Patent Publication Number: US-2011065557-A1

Title: Carton assembly having a waterproof lining

Description:
BACKGROUND OF THE INVENTION 
     I. Related Applications 
     The present disclosure claims the right to priority based on U.S. Provisional Patent Application No. 60/808,577 filed on May 26, 2006, which is incorporated herein by reference. p. II. Field of the Invention 
     The present invention relates to a carton assembly having a waterproof lining. More particularly, the present invention relates to a folded carton, a method of manufacturing a folded carton, and a method for assembling a carton, having a waterproof lining for securing and retaining wet or frozen articles therein. 
     III. Description of the Related Art 
     Collapsible cartons have been used across various industries for storing and transporting articles. Specifically, planar material, such as synthetic, cardstock, paperboard, or “cardboard”, has traditionally been cut and perforated to form blanks which are folded into receptacles for retaining various articles. For example, some industries, including manufacturers and retailers, may provide their customers with such receptacles for transporting and/or storing purchased items. These receptacles are generally provided to the customer in any range of assembly, from completely collapsed to fully constructed cartons. Moreover, they are generally provided to the customer as a unitary or two-piece carton, without any accompanying sheets or liners. 
     In some cases, the articles retained in such cartons contain liquid which may contact and permeate the carton. In the event that these articles include food, such as meat or fish products, whether fresh or frozen, the saturation of the carton by liquids therein (e.g., salt water, oils, etc.) may be undesirable or unsanitary. For example, when ice is used to preserve food products stored in the carton, it is undesirable for melting ice to saturate and impair the structural integrity of the carton. If an item itself is frozen, it may thaw, partially or completely, thereby releasing liquids inside the carton. In another instance, such as when the articles may include inks or other permanent color markings, it is undesirable for the liquids to seep from within the carton to contact, and possibly stain, objects outside of the carton. Furthermore, in some cases, it is undesirable for outside contaminants to contact those articles retained within the carton. 
     Thus, it is desirable to provide an economical and accessible carton for storing and/or transporting various articles. It is also desirable to retain the articles so as to prevent associated liquids in the container from either penetrating, and/or leaking from, the carton, as well as to prevent outside contaminants from possibly contacting the contents of the carton. It is also desirable that the carton be configured so that a wet or frozen item can be loaded into and sealed in the carton quickly, without adding down-time to a packing assembly line. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is directed to a carton, a method of manufacturing a carton, having a waterproof lining, that substantially overcomes one or more of the problems caused by the limitations and disadvantages of related cartons and methods. The methods of the present invention will provide cartons which, when assembled, will have a convenient waterproof lining, a much lower incidence of unusable cartons due to leakage, a quicker loading capability, and consequently, a lower overall cost, to the carton manufacturer, the carton packer/shipper, and the ultimate purchasers of the packaged items. 
     To achieve these and other advantages, and in accordance with the purposes of the invention, as embodied and broadly described, it is an object of the invention to provide a carton assembly comprising: a container portion comprising a base portion, defining a plane, said base portion defined by leading and trailing end edges, and first and second side edges; a leading end flap, foldably attached to, and extending from, the leading end edge; a trailing end flap, foldably attached to, and extending from, the trailing end edge; a first side flap, foldably attached to, and extending from, the first side edge; and a second side flap, foldably attached to, and extending from, the second side edge; wherein said leading and trailing end flaps, and first and second side flaps, fold away from the plane to define a container; and a waterproof lining portion fixed to the container portion, configured to provide an enclosure around an object placed in the container. 
     It is a further object of the invention to provide a method of assembling a carton having a waterproof lining, comprising the steps of: feeding a carton blank in a first direction, the carton blank comprising: a base portion, defining a plane, said base portion defined by leading and trailing end edges, and first and second side edges; a leading end flap, foldably attached to, and extending from, the leading end edge; a trailing end flap, foldably attached to, and extending from, the trailing end edge; a first side flap, foldably attached to, and extending from, the first side edge; and a second side flap, foldably attached to, and extending from, the second side edge; feeding a synthetic sheet under tension in a second direction; cutting a waterproof lining from the synthetic sheet; and affixing the waterproof lining to the carton blank. 
     It is a still further object of the present invention to provide an apparatus for manufacturing a carton having a waterproof lining, comprising: a means for feeding a carton blank in a first direction, the carton blank comprising: a base portion, defining a plane, said base portion defined by leading and trailing end edges, and first and second side edges; a leading end flap, foldably attached to, and extending from, the leading end edge; a trailing end flap, foldably attached to, and extending from, the trailing end edge; a first side flap, foldably attached to, and extending from, the first side edge; and a second side flap, foldably attached to, and extending from, the second side edge; a means for feeding a synthetic sheet under tension in a second direction; a means for cutting a waterproof lining from the synthetic sheet; a means for folding said leading and trailing end flaps, and first and second side flaps, of the carton blank away from the plane to define a container; and a means for fixing the waterproof lining to the carton blank. 
     It is a further object of the invention to provide a method for manufacturing a carton with a waterproof lining. A carton blank is provided, comprising a base portion defining a plane, the base portion defined by leading and trailing end edges, and first and second side edges, the carton blank further including a leading end flap, foldably attached to, and extending from, the leading end edge, a trailing end flap, foldably attached to, and extending from, the trailing end edge, a first side flap, foldably attached to, and extending from, the first side edge, and a second side flap, foldably attached to, and extending from, the second side edge. A waterproof liner is fixed to the carton blank. The leading and trailing end flaps, and first and second side flaps are folded upward, away from the plane to define a container. Definition of the container opens the waterproof liner to receive a wet or frozen object. After the object is placed inside the waterproof liner, the liner is sealed shut and the carton flaps are closed. 
     Preferably, the waterproof liner is a bag. It is further preferable that upon definition of the carton, at least one edge of the waterproof liner overlaps at least one flap of the carton. It is further preferable that the edge of the bag be adhered to the flaps of the container so that, upon definition of the container, the bag is simultaneously opened and held open. It is further preferable that the edge of the bag be adhered to the carton flaps with releasable adhesive. 
     Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the process and apparatus particularly pointed out in the written description and claims, as well as the enclosed drawings. 
     It is to be understood that both the foregoing general description and the following detail description are only exemplary, and are intended to provide further explanation of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings, 
         FIG. 1  is a side view depicting, schematically, an apparatus for constructing the carton assembly of the present invention; 
         FIG. 2   a  is a side view depicting, schematically, a step of applying an adhesive pattern to a carton blank in accordance with the present invention; 
         FIG. 2   b  is a perspective view depicting a step of feeding and folding a synthetic sheet in accordance with the present invention; 
         FIG. 3   a  is a top view of a portion of the apparatus of  FIG. 1  used to reroute the carton blank and affixed waterproof lining; 
         FIG. 3   b  is a partial side view of the apparatus depicted in  FIG. 3   a ; 
         FIGS. 4   a - 4   x  are side views depicting a number of configurations of erected cartons with waterproof linings in accordance with the present invention; 
         FIGS. 5   a - 5   g  are top views depicting unerected cartons having various configurations of adhesive patterns in accordance with the present invention; 
         FIG. 6  is a perspective view depicting a waterproof lining which may be received by the carton of  FIG. 5   f ; 
         FIG. 7  is a perspective view of the waterproof lining of  FIG. 6  disposed within, and adhered to, the carton of  FIG. 5   f ; and 
         FIG. 8  is a perspective view of the embodiment of  FIG. 5   g , with the carton assembled, and ready for loading. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the present embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     The exemplary embodiment of an apparatus for manufacturing a carton assembly of the present invention is shown in  FIG. 1  and is designated generally by reference numeral  20 . In accordance with the invention, a method of constructing a carton having a waterproof lining comprises a step of feeding a carton blank in a first direction, the carton blank comprising: a base portion, defining a plane, said base portion defined by leading and trailing end edges, and first and second side edges; a leading end flap, foldably attached to, and extending from, the leading end edge; a trailing end flap, foldably attached to, and extending from, the trailing end edge; a first side flap, foldably attached to, and extending from, the first side edge; and a second side flap, foldably attached to, and extending from, the second side edge; feeding a synthetic sheet under tension in a second direction; cutting a waterproof lining from the synthetic sheet; and affixing the waterproof lining to the carton blank. 
     As broadly embodied herein, and referring to  FIG. 1 , a plurality of carton blanks  22  are provided, each carton blank  22  being fed between a pair of nip rolls  24  of a standard carton blank feeding apparatus, that is well known in the box-processing art. It is contemplated that the carton blanks  22  may be fed in any orientation. For example, they may be fed with either their longitudinal or transverse axes parallel to the direction of travel. Accordingly, they may be processed, such as with adhesive, in a desired configuration. The nip rolls  24  of the carton blank feeding apparatus feed the carton blanks  22  in sequential order onto a conveyor belt  26 , with a set spacing between each carton blank  22 . The spacing between the carton blanks can be varied depending on the desired feed rate. The feed rate of the blank feeding apparatus can be adjusted by increasing the speed of the nip rolls  24 . 
     Preferably, a vacuum is applied to the conveyor belt  26  to hold the carton blanks  22  firmly against the conveyor belt  26 . Accordingly, a vacuum pump  28  is provided with a manifold  30  leading to the bottom of the conveyor belt  26 . Conveyor belt  26  is provided with a plurality of perforations in order to allow suction from the vacuum pump  28  to draw each carton blank  22  firmly against the belt. 
     Preferably the method may include a step of applying adhesive to a selected position on the surface of each carton blank  22 . As broadly embodied herein, and referring to  FIGS. 1 and 2   a , an adhesive applying section  50  preferably includes a rotating drum  52 . A wedge  54 , made of a resilient material such as rubber or hard synthetic, preferably extends lengthwise along the surface of the drum  52 . An adhesive supply drum  56  rotates alongside the drum  52 , passing through a reservoir  58  containing a liquid adhesive  60 . In some embodiments, an adhesive  60  is a non-permanent, release-type adhesive. Adhesive supply drum  56  picks up the adhesive  60  from the reservoir  58  and applies it to the apex of wedge  54 . 
     Preferably, rotation of the drum  52  is metered to match the feed rate of the carton blanks  22  on the conveyor belt  26 . Hence, the rotational speed of the drum  52  can vary as the carton feed rate varies. As will be understood with reference below to  FIGS. 5   a - g , it is within the scope of the invention to apply the adhesive in a plurality of selected locations on the carton surface so as to result in an adhesive pattern  62  disposed in a desired configuration on each carton blank  22 . 
     Thus, the adhesive applying step, when utilized, may be varied. For example, use of a wedge  54  with one or more separations along its length may be desired in order to apply a broken-line adhesive pattern  62  on the surface of each carton blank  22 . The wedge  54  also can be arranged to define a straight line, a circle, or another pattern, geometric shape, or free forming per customer requirements. The relative position of the adhesive pattern  62  on the surface of a respective carton blank  22  also may be varied. Furthermore, the use of different adhesives having different strengths, e.g., permanent adhesives and temporary adhesives, is contemplated. Additional wedges  54  also may be mounted on the drum  52  to provide additional variations of adhesive patterns  62 . In certain cases, no adhesive may be desired. Hence, in an alternative embodiment, the adhesive applying step may be omitted altogether. 
     In accordance with a method of the invention, a step is provided of feeding a synthetic sheet  64  under tension. As broadly embodied herein, and referring to  FIG. 1 , nip rolls  63  preferably rotate and draw the synthetic sheet  64  under tension. As shown in  FIG. 1 , the direction of travel of the synthetic sheet  64  preferably is in a second direction opposite to the direction in which the carton blanks  22  are fed. However, the invention is not limited to this direction of travel. The synthetic sheet  64  can be fed in the same direction as the carton blanks  22 , at a 90° angle to the carton blanks, or in any other direction relative to the carton blanks  22 . Moreover, the rate of feed of the synthetic sheet  64  can be varied by increasing or decreasing the speed of rotation of the nip rolls  63 . 
     As broadly embodied in  FIG. 1 , the synthetic sheet  64  could comprise a combination of two separate synthetic sheets  66 ,  68 , which are fed from synthetic rolls  70 ,  72 , respectively, to two nip rolls  74 . The synthetic rolls  70 ,  72  preferably rotate freely, with the synthetic sheets  66 ,  68  being pulled by the rotation of the nip rolls  74 . This type of double sheet synthetic may be preferable for increasing the strength and/or waterproof characteristics of the lining. However, the invention is not limited to a double sheet synthetic. A single sheet, or any multiple sheet is within the scope of the invention, simply by adding or deleting synthetic rolls. In one embodiment, a double synthetic sheet may be advantageous for creating a plurality of synthetic bags, for use as the waterproof lining  110  in the cartons  22 . For instance, if sealed along their first and second sides, the synthetic sheets may form a tube, which may be cut and sealed in certain locations along its length to create the desired bags. Alternatively, a synthetic tube, which has been extruded from an annular die, may be formed into bags by preferably cutting and sealing the continuous synthetic tube in certain locations along its length. 
     The synthetic sheet  64  and the waterproof lining  110 , or bag, formed therefrom may be made from any type of synthetic material, such as waxed paper, aluminum foil, or any variety of plastics, rubbers, polyethylenes (e.g., PET), polypropylenes, polyvinyls, and the like. In one embodiment, the synthetic sheet  64  preferably is microwavable and/or ovenable, so as to also provide a convenient cooking receptacle for food products. 
     In accordance with one embodiment of the present invention, a step may be provided for folding the synthetic sheet  64 . The resulting folded synthetic sheet, tube, or bag can have a variety of configurations for providing a waterproof lining consistent with the present invention, as discussed below. 
     As broadly embodied herein, and referring to  FIGS. 1 and 2   b , a folding station  80  includes a horizontal platform  82 , over which the synthetic sheet  64  is draped and pulled. The synthetic sheet  64  defines an angle θ i  with horizontal platform  82 , which preferably is approximately 47° . It has been determined that this angle  8 , provides optimum tension to the synthetic sheet during the feeding and folding stages to prevent stretching and/or tearing of the synthetic sheet  64 . 
     As broadly embodied in  FIG. 2   b , a folding bar  84  is provided to fold the synthetic sheet  64 , thereby creating a base portion  86  and a first side flap  88 .  FIG. 2   b  only depicts one side of the folding station  80 . If desired, a similar folding bar  84  (not shown in  FIG. 2   b ) can be provided on the opposite side, thereby creating a second side flap  90  (not shown in  FIG. 2   b ). The interaction of the folding bar  84  and the horizontal platform  82  creates a synthetic sheet  64  having at least one fold. 
     As broadly embodied in  FIG. 2   b , a cam or “guide plough”  91  can be optionally provided beneath the horizontal surface  82  to crease the side of the first side flap  88 . Cam  91  creates a third crease  93 , dividing the first side flap  88  into a pair of subflaps  92  and  94 . It is further possible to fold the other flap  90  into a pair of subflaps joined by a fourth crease (not shown), by providing another cam or “guide plough” on the opposite side of horizontal surface  82 . 
     The invention is not limited to any particular arrangement of creases and folds in synthetic sheet  64 . It is not even required that the synthetic sheet have two flaps. In some cases, only a single flap will be required, defining the base portion of the synthetic by a first crease and an opposite edge. In fact, in some cases, it is preferable to retain the synthetic sheet  64  in a flat configuration without any intended creases, folds or flaps. In such an embodiment, the synthetic sheet  64  preferably is fixed to a, yet un-folded, carton blank  22  while in its flat configuration. 
     Alternatively, additional creases and flaps may be provided in the synthetic sheet  64 , in order to create any desired configuration to the waterproof lining, by adding additional folding structure to folding station  80 . The invention therefore is not limited to the number of folds that can be provided in the synthetic sheet. The number of folds, flaps and subflaps will be a function of customer preference. To complete the folding step, a pair of nip rolls  96  may be provided, as broadly depicted in  FIG. 2   b , to firmly press the folded synthetic sheet  64  together for further processing. 
     The presently disclosed method preferably also includes the step of cutting the synthetic sheet  64 , as well as an apparatus for performing the cutting step. As broadly embodied herein, and referring to  FIG. 1 , a rotating cutting cylinder  100  is provided, having a plurality of cutting blades  102  projecting therefrom, for cutting the synthetic sheet  64  into sections having leading and trailing end edges, and a second length between the leading and trailing end edges. Preferably, the number of cutting blades  102  is adjustable. 
     As embodied in  FIG. 1 , the cutting cylinder  100  preferably rotates alongside a rotating vacuum drum  104 , such that one of the cutting blades  102  contacts an anvil  106 . Synthetic sheet  64 , after passing between the nip rolls  63 , threads between the cutting cylinder  100  and vacuum drum  104 . Cutting blade  102  then preferably slices a waterproof lining  110  from synthetic sheet  64 . 
     As broadly embodied in  FIG. 1 , each waterproof lining  110 , after being cut from the synthetic sheet  64 , is held against the surface of the vacuum drum  104  by the suction of the vacuum pump  28  via the vacuum manifold  112  and a plurality of apertures in the surface of vacuum drum  104 . Each waterproof lining  110  is then pressed between the vacuum drum  104  and its corresponding carton blank  22 . When adhesive has been applied to the carton blanks  22 , each waterproof lining  110  adheres to the adhesive pattern  62  of each carton blank  22 . In some embodiments, each waterproof lining  110  may be adhered to its corresponding carton blank  22  by varying degrees of permanence, depending on the location and type of adhesive used. For example, in one embodiment, a base portion of the waterproof lining  110  is permanently adhered to the carton blank, whereas first and second side flaps, and leading and trailing end flaps, are releasably attached to respective flaps of the unassembled carton  22 . 
     In accordance with the invention, a step may be provided for folding leading and trailing end flaps of each carton blank  22 , and first and second side flaps of the carton blank. As broadly embodied in  FIG. 1 , each carton blank  22  with affixed waterproof lining  110  proceeds on the conveyor belt  26  to a flap folding section  120 . The flap folding section  120  includes a series of rollers  122 , as are well known in the art, for lifting and folding the box flaps. In the event that the waterproof lining  110  has been affixed to and/or over the flaps of the carton blank  22 , the flaps of the waterproof lining  110  may be folded upwards with the flaps of the carton blank  22 . If the waterproof lining  110  is in its folded configuration over only the base portion  40  of the carton blank  22 , it may remain folded in the center of the carton blank  22  until expanded by an operator or customer. 
     After passing through the rollers  122 , the folded carton blank  22  and waterproof lining  110  may pass into a right angle turn section  124 , where the carton blank  22  and waterproof lining  110  are turned 90° and sent down the conveyor belt  126  for final processing. This step occurs only in a right-angle machine. In other cases, where no right-angle turn is required, the right angle turn section  124  can be eliminated. 
     When a right angle turn is required, and as shown in  FIGS. 3   a  and  3   b , the right angle turn section  124  preferably includes a frame  128  and a plurality of slats  130  bolted to the frame. Preferably, at least one of the slats  130  is tilted at an angle θ 2 , of approximately 15° from the vertical. In addition, it is preferred that the slats  130  are tilted at an angle θ 3  of approximately 5-10° from the horizontal. It has been found that these angles of inclination for the slats  130  are ideal for enabling the slats  130  to hold the waterproof lining  110  down during the right angle turn of the carton, while at the same time avoiding stretching or tearing of each waterproof lining  110 . 
     In the event that the waterproof lining  110  requires heat sealing, a heat sealing station  132  may be provided. The heat sealing station  132  may include a heating element  134 , which lowers onto the waterproof lining  110 , thereby heating it to create a seal in a preferred location, such as along the opening of a bag-shaped waterproof lining  110 . One or more heat sealing stations  132  may be provided in various locations along the manufacturing line of  FIG. 1 . For example, sealing means may be provided before or after the cutting cylinder  100 . 
     Various folded or non-folded configurations of the waterproof lining  110  and the carton  22  currently envisioned by the inventors are depicted broadly in  FIGS. 4   a - 4   x . Each configuration will be discussed briefly below. 
       FIG. 4   a  depicts a simple fold comprising a base  86 , first side flap  88 , and second side flap  90 . In this configuration, the second (or right) side flap  90  lies has over the first (or left) side flap  88 . 
       FIG. 4   b  depicts a simple fold which is the reverse of the configuration depicted in  FIG. 4   a . 
       FIG. 4   c  depicts another embodiment comprising a base  86 , side flap  90 , and side flap  88  folded into subflaps  92  and  94 . 
       FIG. 4   d  depicts a fold which is the reverse of the configuration depicted in  FIG. 4   c , with the sideflap  90  folded into side flaps  92 ′ and  94 ′. 
       FIG. 4   e  depicts a Z-fold, comprising a base  86 . Each side flap has been folded into a pair of subflaps  92 ,  94 , and  92 ′,  94 ′. 
       FIG. 4   f  depicts a fold which is the reverse of the configuration depicted in  FIG. 4   e . 
       FIG. 4   g  depicts a configuration in which the folding bar and guide plough have been removed, so that no folds or creases are applied to the waterproof lining  110 . In this configuration, the waterproof lining  110  consists only of a base portion  86 . 
       FIG. 4   h  depicts a configuration created by attaching yet another guide plough to one side of the folding station in order to create a third subflap  95 . 
       FIG. 4   i  depicts a configuration which is the reverse of the configuration depicted in  FIG. 4   h . 
       FIG. 4   j  depicts an accordion fold, created by removing the folding bar and guide ploughs from one side of the folding station, and attaching one folding bar and two guide ploughs to the other side of the folding station. This folding station arrangement creates a waterproof lining having a base section  86 , with no side flaps on one side, and the other side folded into three subflaps  92 ,  94  and  95 . 
       FIG. 4   k  depicts a configuration which is the reverse of the configuration depicted in  FIG. 4   j . 
       FIG. 4   l  depicts a fold created by removing the folding bar and guide ploughs from one side of the folding station, and attaching one folding bar and one guide plough to the other side of the folding station. This folding station arrangement creates a waterproof lining having a base  86 , with no side flap on one side, and the other side folded into two subflaps  92  and  94 . 
       FIG. 4   m  depicts a configuration which is the reverse of the configuration depicted in  FIG. 41 . 
       FIG. 4   n  depicts a “narrow Z-fold” in which a folding bar and guide plough are provided on each side of the folding station, or that each side flap is folded into subflaps  92 ,  94 , and  92 ′,  94 ′. 
       FIG. 4   o  depicts a “left arrow” configuration including a base  86 , one side flap  88 , and the other side flap folded into subflaps  92 ,  94 . 
       FIG. 4   p  depicts a configuration which is the reverse of the configuration depicted in  FIG. 4   o . 
       FIG. 4   q  depicts a configuration in which at least the first side flap  88  and second side flap  90  are disposed over flaps of the carton  22 . 
       FIG. 4   r  depicts a configuration in which at least the first side flap  88  and second side flap  90  are disposed over and adhered to flaps of the carton  22 . In this embodiment, the waterproof lining  110  is arranged to spread automatically upon opening the flaps of the carton  22 , to protect them from contact with liquid. 
       FIGS. 4   s - t  depict a configuration in which the base portion  86  of the waterproof lining  110  comprises a bag, such as a polyethylene bag, which may be sealed by any suitable sealing means  87 , such as a tie, melted seal, adhesive, “zip-lock”, plurality of folds, clasps, or other sealing mechanisms. 
       FIG. 4   u  depicts a configuration of the carton  22  in which a lid portion  23  is configured to fit over and enclose the carton  22 . Moreover, the waterproof lining  110  is folded over itself to enclose any objects therein. 
       FIG. 4   v  depicts a configuration of the carton  22  in which a first side flap  88  of the waterproof lining  110  is adhered to an outer surface of a flap of the carton  22 . A second side flap  90  of the waterproof lining  110  is adhered to an inner surface of another flap of the carton  22 . In this embodiment, the waterproof lining  110  is preferably arranged with adhesive on one or more surfaces so as to create a seal upon closing the flaps of the carton  22 . 
       FIG. 4   w  depicts the carton  22  and waterproof lining  110  of  FIG. 4   v  in a nearly closed and sealed position. In this embodiment, adhesive disposed on the waterproof lining  110  itself, preferably creates a waterproof, retaining seal. 
       FIG. 4   x  depicts a configuration of the carton  22  and waterproof lining  110  in which only the second side flap  90  of the waterproof lining  110  is adhered to a flap of the carton  22 . The first side flap  88  is preferably free for manipulation by a user but capable of being adhered to a flap of the carton  22 , in any desired configuration, if preferably provided with adhesive. 
       FIGS. 5   a - d  depict various embodiments of the carton  22 , each having a different adhesive pattern  62 . For example, each adhesive pattern  62  may have a different arrangement of lines, strips, or dots of adhesive  60  disposed on the surface of the carton  22 . Specifically, each adhesive pattern  62  may include any preferable arrangement of adhesives on the base portion and/or flaps of the carton. Moreover, various portions of each adhesive pattern  62  may have varying types of adhesive so as to be either permanent or releasable in adhesive strength. 
       FIGS. 5   e - f  depict an alternative style of carton  22  having still further arrangements of adhesive patterns  62 . In the embodiment of  FIG. 5   e , the bag is preferably affixed to the carton  22  by a single strip of adhesive  62 . The single strip of adhesive  62  is preferably a strong adhesive that permanently affixes the bag to the carton  22 . By this embodiment, the bag is only secured to the carton  22  by a single location at the bottom of the bag. Alternatively, in those instances in which the bag is affixed to the carton  22  by a number of adhesive locations, including those on the flaps of the carton  22 , as depicted in  FIG. 5   f , the bag may be held open by the opening of the flaps. 
       FIG. 5   g  depicts an alternative style of a one-piece carton  22  having still further arrangements of adhesive  60 . In this embodiment, the waterproof lining  110  preferably is a gusseted tube of poly that has been cut-off and closed at its bottom end by a heat seal  111 , and adhered to the carton  22  by a permanent adhesive pattern  62   a . The waterproof lining  110  is also preferably secured to at least one set of non-permanent, releasable, adhesive patterns  62   b . For example, suitable releasable adhesives preferably include hot melt adhesives, curable adhesives, pressure sensitive adhesives, epoxies, acrylic adhesives, and any other natural or synthetic non-permanent adhesive. 
     The releasable adhesive patterns  62   b  may be disposed on the inside and/or outside faces of the carton flaps. As illustrated, the waterproof lining  110  is adhered to a set of releasable adhesive patterns  62   b  adjacent to an open end  113  of the waterproof lining  110 . Accordingly, the waterproof lining  110  preferably includes a bag held open by flaps of the carton  22  for the convenient loading and unloading of food and other items. For example, the bag may be releasably affixed to flaps of the carton  22  with releasable adhesive. Moreover, the flaps of the carton  22  may be prevented from coming in contact with fluids or other contents of the bag of the waterproof lining  110 , such as during loading and unloading of the contents. Such a waterproof lining  110 , as embodied in a bag, may be particularly useful in retaining and transporting seafood, such as shellfish and other pointed, and potentially abrasive objects. Moreover, such a bag may be especially reinforced for preventing the trespass of associated liquids into and through the carton  22 . In one embodiment, after loading, the open end  113  may be released from the releasable adhesive patterns  62   b  to be secured for sealing of the bag by other means, as described above, prior to shipping or storage. 
     Referring to  FIG. 8 , when a user opens a carton  22  to its upright, assembled position, the bag is simultaneously pulled upward to its upright and open position, ready to receive a product. After insertion of the product into the open bag, the bag can be closed and sealed and the carton can be closed. Hence, the packing of a carton  22  with wet items, such as meat or seafood, can be performed on a packing assembly line, efficiently and without shutting down the line. 
     As broadly depicted in  FIG. 6 , a waterproof lining  110  is illustrated in a position to be received by a carton  22 . The waterproof lining  110  is illustrated as adhered to the carton  22  in  FIG. 7 . The waterproof lining  110  may be capable of encapsulating an item and retaining liquids within the lining, upon enclosure of the object therein. 
     In each of the embodiments disclosed and depicted herein, the carton  22  is not limited to any particular material or dimensions. For example, in the event that the product to be shipped includes shellfish, or a similar product with points and sharp edges, relatively thick or foamed board may be used to prevent shells and claws from piercing the walls of the carton. It is further contemplated that cartons  22  consistent with the present invention preferably may include any other variety of carton, box, or crate, and any configuration of reinforcements. For example, suitable cartons  22  may include metal wiring, synthetic brackets, corner protectors, corrugations or other braces. Other materials may be selected for other applications, as desired. 
     The process and apparatus described above allows preparation of carton blanks having a prefolded waterproof lining or waterproof bag. The carton blank can be unfolded and assembled into a carton having a folded waterproof lining or a waterproof bag, already inserted and ready to be opened quickly. The novel method of applying adhesive to the carton blank surface, and of using release-type adhesive, results in the waterproof lining being fixed in place, but in some embodiments, being easily removable if the customer does not want a waterproof lining. The novel method of folding the synthetic sheet serves to prevent damage to the synthetic sheet during the preparation process. When a right angle machine is used, the novel use of angled slats in the right angle turn section also prevents damage to the waterproof lining during the preparation process. 
     The above-described apparatus and process consequently produce superior carton blanks with pre-adhered waterproof linings or bags, with far less waste, and consequently a lower cost. 
     The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings, or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles and the practical application of the invention, to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims attached hereto, and their equivalents. Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.