Abstract:
A method of constructing a carrier for bottles (such as two or four craft beer bottles), wherein the layout fits through a digital printer, is disclosed. A flat of beverage board is printed upon (on one side or both, though all exterior surfaces are derived from one side of the board) with individualized and/or short-run graphics. The flat is die-cut and folded into a square or rectangle closed by a tab that is glued on the back of one of side panels, and bottom flaps are folded and glued into place. A riser extends up from each of a pair of opposite sides to support a handle flap, and the handle flaps are glued together across the top of the rectangle.

Description:
REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Application No. 62/117,193, filed Feb. 17, 2015, with title BOTTLE CARRIER, the entire disclosure of which is hereby incorporated by reference. 
     
    
     FIELD 
       [0002]    The present invention relates to carriers for carrying bottles. More specifically, the present invention relates to structures and assembly of cartons for carrying bottles, the cartons being made of paper board and the like and having a handle for carrying the same. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]      FIG. 1  is a plan view of a flat that may be formed into a bottle carrier according to a first embodiment. 
           [0004]      FIG. 2  is a plan view of a flat that may be formed into a carrier according to a second embodiment. 
           [0005]      FIG. 3  is a plan view of a flat that may be formed into a carrier according to a third embodiment. 
           [0006]      FIG. 4  is a plan view of a flat that may be formed into a carrier according to a fourth embodiment. 
           [0007]      FIG. 5  is an expanded plan view of a detail of the flat of  FIG. 4 . 
           [0008]      FIG. 6  is a flowchart depicting a method of forming a carrier from a flat. 
       
    
    
     DESCRIPTION 
       [0009]    For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the invention as illustrated therein are contemplated as would normally occur to one skilled in the art to which the invention relates. 
         [0010]    Generally, one form of the present apparatus is a carrier that holds two bottles, such as those used for craft beer. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles. This embodiment, illustrated in  FIG. 1 , is a flat form  100  that is die-cut from beverage board (such as that known as “20 pt board” available from most paper merchants), though other materials may also be used as will occur to those skilled in the art.  FIG. 1  shows one side (e.g., a front) of flat  100 , and it will be understood that the opposing side (e.g., the corresponding rear) is essentially a mirror image of the view shown. As discussed in further detail below, form  100  may be assembled or formed into an assembled configuration to form the carrier. 
         [0011]    As shown, form  100  includes front panel  110 , back panel  120 , side panels  130 ,  135 , bottom panels  140 ,  145 , and tab  170  that collectively define a container portion  148 . In the embodiment shown, panels  110 ,  120 ,  130 ,  135  define a top edge extending along a line  149 . Form  100  further includes risers  150  and handle flaps  160  from which carrying holes  165  are fully or partially cut out, extending substantially from line  149  away from top edge, to define a handle portion  158 . In alternative embodiments, portions of handle portion may extend below line  149 . For example, segment  180  may extend below line  149 , thus causing portions of handle flaps  160  to lie below line  149 . It will be understood that in some embodiments, after form  100  is assembled into the assembled configuration, some portions of handle portion  158 , such as portions of handle flaps  160 , may lie below line  149 , due to manufacturing or assembly-related anomalies or inconsistencies. In the embodiment shown, holes  165  are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration. 
         [0012]    Container portion  148  includes a plurality of fold lines  10 ,  12 ,  14 ,  16 ,  18 ,  20 ,  22 ,  24  along which portions of form  100  may be folded in order to form the assembled configuration of form  100 . More particularly, fold line  10  extends between panels  135 ,  110 , while fold line  12  extends between panels  110 ,  130 . Fold line  14  extends between panels  130 ,  120 , and fold line  16  extends between panel  160  and flap  170 . Fold line  18  extends between panels  120  and the adjacent bottom panel  140 , while fold line  20  extends between panel  130  and the adjacent bottom panel  145 . Fold line  22  extends between panel  110  the adjacent bottom panel  140 , and fold line  24  extends between panel  135  and the adjacent bottom panel  145 . Fold lines  190  extend between handle flap  160  and riser  150 . In the embodiment shown, fold lines  10 ,  12 ,  14 ,  16 ,  190  are parallel to one another and perpendicular to fold lines  18 ,  20 ,  22 ,  24 . As shown, fold lines  18 ,  20 ,  22 ,  24  are co-linear when form  100  is unassembled. In the embodiment shown, fold lines  10 ,  12 ,  14 ,  16 ,  18 ,  20 ,  22 , and  24  represent imaginary lines along which form  100  may be folded to form the carrier. However, in some embodiments, any or all of fold lines  10 ,  12 ,  14 ,  16 ,  18 ,  20 ,  22 ,  24  may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  100 . Edges and/or fold lines shown herein as parallel or perpendicular might be substantially (but not precisely) parallel or perpendicular, or may have other relative orientations as will occur to those skilled in the art. 
         [0013]    As form  100  is formed by a die cutting process, for example, handle edge segments  180  are also cut, separating each handle flap  160  from its respective neighboring panel  110  or  120 . Moreover, in the embodiment shown, fold lines  190  are scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  100 . However, in other embodiments, one or both of fold lines  190  may not include such features such that fold lines  190  represent imaginary lines along which flaps  160  may be folded. Moreover, in other embodiments, segments  180  and creases  190  may be treated before or after form  100  is created through a die cutting process. 
         [0014]    After form  100  is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels  135 ,  110 ,  130 , and  120  are folded at approximately 90-degree angles to form a rectangular shape, in cross section, such as in cross section along line  149  (e.g., block  302  of  FIG. 6 ). Tab  170  is likewise folded to be inside side panel  135  and attached with any suitable glue or other adhesive or bonding agent or non-adhesive technique such as a tab-and-slot configuration (all generically “glued” or “attached” herein) as will occur to those skilled in the art (e.g., block  304  of  FIG. 6 ). More particularly, panel  135  is folded along fold line  10 , panel  110  is folded along fold line  12 , and panel  120  is folded along fold line  14 , such that panels  110 ,  120  end up being parallel to one another and each end up perpendicular to panels  130 ,  135 . As mentioned above, tab  170  is folded inside panel  135  and bonded thereto, such that a bonding is provided between tab  170  and panel  135  along a third plane that is substantially perpendicular to line  149  and parallel to a second plane (block  306  of  FIG. 6 ). More specifically, in the illustrated embodiment, tab  170  is bonded to the back of panel  135 . Thus, panels  110 ,  120 ,  130 ,  135  will remain in the substantially rectangular cross-sectional shape, due at least in part to the bonding between tab  170  and panel  135 . As shown, panels  110 ,  120  define a length of the rectangular cross-sectional shape, and panels  130 ,  135  define a width of the rectangular cross-sectional shape. In the present embodiment, the length as defined by panels  110 ,  120  is longer than the width defined by panels  130 ,  135 . However, other suitable relative dimensions of panels  110 ,  120 ,  130 ,  135  and other portions of flat  100  that may be provided in order to accommodate a particular amount and/or size of bottles or articles will be apparent to persons skilled in the art in view of the teachings herein. 
         [0015]    In order to form the bottom portion of the expanded carrier configuration of form  100 , bottom panels  140  and  145  are folded up along their respective fold lines  18 ,  20 ,  22 ,  24  and glued together. In the embodiment shown, in the assembled configuration, bottom panels  140 ,  145  lie substantially perpendicularly to each of the panels  110 ,  120 ,  130 ,  135 . Thus, in the embodiment shown, panels  110 ,  120 ,  130 ,  135 ,  140 ,  145  in the assembled configuration define a single compartment extending substantially from bottom panels  140 ,  145  to line  149  (e.g., block  302  of  FIG. 6 ). More particularly, panels  110 ,  120 ,  130 ,  135  define sidewalls of a compartment, while bottom panels  140 ,  145  collectively define a bottom portion or bottom wall of a compartment. 
         [0016]    Handle flaps  160  are folded at fold lines  190  so that they extend perpendicular to risers  150  and parallel to side panels  130  and  135  (blocks  308 ,  310  of  FIG. 6 ). The rear portions of each of handle flaps  160  are glued together such that each of the holes  165  is aligned with the other to form a single opening in handle portion  158 , and such that flaps  160  lie substantially along a second plane in order to form a unitary handle of handle portion  158  (blocks  312 ,  314  of  FIG. 6 ). In the embodiment shown, the second plane essentially bisects container portion  148  such that the handle formed by handle portion  158  lies at the midpoint between panels  130 ,  135 . Thus, in the embodiment shown, handle portion  158  essentially defines two cells above line  149  that are each suitable for holding a bottle. Accordingly, while carton portion  148  defines a single compartment as described above, handle portion  158  allows for an effective separation of bottles or other articles that may be placed in the compartment of carton portion  148 . 
         [0017]    In some implementations, before or after form  100  is cut out, form  100  may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form  100 . In some of these implementations, the text and/or graphics are customized by a third party, automatically computer-generated per a remote customer&#39;s request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities and/or digital printing technology. Because of the configuration of form  100  as described herein, text and graphics need only be applied to one side of form  100  in its flattened configuration in order to display such text and/or graphics on the surfaces of form  100  that are on the outside when form  100  is in its expanded, carrier configuration. 
         [0018]      FIG. 2  shows another embodiment of a form  200  that may be constructed or formed into an assembled configuration to make a carrier configured to hold four bottles. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles as will occur to those having ordinary skill in the art in view this disclosure. This embodiment, illustrated in  FIG. 2 , is also a form  200  that is die-cut from beverage board, though other materials may also be used as will occur to those skilled in the art. Form  200  is similar to form  100 , except for the differences below. Moreover, while  FIG. 2  shows one side (e.g., a front) of flat  200 , it will be understood that the opposing (e.g., rear) side is essentially a mirror image of the view shown in  FIG. 2 . 
         [0019]    Form  200  includes front panel  210 , back panel  220 , side panels  230 ,  235 , bottom panels  240 ,  245 , and tab  270  that collectively define a container portion  248 . In the embodiment shown, panels  210 ,  220 ,  230 ,  235  define a top edge extending along a line  249 . Form  200  also includes risers  250   a,    250   b  and handle flaps  260   a ,  260   b  extending substantially from line  249  away from top edge, that define a handle portion  258 . As shown, handle flap  260   a  and riser  250   a  extend from panel  230  such that a portion of flap  260   a  is outboard of panel  230  and flap  270 . Handle flap  260   b  extends from panels  235 ,  210 , and riser  250   b  extends from panel  235 . 
         [0020]    As form  200  goes through the die-cutting process, handle edge segments  280   a ,  280   b  are also cut, separating handle flap  260   a  from panel  230 , and separating handle flap  260   b  from panels  235 ,  210 . In the embodiment shown, fold lines  290  are scored, perforated, or otherwise treated or configured to facilitate later handling or assembly of the form  200  during the die cutting process. However, in other embodiments, one or both of fold lines  290  do not include such features, so fold lines  290  represent imaginary lines along which flaps  260   a,    260   b  may be folded relative to risers  250   a,    250   b.  Moreover, in other embodiments, segments  280   a,    280   b  and fold lines  290  may be treated before or after form  200  is created through a die cutting process. In the embodiment shown, handle flaps  260   a,    260   b  each include carrying holes  265  that are cut out from handle flaps  260   a,    260   b.  As shown in the present embodiment, holes  265  are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration. In the embodiment illustrated in  FIG. 2 , holes  265  include an obround shape, but in other embodiments may include any other suitable shape as will occur to persons skilled in the art in view of the teachings herein. 
         [0021]    In alternative embodiments, portions of handle portion  258  may extend below line  249 . For example, segments  280   a,    280   b  may extend below line  249 , thus causing portions of handle flaps  260   a,    260   b  to lie below line  249 . It will be understood that in some embodiments, after form  200  is formed into the assembled configuration, some portions of handle portion  258 , such as portions of handle flaps  260   a,    260   b,  may lie below line  249 , due to manufacturing or assembly related anomalies or inconsistencies. 
         [0022]    Container portion  248  comprises a plurality of fold lines  26 ,  28 ,  30 ,  32 ,  34 ,  36 ,  38 ,  40  along which portions of form  200  may be folded in order to form the assembled configuration of form  200 . As shown, fold line  26  extends between panels  220 ,  235 , while fold line  28  extends between panels  235 ,  210 . Fold line  30  extends between panels  210 ,  230 , and fold line  32  extends between panel  230  and flap  270 . Fold line  32  extends between panel  230  and the adjacent bottom panel  240 , while fold line  36  extends between panel  210  and the adjacent bottom panel  245 . Fold line  38  extends between panel  235  and the adjacent bottom panel  240 , and fold line  40  extends between panel  220  and the adjacent bottom panel  245 . Fold lines  290  extend between handle flap  260   a,    260   b  and riser  250   a,    250   b.  In the embodiment shown, fold lines  26 ,  28 ,  30 ,  32 ,  190  are parallel to one another and perpendicular to fold lines  34 ,  36 ,  38 ,  40 . As shown, fold lines  34 ,  36 ,  38 ,  40  are collinear when form  200  is unassembled. In the embodiment shown, fold lines  26 ,  28 ,  30 ,  32 ,  34 ,  36 ,  38 ,  40  represent imaginary lines along which form  200  may be folded to form the carrier. However, in some embodiments, any or all of fold lines  26 ,  28 ,  30 ,  32 ,  34 ,  36 ,  38 ,  40  may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  200 . 
         [0023]    After form  200  is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels  230 ,  210 ,  235 , and  220  are folded at approximately 90-degree angles with each other to form a rectangle, in cross section, such as in cross section along line  249  (e.g., block  302  of  FIG. 6 ). Tab  270  is likewise folded to be inside side panel  220  such that it is glued to the back of panel  220  (e.g., block  304  of  FIG. 6 ). Accordingly, a bonding or non-bonding attachment (as will occur to those skilled in the art) is provided between tab  270  and panel  220  along a third plane that is substantially perpendicular to line  249  and parallel to a second plane (block  306  of  FIG. 6 ). 
         [0024]    In order to form the bottom portion of the expanded carrier configuration of form  100 , bottom panels  240  and  245  are folded up along their respective fold lines  34 ,  36 ,  38 ,  40  and glued together. In the embodiment shown, in the assembled configuration, bottom panels  240 ,  245  lie substantially perpendicularly to each of the panels  210 ,  220 ,  230 ,  235 . Thus, in the embodiment shown, panels  210 ,  220 ,  230 ,  235 ,  240 ,  245  in the assembled configuration define a single compartment extending substantially from bottom panels  240 ,  245  to line  249  (block  302  of  FIG. 6 ). More particularly, panels  210 ,  220 ,  230 ,  235  define sidewalls of a compartment while bottom panels  240 ,  245  collectively define a bottom portion or bottom wall of a compartment. 
         [0025]    Handle flaps  260   a,    260   b  are folded at fold lines  290  so that they extend perpendicular to risers  250   a,    250   b,  and parallel to front and rear panels  210 ,  220  (blocks  308 ,  310  of  FIG. 6 ). The rear portions of each of handle flaps  260   a,    260   b  are glued together such that each of the holes  265  is aligned with the other to form a single opening in handle portion  258 , and such that flaps  260   a,    260   b  lie substantially along a second plane in order to form a unitary handle of handle portion  258  (blocks  312 ,  314  of  FIG. 6 ). In the embodiment shown, the second plane essentially bisects container portion  248  such that handle of handle portion  258  lies at the midpoint between panels  210 ,  220 . Thus, in the embodiment shown, handle portion  258  essentially defines two cells above line  249  that are each suitable for holding two bottles. Accordingly, while container portion  248  defines a single compartment as described above, handle portion  258  allows for an effective separation of bottles or other articles that may be placed in the compartment of container portion  248 . 
         [0026]    In some implementations, before or after form  200  is cut out, form  200  may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form  200 . In some of these implementations, the text and/or graphics are customized by a third-party, automatically computer-generated per a remote customer&#39;s request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities. Due to the configuration of form  200  as described herein, text and graphics need only be applied to one side of form  200  in its flattened configuration in order to display such text and/or graphics on the front or outer portion of form  200  in its expanded, carrier configuration. 
         [0027]      FIG. 3  shows another embodiment of a form  300  that may be constructed or formed into an assembled configuration to make a carrier. Form  300  is substantially similar to form  100 , discussed above with reference to  FIG. 1 , except for the differences below. For that reason, substantially similar or identical structures are not labeled with reference numerals. As shown, form  300  includes exemplary alternative bottom panels  340 ,  342 ,  344 ,  346  that are configured differently than bottom panels  140 ,  145 . As shown, panels  340 ,  344  include a substantially rectangular shape. Panels  342 ,  346  include features that allow those panels to lock together as bottom panels  340 ,  342 ,  344 , and  346  are folded upwardly to form a bottom of carrier. As shown, panel  344  includes dimensions that allow it to substantially cover the surface area of the bottom portion of carrier in the expanded configuration. For example, panel  344  has substantially the same width as panel  110  and a height that substantially matches the width of panel  130  so that panel  344  substantially covers the bottom of the container portion of the carrier when it is assembled. Other suitable configurations (including relative size, shape, and other features) of bottom panels  340 ,  342 ,  344 ,  346  will be apparent to persons skilled in the art in view of the teachings herein. 
         [0028]    Form  300  includes an exemplary alternative handle portion  358 . Particularly, handle portion  358  includes an alternative segment (cut)  380  that includes a substantially straight, horizontal portion  380   a  and a curved portion  380   b,  as seen best in  FIG. 5 . Thus, segment is cut along horizontal portion  380   a  and curved portion  380   b.  Including the curved portion  380   b  in segment  380  may decrease the tendency of handle portion  358  to tear at the junction between the risers  150  and adjoining panels  110 ,  120 , respectively. Form  300  also includes an alternative fold line  390 . Fold line  390  comprises an upper portion  390   a,  middle portion  390   b,  and lower portion  390   c.  As shown, middle portion  390   b  is scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  300 , such as folding of the handle flaps  160 . As shown, upper and lower portions  390   a,    390   c  represent imaginary lines along which form  100  may be folded to form the carrier. However, in other embodiments, upper and lower portions  390   a,    390   c  may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  300 . In some embodiments, such a configuration may give additional strength to handle portion  358 . For example, such a configuration may decrease the tendency of handle portion  358  to tear at the junction between the risers  150  and adjoining panels  110 ,  120 , respectively. Other suitable configurations of handle portion  358  will be apparent to persons skilled in the art in view of the teachings herein. 
         [0029]      FIG. 4  shows another embodiment of a form  400  that may be constructed or formed into an assembled configuration to make a carrier. Form  400  is substantially similar to form  200 , except for the differences below. For that reason, substantially similar or identical structures are not labeled with reference numerals. As shown, form  400  includes exemplary alternative bottom panels  440 ,  442 ,  444 ,  446  that are configured differently from bottom panels  240 ,  245 . Panels  442 ,  446  include features that allow those panels to lock together or be attached more securely to bottom panels  440 ,  444  as bottom panels  440 ,  442 ,  444 , and  446  are folded upwardly to form a bottom of carrier. As shown, panel  444  includes dimensions that allow it to substantially cover the surface area of the bottom portion of carrier in the expanded configuration. For example, panel  444  has substantially the same width as panel  235  and a height that substantially matches the width of panel  210 . Other suitable configurations of bottom panels  440 ,  442 ,  444 ,  446  will be apparent to persons skilled in the art in view of the teachings herein. 
         [0030]    Form  400  includes an exemplary alternative handle portion  458 . Particularly, handle portion  458  includes an alternative segment  480  that includes a horizontal portion  480   a  and a curved portion  480   b,  as seen best in  FIG. 5 . It will be understood that although segments  380 ,  480  and fold lines  390 ,  490  are different, respectively, the portions shown in the close-up view of  FIG. 5  are substantially identical. Thus,  FIG. 5  is used to demonstrate and show such structures of form  400  as well. 
         [0031]    As shown, segment  480  is cut along horizontal portion  480   a  and curved portion  480   b.  Including the radius of curved portion in segment  480  may decrease the tendency of handle portion  458  to tear at the junction between the risers  250   a ,  250   b  and adjoining panels  230  and  210 ,  235 , respectively. Form  400  also includes an alternative fold line  490 . Fold line  490  comprises an upper portion  490   a , middle portion  490   b,  and lower portion  490   c.  As shown, middle portion  490   b  is scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  400 , such as folding of the handle flaps  260   a,    260   b.  As shown, upper and lower portions  490   a,    490   c  represent imaginary lines along which form  100  may be folded to form the carrier. However, in other embodiments, upper and lower portions  490   a,    490   c  may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form  400 . Such a configuration may provide for additional strength of handle portion  458 . For example, such a configuration may decrease the tendency of handle portion  458  to tear at the junction between the risers  150  and adjoining panels  110 ,  120 , respectively. Other suitable configurations of handle portion  458  will be apparent to persons skilled in the art in view of the teachings herein. 
         [0032]    All publications, prior applications, and other documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.