765' - 1768'; fold lines 1769' -
1776';
stacking notches 1778' -1781'; and locking tabs 1782' -1785'.
[00263] Carton 1700' is substantially similar to cartons 1600', except that
gusset
panels are provided adjacent inside side panels 1759' and 1760' with minor
flaps
1739' - 1742' being adhered to inside surfaces of end panels 1711', 1712' and
minor
flaps 1761' - 1764' being affixed to inside minor flaps 1739' - 1742'. The
closure
mechanism for carton 1700' is the same as it is for carton 1600'.
[00264] Carton 1800' (Figs. 67 - 68) includes self-locking top panels as well
as
interior corner supports. For a corrugated paperboard blank, the preferred
direction of
the flutes is indicated by the double arrow in Fig. 67. Blank 1801' includes
bottom
panel 1802'; end panels 1803', 1804'; fold line 1805', interrupted by stacking
openings 1806, 1807'; fold line 1808', interrupted by stacking openings 1809',
1810';
outer side panels 1811', 1812'; fold line 1813', interrupted by stacking
openings
1814', 1815'; fold line 1816', interrupted by stacking openings 1817', 1818';
notched
-51-
CA 02541617 2011-05-20
stacking tabs 1819' - 1822'; side end panels 1823', 1824'; double fold lines
1825',
1826'; stacking notches 1827' - 1830'; gusset panels 1831' - 1834'; fold lines
1835' -
1838'; minor flaps 1839' -1843'; fold lines 1843' - 1846'; minor flaps 1847' -
1850';
fold lines 1851' - 1854'; fold line 1855', interrupted by die-cut stacking
tabs 1856',
1857'; fold line 1858', interrupted by die-cut stacking tabs 1859', 1860';
outer top
panels 1861', 1862'; top corner panels 1863' - 1866'; through-cuts 1867' -
1870';
overlap panels 1871' - 1874'; fold lines 1875' - 1878'; inner top panels
1879', 1880';
fold lines 1881', 1882'; locking tab receiving slots 1883' - 1886'; and knock-
outs
1887' - 1890' (surrounded by oval lines of perforations).
[00265] In carton 1801', the stacking tab structures are incorporated into the
side and
end panel structures, especially upon folding over of the inner side panels to
the
positions inside the outer side panels exposes the hooked stacking and closure
tabs
1819' - 1822'. Minor flaps 1847' - 1850' are affixed to inside surfaces of
outer end
panels 1803, 1804 and minor flaps 1839' - 1843' are affixed to minor flaps
1847' -
1850', while support panels 1871' - 1874' are affixed to outside surfaces of
outer side
panels 1811', 1812'.
[00266] Figs. 69 - 70 illustrate a covered tray with integral lid, and having
stacking
tabs. For a corrugated paperboard blank, the preferred direction of the flutes
is
indicated by the double arrow in Fig. 69. Covered tray 1900' is formed from
blank
1901' (preferably bilaterally symmetrical), which includes bottom panel 1902',
end
panels 1903', 1904'; fold lines 1905', 1906'; outer side panels 1907', 1908';
fold line
1909', interrupted by vent/stacking holes 1910', 1911'; fold line 1912',
interrupted by
vent/stacking holes 1913', 1914'; inner side panels 1915', 1916'; double fold
line
1917', interrupted by T-tab structures 1920', 1921' including offset tab fold
lines
1918', 1919'; double fold line 1922', interrupted by T-tab structures 1925',
1926'
including offset tab fold lines 1923', 1924'; outer side panel minor flaps
1927' -
1930'; fold lines 1931' -1934'; inner side panel minor flaps 1935' - 1938';
inner side
panel notches 1943' - 1946'; top panels 1947', 1948'; fold lines 1949', 1950';
top
corner panels 1951' - 1954'; first overlap panels 1955' - 1958'; fold lines
1959' -
1962'; second overlap panels 1963' - 1966'; fold lines 1967' - 1970'; top
panel
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CA 02541617 2011-05-20
locking tabs 1971' - 1974'. Blank 1901' also includes gusset panels 1975' -
1978';
fold lines 1979' - 1986'; and through cuts 1987' - 1990' (which may be
substituted by
perforations). An alternative embodiment of this carton, carton 1900", is
shown in
Figs. 71 - 72, wherein blank 1901' is nearly identical to blank 1900', except
that panels
1963' - 1966' have been omitted, and panels, corresponding to panels 1927' -
1930' in
blank 1900', have been lengthened. For a corrugated paperboard blank, the
preferred
direction of the flutes is indicated by the double arrow in Fig. 71.
[00267] Carton 1900' features T-shaped stacking tabs similar to the embodiment
of
carton 600', with the notches for capturing locking tabs in the lid panels as
in the
embodiment of carton 1800'. In carton 1900', inner side panel minor flaps
1927' -
1930' are adhered to inside surfaces of end panels 1903', 1904' and minor
flaps 1935'
- 1938' are adhered to outside minor flaps 1927' - 1930', such that gusset
panels 1975'
- 1978' extend diagonally across the corners of the interior volume. Second
overlap
panels 1963' - 1966' are adhered to outside surfaces of end panels 1903',
1904'. As
mentioned, top panels 1947', 1948' may be retained in place through the
capture of
locking tabs 1971' - 1974' which can be received in the notches in T-tab
structures
1925', 1926', 1920' and 1921'. As mentioned, carton 1900' is substantially
identical
in structure and mode of operation to carton 1900'.
[00268] Carton 1800" of Figs. 73 - 74 is substantially identical to carton
1800' of
Figs. 67 - 68, except that blank 1801" is provided with second overlap panels
1891' -
1894', along fold lines 1895' - 1898', and the shortening of panels 1847' -
1850' as
compared to panels 1847' - 1850' in blank 1801'.
[00269] Although processes for forming and packing the foregoing cartons are
provided specifically for the embodiments of Figs. 28 - 30 and 49 - 50, it is
to be
understood that one of ordinary skill in the art, having the present
disclosure before
them, would readily be able to modify existing carton forming equipment, using
ordinary design and engineering skills, for the purposes of erecting, and
subsequently
sealing, the cartons, of each of the embodiments, without departing from the
scope of
the present invention, and without extensive experimentation.
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CA 02541617 2011-05-20
[00270] The carton designs of Figs. 29 - 78 the present invention permit the
carton to
be fully erected with all of the vertical inner and outer flaps and any
attached flaps to
be sealed and properly positioned for maximum stacking performance, but will
allow a
portion of the top flaps (horizontal) to be separated from the vertical outer
end flaps so
that access to the carton cavity can be accomplished for loading of product.
Additional design features incorporated into the separated top flap feature
allow the
top flaps to be sealed or locked into position as desired after the product
has been
loaded.
[00271] As described herein, among the critical features that enable the
cartons of
Figs. 29 - 78, to perform well is the strategic use of slits or perforations
that separate
the top horizontal panel (flap) from the end flaps of a tray or wrap design
having full
overlapping end flaps. These fully overlapping vertical end flaps may include
additional (secondary) flaps which provide additional corner structures for
added stack
strength. Through the utilization of the slits or perforations (nicks), this
permits the
erecting machine to fully set up the carton's stacking features (inner and
outer full
overlapping flaps and inner and where applicable outer minor flaps), but
allows the
horizontal top flaps to remain free or only lightly attached (nicked) to the
end flaps.
[00272] This allows user access to the carton cavity for loading of the
products
through either manual, man-machine interface, or automatic methods. In the
situation
in which a slit is used to separate the top and end structures, the carton can
be
effectively erected with the top flaps left in an upright position upon
discharge from
the erecting machine. In the situation in which nicks are used, keeping the
top and end
panels connected, the top flaps are in a horizontal or closed position upon
discharge
from the machine and opened, through the breaking of the nicks (either
manually or
mechanically) when desired. Final sealing or closure is accomplished with
special
features, such as slot and tab mechanisms, or through the use of additional
material
removed from the vertical end flaps and left attached to the horizontal top
flaps (such
as a flange), which is glued to the outer container walls to facilitate final
closure when
desired. These features, among others, permit this strategic use of the top
flap panel,
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CA 02541617 2011-05-20
while protecting the important functions of the end flaps, can be applied to a
number
of container designs, as shown in the accompanying description and drawings.
[00273] The cartons of Figs. 79 - 84 are preferably fabricated from paper,
paperboard and/or corrugated paperboard, although other materials having
similar
performance characteristics may be employed, as desired or dictated by the
requirements of a particular application. When each of the blanks of Figs. 79 -
84 are
discussed, it is to be understood that the panels which form the corner
support
structures may emanate from panels that are longer, shorter or the same length
as the
panels which extend perpendicularly thereto (in the erected carton), so the
terms "side"
and "end" are not meant to have any binding or constrictive meaning with
respect to
the relative lengths of the sides of the cartons, when erected. Also, in each
of the
following embodiments, the preferred methods of fabrication involve the panels
forming the corner structures being folded and glued, prior to the panels
(from which
the corner structure panels emanate) being folded up perpendicular to the
bottom
panels. This would be a preferred panel folding order, for mechanized
fabricating
systems. However, in alternative embodiments, the folding of the corner
structure
panels could be done after the panels from which the corner support structure
panels
emanate, have been folded upward, perpendicular to the bottom panel. Such an
alternative process could be performed manually, at least, if not
mechanically.
[00274] When referring to the plan illustrations of the blanks, the usual
drawing
conventions for illustration of carton blanks fabricated from paper,
paperboard and/or
corrugated paperboard, as are customarily employed in the art, are applied.
That is,
unless otherwise noted, broken lines indicate scores, fold lines or other
lines of
weakness such as perforations; scalloped lines indicate lines of weakness
forming a
tear strip or similar structure; and solid lines within the interior of, or
extending to the
edge of, a blank, indicate through-cuts.
[00275] Fig. 79 is a plan view for a blank for an open-topped carton, having
stacking
support structures, according to a preferred embodiment of the invention.
Preferably,
blank 2000 is fabricated from corrugated paperboard, with the corrugations
extending
in the direction of the double-headed arrow. Blank 2000 includes bottom panel
2002;
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CA 02541617 2011-05-20
end panels 2012, 2016, connected by fold lines 2004, 2008, respectively; and
front and
rear panels 2018, 2014, connected by fold lines 2010, 2006, respectively.
[00276] Emanating from opposite front and rear edges of end panel 2012, along
fold
lines 2020 and 2022 are first inner support panels 2024, 2026. Emanating from
fold
lines 2028 and 2030, respectively are second inner support panels 2032, 2034.
Emanating from fold lines 2036, 2038 are third inner support panels 2040,
2042.
[00277] Emanating from opposite front and rear edges of end panel 2016, along
fold
lines 2044 and 2046 are first inner support panels 2048, 2050. Emanating from
fold
lines 2052 and 2054, respectively are second inner support panels 2056, 2058.
Emanating from fold lines 2060, 2062 are third inner support panels 2064,
2066.
[00278] Emanating from upper edges of front and rear panels 2018, 2014,
respectively, along fold lines 2072, 2074, 2068, and 2070 are triangular
connection
panels 2080, 2082, 2076, 2078, respectively. First outer support panels 2084,
2086,
2088 and 2090 emanate from triangular connection panels 2076, 2078, 2080,
2082,
respectively, along respective fold lines disposed therebetween. Second outer
support
panels 2100, 2102, 2104, 2106 emanate from the first outer support panels,
along fold
lines 2092, 2094, 2096, 2098. Openings 2108, 2110 are provided to enable
visual
inspection of the contents and/or to facilitate lifting of carton 2000. Figs.
79A - 79F
(in which fold lines are not shown by broken lines), illustrate various stages
in the
articulation of carton 2000. First, first inner support panels 2024, 2026,
2048, 2050
are folded perpendicular to end panels 2012, 2016. Second inner support panels
2032,
2034, 2056, 2058 are folded 180 relative to their respective adjacent first
inner
support panels, so that the first and second inner support panels are face-to-
face
(adhesive of any suitable kind may be applied therebetween to hold the first
and
second inner support panels against one another). This is possible, because
the second
inner support panels are slightly narrower than the first inner support
panels. At about
the same time, third inner support panels 2040, 2042, 2064, 2066 are folded
outwardly
90 (or thereabouts) to positions face-to-face against inside surfaces of end
panels
2012, 2016, and adhered thereto, using any suitable adhesive. At the end of
the
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CA 02541617 2011-05-20
foregoing procedures, four L-shaped support structures are positioned at the
corners of
bottom panel 2002. See Fig. 79B.
[00279] To assemble carton 2000, end panels 2012, 2016 are folded upwardly to
positions perpendicular relative to bottom 2002. See Fig. 79A. At the same
time, rear
panel 2014 is folded up perpendicular to bottom panel 2002, and adhered to
outwardly
facing surfaces of first inner support panels 2024, 2048. Front panel 2018 is
folded up
perpendicular to bottom panel 2002, and adhered to outwardly facing surfaces
of first
inner support panels 2026, 2050. See Fig. 79C. Triangular connection panels
2076,
2078, 2080, 2082 are folded inwardly to positions parallel to bottom panel
2002, atop
the L-shaped support structures. Adhesive may be applied therebetween. See
Fig.
79D. First outer support panels 2084, 2086, 2088, 2090 are folded down, to
positions
overlying outer surfaces of end panels 2012, 2014 and adhered thereto, if
desired. See
Fig. 79E. Second outer support panels 2100, 2102, 2104, 2106 are then folded
perpendicular to the first outer support panels, to positions overlying outer
surfaces of
front and rear panels 2014, 2018 and adhered thereto. See Fig. 79F.
[00280] Fig. 80 is a plan view for a blank for an open-topped carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
Preferably, blank 2200 is fabricated from corrugated paperboard, and the
corrugations
run in the direction of the double-headed arrow. Blank 2200 includes bottom
panel
2202; end panels 2212, 2216, connected by fold lines 2204, 2208, respectively;
and
front and rear panels 2218, 2214, connected by fold lines 2210, 2206,
respectively.
[00281] Emanating from opposite front and rear edges of end panel 2212, along
fold
lines 2220 and 2222 are first inner support panels 2224, 2226. Emanating from
fold
lines 2228 and 2230, respectively are second inner support panels 2232, 2234.
Emanating from fold lines 2236, 2238 are third inner support panels 2240,
2242.
[00282] Emanating from opposite front and rear edges of end panel 2216, along
fold
lines 2244 and 2246 are first inner support panels 2248, 2250. Emanating from
fold
lines 2252 and 2254, respectively, are second inner support panels 2256, 2258.
Emanating from fold lines 2260, 2262 are third inner support panels 2264,
2266.
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CA 02541617 2011-05-20
[00283] Emanating from upper edges of front and rear panels 2218, 2214,
respectively, along fold lines 2272, 2274, 2268 and 2270, are triangular
connection
panels 2280, 2282, 2276 and 2278, respectively. First outer support panels
2284,
2286, 2288 and 2290 emanate from triangular connection panels 2276, 2278,
2280,
2282, respectively, along respective fold lines disposed therebetween. Second
outer
support panels 2300, 2302, 2304, 2306 emanate from the first outer support
panels,
along fold lines 2292, 2294, 2296, 2298. Openings 2308, 2310 are provided to
enable
visual inspection of the contents and/or to facilitate lifting of carton 2200.
[00284] Figs. 80A - 80F illustrate various stages in the articulation of blank
2200, in
which fold lines are not illustrated by broken lines. First, first inner
support panels
2224, 2226, 2248, 2250 are folded perpendicular to end panels 2212, 2216.
Second
inner support panels 2232, 2234, 2256, 2258 are folded to an acute included
angle
relative to their adjacent first inner support panels, so that the first and
second inner
support panels, and the respective adjacent end panels describe triangular
areas. This
is possible, because the second inner support panels are substantially wider
than the
first inner support panels. At about the same time, third inner support panels
2240,
2242, 2264, 2266 are folded outwardly to positions face-to-face against inside
surfaces
of end panels 2212, 2216, and adhered thereto, using any suitable adhesive. At
the end
of the foregoing procedures, four triangle- (or "delta-") shaped support
structures are
positioned at the corners of bottom panel 2202. See Fig. 80B.
[00285] To assemble carton 2200, end panels 2212, 2216 are folded upwardly to
positions perpendicular relative to bottom 2202. See Fig. 80A. At the same
time, rear
panel 2214 is folded up perpendicular to bottom panel 2202, and adhered to
outwardly
facing surfaces of first inner support panels 2224, 2248. Front panel 2218 is
folded up
perpendicular to bottom panel 2202, and adhered to outwardly facing surfaces
of first
inner support panels 2226, 2250. See Fig. 80C. Triangular connection panels
2276,
2278, 2280, 2282 are folded inwardly to positions parallel to bottom panel
2202, atop
the delta-shaped support structures. Adhesive may be applied therebetween. See
Fig.
80D. First outer support panels 2284, 2286, 2288, 2290 are folded down, to
positions
overlying outer surfaces of end panels 2212, 2214 and adhered thereto, if
desired. See
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CA 02541617 2011-05-20
Fig. 80E. Second outer support panels 2300, 2302, 2304, 2306 are then folded
perpendicular to the first outer support panels, to positions overlying outer
surfaces of
front and rear panels 2214, 2208 and adhered thereto. See Fig. 80F.
[00286] Fig. 81 is a plan view of a blank for a double-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
Preferably blank 2400 is fabricated from corrugated paperboard material, and
the
corrugations run in the direction of the double-headed arrow. Blank 2400
includes
bottom panel 2402; end panels 2412, 2416, connected by fold lines 2404, 2408,
respectively; and front and rear panels 2418, 2414, connected by fold lines
2410, 2406,
respectively.
[00287] Emanating from opposite front and rear edges of end panel 2412, along
fold
lines 2420 and 2422 are first inner support panels 2424, 2426. Emanating from
fold
lines 2428 and 2430, respectively are second inner support panels 2432, 2434.
Emanating from fold lines 2436, 2438 are third inner support panels 2440,
2442.
[00288] Emanating from opposite front and rear edges of end panel 2416, along
fold
lines 2444 and 2446 are first inner support panels 2448, 2450. Emanating from
fold
lines 2452 and 2454, respectively are second inner support panels 2456, 2458.
Emanating from fold lines 2460, 2462 are third inner support panels 2464,
2466.
[00289] Emanating from upper edges of front and rear panels 2418, 2414,
respectively, along fold lines 2472, 2474, 2468, 2470 are triangular
connection panels
2480, 2482, 2476, 2478, respectively. First outer support panels 2484, 2486,
2488 and
2490 (which are generally L-shaped) emanate from triangular connection panels
2476,
2478, 2480, 2482, respectively, along respective fold lines disposed
therebetween.
Second outer support panels 2500, 2502, 2504, 2506 emanate from the first
outer
support panels, along fold lines 2492, 2494, 2496, 2498. Hand openings 2532,
2534
are provided to facilitate lifting of carton 2400.
[00290] Lid panels 2514, 2512 emanate from front and rear panels 2418, 2414,
respectively, along fold lines 2510, 2508, respectively. Lid panels 2512, 2514
are
separated by diagonal through cuts from their adjacent triangular connection
panels
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CA 02541617 2011-05-20
2476, 2478; and 2480, 2482, respectively. Closure flaps 2524, 2526 emanate
from
opposite end edges of lid panel 2512, along fold lines 2516, 2518. Closure
flaps 2528,
2530 emanate from opposite end edges of lid panel 2514, along fold lines 2520,
2522.
[00291] Figs. 81A - 81H illustrate various stages in the articulation of blank
2400,
in which fold lines are not illustrated by broken lines. First, first inner
support panels
2424, 2426, 2448, 2450 are folded perpendicular to end panels 2412, 2416.
Second
inner support panels 2432, 2434, 2456, 2458 are folded to an acute included
angle
relative to their respective adjacent first inner support panels, so that the
first and
second inner support panels, and the respective adjacent end panels describe a
triangular area. This is possible, because the second inner support panels are
substantially wider than the first inner support panels. At about the same
time, third
inner support panels 2440, 2442, 2464, 2466 are folded outwardly to positions
face-to-
face against inside surfaces of end panels 2412, 2416, and adhered thereto,
using any
suitable adhesive. At the end of the foregoing procedures, four triangle- (or
"delta-")
shaped support structures are positioned at the corners of bottom panel 2402.
See Fig.
81B.
[00292] To assemble carton 2400, end panels 2412, 2416 are folded upwardly to
positions perpendicular relative to bottom 2402. See Fig. 81A. Rear panel 2414
is
folded up perpendicular to bottom panel 2402, and adhered to outwardly facing
surfaces of first inner support panels 2424, 2448. Front panel 2418 is folded
up
perpendicular to bottom panel 2402, and adhered to outwardly facing surfaces
of first
inner support panels 2426, 2450. See Fig. 81 Triangular connection panels
2476,
2478, 2480, 2482 are folded inwardly to positions parallel to bottom panel
2402, atop
the delta-shaped support structures. See, e.g., Fig. 81D. Adhesive may be
applied
therebetween. First outer support panels 2484, 2486, 2488, 2490 are folded
down, to
positions overlying outer surfaces of end panels 2412, 2416 and adhered
thereto, if
desired. See Fig. 81E. Second outer support panels 2500, 2502, 2504, 2506 are
then
folded perpendicular to the first outer support panels, to positions overlying
outer
surfaces of front and rear panels 2418, 2414 and adhered thereto. See Fig.
81F.
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CA 02541617 2011-05-20
[00293] The resulting structure is an articulated container that is ready to
be filled
with product, as lid panels 2512 and 2514 have not been affixed in place. Lid
panels
2512, 2514 may be raised (Fig. 81G) and product placed in carton 2400. Once
product
has been placed into carton 2400, lid panels 2512, 2514 are folded over to
positions
parallel to and over bottom panel 2402. Adhesive panels 2524, 2526, 2528, 2530
are
folded down, and adhesively affixed to outside surfaces of end panels 2412,
2416,
above the upper edges of L-shaped first outer support panels 2484, 2486, 2488,
2490.
See Fig. 81H.
[00294] Fig. 82 is a plan view of a blank for a double-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
Preferably, blank 2600 is fabricated from corrugated paperboard material, and
the
corrugations run in the direction of the double-headed arrow. Blank 2600
includes
bottom panel 2602; end panels 2612, 2616, connected by fold lines 2604, 2608,
respectively; and front and rear panels 2618, 2614, connected by fold lines
2610, 2606,
respectively.
[00295] Emanating from opposite front and rear edges of end panel 2612, along
fold
lines 2620 and 2622 are first inner support panels 2624, 2626. Emanating from
fold
lines 2628 and 2630, respectively are second inner support panels 2632, 2634.
Emanating from fold lines 2636, 2638 are third inner support panels 2640,
2642.
[00296] Emanating from opposite front and rear edges of end panel 2616, along
fold
lines 2644 and 2646 are first inner support panels 2648, 2650. Emanating from
fold
lines 2652 and 2654, respectively are second inner support panels 2656, 2658.
Emanating from fold lines 2660, 2662 are third inner support panels 2664,
2666.
[00297] Emanating from upper edges of front and rear panels 2618, 2614,
respectively, along fold lines 2672, 2674, 2668, 2670, are triangular
connection panels
2680, 2682, 2676, 2678, respectively. First outer support panels 2684, 2686,
2688 and
2690 emanate from triangular connection panels 2676, 2678, 2680, 2682,
respectively,
along respective fold lines disposed therebetween. Second outer support panels
2700,
2702, 2704, 2706 emanate from the first outer support panels, along fold lines
2692,
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CA 02541617 2011-05-20
2694, 2696, 2698. Hand openings 2732, 2734 are provided to facilitate lifting
of
carton 2600.
[00298] Lid panels 2714, 2712 emanate from front and rear panels 2618, 2614,
respectively, along fold lines 2710, 2708, respectively. Lid panels 2712, 2714
are
separated by diagonal through cuts from their adjacent triangular connection
panels
2676, 2678; and 2680, 2682, respectively. Closure flaps 2724, 2726 emanate
from
opposite end edges of lid panel 2712, along fold lines 2716, 2718. Closure
flaps 2728,
2730 emanate from opposite end edges of lid panel 2714, along fold lines 2720,
2722.
[00299] Figs. 82A - 82H illustrate various stages in the articulation of blank
2600,
in which fold lines are not illustrated by broken lines. First, first inner
support panels
2624, 2626, 2648, 2650 are folded perpendicular to end panels 2612, 2616.
Second
inner support panels 2632, 2634, 2656, 2658 are folded 180 relative to their
adjacent
first inner support panels, so that the first and second inner support panels
are face-to-
face (adhesive of any suitable kind may be applied therebetween to hold the
first and
second inner support panels against one another). This is possible, because
the second
inner support panels are slightly narrower than the first inner support
panels. At about
the same time, third inner support panels 2640, 2642, 2664, 2666 are folded
outwardly
90 (or thereabouts) to positions face-to-face against inside surfaces of end
panels
2612, 2616, and adhered thereto, using any suitable adhesive. At the end of
the
foregoing procedures, four L-shaped support structures are positioned at the
corners of
bottom panel 2602. See Fig. 82B.
[00300] To assemble carton 2600, end panels 2612, 2616 are folded upwardly to
positions perpendicular relative to bottom 2602. See Fig. 82A. Rear panel 2614
is
folded up perpendicular to bottom panel 2602, and adhered to outwardly facing
surfaces of first inner support panels 2624, 2648. Front panel 2618 is folded
up
perpendicular to bottom panel 2602, and adhered to outwardly facing surfaces
of first
inner support panels 2626, 2650. See Fig. 82C. Triangular connection panels
2676,
2678, 2680, 2682 are folded inwardly to positions parallel to bottom panel
2602, atop
the L-shaped support structures. Adhesive may be applied therebetween. See
Fig.
82D. First outer support panels 2684, 2686, 2688, 2690 are folded down, to
positions
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CA 02541617 2011-05-20
overlying outer surfaces of end panels 2612, 2616 and adhered thereto, if
desired. See
Fig. 82E. Second outer support panels 2700, 2702, 2704, 2706 are then folded
perpendicular to the first outer support panels, to positions overlying outer
surfaces of
front and rear panels 2614, 2608 and adhered thereto. See Fig. 82F.
[00301] The resulting structure is an articulated container that is ready to
be filled
with product, as lid panels 2712 and 2714 have not been affixed in place.
Panels 2712
and 2714 are raised up, and product placed into the interior of carton 2600.
See Fig.
82G. Once product has been placed into carton 2600, lid panels 2712, 2714 are
folded
over to positions parallel to and over bottom panel 2602. Adhesive panels
2724, 2726,
2728, 2730 are folded down, and adhesively affixed to outside surfaces of end
panels
2612, 2616, above the upper edges of L-shaped first outer support panels 2684,
2686,
2688, 2690. See Fig. 82H.
[00302] Fig. 83 is a plan view of a blank for a single-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention.
Preferably, blank 2800 is fabricated from corrugated paperboard material, and
the
corrugations run in the direction of the double-headed arrow. Blank 2800
includes
bottom panel 2802; end panels 2812, 2816, connected by fold lines 2804, 2808,
respectively; and front and rear panels 2818, 2814, connected by fold lines
2810, 2806,
respectively.
[00303] Emanating from opposite front and rear edges of end panel 2812, along
fold
lines 2820 and 2822 are first inner support panels 2824, 2826. Emanating from
fold
lines 2828 and 2830, respectively are second inner support panels 2832, 2834.
Emanating from fold lines 2836, 2838 are third inner support panels 2840,
2842.
[00304] Emanating from opposite front and rear edges of end panel 2816, along
fold
lines 2844 and 2846 are first inner support panels 2848, 2850. Emanating from
fold
lines 2852 and 2854, respectively are second inner support panels 2856, 2858.
Emanating from fold lines 2860, 2862 are third inner support panels 2864,
2866.
[00305] Emanating from the upper edge of rear panel 2814 along fold lines
2868,
2870, are triangular connection panels 2872, 2874, respectively. First outer
support
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CA 02541617 2011-05-20
panels 2884, 2886 emanate from triangular connection panels 2872, 2874,
respectively, along respective fold lines 2876, 2878 disposed therebetween.
Second
outer support panels 2896, 2898, 2900, 2902 emanate from the first outer
support
panels, along fold lines 2888, 2890, 2892, 2894. Hand opening knock-outs 2924,
2926
are provided to facilitate lifting of carton 2800.
[00306] Lid panel 2906 emanates from rear panel 2814 along fold line 2904. Lid
panel 2906 is separated by diagonal through cuts from its adjacent triangular
connection panels 2872, 2874, and by parallel cuts 2880, 2882, from first
outer support
panels 2884, 2886. Closure flaps 2912, 2914 emanate from opposite end edges of
lid
panel 2906, along fold lines 2908, 2910, and extend into the voids created by
contoured recesses 2916, 2918.
[00307] Figs. 83A - 83H illustrate various stages in the articulation of blank
2800.
First, first inner support panels 2824, 2826, 2848, 2850 are folded
perpendicular to end
panels 2812, 2816. Second inner support panels 2832, 2834, 2856, 2858 are
folded
180 relative to their adjacent first inner support panels, so that the first
and second
inner support panels are face-to-face (adhesive of any suitable kind may be
applied
therebetween to hold the first and second inner support panels against one
another).
This is possible, because the second inner support panels are slightly
narrower than the
first inner support panels. At about the same time, third inner support panels
2840,
2842, 2864, 2866 are folded outwardly 90 (or thereabouts) to positions face-
to-face
against inside surfaces of end panels 2812, 2816, and adhered thereto, using
any
suitable adhesive. At the end of the foregoing procedures, four L-shaped
support
structures are positioned at the corners of bottom panel 2802. See Fig. 83B.
[00308] To assemble carton 2800, end panels 2812, 2816 are folded upwardly to
positions perpendicular relative to bottom 2802. See Fig. 83A. At the same
time, rear
panel 2814 is folded up perpendicular to bottom panel 2802, and adhered to
outwardly
facing surfaces of first inner support panels 2824, 2848. Front panel 2818 is
folded up
perpendicular to bottom panel 2802, and adhered to outwardly facing surfaces
of first
inner support panels 2826, 2850. See Fig. 83C. Triangular connection panels
2872,
2874 are folded inwardly to positions parallel to bottom panel 2802, atop the
L-shaped
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CA 02541617 2011-05-20
support structures. Adhesive may be applied therebetween. See Fig. 83D. First
outer
support panels 2884, 2886 are folded down, to positions overlying outer
surfaces of
end panels 2812, 2814 and adhered thereto, if desired. See Fig. 83E. Second
outer
support panels 2896, 2898, 2900, 2902 are then folded perpendicular to the
first outer
support panels, to positions overlying outer surfaces of front and rear panels
2814,
2818 and adhered thereto. See Fig. 83F.
[00309] The resulting structure is an articulated container that is ready to
be filled
with product, as lid panel 2906 has not been affixed in place. Lid panel 2906
is raised
(Fig. 83G), and product placed into carton 2800. Once product has been placed
into
carton 2800, lid panel 2906 is folded over to a position parallel to and over
bottom
panel 2802. Adhesive panels 2912, 2914 are folded down, and adhesively affixed
to
outside surfaces of end panels 2812, 2816, above the upper edges of first
outer support
panels 2884, 2886. See Fig. 83H. Thereafter, knockouts 2924, 2926 are pushed
in, to
allow carton 2800 to be carried.
[00310] Fig. 84 is a plan view of a blank for a single-lidded carton, having
stacking
support structures, according to another preferred embodiment of the
invention. Blank
3000 includes bottom panel 3002; end panels 3012, 3016, connected by fold
lines
3004, 3008, respectively; and front and rear panels 3018, 3014, connected by
fold lines
3010, 3006, respectively.
[00311] Emanating from opposite front and rear edges of end panel 3012, along
fold
lines 3020 and 3022 are first inner support panels 3024, 3026. Emanating from
fold
lines 3028 and 3030, respectively are second inner support panels 3032, 3034.
Emanating from fold lines 3036, 3038 are third inner support panels 3040,
3042.
[00312] Emanating from opposite front and rear edges of end panel 3016, along
fold
lines 3044 and 3046 are first inner support panels 3048, 3050. Emanating from
fold
lines 3052 and 3054, respectively are second inner support panels 3056, 3058.
Emanating from fold lines 3060, 3062 are third inner support panels 3064,
3066.
[00313] Emanating from the upper edge of rear panel 3014 along fold lines
3068,
3070, are triangular connection panels 3072, 3074, respectively. First outer
support
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CA 02541617 2011-05-20
panels 3084, 3086 emanate from triangular connection panels 3072, 3074,
respectively, along respective fold lines 3076, 3078 disposed therebetween.
Second
outer support panels 3096, 3098, 3100, 3102 emanate from the first outer
support
panels, along fold lines 3088, 3090, 3092, 3094. Hand opening knockouts 3124,
3126
are provided to facilitate lifting of carton 3000.
[00314] Lid panel 3106 emanates from rear panel 3014 along fold line 3104. Lid
panel 3106 is separated by diagonal through cuts from its adjacent triangular
connection panels 3072, 3074, and by parallel cuts 3080, 3082, from first
outer support
panels 3084, 3086. Closure flaps 3112, 3114 emanate from opposite end edges of
lid
panel 3106, along fold lines 3108, 3110, and extend into the voids created by
contoured recesses 3116, 3118.
[00315] Figs. 84A - 84H illustrate various stages in the articulation of blank
3000,
wherein fold lines are not illustrated with broken lines. To assemble carton
3000, first,
first inner support panels 3024, 3026, 3048, 3050 are folded perpendicular to
end
panels 3012, 3016. Second inner support panels 3032, 3034, 3056, 3058 are
folded to
an included acute angle, relative to their adjacent first inner support
panels, so that the
first and second inner support panels, and adjacent end panels define
triangular
columns. This is possible, because the second inner support panels are wider
than the
first inner support panels. At about the same time, third inner support panels
3040,
3042, 3064, 3066 are folded outwardly to positions face-to-face against inside
surfaces
of end panels 3012, 3016, and adhered thereto, using any suitable adhesive.
See Fig.
84B. At the end of the foregoing procedures, four triangle- (or delta-) shaped
support
structures are positioned at the corners of bottom panel 3002.
[00316] End panels 3012, 3016 are folded upwardly to positions perpendicular
relative to bottom 3002. See Fig. 84A. To complete carton 3000, at the same
time,
rear panel 3014 is folded up perpendicular to bottom panel 3002, and adhered
to
outwardly facing surfaces of first inner support panels 3024, 3048. Front
panel 3018
is folded up perpendicular to bottom panel 3002, and adhered to outwardly
facing
surfaces of first inner support panels 3026, 3050. See Fig. 84C. Triangular
connection panels 3072, 3074 are folded inwardly to positions parallel to
bottom panel
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CA 02541617 2011-05-20
3002, atop the delta-shaped support structures. Adhesive may be applied
therebetween. See Fig. 84D. First outer support panels 3084, 3086 are folded
down,
to positions overlying outer surfaces of end panels 3012, 3014 and adhered
thereto, if
desired. See Fig. 84E. Second outer support panels 3096, 3098, 3100, 3102 are
then
folded perpendicular to the first outer support panels, to positions overlying
outer
surfaces of front and rear panels 3014, 3018 and adhered thereto. See Fig.
84F.
[00317] The resulting structure is an articulated container that is ready to
be filled
with product, as lid panel 3106 has not been affixed in place. Lid 3106 is
raised (Fig.
84G), and product placed therein. Once product has been placed into carton
3000, lid
panel 3106 is folded over to a position parallel to and over bottom panel
3002.
Adhesive panels 3112, 3114 are folded down, and adhesively affixed to outside
surfaces of end panels 3012, 3016, above the upper edges of first outer
support panels
3084, 3086. See Fig. 84H. Then, knockouts 3124, 3126 are pushed in, to enable
carton 3000 to be carried.
[00318] The foregoing description and drawings merely explain and illustrate
the
invention and the invention is not limited thereto, as those skilled in the
art who have
the disclosure before them will be able to make modifications and variations
therein
without departing from the scope of the invention.
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