Note: Descriptions are shown in the official language in which they were submitted.
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IN THE UNITED STATES RECEIVING OFFICE
CARRIER AND METHOD
CROSS REFERENCE INFORMATION
This application claims benefit to and priority of
U.S. patent application Serial No. 11/012,440, filed December
15, 2004 and U.S. patent application Serial No. 11/012,789,
filed December 15, 2004, each of which is hereby incorporated
be reference in its entirety.
This invention relates to carriers for beverages,
food, liquids in containers and other objects, and to methods
of making and using such carriers.
In the above-identified prior patent applications
are disclosed a number of different general-purpose carriers,
and other carriers which are highly advantageous for use in
carrying beverages, e.g., in "six packs" of bottles containing
soft drinks, beer, etc. Other carriers are specially adapted
for use in carrying both beverage cups and solid foods in
sports arenas, fast-food restaurants, etc. The disclosures of
those carriers hereby is incorporated herein by reference.
Although those carriers are highly advantageous,
improvements are desired in order to reduce their
manufacturing costs.
Accordingly, it is an object of the invention to
provide a carrier construction and blank, and a method of
making such a carrier in which the manufacturing cost is
significantly reduced.
It is another object of the invention to provide
such a carrier which is relatively strong and capacious, and
relatively easy to unfold.
It is another object to provide such a carrier that
stands upright and open when being loaded, provides
substantial areas on which advertising can be located, and can
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be used with relative safety and reliability to carry
cumbersome objects with a minimum of spillage.
In many so-called "fast food" stores, movie
theaters, etc., food and beverages are sold which are of
relatively moderate size, along with much larger containers
such as the so-called "buckets" containing popcorn, or fried
chicken, or fried fish or shrimp, etc.
Accordingly, it is an object of the present
invention to provide a carrier and distribution method in
which both relatively small items, such as beverage containers
and relatively large containers, such as "buckets" or
comparable quantities of loose items of solid food can be
carried in a single carrier.
It is another object to provide such a carrier in
which smaller solid food items, such as hamburgers, hotdogs,
sandwiches, candy bars and packages, etc., also can be
carried, preferably separately from the other items.
It also is an object of the invention to provide
such a carrier which is sturdy, relatively inexpensive to
manufacture, easy to set up by food distribution personnel
and/or customers, and relatively easy to carry, preferably
with one hand. In accordance with the present invention, the
foregoing objects are satisfied by providing a carrier with
vertical support panels, each with a receptacle extending
outwardly from its lower region. The carrier is made from
blanks in which foldable panels are arranged in linear arrays.
In the blanks, the vertical support panels can be folded and
bonded to one another back-to-back.
This facilitates the relatively close nesting of
blanks on a sheet of material and thus reduces the amount of
sheet material occupied by each blank and aids in reducing
manufacturing costs.
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Preferably, the side wall panels and vertical
support panels are foldable relative to one another along
lines perpendicular to the longitudinal axis of the array, and
shorter flanges forming the bottom structures of the
receptacles are foldable along lines parallel to the
longitudinal axes.
This facilitates both nesting and automatic folding
to form finished, folded carriers.
It also is preferable that all of the fold lines
parallel to the axes are located along one edge of the blank
to facilitate folding by use of automatic folding equipment.
In one specific embodiment of the invention, there
is provided a carrier blank comprising a sheet of material
shaped to form a linear array of parts, said parts comprising,
first and second vertical support panels, a first group of
foldably interconnected side wall panels and foldable to form
a side wall structure for a first receptacle to be secured to
one of said vertical support panels, and a second group of
foldably interconnected side wall panels foldable to form a
side wall structure for a second receptacle to be secured to
the other of said vertical support panels, and flanges
extending from said side walls and said vertical support
panels and being foldable to form bottom wall structures for
said receptacles, said vertical support panels being foldable
to be secured together back-to-back.
In other respects, the invention comprises the
additional features of the various different carriers
disclosed in the above-identified pending patent applications
whose disclosures are incorporated by reference into this
patent application.
In accordance with the present invention, the
foregoing objects are satisfied by the provision of a carrier
and method in which a vertical central support structure is
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provided, with a pair of foldable receptacles extending from
opposite sides of the central support structure, when the
carrier is unfolded, and a lateral extension which provides a
third receptacle for carrying either a container of much
larger diameter than those which can be carried in the two
first mentioned containers, so as to hold "buckets" of
popcorn, fried chicken, etc., or as a complete container for
such foods, without the bucket.
In providing such a carrier, it is preferred that
the basic carrier construction described in my prior patent
applications be utilized, with modifications, to provide the
carrier structure.
An open tray with a slot in the bottom, or a closed
box with slots in both the top cover and the bottom can be
used by slipping the tray or the box over the upright central
support/handle structure so as to carry additional solid items
such as hotdogs, hamburgers, boxes, bags or bars of candy or
fruit, etc.
In one specific embodiment of the invention, a
retainer panels with one or two beverage-receiving holes are
provided to fit over the tops of the smaller carrier
receptacles so as to stabilize and hold the beverage
containers and prevent them from slipping or tipping from
side-to-side in the receptacles.
The foregoing and other objects and advantages of
the invention will be apparent from or set forth in the
following description and drawings.
IN THE DRAWINGS:
FIGURE 1 is a perspective view of one embodiment of
a carrier constructed in accordance with the present
invention;
FIGURE 2 is a cross-sectional, partially broken-away
view taken along line 2-2 of FIGURE 1;
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n n.r n. . - ...r ......a. ...v .. ...... ......... 5
FIGURE 3 is a side elevation view, also partially
broken away, of the carrier of FIGURE 1 with a food carrying
tray mounted thereon;
FIGURE 4 is a front elevation view, also partially
broken away, of a structure shown in FIGURE 3;
FIGURE 5 is a top plan view, also partially broken
away, of the structure shown in FIGURE 3;
FIGURE 6 is a bottom plan view of a portion of the
carrier shown in FIGURES 1-5 in a partially collapsed
condition;
FIGURE 7 is a schematic diagram illustrating the,
steps in a typical manufacturing process used to manufacture
the carriers shown in FIGURES 1-6 and elsewhere herein;
FIGURE 8 is a top plan view of a pair of nested
blanks used for making the carrier of FIGURES 1-6;
FIGURES 9-11 are views of one of the blanks shown in
FIGURE 8 at various stages of the process of manufacturing the
carrier;
FIGURE 12 is a perspective view of an alternative
food-carrying tray which can be used instead of the tray shown
in FIGURES 3-5;
FIGURE 13 is a perspective view, partially broke
away, of a 6-pack carrier constructed in accordance with the
present invention;
FIGURE 14 is a cross-sectional, partially schematic
view taken along line 14-14 of FIGURE 13;
FIGURE 15 is a bottom plan view of a portion of the
carrier shown in FIGURE 13, with the portion partially
collapsed;
FIGURE 16 is a top plan view of a pair of nested
blanks used to make the carrier shown in FIGURES 13-15;
FIGURE 17 is a perspective view of another carrier
constructed in accordance with the present invention, this
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carrier being adapted to have two carrying compartments
instead of the four compartments of the carrier shown in
FIGURE 1;
FIGURE 18 is a blank used to manufacture the carrier
shown in FIGURE 17;
FIGURE 19 is a top plan view of a pair of nested
blanks of an alternative form used to make a carrier like the
carrier of FIGURE 17;
FIGURE 20 is a bottom plan view of a portion of the
carrier shown in FIGURE 17, with the carrier partially
collapsed;
FIGURE 21 is a front elevation view of another
embodiment of the invention;
FIGURE 22 is a side elevation view of the embodiment
shown in FIGURE 21;
FIGURE 23 is a perspective view of a carrier
constructed in accordance"with the present invention;
FIGURE 24 is a cross-sectional, broken away view
taken along line 23-23 of FIGURE 23;
FIGURE 25 is a bottom plan view of the carrier shown
in FIGURE 23, with the carrier partially unfolded;
FIGURE 26 is a partially schematic side elevation
view of the carrier of FIGURE 23 containing a bucket, beverage
containers and a tray, as used in accordance with one
embodiment of the present invention;
FIGURE 27 is a top plan view of a tray used in the
embodiment shown in FIGURE 26;
FIGURE 28 shows a fiberboard blank used to make the
carrier of FIGURES 23-26;
FIGURE 29 is a perspective view of another
embodiment of the carrier of the invention;
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FIGURE 30 is a perspective, partially broken away,
and partially schematic cross-sectional view taken along line
30-30 of FIGURE 29; and
FIGURE 31 is a top plan view of a blank used to make
the carrier of FIGURES 29 and 30.
FOUR-COMPARTMENT CARRIER
Figures 1, 2, 6 and 8 show a general-purpose four-
compartment carrier 20 with a locking bottom structure. The
four compartments or receptacles can hold beverage cups, cans
or bottles and a variety of other types of objects, such as
potted plants, cans of motor oil or fuel additive, etc.
Figures 7-11 show a preferred method of
manufacturing the carrier 20, as well as other carriers
described herein, and Figures 3-5 show a top tray accessory
for carrying food or other items above the items in the four
compartments of the Figure 1 carrier.
The carrier 20 includes a central support structure
22 including two vertical support panels 23 and 25 glued or
otherwise bonded together. The central support structure 22
has an upper edge 30 and a hand-hole 28 below the upper edge
30, with a foldable hand guard 32.
The upper portion of the central support structure
22 has a front surface panel 24 and a rear surface panel 26,
which are bonded, respectively, to the upper areas of the
panels 23 and 25, thus forming a four-ply handle structure.
A receptacle structure extends outwardly from each
of the two vertical support panels 23 and 25. One receptacle
27 includes a panel folded to form the side walls 34, 36, and
38 and secured at one end to the panel 23 by a flange 47
extending from the left edge of the panel 23 and bonded to the
panel 34.
Similarly, a second receptacle 29 on the opposite
side of the carrier is formed by side walls 40, 43 and 44,
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with a flange 48 extending from the left edge of panel 25
bonded to the panel 44.
Each of the two receptacles has a bottom structure
50 or 52 including a hinged locking panel 64 which extends
completely across the bottom structure (see Figure 2) and has
a locking tab 66 or 72 extending from its outermost edge. The
tabs 66 and 72 fit into slots 68 or 74 at the bottom of the
vertical support panel 23 or 25, as it is shown in greater
detail in Figure 2.
Now referring to Figure 2, as well as to Figure 6,
each of the receptacles has a bottom support structure like
most of the embodiments of the invention described in the
above-identified pending patent applications, and other
embodiments described herein.
Figure 2 is a broken away cross-sectional view taken
along line 2-2 of Figure 1. The carrier shown in Figure 1 is
standing erect on a horizontal surface such as the surface 80
shown in Figure 2. The carrier 20, which is folded and
flattened when shipped, is shown in Figure 1 after it has been
unfolded by the simple operation to be described below.
Referring to Figure 2, the bottom structure 50 of
the left-hand receptacle27 shown in Figure 2 is in the
position it normally takes immediately after the carrier has
been unfolded and before any beverage containers or other
objects have been placed in the receptacle, or before someone
has pushed the panel 64 downwardly to insert the locking tab
466 into the slot 68.
The right-hand receptacle 29 is shown in Figure 2
with a full beverage cup 54 in place. The full cup has
pressed down upon the panel 70 and pressed the locking tab 72
into the slot 74.
The locking or top panels 64 and 70 are rectangular
and are almost as long as the distance between side walls 34
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and 38. The rectangular shape of the panels 64 and 70 thus
advantageously holds the receptacles 27 and 29 open so that
the carrier 20 will sit erect on a horizontal surface with the
receptacles 27 and 29 open so that the carrier easily can be
filled with beverage cups or other objects.
As it,will become apparent from the discussion
below, as the carrier 22 is opened, the bottom panels 64 and
70 are automatically pulled downwardly approximately to an
angle such as that shown for the panel 64 in Figure 2 by the
interlocking bottom structure to be described below.
Referring to Figure 6 of the drawings, the bottom
structure 52 includes the broad locking panel 70 with its tab
72 which is hinged at the bottom of the side wall panel 42.
Also, a panel 88 which extends approximately half way across
the width of the receptacle 29 is hinged from the bottom edge
of the vertical support panel 23.
A first corner structure includes a flange hinged to
the bottom edge of the side panel 44 and consisting of a first
portion 90 and a second portion 91, separated from one another
by a fold line 93.
A second corner structure is located at the corner
of the bottom structure which is opposite to the first corner
structure. The second corner structure, which is hinged from
the lower edge of the side wall panel 40, consists of a first
portion 95 and a second portion 97 joined to the first portion
95 at a fold line 101.
The flange portion 91 is bonded to the top panel 70,
and the flange portion 97 is bonded to the panel 88.
As the carrier is unfolded, the two corner flange
structures pull downwardly on the panels 70 and 88 until they
reach a position spaced somewhat upwardly from the bottom of
the receptacle. Then, top panel 70 is pressed downwardly by
hand or by the weight of an object being placed upon it to
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snap the lock tab into the slot to hold the bottom structure
flat.
The corner structures and the overlapping long
panels together form a very strong multi-ply bottom structure
5 capable of holding substantial loads.
A first divider 56 with an end tab 58 adhered to the
inner surface of the wall 36 divides the left-hand receptacle
27 into two compartments. Similarly, a second divider 62 with
an end tab 62 bonded to the side wall 42 provides a divider
10 for the right-hand receptacle 29.
In addition, gussets 51, 53, 47 and 49 are provided
at the junctions between the side walls 38, 40, 34 and 44 and
the vertical panel structure. These gussets, as well as the
dividers, are optional. The gussets provide added strength
for the carrier structure, if needed.
AUXILIARY TRAY
Figures 3-5 show an auxiliary tray 92 designed for
use with the carrier 420. The tray is substantially the same
as the trays shown in the above-identified patent
applications;
The tray 492 has a bottom wall 104, and four
upstanding side walls 94, 96, 98, and 99. The side walls 494
and 96 have triangular tabs 122 and 134, respectively, which
are glued to the front and rear walls at the corners of the
tray. The side walls are folded onto one another along fold
lines such as lines 118 and 126 at the corners, and fold lines
100 and 120 so as to fold the tray flat for shipment and
storage.
As it is shown in Figure 5, the bottom wall 104 has
an elongated slot 112 which is wider in the middle than at
either end, and two end sections 114 and 116 which are
perpendicular to the section 112. Thus, an "I"-shaped slot is
formed in the bottom wall 104.
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Figure 4 is a broken-away side elevation view
showing two beverage cups 107 and 108 in the carrier 20 and
the tray 490 resting on top of the cups. It can be seen in
Figures 4 and 5 that the gussets 47, 49, 51, and 53 extend
upwardly through portions of the slots 114 and 116, while the
central support structure 22 of the carrier extends upwardly
through the slot 112.
If the gussets are not needed, then the slot can be
simplified to be a single slot without end sections 114 and
116.
Figures 3 and 4 also show that the height of the
beverage cups or other containers which might be present in
the carrier 20 vary to a substantial degree. Thus, the tops
of the cups 107 and 109 shown in Figure 3 extend higher above
the upper edge 106 of the side wall 42 of the carrier than do
the tops of the cups 109 and 110 in Figure 4. However, it is
preferred that the tops of the beverage containers always be
above the upper edge of the side walls of the carrier so that
the containers are easily accessible to grasp them and remove
them from the containers, and to minimize the amount of sheet
material used in the carrier.
MANUFACTURING METHOD
Figure 7 is a schematic diagram showing steps
typically taken in manufacturing carriers in accordance with
the present invention.
Figure 8 shows two blanks 136 and 138 which are to
be folded and glued to form two finished carriers.
Referring first to Figure 7, fiberboard material
usually from a roll 128 is fed first to a printing station 130
where legends, logos, advertising material, etc., are printed
on the areas of a wide sheet of fiberboard material in
positions in which the carriers will be formed. Typically,
the sheet material can be relatively wide, e.g., 50 inches or
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more, depending upon the capacity of the die cutting, folding
and printing equipment used.
The printed sheet material next moves to a die
cutting and scoring machine 132 which die cuts and scores the
material to form blanks such as the blanks 136 and 138.
As it will be explained in greater detail below,
because of the linear array of panels formed by the panels
making up the blanks, several blanks can be "nested" side-by-
side across the width of the sheet material so as to maximize
the usage of material and help minimize the manufacturing cost
of the carrier.
Figure 8 shows two of the blanks 136 and 138 nested side-by-side with one
another. In actuality, three or more
such blanks can be nested side-by-side, but the other blanks
are not shown in order to save space in the drawings.
At the station 132, the sheet material is die-cut
and scored to form fold lines.
Finally, each blank is automatically glued and
folded to form a fully folded carrier, ready for packing and
shipment, as it will be described in greater detail below.
FOUR-COMPARTMENT BLANK STRUCTURE
Referring now to Figure 8, part numbers have been
shown on only one of the blanks, the blank 136, in order to
avoid unnecessary duplication and crowding of the drawing.
The blanks 136, 138, etc., form a linear array of
panels extending in the direction indicated by the arrow 140
which is parallel to the longitudinal axis of the array.
In general, the vertical support panels and side
wall panels are joined together in series along fold lines
perpendicular to the longitudinal axis of the array, and the
panels and flanges forming the bottom structures of the
receptacles are joined to the vertical support panels and side
wall panels along fold lines which are parallel to the axis.
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As it can be seen, the panels 23 and 24 are separate
from one another except that they are joined along a fold line
144. Similarly, panels 25 and 26 are separate but attached
along the fold line 146.
The divider arms 56 and 60 are formed as cutouts
from the material of panels 23 and 25, respectively, with
hinges at fold lines 147 and 149.
All of the flaps or flanges forming the bottom
structures for the two receptacles 27 and 29 are located along
one edge of the linear array. This has the advantage of
enabling automatic folding equipment for the bottoms to be
located along only one edge of the blank as the flaps and
flanges are folded. This can reduce equipment required and/or
can speed the manufacturing process.
FOLDING AND GLUING
Figures 9-11 illustrate the folding and gluing
processes at various stages of completion.
First, as it is shown in Figure 9, adhesive is
applied to the upper surfaces of the panels 24 and 26, and the
panel 24 is folded onto the panel 23 along line 144 and
pressed to adhere it to the panel 23. Similarly, panel 26 is
folded along line 146 onto the upper portion of panel 25 and
adhered in place.
Also, each of the divider arms 56 and 60 is folded
out from its original position, thus leaving an opening 154 or
156 in the panel 23 or 25.
Each of the panels 84, 64, 70 and 88 is folded
upwardly to the position shown in Figure 9.
Each of the corner flaps is folded twice, first
along its lower edge, and then the flaps 105, 76, 91, and 95
are folded downwardly along the diagonal fold line of each of
the corner structures.
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Then, each of the end flanges 46 and 48 is folded
over, the flange 46 to the right, and the flange 48 to the
left.
Next, adhesive is applied to each of the flanges 46
and 48, 58, 105, 76, 91, 95, and 62.
Referring now to Figure 10, next, the blank is
folded along fold lines 150 and 148 shown in Figure 9 to the
shape shown in Figure 10, and the folded-over portions are
pressed onto the portions below them so that the adhesive on
the adhesive-coated surfaces adheres to each of the surfaces
it touches. Thus, the pad 76 adheres to the flap 84, the pad
105 adheres to the flap 64, and the pad 58 adheres to the
middle of the panel 36.
Referring now to Figure 11, next, adhesive is
applied to the surfaces 23 and 25 shown in Figure 10, and the
blank is folded along the center line 152 and the halves are
pressed together in order to bond the two vertical support
panels 23 and 25 together back-to-back, thus forming the
partially-folded carrier blank 158.
The use of linear arrays of panels to form the
carrier structure is highly advantageous not only in that it
allows for closer and more efficient nesting of the blanks,
and produces corresponding material savings, but also in that
more carriers can be produced per linear foot of sheet
material, thus increasing production for a given speed of
sheet material movement. This, of course, can further reduce
manufacturing costs.
The finished folded carrier 160 shown in Figure 11
is ready for packing and shipment to customers. The folded
carrier 160 is advantageous in that it has a relatively small
volume and thus provides savings in shipping containers and
freight costs.
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UNFOLDING THE CARRIER
When the folded carrier 160 it is removed from the
carton to be used by the customer, the customer merely places
5 one hand against the edge 152 and another against the edges
150, 148 of the blank and presses his or her hands together,
applying pressure in the directions 162 and 164, and the
folded-up carrier pops open to the position shown in Figure 1.
The top tray 92 similarly can be folded and shipped
10 to the customer, and can be unfolded quickly and easily for
ready use.
ALTERNATIVE TRAY STRUCTURE
Figure 12 shows an alternative tray structure for
mounting on the handle structure of the carrier shown in
15 Figures 1-11.
The tray structure 166 comprises a closable box
having side walls 168, a bottom wall 188, and a top wall 170
which is hinged at one edge 172 to the side wall 168
The box has a pair of slots 174 and 176, one in the
top wall 170, and one in the bottom wall 182. Each slot is
sized and shaped to received the vertical support structure 22
of the carrier 20 shown in Figure 1. Each slot is covered by
an adhesive strip 178 or 180 to protect the food inside the
box until it is sold.
When the food is sold, the strips 178 and 180 are
peeled off of the box, the vertical support panel 22 is
inserted through the slots, and the food can be carried away
with one hand, together with beverages in the carrier.
As it is disclosed in the above-identified patent
application Serial No. 10/939,264, such covered boxes can be
used to carry hot or cold pizza pies, donuts, and other such
items. The adhesive slot covers protect the food during
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storing, shipping, heating and handling prior to being used to
deliver food to customers.
The box 166 is loaded with food at a processing
location and is sent to remote distribution points, under
refrigeration, if necessary. At the distribution points, the
box can be heated to heat the food, if desired, the strips
removed, the box placed on the carrier and carried away.
If an I-shaped slot in the box top and bottom like
that shown in Figures 3-5 is needed, the adhesive strips would
be shaped and sized to cover the entirety of each slot.
PACKAGED BEVERAGE CARRIER
Figures 13, 14, and 15 show a "packaged" beverage
carrier 190 constructed in accordance with the invention. In
this embodiment, the carrier 190 is a six-pack carrier
designed to hold six bottles of a soft drink, beer, water, or
other beverage. It is of basically the same construction as
the carrier 22 and others shown in the above-identified
pending patent applications, but is specifically constructed
so as to be easily filled by automatic filling equipment
instead of by hand. The filled carriers then are shipped to
stores.
The carrier 190 shown in Figure 13 differs from that
shown in Figures 1-12 also in that the carrier 190 is not as
tall because there is no need for an auxiliary tray
attachment, and because the carrier 190 is designed to have
the same height as existing carriers which it is intended to
replace.
The carrier 190 includes a vertical support
structure 192 with panels 194 and 196 bonded together back-to-
back, and with a front panel 198 and a rear panel 200, a hand-
hole 202 and a foldable hand guard 204. The upper edge of the
vertical support structure is shown at 206.
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Two receptacles 220 and 222 are provided, one
extending from panel 194, and the other from the panel 196.
The first receptacle 220 includes side walls 208, 210, and
212, and the second receptacle 222 has side walls 214, 216,
and 218.
The side walls are secured to the vertical support
structure by means of flanges 270 and 284 extending from the
panels 194 and 196.
Two dividers 258 and 264 in each receptacle extend
from the central support structure and are bonded to the side
wall 210 by means of tabs 262 and 268. Each of the dividers
has a downwardly-extending tapered lower portion 260 or 266
extending to near the bottom of the carrier in order to
provide cushioning between adjacent bottles in the three
compartments formed by the dividers to reduce the possibility
of breakage of the bottles.
Referring now to Figure 14, as well as Figure 13,
each of the two receptacles 220, 222 has a bottom structure
224 or 226 which is similar to one of the bottom structures
shown in Figures 1 and 2, with one of the main differences
being that the top panel 228 is hinged to the vertical support
structure instead of to the side wall opposite the vertical
support structure. Also, the top panel 228 or 232 of the
bottom structure is tapered at its side edges 240.
The tapered edges 240 are provided to minimize
interference between the parts of the bottom structure when
the carrier is unfolded. Although this reduces the tendency
of the top panel to hold the carrier open during filling, this
is not very significant in that the carriers usually are
filled automatically by filling machines which hold the
carriers open during filling.
Each of the top panels 228 or 232 extends across the
bottom structure and has a pair of tabs 230 or 234, each of
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which extends outwardly and projects through one of a pair of
slots 236, 238 in the wall panels 210 and 216 of the carriers
to lock the top panels in place.
The bottom structures 224 and 226 are quite similar
in principle to the bottom structure of the receptacles in the
carrier 220 shown in Figures 1 and 2.
Thus, when a folded carrier is erected by pushing on
opposed sides, the panel 228 or 232 is not depressed all the
way down, but remains partially raised, similar to the bottom
panel 68 shown in Figure 2.
Then, when a full beverage bottle is placed in one
of the receptacles 220 or 222, the weight of the beverage and
bottle presses the top panels downwardly so that the tabs 230
bend and then snap into the slots 236 and 238 so as to lock
the top panel of the bottom structure in place. This
construction, in combination with the remaining panels which
support it, provides an exceptionally strong bottom which
locks automatically, without the need of a separately-actuated
latching structure such as that needed in manufacturing some
prior carriers.
Figure 15 shows a partially-collapsed bottom
structure 226 for the receptacle 222 of the carrier 190 shown
in Figure 13. Two corner structures are provided. One has a
flange 248 extending from the bottom edge of the side wall
214, with a tab 250 connected along the fold line 249 to the
flange 248. The tab 250 is bonded to the broad top panel 232
of the bottom structure 226.
In a corner opposite the corner in which the first
corner flange structure is located is a second flange
structure including a flange 244 extending from the bottom
edge of the side wall 218, with a tab 246 connected to the
flange 244 along a fold line 251. The tab 246 is bonded to
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-- - - ---- ------ --
19
the flange 242 which extends from the bottom edge of the
vertical support panel 196.
The corner flange structures operate in
substantially the same way as the corresponding structures
shown in Figures 1 and 6 to pull the bottom panels downwardly
from a folded-up position so as to unfold the receptacle
structures.
PACKAGED BEVERAGE CARRIER BLANK
Figure 16 shows two linear arrays 288 and 290, each
forming a blank to make a single carrier of the type shown in
Figures 13-15.
Only two linear blanks 288 and 290 are shown in
Figure 16. They are nested together closely to maximize use
of the sheet material. However, in a typical installation, up
to four or more blanks can be nested across the sheet, thus
illustrating the material savings provided by the invention.
The process of making the carrier 190 is
substantially the same as that illustrated in Figures 7-11
above. The sheet material first is printed, then sent to a
die cutting and scoring station, where the sheet is cut and
scored to form the shapes and fold lines indicated in Figure
16.
The various portions of the blanks shown in Figure
16 then are folded and glued substantially as described above,
except that there are two dividers such as the dividers 258
and 264 in each of the receptacles instead of only one.
After the panels 198 and 200 are glued onto the
panels 194 and 196, respectively, the bottom flanges are
folded and glued, as are the end flanges 270 and 284, and the
blank is folded along lines 298 and 296, and finally along
central line 294 to complete a folded carrier, ready for use.
The carrier 190, when folded, has substantially the
shape shown in Figure 11 of the drawings, but is somewhat
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smaller. The folded carrier occupies substantially less area
than the typical prior art "sling-bottom" carrier it is
intended to replace, thus providing savings in shipping
cartons and freight costs when the carriers are shipped to the
5 bottling plants in which they are used.
As with the embodiments shown in Figures 1-11, the
manufacturing process is believed to be faster, as well as
more economical in the use of materials. This is believed to
produce significant cost savings in manufacturing the product.
10 TWO-COMPARTMENT CARRIER
Figure 17 is a perspective view of a two-compartment
version 300 of the four-compartment carrier shown in Figures
1-11. The carrier 300 is essentially the same in construction
as the embodiment shown in Figures 1-11, except it is only
15 half as wide as the other carrier, and has only two
receptacles instead of four.
The carrier 300 has a vertical support structure 302
with vertical support panels 304 and 306, and panels 308 and
310 bonded to the upper surfaces of the vertical support
20 panels. The vertical support panels 304 and 306 are bonded
together back-to-back.
A hand hole 312 and hand guard 314 are provided.
Two receptacles are provided at 316 and 318. The
first receptacle includes side walls 320, 322 and 324, and the
second receptacle includes side walls 326, 327 and 328. The
side wall structures are secured to the central support
structure 308 by means of flanges 330 and 334 which are bonded
to the inside surfaces of the side wall panels 324 and 326,
respectively.
Two bottom structures 336 and 338 are provided.
Each has a top panel 340 or 342 with a projecting tab 344 or
345 which extends through a slot 346 or 347 in side wall 322
or 327.
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21
Figure 20 is a bottom plan view of a partially
folded receptacle 318 showing the top panel 342, the opposing
panel 351 (also see Figure 18), and corner structures.
In one corner structure, a flange 260 extends from
the bottom of the side wall panel 326 and has a tab 348 joined
with it along a fold line 362. The tab 348 is bonded to the
flange 351.
An opposing corner structure includes a flange 364
extending from the bottom edge of the side wall panel 328 and
a tab 366 joined with the flange 364 along a fold line 368.
The tab 366 is bonded to the flange 342.
The foregoing bottom structure automatically pulls
down the bottom panels of each of the receptacles,
substantially as described above in connection with the four-
compartment embodiment.
The bottom of each receptacle, when fully opened, is
approximately square.
A beverage cup 380 is shown in place inside the
receptacle 316 in Figure 17.
GANGED CARRIERS
Figures 21 and 22 are, respectively, a side
elevation view and a front elevation view of a modification of
the invention shown in Figures 17-20 in which a single tray
which is wide enough to receive the handles of two separate
two-cup carriers 390 and 392 is provided so that two of the
two-compartment carriers can be ganged together and carried
with one hand by means of the handle holes 394 and 396. The
tray is shown atop three beverage cups 398, 400, and 406. The
lower portion of each of the two separate carriers is shown at
402 and 404.
If preferred, a single shorter tray can be used with
only one of the carriers shown in Figure 17. Alternatively, a
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22
wider tray can be used which fits onto both of the four-
compartment carrier and the two-compartment carrier.
TWO-COMPARTMENT CARRIER BLANK
Figure 18 shows an array 382 of panels of a linear
blank used to make the carrier shown in Figure 17. The
printing, die cutting and scoring, and folding and gluing
steps are substantially the same as shown above for the four-
cup carrier and the packaged beverage carrier, and will not be
repeated here.
The blanks 382 are nested on a sheet of material
substantially in the manner shown in Figure 19; that is, with
alternate blanks inverted relative to one another. In this
manner, the usage of sheet material is minimized.
Figure 19 shows a pair of modified blanks 384 and
386 which are the same as blank 382 shown in Figure 18, except
that the gussets 370 and 372 (as well as gussets 374 and 378)
are omitted from the blanks 384 and 386. This allows the
blanks to be nested even closer together, thus further
reducing the usage of sheet material.
GENERAL DESCRIPTION - THEATER CARRIER
Figure 23 shows a first embodiment 410 of the
theater carrier of the present invention.
The carrier 410 includes a vertical support
structure 412. Two foldable receptacle structures 435 and 437
are secured to and extend from the vertical support structure
412 when the carrier is unfolded.
One receptacle structure 435 includes side walls
426, 428 and 430, and the second receptacle structure 437
includes vertical side walls 432, 434 and 436. Flaps 442 and
444 extend from the vertical support structure 412 and are
glued to the inside surfaces of panels 430 and 432,
respectively. Foldable bottom structures 460 and 462 extend
from the bottom walls of the receptacle structures.
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Dividers 446 and 448 extend between the vertical
support structure 412 to the opposite side walls 428 and 434
and are glued thereto by means of tabs 448 and 452,
respectively. The dividers 446 and 450 are positioned
relatively close to the ends 430 and 432 so that the
receptacles 435 and 437 are relatively small. The walls 428,
434 and bottom structure 460, 462 extend laterally from the
dividers by a relatively greater distance to form a third much
larger compartment or receptacle 439 to the side of each
receptacle.
CENTRAL SUPPORT STRUCTURE
The central support structure 412 includes a pair of
relatively tall vertical panels 418 and 420 which are glued
together back-to-back. A four-ply handle portion is formed by
panels 414 and 416, which are glued, respectively, to the
upper portions of panels 418 and 420. A handle hole 422 is
provided near the upper edge of the structure 412, with a
folding finger guard structure 424.
It should be understood, of course, that equivalent
structures can be made utilizing only a two-ply or one-ply
vertical support structure, depending upon the weight of the
fiberboard used, expected loads to be carried, etc.
The large receptacle 439 formed by the lateral
extension of the side walls 434 and 428 and the bottom walls
460 and 462 is strengthened by extending the panels 418 and
416 at their lower edges to form extensions 458 and 459, which
are glued together to form a stiff, short vertical spine at
the bottom of the large receptacle 439. Flaps 438 and 440,
extending from the leftmost edges of the panels 426 and 436,
respectively, are glued together, folded over and glued to the
panel 436, as shown.
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BOTTOM STRUCTURES
The bottom structures 460 and 462 are illustrated in
Figures 23, 24, and 25, as well as in Figure 28.
Each bottom structure 460 or 462 includes a broad
top flange or panel 64 hinged at one edge to the panel 418 or
416 and the spine formed by panel portions 458 and 459.
As in prior embodiments of the carriers shown in the
above-identified pending patent applications, the panels 464
and 465 advantageously extend completely across the bottom of
the receptacles they form. Each panel has three short
projections 466, 468 and 470 or 472, 474 and 476, which fit
through slots 478, 480 and 482 or 484, 486 and 488 when the
panels 464 and 465 are completely unfolded and pressed
downwardly by use of hand pressure, or by the pressure of
beverage containers resting on the panels.
The bottom structures 460 and 462 are very much the
same as the bottom structure shown in my above-identified
pending patent applications in that they open automatically
when the folded ends of the folded carrier are pushed towards
one another (in the directions indicated by the arrows 461 and
463 in Figure 25) so that the structure forms a strong
platform to support the top panel 464 or 465 and objects in
the receptacles.
As it is shown in Figures 424 and 425, at the front
corner of the receptacle 435 is a flange or flap 490 with a
tab 494 which is secured to a long flange 506 and which has a
diagonal fold line 495. Similarly, at the rear of the
carrier, a flap 498 extends from the rear wall 426 with a tab
502 which is glued to the undersurface of the panel 464. The
flap 498 folds along a diagonal line 499.
Similarly, the bottom structure 462 includes a flap
or flange 492 hinged to the bottom edge of panel 432. The
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flange 492 has a tab 496 which is glued to a flange 508. The
flange 492 has a diagonal fold line at 497.
Finally, at the rear of structure 462, a flange 500
with a tab 504 is hinged to the wall 432. The tab 504 is
5 glued to the panel 465 and has a diagonal fold line 501.
Referring again to Figure 23, as well as to Figure
28, it can be seen that the panels 464 and 465 are basically
rectangular in shape. The rectangular shape has a beneficial
aspect in that, when the flanges 464 and 465 are pulled
10 downwardly by the corner tabs, the flanges tend to fill the
space between the front and back walls of the receptacles 435
and 437 so that, once the carrier is unfolded by pressing on
the folded ends of the carrier, the carrier will stay open
when resting upon a counter so as to facilitate filling it
15 with items to be carried in the carrier.
When the carrier is folded flat, the rear corners of
the panels 464 and 465 are folded downwardly along the fold
lines 467 and 469, respectively, due to engagement with the
panels 426 and 436. As the carrier is opened and the panels
20 464 and 465 are pressed downwardly, the corners of the panels
press against the panels 426 and 436 and, when the tabs along
the edges of the panels 464 and 465 fit into the mating slots,
the carrier is held fully open. Advantageously, the seating
of the tabs in the slots can be performed simply by placing
25 beverages in the beverage receptacles so that the weight of
the beverages will press downwardly on the panels and properly
seat them.
It should be noted that the bottom edges 454 and 456
of the dividers 446 and 450 are cut at an upward angle as
shown, in order to prevent interference between the panels 464
and 465 and the dividers as the carrier is being unfolded.
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26
FOOD DISTRIBUTION
Figure 26 illustrates the use of the carrier 410 in
a typical food distribution process.
Assume, as an example, that the carrier 410 is being
used in a movie theater selling beverages in cups 514,
"buckets" 510 filled with popcorn 512, and candy bars, in
boxes or bags.
First, the carrier blank is opened by pressing on
the ends of the blank in the directions 461, 463 (Figure 25),
the beverages 514 are put in the receptacles 435 and 437, a
bucket 110 of popcorn 112 is placed in the larger container
439 as shown in Figure 426, with the bottom of the bucket
resting on the vertical spine 458, 459. The popcorn is very
light-weight and is mostly balanced by the weight of the
beverages 514 so that it is relatively easy to carry the
popcorn and the beverages with one hand by using the handle
422.
If the customer purchases bags, boxes or bars of
candy, or other solid foods such as hot dogs, these can be
placed in a tray 516 which slips onto the upper portion of the
vertical support structure 412. Thus, the customer can carry,
in one hand, beverages, a large container of popcorn, and
candy, etc., in the tray. Most of the weight is centered
directly underneath the handle.
If the bucket 510 holds a relatively heavy substance
such as fried chicken or shrimp at 512 instead of the lighter-
weight popcorn, it might be desirable to help support the left
portion of the carrier with the other hand.
Figure 27 is a top plan view of the tray 516, which
is shown in greater detail in several of the above-identified
co-pending patent applications. The tray 516 has a bottom
wall 520 with an elongated slot 522 through which the vertical
support structure 12 fits. It has four side walls 524, 526,
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528 and 530 which are angled upwardly as shown, with the sides
being glued together at the corners.
If preferred, a closed food box can be used instead
of the open tray 516, as is described in my co-pending
application Serial No. 10/939,264 filed September 10, 2004,
and as further described hereinbelow The closed container can
contain donuts, bagels, pizza, or other comestibles, which can
be heated in the box prior to the box being attached to the
carrier.
Smaller beverage cups might not fill the receptacles
435 and 437. For that and other reasons, it may be desired to
provide means for holding the beverage cups stable against
tipping or sliding sideways.
This can be performed, in accordance with another
feature of the invention, by adding flaps 554 and 556, shown
in dashed outline in Figure 28, which fold over the top of the
beverage compartments and have holes 558 and 560,
respectively, to embrace a semi-cylindrical beverage cup and
hold it steady.
The use of this feature is illustrated schematically
in Figure 23 where the beverage retainer hole 560 is shown in
dashed outline. Preferably, the dimensions of the panels 554
and 556 are such as to cause them to rest on the upper edges
of the side walls of the receptacles.
CARRIER-FORMING BLANK
Figure 28 shows a blank for the carrier 410. The
blank is formed advantageously from a single sheet of
fiberboard material. Fold-lines are marked with the letter
"F", and areas to which glue is applied are marked with the
letter "G".
The carrier can be manufactured with a single die
cutting step from a single sheet of material, with folding and
gluing steps following thereafter.
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The carrier can be manufactured in relatively high
volume at a relatively modest cost.
PREFERRED EMBODIMENT
Figures 29-31 show the preferred carrier 531 of the
invention. This carrier 531 is substantially the same as the
carrier shown in Figures 23-28, with certain variations.
Accordingly, the same reference numerals have been used for
the parts of the carrier 531 corresponding to parts of the
carrier 410 shown in Figures 23-28.
One of the differences between the carrier 531 shown
in Figures 29-31 and that shown in Figures 23-28 is that the
rear portions of the vertical side walls 426, 428, 434 and 436
are considerably taller than the corresponding walls of the
first-disclosed carrier. The taller walls are given a curved
cut at 548 or 550 to reduce their height at the front end of
the carrier to provide ready access to the receptacles 435 and
437.
Another change in the carrier 131 is the provision
of two foldable sealing panels 536 and 538 for sealing the
large receptacle 439 from the smaller receptacles 435 and 437
to enable popcorn, fried chicken or other particulate items to
be carried in the large container 439 without a bucket and
without leaking those items into the smaller receptacles.
Each panel 536 and 538 is hinged along a fold line
534 or 532 so that it can be folded downwardly to the position
shown in the directions indicated by arrows 544 and 546, in
Figure 30, in which it forms a vertical wall closing the space
below the lower edge 454 or 456 of the divider 446 or 450 to
seal the large receptacle from the smaller ones.
Optionally, tabs 540 and 542 (Figure 30) can be
provided at the edges of the panels 536 and 538 to mate with
properly located slots in the bottom structure of the carrier
to lock the security panels 536 and 538 into place.
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Alternatively, the locking function can be performed simply by
insuring a frictional engagement between the lower edge of
each panel 536 and 538 and the corresponding bottom structure
of the receptacle in which it is located.
When the carrier 531 is being unfolded, after the
ends of the folded carrier have been pressed towards one
another, the panels 536 and 538 are bent downwardly. This has
the advantage of pressing the upper panels of the bottom
structures downwardly so as to lock them in position.
With this change, the large receptacle 439 can be
used to hold popcorn, fried chicken, or other particulate
foods such as French fries, etc., directly, without the use of
"buckets". This is highly desirable as a cost-saving feature.
Figure 31 shows a blank for a carrier substantially
like that shown in Figures 29 and 30, except that it is of a
size to hold only two beverage cups in the receptacles 435 and
437. In other words, the blank shown in Figure 31 would be
somewhat longer for a four-cup carrier.
As before, fold lines are marked with the letter
"F", and areas to be glued are marked with the letter "G". In
addition, some of the cut lines are marked' with the letter
One of the differences between the blanks shown in
Figure 31 and the carrier shown in Figures 23-28 is that the
flaps 442 and 444 which are used to secure the side walls to
the vertical support panels extend from the right end of the
panels 430 and 432, instead of from the left end of the
vertical support panels.
In addition, it should be understood that one of the
flaps 438 and 440 may be omitted, if desired, so that the
joint at the rear wall of the carrier is formed by a single
flap glued to the vertical side wall.
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It can be seen that the material for the security
panels 536 and 538 is taken from the material which forms the
third and fourth plies of the handle structure shown in Figure
23. Thus, the handle structure of the embodiment shown in
5 Figures 29-31 is only two-ply instead of four. However, this
is not believed to be a substantial disadvantage.
Figure 31 shows the main reason for the extended
height of the walls 426, 428 and 434. They are extended to a
height such that the side wall material extends to the cut
10 line "C" in the center of Figure 31. This greatly facilitates
the automatic formation of the carrier in modern fabrication
equipment.
MATERIALS
The materials of which the carrier of the present
15 invention can be made need not be expensive. Ordinary,
medium-weight fiberboard is believed to be sufficient for most
purposes. For example, it can be 0.20 S.U.S. recycled
newspaper material. If waterproofing beyond the acrylic
coating provided on such board is necessary, a further
20 waterproof coating can be applied on both the inside and
outside surfaces.
It is within the realm of the invention also to make
the carriers out of flexible plastic materials.
If desired, the carriers can be made of plastic
25 materials that are easily washable.so that the carriers can be
reused.
BONDING
Bonding of parts to one another can be done by means
other than adhesives. For example, plastic or plastic coated
30 parts can be bonded together by ultrasonic or heat bonding.
Staples or other mechanical fasteners also can be used.
It can be seen from the foregoing that the invention
well satisfies the objectives set for above. The carrier
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construction which permits the blanks to be made in linear
arrays permits better nesting of the blanks on a sheet of
fiber board material, thus providing significant savings in
the use of materials in the carriers.
Additionally, it is believed that the speed of the
automatic manufacturing of the carriers can be increased, and
the manufacturing cost correspondingly decreased. Additional
savings in the complexity of some of the folding machinery
needed also may be realized.
The above description of the invention is intended
to be illustrative and not limiting. Various changes or
modifications in the embodiments described may occur to those
skilled in the art. These can be made without departing from
the spirit or scope of the invention.
