Abstract:
A new type of secondary locking system for article carriers consisting of at least one secondary male lock with two shoulders that is attached by a neck to the edge of a outer flap on the carrier for use with a primary locking system. An inner flap has a secondary female opening for each secondary male lock. The secondary female opening is formed by a secondary cut line and fold line with the center of the fold line projecting towards the edge of the flap while of the center of the secondary cut line projects away from the edge of the flap to guide the secondary male lock into a flat position against the inside of the inner flap. The shoulders on the secondary male lock are engaged against locking ledges along the extensions of the secondary cut line. A pair of slits may be formed at the end of the fold lines that project inwardly to allow the secondary male lock to slide into a flat position. This locking system is especially useful in wrapping containers that have a flat bottom that would interfere with conventional locking systems.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates generally to a carrier for carrying containers or other types of articles. This carton has a flat primary and secondary locking system for interlocking the bottom flaps. The primary and secondary locks interlock in a flat plane and remain locked in spite of the containers having a flat bottom. This carrier may be used to carry cans and bottles or containers of various shapes and sizes.  
         [0003]     2. Background of the Invention  
         [0004]     Wrap-around carriers for carrying bottles or cans may be secured by locks. These carriers typically have a primary and secondary locking system which interlocks two bottom flaps together. Containers that have flat bottoms frequently interfere with these locking systems as the secondary locks in particular usually need to project into the carton and do not lie in a flat plane. It would be desirable to have a secondary locking system in which the locks lie in a flat plane and securely hold the carrier together.  
       SUMMARY OF THE INVENTION  
       [0005]     Briefly described, the present invention relates to a wrap-around carrier which is held together by a primary and secondary locking system. This carrier has a bottom panel formed from the inner flap and an overlapping outer flap which are interlocked. Each primary lock has a primary male lock which is formed by a slit cut in the outer flap and a primary lock ledge formed in a primary female opening in the inner flap. The primary male lock is engaged with the primary lock ledge with the primary locking system lying flat against the bottom panel of the carrier.  
         [0006]     The secondary locking system has at least one secondary male lock with two shoulders that is connected by a neck to the edge of the outer flap. A secondary female opening is formed in the inner flap for each secondary male lock. This secondary female opening is formed further from the edge of the inner flap than the primary female opening. Each secondary female opening is formed by a cut line and fold line with the fold line being closer to the edge of the inner flap than the cut line. The fold line has a center that is closer to the edge of the inner flap than the ends of the fold line. Preferably, the fold line is arcuate in shape. The cut line for forming this secondary female opening has a center that is further from the edge of the inner flap than the ends of the cut line. Preferably, this secondary cut line is V shaped. This secondary cut line extends beyond each end of the fold line to form a secondary locking ledge along the side of the extension cut remote from the edge of the inner flap with a shoulder of a secondary male lock locked against the locking ledge. The secondary cut line meets, or nearly meets, the fold line at each of its ends. A female flap is formed in this secondary female opening. Placing the fold line and cut line so that the distance between them is wider at the center provides resistance against the female flap folding when the secondary male lock is inserted into the female opening that it assists in guiding the secondary male lock into a position flat against the inside of the inner flap. The center of the cut line being further removed from the edge of the inner flap also helps guide the secondary male lock into a flat position against the inside of the inner flap. A couple of slits may be placed near where each end of the fold line meets the secondary cut line, with the slits extending away from the edge of the inner flap. These slits assist in letting the secondary male lock slide flat against the inner flap. The distance between these slits for each secondary female opening is preferably greater than the distance between the edges of the neck of the secondary male lock to allow the neck to fit between the slits. This helps insure that the locking ledge is not pushed out of the plane of the inner flap which could allow a shoulder to pass through the extension cut and unlock the secondary male lock. A slight turn can be placed in the end of the cut line forming the extension to prevent this cut line from tearing under the stress of the secondary lock being locked.  
         [0007]     The carrier of this invention can be used to carry a single row or multiple rows of containers. This carrier can be used with both bottles and cans and also with plastic tubs.  
         [0008]     The fact that the secondary locking system lies flat against the inside of the inner bottom flap allows this lock system to be used with containers, such as plastic tubs, that have a flat bottom. The primary locking system lies flat against the bottom inner flap as well.  
         [0009]     The carrier of this invention may have open ends. Retaining flaps can be placed on the top or bottom of the ends of this carrier to prevent the bottles or cans from falling out. The locking system of this invention can be used with carriers that have other means of preventing the cans or bottles from falling out of the ends of the carrier or with carriers that are fully enclosed. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.  
         [0011]      FIG. 1  is a plan view of a carrier blank for forming a carrier to contain six cans of one embodiment of this invention.  
         [0012]      FIG. 2  is a perspective view of a carrier made from the blank of  FIG. 1  and wrapped around six cans with the carrier being shown in the inverted position which shows the secondary male locks lined up in preparation for locking.  
         [0013]      FIG. 3  is a perspective view of the carrier of  FIG. 2  with a secondary male locks having being inserted part way into the secondary female openings.  
         [0014]      FIG. 4  is a perspective view of the carrier of  FIG. 3  in which the secondary male locks have been inserted into the secondary female openings and locked.  
         [0015]      FIG. 5A  is a fragmentary view of a primary and secondary lock in the process of being locked.  
         [0016]      FIG. 5  is a fragmentary view of a primary and secondary lock that have been engaged.  
         [0017]      FIG. 6  is a perspective cross-section of a bottom panel of  FIG. 5  taken across line  6 - 6  showing how the primary and secondary locks lie basically flat.  
         [0018]      FIG. 7  is a plan view of a carrier blank for forming a carrier to contain six bottles of one embodiment of this invention.  
         [0019]      FIG. 8  is a perspective view of a carrier made from the blank of  FIG. 7  and wrapped around six bottles with the carrier being shown in the invented position with all of the primary and secondary locks locked.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]     The present invention is primary for use with cans, bottles or tubs used to contain food or drink. The present invention is especially useful in wrapping containers that have a flat bottom.  
         [0021]     As illustrated in  FIG. 1 , the blank  10  for forming one embodiment of this invention is formed from a foldable sheet of material, such as paperboard. The blank  10  for forming the carrier of this invention has an outer flap  12  that is attached to a side panel  14  by fold line  16  and in turn attached to top panel  18  by fold line  20 . Top panel  18  is attached to opposite side panel  22  by fold line  24  and in turn attached to inner flap  26  by fold line  28 .  
         [0022]     Finger flaps  30 A-B may be provided by cut lines  36 A-B and fold lines  32 A-B, which when opened provide finger apertures  36 A-B for carrying the carrier. A dispenser flap  40  is formed in the top panel  18  by tear lines  38 A-B. A starting tab  42  which is attached to dispensing flap  40  by fold line  44  may be provided to start the removal of the dispenser flap  40  which will provide a dispenser opening for removing the cans from the carrier.  
         [0023]     Heel apertures  46 A-F in which fingers of the packaging machine may be inserted to tighten the carrier around a group of cans may be provided. These heel apertures  46 A-F also assist in holding the cans in the proper position. The tops of the cans may be held within the carrier by the provision of tuck-in flaps  48 A-D which are attached to respective side panel  14  or  22  by fold line  50 A-D, and corner gusset panels  52 A-H. These tuck-in flaps  48 A-D and corner gusset panels  52 A-H are constructed by providing fold lines  54 A-H,  56 A-H and  58 A-H. Apertures  60 A-H may be provided to assist in folding the tuck-in flaps  48 A-D and corner gusset panels  52 A-H into position for holding cans in the carrier.  
         [0024]     This carrier is held together by a combination of a primary locking system and a secondary back-up locking system. Primary male locks  64 A-C are formed along fold line  62  for engaging and locking with the respective primary lock ledge  68 A-C formed in primary female aperture  66 A-C.  
         [0025]     The secondary male locks  70 A-E are formed as an extension of outer flap  12  to which they are attached by necks  75 A-C. Secondary female openings  74 A-C are formed in inner flap  26  by secondary cut lines  76 A-C and fold lines  84 A-C which are generally parallel to the terminal edge  88  of the inner flap  26 . Extension cuts  80 A-F of secondary cut line  76 A-E are provided to allow the shoulders  72 A-F of the secondary male locks  70 A-C to pass through the inner flap  26  in the locking operation into the locked position against locking ledges which are illustrated in  FIG. 5A  by numerals  87 E-F. These locking ledges  87 A-F are adjacent the extension cuts  80 A-F on the side of the cut remote from the terminal edge  88  of inner flap  26 . Terminal cuts  82 A-F may be provided at the end of each extension cut  80 A-F to prevent the cut from tearing into the inner flap  26  under the stress imposed by the shoulders  72 A-F of the secondary male locks  70 A-C when they are inserted through the extension cuts  80 A-F during locking.  
         [0026]     The blank  10  is wrapped around a group of six cans in two rows and secured by locking the primary and secondary locks together. The tuck-in flaps  48 A-D are folded inwardly and held in position by the cans adjacent to the ends of the carton and the side panels  14  and  22 . These tuck-in flaps  48 A-D hold the corner gusset panels  52 A-H in position adjacent a corner of a can as illustrated in  FIG. 2 , which shows the carrier in the inverted position. The outer flap  12  is overlapped over the inner flap  26  and the primary male locks  64 A-C are inserted into the primary female apertures  66 A-C and locked against the primary lock ledges  68 A-C as illustrated in  FIGS. 2-4 .  
         [0027]     The secondary male locks  70 A-C are inserted into the secondary female openings  74 A-C as illustrated in  FIG. 3  which also shows the carrier in the inverted position to illustrate the locking of the carrier. The packaging machine continues the locking operation by pushing the secondary male locks  70 A-C fully into the secondary female openings  74 A-C as shown in  FIG. 4 . The secondary male lock  70 A-C is guided into a flat position against the inside of the inner flap  26  by the configuration of the secondary cut line  76 A-C which is further from the terminal edge  88  of the inner flap  26  at the center than the ends of the secondary cut line  76 A-C. This secondary cut line  76 A-C preferably is V shaped with an apex which aids in guiding the secondary male lock  70 A-C into the flat position. The center of the fold line  84 A-C is closer to the terminal edge  88  of the inner flap  26  than the ends of the fold lines. The configuration of the secondary cut lines  76 A-C and fold lines  84 A-C results in the formation of a secondary female flap  77 A-C that is wider at the center than at the ends. This provides resistance against the secondary female flap being pushed inwardly which aids in ensuring that the secondary male locks  70 A-C lie in a flat plane. The secondary female flaps  77 A-C also stay in a flat plane because of their resistance against being pushed inwardly. Each fold line  84 A-C turns at each end until it meets or nearly meets a secondary cut line  76 A-C. The preferred configuration for the secondary female opening  74 A-C is for the fold line  84 A-C to be arcuate in shape and for the secondary cut line  76 A-C to be V shaped and have an apex  78 A-C.  
         [0028]     The manner in which the secondary male lock  70 C enters the secondary female opening  74 C is illustrated in  FIG. 5A . The completion of the inner locking of the primary male lock  64 C against the primary lock ledge  68 C is illustrated in  FIG. 5 .  
         [0029]     As shown in  FIG. 5A  the secondary male lock  70 C is lined up to be inserted into secondary female opening  74 C with the shoulders  72 E-F lined up to be inserted through extension cuts  80 E-F. In order to have a secondary locking system that is flat as possible so it is not hampered by the flap bottoms of the containers, it is necessary that all parts of inner flap  26  and outer flap  12  be in the same plane or only slightly disposed from the plane.  
         [0030]     This feat is aided with the secondary locking system of this invention by the introduction of two additional features which also help insure that the secondary locks remain securely locked. Slits  86 A-F may be provided to permit the slight displacement outwardly of the portion of the inner flap  26  between the slits as shown by slits  86 E and  86 F adjacent to secondary cut line  76 C in  FIGS. 5 and 5 A. These slits  86 A-F extend from the secondary cut line  76 A-E away from the terminal edge  88 . Each slit is located near an end of fold line  84 A-E. This slight displacement between slits  86 E and  86 F is necessary to allow the neck  75 C of the secondary male lock  70 C to be located in the secondary female opening  74 C. These slits  86 A-F allow the locking ledges  87 E-F to return to the plane of the inner flap  26  after the shoulders  72 E-F have passed through extension cuts  80 E-F and the secondary male lock is in the locked position as shown in  FIG. 5A . As shown in  FIGS. 5A and 5 , if the locking ledges  87 E-F were displaced from the plane of inner flap  26  and therefore in a different plane than locking lands  85 E-F on the other side of extension cuts  80 E-F then the shoulders  72 E-F could pass back through extension cuts  80 E-F and the secondary male lock  70 C would become unlocked. In order for the locking ledge  87 E-F to return to the same plane as locking lands  85 E-F, the distance B between the edges  73 E-F of the neck  75 C should be less than the distance A between slits  86 E-F as shown in  FIG. 5A .  
         [0031]     Both the primary male lock  64 C and secondary male lock  70 C are shown in a substantially flap position in  FIG. 6 . The fact that the containers in the carrier have flat bottoms does not interfere with the primary and secondary locking arrangement of this invention.  
         [0032]     This carrier loaded with cans can be carried when finger flaps  30 A-B have been pushed inwardly. This carrier can be opened by tearing tear lines  38 A-B by grasping the starting tab  42  and pulling the dispenser flap  40  open.  
         [0033]     It should be realized that many other types of can packs can utilize the primary and secondary locking arrangement of this invention. The primary and secondary locking system of this invention can also be used to wrap various types of articles and other types of containers such as tubs and bottles. This locking system can be used for locking wrap-around carriers carrying containers in one, two, or more rows.  
         [0034]     A blank  110  for forming another embodiment of this invention which is a wrap-around carrier for carrying six bottles in two rows in illustrated in  FIG. 7 . The carrier made from this blank  110  uses the same primary and secondary locking system as the carrier made from the blank  10  illustrated in  FIG. 1 . The same sequence of numbers from  62  to  82  is used to refer to the locking system in the blank  110  illustrated in  FIG. 7  as are used in  FIG. 1 .  
         [0035]     The blank  110  illustrated in  FIG. 7  has an outer flap  112  connected to a lower side panel  114  by fold line  116  and connected to upper side panel  118  by fold line  120  and in turn connected to top panel  122  by fold line  124  and to upper side panel  126  by fold line  128 . Upper side panel  126  is connected to lower side panel  130  by fold line  132  and to inner flap  134  by fold line  136 .  
         [0036]     The carrier made from the blank  110  has finger apertures  138 A-B for carrying the loaded carrier. Bottle cap apertures  140 A-F are provided for assisting in holding the bottles in the carrier with open ends and also to produce a tighter wrap around the bottles. Expansion slits  142 A-F are provided to prevent the tearing of bottle cap apertures  140 A-F and to allow the nesting of the bottle caps and necks in the bottle cap apertures  140 A-F. End flaps  144  and  148  which are connected to top panel  122  by fold lines  146  and  150  respectively are provided. Gusset panels  152 A-D permit the end flaps  144  and  148  to be folded down to assist in holding the bottles in the carrier. Gusset panels  152 A-D are attached to upper side panel  118  or upper side panel  126  by fold lines  154 A-D.  
         [0037]     Heel apertures  156 A-F may be provided where the heel of the bottle can be nested to assist in holding the bottles in the carrier and the carrier being tightly wrapped around the group of bottles. Using heel aperture  156 A as an example, twin doors  158 A-B are provided which are separated by cut  162 . Expansion slits  164  are provided so the heel of the bottle can nest tightly in a heel aperture  156 A without tearing the carrier.  
         [0038]     The blank  110  is wrapped around a group of bottles in much the same way as the blank  10  is wrapped around a group of cans. The blank  110  is draped over a group of six bottles in two rows and the upper side panels  118  and  126  and lower side panels  114  and  130  folded downwardly. A portion of the bottle cap and neck of the bottle will project through each bottle cap aperture  140 A-F. End flaps  144  and  148  are folded down in into the locked position in which they are held by the gusset panels  152 A-F. The doors  158 A-B of heel aperture  156 A and the doors of the other heel apertures  156 B-F are pushed inwardly and the heel of the bottle inserted between the doors into each heel aperture  156 A-F. The doors, as illustrated by  158 A-B assist in holding the bottle within the heel aperture. The inner flap  134  is folded against the bottom of the bottles with outer flap  112  being folded and overlapping inner flap  134 . The primary male locks  64 A-C are inserted in primary female apertures  66 A-C and engaged with primary lock ledges  68 A-C. Secondary male locks  70 A-C are inserted through secondary female openings  74 A-C so the shoulders  72 A-F of the secondary male locks  70 A-C engage the secondary locking ledges (see  87 E-F in  FIG. 5A ) formed by extension cuts  80 A-F. Both the primary male lock  64 A-C and secondary male lock  70 A-C lie substantially flat against the inside of the inner flap  134 .  
         [0039]     The primary locking system and secondary locking system of this invention can be used for wrap-around carriers for cans, bottles and tubs. It may also be used for fully enclosed carriers, such as twelve pack carriers for cans for locking the ends of the carrier. In this case, the ends of the carrier are interlocked with the primary and secondary locking system of this invention.  
         [0040]     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.