Patent Publication Number: US-4096985-A

Title: Article carrier and blank therefor

Description:
In order to enhance environmental quality and to lower the consumption of energy, a reusable article carrier is required which is both economical and easy to use. By the utilization of such an article carrier, an effective means is provided by which nonreturnable multiple primary packages can be effectively transported and disposed of as refuse or returnable primary packages can be conveniently returned to the point of sale. 
     According to this invention an article carrier is provided and comprises a bottom wall, a pair of side walls foldably joined respectively to the side edges of the bottom wall, a pair of overlapping top panels foldably joined respectively to the upper edges of the side walls, a securing aperture formed in one of the top panels and having a securing edge, the securing edge being disposed in diagonal relation to the side edges of the top panels, a securing tab foldably joined to the other of said top panels and disposed in said securing aperture, and the fold line between the securing tab and the other top wall being disposed in substantial coincidence with the securing edge. 
    
    
     For a better understanding of the invention, reference may be had to the following description taken in conjunction with the accompanying drawing in which 
     FIG. 1 is a plan view of a blank from which the completed carrier is formed and in which FIGS. 2, 3, 4, 5 and 6 depict intermediate stages through which the blank shown in FIG. 1 is manipulated in order to form the completed carrier as shown in FIG. 7. 
    
    
     In the drawings, the numeral 1 designates the bottom wall of the carrier to the side edges of which side walls 2 and 3 are foldably joined respectively along fold lines 4 and 5. Top panels 6 and 7 are foldably joined respectively to the upper edges of side walls 2 and 3 along fold lines 8 and 9. In order to prevent undesirable movement of the articles in the completed carrier, separating tabs 10, 11, 12, 13, 14 and 15 are struck from bottom wall 1 and are foldably joined thereto respectively along fold lines 16, 17, 18, 19, 20 and 21. 
     At one end of bottom wall 1, retaining flap 22 is foldably joined thereto along fold line 23 and, likewise, at the other end of bottom wall 1, retaining flap 24 is foldably joined thereto along fold line 25. 
     In order to complete the necessary end closure structure for the carrier, a series of tuck flaps are provided. More specifically, tuck flaps 26 and 27 are foldably joined to the opposite ends of retaining flap 22 respectively along fold lines 28 and 29. The structure at the opposite end of the carrier is similarly constructed and includes tuck flaps 30 and 31 which are foldably joined to the opposite ends of retaining flap 24 respectively along fold lines 32 and 33. 
     In addition tuck flaps 34 and 35 are provided with flap segments 34a and 35a respectively and are foldably joined respectively to tuck flaps 26 and 27 along fold lines 36 and 37. In similar fashion tuck flaps 38 and 39 include flap segments 38a and 39a respectively and are foldably joined respectively to tuck flaps 30 and 31 along fold lines 40 and 41. Also tuck flaps 34 and 38 are foldably joined to the ends of side wall 2 along fold lines 42 and 43 respectively. Likewise tuck flaps 35 and 39 are foldably joined respectively to the ends of side wall 3 along fold lines 44 and 45. 
     In order to insure that the tuck flaps are held securely in place, a series of locking mechanisms are provided. More specifically, locking apertures 46, 47, 48, and 49 are formed respectively in tuck flaps 26, 27, 30, and 31. Also locking tabs 50, 51, 52 and 53 are struck from tuck flaps 34, 35, 38, and 39 respectively and constitute integral extensions of flap segments 34a, 35a, 38a, and 39a. 
     In order to allow the end closure structure of the carrier to easily conform to the natural curvature of the packaged articles, a series of score lines are provided. More specifically, score lines 54 and 55 are formed in retaining flap 22 and, similarly, score lines 56 and 57 are formed in retaining flap 24. 
     In order to facilitate formation of the carrier, score lines 58 and 59 are formed in side walls 2 and 3 respectively and score lines 60, 61, 62 and 63 are formed respectively in tuck flaps 34, 35, 38, and 39 and define the edges of flap segments 34a, 35a, 38a and 39a. 
     According to one aspect of this invention, carrier locking means is provided in top panels 6 and 7. More specifically securing apertures 64 and 65 are formed in top panel 6 and are defined by holding flaps 66 and 67 which are foldably joined to top panel 6 respectively along fold lines 68 and 69. Holding portions 64a and 65a are defined by edges 64b and 65b and by slits 64c and 65c as is apparent in FIG. 1. The holding flaps 66 and 67 are provided respectively with holding tabs 70 and 71. Also securing apertures 64 and 65 are provided respectively with securing edges 72 and 73. At the opposite end of the blank, securing tabs 74 and 75 are foldably joined to top panel 7 respectively along fold lines 76 and 77 and locking toes 78 and 79 are formed on the side edge 80 of top panel 7. 
     In order to form the completed carrier from the blank shown in FIG. 1, initially it is necessary to fold separating tabs 10-15 into vertical positions and then to position the articles to be packaged on the blank, the articles being omitted from FIGS. 1-4 for purposes of clarity. Then it is necessary to fold retaining flap 22 together with tuck flaps 26, 27, 34 and 35 upwardly along fold lines 23, 42 and 44. Simultaneously the end closure structure at the opposite side of the blank including retaining flap 24 and tuck flaps 30, 31, 38 and 39 is folded upwardly along fold lines 25, 43, and 45. The carrier then appears as shown in FIG. 2. 
     Then side wall 2 together with top panel 6 and side wall 3 together with top panel 7 are elevated and folded respectively along fold lines 4 and 5 to occupy positions substantially perpendicular to bottom wall 1. This causes tuck flaps 34 and 38 to swing into substantial face contacting relation with the inner surface of side wall 2. At the same time tuck flaps 35 and 39 swing into substantial face contacting relation with the inner surface of side wall 3. 
     Following this operation, side wall 2 and tuck flaps 34 and 38 are folded outwardly with respect to the carrier along fold lines 58, 60 and 62 respectively. During this folding operation, fold lines 60 and 62 are in virtual coincidence with fold line 58 and flap segments 34a and 38a are in face contacting relation with the part of side wall 2 which is above fold line 58. Also side wall 3 and tuck flaps 35 and 39 are folded outwardly with respect to the carrier along fold lines 59, 61 and 63 respectively. This operation is performed with fold lines 61 and 63 in substantial coincidence with fold line 59 and with flap segments 35a and 39a in face contacting relation with the part of side wall 3 which is above fold line 59. This causes locking tabs 50, 51, 52 and 53 to remain in the planes of flap segments 34a, 35a, 38a and 39a respectively and to swing out of the plane of their associated tuck flaps 34, 35, 38 and 39 respectively as best shown in FIG. 3. 
     Then side walls 2 and 3 and associated structure are swung inwardly with respect to the carrier. This forces locking tabs 50, 51, 52 and 53 into interlocked relationship respectively with locking apertures 46, 47, 48 and 49. The carrier then appears as shown in FIG. 4. 
     Following this, side walls 2 and 3 are elevated along fold lines 58 and 59 respectively. In addition top panels 6 and 7 are folded over along fold lines 8 and 9 respectively to positions substantially perpendicular to side walls 2 and 3 and top panel 7 is moved into overlapping face contacting relation with top panel 6 while locking toes 78 and 79 are inserted into securing apertures 64 and 65 respectively. Side edge 80 of top panel 7 moves into slits 64c and 65c and holding portions 64a and 65a overlie top panel 7 and are adjacent the apertures defined by securing tabs 74 and 75. Finally securing tabs 74 and 75 are driven through securing apertures 64 and 65 respectively. The carrier then appears as shown in FIG. 7 which represents the completed carrier. 
     Therefore it can be seen that, in the completed carrier, securing edges 72 and 73 of securing apertures 64 and 65 respectively are diagonally disposed with respect to the side edges of top panels 6 and 7. In addition, fold lines 76 and 77 of securing tabs 74 and 75 are disposed in substantial coincidence with securing edges 72 and 73 respectively. This structural feature causes securing edges 72 and 73 to resist any premature unlocking of top panels 6 and 7 and securely hold locking toes 78 and 79 in locked condition. In addition securing tabs 74 and 75 are held in the locked position by means of the holding tabs 70 and 71 of holding flaps 66 and 67 respectively as shown in FIG. 7. Thus securing tabs 74 and 75 are held snugly against securing edges 72 and 73 respectively and any tendency for securing tabs 74 and 75 to swing back into the plane of top panel 7 is prevented. 
     Therefore since no adhesive is used in the construction of this carrier, it is conveniently reusable. Also when it is desired to open the carrier, securing tabs 74 and 75 simply are manually withdrawn from securing apertures 64 and 65 respectively and top panels 6 and 7 are swung apart sidewise and then upwardly to slide locking toes 78 and 79 out of their apertures and to allow for convenient access to the packaged articles. After use, the empty articles are simply replaced in the original carrier for disposal or storage as required. 
     When the top panels of the carrier are unlocked, the overall integrity of the carrier is maintained by the tuck flap structure at each end of the carrier and the associated locking apertures and locking tabs which securely maintain the carrier in set up condition. Therefore by this invention an article carrier is provided which is economical to produce, convenient to use, and available for reuse as necessary in connection with modern returnable primary packages.