Abstract:
A three piece beverage carrier has an outer ply, a partition assembly, and a box with the outer ply secured to the partition assembly and the partition assembly expanded and secured to the box. The outer ply comes from a rectangular blank folded lengthwise and the partition assembly comes from another blank that extends the transverse and cross partitions. The box takes shape from a third blank having wall panels and bottom flaps. The bottom flaps fold and glue together forming the bottom of the carrier. The partition assembly includes a transverse partition and at least one cross-partition. The partition assembly blank has a first body section, a second body section, and a handle section. The first and second body sections have a hinged connection at the handle section and form the transverse partition of the assembly. The first and second body sections further include at least one fold out section that defines the at least one cross-partition of the assembly. The outer ply can be printed separately from the box and prior to assembling of the partition assembly.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This non-provisional patent application claims priority to the provisional application having Ser. No. 60/563,641, which was filed on Apr. 20, 2004 and to the design patent application having Ser. No. 29/200,049, which was filed on Feb. 18, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The three piece beverage carrier relates to beverage packages in general and more specifically to the divided open top containers for long neck beer bottles. Interlocking longitudinal and transverse partitions become a grid-like divider with the edges of the partitions folded and glued for stiffness. The partitions, when placed in an expanded condition within a carton, receive and separate the bottles from contact with each other.  
         [0003]     Basket carriers have had much use carrying bottles of soda, beer, and other beverages. Prior art basket carriers start from a single blank of material. The four walls and the bottom of the carrier, and the partition assembly start as separate flat blanks later folded and formed into a basket for carrying beverages. Complicated machinery performs the intricate folding and gluing that forms a blank into a carrier. Made from a single blank, the carriers do not nest together. Further, printing must be applied to the prior art blanks before assembly of the carriers, adding a step and cost to the production process.  
       SUMMARY OF THE INVENTION  
       [0004]     Generally, the present invention provides a three piece beverage carrier. The carrier comprises an outer ply, a box, and a partition assembly. The partition assembly secures within the box to divide the box into a plurality of bottle receiving cells. The outer ply receives printing and folds over a portion of the partition assembly. The box has two sidewalls, two endwalls, and a bottom. The bottom takes form from folding inward two side flaps and two end flaps that depend from the sidewalls and endwalls respectively. The end flaps parallel the transverse axis of the present invention and fold towards the center of the bottom. The side flaps fold over the end flaps again towards the center of the bottom but cover the end flaps. A line of glue secures one side flap upon the other side flap. When secured, the joint between the sideflaps is offset from the center of the bottom. Preferably, one side flap has a square edge and the other side flap has a tab substantially along the length of the other side flap. The glued bottom and tab lowers the chance of the carrier bottom sagging under the weight of transported bottles therein. In currently available carriers, a center fold increases the sag. Opposite the sideflaps and the endflaps, the sidewalls and the endwalls have linear upper edges. The upper edges can be shaped for different marketing campaigns.  
         [0005]     Then the partition assembly has at least one transverse, or cross, partition having a length substantially equal to the distance between the carrier box endwalls and at least one cross partition having a length substantially equal to the distance between the carrier box sidewalls. Each of the partitions has glue tabs along side edges of the partitions that adhere to the inner surface of the carrier box to secure the partition assembly within the carrier box. Formed from a one piece blank, the partition assembly includes a first body section, a second body section, and a handle section. The first and second body sections are hingedly connected to each other at the top of the partition in the handle section and form the transverse divider of the partition. The handle section has a hinged connection to the top of the first and second body sections. The first and second body sections each include at least one fold-out section to define the at least one cross partition. Preferably, the first and second body sections each include two fold out sections to form four dividers, or cross partitions, which go on to define six cells for bottles.  
         [0006]     Upon folding the first body portion onto the second body portion, the partition assembly has a handle section. The handle section extends away from the body portions. During assembly, the outer ply is folded lengthwise and placed upon the handle section. The outer ply has two lines of glue to secure the outer ply to the handle section. The outer ply has preprinted indicia placed by the carrier manufacturer or others.  
         [0007]     Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiment of the present invention when taken in conjunction with the accompanying drawings. Before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.  
         [0008]     One object of the present invention is to provide a new and improved beverage carrier from separate pieces.  
         [0009]     Another object is to provide such a carrier that is easy to assemble.  
         [0010]     Another object is to provide such a carrier that is formed from a carrier blank, a partition blank, and an outer ply blank.  
         [0011]     Another object is to provide such a carrier with a carrier blank, a partition blank, and an outer ply blank made from different materials and having different coatings to minimize cost.  
         [0012]     Another object is to provide such a carrier which has a squared and flatter bottom for sharper appearance.  
         [0013]     Another object is to provide an outer ply suitable for inking and laminating an unfinished partition assembly that minimizes decoration of the carrier in hidden portions.  
         [0014]     These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  shows an isometric view of the preferred embodiment of the three piece beverage carrier assembled in accordance with the principles of the present invention;  
         [0016]      FIG. 2  shows an exploded view of the preferred embodiment of the three piece beverage carrier;  
         [0017]      FIG. 3  shows a plan view of the components of the three piece beverage carrier in flat blank form;  
         [0018]      FIGS. 4, 5 , and  6  illustrate the outer ply, partition assembly, and carrier box respectively in flat blank form of the three piece beverage carrier;  
         [0019]      FIG. 7  shows partial assembly of the three piece beverage carrier with the folded partition assembly resting upon the flat box and the outer ply approaching the handle section;  
         [0020]      FIG. 8  illustrates further assembly of the three piece beverage carrier with the outer ply secured upon the handle section of the folded partition assembly resting upon the flat box;  
         [0021]      FIG. 9  shows an endwall and a sidewall folded over and secured to the partition assembly in preparation for final assembly of the three piece beverage carrier; and,  
         [0022]      FIG. 10  shows a bottom view of the three piece beverage carrier with the partition assembly installed and glued into the box and the side flaps and end flaps preparing to close and to form the bottom of the three piece beverage carrier. 
     
    
       [0023]     The same reference numerals refer to the same parts throughout the various figures.  
       DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     The present art overcomes the prior art limitations by providing separate pieces for printing and assembly. Beginning on  FIG. 1 , the preferred embodiment of the three piece beverage carrier  1  has an outer ply  2 , a partition assembly  3 , and a box  4 . The outer ply  2  folds upon and joins a handle section  5  of the partition assembly  3 . The outer ply  2  has a generally rectangular scored slot  6  that opens through the handle section  5  through which a person grasps the carrier  1 . The partition assembly  3  divides the interior space  7  of the box  4  into a plurality of cells  8 , six cells  8  for bottles in the present invention  1 . The cells  8  receive and protect individual beverage bottles during shipping. The partition assembly  3  extends for the full height of the present invention  1  and lacks openings of sufficient size for bottles in adjacent cells  8  to contact each other. During movement, the present invention  1  prevents the bottles from damaging each other. The box  4  has two mutually parallel and spaced apart sidewalls  9   a, b  generally parallel to the longitudinal axis of the carrier  1 , and two mutually parallel and spaced apart endwalls  10   a, b  generally perpendicular to the longitudinal axis of the carrier  1 . The end walls  10   a, b  and the sidewalls  9   a, b  have a generally rectangular shape and beneath, the box  4  has a bottom  11  for the carrier  1 .  
         [0025]     Turning to  FIG. 2 , the outer ply  2  has a generally rectangular shape with a center fold  12 . The center fold  12  is parallel to the longitudinal axis of the outer ply  2  and the carrier  1 . Each half of the outer ply  2  has a scored flap  13  that partially detaches from the outer ply  2 , forms a slot  14 , and bends to admit a person&#39;s fingers. The slot  14  has a generally rectangular shape with rounded ends  15 .  
         [0026]     Then the partition assembly  3  has a generally rectangular shape with a handle section  5  and cross partitions  16  beneath the handle section  5 . The cross partitions  16  extend between the sidewalls  9   a, b  of the box  4 . The handle section  5  has a shape similar to the folded outer ply  2 , and a scored slot  6  that partially detaches from the outer ply  2  that bends to admit fingers. The slot  6  has a generally rectangular shape slightly larger than that in the outer ply  2 . The cross partitions  16  fold out from a longitudinal divider  18  and perpendicular to the partition assembly  3  with at least one partition  16  on each side of the handle section  5 . Folding out the partitions  16  creates an opening  19  whereby the two middle cells  8  communicate with each other. Between the outer pairs of cells  8 , the partition assembly  3  creates a solid wall  20 . Opposite the handle section  5 , the cross-partitions  16   e, f  have a glue tab  21   d, e  folded perpendicular to the cross-partition  16   e, f.  And opposite the first cross-partition  16   e,  each side of the partition assembly  3  has a glue tab  22  folded perpendicular to the handle section  5 . The partition assembly  3  glue tabs  22  are diagonally opposed on each side of the partition assembly  3 .  
         [0027]     Beneath the partition assembly  3 , the box  4  has mutually parallel and spaced apart sidewalls  9   a, b  and mutually parallel and spaced apart endwalls  10   a, b.  The end walls  10   a, b  are perpendicular to the sidewalls  9   a, b.  Beneath the box  4  formed by the sidewalls  9   a, b  and end walls  10   a, b,  the box  4  has a bottom  11 . Sideflaps  24   a,    24   b  folded upon endflaps  24   c,    24   d  form the bottom  11  that supports the bottles in the cells  8 . The sideflaps  24   a,    24   b  and end flaps  24   c,    24   d  depend from their respective sidewalls  9   a, b  and endwalls  10   a, b.  Each flap  24   a, b, c  has a hinged connection to each respective wall  9   a, b,    10   a, b.    
         [0028]     Moving to  FIG. 3 , the present invention  1  starts as three blanks of paperboard in flat form, though other materials may be used. The outer ply  2  has a generally rectangular shape with a center fold  12  parallel to the longitudinal axis of the outer ply  2 . Symmetric about the center fold  12 , two slots  14  appear in the outer ply  2 . A partially attached flap  13  occupies each slot  14 . The slot  14  has a generally rectangular shape with rounded ends and each flap  13  has a rectangular shape with one longitudinal edge of the flap  13  connected to the outer ply  2 .  
         [0029]     Next the partition assembly  3  has a single blank with the cross partitions  16  and glue tabs  21 ,  22  punched into paperboard. The punching pattern is a mirror image upon a center fold  25  between the upper and the lower halves of the partition assembly  3 .  
         [0030]     In flat form, the box  4  starts as a single blank and forms a long rectangular shape. The blank divides into four sections  26   a, b, c, d  that correspond to the left and right sides  9   a, b  and the front and back ends  10   a, b,  respectively of the present invention  1 . The four sections  26   a, b, c, d  join together as hinges upon fold lines  27   a, b, c.  The rectangular shape has breaks from punching for alternating sidewalls  9   a, b  and end walls  10   a, b  with appended side flaps  24   a, b  and end flaps  24   c, d.  The side flaps  24   a, b  and the end flaps  24   c, d  form the bottom  11  of the box  4  upon folding. The side flaps  24   a, b  and the end flaps  24   c, d  join the sidewalls  9   a, b  and end walls  10   a, b  as hinges upon fold lines  28   a, b, c, d.  Upon the left sidewall  9   a,  a glue tab  22   a  extends outward from a hinged connection upon a fold line  27   d.  The side flaps  24   a, b  have a generally square end  29  opposite the hinged connection with the sidewall  9   a, b.  The end flaps  24   c, d  though have a tapered end  30  opposite the hinged connection with their respective endwalls  10   a, b.  Preferably, a series of elongated scores as the fold line  27   a, b, c, d,    28   a, b, c, d  ease folding of the blank into the box  4 .  
         [0031]     Over in  FIG. 4 , the outer ply  2  has a flat rectangular form with a center fold  12  upon the center longitudinal axis. Centered and flanking the fold line  12 , two flaps  13  fold beneath the outer ply  2  and towards the center axis of the outer ply  2 . The flaps  13  partially attach upon one side of each slot  6  with both flaps  13  attaching towards the center of the outer ply  2 . The slots  6  have a generally rectangular shape with rounded ends  15 . Lettering and other indicia can be printed upon the outer ply  2  before folding and placement upon the partition assembly  3 .  
         [0032]     In blank flat form shown in  FIG. 5 , the partition assembly  3  begins as a single piece of paperboard from which the longitudinal divider  18  and the cross partitions  16  take form. The blank divides into four sections  23   a, b, c, d  separated by the center fold  25  and slices  16   c, d:  the first body  23   a,  the first handle section  23   b,  the second handle section  23   c,  and the second body  23   d.  The first body  23   a  joins by the first handle section  23   b  to the second handle section  23   c  then to the second body  23   d.  The second body  23   d  is the mirror image of the first body  23   a.    
         [0033]     The first body  23   a  and the second body  23   d  have substantial similarities and form the longitudinal divider  18  and the cross partitions  16  that divide the box  4  into cells  8 . The first body  23   a  and the second body  23   d  each have a portion that forms the longitudinal divider  18 . Glue tabs  22  locate upon the sides of the body sections  23   a, c  and an adhesive strip  22   a  occupies each tab  22 . A middle portion  26   e  in the center of the first body  23   a  and the second body  23   d  is defined by a slice  16   d.  The middle sections  26   e  fold about a fold line  16   b  and upon folding, become the second cross-partitions  16   f.  The middle sections  26   e  each have a tab  21   c  with an adhesive strip  21   e.  Slices  16   c  define the form of the first cross-partitions  16   e  that fold out from a fold line  16   a.  These slices  16   c  are parallel with the longitudinal divider  18  and perpendicular to the fold line  16   a  that defines the first cross partition  16   e.    
         [0034]     The first body  23   a  has a generally rectangular shape with a glue tab  22   a  upon one end. The glue tab  22  width is the same as the height of the box  4 . Upon a pre-scored line  21   a,  the glue tab  22  folds beneath the first body  23   a  and opposite to the cross partitions  16   e, f.  Then glue tabs  21   b, c  form at the ends of the partitions  16   e, f  dividers opposite the divider&#39;s  18  glue tabs  22 . The glue tabs  21   b, c  have an adhesive strip  21   d, e  that can be a continuation of the adhesive strip  21   d, e  applied upon an opposite glue tab  21   b, c.  Opposite from the glue tab  22 , the first body  23   a  has the first partition  16   e.  The first partition  16   e  has a generally rectangular shape attached on one side  16   a  adjacent to the first body  23   a.  The first partition  16   e  has one side  16   c  cut from the first body  23   a  perpendicular to the fold line  16   a  and adjacent to the first handle section  23   b.  The first partition  16   e  separates from the first body  23   a  and folds until perpendicular to the first body  23   a  where the first partition glue tab  21   b  folds parallel to the second partition glue tab  21   c.  Opposite the glue tab  21   b,  the second partition  16   f  has a polygonal shape with one side  16   b  partially attached to the first body  23   a  and the remaining sides scored to detach from the first body  23   a  at a slice  16   d.  Opposite the attachment side  16   b  and the glue tab  22   a  of the first body  23   a,  the second partition  16   f  has a glue tab  21   c.  Upon a pre-scored slice  16   d,  the second partition  16   f  separates from the first body  23   a  and folds until perpendicular to the first body  23   a  where the second partition glue tab  21   c  folds parallel to the sidewall  9   a, b.  The second body  23   d  has partitions  16   e, f  and glue tabs  21   b, c  in a mirror image to the first body  23   a  and the first body  23   a  descriptions of cross partitions  16   e, f  apply to the second body  23   d  in mirror image.  
         [0035]     The first and second handle sections  23   b, c  span between the first body  23   a  and the second body  23   d.  Each handle section  23   b, c  has a generally rectangular shape akin to the outer ply  2 . A center fold  25  parallel to the length of the carrier  1  hingedly connects the first handle section  23   b  to the second handle section  23   c.  A centered slot  17  has rounded ends within each handle section  23   b, c.  After the first body  23   a  folds upon the second body  23   d,  the slots  17  accept the flaps  13  from the outer ply  2 .  
         [0036]      FIG. 6  shows the box  4  in flat blank form prior to folding. The blank divides into four sections that correspond to the front  10   a,  back  10   b,  and the sides  9   a,   9   b  of the present invention  1 . The four sections connect as hinges at fold lines  27   a, b, c.  A glue tab  22  extends across the finished height of the box  4  upon one sidewall. Behind the glue tab  22 , sidewalls  9   a,b  and endwalls  10   a, b  alternate position at hinged connections, starting with a sidewall  9   a.  The sidewalls  9   a,b  and endwalls  10   a, b  have generally rectangular shapes with the length of the sidewalls  9   a, b  exceeding that of the endwalls  10   a, b.  Depending from the sidewalls  9   a, b  and the endwalls  10   a, b,  side flaps  24   a, b  and end flaps  24   c, d  respectively fold upon a fold line  28   a, b, c  parallel to the longitudinal axis of the box  4 . Preferably, a series of elongated scores as the fold lines  28   a, b, c  ease folding of the blank into the box  4 . The side flaps  24   a, b  have a tapered trapezoidal shape with the wider base nearer the box  4 . The end flaps  24   c, d  have a rectangular shape with the corners beveled opposite the box  4 . The sideflap  24   b  further from the glue tab  22  has a glue strip  29   a  parallel to the longitudinal axis of the box  4  and opposite from fold line  28   c.    
         [0037]     Prior to folding the carrier  1  into a familiar box like shape, machinery applies a series of parallel lines of glue  22   a,    21   f, g,  and  18   a  upon the box  4 . The glue tabs  21   b, c  adhere to the sidewalls  9   a, b  forming the cross-partitions  16   e, f  by the glue lines  21   f, g.  The glue lines  21   f, g  extend from close to the top of sections  26   a, b, c,  and  d  and extend nearly to the bottom  11  of the carrier  1 . The glue lines  21   f, g,    18   a  serve to glue the partition assembly  3  into the box  4  as will be described below.  
         [0038]     With the box  4  remaining flat,  FIG. 7  shows the initial assembly of the three piece beverage carrier  1 . Rotating the box  4  from  FIG. 6 , the partition assembly  3  folds upon the box  4 . The first body  23   a  folds over the second body  23   d  with the resulting handle sections  23   b, c  positioned away from the box  4 . The partition assembly  3  centers upon the sidewall  9   b  further from the glue tab  22   a.  The partition assembly  3  glues into place with glue tabs  21   b, c  upon the inner, or unprinted, surface of the box  4 . The cross partitions  16   e, f  remain flat in this figure. The glue tab  22  of the partition  3  adheres to the endwall  10   a  nearer to the glue tab  22   a  of the box  4  and the glue tabs  21   b, c  depending from the cross partitions  16   e, f  adhere to the sidewall  9   b  further from the glue tab  22   a.  These glue tabs  22 ,  21   b, c  adhere one edge of the longitudinal divider  18  to one end of the box  4  and the cross partitions  16   e,f  to a side of the box  4 . With the handle sections  23   b, c  in position upon the box  4 , the outer ply  2  is folded along its fold line  12  and moved towards the handle sections  23   b, c.  Next in  FIG. 8 , the outer ply  2  folds upon the handle  5  with the flaps  13  of the outer ply  2  extending into the slots  17  of the handle  5 .  
         [0039]     Then in  FIG. 9 , the box  4  is folded along the fold line  27   b  as the partition assembly  3  is brought over and upon the endwall  10   b  and sidewall  9   a  closer to the glue tab  22   a.  The endwall  10   a  formerly further from the glue tab  22   a  receives the glue tab  22   a  and joins the sidewall  9   a  to the second endwall  10   a.  This adheres the longitudinal divider  18  to the endwall  10   a  and the cross partitions  16   e, f  to the other sidewall  9   a  of the box  4 . Folding the glue tab  22   a  on fold line  27   d  and the fold lines  27   a, b, c  between the sidewalls  9   a, b  and the endwalls  10   a, b  rotates the box  4  into a rectangular configuration. Upon gluing of the tabs  22 ,  22   a,    21   b, c  to the endwalls  10   a, b  and sidewalls  9   a, b  respectively, the carrier  1  achieves an assembled, but flattened state. The beverage carrier  1  stores and ships flat prior to forming the bottom  11  of the beverage carrier  1  at the bottler.  
         [0040]      FIG. 10  has the box  4  in a rectangular configuration wherein the cross partitions  16   e, f  unfold. The cross partitions  16   e, f  are perpendicular to the sidewalls  10   a, b  while the glue tab  21   b, c  of each cross partition  16   e, f  adheres parallel to a sidewall  10   a, b.  At each end of the partition assembly  3 , a glue tab  22  adheres the first body  23   a  and the second body  23   d,  and to the endwalls  10   a, b  of the box  4 . To form the carrier  1 , the box  4  expands from the flattened state shown in  FIG. 9 . The unfolded cross partitions  16   e, f  form cells  8  suitable for bottles. With the partition assembly  3  joined to the box  4 , the bottom  11  of the carrier  1  forms by folding the end flaps  24   c, d  towards the center of the carrier  1  and upon the partition assembly  3 . Then the sideflaps  24   a, b  fold upon the end flaps  24   c, d  with the sideflap  24   a  folding first and the other sideflap  24   b  securing to the glue strip  29   a.  The glue strip  29   a  holds the bottom  11  together. With the bottom  11  formed a bottler inserts bottles into the carrier  1  and ships the loaded carrier  1  to market.  
         [0041]     From the aforementioned description, a three piece beverage carrier has been described. The three piece beverage carrier is uniquely capable of receiving printing in separate pieces before assembly of the carrier. The three piece beverage carrier and its various components may be manufactured from many materials including but not limited to paperboard, cardboard, chip board, polymers, high density polyethylene HDPE, polypropylene PP, polyethylene terephalate ethylene PETE, polyvinyl chloride PVC, polystyrene PS, nylon, ferrous and non-ferrous metal foils, their alloys, and composites.  
         [0042]     The phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Therefore, the claims include such equivalent constructions insofar as they do not depart from the spirit and the scope of the present invention.