Note: Descriptions are shown in the official language in which they were submitted.
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CARTON AND CARTON BLANK WITH INNER BRACE APERTURES
BACKGROUND
Technical Field
[0001] The technical field relates to cartons for accommodating
containers
and packages formed therefrom.
Related Art
[0002] Cartons for engaging and securing upper portions of containers are
known. The containers are typically inserted through apertures in a bottom
panel of the carton and secured by engaging radially protruding parts of the
containers. One such carton is disclosed in U.S. Pat. No. 6,223,892 to Bakx.
Conventional cartons, however, may not securely retain the containers, or
may fail to satisfy other requirements recognized in the art.
SUMMARY
[0003] According to a first aspect of the invention, a package comprises
a
plurality of containers accommodated in a carton. The carton comprises a top
panel, a bottom panel, a first side panel, a second side panel, a plurality of
first struts extending from the bottom panel along a first row, a plurality of
second struts extending from the bottom panel along a second row, a first row
of first container apertures, each first container aperture being adjacent to
one
of the plurality of first struts, and a second row of second container
apertures,
each second container aperture being adjacent to one of the plurality of
second struts. Each first strut comprises an upper first strut section, a
lower
first strut section foldably connected to the bottom panel, and a first inner
brace aperture. Each second strut comprises an upper second strut section, a
lower second strut section foldably connected to the bottom panel, and a
second inner brace aperture. The inner brace apertures may include lower
brace edges that support flanges of the containers accommodated in the
carton.
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[0004] According to a second aspect of the invention, the side panels of
the
carton can include outer brace apertures through which portions of the
container flanges extend. The outer brace apertures have lower brace edges
that support the undersides of the container flanges. During erection of the
carton, the carton blank can be tightly wrapped around the upper portions of
the containers to securely retain the containers within the carton.
[0005] According to the above aspects of the invention and additional
aspects
described below, the brace apertures and the struts serve to prevent the
containers from inadvertently being pulled downward through the container
apertures, and also prevent excessive movement or pivoting of the containers.
[0005.1] According to one aspect of the present invention there is provided
a
package, comprising a carton, comprising: a top panel; a bottom panel; a first
side panel; a second side panel; a plurality of first struts extending from
the
bottom panel along a first row, each first strut comprising an upper first
strut
section, a lower first strut section foldably connected to the bottom panel,
and
a first inner brace aperture, wherein for each first strut the upper first
strut
section comprises an upper brace edge and the lower first strut section
comprises a lower brace edge that cooperates with the respective upper brace
edge to form the respective first inner brace aperture, each upper brace edge
cooperates with the lower brace edge to define the boundary of the first inner
brace aperture and is collinear with a fold line respectively connecting the
upper first strut section to the lower first strut section; a plurality of
second
struts extending from the bottom panel along a second row, each second strut
comprising an upper second strut section, a lower second strut section
foldably connected to the bottom panel, and a second inner brace aperture; a
first row of first container apertures, each first container aperture being
adjacent to one of the plurality of first struts; a second row of second
container apertures spaced from the first row of container apertures, each
second container aperture being adjacent to one of the plurality of second
struts; and a plurality of containers, each container being accommodated in
one of the container apertures and having a flange with an underside, wherein
the flange of the container in each first container aperture is at least
partially
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accommodated in the first inner brace aperture of the adjacent first strut,
the
flange of the container in each second container aperture is at least
partially
accommodated in the second inner brace aperture of the adjacent second strut,
and the top panel comprises a first top panel and a second top panel, the
second top panel having a plurality of recesses, each recess in the second top
panel having a curved edge that is complimentary in shape with a curved,
distal edge of an adjacent upper second strut section, each curved, distal
edge
being received in a respective curved edge of the second top panel, and each
upper brace edge overlays a top surface of the flange of a respective
container.
[0005.2] According to
a further aspect of the present invention there is
provided a blank, comprising at least one top panel; a first side panel, the
first
side panel having at least one first outer brace aperture; a bottom panel; a
second side panel, the second side panel having at least one second outer
brace aperture; a first row of at least one first container-receiving pattern
in
the bottom panel, each first container-receiving pattern defining an upper
first
strut section, a lower first strut section foldably connected to the upper
first
strut section, and a first inner brace aperture, wherein for each first
container-
receiving pattern the upper first strut section comprises an upper brace edge
and the lower first strut section comprises a lower brace edge that cooperates
with the respective upper brace edge to form the respective first inner brace
aperture, each upper brace edge cooperates with the lower brace edge to
define the boundary of the first inner brace aperture and is collinear with a
fold line respectively connecting the upper first strut section to the lower
first
strut section; and a second row of at least one second container-receiving
pattern in the bottom panel, each second container-receiving pattern defining
an upper second strut section, a lower second strut section foldably connected
to the upper second strut section, and a second inner brace aperture, wherein
each first outer brace aperture is aligned with a first container-receiving
pattern, the at least one top panel comprises a first top panel and a second
top
panel, the second top panel having a plurality of recesses, each recess in the
second top panel having a curved edge that is complementary in shape with a
curved, distal edge of the adjacent upper second strut section, each curved,
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distal edge is for being received in a respective curved edge of the second
top
panel, and each upper brace edge is for overlaying a top surface of a flange
of
a respective container to be included in a package formed from the blank.
[0006] Other aspects, features, and details of the present invention can
be
more completely understood by reference to the following detailed
description, taken in conjunction with the drawings and from the appended
claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0007] According to common practice, the various features of the drawings
discussed below are not necessarily drawn to scale. Dimensions of various
features and elements in the drawings may be expanded or reduced to more
clearly illustrate the embodiments of the invention.
[0008] FIG. I is a plan view of a blank used to form a package according
to a
first embodiment of the invention.
[0009] FIG. 2 illustrates an erection step for forming the first package
embodiment.
[0010] FIG. 3 illustrates an erection step for forming the first package
embodiment.
[0011] FIG. 4 illustrates an erection step for forming the first package
embodiment.
[0012] FIG. 5 illustrates the first package embodiment.
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DETAILED DESCRIPTION
[0013] The present embodiments are addressed to cartons for attachment
to
containers. The cartons engage and secure upper portions of the containers to
form a package.
[0014] FIG. 1 is a plan view of a blank 8 used to form a carton or
carrier 150.
The carton 150 is illustrated in its erected state in FIG. 5, in which it is
attached to
upper portions of containers 170, forming a package 200. As shown in FIG. 1,
the
blank 8 may be wholly or partially symmetric about a longitudinal centerline
CI.
Therefore, certain elements in the drawing figures share common reference
numerals in order to reflect the whole and/or partial longitudinal symmetry.
In
this specification, the terms "bottom," "top," "lower," "upper," and "side"
indicate
orientations determined in relation to a fully erected carton placed in an
upright
configuration.
[0015] Referring to FIG. 1, the blank 8 comprises a first top panel 10
foldably
connected to a first side panel 20 at a first transverse fold line 21, a
bottom panel
30 foldably connected to the first side panel 20 at a second transverse fold
line 31,
a second side panel 40 foldably connected to the bottom panel 30 at a third
transverse fold line 41, and a second top panel 50 foldably connected to the
second
side panel 40 at a fourth transverse fold line 51. An aperture 12 may be
formed in
the first top panel 10 for allowing a user to grasp and carry the package.
[0016] The transverse fold lines 21, 31, 41, 51 in the blank 8 can be
more
generally referred to as "lines of weakness" or "lines of disruption" in the
blank
about which the blank is foldable. Each of the transverse fold lines 21, 31,
41, 51
may be interrupted at one or more locations, for example, and need not be
continuous across the transverse direction of the blank 8. One or more cuts
may
be, for example, placed along one or more of the transverse fold lines 21, 31,
41,
51. In the exemplary embodiment illustrated in FIG. 1, the transverse fold
lines
21, 31, 41, 51 may be cut/crease lines in which the cuts facilitate folding of
the
blank 8 at the fold lines. Any number of cuts may be formed along the fold
lines
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21, 31, 41, 51, and the number and length of the cuts may be selected
according to,
for example, the gauge and the stiffness of the material used to form the
blank 8.
The cuts may be partial cuts (e.g. kiss cuts), or 100% cuts extending through
the
entire thickness of the blank 8.
[0017] The bottom panel 30 includes a plurality of first container-
receiving
patterns 80 and a plurality of second container-receiving patterns 100. The
first
container-receiving patterns 80 are arranged in a first row, and the second
container-receiving patterns 100 are arranged in a second row spaced from the
first
row. Each container-receiving pattern 80, 100 is shaped and sized to receive
an
upper portion of a container 170 that is to be held within the erected carton
150.
In the exemplary embodiment, two columns of first container-receiving patterns
80 and two columns of second container-receiving patterns 100 are formed in
the
bottom panel 30 so that four containers 170 can be accommodated in the erected
carton 150, forming a 2 x 2 package. Other package configurations, such as 2 x
3,
2 x 4 or 2 x 5, 3 x 2, etc. are also within the scope of the present
invention.
[0018] Each first container-receiving pattern 80 defines a first strut
81. Each
second container-receiving pattern 100 defines a second strut 101. Each first
strut
81 includes an upper first strut section 84 and a lower first strut section 86
foldably connected to the upper section 84 at a transverse fold line 82. The
first
lower strut sections 86 are foldably connected to the bottom panel 30 at
transverse
fold lines 88. Each second strut 101 includes an upper second strut section
104
and a lower second strut section 106 foldably connected to the upper section
104
at a transverse fold line 102. The second lower strut sections 106 are
foldably
connected to the bottom panel 30 at transverse fold lines 108.
[0019] The first struts 81 include first inner brace apertures 90 cut
from the
lower first strut sections 86. The second struts 101 include second inner
brace
apertures 110 cut from the lower second strut sections 106. The first inner
brace
apertures 90 include lower brace edges 92, and the second inner brace
apertures
110 include lower brace edges 112. The inner brace apertures 90, 110 are sized
to
receive a part of a flange of a container 170 in the interior of the erected
carton
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150 (illustrated in FIG. 5). The upper first strut sections 104 may each have
a
distal edge 105 that is complementary in shape with recesses 54 cut into the
second top panel 50.
[0020] The first side panel 20 includes first outer brace apertures 22.
The
number of first outer brace apertures 22 may correspond to the number of
columns
of first container-receiving patterns 80 and to the number columns of patterns
100.
Referring also to FIG. 3, each first outer brace aperture 22 is adapted to
receive a
part of an upper flange portion 175 of a container 170 held within an
adjacent,
aligned first container aperture 85 formed from a corresponding first
container-
receiving pattern 80. The first outer brace apertures 22 have lower brace
edges 24
located at or adjacent to the first transverse fold line 21 and cut from the
first side
panel 20. The second side panel 40 includes second outer brace apertures 42
adapted to receive upper flange portions 175 of containers 170 received within
second container apertures 105 formed from the second container-receiving
patterns 100. The number of second outer brace apertures 42 may also
correspond
to the number of columns of first container-receiving patterns 80 and to the
number of columns of patterns 100. The second outer brace apertures 42 have
lower brace edges 44 cut from the second side panel 40. The container-
receiving
patterns 80, 100 and the first and second brace apertures 22, 42 are arranged
in
two columns in FIG. 1. From right to left, each column in the blank 8 includes
an
aligned first outer brace aperture 22, a first container-receiving pattern 80,
a
second container-receiving pattern 100, and a second outer brace aperture 42.
[0021] An exemplary method of erection of the carton 150 to form the
package
200 is discussed below with reference to FIGS. 2-5.
[0022] FIG. 2 is a perspective view of an erection step of the carton
150 and its
initial attachment to the containers 170. Top portions of four containers 170,
including their flanges 175, are inserted through the first and second
container-
receiving patterns 80, 100, one container per pattern. In accordance with the
exemplary embodiment, the flanges 175 are defined by lids that close the
containers 170. Inserting the containers 170 may serve to open up the first
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second container apertures 85, 105 at the first and second container-receiving
patterns 80, 100, respectively. The container apertures 85, 105 may, for
example,
have curved or arcuate sidewalls at each end that may generally conform in
shape
to the exterior profiles of the containers 170. In FIG. 2, the containers 170
push
the first and second struts 81, 101 so that they fold about the transverse
fold lines
88, 108, respectively, and extend generally upwardly from the bottom panel 30.
The flange 175 of each container 170 in a first container aperture 85 extends
in
part through a corresponding inner brace aperture 90 of an adjacent first
strut 81.
The flange 175 of each container 170 in a second container aperture 105
extends
in part through a corresponding inner brace aperture 110 of an adjacent second
strut 101.
[0023] Referring to FIG. 3, the first top panel 10 and the first side
panel 20 are
folded about the transverse fold line 31 so that the panels 10, 20 extend
generally
upwardly. Folding the first side panel 20 upwardly causes the flange 175 of
each
container 170 in a first container aperture 85 to extend in part through a
corresponding, aligned first outer brace aperture 22. The second side panel 40
and
the second top panel 50 are folded about the transverse fold line 41 so that
the
panels 40, 50 extend generally upwardly. The flange 175 of each container 170
in
a second container aperture 105 thus extends in part through a corresponding,
aligned second outer brace aperture 42.
[0024] Referring to FIG. 4, the upper first strut sections 84 of the
first struts 81
are folded over at the fold lines 82 so that each upper first strut section 84
rests on
the upper surface of a flange 175 of a container 170. The flange 175 of each
container 170 in a first container aperture 85 extends in part through a
corresponding, adjacent inner brace aperture 90, with the underside of the
flange
resting on a brace edge 92. Similarly, the upper second strut sections 104 of
the
second struts 101 are folded over at the fold lines 102 so that each upper
first strut
section 104 rests on the upper surface of a flange 175 of a container 170. The
flange 175 of each container 170 in a second container aperture 105 extends in
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part through a corresponding, adjacent inner brace aperture 110, with the
underside of the flange resting on a brace edge 112.
[0025] The second top panel 50 is folded about the transverse fold
line 51 so that
it extends over the tops of the containers 170 disposed within the second row
of
container apertures 105. The upper strut sections 84, 104 now extend generally
parallel to the bottom panel 30. The distal edge 105 of each upper first strut
section 104 is complementary in shape with one of the adjacent recess 54
formed
in the edge of the second top panel 50. The complementary shape of the edges
105 with the recesses 54 allows the upper second strut sections 104 and the
second
top panel 50 to lay adjacent to one another on the top of an adjacent flange
175
without the upper strut sections 104 overlapping the top panel 50. When the
first
top panel 10 is folded over the upper strut sections 104 and the second top
panel
50 to close the top of the package, the resulting top panel will therefore
have a
smoother, flatter appearance.
[0026] The first top panel 10 is folded about the transverse fold line
21 so that
the underside of the first top panel 10 can be adhered or otherwise secured to
the
upper surface of the second top panel 50, forming a top panel 120, as shown in
FIG. 5. If desired, the underside of the first top panel 10 may be adhered to
one or
more of the upper strut sections 84, 104. The carton 150 is therefore closed
about
the upper portions of the containers 170 to complete the package 200. When
viewed from the end, the carton 150 has a generally tubular shape with open
ends.
The width of the top panel 120, measured across the open end of the carton
150, is
less than the width of the bottom panel 30. The first and second side panels
20, 40
therefore slope inwardly toward the top of the package 200.
[0027] When closing the carton 150, the first top panel 10 and the
second top
panel 50 can be brought together and joined relatively tightly so that the
flanges
175 of the containers 170 extend through and are supported in the outer brace
apertures 22, 42 in the side panels 20, 40, respectively. At the exterior edge
of the
carton 150, the undersides of a flange 175 of a container 170 accommodated in
a
first container aperture 85 is thereby securely engaged with a first brace
edge 24,
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and the underside of a flange of a container accommodated in a second
container
aperture 105 is securely engaged with a second brace edge 44.
[0028] In the interior of the carton, the first struts 81 support the
containers 170
accommodated in the first row of container apertures 85, and the second struts
101
support the containers 170 accommodated in the second row of container
apertures
105. Referring also to FIG. 4, the flange 175 of each container 170 in a first
container aperture 85 extends in part through a corresponding first inner
brace
aperture 92. The lower brace edge 94 of the brace aperture 92 is positioned to
exert an upward force on the underside of the container's flange 175.
Similarly,
the flange 175 of each container 170 in a second container aperture 105
extends in
part through a corresponding second inner brace aperture 112. The lower brace
edge 114 of the brace aperture 112 is positioned to exert an upward force on
the
underside of the container's flange 175.
[0029] According to the above embodiment, containers 170 are securely
retained
by the outer brace apertures 22, 42 in the side panels 20, 40 and by the
struts 81,
101 in the carton interior. The containers 170 are thereby secured against
being
pulled downwardly through the bottom panel 30, and are also secured against
excessive translation and/or pivoting within the carton 150.
[0030] The exemplary embodiment shown in FIG. 5 illustrates a carton
150
accommodating four containers 170 arranged in two rows and four columns.
Additional columns, for example, may be added by increasing the width of the
blank 8 (in the transverse direction in FIG. 1) and forming additional opposed
container-receiving patterns 80, 100 in the bottom panel 30 and corresponding
aligned brace apertures 22, 42 in the side panels 10, 20, respectively.
[0031] In this specification, the term "flange" indicates any radially
projecting
rim, collar, ring, raised portion or protrusion extending from an upper
portion of a
container.
[0032] The blank 8 according to the present invention can be, for
example,
formed from coated paperboard and similar materials. The blank can also be
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constructed of other materials, such as cardboard, hard paper, or any other
material having properties suitable for enabling the resultant package to
function at least generally as described in this specification.
[0033] The interior and/or exterior sides of the blank 8 can be coated
with a
clay coating. The clay coating may then be printed over with product,
advertising, price coding, and other information or images. The blank may
then be coated with a varnish to protect any information printed on the blank.
The blank may also be coated with, for example, a moisture barrier layer, on
either or both sides of the blank, or laminated to or coated with one or more
sheet-like materials at selected panels or panel sections.
[0034] In accordance with the exemplary embodiment of the present
invention, a fold line can be any substantially linear, although not
necessarily
straight, form of disruption or weakening in the blank 8 that facilitates
folding
therealong. More specifically, but not for the purpose of narrowing the scope
of the present invention, fold lines include: score lines; crease lines; a cut
or a
series of cuts that extend partially into and/or completely through the
material
along the desired line of weakness; and various combinations of these
features.
[0035] The above embodiments may be described as having one or panels
adhered together by glue. The term "glue" is intended to encompass all
manner of adhesives commonly used to secure carton panels in place.
[0036] The description is not intended to limit the invention to the form
disclosed herein. Also, it is intended that the scope of the claims should not
be limited by the preferred embodiments set forth in the examples, but should
be given the broadest interpretation consistent with the description as a
whole.
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