Abstract:
A carton is provided for displaying balls. The has top, bottom, front, back, and side walls. The top and bottom walls have openings therein sized and shaped to engage the ball substantially along the full circumference of the holes. Additionally, the carton includes interior braces, preferably at the four corners of the box. The ends of the braces have curved edges, the curvature of which correspond to the curvature of the ball, such that the ends of the braces contact the ball substantially along the full length of the braces. The braces preferably urge the ball upwardly (or downwardly) to urge the ball against the edge of the hole in the top (or bottom) wall. The size and shape of the braces and of the holes allow for a frictional engagement of the ball by the carton to reduce the possibility of unassisted movement of the ball relative to the carton. Additionally, the blank from which the carton is formed allows for the carton to be formed easily, quickly, and without the use of glue, staples, or other fastening means.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     This invention relates to cartons, and, in particular, to a paperboard carton formed from a blank, to hold and display balls. 
     There are numerous designs for paperboard cartons to hold balls, such as basketballs, soccer balls, volley balls, baseballs, etc. Many of the cartons, especially for the larger balls, display the ball, rather than enclosing the whole ball. These cartons often have only a one or two lines of contact with the ball in the carton or otherwise do not have a good frictional contact with the ball. Hence, the ball can move or turn in the carton. Movement of the ball in the carton can weaken the holding force of the carton on the ball, as well as the carton itself. 
     When manufacturers package their balls in display cartons, the balls are arranged to display the manufacturers&#39; marks and logos. Because the currently available cartons allow for unassisted movement of the ball (as compared to movement due to consumer handling of the ball), the manufacturers&#39; marks and logos become hidden. It would be beneficial to the manufacturers if the carton would resist such unassisted movement of the ball relative to the carton. 
     Further, many of the cartons currently available are difficult to fold or require complex machinery to form the carton from the blank. 
     BRIEF SUMMARY OF THE INVENTION 
     A new and improved carton for holding and displaying a ball is provided. The carton has a top wall, a bottom wall, a front wall, a back wall, and side walls. The top-to-bottom height of the carton is less than the diameter of the ball. Hence, the top and bottom walls have holes therein through which the ball protrudes when received in the carton. The holes are sized and have a curvature corresponding to the curvature of the ball at a plane of contact between the top and bottom walls and the ball so that the hole edges engage the ball substantially along the full circumference of the openings. The carton also includes interior braces which extend into the carton. Preferably, the braces are positioned at the corners of the box and extend diagonally toward either the top or bottom wall of the carton. The braces have a curved end edges which are sized and to engage the ball substantially along the full length of the respective edges. The engagement of the top and bottom walls and of the braces with the ball substantially preventing unassisted movement of the ball relative to the carton. Further, the upward direction of the braces urges the ball against the top wall hole edge to reinforce the engagement of the top hole edge with the ball, and hence, increase the frictional engagement of the hole edge with the wall. 
     Preferably, the carton is formed from a one-piece, unitary paperboard or cardboard blank. The blank allows for the carton to be folded quickly and easily, and without the use of glue, staples or other forms of chemical or mechanical fasteners. The blank includes a back panel which forms the back of said carton; a top panel and bottom panels hingedly connected to opposite ends of the back panel for forming the top and bottom walls of the carton. An inner front panel is hingedly connected to an end of said bottom panel along a side of said bottom panel opposite the back panel. An outer front panel is hingedly connected to an end of the top panel along a side of said top panel opposite said back panel. Side panels are hingedly connected to opposite sides of said top panel to form said carton side walls. The inner front panel has a cut-out extending inwardly from an end of said inner front panel toward said bottom panel. 
     Flaps are hingedly connected to ends of said side panels and extending beyond said top panel to be on opposite sides of said outer front panel when said blank is laid flat. The flaps include a neck having a bottom edge which, when said blank is folded to form said carton, is generally aligned with a bottom edge of said inner front panel cutout. An ear extends from the neck in a direction (preferably perpendicularly) to allow said ear to be tucked behind said bottom edge of said inner front panel cutout when the carton is formed. Thud, said blank is folded into a carton, the flap neck is on one side of said inner front panel and the ends of said ears are on an opposite side of said inner front panels. The flaps engage said inner front panel to maintain said carton in a folded form without the use of glue, staples, or other chemical (i.e., glue) or mechanical (i.e., staples) fasteners. 
     The blank also includes slots formed along the hinge line between said bottom panel and said inner front panel and corresponding tabs hingedly connected to, and extending from, an end of said outer front panel. When the carton is folded, the tabs are inserted into the slots. The engagement of the tabs and slots holds the outer front panel in place relative to the rest of the panels, and further helps to maintain the carton in its folded form without the use of any fastening means, such as adhesives or staples. 
     The side walls of the carton are made of an outer side panel (which is connected to the top panel) and an inner side panel (which is connected to the bottom panel). The inner and outer side panels are connected by connecting panels. The connecting panels include a brace forming panel to form the rear braces of the carton. Additionally, forward brace forming panels are hingedly connected to an end of the said inner side panels and operatively connected on the sides of the said inner front panel and form the forward braces when said carton is formed from said blank. The forward brace forming panels each comprise a two triangular sections hingedly connected together, so that the forward braces are generally V-shaped in elevation or vertical cross-section. All the braces, as noted above, preferably are offset from the vertical and horizontal axis of the carton, so that the ends or edges of the braces are directed toward the top (or bottom) walls of the carton when the carton is formed. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is a perspective view of a carton of the present invention holding a ball; 
     FIG. 2 is a plan view of the blank from which the carton is formed; 
     FIG. 3 is a plan view of the blank with the side portions folded over, as a first step in forming the carton; 
     FIG. 4 is a front perspective view of the carton, showing the blank being folded from the position of FIG. 3, to form the carton; 
     FIG. 5 is a front perspective view of the carton, showing the interlocking of the front end wall, to lock the carton closed without the use of glue; 
     FIG. 6 is a rear perspective view of the carton, showing the interlocking of the panels which comprise front wall to lock the carton closed; 
     FIG. 7 is a front perspective view of the carton, showing the carton rotated 180° relative to FIG. 6; 
     FIG. 8 is a side perspective view of the carton, showing the carton rotated 90° relative to FIGS. 6 and 7; and 
     FIG. 9 is a horizontal cross-sectional view of the carton; 
    
    
     Corresponding reference numerals will be used throughout the several figures of the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes what I presently believe is the best mode of carrying out the invention. 
     A carton  1  of the present invention is shown generally in FIG. 1 with a ball B received in the carton. The carton  1  is generally rectangular, having a top surface  3 , a bottom surface  5 , side surfaces  7  and  9 , a front surface  11 , and a back surface  13 . The carton has a height (from top to bottom) less than the diameter of the ball B. Hence, the top and bottom surfaces have openings  15  and  17 , respectively through which the ball extends. Hence, the carton top and bottom surfaces define planes through which the ball extends. The openings  15  and  17  are sized and shaped such that the edges  19  of the openings define a radius or curvature corresponding to the radius or curvature of the ball at the planes defined by the carton top and bottom surfaces. Hence, the hole edges  19  contact and frictionally engage the ball substantially along the full extent of the edges  19 . Additionally, as seen in FIGS. 6-9, the carton includes internal rear and forward braces  21   a, b,  which are angled (i.e., not parallel) relative to the top and bottom surfaces  3  and  5 , such that the edges  23  of the braces face or extend toward the top surface  3 . Thus, the braces  21   a, b  urge the ball into contact with the top hole  15  to reinforce the engagement of the top hole  15  with the ball B. The braces  21   a, b,  which are preferably at the four corners of the carton, their edges  23  are sized and shaped to contact and frictionally engage the ball substantially along the full extent of the edges  23 . Hence, the edges  23  define curves having radii which correspond substantially to the curvature of the ball along the line of contact between the ball and the brace. The grip of the opening edges  19  and brace edges  23  on the ball is not sufficiently strong to prevent someone from moving the ball in the carton. However, the contact and frictional engagement of the brace edges  23  and of the opening edges  19  with the ball are strong enough to prevent unassisted movement of the ball relative to the carton  1 . By substantially preventing unassisted movement of the ball B relative to the carton  1 , the ball will generally maintain its original position in the carton (i.e., the position in which the ball was placed when originally packed in the carton). Usually, the balls are positioned in display cartons, such as the current carton  1 , to display the manufacturer&#39;s trademark or logo. Hence, the trademark or logo of the manufacturer will not become hidden view due to unassisted movement of the ball, as can happen with currently available ball displaying cartons. 
     The Carton Blank 
     The blank  31  from which the carton  1  is formed is shown in FIG.  2 . The blank  31  has a bottom panel  33 , a back panel  35 , and a top panel  37  which form the bottom  5 , the back  13 , and the top  3  of the carton  1 , respectively. The bottom, back, and top panels are hingedly connected together along fold lines, with the top and bottom panels  33  and  37  being on opposite sides of the back panel  37 . 
     An inner front panel  39  is hingedly connected to the bottom panel  33  along a fold line. A pair of spaced apart, generally trapezoidal cuts  41  are made in the fold line between the bottom panel  33  and the inner front panel  39 . The cuts  41  form slots  43  (FIG. 5) and tabs  45  (FIG. 4) when the inner front panel  39  is folded up. Additionally, a rectangular cutout  47  having side edges  47   a  and a bottom edge  47   b  extends inwardly from the free or forward edge  39   a  of the panel  39 . As can be appreciated, the inner front panel  39  defines the portion of the carton front  11  which is visible from the inside of the carton  1 . 
     An outer front panel  51  is hingedly connected to the free end of the top panel  37  along a fold line. A pair of tabs  53  extend from the free or forward end  51   a  of the outer top panel  51 . The tabs  53  are undercut, as at  55 , and are positioned on the outer front panel  51  to be aligned with the slots  43  formed by the cuts  41  along the hinge line between the bottom panel  33  and the inner front panel  39 . As can be appreciated, the outer front panel  51  defines the portion of the carton front  11  which is visible from the outside of the carton  1 . 
     A pair of outer side panels  61  are hingedly connected to the sides of the top panel  37 . The outer side panels  61  define the portions of the carton sides  7  and  9  which are visible from the outside of the carton  1 . The outer side panels  61  have a length equal to the length of the top panel  37  and a width equal to the length of the back panel  35 . A flap  63  is hingedly connected to each of the outer side panels  61  at the forward end of the outer side panels  61  to be adjacent, but not connected to, the sides  51   b  of the outer front panel  51 . The flaps  63  each have a generally trapezoidal base  65 , a rectangular neck  67 , and an ear  69  extending outwardly from the outer edge of the neck  67 . 
     Connecting panels  71  are hingedly connected to the bottom of the outer side panels  61 . The connecting panels  71  are adjacent, but not connected, to the back panel  35 . The connecting panels  71  include three sections: a first triangular section  73 ; a second, generally trapezoidal, section  75 , and a third somewhat bat-wing shape section  77 . The first triangular section  73  is hingedly connected to the outer side panels  61  along edges (and fold lines)  73   a . The second section  75  is hingedly connected to the first panel  73  along a side (and fold line)  75   a  and has an inner edge  75   b  which is spaced from the side edges of the back panel  35 . The third section  77  is hingedly connected to the second panel along a side (and fold line)  77   a . Because the second section edge  75   b  is spaced from the side of the back panel  35 , the fold lines  75   a  and  77   a  do not extend the full length of the sides of the second section  75 ; and, a gap  79  is formed between the second sections  75  and the back panel  35 . The outer edge of the third section  79  is, as noted, somewhat bat-winged in shape. It has a first edge  77   b  which extends downwardly and outwardly from the end of the fold line  77   a  (with reference to FIG. 2) and a second edge  77   c  which is curved, and defines a radius equal to the radius of the ball B. The two third sections  77  form the rear braces  21   a ; and the edge  77   c  is the brace edge  23 . 
     Inner side panels  81  are hingedly connected to the side edges of the bottom panel  33  and to the connecting panels  71  along respective hinge or fold lines. The inner side panels  81  define the portions of the carton sides  7  and  9  which are visible from the inside of the carton  1 . The inner side panels  81  have a base section  83  which is generally trapezoidal in shape and has an bottom edge  83   a  and sides  85   b, c . The bottom edge  83   a  extends the length of the bottom panel  33 , and defines the fold line between the bottom panel  33  and the inner side panel  81 . The side  85   b  is adjacent the connecting panel third section  77 , and defines the fold line between the third section  77  and the inner side panel  81 . As described below, the side  85   c  is adjacent a forward brace panel  91 , and defines a fold line between the brace panel  91  and the inner side panel  83 . A rectangular arm  85  extends from the base, and is generally centered with respect to the base inner edge  85   a . The base  83  and arm  85 , in combination, have a width generally equal to the width of the outer side panel  61 . 
     The forward brace panel  91 , as noted, is hingedly connected to the inner side panel  81  along the side panel edge  85   c . The brace panel  91  is formed of two generally triangular sections  93  and  95 , which are divided by a fold line  97  which is aligned and co-linear with the fold line between the bottom panel  33  and the inner front panel  39 . The first brace panel section  91  has a curved outer edge  93   a  which defines one of the brace edges  23 . Thus, the outer edge  93   a  has a curvature substantially equal to the curvature of the ball B along the line of contact between the edge  93   a  and the ball. The second section  95  also has a curved outer edge  95   a  which forms one of the brace edges  23  and hence has a curvature substantially equal to the curvature of the ball B along the line of contact between the edge  95   a  and the ball. The outer edge of the second section  95 , however, is chamfered, as at  95   b ; the chamfered edge  95   b  being generally parallel to the fold line  85   c.    
     A connecting flap  101  is hingedly connected to the brace panel  91  along a hinge line  101   a  between the brace panel second section  95  and the flap  101 . The flap  101  extends generally parallel to the inner front panel  39 , and has an inner edge  101   b  which is parallel to, but spaced from, the side edge of the inner front panel  39 . An ear  103  extends from the forward end of the flap  101  and is connected to the inner front panel  39  along a hinge line  103   a . Because the flap inner edge  101   b  is spaced from the inner front panel  39 , the inner front panel  39 , the flap  101 , the flap ear  103 , and the forward brace second section  95  define a gap  105 . 
     Folding the Blank To Form The Carton 
     To fold the blank  31  to form the carton  1 , the flaps  63 , outer side panels  61 , connecting panels  71 , the inner side panels  81 , the forward brace panels  91 , and the flaps  101  (i.e., the side portions of the blank) are folded over the outer front panel  51 , the top panel  37 , the back panel  35 , the bottom panel  33 , and the inner front panel  39 , respectively, (i.e., the middle or center portion of the blank) to lie flat against, the center portion of the blank, as seen in FIG.  3 . If desired, the connecting panel second sections  75  can be adhered to the back panel  35 , for example by a conventional adhesive or conventional mechanical means, such as staples. Similarly, the connecting flap  101  can be adhered to the inner front panel  39 , with conventional adhesive or by mechanical means. The securement of the blank  31  at the noted areas may ease folding of the blank into the carton. However, the securement of the blank in the position shown in FIG. 3, using either adhesive or mechanical means, is not required to fold the carton from the blank, or to hold the carton in its folded form. If glued or stapled, as noted, the blank can be prefolded, and then transported to the ball manufacture in the intermediate form (as seen in FIG.  3 ), to allow for shipping of the blanks in a generally flat form. If no gluing or stapling is to be performed, the blanks can be shipped flat, either fully laid out (as seen in FIG.  2 ), or prefolded, (as seen in FIG.  3 ). 
     After the blank  31  has been folded to the position shown in FIG. 3, the blank is folded along the fold lines between the back panel  35  and the top and bottom panels  33  and  37 , respectively, as seen in FIG. 4, until the top and bottom panels are generally parallel with each other. Because the connecting panel second section  75  is in contact with the back panel  35 , as the blank is folded around the fold line between the top and back panels  37  and  35 , the outer side panels  61  begin to fold downwardly. Additionally, because the flap  101  is connected to the inner front panel  47 , as the blank is folded about the fold line between the back and bottom panels  35  and  33 , the inner side panels  81  bend upwardly; the connecting panel first section  73  begins to overlay the connecting panel second section  75 ; and the connecting panel third section  77  extends into the chamber defined by the carton to form the rear braces  21   a.    
     The inner front panel  39  is also folded upwardly relative to the bottom panel  33  along the fold line between the inner front panel and the bottom panel. As this occurs, the forward brace panel  91  folds or bends along the hinge lines  85   c ,  97 , and  101   a  to take on a generally V-shape as best seen in FIGS. 6 and 9 to form the forward braces  21   b.    
     The tabs  63  are then folded inwardly to overlay the inner front panel  39 , as seen in FIG.  5 . As seen, the bottom edge of the tab neck  67  is approximately aligned with the edge  47   b  of the inner front panel cutout  47 . Then, the tab ears  69  are positioned behind the inner front panel, as seen in FIG.  6 . Hence, the base  65  and neck  67  are on a front side of the inner front panel  39 , and the ears  69  are on a back side of the inner front panel  39 . The interaction between the tabs  63  and the inner front panel  39  holds the blank in a box shape without the use of adhesive. 
     Lastly, the outer front panel  51  is folded along the fold line between the front panel  51  and the top panel  37  to overlay the tabs  63  and the inner front panel  39 . The tabs  53  on the outer front panel  51  are bent along fold lines between the tabs and the outer front panel  51  and are inserted in the slots  43 . The outer front panel tabs  53  are sized to engage the edges of the slots  43 . The engagement of the tabs  53  with the slots  43  reinforces the interaction between the tabs  63  and the inner front panel  39  to further lock and hold the blank in its carton form. 
     As can be appreciated, because the diameter of the openings  15  and  17  is smaller then the diameter of the ball B, the blank  31  must be folded around the ball, to form the carton around the ball. When the carton is thus formed, the ball will be captured by the carton  1 , as seen in FIG.  1 . As described above, when the carton is folded, the edges  23  of the braces  21   a,b  and the edges  19  of the openings  15  and  17  will engage the ball, and frictionally grip the ball to substantially prevent unassisted movement of the ball B relative to the carton  1 . 
     As various changes could be made in the above constructions without departing from the scope of the invention, 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. For example, the angles of the braces  21   a  and  b  can be changed as desired. Additionally, the braces can be changed, such that all four braces are similar to the front braces  21   b  or so that they are all similar to the rear braces  21   a . Further, the braces can be configured to extend in from the sides, front and back of the carton, rather than from the corners. These examples are merely illustrative.