Note: Descriptions are shown in the official language in which they were submitted.
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
CARTON WITH ACCESS FEATURE
CROSS-REFERENCE TO RELATED APPLICATIONS
100011 This application claims the benefit of U.S. Provisional Patent
Application No. 62/179,178
filed April 29, 2015.
INCORPORATION BY REFERENCE
100021 The disclosure of U.S. Provisional Patent Application No.
62/179,178, which was filed
April 29, 2015, is hereby incorporated by reference for all purposes as if
presented herein in its
entirety.
BACKGROUND OF THE DISCLOSURE
100031 The present disclosure generally relates to a carton for
handling and carrying articles, and
particularly to cartons having a top access feature and liquid-tight or
leakage resistant features.
SUMMARY OF THE DISCLOSURE
100041 In one aspect, the disclosure is generally directed to a carton
for holding a plurality of
articles. The carton comprising a plurality of panels that extends at least
partially around an interior
of the carton, the plurality of panels comprises a bottom panel, a first side
panel, a second side
panel, and a top panel. The plurality of panels forming a first compartment
for holding the plurality
of articles. Liquid-tight features are between the bottom panel and a
respective one of the first side
panel and the second side panel. Access features are in at least the top panel
for accessing the
interior of the carton and forming a second compartment that opens to the
first compartment.
100051 In another aspect, the disclosure is generally directed to a
blank for forming a carton for
holding a plurality of articles. The blank comprising a plurality of panels
comprising a bottom
panel, a first side panel, a second side panel, and a top panel. The plurality
of panels being for
forming a first compartment for holding the plurality of articles in the
carton formed from the
blank. The blank has features for forming liquid-tight features between the
bottom panel and a
respective one of the first side panel and the second side panel in the carton
formed from the blank.
The blank has access features in at least the top panel for allowing access to
the interior of the
carton formed from the blank and for forming a second compartment that opens
to the first
compartment in the carton formed from the blank.
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
100061 In another aspect, the disclosure is generally directed to a
method of forming a carton for
holding a plurality of articles. The method comprising obtaining a blank
comprising a plurality of
panels including a bottom panel, a first side panel, a second side panel, and
a top panel. The blank
comprises features for forming liquid-tight features between the bottom panel
and a respective one
of the first side panel and the second side panel and access features in at
least the top panel. The
method comprises forming a first compartment for holding the plurality of
articles by positioning
the plurality of panels to form an interior of the carton, and activating the
access features to access
the interior of the carton and forming a second compartment that opens to the
first compartment.
100071 In another spaced, the disclosure is generally directed to a
method of expanding the
interior volume of a carton.
100081 According to another aspect of the disclosure, the access
feature in the top panel can be
opened and volume of the carton expanded so that ice, cold water, additional
containers, and/or
other articles can be placed in the carton through the opened top end. The
interior volume of the
carton can be used to retain liquids, such as water resulting from melting
ice, condensation, other
liquids, and articles such as, for example, refuse, particulate matter, etc.
[00091 According to another aspect of the disclosure, the carton
comprises a primary
compartment or bottom receptacle and a secondary compartment above the primary
compartment
that can be assembled to expand the interior of the carton. The bottom
receptacle of the carton can
be constructed to have a height that extends above the bottom panel of the
carton, below which
there are no seams sealed by glue or other adhesives. The bottom receptacle
may therefore be
liquid-tight.
100101 Other aspects, features, and details of the present disclosure
can be more completely
understood by reference to the following detailed description, taken in
conjunction with the
drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
100111 According to common practice, the various features of the
drawings discussed below are
not necessarily drawn to scale. Dimensions of various features and elements in
the drawings may
be expanded or reduced to more clearly illustrate the embodiments of the
disclosure.
100121 FIG. 1 is a plan view of a blank used to form a carton
according to one embodiment of the
disclosure.
100131 FIG. 2 is an exterior view of a partially erected carton
according to one embodiment of the
disclosure.
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
[0014] FIG. 3 is an interior view of a partially erected carton
according to one embodiment of the
disclosure.
[0015] FIG. 4 is an exterior view of a fully erected carton according
to one embodiment of the
disclosure.
100161 FIG. 5 is an exterior view of a carton with a partially
separated access feature according to
one embodiment of the disclosure.
100171 FIG. 6 is an exterior view of a carton with partially separated
access flaps according to
one embodiment of the disclosure.
100181 FIG. 7 is an exterior view of a carton with a partially formed
secondary compartment.
[0019] FIG. 8 is an exterior view of a carton with a partially formed
secondary compartment.
100201 FIG. 9 is an exterior view of a fully erected carton with a
fully formed secondary
compartment.
100211 FIG. 10 is a profile view of a fully erected carton with a
fully formed secondary
compartment.
[0022] FIG. 11 is a top view of a fully erected carton with a fully
formed secondary
compartment.
[0023] Corresponding parts are designated by corresponding reference
numbers throughout the
drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
100241 The embodiments of the present disclosure described below
generally relate to a carton
suitable for storing and dispensing articles such as, for example, beverage
containers. The carton
provides a bottom receptacle suitable for accommodating, for example, liquids,
ice, or other
coolants in the carton bottom. In one exemplary embodiment, ice can be added
to the opened top of
the carton to cool beverage containers held within the carton. As the ice
melts, all or a part of the
resultant runoff water may be held within the bottom receptacle.
[0025] Articles accommodated within the present carton embodiments can
include articles or
containers such as, for example, metallic beverage cans, glass or plastic
bottles, or other containers
such as, for example, those used in packaging foodstuffs and other products.
For the purposes of
illustration and not for the purpose of limiting the scope of the disclosure,
the following detailed
3
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
description describes generally cylindrical metallic beverage containers as
disposed within the
carton. In this specification, the terms "side," "end," "bottom," and "top"
indicate orientations
determined in relation to fully erected, upright cartons.
100261 FIG. 1 is a plan view of a blank 5 used to form a carton 150
(illustrated in FIG. 4)
according to one embodiment of the disclosure. The exterior or printed surface
3 of the blank 5 is
shown in FIG. I. The blank 5 has a longitudinal axis LI extending along a
length of the blank, and
a lateral axis L2 extending along a width of the blank. As discussed in detail
below, the carton 150
includes a bottom receptacle or compartment 153 that is for containing
articles such as beverage
containers C and has liquid-tight feature for retaining liquid, and a top
access features 155 that
forms a secondary compartment 157 on top of the bottom receptacle 153 for
receiving ice or other
coolant and allowing access to the interior of the carton containing the
beverage containers. In the
illustrated embodiment, the carton 150 is sized to house twenty-four
containers C in a single layer
in a 4x6 arrangement, but it is understood that the carton ISO 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, 3x4, 2x6x2, 3x4x2, 3x5, 4x5, 3x6, 2x9, 2x6, 4x4,
etc.).
100271 The blank 5 comprises a bottom panel 10, first and second side
panels 20 foldably
connected to each side of the bottom panel 10 at lateral fold lines 21,
respectively, a second top
panel 30 foldably connected to the first side panel 20 at a lateral fold line
31, and a first top panel
40 foldably connected to the second side panel 20 at a lateral fold line 41.
Adhesive 36 may be
applied to the print or exterior surface 3 of the second top panel 30. A
bottom end panel 60 is
foldably connected to each end of the bottom panel 10 at a longitudinal fold
line 62. A closure flap
70 is foldably connected to a distal end of each bottom end panel 60 at a
longitudinal fold line 71.
In this specification, the terms "end" and "side" are used for ease of
reference, and do not imply
relative sizes of the end panels 20 and the side panels 60, for example.
100281 The first top panel 40 may include a breachable line of
disruption 50 or tear strip
extending generally in the longitudinal direction L I that separates two top
access flaps 52, 54 that
are foldably connected to the first top panel 40 at respective longitudinal
fold lines 55, 57. Each top
access flap includes a respective longitudinal fold line 59, 61 that divides
each top access flap into
respective first and second portions 52a, 52b, 54a, 54b. The top access flaps
52, 54 are separable
from the top panel 40 at respective spaced-apart tear lines 63, 65 that extend
generally laterally
between respective ends of the longitudinal fold lines 55, 57. In one
embodiment, the first top
panel 40 includes top end flaps 67, 69 foldably connected at respective ends
of the top panel at
respective longitudinal fold lines 71, 73. The first top panel 40 could have
other features and/or be
otherwise shaped, arranged, and/or configured without departing from the
disclosure.
4
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
100291 In the illustrated embodiment, the second top panel 30 includes
two second top access
flaps 91, 93 that are separable from each other by a line of weakening 89.
Each of the second top
access flaps 91, 93 are foldably connected to the second top panel 30 at a
respective lateral fold line
95, 97. The access flaps 91,93 include a respective base portion 91a, 93a, a
first end portion 91b,
93b foldably connected to the base portion at a respective first end of the
base portion, and a second
end portion 91c, 93c foldably connected to the base portion at a respective
second end of the base
portion. As shown in Fig. 1, the end portions 91b, 91c, 93b, 93c are removably
connected to the
end flaps 75, 77 at respective longitudinal tear lines 85, 87 and are foldably
connected to a
respective base portion 91a, 93a of the access flaps 91, 93 at a respective
longitudinal fold line 79,
81. In one embodiment, the adjacent first end portions 91b, 93b are separated
by opening 92 in the
second top panel 30 and the adjacent second end portions 91c, 93c are
separated by an opening 94
in the second top panel. A tear line 96 extends between the openings 92, 94
and separates the base
portions 91a, 91b of the access flaps 91, 93. In one embodiment, the line of
weakening 89
comprises the tear line 96 and the openings 92, 94. As shown in Fig. 1, the
fold lines 79, 81 include
cuts 83 that extend into the base portion 91a, 93a of a respective access flap
91, 93. The second
top panel 30 could have other features and/or be otherwise shaped, arranged,
and/or configured
without departing from the disclosure.
100301 A lower gusset 80 is located at each corner of the bottom panel
10, extending between and
connected to an adjacent side panel 20 and bottom end panel 60. Each lower
gusset 80 comprises a
first gusset panel 82 foldably connected to a bottom end panel 60 at the
lateral fold line 21, a
second gusset panel 84 foldably connected to a side panel 20 at the
longitudinal fold line 62 and the
first gusset panel 82 at an oblique fold line 86.
100311 An exemplary method of erecting the carton 150 from the blank 5
is discussed below with
reference to FIGS. 1-4. The carton 150 can be erected with other methods or
folding steps without
departing from the disclosure.
100321 Referring to FIGS. 1 and 2, the blank 5 is folded flat and the
interior surface of the first
top panel 40 is adhered to the print or exterior surface of the second top
panel 30 by the adhesive 36
so that the second top panel is overlapped by the first top panel. The
partially erected blank may
then be opened up into a generally tubular form or sleeve (Fig. 2) having open
ends. The carton
150 may be filled with articles such as, for example, generally cylindrical
beverage containers (not
shown) before closing one or both ends of the carton. From the tubular, open-
ended carton form,
the first and second gusset panels 82, 84 are folded inwardly with respect to
each other about the
oblique fold lines 86. Each bottom end panel 60 and closure flap 70 are folded
upwardly and the
overlapped top end flaps 67, 75 and 69, 77 are downwardly folded. The top end
flaps 67, 69 of the
first top panel 40 extend beyond the top end flaps 75, 77 of the second top
panel 30 so that the top
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
end flaps 67, 69 overlap the bottom end panels 60 and are adhesively attached
thereto. Also, the
distal portions 75b, 77b of the top end flaps 75, 77 overlap the closure flaps
70 and can be
adhesively attached thereto. The ends of the carton 150 can be closed by other
features or forming
steps without departing from the disclosure. At this stage, the containers are
contained in the
interior space 158 of the carton 150 that comprises the lower compartment 153.
100331 FIG. 4 illustrates the carton 150 erected from the blank 5. In
the illustrated embodiment,
the carton 150 is loaded with twenty-four generally cylindrical twelve-ounce
beverage containers C
disposed in a4x6x 1 configuration. Embodiments with alternative configurations
are considered
within the scope of the present disclosure. The carton 150 has a generally
parallelepipedal shape
with the first and second top panels 30, 40 forming a top wall 154 closing a
top end of the carton
150. At each end of the carton 150, the end flaps 67, 69, 75, 77, overlap the
closure flap 70 and
bottom end panel 60. Each of the bottom end panels 60, the side panels 20, and
the gussets 80
cooperate to form the bottom compartment 153 that is a liquid tight lower
receptacle because of the
positioning of the gussets 80.
[00341 An exemplary method of accessing the carton and expanding the
volume of the carton 150
is discussed below with reference to FIGS. 5-11.
100351 Referring to FIGS. 4 and 5, to begin activating the access
features of the carton 150, the
tear strip 50 is removed from the first top panel 40 to access the first top
access flaps 52, 54. Next,
the top access flaps 52, 54 are folded upwardly about respective fold lines
55, 57 in the direction of
arrow Al (Fig. 6) to provide access to the second top access flaps 91, 93. As
shown in Fig. 7, the
second top access flaps 91, 93 are upwardly folded about respective fold line
95, 97 with the end
flaps 75, 77 remaining attached to a respective top end flap 67, 69 and the
end portions 91b, 93b,
91c, 93c remaining attached to the base portion 91a, 93a of the top access
flaps 91,93 at fold lines
79, 8 and separating from the end flaps 75, 77 along the tear line 85, 87. As
shown in Figs. 7 and
8, the end portions 91b, 93b, 91c, 93c of the access flaps 91, 93 are folded
to be approximately 90
degrees from the upwardly folded base portions 91a, 93a of the second top
access flaps 91, 93.
Also, as shown in Fig. 8, the cuts 83 along the fold lines 79, 81 connecting
the end portions 91b,
93b, 91c, 93c to the base portions 9la, 93a form openings 97 in the second top
access flaps 91, 93.
The tear lines 63, 65 that form the first top access flaps 52, 54 are shaped
to form tabs 99 (broadly
"male locking features") in respective edges of the first top access flaps. As
shown in Figs. 9-11,
the first top access flaps 52, 54 are folded about respective fold lines 59,
61 so that the distal
portion 52b, 54b of a respective first top access flap 52, 54 is folded
relative to the base portion 52a,
54a so that both the base portion and the distal portion of each first top
access flap overlaps and is
in face-to-face contact with the end portions 91b, 93b, 91c, 93c of the second
access flaps 91,93
and the tabs 99 are received in a respective opening 97 to lock the first top
access flaps in the
6
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
overlapping engagement with the end portions 91b, 93b, 91c, 93c of the second
top access flap 91,
93 as shown in Figs. 9-11.
100361 As discussed above and shown in the drawings, the top access
features 155 include the
first top access flaps 52, 54 and the second top access flap 91, 93 that
cooperate to form and upper
structure 156 that forms the second compartment 157 above the bottom
receptacle/first
compartment 153 that houses the containers in the interior space 158. In one
embodiment, the
structure forming the secondary compartment 157 comprises a four-sided
structure 156 with two
sides of the structure comprising the base portions 91a, 93a of the second top
access flaps 91, 93
and two ends that comprise the first access flap 52 that overlaps the end
portions 91b, 93b and the
first access flap 54 that overlaps the end portions 91c, 93c. The second
compartment 157 is open to
the bottom receptacle/first compartment 153 and expands the interior volume of
the carton 150 to
allow ice to be placed in the partially enclosed space 159 of the second
compartment 157 and
supported at a location above the containers. The four walls of the structure
156 forming the
second compartment 157 support the ice and funnel the ice and melted cool
water down onto the
containers. The liquid-tight bottom receptacle 153 keeps the cool water and
ice from leaking from
the carton 150 so that the containers stay cold. Containers housed in the
bottom receptacle 153 can
be accessed and withdrawn form the carton 150 through the second compartment
157 that allows
access to the bottom receptacle/first compartment. The second compartment 157
can have other
features and be otherwise shaped, arranged, and/or configured without
departing from the
disclosure.
100371 The features forming the top wall 154 and the access features
155 are shaped and
positioned in a manner to allow the containers to be loaded into the open-
ended sleeve of Figs. 2
and 3 without interference with the first and second top panel 30, 40 that
form the top wall 154.
For example, the second top panel 30 includes oblique edges 72 that are shaped
to provide
clearance to allow the containers to be inserted into the open ended sleeve
without interference.
100381 According to one aspect of the present disclosure, the added
interior volume afforded by
activating the upstanding second compartment 157 on top of the bottom
receptacle/first
compartment 153 increases the carton height allowing a significant volume of
cooling media such
as, for example, ice to be placed on top of the beverage containers. If
desired, additional articles
may be placed in the carton 150 after opening and activating the second
compartment. As the ice
melts, the carton 150 serves to retain all or a portion of the water runoff
from the melting ice by the
liquid-tight features of the bottom receptacle 153.
7
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
100391 According to one embodiment of the present disclosure, the
height of the interior volume
of the carton 150 increases by at least 10% when changed from the closed
configuration illustrated
in FIG. 4, to the open and expanded configuration shown in FIGS. 9-11 with the
second
compartment 157 formed. According to another embodiment of the disclosure, the
second height is
at least 25% greater than the first height. Alternative configurations having
different ratios between
the first and second heights and volumes are considered within the scope of
this disclosure.
100401 The lower gussets 80 may define in part the at least partially
liquid-tight bottom
receptacle/first compartment 153 in the erected carton 150. The height of the
top edge or upper
border of the bottom receptacle 153 represents a portion of the bottom of the
carton 150 below
which no glued seals or seams are formed through which water or other liquid
might leak. That is,
no adhesive seal or other joinder of material where fluid might escape the
carton 150 is located in
the carton at a position below the top edge of the bottom receptacle 153. The
bottom receptacle
153 may therefore be formed from a continuous portion of folded material of
the blank 5. The
receptacle height may be increased or decreased, for example, to accommodate
larger or smaller
anticipated liquid volumes in the carton 150.
100411 The blank 5 can, for example, be constructed of water resistant
material to any degree
desired so that liquid in the bottom of the carton 150 remains in the carton
150 for a selected
amount of time.
100421 Cartons according to the principles of the present disclosure
may be formed from
materials such as, for example, paperboard. Therefore, if exposed to water or
other liquids for
extended periods of time, the carton may allow for the passage of liquid
through the wetted carton
surfaces due to partial permeability of the carton material. In this
specification, the term "liquid-
tight" is generally used to define a portion of a carton that is formed from a
continuous portion of
material or of a portion without any glued seams through which liquid or fine
particulate matter
might leak, and the term "liquid-tight" therefore encompasses cartons that may
become partially
water permeable over time due to prolonged exposure to water or other liquids.
100431 In the above embodiments, the cartons are described as
accommodating twenty-four 12-
ounce cans containers in 4 x 6 x 1 configuration. Other arrangements of
containers, packages,
articles, and other items, however, can be accommodated within a carton
constructed according to
the principles of the present disclosure. For example, a carton constructed
according to the
principles of the present disclosure would also work satisfactorily if the
carton were sized and
shaped to hold articles in other configurations, such as 3 x 4 x 1,3 x 6 x 1,
2 x 4 x 1, 2 x 5 x 1, 2 x 6
x 1,4 x 6 x 1, etc., and multi-tier variations of the aforementioned
configurations.
8
CA 02980191 2017-09-18
WO 2016/176542
PCT/US2016/029997
[0044] The dimensions of the blanks may also be altered, for example,
to accommodate various
container forms. For example, 16-ounce petaloid-shaped bottles, or bottles
having any shape, may
be accommodated within a carton constructed according to the principles of the
present disclosure.
[0045] The blanks according to the present disclosure can be, for
example, formed from coated
paperboard and similar materials. For example, the interior and/or exterior
sides of the blanks can
be coated with a clay coating. The clay coating may then be printed over with
product, advertising,
price coding, and other information or images. The blanks may then be coated
with a varnish to
protect any information printed on the blank. The blanks may also be coated
with, for example, a
moisture barrier layer, on either or both sides of the blank. In accordance
with the above-described
embodiments, the blanks may be constructed of paperboard of a caliper such
that it is heavier and
more rigid than ordinary paper (e.g., a caliper of at least about 14). The
blanks can also be
constructed of other materials, such as cardboard, hard paper, or any other
material having
properties suitable for enabling the carton to function at least generally as
described herein. The
blanks can also be laminated or coated with one or more sheet-like materials
at selected panels or
panel sections.
[0046] The above embodiments may be described as having one or more
panels adhered together
by glue. The term "glue" is intended to encompass all manner of adhesives
commonly used to
secure carton panels in place.
100471 In accordance with the above-described embodiments of the
present disclosure, a fold line
can be any substantially linear, although not necessarily straight, form of
weakening that facilitates
folding therealong. 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 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 the present specification, a
"panel" or "flap" need not be
flat or otherwise planar. A "panel" or "flap" can, for example, comprise a
plurality of
interconnected generally flat or planar portions.
[0048] For purposes of the description presented herein, the term "line
of disruption" can be used
to generally refer to, for example, a cut line, a score line, a crease line, a
tear line, or a fold line (or
various sequential and/or overlapping combinations thereof) formed in a blank.
A "breaehable"
line of disruption is a line of disruption that is intended to be breached
during ordinary use of the
carton. An example of a breachable line of disruption is a tear line.
9
CA 02980191 2017-09-18
WO 2016/176542 PCT/US2016/029997
100491 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 tear line is in the form
of a series of spaced
apart 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.
100501 In the illustrated embodiments, selected fold lines are shown as
including spaced cuts to
facilitate folding along the lines. If the cuts are below or adjacent to a
bottom receptacle portion of
a carton, less than 100% cuts may be used to prevent leakage along the fold
lines. Alternatively,
cuts or scores may be omitted within or near the receptacle portion.
100511 The foregoing description of the disclosure illustrates and
describes various exemplary
embodiments. Various additions, modifications, changes, etc. could be made to
the exemplary
embodiments without departing from the spirit and scope of the claims. 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. Additionally, the
disclosure shows and
describes only selected embodiments of the disclosure, but the disclosure is
capable of use in
various other combinations, modifications, and environments and is capable of
changes or
modifications within the scope of the inventive concept 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.
