Source: http://www.patentsencyclopedia.com/app/20120279897
Timestamp: 2018-01-22 00:47:11
Document Index: 746576266

Matched Legal Cases: ['Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61']

Inventors: Michael R. Schmal (Atlanta, GA, US) O'Neal Alexander (Covington, GA, US) O'Neal Alexander (Covington, GA, US) Mark Baldino (Marietta, GA, US) Mark Baldino (Marietta, GA, US) Michael Cerio (Kennesaw, GA, US) John Murdick Holley, Jr. (Lawrenceville, GA, US) John Murdick Holley, Jr. (Lawrenceville, GA, US) Frank N. Moncrief (Acworth, GA, US) Frank N. Moncrief (Acworth, GA, US) Raymond S. Kastanek (Kennesaw, GA, US) Raymond S. Kastanek (Kennesaw, GA, US) Colin Ford (Woodstock, GA, US) Colin Ford (Woodstock, GA, US)
IPC8 Class: AB65B4310FI
USPC Class: 206593
Class name: Shock protection type (e.g., free fall) with yieldable retainer separator between articles
Patent application number: 20120279897
1. A carton for containing at least one article, the carton comprising: at least one panel at least partially forming an interior of the carton; 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 at least one panel and moveable between a first position that is substantially parallel to the at least one panel and a second position wherein the article protection flap is folded relative to the at least one panel, the article protection flap has features for preventing folding of the article protection flap from the second position to the first position.
2. The carton of claim 1, wherein the article protection flap comprises a first portion of the article protection flap and a second portion of the article protection flap that are foldable relative to each other.
3. The carton of claim 2 wherein the first portion and the second portion are folded relative to each other when the article protection flap is in the second position.
4. The carton of claim 3 wherein the first portion and the second portion are inwardly folded relative to each other.
5. The carton of claim 2 wherein the at least one panel comprises an opening having an edge at least partially formed by a line of weakening defining at least a portion of the article protection flap, the features for preventing folding of the article protection flap comprise a free edge of at least one of the first portion and the second portion that extend beyond the edge of the opening.
6. The carton of claim 5 wherein the line of weakening is a cut line.
7. The carton of claim 5 wherein the line of weakening is a tear line.
8. The carton of claim 5 wherein the features for preventing folding of the article protection flap comprise a distal portion of the first portion and a distal portion of the second portion.
9. The carton of claim 8 wherein the features for preventing folding of the article protection flap comprises a heel portion at the distal end of the flap.
10. The carton of claim 5 wherein the at least one panel comprises a slit adjacent the opening.
11. The carton of claim 1 wherein the article protection flap is foldably connected to the at least one panel at a first fold line.
12. The carton of claim 11 wherein the article protection flap comprises a second fold line extending from the first fold line and a third fold line extending from the first fold line.
13. The carton of claim 12 wherein the article protection flap comprises a central portion at least partially defined by the first fold line, the second fold line, and the third fold line.
14. The carton of claim 13 wherein the first fold line is a lateral fold line, the second fold line extends from the first fold line and the third fold line extends from the first fold line.
15. The carton of claim 14 wherein the second fold line and the third fold line are longitudinal fold lines.
16. The carton of claim 14 wherein the second fold line and the third fold line are curved.
17. The carton of claim 13 wherein the first portion is foldably connected to the central portion at the second fold line and the second portion is foldably connected to the central portion at the third fold line.
18. The carton of claim 1 wherein the at least one article protection flap comprises a plurality of article protection flaps arranged in a 3.times.3 arrangement.
19. The carton of claim 18 wherein the at least one article comprises a plurality of articles, each of the article protection flaps is positioned between two respective adjacent articles of the plurality of articles.
20. The carton of claim 1 wherein the interior has a first end and a second end, the at least one article being arranged in at least one row that extends from the first end to the second end.
21. The carton of claim 20 wherein the at least one article comprises a plurality of articles, and the at least one article protection flap is positioned between two adjacent articles of the plurality of articles.
22. The carton of claim 21 wherein the at least one row comprises at least three rows and the at least one article protection flap comprises at least three article protection flaps, each article protection flap being positioned between adjacent articles in a respective one of the at least three rows.
23. The carton of claim 22 wherein the at least three article protection flaps are primary article protection flaps, the carton further comprising secondary article protection flaps foldably connected to the at least one panel.
24. The carton of claim 1 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel.
25. The carton of claim 24 wherein the plurality of panels further comprises a top panel foldably connected to the first side panel and the second side panel.
26. The carton of claim 1 wherein the carton is a carrier wherein the interior of the carton has a generally open top for receiving at least one of the articles, the plurality of panels further comprises a divider panel for at least partially dividing the interior into a first portion and a second portion.
27. The carton of claim 25 further comprising: at least two end flaps respectively foldably connected to respective panels of the plurality of panels, the end flaps being at least partially overlapped to close an end of the carton; and at least one article protection feature for protecting at least one of the plurality of articles, the at least one article protection feature is positioned between the at least two end flaps.
28. The carton of claim 4 wherein at least one of the first portion and the second portion comprises a deformation for enhancing article protection.
29. The carton of claim 28 wherein the deformation is a first deformation on the first portion and a second deformation on the second portion, the first deformation and the second deformation cooperating to form a pocket between the first portion and the second portion.
30. A blank for forming a carton for containing at least one article, the blank comprising: at least one panel for at least partially forming an interior of the carton formed from the blank; 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 at least one panel and moveable between a first position that is substantially parallel to the at least one panel and a second position wherein the article protection flap is folded relative to the at least one panel, the article protection flap has features for preventing folding of the article protection flap from the second position to the first position in the carton formed from the blank.
31. The blank of claim 30, wherein the article protection flap comprises a first portion of the article protection flap and a second portion of the article protection flap that are foldable relative to each other.
32. The blank of claim 31 wherein the first portion and the second portion are for being folded relative to each other when the article protection flap is in the second position.
33. The blank of claim 31 wherein the at least one panel comprises a line of weakening at least partially defining the article retention flap, the line of weakening forming an opening having an edge in the carton formed from the blank, the features for preventing folding of the article protection flap comprise a free edge of at least one of the first portion and the second portion that extend beyond the edge of the opening in the carton formed from the blank.
34. The blank of claim 33 wherein the line of weakening is a cut line.
35. The blank of claim 33 wherein the line of weakening is a tear line.
36. The blank of claim 33 wherein the line of weakening is shaped to form a distal portion of the first portion and a distal portion of the second portion, the features for preventing folding of the article protection flap comprise the distal portion of the first portion and the second portion.
37. The blank of claim 36 wherein the line of weakening is shaped to form a heel portion at the distal end of the flap, the features for preventing folding of the article protection flap comprises the heel portion.
38. The blank of claim 33 wherein the at least one panel comprises a slit adjacent the line of weakening.
39. The blank of claim 30 wherein the article protection flap is foldably connected to the at least one panel at a first fold line.
40. The blank of claim 39 wherein the article protection flap comprises a second fold line extending from the first fold line and a third fold line extending from the first fold line.
41. The blank of claim 40 wherein the article protection flap comprises a central portion at least partially defined by the first fold line, the second fold line, and the third fold line.
42. The blank of claim 41 wherein the first fold line is a lateral fold line, the second fold line extends from the first fold line and the third fold line extends from the first fold line.
43. The blank of claim 42 wherein the second fold line and the third fold line are longitudinal fold lines.
44. The blank of claim 42 wherein the second fold line and the third fold line are curved.
45. The blank of claim 41 wherein the first portion is foldably connected to the central portion at the second fold line and the second portion is foldably connected to the central portion at the third fold line.
46. The blank of claim 30 wherein the at least one article protection flap comprises a plurality of article protection flaps arranged in a 3.times.3 arrangement.
47. The blank of claim 30 wherein the at least one article protection flap comprise a primary article protection flap foldably connected to the at least one panel and a secondary article protection flap foldably connected to the at least one panel.
48. The blank of claim 30 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel.
49. The blank of claim 48 wherein the plurality of panels further comprises a top panel foldably connected to the first side panel and the second side panel.
50. The blank of claim 30 wherein the carton formed from the blank is a carrier, wherein the interior of the carton has a generally open top for receiving at least one of the articles, the plurality of panels further comprises a divider panel for at least partially dividing the interior into a first portion and a second portion.
51. The blank of claim 48 further comprising: at least two end flaps respectively foldably connected to respective panels of the plurality of panels, the end flaps being at least partially overlapped to close an end of the carton formed from the blank; and at least one article protection feature for protecting at least one of the plurality of articles, the at least one article protection feature is positioned between the at least two end flaps in the carton formed from the blank.
52. The blank of claim 31 wherein at least one of the first portion and the second portion comprises a deformation for enhancing article protection.
53. The blank of claim 52 wherein the deformation is a first deformation on the first portion and a second deformation on the second portion, the first deformation and the second deformation cooperating to form a pocket between the first portion and the second portion.
54. A method of forming a carton, the method comprising: obtaining a blank comprising at least one panel and at least one article protection flap foldably connected to the at least one panel; positioning the at least one panel to at least partially form an interior space of the carton; loading at least one article in the interior space; folding the at least one article protection flap relative to the at least one 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 at least one panel to a second position wherein the article protection flap is folded relative to the at least one panel.
55. The method of claim 54 wherein the loading at least one article comprises loading a plurality of articles.
56. The method of claim 55 wherein the at least one article protection flap comprises a plurality of article protection flaps, and the folding comprises positioning each of the article protection flaps between two respective adjacent articles of the plurality of articles.
57. The method of claim 55 wherein the at least one article protection flap comprises features to facilitate the folding of the flap between adjacent articles.
58. The method of claim 54 wherein the positioning the panels comprises forming a sleeve having a first end and a second end, the blank has a first plurality of end flaps at one end of the blank and a second plurality of end flaps at a second end of the blank, the method comprises closing the first end by at least partially overlapping the first plurality of end flaps and closing the second end by at least partially overlapping the second plurality of end flaps.
59. The method of claim 58 wherein at least one of the closing the first end and the closing the second end is before the folding the at least one article protection flap.
60. The method of claim 58 wherein at least one of the closing the first end and the closing the second end is during the folding the at least one article protection flap.
61. The method of claim 58 wherein at least one of the closing the first end and the closing the second end is after the folding the at least one article protection flap.
62. The method of claim 58 wherein the loading the at least one article comprises arranging a plurality of the articles in at least one row that extends from the first end to the second end, the at least one article protection flap being positioned between two respective adjacent articles in the at least one row.
63. The method of claim 62 wherein the at least one row comprises at least three rows and the at least one article protection flap comprises at least three article protection flaps, the folding comprises positioning each article protection flap between adjacent articles in a respective one of the at least three rows.
64. The method of claim 63 wherein the at least three article protection flaps are primary article protection flaps, the carton further comprising secondary article protection flaps foldably connected to the at least one panel, the method further comprises folding the secondary article protection flaps after the loading of the plurality of articles.
65. The method of carton of claim 54, wherein the article protection flap has features for preventing folding of the article protection flap from the second position to the first position.
66. The method of claim 65 wherein the article protection flap comprises a first portion and a second portion, and the folding of the article protection flap comprises folding the first portion and the second portion relative to each other.
67. The method of claim 66 wherein the first portion and the second portion are folded about a fold line during the folding so that the first portion and the second portion are inwardly folded relative to each other.
68. The method of claim 67 wherein the at least one panel comprises an opening formed by the folding of the article protection flap from the first position to the second position, the opening having an edge at least partially formed by a line of weakening defining at least a portion of the article protection flap, the features for preventing folding of the article protection flap comprise a free edge of at least one of the first portion and the second portion that are positioned to extend beyond the edge of the opening during the folding the first portion and the second portion relative to each other.
69. The method of claim 68 wherein the features for preventing folding of the article protection flap comprises a distal portion of the first portion and a distal portion of the second portion.
70. The method claim 69 wherein the features for preventing folding of the article protection flap comprises a heel of the flap at the distal end of the flap.
71. The method of claim 66 wherein the article protection flap is foldably connected to the at least one panel at a first fold line, the article protection flap comprises a second fold line extending from the first fold line and a third fold line extending from the first fold line, the article protection flap comprises a central portion at least partially defined by the first fold line, the second fold line, and the third fold line, the first fold line is a longitudinal fold line, the second fold line extends from the first fold line and the third fold line extends from the first fold line, the folding the first portion and second portion relative to each other comprises folding the first portion at the second fold line and folding the second portion at the third fold line.
72. The method of claim 54 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel, the positioning the plurality of panels comprises positioning the first side panel and the second side panel relative to the bottom panel.
73. The method of claim 72 wherein the plurality of panels further comprises a top panel foldably connected to the first side panel and the second side panel, the positioning the plurality of panels comprises positioning the top panel relative to the first side panel and the second side panel.
74. The method of claim 54 wherein the carton is a carrier and wherein the interior of the carton has a generally open top for receiving at least one of the articles, the plurality of panels comprises a divider panel and the positioning the panels comprises positioning the divider panel to at least partially divide the interior into a first portion and a second portion.
75. The method of claim 54 wherein the folding the at least one article protection flap comprises engaging the at least one article protection flap with a finger of a mechanism for forming the carton.
76. The method of claim 54 wherein the folding the at least one article protection flap comprises contacting the at least one article and moving the article.
77. A carton for containing at least one article, the carton comprising: a plurality of panels that extends at least partially around an interior of the carton; at least two end flaps respectively foldably connected to respective panels of the plurality of panels, the end flaps being at least partially overlapped to close an end of the carton; at least one article protection feature for protecting the at least one article, the at least one article protection feature is positioned between the at least two end flaps.
78. The carton of claim 77 wherein the at least two end flaps comprises a first end flap and a second end flap, the article protection feature comprises at least one feature on one of the first end flap and the second end flap.
79. The carton of claim 78 wherein the at least one feature comprises a first feature on the first end flap and a second feature on the second end flap.
80. The carton of claim 79 wherein the first feature and the second feature are generally aligned at the closed end.
81. The carton of claim 79 wherein the first feature and the second feature are generally adjacent.
82. The carton of claim 79 wherein the first feature and the second feature are in communication with each other.
83. The carton of claim 80 wherein the first feature comprises a first deformation and the second feature comprises a second deformation.
84. The carton of claim 83 wherein the first deformation comprises an indentation on an exterior surface of the first end flap and the second deformation comprises an indentation on an interior surface of the second end flap.
85. The carton of claim 84 wherein the first feature and the second feature combine to form a pocket in the overlapped first and second end flaps, the pocket being for providing cushioning of the at least one article.
86. The carton of claim 85 wherein the pocket comprises a shock absorbing material that provides cushioning of the at least one of the articles.
87. The carton of claim 86 wherein the material is a thermoplastic adhesive.
88. The carton of claim 86 wherein the material is an adhesive, and the adhesive is further applied between the first end flap and the second end flap to secure the end flaps in a closed position.
89. The carton of claim 85 further comprising a third feature on the first end flap and a fourth feature on the second end flap, the third feature and the fourth feature are generally aligned at the closed end, the third feature comprises an indentation on the exterior surface of the first end flap and the fourth feature comprises an indentation on the interior surface of the second end flap, the pocket is a first pocket and the third feature and the fourth feature combine to form a second pocket in the overlapped first and second end flaps for providing cushioning of the at least one of the articles in the carton.
90. The carton of claim 89 wherein the second pocket comprises a shock absorbing material that provides cushioning of the at least one of the articles in the carton.
91. The carton of claim 89 wherein the plurality of panels comprises a bottom panel and the first pocket is spaced apart from the bottom panel by a first distance, the second pocket is spaced apart from the bottom panel by a second distance, the first distance is less than the second distance.
92. The carton of claim 89 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel, and the first end flap is a side end flap foldably connected to one of the first and second side panels, and the second end flap is a bottom end flap foldably connected to the bottom panel.
93. The carton of claim 77 further comprising at least one article protection flap for protecting the at least one article, the article protection flap is foldably connected to at least one panel of the plurality of panels and is moveable between a first position that is substantially parallel to the at least one panel and a second position wherein the article protection flap is folded relative to the at least one panel, the article protection flap has features for preventing folding of the article protection flap from the second position to the first position.
94. The carton of claim 93 wherein the article protection flap has a first portion and a second portion that are folded relative to each other when the article protection flap is in the second position.
95. The carton of claim 85 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel, and the first end flap is a side end flap foldably connected to one of the first and second side panels, the second end flap is a bottom end flap foldably connected to the bottom panel, and further comprising a third end flap foldably connected to one of the first and second side panels.
96. The carton of claim 95 further comprising a third deformation on the third end flap, the third deformation being generally aligned with the first deformation to form the pocket.
97. The carton of claim 95 wherein the third end flap comprises a notch that is generally aligned with the first feature and the second feature.
98. The carton of claim 85 wherein the pocket is a first pocket and one of the at least two end flaps comprises a base portion and a reinforcement flap foldably connected to the base portion, the one of the at least two end flaps comprises a third feature on the base portion and a fourth feature on the reinforcement flap, the third feature and the fourth feature are generally aligned at the closed end with the third feature and the fourth feature forming a second pocket adjacent the first pocket.
99. The carton of claim 98 wherein the third feature is an indentation on the interior surface of the base portion and the fourth feature is an indentation on the interior surface of the reinforcement flap.
100. The carton of claim 99 wherein the reinforcement flap is in generally face-to-face contact with the base portion.
101. A blank for forming a carton for containing at least one article, the blank comprising: a plurality of panels for extending at least partially around an interior of the carton formed from the blank; at least two end flaps respectively foldably connected to respective panels of the plurality of panels, the end flaps being at least partially overlapped to close an end of the carton formed from the blank; at least one article protection feature for protecting the at least one article, the at least one article protection feature is for being positioned between the at least two end flaps.
102. The blank of claim 101 wherein the at least two end flaps comprises a first end flap and a second end flap, the article protection feature comprises at least one feature on one of the first end flap and the second end flap.
103. The blank of claim 102 wherein the at least one feature comprises a first feature on the first end flap and a second feature on the second end flap.
104. The blank of claim 103 wherein the first feature and the second feature are positioned on the respective end flaps to be generally aligned at the closed end of the carton formed from the blank.
105. The blank of claim 103 wherein the first feature and the second feature are generally adjacent in the carton formed from the blank.
106. The blank of claim 103 wherein the first feature and the second feature are in communication with each other in the carton formed from the blank.
107. The blank of claim 104 wherein the first feature comprises a first deformation and the second feature comprises a second deformation.
108. The blank of claim 107 wherein the first deformation comprises an indentation on an exterior surface of the first end flap and the second deformation comprises an indentation on an interior surface of the second end flap.
109. The blank of claim 108 wherein the first feature and the second feature are for forming a pocket in the overlapped first and second end flaps in the carton formed from the blank, the pocket being for providing cushioning of the at least one article.
110. The blank of claim 109 wherein the pocket comprises a shock absorbing material that provides cushioning of the at least one of the articles.
111. The blank of claim 110 wherein the material is a thermoplastic adhesive.
112. The blank of claim 110 wherein the material is an adhesive, and the adhesive is further applied between the first end flap and the second end flap to secure the end flaps in a closed position in the carton formed from the blank.
113. The blank of claim 109 further comprising a third feature on the first end flap and a fourth feature on the second end flap, the third feature and the fourth feature are for being generally aligned at the closed end of the carton formed form the blank, the third feature comprises an indentation on the exterior surface of the first end flap and the fourth feature comprises an indentation on the interior surface of the second end flap, the pocket is a first pocket and the third feature and the fourth feature are for forming a second pocket in the overlapped first and second end flaps for providing cushioning of the at least one of the articles in the carton formed form the blank.
114. The blank of claim 113 wherein the second pocket comprises a shock absorbing material that provides cushioning of the at least one of the articles in the carton formed from the blank.
115. The blank of claim 113 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel, and the first end flap is a side end flap foldably connected to one of the first and second side panels, and the second end flap is a bottom end flap foldably connected to the bottom panel.
116. The blank of claim 101 further comprising at least one article protection flap for protecting the at least one article, the article protection flap is foldably connected to at least one panel of the plurality of panels and is moveable between a first position that is substantially parallel to the at least one panel and a second position wherein the article protection flap is folded relative to the at least one panel, the article protection flap has features for preventing folding of the article protection flap from the second position to the first position.
117. The blank of claim 116 wherein the article protection flap has a first portion and a second portion that are folded relative to each other when the article protection flap is in the second position.
118. The blank of claim 109 wherein the plurality of panels comprises a bottom panel, a first side panel foldably connected to the bottom panel, and a second side panel foldably connected to the bottom panel, and the first end flap is a side end flap foldably connected to one of the first and second side panels, the second end flap is a bottom end flap foldably connected to the bottom panel, and further comprising a third end flap foldably connected to one of the first and second side panels.
119. The blank of claim 118 further comprising a third deformation on the third end flap, the third deformation is for being generally aligned with the first deformation to form the pocket in the carton formed from the blank.
120. The blank of claim 118 wherein the third end flap comprises a notch that is for being generally aligned with the first feature and the second feature in the carton formed from the blank.
121. The blank of claim 109 wherein the pocket is a first pocket and one of the at least two end flaps comprises a base portion and a reinforcement flap foldably connected to the base portion, the one of the at least two end flaps comprises a third feature on the base portion and a fourth feature on the reinforcement flap, the third feature and the fourth feature are for being generally aligned at the closed end of the carton formed form the blank with the third feature and the fourth feature forming a second pocket adjacent the first pocket in the carton formed from the blank.
122. The blank of claim 121 wherein the third feature is an indentation on the interior surface of the base portion and the fourth feature is an indentation on the interior surface of the reinforcement flap.
123. The blank of claim 122 wherein the reinforcement flap is for being in generally face-to-face contact with the base portion in the carton formed from the blank.
124. A method of forming a carton for containing at least one article, the method comprises: obtaining a blank comprising a plurality of panels and at least two end flaps respectively foldably connected to a respective panel of the plurality of panels; positioning the plurality of panels to form an interior space of the carton; loading at least one article in the interior space; at least partially overlapping the at least two end flaps to close an end of the carton; and forming an article protection feature that is positioned between the at least two end flaps.
125. The method of claim 124 wherein the at least two end flaps comprises a first end flap and a second end flap, the article protection feature comprises at least one feature on one of the first end flap and the second end flap.
126. The method of claim 125 wherein the at least one feature comprises a first feature on the first end flap and a second feature on the second end flap.
127. The method of claim 126 wherein the forming the article protection feature comprises generally aligning the first feature and the second feature at the closed end.
128. The method of claim 127 wherein the forming the article protection feature comprises positioning at least one of the first feature and the second feature so that the first feature and second feature are generally adjacent.
129. The method of claim 127 wherein the forming the article protection feature comprises positioning at least one of the first feature and the second feature so that the first feature and the second feature are in communication.
130. The method of claim 126 wherein the first feature comprises a first deformation and the second feature comprises a second deformation.
131. The method of claim 130 wherein the first deformation comprises an indentation on an exterior surface of the first end flap and the second deformation comprises an indentation on an interior surface of the second end flap.
132. The method of claim 131 wherein the forming the article protection feature comprises combining the first feature and the second feature to form a pocket in the overlapped first and second end flaps, the pocket being for providing cushioning of the at least one article in the carton.
133. The method of claim 132 wherein the forming the article protection feature comprises placing a shock absorbing material in the pocket to provide cushioning of the at least one article.
134. The method of claim 133 wherein the material is a thermoplastic adhesive applied to one of the indentation on the first end flap and the indentation on the second end flap.
135. The method of claim 133 wherein the material is an adhesive, and the method further comprises applying the adhesive between the first end flap and the second end flap to secure the end flaps in a closed position.
136. The method of claim 133 wherein the article protection feature comprises a third feature on the first end flap and a fourth feature on the second end flap, the forming the article protection feature comprising generally aligning the third feature and the fourth feature at the closed end, the third feature comprises an indentation on the exterior surface of the first end flap and the fourth feature comprises an indentation on the interior surface of the second end flap, the pocket is a first pocket and the third feature and the fourth feature combine to form a second pocket in the overlapped first and second end flaps for providing cushioning of the at least one of the articles in the carton.
137. The method of claim 136 further comprising placing a shock absorbing material in the second pocket that provides cushioning of the at least one of the articles in the carton.
138. The method of claim 137 wherein the plurality of panels comprises a bottom panel, and the first pocket is spaced apart from the bottom panel by a first distance, the second space is spaced apart from the bottom panel by a second distance, the first distance is less than the second distance.
139. A method of forming a carton, the method comprising: obtaining a blank comprising a panel and at least one article protection flap foldably connected to the panel; positioning at least two articles to be in contact with the panel; folding the at least one article protection flap relative to the panel after the positioning the at least two articles, the folding comprises moving the article protection flap from a first position that is substantially parallel to the panel to a second position wherein the article protection flap is folded relative to the panel.
140. The method of claim 139 wherein the panel comprises a bottom panel and the method further comprises applying packaging material to the articles to secure the articles to the bottom panel.
141. The method of claim 139 wherein the panel is a bottom panel and the blank further comprises at least one side panel.
142. The method of claim 141 further comprising forming the blank into a tray by folding the at least one side panel relative to the bottom panel.
143. The method of claim 142 wherein the at least one side panel comprises four side panels.
144. The method of claim 143 further comprising applying packaging material to the articles to secure the articles to the tray.
145. The method of claim 142 wherein the at least one side panel comprises a first side panel and a second side pane, and the blank further comprises a top panel.
146. The method of claim 145 further comprising folding the blank by positioning the first side panel and the second side panel relative to the bottom panel to at least partially enclose the at least two articles.
147. The method of claim 146 wherein the blank further comprises a top panel and the folding the blank comprises positioning the top panel relative to the first side panel and the second side panel to form an a sleeve forming an interior of the carton.
148. The method of claim 147 wherein the blank comprises end flaps at at least one end, the method further comprises positioning the end flaps to at least partially close an end of the sleeve.
149. The method of claim 139 wherein the at least one article protection flap comprises a plurality of article protection flaps and the at least two articles comprises a plurality of articles, and the folding comprises positioning each of the article protection flaps between two respective articles of the plurality of articles.
150. The method of claim 139 wherein the article protection flap has features for preventing folding of the article protection flap from the second position to the first position.
151. The method of claim 150 wherein the article protection flap comprises a first portion and a second portion, and the folding of the article protection flap comprises folding the first portion and the second portion relative to each other.
152. The method of claim 139 further comprising positioning the blank and the at least two articles relative to a construct to at least partially enclose the blank and the at least two articles.
153. The method of claim 152 wherein the construct is a sleeve having at least one open end.
154. The method of claim 153 further comprising closing at least one end of the sleeve after the positioning the blank and the at least two articles in an interior space of the sleeve.
155. A carton for containing at least one article, the carton comprising: at least one panel at least partially forming an interior of the carton; at least two end flaps at least partially overlapped to at least partially close the interior of the carton; at least one article protection feature for protecting the at least one article, the at least one article protection feature is positioned between the at least two end flaps; and 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 at least one panel and moveable between a first position that is substantially parallel to the at least one panel and a second position wherein the article protection flap is folded relative to the at least one panel.
156. The carton of claim 155 wherein the article protection flap has features for preventing folding of the article protection flap from the second position to the first position.
157. The carton of claim 156 wherein the article protection flap comprises a first portion of the article protection flap and a second portion of the article protection flap, the first portion and the second portion are foldably connected and are folded relative to each other when the article protection flap is in the second position.
158. The carton of claim 157 wherein the at least one panel comprises an opening having an edge at least partially formed by a line of weakening defining at least a portion of the article protection flap, the features for preventing folding of the article protection flap comprise a free edge of at least one of the first portion and the second portion that extend beyond the edge of the opening.
159. The carton of claim 155 wherein the at least two end flaps comprises a first end flap and a second end flap, the article protection feature comprises a first feature on the first end flap and a second feature on the second end flap.
160. The carton of claim 159 wherein the first feature comprises a first deformation and the second feature comprises a second deformation.
161. The carton of claim 160 wherein the first deformation comprises an indentation on an exterior surface of the first end flap and the second deformation comprises an indentation on an interior surface of the second end flap.
162. The carton of claim 161 wherein the first feature and the second feature combine to form a pocket in the overlapped first end flap and second end flap, the pocket providing cushioning to the at least one article.
163. The carton of claim 162 wherein the pocket comprises a shock absorbing material that provides cushioning to the at least one article.
164. A method of forming a carton, the method comprising: obtaining a blank comprising at least one panel, at least one article protection flap foldably connected to the at least one panel, and at least two end flaps; positioning the at least one panel to at least partially form an interior space of the carton; loading at least one article in the interior space; at least partially overlapping the at least two end flaps to close and end of the carton; forming an article protection feature that is positioned between the at least two end flaps; and folding the at least one article protection flap relative to the at least one 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 at least one panel to a second position wherein the article protection flap is folded relative to the at least one panel.
165. The method of claim 164 wherein the article protection flap has features for preventing folding of the article protection flap from the second position to the first position, the article protection flap comprises a first portion and a second portion that are foldably connected to each other, the folding of the article protection flap comprises folding the first portion and the second portion relative to each other.
166. The method of claim 165 wherein the at least one panel comprises an opening formed by the folding of the article protection flap from the first position to the second position, the opening having an edge at least partially formed by a line of weakening defining at least a portion of the article protection flap, the features for preventing folding of the article protection flap comprise a free edge of at least one of the first portion and the second portion that extend beyond the edge of the opening during the folding the first portion and the second portion.
167. The method of claim 164 wherein the at least two end flaps comprises a first end flap and a second end flap, the article protection feature comprises a first feature on the first end flap and a second feature on the second end flap, and forming the article protection feature comprises generally aligning the first feature and the second feature at the closed end.
168. The method of claim 167 wherein the first feature comprises a first deformation and the second feature comprises a second deformation.
169. The method of claim 168 wherein the first deformation comprises an indentation on an exterior surface of the first end flap and the second deformation comprises an indentation on an interior surface of the second end flap.
170. The method of claim 169 wherein the forming the article protection feature comprises combining the first feature and the second feature to form a pocket in the overlapped first end flap and second end flap, the pocket providing cushioning to the at least one article.
171. The method of claim 170 wherein the forming the article protection feature comprises placing a shock absorbing material in the pocket to provides cushioning to the at least one article.
[0001] This application claims the benefit of U.S. Provisional Application No. 61/518,504, filed May 6, 2011, U.S. Provisional Application No. 61/572,638, filed Jul. 19, 2011, U.S. Provisional Application No. 61/272,249, filed Oct. 7, 2011, U.S. Provisional Application No. 61/548,779, filed Oct. 19, 2011, and U.S. Provisional Application No. 61/570,044, filed Dec. 13, 2011.
[0002] The entire contents of U.S. Provisional Application No. 61/518,504, filed May 6, 2011, U.S. Provisional Application No. 61/572,638, filed Jul. 19, 2011, U.S. Provisional Application No. 61/272,249, filed Oct. 7, 2011, U.S. Provisional Application No. 61/548,779, filed Oct. 19, 2011, and U.S. Provisional Application No. 61/570,044, filed Dec. 13, 2011, are hereby incorporated by reference as if presented herein in their entirety.
[0086] FIG. 5C shows an alternative configuration of the end 7 wherein the side end flaps 37, 43 and bottom end flap 33 are modified from the flaps shown in FIG. 4. In the embodiment of FIG. 5C, the bottom end flap 33 has indentations 155 on the interior surface near the peripheral edge of the bottom end flap that are modified from the embodiment of FIG. 4. Further, the side end flaps 37, 43 each have upper indentations 157 that are modified from the embodiment of FIGS. 4 and 5. Both groups of indentations 155, 157 are elongated from the embodiment of FIGS. 4 and 5, and the indentations 155 on the bottom end flap are each sized to extend between two adjacent indentations 157 on the side end flaps 37, 43. The indentations 155 are in communication with multiple indentations 157 so that the pocket formed by the cooperating indentations forms an article protection feature 11 that is elongated and contacts two adjacent articles C. The elongated article protection feature can be filled with shock absorbing material in a similar manner as described above for the first embodiment. Alternative, the lower indentations on the interior surface of the bottom end flap 33 and the lower indentations 81 on the side end flaps 37, 43 could be similar to the indentations 155, 157 without departing from the disclosure.
[0088] The article protection flaps 13 can be activated by various forming apparatus, some of which will be described below in further detail, or any other suitable method. The activation of a single article protection flap 13 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. 10A and 10B are enlarged portions of the interior surface of the bottom panel 15, with FIG. 10A showing the interior surface of the bottom panel prior to activation of the article protection flap 13, and FIG. 10B showing the interior of the bottom panel after activation of the article protection flap. In one embodiment, a finger or other portion of an apparatus for forming the carton 5 presses against the central portion 125 (FIG. 10A) of the article protection flap 13 to initiate separation of the article protection flap from the bottom panel 13 along the cut 103. As shown in FIGS. 8A, 10A, and 10C, the article protection flap 13 is pivoted upward relative to the bottom panel 15 at the fold line 101 in the direction of arrow Al to create an opening 161 in the bottom panel. As the article protection flap 13 is activated, the first portion 121 and the second portion 123 are folded relative to each other. In one embodiment, the first portion 121 and the second portion 123 of the article protection flap are folded inwardly relative to each other and relative to the central portion 125. As such, the article protection flap 13 provides two layers of material (e.g., the inwardly folded first portion 121 and second portion 123) between adjacent containers C in the carton 5.
[0090] In one embodiment, the configuration of the first portion 121 and the second portion 123 prevents the article protection flap 13 from being downwardly folded from the second or raised position of FIG. 8 to the first or lowered position of FIG. 2. As shown in FIG. 10B, when the first portion 121 and the second portion 123 of the article protection flap 13 are inwardly folded relative to each other, the first and second portions extend beyond the edge 163 of the opening 161 created at the third portion 113 of the cut 103. In one embodiment, an edge 165 (FIG. 10C) of the first portion 121 of the article protection flap 13, formed by the rounded corner 109 of the cut 103 extends beyond the edge 163 of the opening 161. Also, an edge 167 (FIG. 10C) of the second portion 123 of the article protection flap 13 formed by the rounded corner 111 of the cut 103 extends beyond the edge 163 of the opening 161. The positioning of the distal portions of the first portion 121 and second portion 123, including the edges 165, 167 of the article protection flap 13, relative to the edge 163 of the opening 161 prevents the article protection flaps 13 from being downwardly folded to the first position wherein the article protection flaps are substantially parallel to the bottom panel 15. As such, once the article protection flaps 13 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. The article protection flaps 13 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.
Patent applications by Frank N. Moncrief, Acworth, GA US
Patent applications by Mark Baldino, Marietta, GA US
Patent applications by Michael Cerio, Kennesaw, GA US
Patent applications by Michael R. Schmal, Atlanta, GA US
Patent applications by O'Neal Alexander, Covington, GA US
Patent applications by Raymond S. Kastanek, Kennesaw, GA US
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