Abstract:
A carton is provided with side walls that are shaped to securely or tightly enclose a group of tapered cylindrical articles. The curvature of the edges of each side wall is selected to cause the end wall or end closure structure to conform to the tapered shape of articles in the end most row that is disposed adjacent to the respective end closure structure of the carton. More specifically, the edges of each side wall are substantially continuously arcuate and the curvature of the edge is determined such that the maximum width of each side wall is greater than the width of the respective bottom edge of the side wall.

Description:
TECHNICAL FIELD 
   This invention relates generally to cartons and, more specifically, to cartons that are shaped to better enclose a group of articles. 
   BACKGROUND OF THE INVENTION 
   Cartons are commonly used to enclose articles such as conventionally shaped bottles. To securely enclose a group of bottles, the side panels of a carton can be shaped to match the features of a bottle including a tapered neck and a cylindrical base with a relatively larger circular or other shaped cross-section. Accordingly, side panels have been gable-shaped with the lower edge portions of the side panel extending vertically from the bottom panel and the upper edge portions of the side panel extending at an angle from the respective lower edge portion to the top panel so as to follow the taper of the neck of the bottle. 
   Although, the gable-shaped carton is useful for enclosing a group of bottles, the bottom portion of each bottle is not supported as securely as the tapered portion. Therefore, a heretofore unaddressed need exists in the industry to provide a carton that is shaped to better stabilize the bottom portion of each bottle. 
   SUMMARY OF THE INVENTION 
   The various embodiments of the present invention overcome the shortcomings of the prior art by providing a carton with a curved side wall that has a tightening effect on a group of bottles to better stabilize the tapered and bottom portions of a bottle. 
   According to one aspect of the invention, a package includes a carton that encloses a group of articles, where each article is cylindrical with a cross-sectional area that may change in size and shape along the length of the article or otherwise taper, for example from a bottom portion having a maximum cross sectional area to an upper portion having a minimum cross sectional area that is less than the maximum cross sectional area. The carton includes an end closure structure and a pair of opposed side walls that are hingedly connected to opposite edges of the end closure structure, where each side wall includes a top edge, a bottom edge, and an end edge defined by the hinged connection between the side wall and the end closure structure. The end edge is substantially continuously arcuate so that the side wall has a width that varies along extent of the end edge. More specifically, the side wall has a maximum width that is greater than the extent of its bottom edge. The maximum width occurs at a distance from the bottom edge that is no greater than half the carton height, the carton height being defined as the distance between the top edge and the bottom edge. 
   Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims. 
   The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a plan view of an exemplary embodiment of a blank according to the present invention. 
       FIG. 2  is a perspective view of an exemplary embodiment of a carton formed from the blank of  FIG. 1 . 
       FIG. 3  is a perspective view of the carton of  FIG. 2  in an open ended condition. 
       FIG. 4  is a side view of the carton of  FIG. 2  showing the shape of the side walls. 
       FIG. 5  is a side view of the carton of  FIG. 2  showing theshape of the side walls with respect to an exemplary bottle. 
   

   DETAILED DESCRIPTION 
   As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples to illustrate aspects of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known materials or methods have not been described in detail to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but as a basis for the claims and for teaching one skilled in the art to variously employ the present invention. 
   Referring now to the drawings in which like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of an exemplary embodiment of a carton that is adapted for enclosing articles such as glass bottles according to the present invention. Generally speaking, the exemplary carton is formed from any foldable material, but preferably foldable sheet material such as paperboard, corrugated board, plastic, combinations or laminates of these materials, and the like. The carton includes side walls with substantially continuously arcuate or otherwise contoured edges that closely conform to the enclosed articles. 
   Referring now to  FIG. 1 , an exemplary embodiment of an elongated carton blank  100  according to the present invention may be folded and secured or otherwise assembled to form the carton  200  shown in  FIG. 2 . In  FIG. 1 , a unitary blank  100  is shown. Those skilled in the art will understand that two or more blanks may be used to form the illustrated blank  100 . The blank  100  includes primary panels that are hingedly connected one to the next along a longitudinal axis. More specifically, the blank  100  includes an outer top panel  102 , a first side panel  104 , a bottom panel  106 , a second side panel  108 , and an inner top panel  110 . The outer top panel  102  is hingedly connected to the first side panel  104  along fold line  112 , which is substantially transverse to the longitudinal axis of the blank. Thus, fold line  112  defines the top edge of first side panel  104 . The first side panel  104  is hingedly connected to the bottom panel  106  along transverse fold line  114 , which defines the bottom edge of first side panel  104 . The bottom panel  106  is hingedly connected to the second side panel  108  along transverse fold line  116 , which defines the bottom edge of second side panel  108 . The second side panel  108  is hingedly connected to the inner top panel  110  along transverse fold line  118 , which defines the top edge of second side panel  108 . It should be noted that, in an alternative embodiment, an edge flap may be substituted for the inner top panel  110 . In the exemplary embodiment, the bottom panel  106  is substantially wider than the top panels  102 ,  110 . Accordingly, the side panels  104 ,  108  have substantially continuously curving or arcuate end edges and varying width such that a longer bottom edge of each side panel  104 ,  108  is hingedly connected to the bottom panel  106  and a relatively shorter top edge of each side panel  104 ,  108  is hingedly connected to a respective top panel  102 ,  110 . 
   Further, each of the panels  102 ,  104 ,  106 ,  108 , is hingedly connected to opposing and preferably symmetric end flaps, defined in part by substantially longitudinally-oriented fold lines disposed along opposite end edges of the panels  102 ,  104 ,  106 ,  108 . When erected, the end flaps cooperate to form a respective end closure structure  210 ,  212  (shown in  FIG. 2 ). In the embodiments illustrated throughout, each set of end flaps is sufficiently identical that like references have been used, with “a” or “b” affixed to distinguish the components of one end of the carton from the other. In other words, with regard to the illustrated embodiments, typically what applies to the elements designated with an “a” reference applies equally to those elements designated with a “b” reference. Accordingly, for the sake of clarity, the present teaching and description will refer to only those elements with the “a” reference unless a clear understanding of the illustrated embodiments requires a discussion of an element with a “b” reference. 
   A top end flap  120   a  is hingedly connected to the outer top panel  102  along fold line  122   a . A first side end flap  124   a  is hingedly connected along an end edge to the first side panel  104  along fold line  126   a . A bottom end flap  128   a  is hingedly connected to the bottom panel  106  along fold line  130   a . A second side end flap  132   a  is hingedly connected along an end edge to the second side panel  108  along fold line  134   a . It should be noted that each fold line  126   a ,  134   a  forms a plane curve, i.e., fold line  126   a ,  134   a  is substantially continuous and arcuate so as to preferably include no intersecting linear segments, although the degree of curvature along the extent of the fold line  126   a  is not necessarily constant. Rather, it is contemplated that the degree of curvature at any given point P along each fold line  126   a ,  134   a  may be zero, but typically will have some magnitude as dictated by the contour of the intended articles. 
   The side end flaps  124   a ,  132   a  include a respective flap notch  136   a ,  138   a  that facilitates the folding of the side end flaps  124   a ,  132   a  along the arcuate fold lines  126   a ,  134   a , and discourages bowing of the side panels  104 ,  108  during stacking, as will be described in more detail below. 
   The outer top panel  102  and the inner top panel  110  further include optional elements that define a handle and dispenser. More specifically, handle severance lines  140  at least partially define handle punchouts  142  that are hingedly connected to a respective top panel  102 ,  110  along a handle fold line  144 . Here, the handle is illustrated as two elliptical shapes, believed to be comfortable to the user, but all known handles are contemplated and included in the scope of the invention. The blank  100  further includes severance lines  146  that extend from a respective handle severance line  140  and define a panel that may be at least partially torn away to gain access to enclosed articles. Each severance line  146  may be a tear line or any other weakened line that facilitates access to the interior of the carton  200 . It is contemplated that each of the severance lines  146  includes, but is not limited to, a line of perforations, a line of short slits, a line of half cuts, a single half cut, pull tape, rip cords, and any combination of perforations, slits, score lines, half cuts, tape, cord, or the equivalent. As understood by those skilled in the art, the severance lines  146  assist the user with opening the carton and accessing the articles therein. As further understood by one skilled in the art, here the curvature, shape, and/or orientation of the severance lines  146  are merely design choices. Hence, the severance lines  146  are merely illustrative and are not limiting. 
   One method of erecting an open ended tubular carton  200 , as shown in  FIG. 3 , includes folding the blank  100  to connect or otherwise secure the outer surface of the inner top panel  110  to the inside surface of the outer top panel  102 , preferably such that the free edge of the inner top panel is immediately adjacent to the top panel fold line  112 , and such that the respective severance and fold lines  140 ,  142  on the outer and inner top panels  102 ,  110  align to define the handle. More specifically, when the carton  200  is erected, the outer top panel  102  and the inner top panel  110  form a composite top wall  202 , the first side panel  104  forms a first side wall  204 , the bottom panel  106  forms a bottom wall  206 , and the second side panel  108  forms a second side wall  208 . 
   Articles (not shown) may be loaded into the open ends of the tubular carton  200  before folding and securing the end flaps affixed with an “a” reference to form a first end wall  210  and the end flaps affixed with a “b” reference to form a second end wall  212  (shown in  FIG. 2 ). More specifically, the side end flaps  124   a ,  132   a  are folded inwardly along fold lines  126   a ,  134   a , the bottom end flap  128   a  is folded inwardly along fold line  130   a , and the top end flap  120   a  is folded inwardly along fold line  122   a . The flap notches  136   a ,  138   a  facilitate folding the side end flaps  124   a ,  128   a  along the substantially continuously arcuate or otherwise contoured fold lines  126   a ,  134   a  such that the side end flaps  124   a ,  128   a  are allowed to flex as necessary to curve around the base of each end most article. Each flap notch  136   a ,  138   a  preferably extends toward but does not meet the respective fold line  126   a ,  134   a , thereby enabling the side end flaps  124   a ,  128   a  to provide support for the side wall  204 ,  208  along fold line  126   a ,  134   a  to prevent bowing, bulging, or other deformation of the side walls  204 ,  208  when multiple cartons  200  are stacked, while providing flexibility needed to conform to the contours defined by fold lines  126   a ,  134   a . The end flaps  120   a ,  128   a  at least partially overlap the side end flaps  124   a ,  132   a  and may additionally overlap one another. The top panels  102 ,  110  and the end flaps  120   a ,  124   a ,  128   a ,  132   a  may be secured by any means for attaching sheet material including, but not limited to, adhesive, mechanical fasteners, VELCRO, or the like. 
   In the exemplary embodiment, the side walls  204 ,  208  are shaped or otherwise contoured to securely enclose articles (not shown) such as bottles in the carton  200 . The shape and degree of the curvature of the end edges of the side walls  204 ,  208  is selected to conform to the contour and shape of the endmost articles that are disposed adjacent to the end wall closures when the carton  200  is fully loaded. This, the curvature of the end edges of the side walls  204 ,  208 , is most useful when each article gradually tapers or otherwise varies in circumference along its length. By conforming to the shape of the article, the carton  200  offers a tighter fit, thereby discouraging tilting of the articles within, which may result in undesirable clinking that can damage the articles or scuff labels affixed thereto. More specifically, as shown in  FIG. 4 , the width W 1  at the bottom edge of the first side wall  204  is less than the maximum width W 2  at the widest part of the first side wall  204 , as defined as the distance between contact points C where vertical tangent lines T, which are substantially perpendicular to the bottom wall  206 , intersect the arcuate end edges of the first side wall  204 . The contact points C lie above the horizontal plane defined by the bottom wall  206 . More specifically, as shown in  FIG. 5 , the contact points C lie on the artcuate edges of the first side wall  204  within a vertical range between the bottom wall  206  and the shoulder height of an article. For example, in the exemplary embodiment, the contact points C that define the maximum width W 2  of the first side wall  204  are located at a vertical distance H 1  from the bottom wall  206  where the vertical distance H 1  is approximately one-third of the vertical height H 2  of the carton  200 . The width W 3  at the top edge of the side wall  204  is less than the width W 1  at the bottom edge of the side wall  204  and the width W 1  at the bottom edge of the side wall  204  is less than the maximum width W 2 . Thus, the exemplary carton  200  is suitable for enclosing long-necked bottles that taper inward from a maximum circumference at about one-third of the height of the bottle and has a tightening effect on the bottles contained therein to provide additional support to the bottom portion of the bottles. Other embodiments are contemplated to provide a tighter enclosure for the alternatively shaped bottles where the maximum width W 2  is disposed, for example, at about one half the vertical height H 2 . Accordingly, articles that taper equally at both ends and flare in the middle can be accommodated by setting W 1 =W 3  and W 2 &gt;(W 1  or W 3 ). Numerous other article shapes can be accommodated by varying the position of H 1  and the relative lengths of W 1 , W 2 , and W 3 . The most common beverage bottles currently distributed dictate H 1  being disposed at or below approximately one half the carton height H 2 . 
   It must be emphasized that the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. All such modifications, combinations, and variation are included herein by the scope of this disclosure and the following claims.