Abstract:
A carton for holding containers can be converted from a first configuration for storing and shipping the containers therein to a second configuration in which the carton forms an open-top cooler for chilling and serving the containers. A beverage container cooling carton is dimensioned for increased ice surface contact with the outer surfaces of a number of the beverage containers such that heat transfer between the ice and beverage containers occurs efficiently.

Description:
[0001]    This claims the benefit of U.S. Provisional Patent Application Ser. No. 62/259,694, filed Nov. 25, 2015 and hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates to a carton and a blank for forming the carton for containing a number of articles, and in particular, to a carton, the capacity of which can be increased to accommodate additional items and provide access to the articles in the carton. 
         [0003]    Cartons for encasing multiple articles are useful for enabling consumers to obtain and transport a desired quantity of individual articles such as soft drinks or other beverages. 
         [0004]    It is often desirable to serve a large quantity of containers, such as beverage and foodstuff containers, in a chilled condition. It may be desirable or necessary to chill such containers at locations or events for which there is little or no access to refrigerators or freezers, or at events for which it is not desirable to use refrigerators or freezers. For example, a large quantity of beverage and foodstuff containers may be served at parties, cookouts, picnics or vacation spots where it is desired to chill the containers for an extended period of time. In such cases, it is customary to place the containers in a cooler containing ice, which often requires the containers to be removed from their original packaging. In some cases, it would be advantageous to be able to chill containers in their original packaging without having to provide a separate cooler. Such cartons need to be strong enough to support multiple articles. It is also desirable for such cartons to be easy to handle and portable. It is also useful for the consumer to be able to add ice-cubes into such a carton to cool the beverage cans or bottles contained within the carton. It is also often desirable for the cartons to be adaptable so that the capacity of the carton can be increased to accommodate the addition of ice-cubes. 
         [0005]    Such cartons are known in the art, but each has certain drawbacks. Many such cartons do not provide a means for increasing the capacity of the carton to accommodate the addition of ice cubes and so the carton is limited in the number of ice cubes which it can receive and the degree to which the containers in the carton are adequately chilled. 
         [0006]    A carton having additional side and end panels which can be unfolded to provide additional capacity to the carton is known, but many such cartons require a considerable quantity of material to form the carton. 
         [0007]    The prior art devices suffer from several drawbacks. The prior art devices do not allow incorporation of refrigeration elements into a standard paperboard beverage carton. Moreover, the prior art devices fail to effectively maximize the contact areas between the beverage containers and chilling elements, which enhances the cooling function provided by such chilling elements. These and other drawbacks of the prior art are overcome by this invention. 
         [0008]    In view of the above, it is desirable to provide a carton that is convertible from a first configuration for holding containers during storage and/or transport to a second configuration in which the carton forms a cooler configured to receive ice for chilling and serving the containers while minimizing the amount of material required to form the carton. 
       SUMMARY OF THE INVENTION 
       [0009]    One aspect of this invention is a carton for holding a number of containers. In one example, the carton has a number of panels extending at least partially around an interior of the carton. The panels can include a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, and an expansion mechanism. Opposite ends of the side panels may be respectively foldably connected to gusset folds that are mounted to end flaps extending from the bottom panel. An access feature for providing access to the interior of the carton (e.g., a dispenser) may extend in at least the top panel. 
         [0010]    The bottom panel, first and second side panels and a top panel may together extend at least partially around an interior of the carton. The gusset folds, optionally in conjunction with expansion panels, may provide expandable connections between the top panel and the side panels. The expandable connections may be spaced apart from one another, and the expandable connections may be expandable so that the side panels are moved outwardly relative to the top panel, from an inner configuration to an outer configuration, to at least partially define an upwardly open space for being open to the interior by way of the dispenser. 
         [0011]    Each of the gusset folds may include one or more pleats. In one specific example, each expandable connection includes a gusset flap connected to one of the panels, an intermediate flap and a gusset flap connected to the bottom end flap. 
         [0012]    The foregoing presents a simplified summary of some aspects of this invention to provide a basic understanding. The foregoing summary is not extensive and is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. The purpose of the foregoing summary is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later and other aspects will become apparent from the following. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
           [0014]      FIG. 1  is a top plan view of a blank used to form a carton according to a first embodiment of this invention; 
           [0015]      FIG. 2A  is an enlarged view of the gusset flaps joining a side panel to a bottom panel end flap being folded to erect a carton from the blank of  FIG. 1 ; 
           [0016]      FIG. 2B  is a view of the blank of  FIG. 1  being folded and erected into the carton; 
           [0017]      FIG. 3A  is an enlarged view of expansion panels connecting a top panel flap to a side panel of the carton blank of  FIG. 1 ; 
           [0018]      FIG. 3B  is a view similar to  FIG. 2B  with the expansion panels folded as shown in  FIG. 3A ; 
           [0019]      FIG. 4A  is an enlarged view of one of the top panels being folded inwardly to form the carton blank into a tubular configuration; 
           [0020]      FIG. 4B  is a view of the carton formed from the blank of  FIG. 1  with beverage containers being inserted into an open end of the carton; 
           [0021]      FIG. 5  is a perspective view of the carton of  FIG. 4B  being expanded into an expanded configuration by expanding the expansion panels along each side of the carton; 
           [0022]      FIG. 6  is a view of the carton of  FIG. 5  with a dispenser panel being removed from the carton; 
           [0023]      FIG. 7  is a view of the carton of  FIG. 6  with the dispenser panel removed and ice added to the carton for chilling the beverage containers therein; 
           [0024]      FIG. 8  is a top plan view of a second embodiment of a blank used to form a carton according to this invention; 
           [0025]      FIG. 9  is a perspective view of a carton erected from the carton blank of  FIG. 8  with a dispenser finger flap being depressed to initiate removal of a dispenser panel; 
           [0026]      FIG. 10  is a view similar to  FIG. 9  with the dispenser panel of the carton being removed from the carton; 
           [0027]      FIG. 11  is a perspective view of the carton of  FIG. 10  in an expanded configuration with ice added to the carton for chilling the beverage containers therein; 
           [0028]      FIG. 12  is a top plan view of a third embodiment of a blank used to form a carton according to this invention; 
           [0029]      FIG. 13  is a perspective view of a carton erected and filled utilizing the carton blank of  FIG. 12  with the dispenser flaps being torn from the carton; 
           [0030]      FIG. 14  is a view similar to  FIG. 13  with a dispenser panel of the carton being removed to expose the beverage containers therein; and 
           [0031]      FIG. 15  is a view of the carton of  FIGS. 13 and 14  in an expanded configuration with ice added to the carton for chilling the beverage containers therein. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    Exemplary embodiments of this invention are described below and shown in the accompanying drawings, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of this invention. 
         [0033]    This invention generally relates to opening, dispensing, and cooling features for 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, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof. 
         [0034]    Cartons according to this invention can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the invention, the following detailed description describes beverage containers (e.g., aluminum beverage cans) as disposed within the carton embodiments. 
         [0035]    The carton can be used to house a number of articles such as containers C (shown by way of example in  FIGS. 6, 7, 10, 11 and 13-15 ). In the embodiments shown in the drawings, the containers C are generally-cylindrical cans, and the carton is sized to house twenty-four containers C in a single layer in a 4×6 arrangement. However, the carton may be sized and shaped to hold containers C of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 3×8, 3×6, 2×6, 2×6×2, 3×4, 2×9, 4×3×2, etc.). The containers C could be otherwise shaped, arranged, and/or configured without departing from the invention. For example, the containers C could be beverage bottles or other containers. 
         [0036]    Referring to  FIGS. 1, 8 and 12  in which first, second and third embodiments, respectively, of a carton blank  10  according to this invention are shown. The carton blanks  10  are used to form a carton  12  as shown in subsequent drawings and intended to contain a number of beverage containers C. Moreover, the carton  12  formed from the carton blank  10  according to various embodiments of this invention may be transformed from a first storage and travel configuration to an expanded configuration into which ice  14  or another medium for chilling the beverage containers C within the carton  12  may be added. 
         [0037]    The carton blanks  10  of  FIGS. 1, 8 and 12  each include a print side as shown in  FIGS. 1, 8 and 12  and an opposite non-print side. The carton blanks  10  each include a central bottom panel  16  bordered on either side by one of two side panels  18 . Each side panel  18  has a pair of expansion panels  20   a ,  20   b  joined thereto opposite from the bottom panel  16 . A top panel  22  is joined to the expansion panels  20 . A number of transverse fold lines  24 ,  26 ,  28 ,  30  extend generally parallel with one another between the top, expansion, side and bottom panels of the carton blanks  10 . Each carton blank  10  also includes a pair of longitudinal fold lines  32  extending generally perpendicular to the transverse fold lines. Extending outwardly from one of the longitudinal fold lines are top panel flaps  34  and bottom panel flaps  36  connected to the respective top and bottom panels  22 ,  16 . 
         [0038]    In various embodiments of the carton blank  10  according to this invention, the carton blank  10  is symmetric about both a longitudinal and a lateral line bisecting the carton blank  10  in those directions. 
         [0039]    A gusset fold  38  joins a lateral side edge of each bottom panel flap  36  to the adjacent side panel  18  via fold lines  39 ,  41 . Each gusset fold  38  according to various embodiments of this invention includes three gusset flaps  40 ,  42 ,  44  each separated by gusset fold lines  46 ,  48  as shown in  FIGS. 1, 8 and 12 . Two of the gusset flaps  40 ,  44  include a series of parallel score lines  50  to assist in the folding operation of the gusset fold  38 . The score lines  50  on the gusset flaps  40 ,  44  stiffen the gusset flaps  40 ,  44  thereby minimizing bowing between the folding gusset fold lines  46 ,  48 . 
         [0040]    The cartons  12  erected from the respective carton blanks  10  of  FIGS. 1, 8 and 12  each include a dispenser  52  formed by a dispenser panel  54  which is located at least in part in each top panel  22  of the carton blank  10 . The dispenser panel  54  is defined in part by a dispenser tear line  56 . The portions of the dispenser tear line  56  in each top panel  22  extend generally parallel to one another and parallel to the longitudinal fold lines  32  of the carton blank  10  while other portions of the tear line  56  intersects at least some of the transverse fold lines  24 ,  26 ,  28  ( FIG. 1 ). The dispenser tear line  56  also extends into and through the expansion panels  20   a ,  20   b  in the carton blank  10  of  FIG. 1 . The dispenser tear line  56  extends along the transverse fold line  24  between the extension panels  20   a ,  20   b  and the associated top panel  22  in the carton blank  10  of  FIG. 8 . The dispenser tear line  56  of the dispenser  52  in the carton blank  10  of  FIG. 12  extends through the expansion panels  20  and into the adjacent side panel  18  to thereby form a dispenser flap  58 . A dispenser finger flap  60  is provided along the dispenser panel tear line  56  in the top panel  22  of the embodiment of the blank  10  of  FIG. 8 . A fold line  63  may be included in the dispenser panel  54  spaced from the finger flap  60  to allow for leverage when grasping the dispenser panel  54  at the finger flap  60  and tearing the dispenser tear line  56 . The dispenser finger flap  60  is provided along the dispenser tear line  56  in one or both of the side panels  18  of the embodiment shown in  FIG. 12 . Curved score lines  57  are provided in the side panels  18  of the embodiments in  FIGS. 1-11  to relieve stresses in the side panels  18  when the carton  12  is in an expanded configuration as discussed herein below. 
         [0041]    Handles  61  are provided on each end of the carton  12 . A handle aperture  62  is formed in each of the bottom panel end flaps  36  of the carton blanks  10  of  FIGS. 1, 8 and 12 . A bottom panel extension flap  64  is formed along the distal end of each bottom panel  36  of the carton blank  10  of  FIG. 1  and is joined to the bottom panel flap  36  by an extension panel fold line  66 . Handle apertures  68  are also provided on the top panel end flaps  34 . A flap  70  is formed within the handle aperture  62  of the bottom panel flaps  36  of the carton blanks  10  of  FIGS. 8 and 12  and is intended to keep the beverage containers C from catching on the handle apertures  62  when the beverage containers C are loaded into the carton  12 . The flap  70  may be joined to the surrounding carton blank  10  by a fold line along the edge adjacent to the longitudinal fold lines  32  and a tear line or series of nicks adjacent a free edge of the flap  34  or  36  so that the flap may be folded inwardly when the handle  61  is in use (see  FIG. 5 ). 
         [0042]    In the embodiment of the carton blank  10  shown in  FIG. 1 , partial flaps  70   a  are provided within the handle apertures  68  to prevent tipping of the beverage containers C when they are loaded into the carton  12  formed from the blank  10  similar to the flaps  70  in  FIGS. 8 and 12  in the handle apertures  62  of the bottom end flaps  36 . 
         [0043]    A glue line  72  is provided on one of the top panels  22 . When the carton blank  10  is folded about the various transverse fold lines  24 ,  26 ,  28 ,  30 , the top panels  22  overlap each other and are adhered together by the glue line  72  to form a unitary top panel from the multiple top panels  22  of the blank  10 . 
         [0044]    The pairs of expansion panels  20   a ,  20   b  are likewise adhered together by one or more glue deposits  74  provided on the print side of one of the expansion panels  20  of each pair of expansion panels. The glue deposit  74  is a single line of glue on the carton blanks  10  of  FIGS. 8 and 12  and is provided in three discrete ovals  74  in the carton blank  10  of  FIG. 1 . The glue deposit  74  is limited to the portion of the expansion panels  20  between the dispenser tear lines  56  as shown in  FIGS. 1, 8 and 12 . 
         [0045]    The carton blanks  10  of  FIGS. 8 and 12  also include triangular punch-outs or openings  76  at the intersection of the expansion panel fold lines  24 ,  26  and the dispenser tear line  56 . 
         [0046]    The carton blanks  10  of  FIGS. 1, 8 and 12  each may be folded into cartons  12  for containing a number of beverage containers C forming a package according to various aspects of this invention. The carton blanks  10  are initially folded about their respective transverse fold lines  24 ,  26 ,  28 ,  30  to form a generally tubular configuration with the top panels  22  at the opposite longitudinal ends of the blanks  10  overlapping and being glued to one another via glue line  72  to combine to form a top panel of the carton  12 . Either of the bottom panel flaps  36  may be folded upwardly to form an end of the carton  12  or the carton blank  10  may be formed into a generally open tubular configuration for the beverage containers C to be inserted into the tube after which one or both of the ends of the cartons  12  may be erected. The insertion of the beverage containers C into the tubular configuration is shown generally in  FIG. 4B . The gusset folds  38  joining the bottom panel end flaps  36  to the respective side panels  18  are folded as generally shown in  FIG. 2A  with the center generally triangular shaped gusset flap  42  folded inwardly toward the interior of the carton  12  and the bottom panel end flap  36  folded upwardly about the adjacent longitudinal fold line  32  to be generally perpendicular to the bottom panel  16  and the adjacent side panels  18 . 
         [0047]    Another aspect of erecting the respective cartons  12  from the associated carton blanks  10  is the expansion panels  20  positioned between the side panel  18  and associated top panel  22 . As shown generally in  FIG. 3A , the expansion panels  20   a ,  20   b  are folded inwardly into a generally face-to-face juxtaposition with the print side of each expansion panel  20  adhered to the print side of the associated expansion panel  20  by the glue deposit  74 . As previously noted, the glue deposit  74  does not extend to the outer ends  20   c ,  20   d  of the expansion panels  20 , but is contained between the dispenser tear lines  56  extending into the expansion panels  20 . 
         [0048]    Once the carton blank  10  is erected into the carton  12  and filled with the containers C, the ends of the carton  12  are closed and sealed to thereby form a package including a carton  12  filled with containers C as shown generally in  FIGS. 9 and 13 . The erected and filled carton  12  forming the package is presented in a first configuration in which the expansion panels  20  are adhered together and the carton  12  forms a generally parallelepiped construction. The package is then suitable for storage, shipping, transport and display. Once the user is ready for accessing and chilling the beverage containers C within the carton  12 , the carton  12  may be expanded to a second, expanded configuration as generally shown in  FIGS. 7, 11 and 15 . Removal of the dispenser panel  54  from the carton  12  allows for the transformation of the carton  12  from the first configuration to the second expanded configuration. 
         [0049]    Removal of the dispenser panel  54  from the carton  12  according to one embodiment is shown in  FIG. 6 . In the embodiment of  FIGS. 1-7 , the fold line  26  between the expansion panels  20   a ,  20   b  is also a tear line to allow for separation of the dispenser panel  54 . As such, the outboard expansion panel  20   b  remains adhered to the adjacent side panel  18  even after the dispenser panel  54  is removed. The glue deposit  74  between the adjacent expansion panels  20   a ,  20   b  is separated when the dispenser panel  54  is removed. 
         [0050]    Removal of the dispenser panel  54  according to another embodiment is shown in  FIGS. 9 and 10  in which the dispenser finger flap  60  in the top panel  22  is initially depressed inwardly allowing the user to grasp the dispenser panel  54  for removal from the carton  12  by tearing along the dispenser tear line  56 . The fold line  24  between the top panel  22  and the adjacent expansion panel  20   b  is also a tear line so both expansion panels  20   a ,  20   b  remain attached to the side panel  18  when the dispenser panel  54  is removed. 
         [0051]    The dispenser panel  54  according to the third embodiment of this invention is removed from the carton  12  as shown in  FIGS. 13 and 14  by initially depressing inwardly and removal of the finger flap  60  at one or both sides of the carton  12  as shown in  FIG. 13 . The dispenser flap  58  can then be pivoted upwardly and grasped by the user to pull the dispenser panel  54  upwardly as shown in  FIG. 14  thereby tearing the dispenser panel  54  from the carton  12  along the dispenser tear line  56 . Both of the expansion panels  20   a ,  20   b  and the dispenser flap  58  on each side of the dispenser panel  54  are removed from the carton  12  with the dispenser panel in this embodiment. 
         [0052]    Removal of the dispenser panel  54  frees the end portions  20   c ,  20   d  of the expansion panels  20  in each embodiment. As such, after the dispenser tear line  56  is torn, the outer ends  20   c ,  20   d  of the expansion panels  20  which are not adhered together expand into the configuration shown in  FIGS. 6-7, 11 and 15  thereby allowing the side panels  18  to pivot outwardly about the transverse fold lines  30  bordering the bottom panel  16  of the carton  12 . The gusset folds  38  joining the side panels  18  to the end flaps  36  of the carton  12  further allow for the transformation of the carton  12  into the expanded configuration shown in  FIGS. 6, 7, 11 and 15 . Advantageously, when the carton  12  is expanded to the expanded configuration, the beverage containers C adjacent to the side panels  18  are allowed to tilt or pivot outwardly along with the adjacent side panel  18 . Note the position and orientation of the containers C adjacent the side panels  18  in  FIGS. 10 and 14  in which these containers C are similarly oriented in an upright position relative to the containers C in the interior rows versus the position and orientation of the containers C adjacent the side panels  18  in  FIGS. 11 and 15  in which those containers C are tilted and/or pivoted outwardly when the carton  12  is in the expanded configuration. This provides for added space between the beverage containers C to accommodate ice  14  or another medium to chill the beverage containers C while they remain within the carton  12 . Advantageously, each of the beverage containers C has increased exposure when the carton  12  is in the expanded configuration for direct contact with the ice  14  or other chilling medium as generally shown in  FIGS. 7, 11 and 15 . Moreover, once the beverage containers C are sufficiently chilled, the carton  12  provides convenient and ready access to all of the beverage containers C positioned beneath the dispenser panel  54 . Once selected beverage containers C are removed from the carton  12 , remaining beverage containers C may be repositioned within the carton  12  for more convenient access and removal as desired. 
         [0053]    One aspect of the expandable beverage carton  12  according to various embodiments of this invention is that the entire bottom portion of the carton  12  in the expanded configuration remains intact thereby containing not only the beverage containers, but the ice  14  and any water which may melt within the carton  12  thereby avoiding or minimizing drainage from the carton  12 . The non-print side of the carton blank  10  may be coated with an appropriate film or other fluid barrier to enhance the retention of water within the carton as desired. 
         [0054]    Another aspect of various embodiments of this carton  12  in the expanded configuration is that the handles  61  positioned on the opposite ends of the carton  12  remain intact and structurally functional for further transport of the carton  12  in the expanded configuration and its contents as necessary even after the dispenser panel  54  has been removed. 
         [0055]    In general, the blank  10  may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank  10  can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton  12  to function at least generally as described above. The blank  10  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 blank  10  may then be coated with a varnish to protect information printed on the blank  10 . The blank  10  may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. The blank  10  can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
         [0056]    While various features of this invention have been described as tear lines or fold lines, such features may have other characteristics. 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 this invention 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 this invention. 
         [0057]    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 this invention, fold lines may 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. 
         [0058]    From the above disclosure of the general principles of this invention and the preceding detailed description of at least one embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, I desire to be limited only by the scope of the following claims and equivalents thereof.