Note: Descriptions are shown in the official language in which they were submitted.
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
CARTON FOR CONTAINERS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This
application claims the benefit of U.S. Provisional Patent Application No.
62/727,148,
filed on September 5, 2018, and U.S. Provisional Patent Application No.
62/700,534, filed on July
19, 2018.
INCORPORATION BY REFERENCE
[0002] The
disclosures of U.S. Design Patent Application No. 29/675,323, filed on
December 31,
2018, U.S. Provisional Patent Application No. 62/727,148, filed on September
5, 2018, and U.S.
Provisional Patent Application No. 62/700,534, filed on July 19, 2018, are
hereby incorporated by
reference for all purposes as if presented herein in their entirety.
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 a top-loading
configuration with a gusseted top portion and tapered sides.
SUMMARY OF THE DISCLOSURE
[0004] In
general, one aspect of the disclosure is directed to a carton for holding a
plurality of
containers. The carton can be configurable between an open configuration and a
closed
configuration. The carton can comprise a plurality of panels that extends at
least partially around
an interior of the carton, a top end having an open width in the open
configuration and a closed
width in the closed configuration, and a bottom end disposed opposite to the
top end. The bottom
end can have a bottom width. In the open configuration, the top end can be at
least partially open
and the plurality of panels can be positioned so that the open width of the
top end is greater than
the bottom width of the bottom end. In the closed configuration, the top end
can be at least
partially closed and the plurality of panels is positioned so that the closed
width is less than the
open width.
[0005] In
another aspect, the disclosure is generally directed to a blank for forming a
carton for
holding a plurality of containers. The carton can be configurable between an
open configuration
and a closed configuration. The blank can comprise a plurality of panels and a
top marginal area
for forming a top end when the carton is formed from the blank. The top end
can have an open
width in the open configuration and a closed width in the closed configuration
when the carton is
1
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
formed from the blank. The blank further can comprise a bottom marginal area
for forming a
bottom end disposed opposite to the top end when the carton is formed from the
blank. The
bottom end can have a bottom width when the carton is formed from the blank.
In the open
configuration of the carton formed from the blank, the top end can be at least
partially open and
the plurality of panels can be positioned so that the open width of the top
end is greater than the
bottom width of the bottom end. In the closed configuration of the carton
formed from the blank,
the top end can be at least partially closed and the plurality of panels can
be positioned so that the
closed width is less than the open width.
[0006] In another aspect, the disclosure is generally directed to a method
of forming a carton for
holding a plurality of containers. The method can comprise obtaining a blank
comprising a
plurality of panels and forming a carton from the blank. The forming the
carton can comprise
folding the plurality of panels to extend at least partially around an
interior of the carton. The
carton can comprise a top end and a bottom end disposed opposite to the top
end, and the bottom
end can have a bottom width. The method further can comprise configuring the
carton in an open
configuration wherein the top end is at least partially open. The configuring
the carton in the
open configuration can comprise positioning the plurality of panels so that
the top end has an
open width that is greater than the bottom width of the bottom end. The method
also can
comprise configuring the carton in a closed configuration by at least
partially closing the top end
and positioning the plurality of panels so that the top end has a closed width
that is less than the
open width.
[0007] 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. It is within
the scope of the
present disclosure that the above-discussed aspects be provided both
individually and in various
combinations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] 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.
[0009] Fig. 1 is a plan view of a blank used to form a carton according to
a first exemplary
embodiment of the disclosure.
[0010] Figs. 1A and 1B are detail plan views of respective portions of the
blank of Fig. 1.
2
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0011] Fig. 2 is a schematic elevation view of a container according to the
first exemplary
embodiment of the disclosure.
[0012] Fig. 3 is a schematic plan view of an arrangement of the containers
of Fig. 2 according to the
first exemplary embodiment of the disclosure.
[0013] Fig. 4 is a plan view of a partially-formed carton according to the
first exemplary embodiment
of the disclosure.
[0014] Fig. 5 is a perspective view of the carton formed from the blank of
Fig. 1 in an open
configuration according to the first exemplary embodiment of the disclosure.
[0015] Fig. 6 is a perspective top view of the carton of Fig. 5 in the open
configuration.
[0016] Figs. 7 and 8 are elevation views of the carton of Fig. 5 in the
open configuration.
[0017] Fig. 9 is a perspective view of the cart of Fig. 5 in a closed
configuration according to the
first exemplary embodiment of the disclosure.
[0018] Fig. 10 is a plan view of a blank used to form a carton according to
a second exemplary
embodiment of the disclosure.
[0019] Fig. 11 is a detail view of a gusset of the blank of Fig. 10.
[0020] Fig. 12 is a detail view of a carton formed from the blank of Fig.
10 showing the formed
gusset of Fig. 11 according to the second exemplary embodiment of the
disclosure.
[0021] Fig. 13 is a plan view of a blank used to form a carton according to
a third exemplary
embodiment of the disclosure.
[0022] Corresponding parts are designated by corresponding reference
numbers throughout the
drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0023] The present disclosure generally relates to cartons that contain
articles such as containers,
bottles, cans, etc. The articles can be used for packaging food and beverage
products, for
example. The articles can be made from materials suitable in composition for
packaging the
particular food or beverage item, and the materials include, but are not
limited to, aluminum
and/or other metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS,
PVC, EVOH,
and Nylon; and the like, or any combination thereof.
3
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0024]
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 the carton embodiments. In this specification, the terms
"inner," "interior,"
"outer," "exterior," "lower," "bottom," "upper," and "top" indicate
orientations determined in
relation to fully erected and upright cartons.
[0025] Fig.
1 is a plan view of the exterior side 1 of a blank, generally indicated at 3,
used to form a
carton 5 (Figs. 5-9) 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 (Figs. 2 and
3). In one
embodiment, the containers are bottles having a wide bottom portion BP and a
narrow top or neck
N. In the illustrated embodiment, the carton 5 is sized to house twelve
containers C in a single
layer in a 3x4 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., 1x6, 2x6, 4x6, 3x8, 2x6x2, 3x4x2, 2x9, 3x6, etc.), or just
a single article. In
one embodiment, the carton 5 includes handle features, generally indicated at
11, for forming a
handle 12 (Fig. 9) for grasping and carrying the carton. In the illustrated
embodiment, the carton
is configurable between an open or top-loading configuration 101 (Figs. 5-8)
and a closed
configuration 102 (Fig. 9).
[0026] The
blank 3 has a longitudinal axis Li extending generally in the direction of the
length of the
blank and a lateral axis L2 extending generally in the direction of the width
of the blank. The
blank 3 includes a first side panel 23 foldably connected to a first end panel
25 at a lateral fold
line 27. A second side panel 31 is foldably connected to the first end panel
25 at a lateral fold line
33. A second end panel 37 is foldably connected to second side panel 31 at a
lateral fold line 39.
An attachment panel 41 is foldably connected to the first side panel 23 at a
lateral fold line 43.
Alternatively, the attachment panel 41 could be foldably connected to the
second end panel 37. In
the illustrated embodiment, the lateral fold lines 27, 33, 39, 43 extend
generally in the lateral
direction L2; however, as described in more detail below, one or more of the
lateral fold lines 27,
33, 39, 43 can be at least partially oblique with respect to the lateral
direction L2.
[0027] As
shown in Figs. 1, 1A, and 1B, the first side panel 23 is further foldably
connected to the
first end panel 25 by a first gusset 45, the first end panel 25 is further
foldably connected to the
second side panel 31 by a second gusset 47, the second side panel 31 is
further foldably connected
to the second end panel 37 by a third gusset 49, and the attachment panel 41
is further foldably
connected to the first side panel 23 by a fourth gusset 51. In the illustrated
embodiment, each of
the gussets 45, 47, 49, 51 can include a first gusset panel 53 foldably
connected to a second gusset
panel 55 along a first gusset fold line 57, which can be generally collinear
with a respective one of
4
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
the lateral fold lines 27, 33, 39, 43. In one embodiment, each of the first
gusset panels 53 can be
foldably connected to one of the first side panel 23 and the second side panel
31 along a second
gusset fold line 59, and each of the second gusset panels 55 can be foldably
connected to one of
the first end panel 25, the second end panel 37, and the attachment panel 41
along a third gusset
fold line 61. In the illustrated embodiment, the second gusset fold lines 59
and the third gusset
fold lines 61 are oblique with respect to the first gusset fold lines 57. In
an exemplary
embodiment, the second gusset fold lines 59 and the third gusset fold lines 61
can be cut-crease
style fold lines and the first gusset fold lines 57 can include spaced
perforations or cuts so that the
first gusset fold lines 57 are weakened with respect to the second gusset fold
lines 59 and the third
gusset fold lines 61. In one embodiment, the weakened first gusset fold lines
57 can be used as
tear lines as described in more detail below.
[0028] As
shown in Figs. 1, 1A, and 1B, the gussets 45, 49, 51 can include respective
gusset
openings 131 defined by edges of the gusset panels 53, 55 and the respectively
adjacent panels 23,
25, 41, 37, 41. In addition, the gusset 47 can include a gusset opening 121
defined by the edges
of the gusset panels 53, 55 of the gusset 47 and the panels 25, 31. The gusset
opening 121 can be
similar to the gusset openings 131 but is enlarged in the illustrated
embodiment to cooperate with
the dispenser features as described in more detail below. In an alternative
embodiment, the gusset
opening 121 can be similar or identical to the gusset openings 131 (e.g., if
the dispenser features
are omitted). In the illustrated embodiment, the gusset panels 53, 55 extend
from the gusset
openings 121, 131 to a top edge 132 of the respective gussets at a top
marginal area of the blank 3
and the gusset panels 53, 55 are spaced apart from the respective lateral fold
lines 27, 33, 39, 43
by the gusset openings 121, 131. The gussets 45, 47, 49, 51 could be otherwise
shaped, arranged,
positioned, and/or configured without departing from the disclosure. For
example, the gusset fold
lines 57, 59, 61 could be any suitable type of fold, score, cut, or crease.
[0029] As
shown in Fig. 1, the first side panel 23 is foldably connected to a first side
top flap 65 and
a first side bottom flap 67. The first end panel 25 is foldably connected to a
first end top flap 69
and a first end bottom flap 71. The second side panel 31 is foldably connected
to a second side
top flap 73 and a second side bottom flap 75. The second end panel 37 is
foldably connected to a
second end top flap 77 and a second end bottom flap 79. When the carton 5 is
erected, the top
flaps 65, 69, 73, 77 close a first (e.g., top) end 81 of the carton (Fig. 9),
and the bottom flaps 67,
71, 75, 79 close a second (e.g., bottom) end 83 of the carton (Figs. 5-9). In
accordance with an
alternative embodiment of the present disclosure, different panel and flap
arrangements can be
used for at least partially closing the ends 81, 83 of the carton 5.
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0030] The
top flaps 65, 69, 73, 77 of the top end 81 extend along a first (e.g., top)
marginal area 80
of the blank 3, and are foldably connected at a first longitudinal fold line
85 that extends along the
length of the blank. The bottom flaps 67, 71, 75, 79 of the bottom end 83
extend along a second
(e.g., bottom) marginal area 82 of the blank 3, and are foldably connected at
a second longitudinal
fold line 87 that extends along the length of the blank. The longitudinal fold
lines 85, 87 may be,
for example, substantially straight, or offset at one or more locations to
account for blank
thickness or for other factors. For example, the first longitudinal fold line
85 can be interrupted
by the gussets 45, 47, 49 as shown in Fig. 1. In one embodiment, the top
marginal area 80 and the
bottom marginal area 82 can form the respective top end 81 and bottom end 83
when the carton 5
is formed. The flaps 65, 67, 69, 71, 73, 75, 77, 79 could be otherwise shaped,
arranged,
positioned, and/or configured without departing from the disclosure.
[0031] In
the illustrated embodiment, the second longitudinal fold line 87 can extend
generally in the
longitudinal direction Li; however, as shown in Fig. 1, each segment 87a, 87b,
87c, 87d of the
longitudinal fold line 87 can extend at least partially downwardly (e.g.,
slightly downwardly)
from the respective lateral fold lines 27, 33, 39, 43. For example, the
segment 87a and the first
lateral fold line 27 can extend at an angle Al and the segment 87b and the
first lateral fold line 27
can extend at an angle A2, wherein the angles Al and A2 are greater than 90
degrees. In one
exemplary embodiment, the angle Al is approximately 90.45 degrees and the
angle A2 is
approximately 90.23 degrees. The lateral fold lines 33, 39, 43 can be
similarly or identically
configured with respect to the segments 87b, 87c, 87d, 87a. This configuration
of the lateral fold
lines 27, 33, 39, 43 and the longitudinal fold line 87 can result in the
carton 5 being wider at its
top than at its bottom in the top-loading configuration 101. For example, the
blank 3 can have a
first bottom dimension D 1 a at its bottom (e.g., along the bottom marginal
area 82 of the blank 3)
and a first top dimension D lb at its top (e.g., along the top marginal area
80 of the blank 3),
wherein the first top dimension D lb is greater than the first bottom
dimension D la. In one
embodiment, the first bottom dimension Dla can be the spacing between the
bottom ends of the
lateral fold lines 27, 43 or the length of the segment 87a of the longitudinal
fold line 87, and the
first top dimension D lb can be the spacing between the first gusset fold
lines 57 of the gussets 45,
51. Similarly, the blank 3 can have a second bottom dimension D2a at its
bottom (e.g., along the
bottom marginal area 82 of the blank 3) and a second top dimension D2b at its
top (e.g., along the
top marginal area 80 of the blank 3), wherein the second top dimension D2b is
greater than the
second bottom dimension D2a. In one embodiment, the second bottom dimension Dl
a can be the
spacing between the bottom ends of the lateral fold lines 27, 33 or the length
of the segment 87b
of the longitudinal fold line 87, and the second top dimension D2b can be the
spacing between the
first gusset fold lines 57 of the gussets 45, 47. In one exemplary embodiment,
the first bottom
dimension D 1 a can be approximately 276.00 millimeters, the first top
dimension D lb can be
6
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
approximately 280.00 millimeters, the second bottom dimension D2a can be
approximately
207.00 millimeters, and the second top dimension D2b can be approximately
209.00 millimeters.
The blank 3 can have similar dimensions corresponding to the second side panel
31 and the
second end panel 37 that can be similarly or identically configured to the
dimensions associated
with the respective first side panel 23 and first end panel 25. Any of the
panels 23, 25, 31, 37, 41
and/or the fold lines 27, 33, 39, 43, 85, 87 could be otherwise shaped,
arranged, positioned, and/or
configured without departing from the disclosure.
[0032] As
shown in Fig. 1, the blank 3 can include dispenser features 117 for forming a
dispenser in
the carton 5. In the illustrated embodiment, the dispenser features 117 can
include a tear strip 119
(e.g., in at least the second side panel 31) and the gusset opening 121 of the
gusset 47 can act as
an access feature at one end of the tear strip 119. In one embodiment, the
gusset opening 121
acting as the access feature can facilitate initial tearing of the tear strip
119. In the illustrated
embodiment, the dispenser features 117 further can include at least a portion
of the first gusset
fold lines 57 of one or more of the gussets 45, 47, 49, 51, wherein one or
more of the first gusset
fold lines 57 can be in the form of a perforated tear line. The dispenser
features 117 could be
omitted or could be otherwise shaped, arranged, positioned, and configured
without departing
from the disclosure. For example, the dispenser features could include
additional tear lines and/or
break-away glue features for further forming the dispenser opening.
[0033] As
shown in Fig. 1, the blank 3 can include a window 123 for viewing the
containers C in the
interior of the carton 5. In an exemplary embodiment, the window 123 can
include an aperture in
the second side panel 31. In one embodiment, the window 123 could remain open
or could be at
least partially covered by a transparent or translucent material (not shown).
The window could be
otherwise shaped, arranged, positioned, and configured without departing from
the disclosure.
[0034] As
shown in Fig. 1, the blank 3 can also include an intermediate longitudinal
fold line 133
extending across the first side panel 23 and the end panels 25, 37. The fold
line 133 can have
portions that are angled with respect to one another similarly to the fold
line 87, as described in
more detail above. The fold line 133 could be omitted or could be otherwise
shaped, arranged,
positioned, and configured without departing from the disclosure. For example,
the fold line 133
could also extend across the second side panel 31 (e.g., adjacent the
dispenser feature 117 or in
the case that the dispenser features 117 are omitted).
[0035] As
shown in Figs. 1 and 1A, the handle features 11 that form the handle 12 can
include an
inner handle panel 135a at least partially defined by cut or tear lines 137a
extending to an edge of
the first side top flap 65 and extending across the fold line 85 and into the
first side panel 23.
Curved cuts at the ends of the tear lines 137a in the first side panel 23 can
act as tear stops to help
7
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
prevent unwanted tearing of the first side panel 23 when the carton 5 is
grasped at the handle 12.
In the illustrated embodiment, inner comfort flaps 139a can be foldably
connected to the inner
handle panel 135a along fold lines 141a and inner tabs 143a can be foldably
connected to the first
side top flap 65 along fold lines 145a. In one embodiment, the fold lines 141a
can include spaced
cuts and a crease at one end and the fold lines 145a can include spaced cuts
as shown in Figs. 1
and 1A. The inner comfort flaps 139a can be separable from the first side top
flap 65 and the
inner tabs 143a along a cut or tear line 147a and the inner tabs 143a can be
separable from the
first side top flap 65 along tear or cut lines 149a, which can include curved
tear stops as shown in
Figs. 1 and 1A. In the illustrated embodiment, the handle features 11 further
can include
openings 151 on either side of the inner handle panel 135a and adjacent the
inner comfort flaps
139a and inner tabs 143a.
[0036] As
shown in Figs, 1 and 1B, the handle features 11 also can include an outer
handle panel
135b at least partially defined by cut or tear lines 137b extending to an edge
of the second side top
flap 73 and extending across the fold line 85 and into the second side panel
31. Curved cuts at the
ends of the tear lines 137b in the second side panel 31 can act as tear stops
to help prevent
unwanted tearing of the second side panel 31 when the carton 5 is grasped at
the handle 12. In the
illustrated embodiment, outer comfort flaps 139b can be foldably connected to
the outer handle
panel 135b along fold lines 14 lb and outer tabs 143b can be foldably
connected to the second side
top flap 73 along fold lines 145b. In one embodiment, the fold lines 14 lb can
be cut-crease style
fold lines and the fold lines 145b can include spaced cuts as shown in Figs. 1
and 1B. The outer
comfort flaps 139b can be separable from the second side top flap 73 and the
outer tabs 143b
along a cut or tear line 147b and the outer tabs 143b can be separable from
the second side top
flap 73 along tear or cut lines 149b, which can include curved tear stops as
shown in Figs. 1 and
1B. In the illustrated embodiment, each of the outer comfort flaps 139b can
include an enlarged
portion 153 at least partially defined by a curved (e.g., arc-shaped) portion
of the tear line 147b.
Any of the handle features 11 could be omitted or could be otherwise shaped,
arranged,
positioned, and configured without departing from the disclosure.
[0037] In
accordance with the exemplary embodiment, the blank 3 can be erected into the
carton 5 by
folding the blank 3 along fold lines 27, 33, 39, and 43 and overlapping the
attachment panel 41
with the second end panel 37. In one embodiment, the second end panel 37 can
have a cutout or
edge configured to extend along the third gusset fold line 61 of the gusset 51
at the attachment
panel 41. As shown in Fig. 4, the blank 3 can be folded along fold lines 27,
39 and along the fold
lines 57 of the gussets 45, 49 so that the first side panel 23 is in an
overlapping relationship with
at least a portion of the first end panel 25 and the second side panel 31 and
the second end panel
37 is in an overlapping relationship with at least a portion of the second
side panel 31 and the
8
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
attachment panel 41, which can be glued to the second end panel 37 to form an
open-ended
sleeve. The open-ended sleeve can be folded along the fold lines 27, 33, 39,
43 to move the side
panels 23, 31 to be disposed opposite one another and the end panels 25, 37 to
be disposed
opposite one another, and the bottom end 83 of the carton 5 can be closed by
respectively
overlapping and adhering the bottom flaps 67, 71, 75, 79 (Figs. 5, 6, and 9).
The carton 5 having
a closed bottom 83 and open top 81 is in the top-loading configuration 101
according to one
embodiment (e.g., Fig. 5-8).
[0038] In
the top-loading configuration, the carton 5 can be ready to receive an
arrangement 103 of
the containers C (Fig. 3). As shown in Fig. 3, the arrangement 103 can have a
first dimension X
and a second dimension Y, wherein the dimension X is generally equal to the
width (e.g.,
diameter) W of the containers C times the number of rows of containers and the
dimension Y is
generally equal to the width W times the number of columns of containers.
[0039] In
one embodiment, the carton 5 can be at least partially tapered at the side
panels 23, 31 and
end panels 25, 37 so that the carton 5 is wider at the top end 81 than at the
bottom end 83 in the
top-loading configuration 101. Accordingly, the top flaps 65, 69, 73, 77 can
be spaced outwardly
at the top end 81 of the carton, generally out of the way of the loading of
the containers C. In the
illustrated embodiment, the first bottom dimension D la of the blank 3
corresponds to a first
bottom width D la (Fig. 7) of the carton 5 and the first top dimension D lb of
the blank 3
corresponds to a first open width D lb (Fig. 7) of the carton 5 in the top-
loading configuration
101. Similarly, the second bottom dimension D2a of the blank 3 corresponds to
a second bottom
width D2a (Fig. 8) of the carton 5 and the second top dimension D2b of the
blank 3 corresponds
to a second open width D2b (Fig. 8) of the carton 5 in the top-loading
configuration 101. In one
embodiment, the second open width D2b of the carton 5 includes the first end
panel 25 and its
adjoining gusset panels 55 of the gussets 45, 47 and, on the opposing side of
the carton 5, the
second open width D2b includes the second end panel 37, the adjoining gusset
panel 55 of the
gusset 49 and the gusset panel 55 of the gusset 51 when the attachment panel
41 is adhered in
face-to-face contact with the second end panel 37 so that the second open
width D2b is the same
at both end panels 25, 37. As shown in the figures, the first widths D la, D
lb of the carton 5 are
longer than the respective second widths D2a, D2b and the first widths D 1 a,
D lb are
perpendicular to the second widths D2a, D2b. The widths D la, D2a, D lb, D2b
could be
otherwise configured without departing from the disclosure. For example, the
carton 5 could be
configured so that the first widths D 1 a, D lb are equal to the respective
second widths D2a, D2b
or the second widths are longer than the respective first widths, for example.
9
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0040] In
one embodiment, the first bottom width Dla can be less than the dimension X
and the first
open width D lb can be approximately equal to the dimension X in the top-
loading configuration
101. Similarly, the second bottom width D2a can be less than the dimension Y
and the second
open width D2b can be approximately equal to the dimension Y in the top-
loading configuration
101. Accordingly, the side panels 23, 31 can be spaced apart by less than the
dimension Y (e.g.,
by the second bottom width D2a) at the bottom end 83 of the carton 5 and the
end panels 25, 37
can be spaced apart by less than the dimension X (e.g., by the first bottom
width D 1 a) at the
bottom end 83. Additionally, the side panels 23, 31 can be spaced apart by
approximately the
dimension Y (e.g., by the second open width D2b) at the top end 81 and the end
panels 25, 37 can
be spaced apart by approximately the dimension X (e.g., by the first open
width D lb) at the top
end 81 in the top-loading configuration 101.
[0041] As
the arrangement 103 of containers C is loaded into the carton 5, the
arrangement 103 can
move past the first longitudinal fold line 85 where the first open width D lb
and second open
width D2b of the carton 5 are approximately the same as the respective length
X and width Y of
the arrangement 103 in the top-loading configuration 101 so that the
containers easily move into
the interior 105 of the carton 5. As the arrangement 103 continues to move
into the interior 105
towards the bottom 83, the side panels 23, 31 and the end panels 25, 37 taper
inwardly (e.g.,
according to the angles Al, A2 of the lateral fold lines 27, 33, 39, 43 with
respect to the second
longitudinal fold line 87) until the containers C engage the bottom 83 of the
carton 5. The
dimensions of the carton at the bottom 83 are smaller than the dimensions of
the arrangement 103
(e.g., the first bottom widths D la and the second bottom width D2a are
smaller than the
respective dimensions X, Y) so that the carton fits tightly around the
arrangement 103. This
configuration can help retain the containers C in the carton 5 and can help
limit or eliminate
movement of the containers C in the carton, wherein movement could otherwise
result in rattling
and/or breaking of the containers. The tight fit of the carton at its bottom
can also help avoid
reorientation (e.g., turning) of the containers in the carton (e.g., the
containers can be orientated so
that the labels are facing a particular direction in the container, such as to
be visible through the
window 123 in the carton). The containers C could be otherwise loaded into the
carton 5 without
departing from the disclosure.
[0042] After
the containers C are loaded into the carton 5, the gussets 45, 47, 49, 51 can
be folded
along the first gusset fold lines 57 so that the gusset panels 53, 55 of each
gusset are positioned at
least partially in face-to-face contact. Further, the gussets 45, 47, 49, 51
can be folded along the
second gusset fold line 59 or the third gusset fold line 61 against the
adjacent side panel 23, 41 or
the adjacent end panel 25, 37 or attachment panel 41. In one embodiment, the
gusset panels 53,
55 can be glued together, the gusset panels 53 can be glued to the side panels
23, 31, and/or the
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
gusset panels 55 can be glued to the end panels 25, 31 or the attachment panel
41 in each of the
gussets. The top 81 of the carton can be closed by respectively overlapping
and adhering the top
flaps 65, 67, 73, 77. In one embodiment, the top 81 can be closed and the
gussets 45, 47, 49, 51
can be folded at the same time or in any suitable sequence. The carton 5 is
shown in the closed
configuration 102 having folded gussets and a closed top in Fig. 9. The carton
5 could be
otherwise formed and/or closed without departing from the disclosure.
[0043] Once
the gussets 45, 47, 49, 51 are folded, the side panels 23, 31 and the end
panels 25, 37
can extend generally vertically from the bottom 83 to a point that is
generally aligned with the
shoulders S of the containers (Fig. 2) (e.g., proximate to the lowermost ends
of the gussets 45, 47,
49, 51 and/or along the fold line 133). As shown in Fig. 9, the top wall
formed by the top flaps
65, 69, 73, 77 can be smaller than the bottom wall formed from the bottom
flaps 67, 71, 75, 79
and the upper portion of the carton 5 can be tapered inwardly from the
shoulders S and/or the fold
line 133 to the top wall to fit more tightly around the narrower tops N of the
containers C.
Accordingly, in the closed configuration 102 of the carton 5, the panels 23,
25, 31, 37 are
positioned so that the top end 81 has a first closed width Dlc and a second
closed width D2c (Fig.
9). In one embodiment, the first closed width D lc is less than the first open
width D lb and the
second closed width D2c is less than the second open width D2b. In addition,
as shown in Fig. 9,
the first closed width Dlc is less than the first bottom width D la and the
second closed width D2c
is less than the second bottom width D2a due to the inwardly-tapering upper
portions of the
panels. As shown in Fig. 9, the closed widths D 1 c, D2c are perpendicular to
one another in one
embodiment. The closed widths Dl c, D2c of the top end 81 could be otherwise
configured
without departing from the disclosure. In one embodiment the bottom widths D
la, D2a of the
carton 5 can remain the same (e.g., substantially or approximately the same)
when the carton is in
the top-loading configuration 101 and in the closed configuration 102.
Alternatively, the bottom
widths could change when the carton is closed.
[0044] In
one embodiment, the fold line 133 can be at least partially aligned with the
shoulders S of
the containers C (Fig. 2) so that the fold line 133 forms shoulder creases in
each of the first side
panel 23 and end panels 25, 37 that can allow the upper portions of the panels
23, 25, 37 to fold
inwardly with respect to the lower portions of the respective panels adjacent
the shoulders S of the
containers C (Fig. 9). In one embodiment, the upper portion of the second side
panel 31 can also
fold inwardly with respect to its lower portion similarly to panels 23, 25, 37
even though the fold
line 133 does not extend across the second side panel 31 in the blank 3
illustrated in Fig. 1. The
inwardly-tapering upper portion of the carton 5 can help to retain or more
tightly pack the narrow
top portions N of the containers in the carton and the fold line 133 can help
facilitate the folding
of the upper portions of the panels with respect to their lower portions.
11
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0045] In
one embodiment, portions of the carton 5 can flex and/or stretch around
portions of the
containers C. In one embodiment, at least the lateral fold lines 33, 43 can be
weakened fold lines
(e.g., can be cut-crease fold lines as shown in Fig. 1) to facilitate the
reshaping of the carton from
the top-loading configuration 103 with the wider top 81 (Fig. 4) to the fully
closed configuration
with the generally vertical lower portions of the sides and ends (Fig. 9). In
addition, in one
embodiment, the grain direction G can be configured to run generally in the
lateral L2 direction in
the blank (e.g., vertically in the sides and ends in the carton) to allow the
carton to bow outward
and give more space for product clearance (e.g., to flex around portions of
the containers C).
Further, in an exemplary embodiment, the grain direction G can facilitate the
top flaps 65, 69, 73,
77 to bend inwardly. In an alternative embodiment, one or more of the panels
23, 25, 31, 37 can
be generally vertical from the bottom 83 to the top 81 of the carton 5.
[0046] When
the top 81 of the carton 5 is closed, the second side top flap 73 can overlap
the first side
top flap 65 so that the handle features 11 (Figs. 1-7) form the handle 12
(Fig. 9). In the illustrated
embodiment, the outer handle panel 135b, the outer comfort flaps 139b, and the
outer tabs 143b
can at least partially overlap the respective inner handle panel 135a, inner
comfort flaps 139a, and
inner tabs 143a, and the enlarged portions 153 of the outer comfort flaps 139b
can be at least
partially aligned with the openings 151 in the first side top flap 65 so that
the openings 151 can
provide clearance for the enlarged portions 153 to fold inwardly when the
handle is actuated. In
one embodiment, at least the handle panels 135a, 135b can be glued together
and portions of the
side top flaps 65, 73 outside the handle features 11 can be glued together.
The handle 12 could be
otherwise formed without departing from the disclosure.
[0047] In
one embodiment, the handle 12 can be actuated so that one can grasp the handle
to carry
the carton 5 by pushing inwardly on one or both of the outer comfort flaps
139b and the outer tabs
143b on one or both sides of the outer handle panel 135b with the fingers of a
hand. The outer
comfort flaps 139b and the outer tabs 143b can push inwardly on the inner
comfort flaps 139a and
the inner tabs 143a so that the comfort flaps 139b, 139a and the tabs 143b,
143a at least partially
separate from one another and from the side top flaps 73, 65 and fold inwardly
along the fold
lines 139b, 139a, 145b, 145a. When the tabs 143b, 143a and the comfort flaps
139b, 139a are
folded inwardly, an enlarged opening is formed in the top flaps 73, 65 for the
hand to grasp the
handle panels 135b, 135a. After folding the comfort flaps and tabs inwardly,
the hand can grasp
the overlapped handle panels 135b, 135a on one or both sides of the handle
panels and pull
upwardly, at least partially separating the handle panels 135b, 135a from the
side top flaps 73, 65
and/or the side panels 31, 23 along the tear lines 137b, 137a while the handle
panels 135b, 135a
remain attached to at least the side panels 31, 23 so that the carton 5 can be
lifted and carried by
the handle 12. The handle 12 could be otherwise actuated without departing
from the disclosure.
12
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0048] In
one embodiment, the dispenser features 117 can be actuated in the carton 5 to
form a
dispenser opening (not shown) in the carton 5 by tearing the tear strip 119
from the access feature
of the gusset opening 121 across the second side panel 31. The dispenser
features 117 can be
further actuated by pulling upwardly on the dispenser to tear along the
weakened first gusset fold
lines 57 of one or more of the gussets 45, 47, 49, 51. The dispenser features
117 could be
otherwise actuated without departing from the disclosure.
[0049] The
carton 5 could be otherwise shaped, arranged, positioned, and/or configured
without
departing from the disclosure.
[0050] Fig.
10 is a plan view of an exterior surface 201 of a blank 203 for forming a
carton 205 (Fig.
12) according to a second embodiment of the disclosure. The second embodiment
is generally
similar to the first embodiment, except for variations noted and variations
that will be apparent to
one of ordinary skill in the art. Accordingly, similar or identical features
of the embodiments
have been given like or similar reference numbers. As shown in Figs. 10 and
11, the blank 203
can include a gusset 245 with a one-way fold feature 311. In one embodiment,
the one-way fold
feature can include a tab 313 that can interrupt the first gusset fold line
258 of the gusset 245. In
the illustrated embodiment, the tab 313 can be at least partially defined by a
cut 315, which can
have a generally vertical portion and curved or angled ends. As shown in Figs.
10 and 11, the tab
313 extends from the first gusset panel 53 and is separable from the second
gusset panel 55 along
the cut 315. In one embodiment, the tab 313 can be configured to resist
outward folding of the
gusset 245 at the first gusset fold line 258 while allowing the gusset 245 to
fold inwardly as
shown in Fig. 12. Accordingly, the one-way fold feature 311 can help avoid
undesirable outward
folding of the gusset. The gusset 245 could be otherwise shaped, arranged,
positioned, and
configured without departing from the disclosure. Further, any of the gussets
247, 249, 251 could
include a one-way fold feature similar or identical to the gusset 245.
[0051] As
shown in Figs. 10 and 11, the gussets 245, 249, 251 can include a curved fold
line or tear
line 263 extending from the bottom ends of the gusset fold lines 59, 61 so
that the first gusset
panels 53 are foldably connected to the side panels 223, 231 at the curved
lines 263 and the
second gusset panels 55 are foldably connected to the end panels 225, 237 at
the curved lines 263.
In an alternative embodiment, the gusset opening 121 can be omitted in the
gusset 47 and the
gusset 47 can include a curved line 263 extending from the ends of the 59, 61
(e.g., in an
embodiment wherein the dispenser features 117 are omitted).
13
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0052] In
one embodiment, the handle features 211 of the blank 203 can include two
handle flaps
289 foldably connected to a handle grip portion 291 of the top side flap 273
along respective fold
lines 293. The handle flaps 289 can be at least partially separable from the
side top flap 273 along
a respective cut or tear line 295. The handle features 211 further can include
two handle openings
297 in the side top flap 265 extending on either side of a handle grip portion
299 of the side top
flap 265 and two inner handle flaps 325 foldably connected to the handle grip
portion 299 of the
side top flap 265 adjacent the handle openings 297 along fold lines 327. When
the handle (not
shown) is formed from the handle features 211 in the carton 205 (e.g., when
the top flaps 265, 273
are overlapped to at least partially close the top end of the carton 205), the
handle grip portions
291, 299 can be overlapped, the handle flaps 289 can at least partially
overlap the inner handle
flaps 325, and the handle flaps 289 can be generally aligned with the
respective handle openings
297. Accordingly, the handle formed from the handle features 211 can be
grasped by folding the
handle flaps 289, 325 inwardly and gripping the handle grip portions 291, 299.
The handle
features 211 could be omitted or could be otherwise shaped, arranged,
positioned, and configured
without departing from the disclosure.
[0053] The
blank 203 and the carton 205 could be otherwise shaped, arranged, positioned,
and/or
configured without departing from the disclosure.
[0054] Fig.
13 is a plan view of an exterior surface 401 of a blank 403 for forming a
carton (not
shown) according to a third embodiment of the disclosure. The third embodiment
is generally
similar to the prior embodiments, except for variations noted and variations
that will be apparent
to one of ordinary skill in the art. Accordingly, similar or identical
features of the embodiments
have been given like or similar reference numbers. As shown in Fig. 13, the
dispenser features
117 and the window 123 are omitted in the second side panel 431 of the blank
403. In the
illustrated embodiment, the blank 403 can include gussets 445, 447, 449, 451,
wherein the second
gusset fold line 59 and the third gusset fold line 61 in each gusset 445, 447,
449, 451 can be
connected at their lower ends by a respective curved cut 463 so that the
second gusset fold line 59,
the third gusset fold line 61, and the cut 463 generally form a U- or V-shaped
fold. In the
illustrated embodiment, each of the gusset fold lines 57, 59, 61 can be a cut-
crease fold line. The
gussets 445, 247, 449, 451 could be omitted or could be otherwise shaped,
arranged, positioned,
and configured without departing from the disclosure.
[0055] In
the illustrated embodiment, the handle features 411 of the blank 403 can
include two
handle flaps 489 foldably connected to a handle grip portion 491 of the top
side flap 273 along
respective fold lines 493. The handle flaps 489 can be at least partially
separable from the side
top flap 273 along a respective cut or tear line 495. The handle features 411
further can include
two handle openings 497 in the side top flap 265 extending on either side of a
handle grip portion
14
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
499 of the side top flap 265. When the handle (not shown) is formed from the
handle features 411
(e.g., when the top flaps 265, 273 are overlapped to at least partially close
the top end of the
carton), the handle grip portions 491, 499 can be overlapped and the handle
flaps 489 can be
generally aligned with the respective handle openings 497. Accordingly, the
handle formed from
the handle features 411 can be grasped by folding the handle flaps 489
inwardly through the
handle openings 497 and gripping the handle grip portions 491, 499. The handle
features 411
could be otherwise shaped, arranged, positioned, and/or configured without
departing from the
disclosure.
[0056] The
blank 403 could be otherwise shaped, arranged, positioned, and/or configured
without
departing from the disclosure.
[0057] Any
of the features of the various embodiments of the disclosure can be combined
with,
replaced by, or otherwise configured with other features of other embodiments
of the disclosure
without departing from the scope of this disclosure.
[0058] 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. 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.
[0059] 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.
CA 03105551 2020-12-30
WO 2020/018756
PCT/US2019/042350
[0060] 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.
[0061] 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.
[0062] 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 that are within the
scope of the claims.
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.
16
