Patent Publication Number: US-7913844-B2

Title: Article carrier with retention features

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of prior PCT Application No. PCT/US2008/071134, filed Jul. 25, 2008, entitled “Carrier With Retention Features,” which PCT application claims the benefit of U.S. Provisional Application No. 60/952,095, filed on Jul. 26, 2007. 
    
    
     INCORPORATION BY REFERENCE 
     The entire disclosures of PCT Application No. PCT/US2008/071134, filed Jul. 25, 2008, and U.S. Provisional Application No. 60/952,095, filed Jul. 26, 2007, are incorporated by reference as if set forth in their entireties. 
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to carriers for holding and dispensing beverage containers or other types of articles. 
     SUMMARY OF THE DISCLOSURE 
     In general, one aspect of the disclosure is directed a carton for carrying a plurality of articles. The carton comprises a top retainer comprising a top retention panel, a side retention panel, and a tuck-in panel. The top retention panel, side retention panel, and tuck-in panel are joined at an intersection of lines of weakening. The intersection comprises at least two cut portions of respective lines of weakening and at least one fold line. 
     In another aspect, the disclosure is directed to a method of forming a carton from a blank as shown and/or described herein. 
     In another aspect, the disclosure is generally directed to a carton for carrying a plurality of articles. The carton comprises a top panel, a side panel foldably connected to the top panel at a first line of weakening, and a top retainer foldably connected to the top panel and the side panel. The top retainer comprises a top retention panel foldably connected to the top panel at a second line of weakening, a side retention panel foldably connected to the top retention panel at a portion of the first line of weakening, and a tuck-in panel foldably connected to the at least one side panel at a third line of weakening. The second line of weakening and the third line of weakening each comprise a cut-crease line having at least one cut portion and at least one score line portion. 
     In another aspect, the disclosure is generally directed to a blank for forming a carton for holding a plurality of articles. The blank comprises a top panel, a side panel foldably connected to the top panel at a first line of weakening, and retainer features foldably connected to the top panel and the at least one side panel. The retainer features comprise a top retention panel foldably connected to the top panel at a second line of weakening, a side retention panel foldably connected to the top retention panel at a portion of the first line of weakening, and a tuck-in panel foldably connected to the at least one side panel at a third line of weakening. The second line of weakening and the third line of weakening each comprise a cut-crease line having at least one cut portion and at least one score line portion. 
     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 used to form a carton according to a first embodiment of the disclosure. 
         FIG. 1A  is an enlarged portion of  FIG. 1 . 
         FIG. 2  is a perspective of an interior surface of the blank of  FIG. 1  with containers placed thereon. 
         FIG. 3  is an enlarged portion of  FIG. 2 . 
         FIG. 4  is an enlarged portion of the blank of  FIG. 2  that has been folded to form the carton. 
         FIG. 5  is a perspective of a bottom of the carton. 
         FIG. 6  is a perspective of a top of the carton with containers removed to show internal details of the carton. 
         FIG. 7  is a plan view of an exterior surface of a blank used to form a carton according to a second embodiment of the disclosure. 
         FIG. 7A  is an enlarged portion of  FIG. 7 . 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     The present disclosure generally relates to various features for cartons or carriers that contain articles such as containers, bottles, cans, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, aluminum and/or other metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof. 
     Cartons or carriers 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 beverage containers (e.g., aluminum beverage cans) as disposed within the carrier embodiments. 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 an exterior surface  2  of a blank  3 , used to form a carton  5  ( FIG. 4 ) according to a first embodiment of the disclosure. The carton  5  can be used to house a plurality of articles such as containers C ( FIG. 3 ). In the illustrated embodiment, the containers C are beverage cans and the carton  5  is sized to house six containers in a single layer in a 2×3 arrangement. But, it is understood that the carton  5  may be sized and shaped to hold containers C of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 1×6, 2×6, 2×4, 2×2, 2×6×2, 2×4×2, 2×9, etc.). In the illustrated embodiment, the carton  5  is a carrier having generally open ends  6 ,  8  ( FIG. 6 ) that wraps around the containers C (e.g., the carton  5  may be referred to as a wrap-around carton). The carton  5  could be otherwise shaped and arranged such the ends  6 ,  8  are at least partially closed such as by end flaps (not shown) or other closing mechanisms. 
     The blank  3  has a longitudinal axis L 1  and a lateral axis L 2 . In the illustrated embodiment, the blank  3  comprises a top panel  10  foldably connected to a first side panel  20  at a first lateral fold line  21 , a first bottom panel  30  foldably connected to the first side panel  20  at a second lateral fold line  31 , a second side panel  40  foldably connected to the top panel  10  at a third lateral fold line  41 , and a second bottom panel  50  foldably connected to the second side panel  40  at a fourth lateral fold line  51 . In the illustrated embodiment, the first bottom panel  30  includes a first bevel panel  32  defined by lateral fold lines  33  and  31 . The second bottom panel  50  includes a second bevel panel  52  defined by lateral fold lines  51  and  53 . 
     The first bottom panel  30 , which is the inner bottom panel flap in the assembled carton  5 , includes cutouts forming primary female locking edges  60  that are shaped and positioned to engage primary male locking tab projections  70  on the second bottom panel  50 . The first bottom panel  30  also includes slits  62  shaped and positioned to receive outer secondary locking tab projections  72  of the second bottom panel  50 . The second bottom panel  50 , which is the outer bottom panel in the completed carton  5 , includes a lateral fold line  74  which is interrupted by the slits that define the primary male locking tab projections  70 . Although the locking elements of the blank  3  are illustrated to demonstrate a typical bottom panel locking arrangement suitable for use with the carton  5  ( FIG. 5 ), it is understood that any alternative form of bottom panel locking structure may be employed without departing from the disclosure. 
     In one embodiment, slits at least partially define heel cutout panels  36  that are foldably attached to the first bottom panel  30  at lateral fold lines  37 . Each heel cutout panel  36  is sized to receive a bottom peripheral edge of a container C loaded in the carton  5 . Similarly, heel cutout panels  56  are foldably attached to the second bottom panel  50  at lateral fold lines  57 . In  FIG. 1 , the blank  3  includes three heel cutout panels  36 ,  56  in each bottom panel  30 ,  50 , which are arranged to accommodate the six containers C in a 2×3 (two columns and three rows) arrangement. Alternatively, the heel cutout panels  36 ,  56  may be otherwise arranged and positioned in the blank, or the heel cutout panels may be omitted without departing from the scope of the disclosure. 
     As shown in  FIG. 1 , the blank  3  includes handle features for forming a handle  7  in the carton  5 . The handle features include a first finger flap  12  and a second finger flap  14 , each respectively formed by slits and foldably attached to the top panel  10  at respective longitudinal fold lines  13 ,  15 . The handle  7  could include other features for carrying the carton  5 , the finger flaps  12 ,  14  could be omitted or otherwise shaped and arranged, or the handle  7  could be omitted from the carton. 
     In the illustrated embodiment, the top panel  10  is generally rectangular having top retainer features in the form of a top retainer  80  located at each corner. The top retainers  80  each include a top retention panel  82  foldably attached to the top panel  10  at an oblique line of weakening  85  (e.g., fold line), a side retention panel  84  foldably attached to the top retention panel at a portion of one of the lateral fold lines  21 ,  41 , and a tuck-in panel  86  foldably attached to one of the side panels  20 ,  40  at a second oblique line of weakening  87  (e.g., fold line). Each tuck-in panel  86  is foldably attached to a respective side retention panel  84  at a third oblique line of weakening line  89  (e.g., fold line). In the embodiment of  FIG. 1 , each tuck-in panel  86  and side retention panel  84  are separated by a cut  91  extending from the oblique line of weakening  89  to an edge  92  of the blank  3 . As shown in  FIG. 1A , the cut  91  is a generally J-shaped slit so that the cut has a curved portion  91   a  adjacent the line of weakening  89  and a straight portion  91   b  extending to the edge  92  of the blank  3 . Alternatively, the cut  91  (e.g., slit) could be other shapes without departing from the disclosure. 
     In the illustrated embodiment, the oblique line of weakening  87  comprises a cut-crease line that includes cut portions  95   a  through  95   e  and score line portions  97   a  through  97   e . In on embodiment, the line of weakening  87  includes five cut portions  95   a  through  95   e  and six score line portion  97   a  through  97   e  but the line of weakening  87  could be otherwise formed. Each cut portion  95   a  through  95   e  comprises a cut that extends substantially through the thickness of the blank to cause the blank  3  to tear or form an opening  98   a  through  98   e  ( FIG. 4 ) when the blank is formed into the carton  5 . Each score line portion  97   a  through  97   e  comprises an indentation in a surface of the blank that does not extend substantially through the thickness of the blank  3  so that the blank does not tear or separate along the length of the score line. As shown in  FIG. 1A , one of the cut portions  95   a  of the line of weakening  87  intersects the lateral fold line  41  at a location that is adjacent to a first edge  41   a  ( FIG. 1A ) of the lateral fold line  41 . Throughout this disclosure, each cut and cut portion may more specifically be in the form of a slit. 
     In the illustrated embodiment, the line of weakening  85  is a cut-crease line that includes a cut portion  85   a  and a score line portion  85   b . As shown in  FIG. 1A , the cut portion  85   a  intersects the lateral fold line  41  at a location that is adjacent to a second edge  41   b  ( FIG. 1A ) the lateral fold line  41 . The cut portions  95   a ,  85   a  may extend into and intersect portions of the lateral fold lines  21 ,  41  or the cut portions  95   a ,  85   a  may terminate at a location that is adjacent and/or abutting the lateral fold lines  21 ,  41 . The cut portion  85   a  forms an opening  94  ( FIG. 4 ) when the blank  3  is formed into the carton  5 . A portion of the lateral fold line  21 ,  41  between the cut portions  95   a ,  85   a  forms a section of material  22  ( FIG. 4 ) between the openings  98   a ,  94  formed by the respective cut portions. The score line portions  97   a  through  97   e  of the line of weakening  87  form respective sections of material between the openings  98   a  through  98   e  formed from the cut portions  95   a  through  95   e.    
     In the illustrated embodiments the lateral fold lines  21 ,  41  and oblique fold lines  89  are lines of weakening in the form of score lines that comprise an indentation in a surface of the blank  3  that does not extend substantially through the thickness of the blank so that the blank does not tear or separate along the length of the score line. The lines of weakening  21 ,  41 ,  89  could be other than illustrated (e.g., continuous cut-score lines, intermittent cut-score lines, etc.) without departing from the disclosure. 
     In the illustrated embodiment, the cut portion  95   a  of the line of weakening  87  intersects the lateral fold lines  21 ,  41  at an intersection  93  spaced from the edge  92  of the blank  3  by a first distance D 1 . As shown in  FIG. 1A , the cut portion  85   a  of the line of weakening  85  intersects the lateral fold line  21 ,  41  at the intersection  93  so that the respective ends of the lines of weakening  85 ,  87  that intersect the lateral fold line  21 ,  41  are spaced from the edge  92  of the blank by the same distance D 1 . 
     In the illustrated embodiment, the lateral fold lines  21 ,  41  have a length L 3  ( FIG. 1 ) of at least approximately 188 mm (7.4 inches) and the distance D 1  is at least approximately 12.6 mm (½ inch). In one embodiment, D 1  is at least approximately 5 percent of the length L 3 . All dimensional information presented herein is intended to be illustrative of typical embodiments of the disclosure and is not intended to be limiting. Further, the various features of the blank  3  and carton  5  may have dimensions other than listed herein, without departing from the scope of this disclosure. 
     In the illustrated embodiment, the line of weakening  89  is a score line that extends from the intersection  93  of the oblique lines of weakening  85 ,  87  and the lateral fold line  21 ,  41 . The line of weakening  89  could be other than illustrated (e.g., continuous cut-score lines, intermittent cut-score lines, etc.) without departing from the disclosure. 
     An exemplary method of erecting the carton  5  will now be discussed with reference to  FIGS. 2-6 .  FIGS. 2 and 3  illustrate an initial step in erection of the carton  5 , in which containers C are placed top side down on the interior side  4  of the top panel  10  of the blank  3 . Referring to  FIG. 4 , the side panels  20 ,  40  are then folded upwardly toward the containers C. As the side panels  20 ,  40  are folded upwardly, the tuck-in panels  86  are respectively tucked inwardly about the fold lines  87 . At the same time and as a result, the side retention panels  84  are drawn inwardly and the top retention panels  82  are drawn upwardly to the position shown in  FIG. 4 . The top retention panels  82  and side retention panels  84  cooperate to partially wrap around portions of the containers C to respectively form the top retainers  80  at the four top corners of the carton  5 . After the second bottom panel  50  is secured to the first bottom panel  30  as discussed below, the tuck-in panels  86  and retention panels  82 ,  84  are held in place by virtue of the tuck-in panels being respectively sandwiched (e.g., held, pinched, etc.) between the containers C and the interior surface of the side panels  20 ,  40 . 
     As illustrated in  FIG. 5 , the second bottom panel  50  is secured to the first bottom panel  30  by first respectively engaging primary male locking tabs  70  with the primary female locking edges  60 . The male locking flaps  72  are respectively inserted through, and cooperatively interact with, the slits  62  to further secure the second bottom panel  50  to the first bottom panel  30 . The secured together bottom panels  30 ,  50  cooperate to form a bottom panel  90  of the carton  5 . The heels of containers C are respectively associated with the cutout panels  36 ,  56  to allow tight wrapping of the carton  5  around containers C. 
       FIG. 6  shows the assembled carton  5  with the containers C removed to show the positioning of the tuck-in panels  86  and retention panels that form the top retainers  80 . When the tuck-in panels  83  are folded inwardly about the fold lines  87 , the retention panels  82 ,  84  are respectively positioned to abut a top portion of the containers C adjacent thereto to assist in retaining the containers in the carton  5 . As shown in  FIG. 6 , the J-shaped cut  91  between each tuck-in panel  86  and side retention panel  84  allows the edge of the side retention panel adjacent the cut  91  to be independently positionable relative to the tuck-in panel. When the tuck-in panel  86  is folded inward and positioned along the interior surface of one of the side panels  20 ,  40 , the side retention panel  84  is allowed to separate from the tuck-in panel at the J-shaped cut  91  so that the side retention panel  84  and the top retention panel  82  are positioned to retain the containers C in the carton  5 . 
       FIGS. 7 and 7A  illustrate a blank  103  used to form a carton according to a second embodiment of the present disclosure. The second embodiment is like the first embodiment shown and described with reference to  FIGS. 1-6 , except for variations noted and other variations that would be apparent to one of ordinary skill in the art. In  FIGS. 7 and 7A , like reference numbers as to the reference numbers shown in  FIGS. 1-6  indicate like or similar elements, with the reference numbers in  FIGS. 7 and 7A  being preceded by “1.” The blank  103  includes top retainers  180  similar to the top retainers  80  of the first embodiment. In the embodiments of  FIGS. 7 and 7A , the tuck-in panel  186  and side retention panel  184  at each corner of the top panel  10  are separated by a notch  191  (e.g., cut out) adjacent the oblique line of weakening  189  connecting the tuck-in panel and side retention panel. The notch  191  replaces the J-shaped cut  91  of the first embodiment. Differently shaped notches  191 , or the like, are within the scope of the present disclosure. 
     The blank according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blank can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blank may then be coated with a varnish to protect any information printed on the blank. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
     In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines can include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends at least 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 
     The foregoing description illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction, 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 present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. It will be understood by those skilled in the art that while the present disclosure has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the claims. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the disclosure.