Note: Descriptions are shown in the official language in which they were submitted.
CARTON WITH ARTICLE PROTECTION FEATURE
[0001]
[0002]
BACKGROUND OF THE DISCLOSURE
[0003] The present disclosure generally relates to cartons for holding
beverage containers or other
types of articles. More specifically, the present disclosure relates to
cartons having an article
protection feature and/or article protection flap that protects the containers
or articles from breakage.
SUMMARY OF THE DISCLOSURE
[0004] In general, one aspect of the disclosure is directed to a carton for
containing at least one
article. The carton comprises at least one panel at least partially forming an
interior of the carton. At
least one article protection flap is for protecting the at least one article.
The at least one article
protection flap is foldably connected to the at least one panel and moveable
between a first position
that is substantially parallel to the at least one panel and a second position
wherein the article
protection flap is folded relative to the at least one panel. The article
protection flap has features for
preventing folding of the article protection flap from the second position to
the first position.
[0005] In another aspect, the disclosure is generally directed to a blank
for forming a carton for
containing at least one article. The blank comprises at least one panel for at
least partially forming an
interior of the carton formed from the blank. At least one article protection
flap is for protecting the
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at least one article. The at least one article protection flap is foldably
connected to the at least one
panel and moveable between a first position that is substantially parallel to
the at least one panel and
a second position wherein the article protection flap is folded relative to
the at least one panel. The
article protection flap has features for preventing folding of the article
protection flap from the
second position to the first position in the carton formed from the blank.
[0006] In another aspect, the disclosure is generally direct to a method of
forming a carton. The
method comprises obtaining a blank comprising at least one panel and at least
one article protection
flap foldably connected to the at least one panel. The method comprises
positioning the at least one
panel to at least partially form an interior space of the carton, loading at
least one article in the
interior space, and folding the at least one article protection flap relative
to the at least one panel after
the loading the at least one article. The folding comprises moving the article
protection flap from a
first position that is substantially parallel to the at least one panel to a
second position wherein the
article protection flap is folded relative to the at least one panel.
[0007] In another aspect, the disclosure is generally directed to a carton
for containing at least one
article. The carton can comprise at least one panel at least partially forming
an interior of the carton
and at least one article protection flap for protecting the at least one
article. The at least one article
protection flap can be foldably connected to the at least one panel along a
lateral fold line and
moveable between a first position that is substantially parallel to the at
least one panel and a second
position wherein the at least one article protection flap is folded relative
to the at least one panel.
The at least one article protection flap comprises a longitudinal crease, a
first corner spaced apart
from the longitudinal crease by a first distance, and a second corner spaced
apart from the
longitudinal crease by a second distance. The second distance can be greater
than the first distance.
[0008] In another aspect, the disclosure is generally directed to a blank
for forming a carton for
containing at least one article. The blank can comprise at least one panel for
at least partially forming
an interior of the carton formed from the blank and at least one article
protection flap for protecting
the at least one article. The at least one article protection flap can be
foldably connected to the at
least one panel along a lateral fold line and moveable between a first
position that is substantially
parallel to the at least one panel and a second position wherein the at least
one article protection flap
is folded relative to the at least one panel. The at least one article
protection flap comprises a
longitudinal crease, a first corner spaced apart from the longitudinal crease
by a first distance, and a
second corner spaced apart from the longitudinal crease by a second distance.
The second distance
can be greater than the first distance.
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[0009] In another aspect, the disclosure is generally direct to a method of
forming a carton. The
method can comprise obtaining a blank comprising at least one panel and at
least one article
protection flap foldably connected to the at least one panel along a lateral
fold line. The at least one
article protection flap comprises a longitudinal crease, a first comer spaced
apart from the
longitudinal crease by a first distance, and a second corner spaced apart from
the longitudinal crease
by a second distance. The second distance can be greater than the first
distance. The method further
can include positioning the at least one panel to at least partially form an
interior space of the carton,
and folding the at least one article protection flap relative to the at least
one panel. The folding
comprises moving the at least one article protection flap from a first
position that is substantially
parallel to the at least one panel to a second position wherein the at least
one article protection flap is
folded relative to the at least one panel.
[0010] In another aspect, the disclosure is generally directed to a carton
for containing at least one
article. The carton can comprise at least one panel at least partially forming
an interior of the carton
and at least one article protection flap for protecting the at least one
article. The at least one article
protection flap can be foldably connected to the at least one panel and can be
moveable between a
first position that is substantially parallel to the at least one panel and a
second position wherein the
at least one article protection flap is folded relative to the at least one
panel. The at least one article
protection flap can comprise features for preventing folding of the at least
one article protection flap
from the second position to the first position. The features can comprise at
least one stop edge that
selectively engages the at least one panel.
[0011] In another aspect, the disclosure is generally directed to a blank
for forming a carton for
containing at least one article. The blank can comprise at least one panel for
at least partially forming
an interior of the carton formed from the blank and at least one article
protection flap for protecting
the at least one article. The at least one article protection flap can be
foldably connected to the at
least one panel and moveable between a first position that is substantially
parallel to the at least one
panel and a second position wherein the at least one article protection flap
is folded relative to the at
least one panel. The at least one article protection flap can be at least
partially defined by a line of
weakening and can comprise features for preventing folding of the article
protection flap from the
second position to the first position in the carton formed from the blank. The
features can comprise
at least one stop edge for being at least partially formed by the line of
weakening of the at least one
article protection flap. The stop edge can be for selectively engaging the at
least one panel when the
carton is formed from the blank.
[0012] In another aspect, the disclosure is generally direct to a method of
forming a carton. The
method can comprise obtaining a blank comprising at least one panel and at
least one article
protection flap foldably connected to the at least one panel and at least
partially separable from the at
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least one panel along a line of weakening. The method further can comprise
positioning the at least
one panel to at least partially form an interior space of the carton and
folding the at least one article
protection flap relative to the at least one panel. The folding can comprise
moving the at least one
article protection flap from a first position that is substantially parallel
to the at least one panel to a
second position wherein the at least one article protection flap is folded
relative to the at least one
panel. The folding further can comprise forming a stop edge of the at least
one article protection flap
from the line of weakening, the stop edge selectively engaging the at least
one panel.
[0013] In another aspect, the disclosure is generally directed to a carton
for containing at least one
article. The carton can comprise at least one panel at least partially forming
an interior of the carton
and at least one article protection flap for protecting the at least one
article. The at least one article
protection flap can be foldably connected to the at least one panel along a
lateral fold line and
moveable between a first position that is substantially parallel to the at
least one panel and a second
position wherein the at least one article protection flap is folded relative
to the at least one panel.
The article protection flap comprises at least one tab extending laterally
from a central portion of the
at least one article protection flap,
[0014] In another aspect, the disclosure is generally directed to a blank
for forming a carton for
containing at least one article. The blank can comprise at least one panel for
at least partially forming
an interior of the carton formed from the blank and at least one article
protection flap for protecting
the at least one article. The at least one article protection flap can be
foldably connected to the at
least one panel along a lateral fold line and moveable between a first
position that is substantially
parallel to the at least one panel and a second position wherein the at least
one article protection flap
is folded relative to the at least one panel. The article protection flap can
comprise at least one cut
for forming at least one tab extending laterally from a central portion of the
at least one article
protection flap when the carton is formed from the blank.
[0015] In another aspect, the disclosure is generally direct to a method of
forming a carton. The
method can comprise obtaining a blank comprising at least one panel and at
least one article
protection flap foldably connected to the at least one panel along a lateral
fold line, positioning the at
least one panel to at least partially form an interior space of the carton,
and folding the at least one
article protection flap relative to the at least one panel. The folding can
comprise moving the at least
one article protection flap from a first position that is substantially
parallel to the at least one panel to
a second position wherein the at least one article protection flap is folded
relative to the at least one
panel. The folding further can comprise forming at least one tab extending
laterally from a central
portion of the at least one article protection flap.
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[0016] In another aspect, the disclosure is generally directed to a carton
for containing at least one
article. The carton comprises a plurality of panels that extends at least
partially around an interior of
the carton. At least two end flaps are respectively foldably connected to
respective panels of the
plurality of panels. The end flaps are for being at least partially overlapped
to close an end of the
carton. At least one article protection feature is for protecting the at least
one article. The at least
one article protection feature is positioned between the at least two end
flaps.
[0017] In another aspect, the disclosure is generally directed to a blank
for forming a carton for
containing at least one article. The blank comprises a plurality of panels for
extending at least
partially around an interior of the carton formed from the blank. At least two
end flaps respectively
foldably connected to respective panels of the plurality of panels. The end
flaps are for being at least
partially overlapped to close an end of the carton formed from the blank. At
least one article
protection feature is for protecting the at least one article. The at least
one article protection feature
is for being positioned between the at least two end flaps.
[0018] In another aspect, the disclosure is generally directed to a method
of forming a carton for
containing at least one article. The method comprises obtaining a blank
comprising a plurality of
panels and at least two end flaps respectively foldably connected to a
respective panel of the plurality
of panels. The method comprises positioning the plurality of panels to form an
interior space of the
carton, loading at least one article in the interior space, at least partially
overlapping the at least two
end flaps to close an end of the carton, and forming an article protection
feature that is positioned
between the at least two end flaps.
[0019] In another aspect, the disclosure is generally directed to a method
of forming a carton. The
method comprises obtaining a blank comprising a panel and at least one article
protection flap
foldably connected to the panel. The method comprises positioning at least two
articles to be in
contact with the panel and folding the at least one article protection flap
relative to the panel after the
positioning the at least two articles. The folding comprises moving the
article protection flap from a
first position that is substantially parallel to the panel to a second
position wherein the article
protection flap is folded relative to the panel.
[0020] In another aspect, the disclosure is generally directed to a carton
for containing at least one
article. The carton comprises at least one panel at least partially forming an
interior of the carton. At
least two end flaps are at least partially overlapped to at least partially
close the interior of the carton.
At least one article protection feature is for protecting the at least one
article. The at least one article
protection feature is positioned between the at least two end flaps. At least
one article protection flap
is for protecting the at least one article. The at least one article
protection flap is foldably connected
to the at least one panel and is moveable between a first position that is
substantially parallel to the at
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least one panel and a second position wherein the article protection flap is
folded relative to the at
least one panel.
[0021] In another aspect, the disclosure is generally directed to a method
of forming a carton. The
method comprises obtaining a blank comprising at least one panel, at least one
article protection flap
foldably connected to the at least one panel, and at least two end flaps. The
method comprises
positioning the at least one panel to at least partially form an interior
space of the carton, loading at
least one article in the interior space, at least partially overlapping the at
least two end flaps to close
and end of the carton, forming an article protection feature that is
positioned between the at least two
end flaps, and folding the at least one article protection flap relative to
the at least one panel after the
loading the at least one article. The folding comprises moving the article
protection flap from a first
position that is substantially parallel to the at least one panel to a second
position wherein the article
protection flap is folded relative to the at least one panel.
[0022] In another aspect, the present disclosure is generally directed to a
carton having at least one
protection feature.
[0023] In another aspect, the present disclosure is generally directed to a
blank for forming a carton
having at least one protection feature.
[0024] In another aspect, the present disclosure is generally directed to a
method of forming a carton
having at least one protection feature for protecting articles held in the
carton from breakage.
[0025] Other aspects, features, and details of the present disclosure can
be more completely
understood by reference to the following detailed description of exemplary
embodiments taken in
conjunction with the drawings.
[0026] Those skilled in the art will appreciate the above stated advantages
and other advantages and
benefits of various additional embodiments reading the following detailed
description of the
embodiments with reference to the below-listed drawing figures. Further, 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 disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Fig. 1 is a plan view of an exterior surface of a blank for forming
a carton according to a first
embodiment of the disclosure.
[0028] Fig. 2 is an end perspective of the partially assembled carton of
the first embodiment.
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[0029] Fig. 3 is an end view similar to Fig. 2 with articles added to the
partially assembled carton.
[0030] Fig. 4 is a view similar to Fig. 3 but showing the carton further
assembled.
[0031] Fig. 4A is a view similar to Fig. 4 but showing alternative features
of the carton.
[0032] Fig. 5 is an enlarged portion view of Fig. 4.
[0033] Fig. 5A is a view similar to Fig. 5 but showing alternative features
of the carton.
[0034] Fig. 5B is across-section taken along the plane 5B-5B of Fig. 5A.
[0035] Fig. 5C is a view similar to Fig. 5 but showing alternative features
of the carton.
[0036] Fig. 6 is a side perspective showing the carton of Fig. 5 further
assembled.
[0037] Fig. 7 is an end view showing the carton of Fig. 6 further
assembled.
[0038] Fig. 8 is an end view showing the carton further assembled.
[0039] Fig. 8A is an end view of a partially assembled carton of the first
embodiment with the article
protection flaps in the second position.
[0040] Fig. 9 is a cross-section taken along the plane 9-9 of Fig. 8.
[0041] Fig. 9A is a cross-section taken along the plane 9A-9A of Fig. 8.
[0042] Fig. 9B is a view similar to Fig. 9 but showing alternative features
of the carton.
[0043] Fig. 9C is a view similar to Fig. 9A but showing alternative
features of the carton.
[0044] Fig. 10A is a top plan view of an enlarged portion of a bottom panel
of Fig. 1 showing an
article protection flap in a First position.
[0045] Fig. 10B is a top plan view of the article protection flap of Fig.
10A in a second position.
[0046] Fig. 10C is a cross-section taken along the plane 10C-10C of Fig.
10B.
[0047] Fig. 10D is a view similar to Fig. 10A but showing alternative
features of the article
protection flap.
[0048] Fig. 10E is a view similar to Fig. 10B but showing the article
protection flap of Fig. 10D.
[0049] Fig. 1OF is a cross-section taken along the plane 10E-10F of Fig.
10E.
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[0050] Fig. 11 is a plan view of a system for activating the article
protection flaps of one
embodiment of the disclosure.
[0051] Fig. 12 is an enlarged portion of Fig. 11.
[0052] Fig. 13 is a partial schematic view of a system for activating the
article protection flaps of an
alternative embodiment of the disclosure.
100531 Fig. 14 is a partial schematic view of a system for activating the
article protection flaps of an
alternative embodiment of the disclosure.
100541 Fig. 15 is a plan view of a blank for forming a carton according to
an alternative embodiment
of the disclosure.
100551 Fig. 16 is a plan view of a blank for forming a carton according to
an alternative embodiment
of the disclosure.
[0056] Fig. 17 is a plan view of a blank for forming a carton according to
an alternative embodiment
of the disclosure.
[00571 Fig. 17A is an enlarged portion of the bottom panel of Fig. 17
showing an article protection
flap.
[0058] Fig. 18 is a plan view of a bottom panel of the carton of the
embodiment of Fig. 17 with the
article protection flaps in a second position.
[0059] Fig. 19 is an end view of a partially assembled carton of the
embodiment of Fig. 17 with the
article protection flaps in the second position.
[0060] Fig, 20 is a plan view of a blank for forming a carton according to
an alternative embodiment
of the disclosure.
100611 Fig. 20A is an enlarged portion of the bottom panel of Fig. 20
showing an article protection
flap.
[0062] Fig. 21 is a plan view of an exterior surface of a bottom panel of a
carton according to an
alternative embodiment of the disclosure with articles contained in the carton
shown in hidden lines.
[0063] Fig. 22 is a perspective view of an interior surface of the bottom
panel of the carton of the
embodiment of Fig. 21 showing article protection flaps.
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[0064] Fig. 23 is a perspective view of the interior surface of the bottom
panel of the carton of the
embodiment of Fig. 21 showing the article protection flaps in a second
position.
[0065] Fig. 24 is a plan view of an exterior surface of a blank for forming
a carton according to an
alternative embodiment of the disclosure.
[0066] Figs. 25-27 are various views of forming the carton according to the
embodiment of Fig. 24.
[0067] Fig. 27A is a cross-section taken along the plane 27A-27A of Fig.
27.
[0068] Fig. 27B is a cross-section taken along the plane 27B-27B of Fig.
27.
[0069] Fig. 28 is a plan view of an exterior surface of a blank for forming
a carton according to an
alternative embodiment of the disclosure.
[0070] Fig. 29 is a plan view of an exterior surface of a blank for forming
a carton according to an
alternative embodiment of the disclosure.
[0071] Fig. 30 is a perspective view of a carton according to the
embodiment of Fig. 29.
[0072] Figs. 31A-31C are various views of a blank and carton according to
an alternative
embodiment.
[0073] Figs. 32A-32C are various views of a blank and carton according to
an alternative
embodiment.
[0074] Figs. 33A-33C are various views of a blank and carton according to
an alternative
embodiment of the disclosure.
[0075] Fig. 34 is a top plan view of an enlarged portion of a bottom panel
of a carton showing an
article protection flap in a first position according to an alternative
embodiment of the disclosure.
[0076] Fig. 35 is a plan view of an enlarged portion of the bottom panel of
the carton of the
embodiment of Fig. 34 with the article protection flap in a second position.
[0077] Fig. 35A is a top plan view of the article protection flap of Fig.
35 in the second position.
[0078] Fig. 35B is a cross-sectional view of the article protection flap of
Fig. 35 in the second
position.
[0079] Fig. 36 is a plan view of the bottom panel of Fig. 35 showing three
article protection flaps in
the second position.
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[0080] Fig, 37 is a top plan view of an enlarged portion of a bottom panel
of a carton showing two
article protection flaps in a first position according to two alternative
embodiments of the disclosure.
[0081] Fig. 38 is a bottom view of the enlarged portion of the bottom panel
of Fig. 37 with the article
protection flap partially folded into a second position.
[0082] Figs. 39 and 40 are perspective views of the article protection flap
of Fig. 37 with the article
protection flap in the second position.
[0083] Fig. 41 is a top plan view of an enlarged portion of a bottom panel
of a carton showing an
article protection flap in a first position according to an alternative
embodiment of the disclosure.
[0084] Figs. 42 and 43 are perspective views of the article protection flap
of Fig. 41 with the article
protection flap in the second position.
[0085] Fig. 44 is a top plan view of a bottom panel of a carton showing an
arrangement of article
protection flaps in a first position according to an alternative embodiment of
the disclosure.
[0086] Fig. 45 is a top plan view of an enlarged portion of the bottom
panel of Fig. 44 showing one
of the article protection flaps of Fig. 44,
[0087] Figs. 46 and 47 are perspective views of the article protection flap
of Fig. 45 with the article
protection flap in the second position.
[0088] Corresponding parts are designated by corresponding reference
numbers throughout the
drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0089] The present disclosure generally relates to cartons that contain a
single article or a plurality
of articles such as containers, bottles, cans, etc., and protection features
of such cartons that protect
the article or articles or containers from breakage, damage, or deformation,
The article(s) can be used
for packaging food and beverage products, for example, or any other item. The
article(s) can be
made from materials suitable in composition for packaging the particular food
or beverage item, or
other item, and the materials can include, but are not limited to, glass or
other breakable material;
aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS,
PVC, EVOH,
and Nylon; paperboard; and the like, or any combination thereof, or any other
suitable material.
[0090] Cartons according to the present disclosure can accommodate articles
of any shape. For the
purpose of illustration and not for the purpose of limiting the scope of the
disclosure, the following
detailed description describes beverage containers (e.g., glass beverage
bottles) as disposed within
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the carton embodiments. In this specification, the terms "lower," "bottom,"
"upper" and "top"
indicate orientations determined in relation to fully erected and upright
cartons.
[0091] Fig. 1 is a plan view of the exterior side 1 of a blank, generally
indicated at 3, used to form a
carton 5 (Fig. 8) according to a first exemplary embodiment of the disclosure.
The carton 5 can be
used to house a plurality of articles such as containers C (Fig. 3). In the
illustrated embodiment, the
containers C are bottles having a wide bottom B and a narrow top T including a
cap CP. In the
illustrated embodiment, the carton 5 is sized to house eighteen containers C
in a single layer in a 3x6
arrangement, but it is understood that the carton 5 may be sized and shaped to
hold containers of a
different or same quantity in more than one layer and/or in different
row/column arrangements (e.g.,
lx6, 2x6, 4x6, 3x8, 2x6x2, 3x4x2, 2x9, 3x4, etc.), or just a single article.
[0092] In one embodiment, the carton 5 has a first end 7 and a second end 9
each having article
protection features 11, 11A, 11B (Fig. 8) for protecting at least one article
C of the plurality of
articles. Alternative, only a single article C could be provided in the carton
5. As will be further
discussed below, the carton 5 of the first embodiment may have article
protection flaps 13 for
protecting the at least one article. The article protection features 11
cushion the ends 7, 9 of the
carton and prevent or reduce the likelihood of breakage of the containers C.
In one embodiment, the
article protection flaps 13 are moveable between a first position (Fig. 10A)
and a second position
(Figs. 8A and 10B) placed between adjacent containers C in the carton to
reduce movement of the
containers in the carton and prevent breakage of the containers. The carton 5
can have other features
(e.g., handle, dispenser, etc.) without departing from the disclosure.
[0093] The blank 3 has a longitudinal axis Ll and a lateral axis L2. In the
embodiment of Fig. 1, the
blank includes a bottom panel 15 foldably connected to a first side panel 17
at a lateral fold line 19.
A second side panel 21 is foldably connected to the bottom panel 15 at a
lateral fold line 23. A top
panel 25 is foldably connected to the first side panel 17 at a lateral fold
line 27, and foldably
connected to an adhesive panel 29 at a lateral fold line 31.
[0094] The bottom panel 15 is foldably connected to a first bottom end flap
33 and a second bottom
end flap 35. The first side panel 17 is foldably connected to a first side end
flap 37 and a second side
end flap 39. The second side panel 21 is foldably connected to a first side
end flap 43 and a second
side end flap 45. The top panel 25 is foldably connected to a first top end
flap 47 and a second top
end flap 49. In one embodiment, when the carton 5 is erected, the end flaps
33, 37, 43, 47, close the
first end 7 of the carton, and the end flaps 35, 39, 45, 49 close the second
end 9 of the carton. In
accordance with an alternative embodiment of the present disclosure, different
flap arrangements can
be used for closing the ends 7, 9 of the carton 5.
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[0095] The end flaps 33, 37, 43, 47 extend along a first marginal area of
the blank 3, and are
foldably connected at a first longitudinal fold line 61 that extends along the
length of the blank. The
end flaps 35, 39, 45, 49 extend along a second marginal area of the blank 3,
and are foldably
connected at a second longitudinal fold line 63 that also extends along the
length of the blank. The
longitudinal fold lines 61, 63 may be, for example, substantially straight, or
offset at one or more
locations to account for blank thickness or for other factors. In one
embodiment, the side panels 17,
21 have respective diamond panels 65 that are formed by a fold line 67 that is
spaced inwardly from
the respective longitudinal fold line 61, 63. Also, the side end flaps 37, 39,
43, 45 have a respective
lateral fold line 69 extending from a diamond panel 65 to allow a respective
end 7, 9 to angle
inwardly so that the top of the carton 5 at each end (the portion of the fold
line 61, 63 connecting the
top end flap 47, 49) is closer to the center of the carton than the bottom of
the carton at each end (the
portion of the fold line 61, 63 connecting the bottom end flap 33, 35). In
this way, the ends 7, 9 are
tapered ends, but it is understood that the ends of the carton 5 could be
otherwise shaped, arranged,
and/or configured (e.g., straight or non-tapered) without departing from the
disclosure.
[0096] In the embodiment of Fig. 1, the blank 3 has handle features for
forming a handle 71. In the
illustrated embodiment, the handle features comprise handle flaps 73 foldably
connected to a
respective top end flap 47, 49 at a longitudinal fold line 75, and notches or
openings 77 in the side
end flaps 37, 39, 43, and 45. The openings 77 cooperate to provide an opening
at a respective closed
end 7, 9 to allow a respective handle flap 73 to be inwardly folded so that
the carton 5 can be grasped
at a respective end. The blank 3 can have other features for forming the
handle 71, or the blank
and/or carton 5 can have a handle that is alternatively shaped, arranged,
and/or configured without
departing from the disclosure. Further, the handle 71 can be omitted without
departing from the
disclosure.
[0097] In one embodiment, the blank 3 has features for forming the article
protection features 11 of
the carton 5. As shown in Fig. 1, the side end flaps 37, 39, 43, 45 have
deformations in the form of
indentations 81 on the exterior surface of the blank 3 such that the
indentations from a protrusion on
the interior surface of the blank. The bottom end flap 33, 35 each have two
rows of deformations in
the form of indentations 83 on the interior surface of the blank 3 such that
the indentations on the
interior surface form a protrusion on the exterior surface 1 of the blank 3.
As shown in Fig. 1, the top
end flaps 47, 49 each have a respective distal edge 87, 89 having comer
notches 91 and a center notch
93. The indentations 81, 83 can be any deformation on a surface of a
respective side end flaps 37, 39,
43, 45 or bottom end flap 33, 35 such that the deformation can be any suitable
shape (e.g., a concave
depression or protrusion, convex depression or protrusion, flat depression or
protrusion, embossed
area, debossed area, etc., or any other suitable shape). Furthermore, the
indentations 81, 83 could be
formed on the interior or exterior surface of one or more of the first side
panel 17, second side panel
21, top panel 25, bottom panel 15, or top end flaps 47, 49 without departing
from the disclosure.
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[00981 In the first embodiment, the blank 3 includes nine article
protection flaps 13 arranged in a
3x3 arrangement, but the blank could have more or less than nine article
protection flaps, and the
flaps could be otherwise arranged in other suitable row/column arrangements or
in a random
configuration on the bottom panel 15, including a single row or single column
configuration, or any
other suitable configuration. The description herein will describe the
detailed arrangement and
configuration of a single article protection flap 13; however, the arrangement
and configuration of the
other article protection flaps will be similar or identical. In other
embodiments, the blank 3 can
include article protection flaps that are different, similar, or identical to
other article protection flaps
without departing from the disclosure. In the embodiment of Fig. 1, the middle
row of article
protection flaps 13 are oriented 180 degrees relative to a row of article
protection flaps that are closer
to a respective fold line 61, 63. In other embodiments, the article protection
flaps 13 could be
otherwise shaped, arranged, and/or configured without departing from the
disclosure.
[0099] As shown in Figs. 1 and 10A, the article protection flaps 13 are
each foldably connected to
the bottom panel 15 at a respective lateral fold line 101 and are each at
least partially defined by a
line of weakening 103 in the bottom panel. In one embodiment, the line of
weakening 103 is a cut,
but the line of weakening could comprises other forms of weakening (e.g., a
tear line that comprises
cut lines separated by breakable nicks, a tear line that is formed by a series
of spaced apart cuts, etc.)
that allows the article protection flap 13 to separate from the bottom panel
15 without departing from
the disclosure. The cut 103 has a first portion 105 that is generally curved
and extending from a first
end 106 of the fold line 101 and a second portion 107 that is generally curved
and extending from a
second end 108 of the fold line 101. Both the first portion 105 and the second
portion 107 of the cut
103 extend away from the fold line 101 and form a respective rounded corner
109, 111 of the cut that
transitions to a third portion 113 of the cut. The third portion 113 is
generally straight and extends in
the lateral direction L2 between the two rounded corners 109, 111, hi one
embodiment, a slit or cut
112 is located adjacent the third portion 113 of the cut 103. As show in Figs.
1 and 10A, the article
protection flap 13 comprises a second fold line 117 extending from the first
end 106 of the first fold
line 101 and a third fold line 119 extending from the second end 108 of the
first fold line. In the first
embodiment, the second and third fold lines 117, 119 are longitudinal fold
lines that are generally
parallel and extend in the longitudinal direction LI of the blank 3. The fold
lines 101, 117, 119 and
cuts 103, 105 could be otherwise shaped, arranged, configured, and/or omitted
such that the article
protection flap 13 has any other suitable shape or configuration without
departing from the
disclosure.
[00100] In one embodiment, the first portion 105 of the cut 103, the
rounded corner 109 of the cut, a
portion of the third portion 113 of the cut, and the second fold line 117 at
least partially define a first
portion 121 of the article protection flap 13. The second portion 107 of the
cut 103, the rounded
corner 111 of the cut, a portion of the third portion 113 of the cut, and the
third fold line 119 at least
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partially define a second portion 123 of the article protection flap. A
central portion 125 of the
article protection flap is at least partially defined by the first fold line
101, second fold line 117, third
fold line 119, and a portion of the third portion 113 of the cut 103. The
first portion 121 of the article
protection flap 13 is foldably connected to the central portion 125 at the
second fold line 117. The
second portion 123 of the article protection flap 13 is foldably connected to
the central portion 125 at
the third fold line 119. The first portion 121 and the second portion 123 are
foldable relative to each
other and the central portion 125 by way of the fold lines 117, 119.
Alternatively, the first portion
121 and second portion 123 could be foldably connected at a single fold line
without departing from
the disclosure.
[00101] Figs. 2-8 show one exemplary method of forming the carton 5 and the
article protection
features 11. As shown in Fig. 2, the blank 3 can be formed into a sleeve 131
having open ends 7, 9
by folding the bottom panel 15, side panels 17, 21, and top panel 25 along
respective fold lines 19,
23, 27, 31. The adhesive panel 29 can be adhesively secured to the second side
panel 21 by glue or
other suitable adhesive, As. shown in Fig. 3, containers C can be placed into
an interior space 133 of
the sleeve 131. One of the ends 7, 9 can be closed prior to loading the
containers C or both of the
ends 7, 9 can be closed after loading the containers into the interior space
133. The closing of the
first end 7 is described below, but it is understood that the second end 9 can
be closed in a similar
manner, with the article protection features 11 in the second end being formed
in a similar manner as
the article protection features in the first end. Alternatively, the second
end 9 could have different
flap closing sequence or arrangement and the article protection features 11
could be otherwise
shaped, arranged, configured, and/or omitted without departing from the
disclosure.
[00102] As shown in Figs. 3 and 4, the first end 7 is closed by first
inwardly folding the side end flaps
37, 43. As shown in Figs. 5-7, the bottom end flap 33 is upwardly folded and
the top end flap 47 is
downwardly folded to close the end 7 of the carton 5. The article protection
features 11 in the first
end of the carton 5 are formed during the closing of the end flaps 33, 37, 43,
47, As shown in Fig. 6,
the indentations 81 on the exterior surface of the side end flaps 37, 43 are
aligned with the
indentations 83 on the interior surface of the bottom end flap 33 to form a
respective article
protection feature 11. As shown in Figs. 8 and 9, the outermost article
protection features (when
'viewing the end 7 as shown in Fig. 9) are identified by reference number 11A
and are formed by the
indentation 81 on the side end flap 43 and the indentation 83 on the bottom
end flap 33 that cooperate
to form a pocket 135 in the overlapped end flaps. In one embodiment, the width
of the pocket 135 as
viewed in Fig. 9 is approximately equal to the combined amount of depression
of each of the
indentations 81, 83. The indentations 81 are on the exterior surface of the
side end flaps 37, 43 and
the indentations 83 are on the interior surface of the bottom end flap 33 so
that the indentations 81,
83 cooperate to form the pocket 135. Alternatively, the article protection
features 11 could comprise
only a single indentation 81, 83, or one of the indentations 81, 83 could be
larger or smaller than the
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other, or the indentations 81, 83 could be offset from one another, without
departing from the
disclosure. Moreover, the indentations 81, 83 could be arranged such that the
protrusions are in
direct contact with each other.
[00103] In one embodiment, the middle article protection features 11B
(Figs. 8 and 9A) are formed by
an indentation 81 on each of the side end flaps 37, 43 and an indentation on
the bottom end flap 33.
As shown in Fig. 9A, the indentation 81 near the edge of the inner side end
flap 43 receives the
indentation 81 near the edge of the outer side end flap 37, and the
indentation 83 on the bottom end
flap 33 cooperates with the indentation on the outer side end flap 37 to form
the pocket 137. The
article protection features 11A, 11B, and pockets 135, 137 could be otherwise
shaped, arranged,
positioned, and/or configured without departing from the disclosure.
[00104] Figs. 9B and 9C show alternative configurations of the article
protection features 11A, 11B
having pockets 135, 137 similar to the embodiments of Figs. 9 and 9A but
filled with shock absorbing
material 139. In one embodiment, the shock absorbing material 139 is a
thermoplastic adhesive. The
shock absorbing material 139 can comprise thermoplastic adhesive that can be
hot-melt adhesive
including a low temperature hot melt thermoplastic adhesive or a high
temperature hot melt
thermoplastic adhesive such as are commercially available. Such hot melt
adhesive can include
ethylene vinyl acetate (EVA) or any other suitable material. For example, the
shock absorbing
material 139 can comprise any suitable foam, gel, liquid, or solid, that can
be located in the pocket
135, 137 and provide cushioning of the impact forces exerted on the carton 5.
For example, the
shock absorbing material could comprise any suitable heat activation material,
UV activation
material, laser activation material, Styrofoam, thermoplastic, hot melt
adhesive, or any material that
takes up space in the pocket 135, 137 to provide cushioning to the containers
C. The article
protection features 11 can comprise the same or different thermoplastic
adhesive that is used to form
and close the carton 5 without departing from the disclosure. In one
embodiment, the adhesive used
to form the shock absorbing material 139 can be further applied to one or more
of the end flaps 33,
37, 43, 47 to secure the end flaps in the closed configuration of the end 7.
[00105] As shown in Fig. 9, the lower article protection feature 11, 11A,
11B is spaced apart from the
bottom panel 15 by a first distance D1 and the upper article protection
feature 11, 11A, 11B is spaced
apart from the bottom panel by a second distance D2. In one embodiment, the
second distance D2 is
greater than the first distance DI. The distances D1 can be selected so that
the lower article
protection feature 11 contacts the container C near a bottom portion B of the
container. The distance
D2 can be selected so that the upper article protection feature 11 contacts
the container C near the
shoulder S of the container. The positioning of the upper and lower article
protection features 11
provides a respective container C with two contact points with the shock
absorbing features at the end
7 of the carton 5 so that each respective container C is stabilized and
cushioned against impacts
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occurring at the end of the carton. The article protection features could be
otherwise arranged and
positioned without departing from the disclosure.
[00106] Fig. 4A shows an alternative configuration of the end 7 wherein the
side end flap 37 has two
notches 141 instead of the indentations 81. The notches 141 allow the
indentations 81 near the edge
of the exterior surface of the side end flap 43 to cooperate with the middle
indentations 83 on the
bottom end flap 33 to form a pocket similar to the pocket 135 shown in Fig. 9,
but with the pocket
135 being wider as a result of the intervening layer of material from the side
end flap 37.
[00107] Figs. 5A and 5B show an alternative configuration of the end 7
wherein the bottom end flap
33 is modified from the bottom end flap shown in Fig. 4. In the embodiment of
Figs. 5A and 5B, the
indentations 83 on the interior surface near the peripheral edge of the bottom
end flap 33 of Fig. 4 are
replaced by a deformation 149 at the peripheral edge of the bottom end flap
33. The deformation 149
includes a series of indentations 151 on the interior surface of the bottom
end flap 33 that are
adjacent to a respective indentation on the exterior surface 153 of the bottom
end flap. The
indentations 151 on the interior surface of the bottom end flap 33 communicate
with the upper
indentations 81 on the side end flaps 37, 43 to form a respective pocket or
series of pockets.
Alternatively, the upper indentations 81 on the side end flaps 37, 43 could be
replaced with a
deformation similar to the deformation 149 of the bottom end flap, or any
other configuration that is
suitable for creating a pocket or series of pockets that form the article
protection features.
[00108] Fig. 5C shows an alternative configuration of the end 7 wherein the
side end flaps 37, 43 and
bottom end flap 33 are modified from the flaps shown in Fig. 4. In the
embodiment of Fig. 5C, the
bottom end flap 33 has indentations 155 on the interior surface near the
peripheral edge of the bottom
end flap that are modified from the embodiment of Fig. 4. Further, the side
end flaps 37, 43 each
have upper indentations 157 that are modified from the embodiment of Figs. 4
and 5. Both groups of
indentations 155, 157 are elongated from the embodiment of Figs. 4 and 5, and
the indentations 155
on the bottom end flap are each sized to extend between two adjacent
indentations 157 on the side
end flaps 37, 43. The indentations 155 are in communication with multiple
indentations 157 so that
the pocket formed by the cooperating indentations forms an article protection
feature 11 that is
elongated and contacts two adjacent articles C. The elongated article
protection feature can be filled
with shock absorbing material in a similar manner as described above for the
first embodiment.
Alternative, the lower indentations on the interior surface of the bottom end
flap 33 and the lower
indentations 81 on the side end flaps 37, 43 could be similar to the
indentations 155, 157 without
departing from the disclosure.
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[00109] In the first embodiment, the loaded and closed carton 5 of Fig. 8
is further processed so that
the article protection flaps 13 are activated. The article protection flaps 13
are foldably connected to
the bottom panel 15 and moveable between a first position (Fig. 2) that is
substantially parallel to the
bottom panel and a second position (Fig. 8A) wherein the article protection
flaps are folded relative
to the bottom panel. In one embodiment, the article protection flaps 13 are
raised or activated to the
position of Fig. 8A, and the article protection flaps have features for
preventing the folding of the
article protection flaps from the second position back to the first position.
Fig. 8A illustrates an
outermost row of containers C removed and the end flaps 33, 37, 43, 47 at the
end 7 open so that the
article protection flaps 13 are visible. It is understood that the article
protection flaps 13 will be
activated to the second position (Fig. 8A) after the ends 7, 9 of the carton 5
have been closed.
Alternatively, the article protection flaps 13 could be activated prior to
closing one or both of the
ends 7, 9 of the carton 5 without departing from the disclosure.
[00110] The article protection flaps 13 can be activated by various forming
apparatus, some of which
will be described below in further detail, or any other suitable method. The
activation of a single
article protection flap 13 will be described in detail herein, but it is
understood that the other article
protection flaps can be activated in a similar or different manner without
departing from the
disclosure. Figs. 10A and 10B are enlarged portions of the interior surface of
the bottom panel 15,
with Fig. 10A showing the interior surface of the bottom panel prior to
activation of the article
protection flap 13, and Fig. 10B showing the interior of the bottom panel
after activation of the article
protection flap. In one embodiment, a finger or other portion of an apparatus
for forming the carton
presses against the central portion 125 (Fig. 10A) of the article protection
flap 13 to initiate
separation of the article protection flap from the bottom panel 13 along the
cut 103. As shown in
Figs. 8A, 10A, and 10C, the article protection flap 13 is pivoted upward
relative to the bottom panel
at the fold line 101 in the direction of arrow Al to create an opening 161 in
the bottom panel. As
the article protection flap 13 is activated, the first portion 121 and the
second portion 123 are folded
relative to each other. In one embodiment, the first portion 121 and the
second portion 123 of the
article protection flap are folded inwardly relative to each other and
relative to the central portion
125. As such, the article protection flap 13 provides two layers of material
(e.g., the inwardly folded
first portion 121 and second portion 123) between adjacent containers C in the
carton 5.
[00111] In one embodiment, the article protection flaps 13 are upwardly
folded to the second (raised)
position shown in Fig. 8A, or the article protection flaps can be upwardly
folded to a second (raised)
position shown in Fig. 10C. In one embodiment, the upwardly folding of the
article protection flaps
13 causes the containers C in the carton 5 to move to accommodate the space
required for the article
protection flaps in the second position with the first portion 121 and second
portion 123 folded
relative to each other. The movement of the containers C when the article
protection flaps 13 are
upwardly folded and located between adjacent containers, tightens the packing
of the containers in
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the carton 5 so that the movement of the containers is limited by the
positioning of the article
protection flaps 13 and the respective end flaps 33, 37, 43, 47 and 35, 39,
45, 49 at the closed ends 7,
9 of the carton. The article protection flaps 13 are pressed against two
adjacent containers C to
initiate movement of the containers and provide the tightening feature of the
article protection flaps.
[00112] In one embodiment, the configuration of the first portion 121 and
the second portion 123
prevents the article protection flap 13 from being downwardly folded from the
second or raised
position of Fig. 8 to the first or lowered position of Fig. 2. As shown in
Fig, 10B, when the first
portion 121 and the second portion 123 of the article protection flap 13 are
inwardly folded relative to
each other, the first and second portions extend beyond the edge 163 of the
opening 161 created at the
third portion 113 of the cut 103. In one embodiment, an edge 165 (Fig. 10C) of
the first portion 121
of the article protection flap 13, formed by the rounded corner 109 of the cut
103 extends beyond the
edge 163 of the opening 161. Also, an edge 167 (Fig. 10C) of the second
portion 123 of the article
protection flap 13 formed by the rounded corner 111 of the cut 103 extends
beyond the edge 163 of
the opening 161. The positioning of the distal portions of the first portion
121 and second portion
123, including the edges 165, 167 of the article protection flap 13, relative
to the edge 163 of the
opening 161 prevents the article protection flaps 13 from being downwardly
folded to the first
position wherein the article protection flaps are substantially parallel to
the bottom panel 15. As
such, once the article protection flaps 13 arc raised to the second position
and positioned between
adjacent containers C, the article protection flaps stay in the upwardly
folded position providing
cushioning and protection between adjacent containers. The article protection
flaps 13 could be
otherwise shaped, arranged, and/or configured to have other features for
preventing the article
protection flaps from returning to the first or lowered position without
departing from the disclosure.
[00113] Figs. 10D-10F show an article protection flap 13 having alternative
features. In the
embodiment of Figs. 10D-10F, the first portion 121 and the second portion 123
of the article
protection flap 13 each have a respective deformation 171, 173 in the form of
an indentation on the
exterior surface of the article protection flap 13. The article protection
flap 13 of the embodiment of
Figs. 10D-10F is activated in a similar manner as described above for the
previous embodiment,
wherein the first portion 121 is folded relative to the second portion 123 of
the article protection flap.
As shown in Fig, 10F, the indentations 171, 173 of the respective first and
second portions 121, 123
cooperate to form a space 175 between the first portion and the second portion
of the article
protection flaps 13. The space 175 can comprise shock absorbing material, such
as the shock
absorbing material 139 discussed above for the article protection features 11,
or any other suitable
material. The space 175 between the first and second portions 121, 123 of the
article protection flap
13 of Fig. 1OF provides enhanced article protection and reduction of breakage
of the containers C.
The deformations 171, 173 could be otherwise shaped, arranged, configured,
positioned, and/or
omitted without departing from the scope of the disclosure.
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[00114] One embodiment of a system 181 for activating the article
protection flaps 13 is illustrated in
Figs. 11 and 12. In one embodiment, the cartons 5, having containers C loaded
and the ends 7, 9
closed, are conveyed via an inlet conveyor 183 to a first or inlet end 185 of
the system 181.
However, the system 181 could also be used to activate the article protection
flaps 13 of the cartons 5
prior to closing one or both of the ends 7, 9. The system 181 comprises a sled
187 that receives a
carton 5 from the inlet conveyor 183 such that the bottom panel 15 of the
carton is in contact with the
top surface 189 of the sled. The sled 187 is operatively attached to a cam
track array or section 191
that includes a series of spaced rails 193 (Fig. 12) with a series of cam
tracks 195 mounted
therebetween. The sled 187 comprises a series of actuating fingers 197
pivotally mounted to the sled
and moveable through a respective slot 199 in the top surface 189 of the sled.
The actuating fingers
197 have a lower portion that engages a respective cam track 195 such that the
actuating finger 197 is
raised or lowered in the slot 199 by the slope of the cam track. As the sled
187 with carton 5
mounted on the top surface 189 moves in the direction of arrow A2 (Fig. 11),
the fingers 197 are
raised and lowered in the slots 199 to activate the article protection flaps
13 in the bottom panel 15.
After the article protection flaps 13 are activated by the system 181, the
carton 5 exits an exiting end
201 of the system for further handling and packaging. The system 180 could be
alternatively shaped,
arranged, and/or configured without departing from the disclosure.
[00115] Fig. 13 illustrates an alternative embodiment of a system 207 for
activating the article
protection flaps 13 of the carton 5. The system 297 comprises a cassette 209
that can be mounted
along the path of travel of the carton 5 in a packaging machine. In one
embodiment, the cassette 209
comprises a series of actuating fingers 211 mounted to a chain 213. The
fingers 211 move along a
cam track 215 that receives a portion of the fingers 211 as the fingers are
conveyed around the
cassette. As the fingers 211 move along the cam track 215, the fingers can be
positioned between
non-engaging and engaging positions for selectively activating the article
protection flaps 13 of the
carton 5. The system 207 could be alternatively shaped, arranged, and/or
configured without
departing from the disclosure.
[00116] Fig. 14 shows features of an alternative embodiment of a system 221
for activating the article
protection flaps 13 of the carton 5. As with the previous embodiments, the
system 221 can be
mounted along a path of travel of the cartons Sin a packaging machine. In the
embodiment of Fig.
14, the system 221 includes a series of starred wheels or finned discs 223
that will engage and
activate the article protection flaps 13 as the cartons move through or along
system 221. The star
wheels 223 each generally includes a series of actuating fingers 225 arranged
in groups or sets spaced
about the circumference or periphery 227 of each of the star wheels. In one
embodiment, each of the
star wheels 223 is positioned to activate a respective row of article
protection flaps 13 in the bottom
panel 15 of the carton. The actuating fingers 225 engage a respective article
protection flap 13 and
move the article protection flap from the first (lowered) position that is
substantially parallel to the
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bottom panel 15 to the second (raised) positioned wherein the article
protection flap 13 is folded
relative to the bottom panel. The system 221 could be alternatively shaped,
arranged, and/or
configured without departing from the disclosure.
[00117] Fig. 15 is an alternative embodiment of a blank 303 that is similar
to the blank 3 of the first
embodiment. Accordingly, like or similar features will be indicated with like
or similar reference
numbers. The blank 303 is for forming a carton 5 having article protection
features 11 in respective
ends 7, 9 of the carton as discussed above for the first embodiment. As with
the embodiment of Fig.
1, the blank 303 has end flaps 33, 37, 43, 47 and 35, 39, 45, 49 that have
respective indentations or
features 81, 83 that cooperate to form the article protection features 11. In
contrast to the first
embodiment, the blank 303 has a bottom panel 15 that does not have article
protection flaps 13. The
blank 303 could have other features and could be otherwise shaped, arranged,
and/or configured
without departing from the disclosure.
[00118] Fig. 16 is an alternative embodiment of a blank 403 that is similar
to the blank 3 of the first
embodiment Accordingly, like or similar features will be indicated with like
or similar reference
numbers. The blank 403 is for forming a carton 5 having article protection
flaps 13 foldably
connected to the bottom panel 15 as discussed above for the first embodiment.
In contrast to the first
embodiment, the blank 403 has end flaps 33, 37, 43, 47 and 35, 39, 45, 49 that
are free of respective
indentations or features 81, 83 that cooperate to form the article protection
features 11 of the carton 5
of the first embodiment. The blank 403 could have other features and could be
otherwise shaped,
arranged, and/or configured without departing from the disclosure.
[00119] Figs. 17-19 show an alternative embodiment of a blank 503 for
forming a carton 505 that is
similar to the blank 3 and carton 5 of the first embodiment. Accordingly, like
or similar features will
be indicated with like or similar reference numbers. The blank 503 has article
protection flaps 513
that are similar to the article protection flaps 13 of the first embodiment.
The blank 503 has fifteen
article protection flaps 513 arranged in a 5x3 arrangement, but the blank
could have more or less than
fifteen article protection flaps and the article protection flaps could be
otherwise arranged. In the
embodiment of Figs. 17-19, the article protection flaps 513 are foldably
connected to the bottom
panel 15 at a lateral fold line 520 and are at least partially defined by a
cut 522 or other line of
weakening in the bottom panel. Two oblique fold lines 524, 526 extend from
respective ends of the
lateral fold line 520 to define a central portion 528 of the article
protection flap 513. A first portion
530 of the article protection flap 513 is foldably connected to the central
portion 528 at the oblique
fold line 524 and a second portion 532 is foldably connected to the central
portion 528 at the oblique
fold line 526. In addition to the distal portions of the first portion 530 and
second portion 532, the
features that prevent the article protection flap 513 from being downwardly
folded include a heel 534
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formed at a distal portion of the article protection flap. In the illustrated
embodiment, the heel 534 is
a rounded protrusion that extends beyond the edge of the first and second
portions 530, 532.
[00120] Fig. 18 illustrates a view of the bottom panel 15 of the carton 505
after the article protection
flaps 15 have been activated and positioned in the second (raised) position
between adjacent
containers C. As shown in Figs, 18 and 19, the openings 561 is formed in the
bottom panel 15 when
the article protection flaps 513 are moved to the second position between
adjacent containers. As
shown in Fig. 19, the first and second portions 530, 532 are folded with
respect to one another when a
respective article protection flap 513 is positioned in the second position.
In the raised position, the
first portion 530, second portion 532, and heel 534 of each respective article
protection flap 513
interfere with the edges of the bottom panel 15 at the opening 561 to prevent
with the article
protection flap from being moved to the first position that is substantially
parallel to the bottom panel
15. The article protection flaps 513 could be otherwise shaped, arranged,
configured, and/or
positioned without departing from the disclosure.
[00121] Figs. 20 and 20A illustrate various features of a blank 603
according to an alternative
embodiment of the disclosure and having similar features of the first
embodiment. Accordingly, like
or similar features will be indicated with like or similar reference numbers.
The blank 603 has article
protection flaps 613 that are similar in shape as the article protection flaps
513 of the previous
embodiment, hi the embodiment of Figs. 20 and 20A, the article protection
flaps 613 are foldably
connected to the bottom panel 15 at a lateral fold line 620 and are at least
partially defined by a cut
622 or other line of weakening in the bottom panel. Two curved fold lines 624,
626 extend from
respective ends of the lateral fold line 620 to define a central portion 628
of the article protection flap
613. A first portion 630 of the article protection flap 613 is foldably
connected to the central portion
628 at the curved fold line 624 and a second portion 632 is foldably connected
to the central portion
628 at the curved fold line 626. The article protection flap 613 comprises a
heel 634 formed at a
distal portion of the article protection flap. In the illustrated embodiment,
the heel 634 is a rounded
protrusion that extends beyond the edge of the first and second portions 630,
632 (e.g., is the farthest
portion of the article protection flap 613 from the fold line 620). In the
embodiment of Figs. 20 and
20A, the article protection flap 613 includes a lateral fold line 636
extending across the first portion
630 and the second portion 632 at the widest portion of the article protection
flap and a longitudinal
fold line 638 extending from the lateral fold line across the heel portion 634
to the cut 622. The fold
lines 636, 638 facilitate the activation of the article protection flap 613
and the folding of the first
portion 630 relative to the second portion 632. The article protection flaps
613 could be otherwise
shaped, arranged, configured, and/or positioned without departing from the
disclosure.
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[00122] Figs. 21-23 illustrate various features of a blank 703 and carton
705 of an alternative
embodiment having similar features as the first embodiment of the disclosure.
Accordingly, like or
similar features will be indicated with like or similar reference numbers. The
blank 703 has a bottom
panel 15 with article protection flaps 713 that are foldably connected to the
bottom panel at a lateral
fold line 720. In the embodiment of Figs. 21-23 two curved fold lines 724, 726
extend from
respective ends of the lateral fold line 720 and define a central portion 728
of the article protection
flap 713. The first portion 730 is foldably connected to the central portion
728 of the article
protection flap 713 at the fold line 724 and the second portion 732 is
foldably connected to the
central portion at the fold line 726. The location of the containers C is
shown in hidden lines in Fig.
21, with the article protection flaps 713 in the first (lowered) position
wherein the article protection
flaps are substantially parallel to the bottom panel.
[00123] Fig. 22 shows the article protection flaps 713 being moved to the
second position, and Fig. 23
shows the article protection flaps substantially in the second position. In
both Figs. 22 and 23 one
row of containers C has been removed to show the positioning of the article
protection flaps 713. As
with the previous embodiments, an opening 761 is formed in the bottom panel 15
that corresponds
with the shape of the article protection flap 713 in the first position. As
shown in Fig. 23, the first
and second portions 730, 732 are curved or contoured to match the shape of the
container C so that
the container is held in secure engagement with the article protection flap
'713. As with the previous
embodiments, the article protection flaps 713 are prevented from being moved
from the second
(raised) position to the first (lowered) position by the interference of the
folded first and second
portions 730, 732 with the edge 763 of the bottom panel 15 at the opening 761.
The folding of the
first and second portions 730, 732 relative to each other and the central
portion 730 causes the distal
portions of the first and second portions to extend beyond the edge 763
forming the opening. The
article protection flaps 713 could be otherwise shaped, arranged, configured,
and/or positioned
without departing from the disclosure.
[001241 Figs. 24-27 show an alternative embodiment of a blank 803 for
forming a carton 805 that is
similar to the blank 3 and carton 5 of the first embodiment. Accordingly, like
or similar features will
be indicated with like or similar reference numbers. The blank 803 has article
protection flaps 13 that
are the same as the article protection flaps of the first embodiment. The
blank 803 has end flaps 33,
37, 43, 47 and 35, 39, 45, 49 that have respective indentations or features
81, 83 that cooperate to
form the article protection features 811 that are similar to the article
protection features 11, 11A, 11B
of the first embodiment. The blank 803 could have other features without
departing from the
disclosure.
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[00125] In the embodiment of Figs. 24-27, each of the top end flaps 47, 49
has a reinforcement flap
814 foldably connected to a base portion 816 of the top end flap at a
longitudinal fold line 818. In
one embodiment, the base portion $16 of each top end flap 47, 49 has a group
of indentations 83a on
the interior surface of the base portion 816 of the end flap, and the
reinforcement flap 814 has a group
of indentations 83b on the interior surface of the end flap. As with the first
embodiment, the side end
flaps 37, 39, 43, 45 have indentations 81 on the exterior surface of the side
end flaps and the bottom
end flaps 33, 35 have indentations 83 on the interior surface of the bottom
end flaps. In the
embodiment of Figs. 24-27, each of the side end flaps 43, 45 have only a
single indentation 81 on the
lower row of indentations and an edge having notches 810 instead of a second
indentation on the
lower row. The blank 803 could have other arrangements of indentations 81, 83
or other features for
forming the article protection features 811 without departing from the
disclosure.
[00126] As shown in Figs. 25-27B, when the ends 7, 9 of the carton 805 are
closed, the reinforcement
flap 814 of each top end flap 47, 49 is folded at the fold line 818 to be in
face-to-face contact with the
interior surface of the base portion 816 of each end flap. As with the
previous embodiments, only the
closing of the first end 7 of the carton 805 is shown, but it is understood
that the second end 9 could
be closed in a similar manner as described for the first end. When the
reinforcement flap 814 is
folded, the indentations 83b on the reinforcement flap 814 are aligned and in
contact with the
indentations 83a on the base portion 816. The indentations 83a, 83b cooperate
to form a pocket 836
(Fig. 27A) in the top end flap 47, 49 that is similar to pockets 135 discussed
above for the first
embodiment and shown in Fig. 9.
[00127] In the embodiment of Figs. 24-27B, the indentations 81 on the side
end flaps 37, 39, 43, 45
and the indentations 83 on the bottom end flaps 33, 35 cooperate to form an
upper pocket 135 that is
similar to the upper pocket 135 described above for the first embodiment and
shown in Fig. 9. The
upper article protection feature 811A of the outermost article protection
features (e.g., closest to the
side panels 17, 21 when viewed from Fig. 27) comprises the pocket 836 formed
by the reinforcement
flap 814 and the base portion 816 of the top end flaps 47, 49 and the upper
pocket 135 that is formed
by the bottom end flap 33, 35 and the side end flaps 37, 39, 43, 45. The lower
article protection
features 811B of the outermost article protection features comprises the lower
pocket 135 that is
formed by the indentation 83 on the bottom end flaps 33, 35 and the
indentation 81 on the side end
flaps 37, 39, 43, 45. Either or both of the pockets 836, 135 that form the
article protection features
811A, 811B could comprise shock absorbing material as described above for the
first embodiment,
The article protection features 811A, 811B could be formed by other features
of the blank 803
without departing from the disclosure.
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[00128] As shown in Figs. 27 and 27B, the upper article protection feature
811C of the middle article
protection features (e.g., between the two outer article protection features
811A) comprises the
pocket 836 in the top end flaps 47, 49 and the upper pocket 137 that is formed
by the indentations 81
of bottom end flaps 33, 35 and the overlapped portions of the side end flaps
37, 39, 43, 45. The
lower article protection features 811D of the middle article protection
features comprises the lower
pocket 137 that is formed by the indentations 81 of the overlapped portions of
the side end flaps 43.
As with the previous embodiments, any or all of the pockets 135, 137, 836
could be filled with shock-
absorbing material 139 without departing from the disclosure. The pockets 135,
137 can be similar to
the corresponding pockets shown in Fig. 9 for the first embodiment, or the
pockets could be
otherwise shaped, arranged, configured, and/or omitted. Any of the article
protection features 811,
811A, 811B, 811C, 811D could be otherwise shaped, arranged, and/or configured
without departing
from the disclosure.
[00129] In one embodiment, the reinforcement flaps 814 are folded under the
base portion 816 to
provide an extra layer of material to reinforce and enhance the cushioning and
protection of the
container C by the article protection features 811A in the closed ends 7, 9 of
the carton 805.
Alternatively, the reinforcement flap 814 could be folded over and be in
contact with the exterior
surface of the base portion 816 so that the reinforcement flap is in face-to-
face contact with the
exterior surface of the base portion. Alternatively, the reinforcement flaps
814 and base portions 816
could be otherwise shaped, arranged, and/or configured without departing from
the disclosure.
[00130] Fig. 28 illustrates various features of a blank 903 for forming a
carton of an alternative
embodiment having similar features as the first embodiment of the disclosure.
Accordingly, like or
similar features will be indicated with like or similar reference numbers. The
blank 903 has a bottom
panel 15 with primary article protection flaps 913 that are arranged in a
single row of three article
protection flaps. Secondary article protection flaps 914 are foldably
connected to the bottom panel
15 and are spaced apart from a respective primary article protection flap 913.
In the illustrated
embodiment, four secondary article protection flaps 914 are included, but more
or less than four
secondary article protection flaps could be used, or the secondary article
protection flaps could be
otherwise shaped, arranged, and/or configured without departing from the
disclosure. The secondary
article protection flaps 914 provide additional cushioning of the containers C
and tightening of the
carton 5 formed from the blank 903.
[00131] In one embodiment, the secondary article protection flaps 914 are
smaller than the primary
article protection flaps 913, but it is understood that the article protection
flaps could be otherwise
shaped, arranged, and/or configured. The primary and second article protection
flaps 913, 914 can be
moved to a second (raised) position in a similar manner as described above for
the previous
embodiments. In the illustrated embodiment, the blank 903 comprises a second
top panel 926 that is
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placed in face-to-face contact with the first top panel 25 to reinforce the
top panel of the carton
formed from the blank 903. However, it is understood that the primary article
protection flaps 913
and secondary article protection flaps 914 could be included on any other
style of blanks (e.g., blanks
similar to the blank 3 of Fig. 1 having only a single top panel 25) for use in
forming any other style of
carton without departing from the disclosure,
[00132] Figs. 29-30 illustrate various features of a blank 1003 for forming
a carton 1005 of an
alternative embodiment having similar features as the first embodiment of the
disclosure.
Accordingly, like or similar features will be indicated with like or similar
reference numbers. The
blank 1003 is for forming the carton 1005 that is a carrier having an interior
space 1008 that has a
generally open top with a divider 1010 that at least partially divides the
interior space into a front
portion 1012 and a back portion 1014. In one embodiment, the divider 1010
comprises a handle 1016
and the divider does not extend down to the bottom panel 1015. The divider
1010 could be otherwise
shaped, arranged, and/or configured without departing from the disclosure.
1001331 In the illustrated embodiment, the blank 1003 has a front panel
1020, back panel 1022, and
respective side panels 1024, 1026, 1028, 1030 for forming the sides of the
carton 1005. The blank
1003 has divider panels 1032, 1034, 1036, 1038 that combine to form the
divider 1010 of the carton
1005. In one embodiment the bottom panel 1015 is foldably connected to the
back panel 1022 but the
bottom panel 1015 could be otherwise arranged without departing from the
disclosure. The bottom
panel 1015 includes article protection flaps 1013 that are similar to the
article protection flaps 13 of
the first embodiment. The article protection flaps 1013 are foldably connected
to the bottom panel
,1015 and arranged in a single row of three flaps. In the illustrated
embodiment, the article protection
flaps 1013 are positioned in the second (raised) position in a similar manner
as the previous
embodiments. The article protection flaps 1013 are positioned on the bottom
panel 1015 so that the
flaps are placed between adjacent containers C, with one of the adjacent
containers being located in
the front portion 1012 of the interior space 1008 and the other of the
adjacent containers being
located in the hack portion 1014 of the interior space. The article protection
flaps 1013 could be
otherwise shaped, arranged, and/or configured without departing form the
disclosure.
[00134] Figs. 31A-31C illustrate various features of a blank 1103 for
forming a carton 1105 of an
alternative embodiment having similar features as the previous embodiments of
the disclosure.
Accordingly, like or similar features will be indicated with like or similar
reference numbers. The
blank 1103 is a single panel for supporting the plurality of containers C. The
blank 1103 comprises
article protection flaps 1113 similar to the article protection flaps 13 of
the earlier embodiments. The
carton 1105 is formed by placing the plurality of containers C on the blank
1103 and then activating
the article protection flaps 1113 by moving the article protection flaps from
the first position that is
substantially parallel to the blank 1103 to the second position wherein the
article protection flaps are
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folded relative to the panel of the blank. In one embodiment, the carton 1105
can be further assembly
by applying an overwrap of shrink-wrap (e.g., shrinkable polymer film) or
other packaging material
M so that the containers are securely attached to the blank 1103. In the
embodiment of Figs. 31A-
31C the blank 1103 is a bottom panel, but the blank could be otherwise shaped,
arranged, or
configured without departing from the disclosure.
[00135] In an alternative embodiment, blank 1103 and articles C with
activated article protection
flaps 113 can be positioned relative to a construct to at least partially
enclose the blank and the at
least two articles. In one embodiment the construct can be a sleeve similar to
the sleeve 131 of Fig.
2. Further the construct can have at least one open end, such as the ends 7, 9
that can be closed by
respective end flaps. The blank 1103 and articles C can be positioned in an
interior of the sleeve
prior to closing both the ends 7, 9, or one of the ends can be closed prior to
positioning the blank and
articles. Alternatively, the construct could be a lid that fits over the tops
of the articles C, and the lid
could have one or more side panels extending down from a top panel.
[00136] Figs. 32A-32C illustrate various features of a blank 1203 for
forming a carton 1205 of an
alternative embodiment having similar features as the previous embodiments of
the disclosure.
Accordingly, like or similar features will be indicated with like or similar
reference numbers. The
blank 1203 comprises a bottom panel 1214 and four side panels 1218, 1220,
1222, 1224 for forming a
tray 1226 (Fig. 32B) having an interior space tor holding the container C. The
blank 1203 comprises
article protection flaps 1213 similar to the article protection flaps 13 of
the earlier embodiments. The
carton 1205 is formed by placing the plurality of containers C on the bottom
panel 1214 of the blank
1203 and upwardly folding the side panels 1218, 1220, 1222, 1224 to form the
tray 1226. The article
protection flaps 1213 are activated by moving the article protection flaps
from the first position that is
substantially parallel to the bottom panel 1214 to the second position wherein
the article protection
flaps are folded relative to the bottom panel of the blank 1203. in one
embodiment, the carton 1205
can be further assembled by applying an overwrap of shrink-wrap (e.g.,
shrinkable polymer film) or
other packaging material M so that the containers are securely attached to the
tray 1226. In the
embodiment of Figs. 32A-32C the blank 1203 is configured for forming the tray
1226, but the blank
could be otherwise shaped, arranged, or configured without departing from the
disclosure.
[00137] Figs. 33A-33C illustrate various features of a blank 1303 for
forming a carton 1305 of an
alternative embodiment having similar features as the previous embodiments of
the disclosure.
Accordingly, like or similar features will be indicated with like or similar
reference numbers. The
blank 1303 is generally similar to the blank 3 of the first embodiment in that
the blank of Figs. 33A-
33C comprises a bottom panel 1315 and a first side panel 1317, a second side
panel 1321, and a top
panel 1325. The blank 1303 comprises article protection flaps 1313 similar to
the article protection
flaps 13 of the earlier embodiments. The carton 1305 is formed by placing the
plurality of containers
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C on the bottom panel 1214 of the blank 1203 and upwardly folding the side
panels 1317, 1321
around the containers on the bottom panel to partially form the carton as
shown in Fig. 33B. Next,
the top panel 1325 is downwardly folded to close the interior of the carton
1305 and the ends 1307,
1309 are closed by closing respective end flaps 1333, 1337, 1343, 1347 and
1335, 1339, 1345, and
1349. The article protection flaps 1313 are activated by moving the article
protection flaps from the
first position that is substantially parallel to the bottom panel 1315 to the
second position wherein the
article protection flaps are folded relative to the bottom panel 1315 of the
blank 1303. The blank
1303 could be otherwise shaped, arranged, or configured without departing from
the disclosure.
[00138] Figs. 34-
36 show article protection flaps in a bottom panel of a carton according to an
alternative embodiment having similar features as the previous embodiments of
the disclosure. The
article protection flap 1413 is generally similar to the article protection
flaps 13 of the first
embodiment in that the article protection flap of Figs. 34-36 is foldably
connected to the bottom panel
1415 at a respective lateral fold line 1501 and is at least partially defined
by a line of weakening 1503
in the bottom panel. In the embodiment of Figs. 34-36, the blank can include
any suitable number of
article protection flaps 1413 and/or other article protection flaps. For
example, the blank can include
three article protection flaps 1413 arranged in a 1x3 arrangement (Fig. 36),
but the blank could have
more or less than three article protection flaps, and the flaps could be
otherwise arranged in other
suitable row/column arrangements or in a random configuration on the bottom
panel 1415, including
a single row or single column configuration, multiple row/column
configurations, or any other
suitable configuration. The
description herein will describe the detailed arrangement and
configuration of a single article protection flap 1413; however, the
arrangement and configuration of
the other article protection flaps will be similar or identical. In an
alternative embodiment, one or
more article protection flaps 1413 can be used with article protection flaps
have different
arrangements and configurations. In the illustrated embodiment, the article
protection flap 1413 can
have a longitudinal axis Li and a lateral axis L2. In other embodiments, the
blank can include article
protection flaps that are different, similar, or identical to other article
protection flaps without
departing from the disclosure. in other embodiments, the article protection
flaps 1413 could be
otherwise shaped, arranged, and/or configured without departing from the
disclosure.
[00139] In one
embodiment, the line of weakening 1503 is a cut or cut line, but the line of
weakening
could comprise other forms of weakening (e.g., a tear line that comprises cut
lines separated by
breakable nicks, a tear line that is formed by a series of spaced apart cuts,
etc.) that allows the article
protection flap 1413 to separate from the bottom panel 1415 without departing
from the disclosure.
As shown in Fig. 34, the cut 1503 can include two nicks 1504. In an
alternative embodiment, the cut
1503 could include any suitable number of nicks 1504. The cut 1503 has a first
portion 1505 that is
generally curved and extends from a first end 1506 of the lateral fold line
1501 and a second portion
1507 that is generally curved and extends from a second end 1508 of the
lateral fold line. Both the
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first portion 1505 and the second portion 1507 of the cut 1503 extend away
from the fold line 1501
and fon-n a respective corner 1509, 1511 of the cut that transitions to a
third portion 1513 of the cut.
In the illustrated embodiment, each of the corners 1509, 1511 includes a
respective recess or notch
1514 with a stop edge 1516 and a shoulder 1518. As shown in Fig. 34, a cut
line 1519 extends from
each notch 1514 into the article protection flap 1413 adjacent the respective
shoulder 1518.
[00140] As shown in Fig. 34, the third portion 1513 of the cut can extend
obliquely and inwardly
from each of the corners 1509, 1511 to a tab portion 1520 that generally
projects outwardly from the
article protection flap 1413 and forms a receiving recess 1522 in the bottom
panel 1415 when the
article protection flap 1413 is folded into the second position (Figs. 35-
35B). In the illustrated
embodiment, a slit or cut 1512 is located adjacent the tab portion 1520 of the
cut 1503. In one
embodiment, the article protection flap 1413 can include a longitudinal fold
line 1517 extending
along the longitudinal axis Li from the lateral fold line 1501 to an opposing
portion of the cut 1503
(e.g., adjacent the cut 1512). As shown in Fig. 34, the article protection
flap 1413 can include a first
portion 1521 foldably connected to a second portion 1523 along the
longitudinal fold line 1517. The
fold lines 1501, 1 517 and the cuts 1503, 1512 could be otherwise shaped,
arranged, configured,
and/or omitted such that the article protection flap 1413 has any other
suitable shape or configuration
without departing from the disclosure.
[00141] In the embodiment of Figs, 34-36, the article protection flaps 1413
are activated in an at least
partially closed carton 5 with containers C loaded therein. He article
protection flaps 1413 are
foldably connected to the bottom panel 1415 and moveable between a first
position (Fig. 34) that is
substantially parallel to the bottom panel and a second position (Figs. 35-
35B) wherein the article
protection flaps are folded relative to the bottom panel. In one embodiment,
the article protection
flaps 1413 are raised or activated to the position of Figs. 35-35B, and the
article protection flaps have
features for preventing the folding of the article protection flaps from the
second position back to the
first position. It is understood that the article protection flaps 1413 can be
activated to the second
position (Figs. 35-35B) and the carton can be erected and closed similarly or
identically to that
described for the first embodiment, Alternatively, the article protection
flaps 1413 could be
otherwise activated and the carton can be otherwise erected and closed without
departing from the
disclosure.
[00142] The article protection flaps 1413 can be activated by various
forming apparatus, some of
which are described in further detail in the first embodiment, or any other
suitable method. The
activation of a single article protection flap 1413 will be described in
detail herein, but it is
understood that the other article protection flaps can be activated in a
similar or different manner
without departing from the disclosure. Figs. 34 and 35 are enlarged portions
of the bottom panel
1415, with Fig. 34 showing the interior surface of the bottom panel prior to
activation of the article
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protection flap 1413, and Fig. 35 showing the exterior of the bottom panel
after activation of the
article protection flap. Additionally, Fig. 35A shows an interior view of the
enlarged portion of the
bottom panel 1415 showing a top view of the article protection flap 1413 in
the second position, and
Fig. 35B shows a cross-section of the enlarged portion of the bottom panel
1415 with the article
protection flap 1413 in the second position. In one embodiment, a finger or
other portion of an
apparatus for forming the carton presses against a central portion (e.g., at
or near the crease 1517) of
the article protection flap 1413 to initiate separation of the article
protection flap from the bottom
panel 1415 along the cut 1503. As shown in Figs. 35-35B, the article
protection flap 1413 is pivoted
upward relative to the bottom panel 1415 at the fold line 1501 to create an
opening 1561 in the
bottom panel.
[00143] As the article protection flap 1413 is activated, the corners 1509,
1511 can be folded relative
to each other at least partially along the crease 1517. Accordingly, the
article protection flap 1413
can provide two layers of material in a general wedge shape between adjacent
containers C in the
carton. As the article protection flap 1413 is folded into the interior of the
carton, the edges of the
article protection flap formed at the third portion 1513 of the cut 1503 can
move into the receiving
recess 1522 of the bottom panel 1415, and the corners 1509, 1511 can be folded
together and forced
through the cut 1512 into the interior of the carton. The corners 1509, 1511
then can spread out to
form the general wedge shape shown in Figs. 35 and 35A. In one embodiment,
with the corners
1509, 1511 in the interior of the carton, the notches 1514 of the article
protection flap 1413 can
engage an edge or retention portion 1524, which can be at or near a respective
corner of the receiving
recess 1522 of the bottom panel 1415 (Figs. 35 and 35A). Accordingly, the stop
edges 1516 (shown
in phantom in Fig. 36) can engage the interior surface of the bottom panel
1415 (Figs. 35A and 35B)
and the shoulders 1518 can engage the edge of the receiving recess 1522 (Fig.
35B) to help retain the
article protection flap 1413 in the interior of the carton. As such, once the
article protection flaps
1413 are raised to the second position and positioned between adjacent
containers C, the article
protection flaps stay in the upwardly folded position providing cushioning and
protection between
adjacent containers according to one embodiment.
[00144] In one embodiment, the upwardly folding of the article protection
flaps 1413 causes the
containers C in the carton to move to accommodate the space required for the
article protection flaps
in the second position. The movement of the containers C when the article
protection flaps 1413 are
upwardly folded and located between adjacent containers, tightens the packing
of the containers in
the carton so that the movement of the containers is limited by the
positioning of the article
protection flaps 1413, the side panels, and the closed ends of the carton. The
article protection flaps
1413 are pressed against two adjacent containers C to initiate movement of the
containers and
provide the tightening feature of the article protection flaps. The article
protection flaps 1413 could
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S2014/037642
be otherwise shaped, arranged, and/or configured to have other features for
preventing the article
protection flaps from returning to the first or lowered position without
departing from the disclosure.
100145] Figs. 37-40 show two article protection flaps in a bottom panel of
a carton according to
alternative embodiments having similar features as the previous embodiments of
the disclosure. The
article protection flaps 1613, 1613' are generally similar to the article
protection flaps 13 of the first
embodiment and/or the article protection flap 1413 of the embodiment of Figs.
34-36. As shown in
Fig. 37, the article protection flap 1613 includes notches 1514 that are
similar to the notches of the
article protection flap 1413 shown in Fig. 34. The notches are omitted in the
article protection flap
1613' as shown in Fig. 37.
[00146] As shown in Fig. 37, the fold line 1701 comprises a lateral cut
that is aligned with and spaced
apart from the ends of the line of weakening 1703. The fold line 1701 could be
any suitable fold line
(e.g., a crease, a score, a cut-crease line, etc.) or other line of weakening
without departing from the
disclosure. In one embodiment, the line of weakening 1703 is a cut, but the
line of weakening could
comprise other forms of weakening (e.g., a tear line that comprises cut lines
separated by breakable
nicks, a tear line that is formed by a series of spaced apart cuts, etc.) that
allows the article protection
flap 1613 to separate from the bottom panel 1615 without departing from the
disclosure. As shown in
Fig. 37, the cut 1703 can include two nicks 1704. In an alternative
embodiment, the cut 1703 could
include any suitable number of nicks 1704. The cut 1703 has first and second
portions 1705, 1707
that are generally curved. Both the first portion 1705 and the second portion
1707 of the cut 1703
extend away from the fold line 1701 and form a respective corner 1709, 1711 of
the cut that
transitions to a third portion 1713 of the cut. In one embodiment, the corners
1709, 1711 can include
notches 1514 as described above with respect to Figs. 34-36. In the embodiment
shown in Figs. 37-
40, the recess in the bottom panel is omitted, and the notches 1514 can engage
the edge of the bottom
panel formed by the third portion 1713 of the cut 1703. The corners 1709, 1711
could be otherwise
shaped, arranged, configured, and/or omitted without departing from the
disclosure. In the illustrated
embodiment, the third portion 1713 is generally straight or slightly curved
and extends in the lateral
'direction L2 between the two corners 1709, 1711. In one embodiment, a slit or
cut 1712 is located
adjacent the third portion 1713 of the cut 1703, and the article protection
flap 1613 comprises a
longitudinal crease or fold line 1717.
[00147] As shown in Fig. 37, the article protection flap 1613 can include
two generally arcuate cuts
1726 that are spaced apart from one another in a central portion 1725 of the
article protection flap
between the longitudinal fold line 1717 and the lateral fold line 1701. The
generally arcuate cuts
1726 can form projections or tabs 1728 (Figs. 39 and 40) when the article
protection flap 1613 is
activated. The tabs 1728 can resist folding of the central portion of the
article protection flap as the
article protection flap is activated and can lock against and/or abut the
heels of adjacent containers C
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in the carton to help maintain the wedge shape of the article protection flap
in the second position.
Fig. 38 shows that the corners 1709, 1711 can be brought together during
activation of the article
protection flap, with the corners sliding though the slit 1712. Figs. 39 and
40 show the article
protection flap 1613 folded to the interior of the carton and illustrate the
tabs 1728 extending outward
from the central portion of the article protection flap. As shown in Figs. 39
and 40, the tabs 1728 can
separate from the outer portions 1721, 1723 of the article protection flap
1613 as the corners 1709,
1711 are folded together to help maintain the width of the central portion
1725 of the article
protection flap. As shown in Fig. 38, the arcuate cuts 1726 can form edges
1730 of the respective
outer portions 1721, 1723 adjacent respective openings in the article
protection flap 1613. The fold
lines 1701, 1717 and cuts 1703, 1705, 1712, 1726 could be otherwise shaped,
arranged, configured,
and/or omitted such that the article protection flap 1613 has any other
suitable shape or configuration
without departing from the disclosure. Additionally, the generally arcuate
cuts 1726 and/or the tabs
1728 could be incorporated into any suitable article protection flap.
[00148] Figs. 41-43 show an article protection flap in a bottom panel of a
carton according to an
alternative embodiment having similar features as the previous embodiments of
the disclosure. The
article protection flap 1813 is generally similar to the article protection
flaps 1613 of the embodiment
shown in Figs. 37-40. In the illustrated embodiment, the article protection
flap 1813 is foldably
connected to the bottom panel 1815 at a respective lateral fold line 1901 and
is at least partially
defined by a line of weakening 1903 in the bottom panel. The blank can include
any suitable number
of article protection flaps 1813 and/or other article protection flaps. For
example, the blank can
include three article protection flaps 1813 arranged in a 1x3 arrangement, but
the blank could have
more or less than three article protection flaps, and the flaps could be
otherwise arranged in other
suitable row/column arrangements or in a random configuration on the bottom
panel 1815, including
a single row or single column configuration, multiple row/column
configurations, or any other
suitable configuration. In the illustrated embodiment, the article protection
flap 1813 can have a
longitudinal axis Ll and a lateral axis L2. The article protection flaps 1813
could be otherwise
shaped, arranged, and/or configured without departing from the disclosure.
[00149] As shown in fig. 41, the fold line 1901 comprises a lateral cut
that is aligned with and spaced
apart from the ends of the line of weakening 1903. The fold line 1901 could be
any suitable fold line
(e.g., a crease, a score, a cut-crease line, etc.) or other line of weakening
without departing from the
disclosure. In one embodiment, the line of weakening 1903 is a cut, but the
line of weakening could
comprise other forms of weakening (e.g., a tear line that comprises cut lines
separated by breakable
nicks, a tear line that is formed by a series of spaced apart cuts, etc.) that
allows the article protection
flap 1813 to separate from the bottom panel 1815 without departing from the
disclosure. For
example, as shown in Fig. 41, two nicks 1904 are formed in the line of
weakening 1903 to help retain
the article protection flap 1813 in the first position until it is actuated.
The cut 1903 has first and
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second portions 1905, 1907 that extend away from the fold line 1901 and form a
respective corner
1909, 1911 of the cut that transitions to a third portion 1913 of the cut. In
the illustrated embodiment,
the first portion 1905 of the cut is generally straight and oblique with
respect to the longitudinal
direction L 1 and the lateral direction L2. The second portion 1907 can be
generally curved in the
exemplary embodiment.
[00150] As shown in Fig. 41 ,the first corner 1909 is spaced apart from a
longitudinal crease or fold
line 1917 in the article protection flap by a distance D3, and the second
corner is spaced apart from
the longitudinal fold line 1917 by a distance D4. In one embodiment, the
distance D4 is greater than
the distance D3. Accordingly, the article protection flap 1813 is asymmetrical
and can include a
smaller first portion or flap 1921 and a larger second portion or flap 1923 as
shown in Fig. 41. The
corners 1909, 1911 could be otherwise shaped, arranged, configured, and/or
omitted without
departing from the disclosure. In the illustrated embodiment, the third
portion 1913 is generally
straight or slightly curved and extends in the lateral direction L2 between
the two corners 1909, 1911.
In one embodiment, a slit or cut 1912 is located adjacent the third portion
1913 of the cut 1903.
[00151] As shown in Fig. 41, the article protection flap 1813 can include
two generally arcuate cuts
1926 that are spaced apart from one another in a central portion 1925 of the
article protection flap
between the longitudinal fold line 1917 and the lateral fold line 1901. The
generally arcuate cuts
1926 can form projections or tabs 1928 (Figs. 42 and 43) when the article
protection flap 1913 is
activated. The cuts 1926 and the tabs 1928 can be similar to the cuts 1726 and
the tabs 1728 in the
embodiment shown in Figs. 37-40. The tabs can resist folding of the central
portion of the article
protection flap as the article protection flap is activated and can lock
against and/or abut the heels of
adjacent containers C in the carton to help maintain the wedge shape of the
article protection flap in
the second position.
[00152] In the embodiment of Fig. 41-43, the article protection flaps 1813
are activated in an at least
partially closed carton with containers C loaded therein. The article
protection flaps 1813 are
moveable between a first position (Fig. 41) that is substantially parallel to
the bottom panel 1815 and
a second position (Figs. 42 and 43) wherein the article protection flaps are
folded relative to the
bottom panel. In one embodiment, the article protection flaps 1813 have
features for preventing the
folding of the article protection flaps from the second position back to the
first position. It is
understood that the article protection flaps 1813 can be activated to the
second position and the
carton can be erected and closed similarly or identically to that described in
the embodiment
including Figs. 37-40. Alternatively, the article protection flaps 1813 could
be otherwise activated
and the carton can be otherwise erected and closed without departing from the
disclosure.
[00153] The article protection flaps 1813 can be activated by various
forming apparatus, some of
which are described in further detail in the prior embodiments or any other
suitable method. The
activation of a single article protection flap 1813 will
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be described in detail herein, but it is understood that the other article
protection flaps can be
activated in a similar or different manner without departing from the
disclosure. In one embodiment,
a finger or other portion of an apparatus for forming the carton presses
against a central portion (e.g.,
at or near the crease 1917) of the article protection flap 1813 to initiate
separation of the article
protection flap from the bottom panel 1815 along the cut 1903, breaking the
nicks 1904. In one
embodiment, the article protection flap 1813 is pivoted upward relative to the
bottom panel 1815 at
the fold line 1901 to create an opening 1961 (Figs. 42 and 43) in the bottom
panel.
[00154] As the article protection flap 1813 is activated, the portions
1921, 1923 can be folded relative
to each other at least partially along the crease 1917 so that the corner 1909
is folded against the
portion 1923 as shown in Fig. 43. Accordingly, the article protection flap
1913 can provide two
layers of material in a general wedge shape between adjacent containers C in
the carton. As the
article protection flap 1913 is folded into the interior of the carton, at
least the corner 1911 can be
forced through the cut 1912 into the interior of the carton. The tabs 1928
formed from the arcuate
cuts 1926 can separate from the portions 1921, 1923 as the portions are folded
together to help
maintain the width of the central portion 1925 of the article protection flap.
The fold lines 1901,
1917 and cuts 1903, 1912, 1926 could be otherwise shaped, arranged,
configured, and/or omitted
such that the article protection flap 1813 has any other suitable shape or
configuration without
departing from the disclosure.
[00155] In one embodiment, the upwardly folding of the article protection
flaps 1813 causes the
containers C in the carton to move to accommodate the space required for the
article protection flaps
in the second position. The movement of the containers C when the article
protection flaps 1813 are
upwardly folded and located between adjacent containers, tightens the packing
of the containers in
the carton so that the movement of the containers is limited by the
positioning of the article
protection flaps 1813, the side panels, the closed ends of the carton, and/or
suitable features. The
article protection flaps 1813 are pressed against two adjacent containers C to
initiate movement of the
containers and provide the tightening feature of the article protection flaps.
[00156] The asymmetric shape of the article protection flap 1813 has the
benefit of forming a smaller
hole 1961 in the bottom panel 1815 than a symmetric flap because of the
smaller portion 1921.
However, the larger portion 1923 can still engage the interior surface of the
bottom panel 1815 to
help prevent the article protection flap 1813 from folding through the opening
1961 from the second
position. For example, in one embodiment, the hole 1961 formed by each article
protection flap 1813
could be about nine percent smaller than if the portion 1921 were the same
size as the portion 1923
(e.g., a symmetrical flap). Accordingly, the asymmetric article protection
flap 1813 is able to provide
two plies of material between adjacent containers C and to resist folding from
the second position
while, at the same time, reducing weakening of the bottom panel 1815.
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[00157] Figs. 44-47 show an article protection flap in a bottom panel of a
carton according to an
alternative embodiment having similar features as the previous embodiments of
the disclosure. The
article protection flap 2013 is generally similar to the article protection
flap 1813 of the embodiment
shown in Figs. 41-43. The article protection flap 2013 lacks the arcuate cuts
1926 and the tabs 1928
formed from the arcuate cuts of the embodiment shown in Figs. 41-43. Instead,
the article protection
flap 2013 can include a generally U- or V-shaped crease or fold line 2127,
wherein the fold line 2117
extends from the vertex of the V-shaped crease 2127 and the line of weakening
2103 extends from
the ends of the V-shaped crease 2127. Accordingly, the V-shaped crease 2127
can help retain the
width of the central portion 2125, which is generally triangular, as shown in
Fig. 46. Additionally,
the corner 2111 of the article protection flap 2013 has a more pronounced
point than the article
protection flap 1813 of the embodiment of Figs. 41-43. As shown in Fig. 44,
nine article protection
flaps 2013 can be arranged in a 3x3 configuration with alternating
orientations. However, the blank
could have more or less than nine article protection flaps, and the flaps
could be otherwise arranged
in other suitable row/column arrangements or in a random configuration on the
bottom panel 2015,
including a single row or single column configuration, multiple row/column
configurations, or any
other suitable configuration. The article protection flaps 2013 could be
otherwise shaped, arranged,
and/or configured without departing from the disclosure.
[00158] The cartons of any of the illustrated or non-illustrated
embodiments of the disclosure could
have other features (e.g., dispenser features, handle features, reinforcement
features, etc.) without
departing from the disclosure. Also, the cartons could be otherwise shaped,
arranged, or configured
and the cartons could be configured to hold articles other than beverage
containers C without
departing from the disclosure.
[00159] In general, the blanks of any of the illustrated or non-illustrated
embodiments may be
constructed from paperboard having a caliper so that it is heavier and more
rigid than ordinary paper.
The blank can also be constructed of other materials, such as cardboard, or
any other material having
properties suitable for enabling the carton to function at least generally as
described above. The
blank can be coated with, for example, a clay coating. The clay coating may
then be printed over
with product, advertising, and other information or images. The blanks may
then be coated with a
varnish to protect information printed on the blanks. The blanks may also be
coated with, for
example, a moisture barrier layer, on either or both sides of the blanks. The
blanks can also be
laminated to or coated with one or more sheet-like materials at selected
panels or panel sections.
[00160] As an example, a tear line can include: a slit that extends
partially into the material along the
desired line of weakness, and/or a series of spaced apart slits that extend
partially into and/or
completely through the material along the desired line of weakness, or various
combinations of these
features. As a more specific example, one type of tear line is in the form of
a series of spaced apart
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slits that extend completely through the material, with adjacent slits being
spaced apart slightly so
that a nick (e.g., a small somewhat bridging-like piece of the material) is
defined between the
adjacent slits for typically temporarily connecting the material across the
tear line. The nicks are
broken during tearing along the tear line. The nicks typically are a
relatively small percentage of the
tear line, and alternatively the nicks can be omitted from or torn in a tear
line such that the tear line is
a continuous cut line. That is, it is within the scope of the present
disclosure for each of the tear lines
to be replaced with a continuous slit, or the like. For example, a cut line
can be a continuous slit or
could be wider than a slit without departing from the present disclosure.
[00161] In accordance with the exemplary embodiments, a fold line can be
any substantially linear,
although not necessarily straight, form of weakening that facilitates folding
there along. More
specifically, but not for the purpose of narrowing the scope of the present
disclosure, fold lines
include: a score line, such as lines formed with a blunt scoring knife, or the
like, which creates a
crushed or depressed portion in the material along the desired line of
weakness; a cut that extends
partially into a material along the desired line of weakness, and/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. In situations where cutting is used to create
a fold line, typically the
cutting will not be overly extensive in a manner that might cause a reasonable
user to incorrectly
consider the fold line to be a tear line.
[00162] The above embodiments may be described as having one or more panels
adhered together by
glue during erection of the carton embodiments. The term "glue" is intended to
encompass all
manner of adhesives commonly used to secure carton panels in place.
[00163] The foregoing description of the disclosure illustrates and
describes various embodiments.
As various changes could be made in the above construction without departing
from the scope of the
disclosure, it is intended that all matter contained in the above description
or shown in the
accompanying drawings shall be interpreted as illustrative and not in a
limiting sense. Furthermore,
the scope of the present disclosure covers various modifications,
combinations, alterations, etc., of
the above-described embodiments. Additionally, the disclosure shows and
describes only selected
embodiments, but various other combinations, modifications, and environments
are within the scope
of the disclosure as expressed herein, commensurate with the above teachings,
and/or within the skill
or knowledge of the relevant art. Furthermore, certain features and
characteristics of each
embodiment may be selectively interchanged and applied to other illustrated
and non-illustrated
embodiments of the disclosure.
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