Abstract:
Disclosed herein is a flexible liner for a paneled fiberboard carton. The flexible liner is adhesively attached to the inner sides of the carton&#39;s panels creating demonstrably stronger carton walls and having the same top-load compression strength as standard, conventionally constructed liners. The flexible liners disclosed herein are unique in their die-cut construction resulting in liner panels, and optionally flaps, that are separated from adjacent liner panels by a plurality of slots and flexibly attached to adjacent panels by a plurality of bridges.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of the filing date of Provisional Patent Application No. 62/351,898, filed Jun. 17, 2016. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The flexible carton liner disclosed herein provides an improvement for the consumer packaging industry. Carton liners are commonly used to increase the structural strength of cartons. They are constructed to approximate the size and shape of the carton&#39;s panels, and perhaps its flaps, and adhered to the inner side of the carton, typically resulting in a snug fit between the liner and the carton. The snug fit between the carton and the liner generally results in a lack of flexibility in the lined carton. 
       DESCRIPTION OF THE PRIOR ART 
       [0003]    U.S. Pat. No. 3,980,005, which issued to Buonaiuto on Sep. 14, 1976, describes a shipping carton liner which consists of a unitary sheet of synthetic plastic foam composed of a plurality of panels separated by grooves or score lines of sufficient depth and of a configuration to enable the panels to be swung from coplanar to mutually perpendicular orientation. A resilient layer is then applied to the foam, at least along the score line portions thereof that is characterized by a tear strength and flexibility greater than the foam. The layer of resilient material and the score lines form a hinge for the pivotal movement of the panels. 
         [0004]    Notwithstanding the acknowledged flexibility of the liner panels devised and disclosed by Buonaiuto, there remains a need for a liner with flexible panels and/or flaps that can be fabricated from a variety of materials, especially and most importantly from the same material as the carton and without the addition of a “resilient material.” 
       SUMMARY OF THE INVENTION 
       [0005]    Disclosed herein is a flexible reinforcement liner for a paneled fiberboard carton said liner comprising a plurality of planar panels sized to conform with, and adhesively attach to, the inner surface of said carton panels and wherein the flexible liner is characterized by having panels separated from adjacent liner panels by a plurality of slots and flexibly attached to adjacent liner panels by a plurality of bridges. 
         [0006]    A preferred embodiment of the flexible liner features a liner wherein all the panels of the liner are separated from adjacent panels by a plurality of slots and flexibly jointed or attached to adjacent panels by a plurality of bridges. Another variation of the flexible liner features a liner having a plurality of flaps attached to the liner panels wherein the panels and flaps are separated from adjacent panels by a plurality of slots and attached to the adjacent panels by a plurality of bridges. 
         [0007]    Preferably, the bridges of the flexible liner are created by die-cutting slots and discarding the “slot.” The die-cut slots form bridges that are obliquely angled between adjacent liner panels and arrayed so that the bridges positioned above a medially drawn transverse line are mirror images of obliquely angled bridges positioned below the medially drawn transverse line. The carton and liner are typically made of fiberboard, but other materials may prove suitable and even preferable, depending on the nature and purpose of the carton and its contents. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0008]      FIG. 1  is a perspective view of the flexible liner disclosed herein in elevated juxtaposition to its carton. 
           [0009]      FIG. 2  is a top plan view of the flexible liner and carton depicted in  FIG. 1 . 
           [0010]      FIG. 3  is an enlarged view of the flexible bridges isolated in  FIG. 2 . 
           [0011]      FIG. 4  is a perspective view of another embodiment of the flexible liner disclosed herein in elevated juxtaposition to its carton. 
           [0012]      FIG. 5  is a top plan view of the flexible liner and carton of  FIG. 4 . 
           [0013]      FIG. 6  is a perspective view of another embodiment of the flexible liner disclosed herein in elevated juxtaposition to ins carton. 
           [0014]      FIG. 7  is a top plan view of the flexible liner and carton of  FIG. 6 . 
           [0015]    And,  FIG. 8  is an enlarged view of the flexible bridges isolated in  FIG. 7 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    The flexible liner disclosed herein is unique in the manner and means with which panels of the liner are attached to an adjacent panel or flap of the liner and wherein the manner and means impart the flexibility and other properties that make the disclosed liner advantageous to the industry. 
         [0017]    Referring to the drawing,  FIG. 1  depicts a flexible liner  10  and its corresponding carton  20 . The carton is to be substantiated or strengthened by the attachment of the liner to the inner surface of the carton. The liner consists of a plurality of panels: a width bottom panel  11 , a depth rear panel  12 , a depth front panel  13  and depth end panels  14 . The liner is characterized by having its panels separated by a plurality of slots m and joined by a plurality of bridges n (see  FIG. 4 ). More specifically, depth end panels  14  are separated from, and joined to, their adjacent panels  12  and  13  by slots m and bridges n. Additionally, width bottom panel  11  is separated from and joined to its adjacent panels, depth rear panel  12  and depth front panel  13 , by slots m and bridges n. In the flexible liner manufacturing process, die-cutting slots create the slots m and bridges n. 
         [0018]    Also depicted in  FIG. 1  is the carton  20 , which is to be augmented by liner  10 . Carton  20  consists of a plurality of panels, flaps, a tab and a tear strip z. The panels include: a depth rear panel  21 , a width cover panel  22 , a depth front panel  23 , a width bottom panel  24 , depth end minor panels  27 , depth end major panels  28 ; and a depth cover flap  25 , dust flaps  29  and depth cover tab  26 . Furthermore, the panels, flaps and tab of carton  20  are separated by working scores or creases, represented by broken lines, to permit folding and assemblage of the carton. 
         [0019]      FIG. 2  depicts the assemblage of flexible liner  10  and carton  20 .  FIG. 2  is a plan view of the liner  10  overlaying carton  20 .  FIG. 2  also isolates the slots m and bridges n, which are enlarged and the subject of  FIG. 3 . The slots m and bridges n joining the panels of the liner are positioned over the carton panel junctures while the panels of the liner are adhered to the panels of the carton. The slots m and bridges n impart flexibility to the lined carton allowing the lined carton to be easily folded and formed into a finished container and eliminating the risk of cracking at the crease lines of the carton. The slots are die-cut to varying lengths depending on the size of the carton and the width of the slot can vary depending on the material thickness of the liner. 
         [0020]    More specifically, the bridges n are created by the cutting slots m and are obliquely angled across the juncture of the bridged panels. Most preferably, the die-cut slots form bridges that are obliquely angled between adjacent liner panels and arrayed so that the bridges positioned above a medially drawn transverse line X-Y are mirror images of obliquely angled bridges positioned below the medially drawn transverse line. 
         [0021]      FIG. 3  is an enlarged, isolated plan view of slots m and bridges n positioned between panels  11  and  13 . In this depiction, there are six bridges. Preferably, each bridge is offset from each panel and disposed between the adjacent panels obliquely. The angularity of the bridges and offsets on their attachment to the panels is desirable to ensure that the flexibility of the liner is imparted to the finished carton. Ideally, and when possible, the bridges are disposed so that an equal number of paired bridges is angled upwardly, left to right, and downwardly, left to right, between adjacent liner panels. The alternation of bridge angularity facilitates folding the finished carton in a symmetrical fashion. 
         [0022]    Referring next to  FIG. 4 , a perspective view of a second embodiment of the flexible liner  30  and its associated carton  40 . Specifically, the liner consists of four panels, sized and configured to correspond with the corresponding panels of the carton: a width right side  31 , a width left side  33 , a length rear side  32  and a length front side  34 . A plurality of slots forming vertical flexible bridges Y is cut over the juncture of each panel. The slots separate each panel from its adjacent panel and each bridge joins each panel to its adjacent panel. 
         [0023]    The carton  40  corresponding to liner  30  also consists of four panels: width right side  41 , width left side  43 , length rear side  42  and length front side  44 . Carton  40  also includes major  47  and minor  46  flaps and glue flap  45 . Furthermore, the panels and flaps of carton  40  are separated by creases depicted by broken lines to permit folding and assemblage of the carton. 
         [0024]      FIG. 5 , a top plan view, depicts the assemblage of flexible liner  30  and carton  40  wherein each panel of the flexible liner fits with in the perimeter of a corresponding panel of the carton. Each flexible liner panel is adhesively adhered to its corresponding panel of the liner. The lined cartons are stacked and shipped flat to the vendee for assemblage and containment. 
         [0025]    Slots are cut between the panels and/or flaps of the liner to form bridges that are obliquely angled relative to the fold creases on the cartons. And while the angle of obliqueness is preferably the same for any specific or particular liner design, the direction of the angularity is preferably alternated. Experience has demonstrated that it is preferable for approximately half the bridges to be arrayed and angled in one direction, while the other half are arrayed and angled in the opposite direction, as depicted in  FIG. 4 . 
         [0026]      FIG. 6  depicts a third embodiment of the flexible liner  50  disclosed herein and its associated carton  60 . Specifically, the flexible liner  50  consists of width right panel  51 , length rear panel  52 , width left panel  53 , length front panel  54 , minor flaps  56 , major flaps  57  and glue flap  55 . All flaps are separated from and attached to their adjacent panels by slots and bridges, and adjacent panels, width front panel  54  and width right panel  51 . The slots and bridges separating and joining panels  51  and  54  are isolated and enlarged in  FIG. 8 . 
         [0027]    The carton  60  associated with flexible liner  50  consists of width right panel  61 , length rear panel  62 , width left panel  63 , length front panel  64 , minor flaps  66 , major flaps  67  and glue flap  65 . 
         [0028]    Figure depicts the assemblage of flexible liner  50  and carton  60 . The slots and bridges separating and connecting panels  54  and  51 , and isolated for enlargement in  FIG. 8 , enable the lined carton to be pre-folded for shipping to the vendee for containment.  FIG. 8  clearly depicts the flexible separation of panels  54  and  51  by slots n and the joinder of said panels by the bridges m resulting from the cutting of slots n. 
         [0029]    While the foregoing is a detailed and complete description of the preferred embodiments of the disclosed flexible carton liner, it should be apparent that numerous variations and modifications can be made and employed to implement the overall purpose of the disclosed liner without deviating or departing from the spirit of the invention, which is fairly defined by the appended claims.