Abstract:
A bottle carrier is foldable from a single blank, and is relatively strong, inexpensive to manufacture, aesthetic in appearance, and easy to assemble. The carrier has several advantages: it provides a reduction in paper board costs, improves manufacturing costs, retains the “basket” features demanded by the marketing needs of the beverage industry, and improves packaging line production at the beverage manufacturing location. The carrier is made by folding operations and separation along score lines. The carrier has internal longitudinal and transverse product separation, handle reinforcement, and bottom closure flaps. The carrier blank is formed as a die cut component, which is then assembled by folding and adhesive applied to designated locations. The finished carrier is then collapsed for transit, and the bottom flap can be secured at the manufacturing location. In a second embodiment, the bottom is already secured, and folds away from the partition portions when collapsed for transit. The collapsed carrier is then delivered to the beverage or glass manufacturing location. The carrier is then erected, and thus is ready for filling with product. The carrier can be filled either on or off a bottling line.

Description:
This application claims the benefit of provisional application 60/237,191 filed Oct. 3, 2000. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to foldable blanks for forming bottle carriers, and to a process and method for assembling a bottle carrier from foldable blanks. 
     BACKGROUND OF THE INVENTION 
     Packages are known in the prior art for carrying bottles or cans. Such carriers can be formed of plastic, cardboard, or other materials. However, it is a problem in the art to provide a bottle carrier which is relatively strong, inexpensive to manufacture, aesthetic in appearance, and easy to assemble. 
     U.S. Pat. No. 4,327,829 to Hughes teaches a display carton and blank therefor. The assembled carton has openable ends. 
     U.S. Pat. No. 4,509,640 to Joyce teaches a carton with separators, a blank, and an apparatus for erecting a carton from the blank. A relatively complex blank and folding operation are shown. 
     U.S. Pat. No. 4,588,077 to Champlin et al. teaches a carrier handle. The carrier handle is formed by a folded blank having two holes, the two holes being in overlying relationship in the assembled carrier to form a handle portion. 
     U.S. Pat. No. 4,406,365 to Kulig discloses a basket type bottle carrier. The bottle carrier has an integral handle portion formed from holes in the blank used to form the carrier. 
     U.S. Pat. No. 5,709,298 to Harris teaches a basket-style carrier with non-collapsing end panels. The carrier is formed from a single blank, the blank having holes forming the handle portion. 
     U.S. Pat. No. 4,770,294 to Graser teaches a two-piece beverage carrier. The carrier is formed from two foldable blanks. 
     U.S. Pat. No. 4,362,240 to Elward teaches an article carrier carton. The carton is formed from a blank and can carry six bottles. 
     U.S. Pat. No. 4,147,290 to Stout teaches an article carrier handle structure. The handle is formed from a blank having interrupted cut lines. 
     U.S. Pat. No. 2,382,844 to Arneson is directed to a bottle carrier. The carrier is formed from a blank, and includes hole portions used to form a handle. 
     U.S. Pat. No. 2,239,564 to Lyons, Jr., is directed to a folding bottle carrying carton. The carton is formed from a blank, and has a handle. 
     SUMMARY OF THE INVENTION 
     From the foregoing, it is seen that it is a problem in the art to provide a device meeting the above requirements. According to the present invention, a device is provided which meets the aforementioned requirements and needs in the prior art. Specifically, the device according to the present invention provides bottle carrier which is relatively strong, inexpensive to manufacture, aesthetic in appearance, and easy to assemble. 
     The beverage industry markets products in a printed paper board carrier holding multiple units of glass and plastic containers. This package is commonly referred to as a basket. The “basket” provides individual product separation minimizing product damage during the shipping and distribution cycle. Current “baskets” in use provide attractive graphics which are multi-color printed, have a substantial carry handle, and have an open top which facilitates easy access, removal, and replacement of the product. 
     The basic “basket” as now commonly used has existed for several decades. Over the years there have been minor revisions to this basic “basket” for the sake of cost reduction. The “basket” has survived the marketing needs of the beverage industry by providing a consumer friendly package to the end user. 
     The paper board used on current “baskets” is a special custom formulated sheet. This special sheet is used for the total one-piece “basket”. The sheet provides excellent white printing surface, superior tear strength, improved stiffness, and surfaces and finish resistant to moisture absorption. The beverage and packaging industries are continually seeking a more cost effective package while retaining the consumer friendly features of the present “basket”. 
     The carrier according to the present invention has:several advantages. It provides a reduction in paper board costs. It improves manufacturing costs of the present “basket”. It retains the “basket” features demanded by the marketing needs of the beverage industry. And, it improves packaging line production at the beverage manufacturing location. 
     More specifically, the carrier according to the present invention is made by folding a single blank made from paper board. This single blank, when completely folded and glued as necessary, forms both a handle portion and a plurality of compartments for holding beverage containers. This blank includes elements which will become a shell portion which provides all “basket” printed panels and a handle visible to the consumer on the display shelf. The blank can be made from a white coated paper board or other material combination providing an adequate printing surface. 
     The blank, in addition to elements which will form the shell portion, also includes elements forming the internal longitudinal and transverse product separation, handle reinforcement, and bottom closure flaps. This portion includes what is called in the trade a partition assembly. The partition assembly does not require printing, since it is not readily visible to the consumer when filled with articles to be carried. 
     The single blank, which forms both the shell portion and the partition assembly, is preferably formed as a die cut sheet, which is then accurately folded and joined by adhesive applied to designated locations. The thus-folded and secured assembly is then further folded and glued to form a collapsed “basket”. The collapsed “basket” is then delivered to the beverage or glass manufacturing location. The “basket” is then erected, and—in a first embodiment—bottom flaps are folded and adhesively secured, and thus is ready for filling with product. The “basket” can be filled either on or off a bottling line. In a second embodiment, the bottom flaps are pre-glued and are part of the fold assembly provided to the beverage or glass manufacturing location. 
     Other objects and advantages of the present invention will be more readily apparent from the following detailed description when read in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view of a blank for a partition assembly used to form a carrier, according to one embodiment of the present invention. 
     FIG. 2 is a perspective view of a bottle carrier according to the present invention, formed from the blank of FIG.  1 . 
     FIG. 3 is an elevational view of a blank used to form a beverage carrier, according to a second embodiment of the present invention. 
     FIG. 4 is a perspective view of a second embodiment of a bottle carrier according to the present invention, formed from the blank of FIG.  3 . 
     FIG. 5 is a schematic view of a plurality of blanks similar to that of FIG. 3, in a typical manufacturing arrangement. 
     FIG. 6 is a schematic view of a plurality of blanks similar to that of FIG. 5, but with double the number of blanks in adjoining relation, in another typical manufacturing arrangement. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 is an elevational view of a partition assembly blank  1  used to form a carrier  100  shown in FIG.  2 . This embodiment is referred to herein as a four-fold embodiment. The partition assembly blank  1  includes holes  11 ,  54 , and  68  used to form the handle portion (which includes handle components  10 ,  28 ,  62 ) when the partition assembly blank  1  is folded. The partition assembly blank  1  includes a front portion  14 , a flap  16 , a side panel  18 , a rear portion  20 , and a bottom flap portion  22 . 
     The portion  10  is joined to the panels  12  and  14  by an easily-broken tear line having soft nick release portions  7 ,  8 , and  9  as shown in FIG.  1 . The panel  12  is joined to the panel  14  along a fold line  15 , and the panel  16  is joined to the panel  14  by a fold line  6 . The panel  14  is joined to the panel  18  along a fold line  17 , and the panel  18  is joined to the panel  20  by a fold line  24 . 
     Also as shown in FIG. 1, the panel  18  is joined to a panel  39  along a fold line  19  which includes an easily-broken tear line having soft nick release portions  45 ,  46 , and  47 . The panel  39  is joined to a panel  26  by a fold line  27 , and is joined to a panel  30  by a fold line  31 . The panel  26  is separated from the panel  18  along the cut line  34 , so that panels  26  and  18  are separate. The panel  30  is separated from the panels  20  and  50  along the cut line  33 , so that panel  30  is completely separate from the panels  20  and  50 . 
     The panel  39  includes the aperture  54 , which forms part of the handle portion. The panel  39  is joined by a fold line  5  to panel  28 . The panel  28  includes a foldable portion  29  with separated side edge portions (unnumbered) to make it easier to fold. The panel  20  is joined to a panel  22  along a fold line  25 , and the panel  22  has an extension  23 . The panel  20  is joined to the panel  50  along a fold line  51 , and the panel  50  is joined to the panel  60  by a fold line  52 . The panel  60  is joined to a panel  90  along a fold line  88 , and the panel  60  includes an upper portion having a handle aperture  68  therein. 
     The panel  60  includes a pair of partition members  70  and  72 , which are connected to the panel  60  by respective fold lines  61  and  64 . The partition members  70  and  72  have edges, which are respectively severed from the panel  60  along respective score lines  62  and  69 . The partition member  70  has a right end portion foldable along fold lines  64 ,  64 , and a flap portion separated by a score line  63 . Similarly, the partition member  72  has a right end portion foldable along fold lines  73 ,  73  and a flap portion separated by a score line  74 . 
     The panel  90  includes a pair of partition members  80  and  82 , which are connected to the panel  90  by respective fold lines  91  and  101 . The partition members  80  and  82  have edges, which are respectively severed from the panel  90  along respective score lines  92  and  81 . The partition member  80  has a left end portion foldable along fold lines  101 ,  101 , and a flap portion separated by a score line  102 . Similarly, the partition member  82  has a left end portion foldable along fold lines  86 ,  86  and a flap portion separated by a score line  85 . 
     The panel  90  is connected to portion  95  by fold lines  96 ,  96 , and is separated from the portion  95  by a score line  93 . The panel  90  has a lowermost portion  97 , which is an extension formed to provide an additional glue or adhesive area below the handles. 
     In use, the blank  1  is folded as follows. Fold line  88  is the first fold, fold line  31  is the second fold, fold line  27  is the third fold, fold line  51  is the fourth fold, fold line  17  is the fifth fold, and fold line  5  is the sixth fold. The remaining folds, and glue/adhesive areas, will be readily understood by any one having skill in the art of foldable blanks for beverages. 
     FIG. 2 is a perspective view of a bottle carrier  100  according to the present invention. In this view, a top portion includes a handle (components  10 ,  28 ,  62 ), and a bottom flap portion  22  which is secured by adhesive to a flap  16  at a manufacturing location. The bottle carrier  100  has a front portion  14 , rear portion  20 , a side panel  18  connecting the front and rear portions  14  and  20 . 
     The combination carrier and handle apparatus  100  for accommodating a plurality of articles (not shown), are arranged in a pair off substantially parallel co-extensive rows. A single partition blank  1  is made from paper board preferably having at least one white printable side. Said single partition blank  1  includes a first partial side portion  12  joined to a front portion  14  along a first fold line  15 , a foldable flap  16  located beneath the front portion  14 . A side panel  18  is joined to the front portion  18  along a second fold line  17 . A rear portion  20  is joined to the side panel  19  along a third fold line  24 . A foldable bottom flap  22  is located beneath the rear portion  20 . A second partial side portion  50  is joined to the rear portion  20  along a fourth, fold line  51 . A first center panel  60  is joined to the second partial side portion  50  along a fifth fold line  52 , and a second center panel  97  is joined beneath the first center panel  60  along a sixth fold line  88 . 
     A first handle portion  10  is joined above the first partial side portion  12  and the front portion  14  with a easily-broken score line  7 ,  8 ,  9 . A second handle portion  39  is joined above the side panel  18  and the rear portion  20  with an easily broken score line  45 ,  46 ,  47 . 
     A third handle portion  68  extends above the center panel  60 . The first handle portion  10 , the second handle portion  39  and the third handle portion  68  each include a respective handle aperture  11   54 ,  68  sized and positioned to form an aligned handle portion there-through. 
     The first and second partition members  70 ,  72  are foldably connected to the first center panel  60 . The first and second partition members  70 ,  72  each have edges which are severed along respective score lines  62 ,  69 . A first and second flap portion are separated by a respective score line, as shown in FIG.  1  and FIG.  2 . 
     The third and fourth partition members  80 ,  82  are foldably connected to the second center panel  97 . The third and fourth partition members  80 ,  82  each have edges which are severed along respective score lines  81 ,  92 . A third and fourth flap portion are separated by a respective score line, also shown in FIG.  1  and FIG.  2 . 
     The foldable flap  16  located beneath the front portion  14  is glued to the bottom flap  22  located beneath the rear portion  20 . The first, second, and third handle portions are aligned and glued together as best shown in FIG.  2 . The first and second flap portions  70 ,  72  are glued to the rear portion  20  in a manner to form article sized compartments therebetween, and the third and fourth flap portions  80 ,  82  are glued to the front portion  14  in a manner to form article sized compartments therebetween. 
     The bottle carrier  100  also includes an opposed pair of sidewalls  12  and  50  which together connect the front and rear portions  14  and  20 . A partition member  90  is visible in this view, as are folded connecting extensions  70  and  72  which are respectively adhered to the wall  14 . The bottle carrier  100  also includes additional extensions on the opposite side of the partition  90 , which are not visible in FIG.  2 . 
     FIG. 3 is an elevational view of a partition assembly blank  1  used to form a carrier  200  shown in FIG.  4 . This embodiment is referred to herein as a six-fold embodiment. The partition assembly blank  2  includes holes  245  and  260  which are used to form the handle portion (which includes handle components  235 ,  236 ,  238 ,  239 ,  257 ,  258 , and  299 ) when the partition assembly blank  2  is folded. The partition assembly blank  2  includes a front portion  220 , a flap  221 , side panel portions  225  and  230 , a rear portion  240 , a side panel portion  216 , another side panel portion  250 , and bottom flap portions  246 ,  247 . 
     As shown in FIG. 3, a panel  210  is connected to the panel  216  by a fold line  211 , and the panel  216  is connected to the panel  220  by a fold line  215 . The panel  220  is connected to the flap  221  by a fold line  222 , and the panel  220  is connected to the panel  225  by a fold line  223 . The panel  225  is connected to a panel  230  by a fold line  226 , and the panel  230  is connected to the panel  240  by a fold line  231 . 
     The panel  240  is connected to the handle portion panel  235  by a fold line  242  which is extensively scored and therefore readily frangible, and the panel  240  is connected to the panel  250  by a fold line  243 . The panel  240  is connected to the panel  246  by a fold line  241 . The panel  246  is connected to the panel  247  by a fold line  248 . The handle portion panel  235  is connected to a panel  299  by a fold line  234 . The panel  299  is separated from adjacent panels  230  and  240  by a score line  233 . The panel  235  is connected to a panel  236  by a fold line  237 . The panel  236  has a flap portion  239  foldable along fold line  238  which has severed right and left ends to facilitate folding. 
     The panel  250  is connected to a panel  270  by a fold line  271 , and is connected to a panel  256  by a fold line  251 . The panel  270  is connected to the panels  246  and  247  by fold lines  271 ,  271 . The panel  270  is connected to a panel  276  by fold lines  301 ,  301 , the panel  276  having a flap portion bounded by a score line  272  and separated by a fold line  273 . The panel  276  is further bounded by a score line  277 ,  277 , and includes a right flap portion  278  separated by a score line  278  and a fold line  279 . 
     The panel  270  and the panel  276  both bound a panel  285  which has a flap portion which extends downwardly a distance E to add handle strength. The panel  276  is connected to a panel  292  by fold lines  279 ,  279 , and is separated therefrom by a score lines  277 ,  277 . The panel  292  is separated by score lines  293 ,  293 . The panel  292  also includes a right flap portion  284  connected to the panel  292  by fold lines  281 ,  281  and separated from the panel  292  by a score line  282 . 
     The panel  276  is connected to the panel  256  by a fold line  303 . The panel  256  has an aperture  260  and is connected to the panel  258  by a fold line  257 . The panel  256  is connected to a panel  268  by fold lines  267 ,  267 . The panel  256  is connected to a partition portion  261  along a fold line  263 , and is separated therefrom by a score line  262 . The partition panel  261  has a flap portion  264  connected along a fold line  265 . The panel  256  is also connected to a partition portion  304  by fold lines  305 ,  305 , and is separated therefrom by a score line  269 . 
     In use, the blank  2  is folded as follows. Fold line  301  is the first fold (and is folded up), fold line  303  is the second fold, fold lie  234  is the third fold, fold line  251  is the fourth fold, fold line  267  is the fifth fold (a reverse partial fold), fold line  231  is the sixth fold, and fold line  226  is the seventh fold. The fold line  267 , releasing the partial fold of the fifth fold, is considered as the eight fold. The fold line  211  is the ninth fold, and the fold line  223  is the tenth fold. The fold line  306  is the eleventh fold (and is a double fold). The fold line  248  is the twelfth fold. The remaining folds, and glue/adhesive areas, will be readily understood by any one having skill in the art of foldable blanks for beverages. 
     FIG. 4 is a perspective view of a second embodiment of a bottle carrier  200  and is formed from the blank  2  of FIG.  3 . The handle portion  235 ,  236 ,  260  includes handle components  235 ,  236 ,  238 ,  239 ,  257 ,  258 , and  299  when the partition assembly blank  2  is folded. The carrier  200  includes a front portion  220 , a flap  221 , side panel portions  225  and  230 , a rear portion  240 , a side panel portion  216 , another side panel portion  250 , and bottom flap portions  246 ,  247 . The flap  221  is glued or adhered to the bottom flap portion  247 , to secure the bottom of the carrier  200 . 
     The carrier  200  includes partition portions  276  and  292 . Opposed partition panel portions are also present on the other side of the panel  256 , but are not visible in FIG.  4 . 
     The carrier  200  of FIG. 4 can thereby be collapsed by downward extension of the bottom flap portions  246 ,  247  and folding thereof along fold line  248 , the remaining portions of the carrier  200  being, collapsed in a usual manner known to those in the package carrier art. 
     FIG. 5 is a schematic view of a plurality of blanks  2  similar to that of FIG. 3, in a typical manufacturing arrangement. 
     FIG. 6 is a schematic view of a plurality of blanks  2  similar to that of FIG. 5, but with double the number of blanks in adjoining relation, in another typical manufacturing arrangement. 
     The invention being thus described, it will be evident that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention and all such modifications are intended to be included within the scope of the claims.