Patent Publication Number: US-2010127058-A1

Title: Article carrier

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 61/116,878, filed Nov. 21, 2008, the entirety of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     This invention relates to packaging articles, and more specifically, to a carrier for articles each having tapered bottoms. 
     BACKGROUND OF THE INVENTION 
     Article carriers are known in the art, and desirably facilitate a visually appealing packaging alternative, while providing convenience for transporting and supporting articles. Some article carriers are constructed to transport and support tapered articles (e.g., cans, bottles and cups) each having a top and/or bottom narrower than the other part of that article. Such carriers generally include top and bottom walls, one or both with opening, and perimeter walls for retaining the articles in contact with the bottom wall. Yet, the walls do not fully enclose the articles, thus providing inadequate support when transporting the articles. Additionally, the height of the perimeter walls is usually less than the height of the articles so as to expose the articles. This type of carrier also may include a handle or other means for lifting the carrier, the handle extending above the tops of the upright articles. Conversely, a carrier that is capable of transporting or supporting tapered articles may also include top and bottom walls with apertures and perimeter walls, but the perimeter walls are generally equal in height to the enclosed articles. Due to the height of the perimeter walls, this type of article generally does not have a handle, but requires one to hold the entire carrier or use only the finger apertures along the top surface of the carrier. Thus, the height of the perimeter walls limit the extent to which it is possible to display a tapered article and the extent to which one may carry the carrier and the enclosed articles. 
     There is therefore a need for a carrier that can adequately support tapered articles and also provide maximum visibility of the articles. 
     SUMMARY OF THE INVENTION 
     The present invention with its various embodiments provides a carrier that will visually expose articles such as cans, bottles, cups, etc. while maintaining them stability and portability. The carrier may have closed ends, thereby providing additional support and increased strength to the carrier and the loaded articles. 
     According to one aspect of the present invention, the carrier is formed from a blank. The blank has a plurality of panels including a primary/top panel with a center longitudinal slot, a pair of base panels, and a pair of side panels which are hingedly connected to the top panel and to the respective base panels along fold lines. Hingedly connected to each of the base panels and the top panel is a pair of opposing end panels or flaps. A pair of end flaps may also be hingedly connected to each side panel of the carrier as well in certain embodiments to provide more support for the closed ends. When the carrier is assembled, the end flaps overlap to form the closed ends. Additionally, an insert panel with means for supporting the top panel may be foldably attached along a fold line to one of the opposed side edges of at least one of the base panels. 
     The top panel may includes a plurality of receiving apertures that are positioned, in the embodiments, in a grid-like pattern with each receiving aperture being equal distance apart from each adjacent receiving aperture. However, it is contemplated that the apertures may be arranged in any suitable pattern, regular or irregular. Each base panel may also include a plurality of base apertures positioned side by side in a grid. When the carrier is assembled, the pair of base panels forms a composite base panel, and the base apertures are vertically aligned beneath the receiving apertures of the top panel. Each base aperture has a continuous edge and may have at least two legs hingedly connected along the continuous edge of each base aperture. The receiving apertures and the base apertures are positioned in registry with one another to cooperatively support articles, specifically a tapered article including wide mouth containers. As used herein, the term “tapered article” refers to a container having a top or bottom the circumference or cross section of which less than that of the remainder of the article. The term “wide mouth container” refers to a container having an opening the circumference or cross-section of which is relatively larger than that of its base. For example, a wide mouth container may be a flared cylinder with outwardly sloping walls. The legs of the base apertures may extend obliquely from the edge of the base apertures when a container is placed into the receiving aperture and subsequently into the base aperture. In this position, the legs support the articles and maintain the stability of the carrier. 
     The carrier includes a handle that is formed from the insert panel described above. The handle extends upright through the slot in the top panel while the means for support prevents the handle from passing completely through the slot. The handle therefore provides a means for transporting the carrier and supporting the structural integrity of the carrier. Optionally, the handle is strengthened with one or more hingedly connected overlays that form a multi-ply composite handle. The handle also includes an aperture with a foldably attached cushioning flap for comfort and ease when the carrier is being carried. In alternate embodiments, the handle may be strengthened by using a stronger material for the insert panel or by laminating the insert panel. The handle aperture can be replaced with an ergonomically shaped handle that provides a comfortable hand-hold, such as a T-shaped handle. 
     In other alternative embodiments, the carrier may be modified to accommodate additional or fewer articles. The blank for a larger carrier, for example, would include larger panels and side panels to accommodate more receiving apertures and base apertures or smaller panels and side panels for fewer receiving apertures and base apertures. The blank for a carrier of larger articles might have fewer and larger receiving apertures and base apertures. The number or size of insert panels may increase or decrease. 
     Accordingly, the foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a blank for forming a carrier in accordance with an exemplary embodiment of the invention; 
         FIG. 2  is a perspective view of the carrier formed from the blank of  FIG. 1 . 
         FIG. 3  is a perspective view of a carrier of a second embodiment loaded with tapered articles; 
         FIG. 4  is a perspective view of a blank for forming a carrier of a third embodiment; and 
         FIG. 5  is a perspective view of a blank for forming a carrier of a fourth embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not limiting but serve as a basis for the claims and for teaching one skilled in the art to variously employ the present invention. 
     Referring now to the drawings in which like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of an exemplary embodiment of a carrier that is formed from a blank according to the present invention. The blank and carrier are formed from paperboard or other foldable sheet material, for example plastics material or the like, to which there has been added cut and fold lines. The carrier is used to hold and visually expose articles while maintaining stability and portability of the articles. In the illustrated embodiment, a unitary blank is used to make a single carrier, although it is foreseen that two or more blanks may be combined for example to form the carrier. 
     Referring to  FIG. 1 , there is shown a blank  10  for constructing a carrier with closed ends. For the purposes of reference, the side of the blank  10  shown in  FIG. 1  is defined as the outside surface, and the opposing side of the blank  10  is defined as the inside surface. The blank  10  includes an insert panel  15 , a first base panel  20 , a first side panel  25 , a primary panel in the form of a top panel  30 , a second side panel  35 , and a second base panel  40 . Each of the panels  15 ,  20 ,  25 ,  30 ,  35 , and  40  is foldably connected at side edges along transverse fold lines  18 ,  22 ,  28 ,  32 ,  38 , and  42  to each subsequent panel. In this exemplary embodiment, the blank  10  also includes base flaps  2   a ,  2   b ,  2   c , and  2   d , end panels or flaps  4   a ,  4   b ,  4   c ,  4   d  and top flaps  6   a  and  6   b  foldably connected at the respective longitudinal fold lines  19   a ,  19   b ,  21   a ,  21   b ,  23   a ,  23   b ,  24   a ,  24   b ,  27   a , and  27   b  along the end edges of the respective base panels  20 ,  40 , side panels  25 ,  35 , and the top panel  30 . The end flaps  4   a ,  4   b ,  4   c , and  4   d  are separated from the base flaps  2   a ,  2   b ,  2   c , and  2   d  and top flaps  6   a  and  6   b  by means of cuts  61   a ,  61   b ,  63   a ,  63   b ,  65   a ,  65   b ,  67   a  and  67   b . Those skilled in the art will recognize that any of the flaps could also be connected via web panels. Furthermore, the end flaps  4   a ,  4   b ,  4   c , and  4   d  could be omitted from the blank  10  without jeopardizing the ability to enclose the ends of the carrier as will be discussed in further detail below. 
     The insert panel  15  is foldably attached along fold line  18  to the first base panel  20  and includes means for support, depicted as shoulders  70   a  and  70   b  in this embodiment. An overlay  75  hingedly connects to an edge of the insert panel  15  along fold line  14 , which extends from the distal edge of the insert panel to the upper extent of the shoulder  70   a . The overlay  75  strengthens the insert panel  15  by providing greater rigidity when the carrier is formed and the insert panel  15  is used as a handle A (See  FIG. 2 ). It is, however, contemplated that the insert panel  15  may be strengthened instead or additionally by using a stronger material or by laminating the insert panel. In the illustrated embodiment, the overlay  75  is a mirror image of a portion of the insert panel  15 . Furthermore, each panel has a complementary aperture  80 ,  90  with foldably connected aperture flaps  85  and  95 , all of which align when the overlay  75  is secured to the insert panel  15 , as will be described in greater detail below. 
     As further shown in  FIG. 1 , the first  20  and second base panels  40  each include a plurality of base apertures  45  which are situated side by side and equal distances apart. In other words, the base apertures  45  are arranged in a matrix like formation having uniform columns and rows, although other arrangements are foreseeable. Connected along the continuous edge of each aperture  45  and hingedly attached along fold lines  47  are legs  50 . In the embodiment illustrated in  FIG. 1 , multiple legs are hingedly attached to the base apertures  45 . Specifically, innermost ones of the base apertures  45  include three legs  50  attached thereto and outermost ones of the base apertures  45  include two legs  50  attached thereto. However, in alternative embodiments, legs  50  can be omitted from any of the base apertures  45 , a single leg  50  can be hingedly attached to any of the base apertures  45 , and multiple legs  50  can be hingedly attached to any of the base apertures  45 . In general, a sufficient number of legs  50  is selected so as to adequately balance and/or support a tapered article B (shown in  FIG. 3 ) when the carrier is formed and loaded. Those skilled in the art understand that the number of legs may vary by design. 
     Additionally, the legs  50  may be positioned so as not to obstruct the view of articles B when the carrier is loaded. For example, referring to the embodiment illustrated in  FIG. 1 , the legs  50  are so positioned so as to be hingedly attached to the portion of the edge of the apertures  45  that is innermost. The innermost portion of the edge of the aperture  45  can be described as that which is not adjacent or tangentially contacting the edges of the base panels  20 ,  40 , which are defined by the fold lines  18 ,  19   a ,  19   b ,  22 ,  27   a ,  27   b ,  38 ,  42 . 
     The second base panel  40  also includes a support flap  65  foldably connected to the side edge of the second base panel  40  along fold line  42 . The top panel  30  includes a transversely extending elongated slot  60  centrally positioned therein and a plurality of receiving apertures  55  which are juxtaposed equal distance apart. Like the base apertures  45 , the receiving apertures  55  are arranged in a complementary matrix-like formation with uniform columns and rows. 
     From the blank  10  described above, the exemplary carrier  100  of  FIG. 2  may be formed. The following method of forming the carrier is provided for purposes of teaching and not for limitation, so it should be understood that any of the steps described below may or may not be used in this method and may be followed in any order. To erect the exemplary carrier  100 , the overlay  75  is folded along the fold line  14  into a face contacting relation with the insert panel  15  so that the inner surface of the overlay  75  contacts the inner surface of the insert panel  15  to form a composite handle A. The insert panel  15  and the overlay  75  are secured together by any means of securing known or yet to be developed, such as, but not limited to glue or staples. It is, however, not required that the overlay  75  and insert panel  15  be securely fastened to one another. Rather, the slot  60  may be sufficiently narrow to maintain a close relation between the insert panel  15  and the overlay  75 . 
     Once assembled, the composite handle A is folded inwardly along the fold line  18  and then the distal end of the handle A is positioned and inserted into the longitudinal slot  60  of the top panel  30 . The first base panel  20  consequently is folded inwardly along the fold line  22  and the first side panel  25  is folded inwardly along the fold line  28 . Alternatively, the blank is folded along the fold line  28  so that the side panel  25  is substantially perpendicular to the top panel  30 . Then the first base panel  20  is folded along the fold line  22  until the first base panel is substantially parallel to the top panel  30 , with the base apertures  45  in registry with the receiving apertures  55 . The handle A is pulled through the slot  60  until the shoulders  70   a  and  70   b  of the handle A lodge against the ends of the elongated slot  60  in the top panel  30 . The width of the shoulders  70   a  and  70   b  is greater than the width of the longitudinal slot  60  to provide support for the top panel  30  and to maintain the desired spacing from the base panels  20 ,  40 . In a similar manner, on the opposite side, the second base panel  40  is folded inwardly along the fold line  38  and the second side panel  35  then folds inwardly along the fold line  32  toward the top panel  30  until the outer surface of the support flap  65  comes into proximity to the shoulders of the insert panel  15 . The outer surface of the support flap  65  is secured to the shoulders  70   a  and  70   b  of the insert panel  15  by a suitable means of securing known or yet to be known in the art, such as glue or staples. Consequently, the inside surfaces of the first and second base panels, the first and second side panels, and the top panel face one another. 
     The first  20  and second base panels  40  substantially coplanar and together form a composite base panel  20 / 40  that underlies the top panel  30 . Once the panels  20 / 40 ,  25 ,  30 , and  35  are substantially in place, the base flaps  2   a ,  2   b ,  2   c , and  2   d  are folded inward and upward along fold lines  19   a ,  19   b ,  27   a , and  27   b , the end flaps  4   a ,  4   b ,  4   c , and  4   d  are folded inward along fold lines  21   a ,  21   b ,  24   a , and  24   b , and the top flaps  6   a  and  6   b  are folded downward along fold lines  23   a  and  23   b . The outside surfaces of the flaps  2   a ,  2   b ,  2   c ,  2   d ,  4   a ,  4   b ,  4   c ,  4   d ,  6   a , and  6   b  are then substantially overlapped in any order to form the closed ends  110   a ,  100   b  ( FIG. 2 ) of the carrier  100 . The flaps are securely fastened to one another by a suitable means of securing. The closed ends  110   a ,  110   b , along with the shoulders  70   a  and  70   b  that support the top panel  30 , are elements of the support system for the carrier  100  that establish and maintain the structural integrity and ensure that the carrier  100  is plumb and stable. 
     The receiving apertures  55 , depicted in  FIG. 2 , are positioned in registry with respective ones of the base apertures  45  for receiving articles. In the embodiment illustrated in  FIGS. 1 and 2 , certain of the receiving apertures  55  are tangentially in contact with one or more fold lines  23   a ,  23   b ,  28 , and  32  so as to allow an article B (such as shown in  FIG. 3 ) to contact or touch the inside surface of the respective flap  2   a ,  2   b ,  2   c ,  2   d ,  4   a ,  4   b ,  4   c ,  4   d ,  6   a ,  6   b  or side panel  25  or  35 . Referring to  FIG. 1 , certain of the receiving apertures  45  are also tangentially in contact with one or more fold lines  19   a ,  19   b ,  22 ,  38 ,  27   a  and  27   b  so as to allow an article B (such as shown in  FIG. 3 ) to contact or touch the inside surface of the respective flap  2   a ,  2   b ,  2   c ,  2   d ,  4   a ,  4   b ,  4   c ,  4   d ,  6   a ,  6   b  or side panel  25  or  35 . Thus, the article B and respective flap  2   a ,  2   b ,  2   c ,  2   d ,  4   a ,  4   b ,  6   a ,  6   b  or side panel  25  or  35  support one another to improve the strength and stability of the carrier. 
       FIG. 3  shows an article carrier  200  of a second embodiment that has been loaded with, by example and not by way of limitation, four tapered articles B. As used herein, the term “taper” is expansively defined as to become narrower at one end. A blank for forming the carrier of this embodiment may have the sequence of panels similar to that of the panels of the blank  10 . The shape and size of each panel of the blank differ from those of blank  10  in  FIG. 1 . However, the function of each panel of the blank is substantially similar to that of each panel of the blank  10 . Thus, like reference numerals have been used to denote like features, albeit the reference numerals in  FIG. 3  have been raised by a factor ‘ 200 ’ to indicate that they relate to those of the blank  10  of the first embodiment. 
     The carrier of the second embodiment has been modified to accommodate less articles than the carrier of the first embodiment by narrowing the top panel  230 , the first and second base panels and the first and second side panels  235  (only one shown). The illustrated article B gradually becomes narrower at the base of the article B forming a relatively wide mouth. The mouth of the article B is wider than the receiving aperture  255  in the top panel  230  so that the article B will sit inside the receiving aperture  255  without falling through. At some point along the extent of the article B, the width of its neck is substantially the same as that of the receiving aperture  255 , and the width of the base of the article B is substantially the same as the base aperture  245 . In the exemplary embodiment, the height of the article B is greater than the height of the closed ends  206   a  (only one shown) of the carrier  200  for stability of the article B when seated in the carrier  200 . As used in this paragraph, the term “same” means similar in dimension, with adequate clearance allotted for insertion and removal, and sufficient contact for a bracing fit. 
     Returning to  FIGS. 1 and 2 , when the article B is placed into a receiving aperture  55  and subsequently into the base aperture  45 , the leg(s)  50  surrounding the edge of the base aperture  45  are folded downwardly along the fold lines  47  and extend substantially obliquely or perpendicularly with respect to the first and second base panels  20 ,  40  to support the articles and the carrier  100 . The vertical length of the legs  50  are generally equal to each other so that the carrier  100  is balanced and held upright while also supporting the article B. 
     The handle A of the loaded carrier  200  shown in  FIG. 3  provides for easy transportation of the carrier  200 . The handle A comprises an aperture  290  for inserting one&#39;s hand and an aperture flap  295  to enhance the comfort of the grip of handle A. If an overlay is used to strengthen the insert panel, as depicted in the first exemplary embodiment, the aperture flaps of the overlay and the insert panel may be fastened together to form a two-ply flap. 
       FIGS. 4 and 5  show primary blanks  300 ,  400  for forming carriers according to third and fourth embodiments respectively. The blanks  300  and  400  are formed from foldable sheet material similar to the one used to make blank  10  in  FIG. 1 . The sequence of the panels of each of the blanks  300  and  400  is similar to that of blank  10 . The function of each panel of each blank  300 ,  400  is also substantially similar to that of the blank  10 . However, the shape and size of each panel of each blank  300 ,  400  differ from those of blank  10 . Thus, like reference numerals have been used to denote like features, albeit the reference numerals in  FIG. 4  have been raised by a factor ‘ 300 ’ and the reference numerals in  FIG. 5  have been raised by a factor ‘ 400 ’, so as to indicate that they relate to those of the blank  10  of the first embodiment. 
     Each of the blanks  300  and  400  has been modified to form a carrier (not shown) to accommodate more articles by widening the top panel  330 ,  430  the first and second base panels  320 ,  340 ,  420 ,  440 , and the first and second side panels  325 ,  335 ,  425 ,  435 . Optionally, additional or doubly reinforced insert panels  315   a ,  315   b ,  415  and corresponding overlays  375   a ,  375   b ,  475   a ,  475   b  can be included to support more articles. As dictated by the particular application, the dimensions of each insert panel  15 ,  315   a ,  315   b ,  415  itself is a design decision, the objective being to support the intended number, size, and configuration of articles. The dimensions of other corresponding elements, i.e., the flaps of all panels, side panels, and the slot of the top panel can be constructed in the same manner. 
     It must be emphasized that the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. All such modifications, combinations, and variations are included herein by the scope of this disclosure and the following claims.