Patent Publication Number: US-9840358-B2

Title: Carton with article protection feature

Description:
INCORPORATION BY REFERENCE 
     The entire contents of U.S. patent application Ser. No. 13/419,740, filed Mar. 14, 2012, is hereby incorporated by reference as if presented herein in its entirety. 
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to cartons for holding beverage containers or other types of articles. More specifically, the present disclosure relates to cartons having an article protection flap and/or access feature that protects the containers or articles from breakage. 
     SUMMARY OF THE DISCLOSURE 
     In general, one aspect of the disclosure is directed to a carton for containing at least one article. The carton comprises a plurality of panels at least partially forming an interior of the carton. The plurality of panels comprises a first panel and a second panel, the first panel and the second panel being in face-to-face contact to at least partially form the interior of the carton. The first panel comprises at least one article protection flap for protecting the at least one article. The at least one article protection flap is foldably connected to the first panel and moveable between a first position that is substantially parallel to the first panel and a second position wherein the article protection flap is folded relative to the first panel. The second panel comprises at least one access feature for positioning the at least one article protection flap from the first position to the second position. 
     In another aspect, the disclosure is generally directed to a blank for forming a carton for containing at least one article. The blank comprises a plurality of panels for at least partially forming an interior of the carton formed from the blank. The plurality of panels comprising a first panel and a second panel, the first panel and the second panel are for being in face-to-face contact to at least partially form the interior of the carton formed from the blank. The first panel comprises at least one article protection flap for protecting the at least one article. The at least one article protection flap is foldably connected to the first panel and moveable between a first position that is substantially parallel to the first panel and a second position wherein the article protection flap is folded relative to the first panel. 
     In another aspect, the disclosure is generally direct to a method of forming a carton. The method comprises obtaining a blank comprising a plurality of panels comprising a first panel and a second panel. The first panel comprising at least one article protection flap foldably connected to the first panel, and the second panel comprising at least one access feature. The method comprises positioning the plurality of panels to at least partially form an interior of the carton comprising positioning the first panel and the second panel to be in face-to-face contact, and loading the at least one article in the interior of the carton. The method further comprises accessing the at least one article protection flap through the access feature and folding the at least one article protection flap relative to the first panel after the loading the at least one article. The folding comprises moving the article protection flap from a first position that is substantially parallel to the first panel to a second position wherein the article protection flap is folded relative to the first panel. 
     Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims. 
     Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. Further, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of an exterior surface of a blank for forming a carton according to a first embodiment of the disclosure. 
         FIG. 2  is an end perspective of the partially assembled carton of the first embodiment. 
         FIG. 3  is a perspective of an assembled carton of the first embodiment. 
         FIG. 4  is a side perspective of an assembled carton of the first embodiment. 
         FIG. 5  is a perspective view of an interior surface of the bottom panel of the carton of the first embodiment showing article protection flaps. 
         FIG. 6  is a perspective view of the interior surface of the bottom panel of the carton of the first embodiment showing the article protection flaps in a second position. 
         FIG. 7  is a perspective view of the interior surface of the bottom panel of the carton of the embodiment showing the article protection flaps in a second position. 
         FIG. 8  is a plan view of an exterior surface of a blank for forming a carton according to a second embodiment of the disclosure. 
         FIG. 9  is an end perspective of the partially assembled carton of the second embodiment. 
         FIG. 10  is a side perspective of an assembled carton of the second embodiment showing access features. 
         FIG. 11  is a side perspective of an assembled carton of the second embodiment. 
         FIG. 12  is a plan view of an exterior surface of a blank for forming a carton according to a third embodiment of the disclosure. 
         FIG. 13  is a plan view of a second bottom panel of the carton of the embodiment of  FIG. 12  showing the access features. 
         FIG. 14  is a plan view of a first bottom panel of the carton of the embodiment of  FIG. 12  with the article protection flaps in the first position. 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     The present disclosure generally relates to cartons that contain a single article or a plurality of articles such as containers, bottles, cans, etc., and protection features of such cartons that protect the article or articles or containers from breakage, damage, or deformation. The article(s) can be used for packaging food and beverage products, for example, or any other item. The article(s) can be made from materials suitable in composition for packaging the particular food or beverage item, or other item, and the materials can include, but are not limited to, glass or other breakable material; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; paperboard; and the like, or any combination thereof, or any other suitable material. 
     Cartons according to the present disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes food product containers (e.g., glass jars or beverage bottles) as disposed within the carton embodiments. The containers could also be beverage containers (e.g., glass beverage bottles) without departing from the disclosure. In this specification, the terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected and upright cartons. 
       FIG. 1  is a plan view of the exterior side  101  of a blank, generally indicated at  103 , used to form a carton  105  ( FIG. 3 ) according to a first exemplary embodiment of the disclosure. The carton  105  can be used to house a plurality of articles such as containers C ( FIG. 5 ). In the illustrated embodiment, the containers C are glass containers. In the illustrated embodiment, the carton  105  is sized to house twelve containers C in a single layer in a 3×4 arrangement, but it is understood that the carton  105  may be sized and shaped to hold containers of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 1×6, 2×6, 4×6, 3×8, 2×6×2, 3×4×2, 2×9, 3×4, etc.), or just a single article. 
     The blank  103  has a longitudinal axis L 1  and a lateral axis L 2 . In the embodiment of  FIG. 1 , the blank includes a first bottom panel  109  and a second bottom panel  107 . The second bottom panel  107  foldably connected to a first side panel  111  at a lateral fold line  121 . The first bottom panel  109  is foldably connected to a second side panel  113  at a lateral fold line  123 . A top panel  125  is foldably connected to the first side panel  111  at a lateral fold line  127 , and foldably connected to the second side panel  113  at a lateral fold line  129 . 
     The second bottom panel  107  is foldably connected to a first bottom end flap  131  and a second bottom end flap  133 . The first side panel  111  is foldably connected to a first side end flap  135  and a second side end flap  137 . The second side panel  113  is foldably connected to a first side end flap  139  and a second side end flap  141 . The top panel  125  is foldably connected to a first top end flap  143  and a second top end flap  145 . In one embodiment, when the carton  105  is erected, the end flaps  131 ,  135 ,  139 ,  141 , close the first end  151  of the carton  105 , and the end flaps  133 ,  137 ,  141 ,  145  close the second end  153  of the carton  105 . In accordance with an alternative embodiment of the present disclosure, different flap arrangements can be used for closing the ends  151 ,  152  of the carton  105 . 
     The end flaps  131 ,  135 ,  139 ,  141  extend along a first marginal area of the blank  103 , and are foldably connected at a first longitudinal fold line  157  that extends along the length of the blank. The end flaps  133 ,  137 ,  141 ,  145  extend along a second marginal area of the blank  103 , and are foldably connected at a second longitudinal fold line  159  that also extends along the length of the blank  103 . The longitudinal fold lines  157 ,  159  may be, for example, substantially straight, or offset at one or more locations to account for blank thickness or for other factors. 
     In the embodiment of  FIG. 1 , the blank  103  has handle features for forming a handle  161 . In the illustrated embodiment, the handle features comprise a handle flap  163  foldably connected to a respective first side panel  111  at a longitudinal fold line  165 . The blank  103  can have other features for forming the handle  161 , or the blank and/or carton  105  can have a handle that is alternatively shaped, arranged, and/or configured without departing from the disclosure. Further, the handle  161  can be omitted without departing from the disclosure. 
     In the first embodiment, the blank  103  includes nine article protection flaps  171  arranged in a 3×3 arrangement in the first bottom panel  109 , but the blank  103  could have more or less than nine article protection flaps  171 , and the flaps could be otherwise arranged in other suitable row/column arrangements or in a random configuration on the first bottom panel  109 , including a single row or single column configuration, or any other suitable configuration. In the embodiment of  FIG. 1 , the middle row of article protection flaps  171  are oriented 180 degrees relative to a row of article protection flaps that are closer to side edges  173 ,  175 . In other embodiments, the article protection flaps  171  could be otherwise shaped, arranged, and/or configured without departing from the disclosure. 
     As shown in  FIGS. 1 and 5 , the article protection flaps  171  are each foldably connected to the second bottom panel  109  at a respective lateral fold line  177  and are each at least partially defined by a line of weakening  179  in the first bottom panel  109 . In one embodiment, the line of weakening  179  is a cut, but the line of weakening could comprises other forms of weakening (e.g., a tear line that comprises cut lines separated by breakable nicks, a tear line that is formed by a series of spaced apart cuts, etc.) that allows the article protection flap  171  to separate from the bottom panel  109  without departing from the disclosure. As shown in  FIG. 5 , the cut  179  has a first portion  181  that is generally curved and extending from a first end  185  of the fold line  177  and a second portion  183  that is generally curved and extending from a second end  187  of the fold line  177 . Both the first portion  181  and the second portion  183  of the cut  179  extend away from the fold line  177  and form a respective rounded corner  180 ,  182  of the cut  179 . As shown in  FIGS. 1 and 5 , the article protection flap  171  comprises a second fold line  184  extending from the middle of the first fold line  177 . A first portion  176  and a second portion  178  of the article protection flap  171  are foldably connected along the second fold line  184 . In one embodiment, a slit or cut  188  is positioned adjacent the second fold line  184 . In the first embodiment, the second fold line  184  is a longitudinal fold line that is generally parallel to and extends in the longitudinal direction L 1  of the blank  103 . The fold lines  177 ,  184 , and cuts  179 ,  188  could be otherwise shaped, arranged, configured, and/or omitted such that the article protection flap  171  has any other suitable shape or configuration without departing from the disclosure. 
     In one embodiment, the blank  103  includes nine access features  189  for positioning the article protection flaps  171  to a second position while substantially covering the apertures  168  formed from the activation of the article protection flaps  171 . The access feature  189  also helps prevent foreign matter from entering the carton  103  while the article protection flaps  171  are activated. The access features  189  are arranged in a 3×3 arrangement, but the blank  103  could have more or less than nine access features  189 , and the access features could be otherwise arranged in other suitable row/column arrangements or in a random configuration on the first bottom panel  107 , including a single row or single column configuration, or any other suitable configuration. In the embodiment of  FIG. 1 , the middle row of access features are oriented 180 degrees relative to a row of access features that are closer to a respective fold line  157 ,  159 . In other embodiments, the access features could be otherwise shaped, arranged, and/or configured without departing from the disclosure. 
     As shown in  FIGS. 1 and 4 , the access features  189  are at least partially defined by a line of weakening with three portions  191 ,  193 , and  195 ; however the access feature  189  can comprise more or less lines of weakening without departing form the disclosure. In one embodiment, the lines of weakening are cuts, but the line of weakening could comprises other forms of weakening (e.g., a tear line that comprises cut lines separated by breakable nicks, a tear line that is formed by a series of spaced apart cuts, an opening, etc.) that allows the access feature  189  to open without departing from the disclosure. The access feature  189  has a first portion  191  that is generally straight and extending the length of and in alignment with lateral fold line  177  of the article protection flaps  171 . The access feature  189  has a second portion  193  that is generally straight and extends perpendicular from the center of the first portion  191 . The third portion  195  of the access feature  189  is generally oblique and extends from the edge of the second portion  193  toward the first portion  191 . In other embodiments, the blank  103  can include access features  189  that are different, similar, or identical to the access features without departing from the disclosure. 
       FIGS. 2-7  show one exemplary method of forming the carton  105  and the article protection features  171 . At various stages of the erecting process, glue or other adhesive can be applied to various portions of the blank  103 . As shown in  FIG. 2 , the blank  103  can be formed into a sleeve  102  having open ends  104 ,  106  by folding the first bottom panel  109 , second bottom panel  107 , side panels  111 ,  113 , and top panel  125  along respective fold lines  121 ,  123 ,  127 ,  129 . The first bottom panel  109  and second bottom panel  107  are positioned in face-to-face contact to form an interior of the carton  105 . The access features  189  are positioned in registration with the article protection flaps  171 . The first bottom panel  109  can be adhesively secured to the second bottom panel  107  by glue lines  106  or other suitable adhesive. Containers C can be placed into an interior space  108  of the sleeve  102 . One of the ends  151 ,  153  can be closed prior to loading the containers C or both of the ends  151 ,  153  can be closed after loading the containers into the interior space  108 . The closing of the first end  151  is described below, but it is understood that the second end  153  can be closed in a similar manner. Alternatively, the second end  153  could have different flap closing sequence or arrangement and the article protection features  171  and access features  189  could be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure. 
     As shown in  FIGS. 3 and 4 , the first end  151  is closed by first inwardly folding the side end flaps  135 ,  139 . The bottom end flap  131  is upwardly folded and the top end flap  143  is downwardly folded to close the end  151  of the carton  105 . In one embodiment, the second end  153  is closed in a similar manner as the first end  151 . The bottom end flap  133  is upwardly folded and the second top end flap  145  is downwardly folded to close the end  153  of the carton  105 . 
     In the first embodiment, the loaded and closed carton  105  of  FIG. 4  is further processed so that the article protection flaps  171  are activated. The access features  189  are adjacent to and in alignment with the article protection flaps  171  such that the article protection flaps  171  are engaged through the bottom access features  189  and moved to a position where the flaps  171  are located between the containers C. The engaged article protection flaps  171  tighten the packing of the container C in the carton  105  which helps minimize article breakage. The article protection flaps  171  are foldably connected to the bottom panel  109  and moveable between a first position ( FIG. 5 ) that is substantially parallel to the bottom panel  109  and a second position ( FIGS. 6-7 ) wherein the article protection flaps  171  are folded relative to the bottom panel  109  and are located between adjacent containers C. In one embodiment, the article protection flaps  171  are raised or activated to the position of  FIG. 7 , and the article protection flaps  171  have features for preventing the folding of the article protection flaps  171  from the second position back to the first position. It is understood that the article protection flaps  171  will be activated to the second position ( FIGS. 6-7 ) after the ends  151 ,  153  of the carton  105  have been closed. Alternatively, the article protection flaps  171  could be activated prior to closing one or both of the ends  151 ,  153  of the carton  105  without departing from the disclosure. 
     The article protection flaps  171  can be accessed through the access feature  189  by an actuator of a carton forming machine, some of which will be described below in further detail. The activation of a single article protection flap  171  will be described in detail herein, but it is understood that the other article protection flaps can be activated in a similar or different manner without departing from the disclosure.  FIGS. 5 and 6  are enlarged portions of the interior surface  108  of the bottom panel  109 , with  FIG. 5  showing the interior surface of the bottom panel  109  prior to activation of the article protection flap  171 , and  FIG. 6  showing the interior of the bottom panel  109  after activation of the article protection flap  171  with a container C removed to show the positioning of the article protection flaps. In one embodiment, the actuator for forming the article protection flap  171  presses through second bottom panel  107  via the access feature  189  and presses against the fold line  187  ( FIG. 5 ) of the article protection flap  171  to initiate separation of the article protection flap from the bottom panel  109  along the cut  179 . As shown in  FIGS. 6 and 7 , the article protection flap  171  is pivoted upward relative to the bottom panel  109  at the fold line  177 . As the article protection flap  171  is activated, the first portion  176  and the second portion  178  are folded relative to each other. In one embodiment, the first portion  176  and the second portion  178  of the article protection flap  171  are folded inwardly along second fold line  184 . As such, the article protection flap  177  provides two layers of material (e.g., the inwardly folded first portion  176  and second portion  178 ) between adjacent containers C in the carton  105 . 
     In one embodiment, the upwardly folding of the article protection flaps  171  causes the containers C in the carton  105  to move to accommodate the space required for the article protection flaps in the second position with the first portion  176  and second portion  178  folded relative to each other. The movement of the containers C when the article protection flaps  171  are upwardly folded and located between adjacent containers, tightens the packing of the containers in the carton  105  so that the movement of the containers is limited by the positioning of the article protection flaps  171  and the respective end flaps  131 ,  135 ,  139 ,  143  and  133 ,  137 ,  141 ,  145  at the closed ends  151 ,  153  of the carton  105 . The article protection flaps  171  are pressed against two adjacent containers C to initiate movement of the containers and provide the tightening feature of the article protection flaps  171 . 
     In one embodiment, the configuration of the first portion  176  and the second portion  178  prevents the article protection flap  171  from being downwardly folded from the second or raised position of  FIG. 6  to the first or lowered position as shown in  FIG. 5 , when the first portion  176  and the second portion  178  of the article protection flap  171  are inwardly folded relative to each other. Also, an edge  134  of the second portion  178  of the article protection flap  171  formed by the rounded corner  182  of the cut  183  extends beyond the edge of the opening  168 . The positioning of the distal portions of the first portion  176  and second portion  178 , including the edges  132 ,  134  of the article protection flap  171 , relative to the edge  136  of the opening  168  prevents the article protection flaps  171  from being downwardly folded to the first position wherein the article protection flaps  171  are substantially parallel to the bottom panel  109 . As such, once the article protection flaps  171  are raised to the second position and positioned between adjacent containers C, the article protection flaps stay in the upwardly folded position providing cushioning and protection between adjacent containers. In the embodiment of  FIGS. 1-7 , the article protection flaps  171  of the two outer rows have a straight corner  196  that is truncated compared to the rounded corners  180 ,  182 . The article protection flaps  171  could be otherwise shaped, arranged, and/or configured to have other features for preventing the article protection flaps from returning to the first or lowered position without departing from the disclosure. 
       FIGS. 8-11  illustrate an alternative embodiment of the disclosure that is similar to the blank  103  of the first embodiment. Accordingly, like or similar features will be indicated with like or similar reference numbers. The blank  203  is for forming a carton  205  having article protection flaps  271  foldably connected to the first bottom panel  209  and access features  289  in the second bottom panel  207  of the carton  205  as discussed above for the first embodiment. In the embodiment of  FIGS. 8-11 , the article protection flaps  271  and access features  289  are arranged in a 2×2 configuration. The blank  203  has handle features  264  for forming a handle  261 . In the illustrated embodiment, the handle features comprise handle flaps  263  foldably connected to a respective top end flap  243 ,  245  at a longitudinal fold line  265 , and notches or openings  244  in the side end flaps  235 ,  239 ,  237 , and  241 . The openings  266  cooperate to provide an opening at a respective closed end  251 ,  253  to allow a respective handle flap  263  to be inwardly folded so that the carton  205  can be grasped at a respective end. The blank  203  can have other features for forming the handle  261 , or the blank and/or carton  205  can have a handle that is alternatively shaped, arranged, and/or configured without departing from the disclosure. Further, the handle  261  can be omitted without departing from the disclosure. The blank  203  could have other features and could be otherwise shaped, arranged, and/or configured without departing from the disclosure. 
       FIGS. 12-14  illustrate a blank  303  and carton  305  of a third embodiment of the disclosure that is similar to the blank  103  of the first embodiment, but the bottom panel  109  is detached and replaced with an insert  309  with article protection flaps  371  arranged in a 4×3 configuration. The insert  309  is inserted into the erected carton  305  and placed in face-to-face contact with the bottom panel  307  before inserting the containers C. The bottom panel  307  comprises twelve access features  389  arranged in a 4×3 configuration for registration with the article protection flaps  371 . Accordingly, like or similar features will be indicated with like or similar reference numbers between the embodiments. The article protection flaps  371  and access features  389  can otherwise be shaped, arranged, and configured without departing from the disclosure. 
     The cartons of any of the illustrated or non-illustrated embodiments of the disclosure could have other features (e.g., dispenser features, handle features, reinforcement features, etc.) without departing from the disclosure. Also, the cartons could be otherwise shaped, arranged, or configured and the cartons could be configured to hold articles other than beverage containers without departing from the disclosure. 
     In general, the blanks of any of the illustrated or non-illustrated embodiments may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
     As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. 
     In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding there along. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line. 
     The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place. 
     The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.