Abstract:
A cooler carton for items such as beverage containers is erected from a blank ( 11 ) having a unique configuration of panels ( 12, 13, 14, 16, 17, 41, 47, 56, 66, 96, 99 ), tabs ( 28, 29, 31, 32 ), flaps ( 111 ), creases ( 18, 19, 21, 22, 33, 34, 36, 37, 42, 48, 57, 67, 77, 87 ), perforations ( 23, 26, 27 ), cut-creases ( 24, 97, 101 ), and gussets ( 46, 52, 81, 91 ). The erected carton has top panels ( 12, 17 ) forming a top with a central longitudinal perforation line ( 23, 26 ) and oblique cut-creases and perforation lines ( 24, 27 ) extending from the ends of the central perforation line ( 23, 26 ) to the corners of the top. Flaps ( 111 ) are formed at respective end portions of the top by folded tabs ( 28, 29, 31, 32 ). In use, the carton is erected and filled with articles to be contained. An end user may open the carton by pulling up and back on the flaps ( 111 ) at the end portions of the top, which severs the oblique cut-creases and perforation lines ( 23, 26 ), and severs the top along its central perforation line ( 23, 26 ). As a result, the top opens up and forms a containment skirt that extends above the level of beverage containers in the carton. Ice can then be added atop the containers to cool their contents and the ice is contained by the skirt. Gussets ( 46, 52, 81, 91 ) are formed at the lower corner portions of the carton, which, along with a moisture barrier, prevent accumulated water from melting ice from leaking from the bottom region of the carton.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of International Application No. PCT/US2008/000716, filed Jan. 18, 2008, entitled “Cooler Carton,” which designates the United States of America and which claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/881,286, filed Jan. 19, 2007. 
     
    
     BACKGROUND 
       [0002]    Dispensing cartons for beverage cans and a wide variety of other items are known. Conventional dispensing cartons may have a panel or combination of panels formed with a dispensing feature through which items may be obtained by a user. Coolers for cooling beverages and other items also are known. Such coolers may include insulated bodies into which are placed items to be cooled along with ice to cool the items. A need exists for a dispensing carton that also can be used for cooling items contained therein as well as dispensing the items through a dispensing feature. It is to the provision of such a carton, a method of erecting the carton, and a blank from which the carton is erected that the present invention is primarily directed. 
       SUMMARY 
       [0003]    The entire disclosures of International Application No. PCT/US2008/000716 and U.S. Provisional Application No. 60/881,286 are hereby incorporated by reference in their entirety as though fully set forth herein. 
         [0004]    Briefly described, the present invention comprises a carton, a carton blank for from which the carton may be erected, and a method of erecting the carton from the carton blank. According to one embodiment, the carton blank comprises at least an outer top panel, a first side panel, a bottom panel, a second side panel, and an inner top panel, all generally rectangular in shape and foldably connected one to the next along creases. The blank further includes various end panels foldably connected to the ends of respective ones of the above panels and configured to be folded to form the closed ends of a carton erected from the blank. The end panels connected to the first and second side panels have oblique double creases formed therein that fold inwardly when the end panels are folded to close the ends of the carton to define gussets in the bottom corner portions of a fully erected carton. Tabs, separated by gaps, extend from the ends of the outer top panel and these tabs, when folded according to the method of the invention, form openable flaps on either end portion of the top of a fully erected carton. Each of the outer top panel and the inner top panel, which overlie one another in the erected carton, are formed with central perforation lines along their center portions and oblique perforation lines that extend from the ends of the central perforation lines to the corners of panels. 
         [0005]    The carton is erected from the blank by folding and gluing the various panels and tabs as described in detail below to form an erected carton. At some point in the process, the carton may be filled with beverage cans (or another item or product) before it is completely closed. When it is desired to open the carton, the flaps on either end of the top panels are pulled up and back, which breaches the top of the carton along the oblique perforation lines. The outer and inner top panels are separated along their respective perforation lines and opened up. The result is an open carton revealing the beverage cans or other items therein, with a surrounding skirt that extends above the tops of the cans. Ice can be added on top of the beverage cans to cool the beverage therein and the ice is contained by the upwardly open surrounding skirt. Beverage cans are dispensed by searching through the ice and grasping a can when located under the ice. 
         [0006]    As the ice melts, water collects in the bottom region of the container. The gussets, mentioned above, that are formed at the bottom corner portions in this region insure that the region is bounded by a continuous section of paperboard with no seams or glue lines through which the water can leak. This, in conjunction with a coating of water resistant material on the inside surfaces of the carton in one embodiment, insures that water from melted ice is contained within the bottom region of the container and does not readily leak out onto floors or other supporting surfaces. 
         [0007]    Additional features, aspects, and details of the present invention will become more completely understood upon review of the detailed description and claims set forth below taken in conjunction with the various drawing figures, which are briefly described as follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a plan view of a carton blank that embodies principles of the present invention in one form. 
           [0009]      FIG. 2  shows the carton blank of  FIG. 1  with its top or print side facing upwardly. 
           [0010]      FIG. 3  shows the carton blank of  FIG. 1  with its top or print side facing downwardly. 
           [0011]      FIGS. 4-20  illustrate, in one form, the series of steps carried out in erecting the carton of the invention from the blank of  FIGS. 1-3 . 
           [0012]      FIGS. 21-26  illustrate, in one form, the series of steps carried out in opening the erected carton for adding ice and/or dispensing the contents of the carton. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    The invention generally relates to cartons suitable for storing and dispensing articles such as, for example, beverage containers, and methods of erecting such cartons from a carton blank. Articles that may be contained by such cartons include, but are not limited to, petaloid bottle containers, beverage cans, glass or plastic bottles, or other containers such as those used in the packaging of juices and other foodstuffs. For purposes of illustration and not limitation, the detailed description below describes one embodiment of the invention within the context of a carton for beverage cans. However, any other appropriate containers or articles might be substituted for the beverage cans within the scope of the invention. Further, references herein to “end,” “side,” “bottom,” and “top” refer to orientations or positions of elements when the carton is erected and disposed in an upright orientation. The terms “upper,” “lower,” “vertical,” “horizontal,” and “oblique” generally refer to the location and/or orientation of an element or line with respect to a drawing figure in which it appears. 
         [0014]    Referring now in more detail to the drawing figures, wherein like reference numerals indicate like parts throughout the several views,  FIG. 1  illustrates a carton blank  11  from which a carton according to this invention ( FIG. 20 ) may be erected. The blank  11  is shown with its outside or print side up. The blank  11  includes a outer top panel  12 , a first side panel  13 , a bottom panel  14 , a second side panel  16 , and an inner top panel  17 . The outer top panel  12  is foldably connected to the first side panel  13  along vertical crease  18  and the first side panel  13  is foldably connected to the bottom panel  14  along vertical crease  19 . Similarly, the bottom panel  14  is foldable connected to the second side panel  16  along vertical crease  21  and the second side panel  16  is foldably connected to the inner top panel along vertical crease  22 . 
         [0015]    A vertical perforation line  23  substantially bisects the central portion of the outer top panel  12  and oblique cut-creases  24  extend from near the ends of the perforation line  23  to the corners of the outer top panel  12 . Similarly, a vertical perforation line  26  substantially bisects the central portion of the inner top panel  17 , but for this panel, oblique perforation lines  27 , rather than cut-creases, extend from the ends of perforation line  26  to the corners of inner top panel  17 . Partial cutouts  25  are formed along the outboard side of oblique cut-creases  24  of panel  12  by partial cuts bounding a rectangular region. While the partial cutouts  25  are rectangular in the illustrated embodiment, they may be formed in other shapes if desired. 
         [0016]    Upper tabs  28  and  29  are foldably connected to the outer top panel  12  along horizontal cut-creases  33  and  34  respectively and lower tabs  31  and  32  are foldably connected to the outer top panel  12  along horizontal cut-creases  36  and  37  respectively. The upper tabs  28  and  29  are separated by a vertical cut out gap  38 , which extends into the outer top panel  12  to a position near the intersection of oblique cut-creases  24  and the upper end of perforation line  23 . Similarly, the lower tabs  31  and  32  are separated by a vertical cut out gap  39 , which extends into the outer top panel  12  to a position near the intersection of oblique cut-creases  24  and the lower end of perforation line  23 . The perforation line  23  and the oblique cut-creases  24  are configured to be torn when the carton of this invention is opened up, as described in more detail below. 
         [0017]    An upper end panel  41  is foldably connected to first side panel  13  along crease  42 , which includes a partial cut  43  at one end portion. An oblique double score line  44  is formed in the upper end panel  41  and defines a gusset  46  on the right hand portion of first end panel  41  in  FIG. 1 . Upper end panel  41  is separated from tab  29  along cut line  50 . A lower end panel  47 , which is a mirror image of upper end panel  41 , is foldably connected to first side panel  13  along crease  48 , which includes a partial cut  49  at one end. An oblique double score line  51  is formed in the lower end panel  47  and defines a gusset  52  on the right hand portion of the second end panel  47  in  FIG. 1 . Lower end panel  47  is separated from tab  23  along cut line  60 . The gussets  46  and  52  are configured to fold inwardly to form a water resistant bottom corner portion of a carton when the blank is erected, as detailed more fully below. 
         [0018]    Upper end panel  56  is foldably connected to bottom panel  14  along crease  57  and is divided by crease  58  into an upper section  59  and a lower section  61 . The lower section  61  of upper end panel  56  is foldably connected to upper end panel  41  along crease  62 , which includes a partial cut  61  along part of its length. Lower end panel  66  is foldably connected to bottom panel  14  along crease  67  and is divided by a crease  68  into a lower section  69  and an upper section  71 . The upper section  71  of lower end panel  66  is foldably connected to lower end panel  47  along crease  72 , which includes a partial cut  73  along part of its length. 
         [0019]    Upper end panel  76  is foldably connected to second side panel  16  along crease  77 , which includes a partial cut  78  along part of its length. An oblique double score line  79  is formed in the upper end panel  76  and defines a gusset  81  on the left hand portion of the upper end panel  76 . The upper end panel  76  is foldably connected to the lower section  61  of end panel  56  along crease  82 , which includes a partial cut  83  along part of its length. Lower end panel  86  is foldably connected to second side panel  16  along crease  87 , which includes a partial cut  88  along part of its length. An oblique double score line is formed in the lower end panel  86  and defines a gusset  91  on the left hand portion of the lower end panel  86  in  FIG. 1 . The lower end panel  86  is foldably connected to the upper section  71  of end panel  66  along crease  92 , which includes a partial cut  93  along part of its length. Like gussets  46  and  52 , gussets  81  and  91  are configured to fold inwardly when the blank is erected to form a water resistant bottom corner portion when the carton of this invention is erected. 
         [0020]    Upper end panel  96  is foldably connected to inner top panel  17  along cut-crease  97  and is separated from upper end panel  76  along cut line  98 . Similarly, lower end panel  99  is foldably connected to inner top panel  17  along cut-crease  101  and is separated from lower end panel  86  along cut line  102 . 
         [0021]    With the carton blank of the invention described in detail, an exemplary method of erecting the blank  11  into the carton of the invention will now be described with reference to  FIGS. 2-20 .  FIG. 2  simply illustrates the carton blank shown in  FIG. 1  with its exterior or print side up. This figure is essentially the same as  FIG. 1  and thus need not be described in detail.  FIG. 3  illustrates the carton blank  11  flipped over with its interior or second side up. For clarity of description, the interior side of the carton blank is lightly stippled throughout the figures to distinguish it from the exterior or print side of the blank. Some of the major elements of the blank  11  are identified with their reference numbers in  FIG. 3  for purposes of orientation, including panels  12 ,  13 ,  14 ,  16 , and  17  as well as creases  34 ,  35 ,  36 ,  37 ,  42 ,  48 ,  57 ,  67 ,  77 , and  87  and cut-creases  97  and  101 . It will be appreciated that the preferred embodiment of the blank  11  is symmetric about a horizontal center line in  FIG. 1  so that the configuration of the interior side of the blank shown in  FIG. 3  is the same as that of the exterior side of  FIGS. 1 and 2 , with reference numerals flipped top-to-bottom and bottom-to-top respectively. The erection sequence described below begins with the carton blank  11  as shown in  FIG. 3 . 
         [0022]    To erect the carton of this invention from the carton blank  11 , the blank is folded along crease  22  as shown in  FIG. 4  so that inner top panel  17  overlies second side panel  16  (not visible in  FIG. 4 ) and partially overlies bottom panel  14 . The blank is then folded along crease  19  ( FIG. 5 ) until the outer top panel  12  overlies and substantially aligns with inner top panel  17  ( FIG. 6 ). Glue or other appropriate adhesive is applied between the inner and outer top panels  12  and  17  so that these two panels become securely affixed to one another when folded into the configuration shown in  FIG. 6 . It has been found advantageous to apply the glue in strips or beads that extend along and on either side of the perforation line  26  for substantially the full length of the panel  17  in order to obtain a secure reliable bond between the outer top panel  12  and the inner top panel  17 . 
         [0023]    Referring to  FIGS. 7-9 , glue  107  is dispensed on the outer top panel  12  on the inboard sides of oblique cut-creases  24  opposite the partial cutouts  25 . The glue is dispensed in a size and shape to insure that when the blank is folded along oblique cut-creases  24 , the glue will engage the folded portion only within the partial cutouts. The blank is folded along one of the oblique cut-creases  24  so that the tab  31  extends out laterally relative to perforation line  23  ( FIG. 7 ) and the resulting triangular section  108  overlies the surface of panel  12 . When thus folded, the glue  107  bonds the triangular section  108  to the panel  12 , but only within the area of the partial cutout  25 . A back fold is then made along cut-crease  36  ( FIG. 8 ) and the fold in continued until the tab  31  overlies the outer and inner top panels  12  and  17  respectively and overlies the triangular portion  108  created in the previous fold ( FIG. 9 ). Referring to  FIGS. 10-12 , the blank  11  is folded along the adjacent oblique cut-crease  24  until the adjacent tab  32  extends out laterally relative to the perforation line  23  and the resulting triangular section  108  overlies the surface of panel  12 . When thus folded, the glue bonds the triangular section  108  to the panel  12 , but only within the area of the partial cutout  25 . A back fold is made along cut-crease  37  ( FIG. 11 ) and glue  109  is applied to the distal edge of adjacent tab  31 . The back fold is continued until the tab  32  overlies the outer and inner top panels  12  and  17  respectively, overlies the triangular section  108 , and the distal edge of the tab  32  overlies the distal edge of the tab  31  ( FIG. 12 ), whereupon the glue  109  securely bonds the distal edges of the tabs  31  and  32  together to form a unitary flap  111 . 
         [0024]    The just described process is carried out in the same way with tabs  28  and  29  ( FIG. 13 ) until these tabs also form a unitary flap  111  on the opposite end of outer top panel  12  ( FIG. 14 ). It will be noted that, when the flaps are completed, a short section on the end of gaps  38  and  39  protrudes slightly from underneath and beyond the edges of the flaps  111 . Further, as perhaps most apparent in  FIG. 12 , the junctions of the vertical perforation line  26  and the oblique cut-creases  27  on the inner top panel  17  (see  FIG. 1 ) are exposed beneath the protruding short sections of the gaps  38  and  39 . This configuration facilitates the opening of the fully erected carton by a user as described in more detail below. 
         [0025]    As illustrated in  FIGS. 15 and 16 , the carton is next opened up by folding the blank upwardly along creases  19  and  21  in a rather pantograph fashion until the carton forms a tube-like configuration with open ends ( FIG. 16 ). In this configuration, the carton sits upright on bottom panel  14  with the outer and inner top panels  12  and  17  and the just described unitary flaps  111  defining the top of the carton. 
         [0026]      FIGS. 17-20  illustrate one folding sequence that forms the ends of the carton of this invention. Folding of the end panel  66  upwardly along crease  67  is begun as shown in  FIG. 17 . As the end panel  66  begins to fold upwardly, end panels  47  and  86  begin to fold inwardly along creases  48  and  87  respectively because of their connection to end panel  56  along creases  72  and  92 . At the same time, the end panels  47  and  86  begin to fold onto themselves along respective double score lines  51  and  91 . The folding upwardly of the end panel  66  and inwardly of end panels  47  and  86  is continued until the end panel  66  at least partially overlies the end panels  47  and  86 , as best illustrated in  FIG. 18 . Glue can be applied to secure the end panel  66  to the end panels  47  and  86  if desired. In this configuration, the end panels  47  and  86  are completely folded over onto themselves along double score lines  51  and  91  to form gussets in the lower corner portions of the carton. These gussets are configured to provide a continuous layer of paperboard with no breaks or glue seams, which, in turn, forms a carton that, when properly treated, is capable of containing a certain amount of water or other liquid in at least its lower region without leaking. 
         [0027]    With the end panel  66  folded up ( FIG. 18 ), the end panel  99  can then be folded down along cut-crease  101  ( FIG. 19 ) until it overlies and is secured with glue to the upper section  69  of end panel  66  to close off the carton on one end with the other end still open. Alternately, end panel  99  can be folded down behind end panel  66  before panel  66  is completely folded, in which case end panel  66 , and particularly the upper portion  69  of end panel  66 , will overlie and be glued to the underlying end panel  99  to close of one end of the carton. In this configuration (one end closed and the other open), containers such a beverage cans can be packed into the carton from the open end, whereupon the same folding and gluing procedure just described is carried out at the open end of the carton to close off the other end of and complete the erection of the carton. Those of skill In the art will understand that while packing containers in a carton from an open end is one method of filling the carton with product, other methods are also known and may be applied with the present invention. For example, it is known to erect a carton around a grouping of containers and the carton of the present invention is adaptable to this and other alternative loading methods. Regardless of the loading method employed,  FIG. 20  illustrates the fully erected carton of the invention, which, in the preferred embodiment, contains beverage cans for shipment to consumers. 
         [0028]      FIGS. 21-26  illustrate one method, most likely employed by an end user, of opening up the container of the present invention to add ice if desired for cooling the contents and for dispensing the contents of the carton.  FIG. 21  shows the carton right side up with its outer top panel  12  bearing perforation line  23  and being connected along crease  18  to first side panel  13 . Shown on one end of the carton is flap  111 , which is formed of tabs  31  and  32  adhered together along their overlapping ends as described above. To open the carton a user first inserts a finger into the short portion of the gap  39  that protrudes slightly beyond the edge of the flap  111 . The tip of the finger is then urged downwardly to breach the intersection of perforation line  26  and oblique cut-creases  27  of the underlying inner top panel  17 , which intersection is located just under the protruding portion of gap  39 . This step of the opening process is illustrated in  FIG. 21 . 
         [0029]    Next, the user pulls up and back on the flap  111 , which begins to open up a chimney on one end of the carton ( FIG. 22 ). As the flap  111  is pulled up, the partial cutouts  25 , which are adhered to the outer top panel  12 , tear out and remain attached to the top panel by virtue of the glue beneath. It will thus be seen that applying adhesive to the end portions of the top panel only in the areas where the partial cutouts overlie the outer top panel  12  serves to hold the flaps  111  down flat against the outer top panel  12  until it is desired to open the carton. The partial cutouts then tear out as flaps  111  are pulled up and back to allow the carton to be opened.  FIG. 23  illustrates the flap  111  pulled completely up and back by a user to open up a chimney fully on one end of the outer top panel  12 . The same procedure is then followed at the other end of the carton forming two open chimneys, one at each end of the outer top panel  12  ( FIG. 24 ). 
         [0030]    With the two chimneys opened up, the user then begins to tear the outer top panel  12  and the underlying inner top panel  17  along perforation line  23  in the outer top panel and perforation line  26  in the inner top panel ( FIG. 25 ). The perforation lines are constructed so that tearing the panels along them is relatively easy for a typical user. When the outer and inner top panels  12  and  17  have been completely torn along their perforation lines  23  and  26  respectively, the user then pulls back the resulting partial panels to open up the carton completely revealing product within, which, in the preferred embodiment, is beverage cans  112  ( FIG. 26 ). As shown in  FIG. 26 , when the carton is opened, the flaps  111  and the remnants of panels  12  and  17  extend upwardly a substantial distance above the tops of the beverage cans and form a containment skirt. A user can thus add ice to the open carton for cooling the beverage in the cans therein and the ice is contained by the containment skirt on top of and contacting the cans. Cooled beverage cans can then be obtained from the carton by digging through the ice until a can be located, grasped, and pulled from the ice. 
         [0031]    As the ice in the carton begins to melt, water collects in the bottom of the carton. The unique design of the gussets  46 ,  52 ,  81 , and  91  in the bottom corner portions of the carton, in conjunction with a water resistant coating on the inside of the carton, insures that, for at least the height of the gussets, there are no glued seams around the carton through which the collecting water can leak. Accordingly, water from the melting ice is retained in the bottom portion of the carton and does not leak onto a floor or other supporting surface. Thus, in this region, the carton may be said to be water-tight or liquid-tight. However, cartons of this invention may be formed of paperboard, which, if exposed to water or other liquids for extended periods of time may allow the liquid to leak through the wetted carton surfaces due to partial permeability of the carton material. Accordingly, “liquid-tight,” “water-tight,” and terms of similar import generally mean a region of a carton that is bounded by a continuous section of material or by a section without any glued seams through which liquid or fine particles might leak. These terms thus include cartons that may become partially water permeable over time due to prolonged exposure to water or other liquids. 
         [0032]    In the above embodiments, the carton of the invention is described and shown ( FIG. 26 ) in the context of containing 18 12-ounce beverage cans in a 6×3×1 configuration. Other arrangements of containers, packages, articles, and other items, however, can be accommodated within a carton constructed according to principles of the present invention. For example, the carton of this invention also will work satisfactorily if the carton is sized and shaped to hold articles in other configurations such as 4×3×1; 3×4×1; 2×4×1; 2×5×1; etc. The dimensions of the blank  11  also may be altered, for example, to accommodate various container forms such as, for instance, 16-ounce petaloid bottles. 
         [0033]    The blank  11  may be formed, for example, from paperboard comprising clay coated newsprint (CCN), solid unbleached sulfate board (SUS), and other materials. In general, the blank may be constructed from paperboard having a caliper of at least about 14 so that it is heavier and more rigid than other paper. The blank also can be constructed of other materials such as cardboard, plastic sheet material, plastic coated paperboard, or any material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated such as, for example, with a clay coating. The clay coating may then be printed over with product information, advertising, and other information and/or images. The blank may be coated with a varnish to protect information printed on the blanks. The blank also may be coated, particularly on its interior surfaces, a moisture barrier layer comprising wax, varnish, or other appropriate materials. In this regard, such a moisture barrier layer is particularly preferred on the interior walls of the carton in the region of the carton that collects and holds water from melting ice. The blank also can be laminated or coated with one or more sheet-like materials at selected panels or panel sections. 
         [0034]    In this specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections. The preferred embodiment may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place. 
         [0035]    Certain fold lines or “creases” are described herein as including spaced cuts or “partial cuts” along their length to facilitate folding along the lines. If the cuts are below or adjacent to the bottom region of the carton intended to hold water, cuts that extend less than completely through the carton material may be used to prevent leakage along the creases. Alternatively, cuts may be omitted within or near the region of the container that is intended to hold water. 
         [0036]    It will be understood by skilled artisans that while the present invention has been discussed with reference to exemplary embodiments, various additions, deletions, and modifications can be made to the illustrated embodiments without departing from the spirit and scope of the invention as set forth in the claims.