U.S. patent application number 10/062914 was filed with the patent office on 2003-07-31 for sleeve style beverage carton.
This patent application is currently assigned to The C.W. Zumbiel Co.. Invention is credited to Wilson, Robert W..
Application Number | 20030141353 10/062914 |
Document ID | / |
Family ID | 27610380 |
Filed Date | 2003-07-31 |
United States Patent
Application |
20030141353 |
Kind Code |
A1 |
Wilson, Robert W. |
July 31, 2003 |
SLEEVE STYLE BEVERAGE CARTON
Abstract
An improved sleeve style beverage carton can be processed at or
near peak production rates for carton blanks and without the need
for manual removal of scrap from apertures in the carton blank. The
increase in production rates and efficiency is principally obtained
because the stripper pins on the stripper drum used in producing
the carton blank consistently and reliably puncture and remove the
scrap from apertures in the die cut carton blank thereby
alleviating the need to slow or stop the machine for manual removal
of the scrap. Advantageously, gusset holes which are die cut in the
carton blank are preferably generally trapezoidal-shaped to provide
for increased surface area of the gusset hole relative to prior art
configurations. The trapezoidal-shaped larger gusset holes provide
for a more consistent and reliable removal of the carton material
scrap from the gusset hole during production of the blank.
Inventors: |
Wilson, Robert W.; (Pleasant
Plane, OH) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
The C.W. Zumbiel Co.
Cincinnati
OH
|
Family ID: |
27610380 |
Appl. No.: |
10/062914 |
Filed: |
January 31, 2002 |
Current U.S.
Class: |
229/103.2 ;
206/427 |
Current CPC
Class: |
B26D 7/1836 20130101;
B65D 2571/0045 20130101; B65D 2571/00728 20130101; B65D 2571/0087
20130101; B65D 2571/00549 20130101; B65D 2571/0066 20130101; B31B
50/146 20170801; B65D 2571/00141 20130101; B65D 71/36 20130101 |
Class at
Publication: |
229/103.2 ;
206/427 |
International
Class: |
B65D 005/08 |
Claims
I claim:
1. A tubular carton sleeve adapted to be formed into a carton for
holding a plurality of beverage containers, the carton sleeve
comprising: a top wall; a bottom wall spaced from the top wall; a
pair of spaced sidewalls foldably joined along respective sides
thereof and extending between the top and bottom walls; a plurality
of major end flaps each of which is foldably joined to an end of
one of the sidewalls; wherein the major end flaps are adapted to be
folded relative to the respective sidewall and cooperate together
to form a pair of spaced end walls of the carton; a plurality of
minor end flaps each of which is foldably coupled to an end of one
of the top and bottom walls; wherein the minor end flaps are
adapted to be folded relative to the respective top and bottom
walls and juxtaposed to a face of the respective major end flap to
form the end walls; a plurality of gussets each of which is
foldably joined to one of the major end flaps and an adjacent one
of the minor end flaps; and a plurality of gusset holes each of
which is defined at a juncture of one of the top and bottom walls,
one of the sidewalls, one of the major end flaps, one of the minor
end flaps and one of the gussets; wherein each of the gusset holes
is generally trapezoidal shaped to provide for increased surface
area of the gusset hole and more reliable removal of carton
material from the gusset hole during production of the carton
sleeve.
2. The carton sleeve of claim 1 further comprising: a plurality of
bevel panels each of which is foldably joined to the end of one of
the top and bottom walls and foldably joined to one of the minor
end flaps; wherein each of the bevel panels is generally
rectangular shaped.
3. The carton sleeve of claim 1 wherein each of the gusset holes is
greater than about 0.35 square inches.
4. The carton sleeve of claim 3 wherein each of the gusset holes is
at least about 0.4 square inches.
5. The carton sleeve of claim 4 wherein each of the gusset holes is
between about 0.4293 square inches and about 0.4554 square
inches.
6. The carton sleeve of claim 1 further comprising: a carrying
handle formed in the top wall.
7. The carton sleeve of claim 1 further comprising: at least one
outlet port in one of the sidewalls adapted to dispense the
beverage containers there through, the outlet port being defined by
perforated cut lines in the sidewall.
8. The carton sleeve of claim 1 wherein each of the gusset holes
has first, second, third and fourth edges; with respect to each of
the gusset holes proximate the top wall, the first and second edges
are generally parallel to one another and the third and fourth
edges are obliquely oriented relative to each other and relative to
the first and second edges.
9. The carton sleeve of claim 1 wherein each of the gusset holes
has first, second, third and fourth edges; with respect to each of
the gusset holes proximate the bottom wall, the first and second
edges are generally parallel to one another, the third edge is
perpendicular to the first and second edges and the fourth edge is
obliquely oriented relative to the first, second and third
edges.
10. The carton sleeve of claim 1 further comprising: a pair of
bottom lap panels each of which is foldably joined to one of the
sidewalls, the bottom lap panels being joined to each other in
overlapping relation to form the bottom wall.
11. The carton sleeve of claim 1 wherein a major axis of each of
the gusset holes is generally parallel to a longitudinal axis of
the carton sleeve.
12. A tubular carton sleeve adapted to be formed into a carton for
holding a plurality of beverage containers, the carton sleeve
comprising: a top wall; a carrying handle formed in the top wall; a
bottom wall spaced from the top wall; a pair of spaced sidewalls
foldably joined along respective sides thereof and extending
between the top and bottom walls; a pair of bottom lap panels each
of which is foldably joined to one of the sidewalls, the bottom lap
panels being joined to each other in overlapping relation to form
the bottom wall; at least one outlet port in one of the sidewalls
adapted to dispense the beverage containers there through, the
outlet port being defined by perforated cut lines in the sidewall;
a plurality of major end flaps each of which is foldably joined to
an end of one of the sidewalls; wherein the major end flaps are
adapted to be folded relative to the respective sidewall and
cooperate together to form a pair of spaced end walls of the
carton; a plurality of minor end flaps each of which is foldably
coupled to an end of one of the top and bottom walls; wherein the
minor end flaps are adapted to be folded relative to the respective
top and bottom walls and juxtaposed to a face of the respective
major end flap to form the end walls; plurality of bevel panels
each of which is foldably joined to the end of one of the top and
bottom walls and foldably joined to one of the minor end flaps;
wherein each of the bevel panels is generally rectangular shaped; a
plurality of gussets each of which is foldably joined to one of the
major end flaps and an adjacent one of the minor end flaps; a
plurality of gusset holes each of which is defined at a juncture of
one of the top and bottom walls, one of the sidewalls, one of the
major end flaps, one of the minor end flaps and one of the gussets;
wherein each of the gusset holes is generally trapezoidal shaped to
provide for increased surface area of the gusset hole and more
reliable removal of carton material from the gusset hole during
production of the carton sleeve; wherein a major axis of each of
the gusset holes is generally parallel to a longitudinal axis of
the carton sleeve; wherein each of the gusset holes has first,
second, third and fourth edges; with respect to each of the gusset
holes proximate the top wall, the first and second edges are
generally parallel to one another and the third and fourth edges
are obliquely oriented relative to each other and relative to the
first and second edges; and with respect to each of the gusset
holes proximate the bottom wall, the first and second edges are
generally parallel to one another, the third edge is perpendicular
to the first and second edges and the fourth edge is obliquely
oriented relative to the first, second and third edges.
13. The carton sleeve of claim 12 wherein each of the gusset holes
is between about 0.4293 square inches and about 0.4554 square
inches.
14. A blank for a tubular carton comprising: a top wall; a pair of
sidewalls each foldably joined to the top wall; a pair of bottom
lap panels each foldably joined to one of the sidewalls; wherein
the bottom lap panels are adapted to folded relative to the
respective sidewall and joined to each other in overlapping
relation to form a bottom wall; a plurality of major end flaps each
of which is foldably joined to an end of one of the sidewalls; a
plurality of minor end flaps each of which is foldably coupled to
an end of one of the top wall and the bottom lap panels; a
plurality of gussets each of which is foldably joined to one of the
major end flaps and an adjacent one of the minor end flaps; and a
plurality of gusset holes each of which is defined at a juncture of
one of the top wall and one of the bottom lap panels, one of the
sidewalls, one of the major end flaps, one of the minor end flaps
and one of the gussets; wherein each of the gusset holes is
generally trapezoidal shaped to provide for increased surface area
of the gusset hole and more reliable removal of carton material
from the gusset hole during production of the blank.
15. The blank of claim 14 further comprising: a plurality of bevel
panels each of which is foldably joined to the end of one of the
top wall and the bottom lap panels and foldably joined to one of
the minor end flaps; wherein each of the bevel panels is generally
rectangular shaped.
16. The blank of claim 14 wherein each of the gusset holes is
greater than about 0.35 square inches.
17. The blank of claim 16 wherein each of the gusset holes is at
least about 0.4 square inches.
18. The blank of claim 17 wherein each of the gusset holes is
between about 0.4293 square inches and about 0.4554 square
inches.
19. The blank of claim 14 further comprising: a carrying handle
formed in the top wall.
20. The blank of claim 14 further comprising: at least one outlet
port in one of the sidewalls adapted to dispense beverage
containers there through, the outlet port being defined by
perforated cut lines in the sidewall.
21. The blank of claim 14 wherein each of the gusset holes has
first, second, third and fourth edges; with respect to each of the
gusset holes proximate the top wall, the first and second edges are
generally parallel to one another and the third and fourth edges
are obliquely oriented relative to each other and relative to the
first and second edges.
22. The blank of claim 14 wherein each of the gusset holes has
first, second, third and fourth edges; with respect to each of the
gusset holes proximate one of the bottom lap panels, the first and
second edges are generally parallel to one another, the third edge
is perpendicular to the first and second edges and the fourth edge
is obliquely oriented relative to the first, second and third
edges.
23. The blank of claim 14 wherein a major axis of each of the
gusset holes is generally perpendicular to a machine direction axis
of the blank.
24. A blank for a tubular carton comprising: a top wall; a carrying
handle formed in the top wall; a pair of sidewalls each foldably
joined to the top wall; at least one outlet port in one of the
sidewalls adapted to dispense beverage containers there through,
the outlet port being defined by perforated cut lines in the
sidewall; a pair of bottom lap panels each foldably joined to one
of the sidewalls; wherein the bottom lap panels are adapted to
folded relative to the respective sidewall and joined to each other
in overlapping relation to form a bottom wall; a plurality of major
end flaps each of which is foldably joined to an end of one of the
sidewalls; wherein the major end flaps are adapted to be folded
relative to the respective sidewall and cooperate together to form
a pair of spaced end walls of the carton; a plurality of minor end
flaps each of which is foldably coupled to an end of one of the top
wall and the bottom lap panels; wherein the minor end flaps are
adapted to be folded relative to the respective top wall and bottom
lap panels and juxtaposed to a face of the respective major end
flap to form the end walls; a plurality of bevel panels each of
which is foldably joined to the end of one of the top wall and the
bottom lap panels and foldably joined to one of the minor end
flaps; wherein each of the bevel panels is generally rectangular
shaped; a plurality of gussets each of which is foldably joined to
one of the major end flaps and an adjacent one of the minor end
flaps; and a plurality of gusset holes each of which is defined at
a juncture of one of the top wall and one of the bottom lap panels,
one of the sidewalls, one of the major end flaps, one of the minor
end flaps and one of the gussets; wherein each of the gusset holes
is generally trapezoidal shaped to provide for increased surface
area of the gusset hole and more reliable removal of carton
material from the gusset hole during production of the blank; a
major axis of each of the gusset holes being generally
perpendicular to a machine direction axis of the blank; wherein
each of the gusset holes has first, second, third and fourth edges;
with respect to each of the gusset holes proximate the top wall,
the first and second edges are generally parallel to one another
and the third and fourth edges are obliquely oriented relative to
each other and relative to the first and second edges; and with
respect to each of the gusset holes proximate one of the bottom lap
panels, the first and second edges are generally parallel to one
another, the third edge is perpendicular to the first and second
edges and the fourth edge is obliquely oriented relative to the
first, second and third edges.
25. The blank of claim 24 wherein each of the gusset holes is
between about 0.4293 square inches and about 0.4554 square inches.
Description
FIELD OF THE INVENTION
[0001] This invention relates to cartons. More specifically, this
invention relates to an improved beverage carton and associated
blank and carton sleeve that improves production rates and
efficiencies.
BACKGROUND OF THE INVENTION
[0002] In the marketing of soft drinks, beer and other beverages,
such retail consumer products are commonly sold in cans which are
grouped together in six or 12 packs. Particularly in the case of 12
can packs, the cans are commonly packaged in cartons to make it
easier to handle the product for the wholesaler and the retailer as
well as for the retail consumer.
[0003] There are any number of different types of can cartons. One
particular type of carton that has found significant commercial
success over the years is referred to as a "wrap around" carton. In
a wrap around carton, a number of cans, typically 12, are wrapped
in a paperboard box or carton that includes top and bottom wall
panels, sidewall panels and end flaps on each end. The end flaps at
each end of the carton are sealed one to the other, thereby
providing a closed or sealed package or carton for the cans.
[0004] A common carton production method involves converting
paperboard into carton blanks and then into folded cartons which
are eventually erected and filled with the beverage cans. The
fabrication of beverage cartons typically begins with paperboard
being drawn in a web from a roll of paperboard. Commonly, one
surface of the paperboard is printed with a desired graphic design.
The paperboard web is then die cut into multiple individual carton
blanks. The printed carton blanks are then transferred typically
within the same carton manufacturing facility, to a folder/gluer
machine where each carton blank is folded and glued into a
flattened sleeve or fill-ready carton configuration. The flattened
cartons or sleeves are packed and then palletized for shipment to a
customer such as a soft drink canner or the like.
[0005] During the conversion of the paperboard into a carton
sleeve, the web of paperboard commonly passes between various
counter rotating rollers including an impression roller and a
stripper drum. Typically, a carton blank includes certain holes or
apertures and after each hole is die cut in the paperboard, the
paperboard material must be removed from the hole portions of the
web as scrap. Such scrap pieces of paperboard are removed by a
series of pins arranged on the stripper drum and appropriately
configured for the particular carton blank in production.
Optimally, the pins puncture the scrap portions of the paperboard
and continued movement of the paperboard web and rotation of the
stripper drum pulls or strips the scraps from the web.
[0006] However, one inherent requirement in the stripping process
is that the pins on the stripper drum be appropriately aligned with
the scrap portions of the paperboard web for removal. If the pins
do not puncture the scrap portion of the web, the scrap is not
removed by the stripper drum and an operator must manually remove
the scrap downstream from the stripper drum, for example, by
punching the scrap with a screw driver or other tool. Because of
the size and processing speed of the converting equipment, it is
often difficult to accurately and precisely align the stripper drum
with the web for consistent removal of the scrap by the stripper
drum. The manual removal of the scrap results in a very inefficient
beverage carton sleeve production process. The die cutting machines
cannot operate at peek production speeds because of the consistent
need to manually remove the scrap from the die cut carton
blanks.
[0007] For example, one known type of carton blank is disclosed in
U.S. Pat. No. 5,292,059, which is incorporated herein by reference
in its entirety. The carton blank shown in the '059 patent includes
a number of generally triangular-shaped apertures identified by
reference numeral 86 in that patent. Such a carton blank is
generally shown in FIG. 1 herein. The triangular-shaped apertures
according to the '059 patent assist in providing a carton having
end walls of increased flatness so that it can be utilized as a
billboard, display or advertising space while still maintaining
adequate structural integrity for the carton.
[0008] However, one shortcoming of the carton blank shown in the
'059 patent and FIG. 1 herein is that the triangular apertures are
sized and configured so that the scrap is not consistently,
reliably and efficiently removed from the carton blank during
production. Therefore, production of carton blanks of this type are
significantly more slower because the machines on which the
paperboard is converted to produce such carton blanks cannot run at
peak speeds due to the fact that the scrap from the triangular
apertures often must be manually removed.
SUMMARY OF THE INVENTION
[0009] As such, there is a need for an improved carton blank and
sleeve style carton design which enables the carton manufacturing
process to be more efficient and deliver higher production
rates.
[0010] Moreover, there is a need for such a carton blank and carton
design which provides certain advantages and benefits of known
carton designs without the need for repeated manual removal of
scrap from apertures in the carton blank during the production
process.
[0011] These and other objectives of this invention have been
attained by an improved carton and blank design in which the
paperboard web can be processed at or near peak production rates
into carton blanks and without the need for manual removal of scrap
from apertures in the carton blank. Specifically, the carton blank
according to this invention can be processed at or near peak
production rates of about 625 feet per minute which is a 30 percent
or more increase in production rates achieved for similar carton
blanks, such as those shown in U.S. Pat. No. 5,292,059 and the
like. The increase in production rates is principally obtained
because the stripping pins on the stripper drum consistently and
reliably puncture and remove the scrap from apertures in the die
cut carton blank thereby alleviating the need to slow or stop the
machine for manual removal of the scrap.
[0012] In one presently preferred embodiment of this invention, a
tubular carton sleeve is adapted to be formed into a carton for
holding beverage containers. The carton sleeve is erected and
formed from a carton blank that includes a top wall and a pair of
sidewalls that are each foldably joined to the top wall. A pair of
bottom lap panels are each foldably joined to one of the sidewalls
and are adapted for folding relative to the respective sidewalls
and joined to each other in overlapping relation to form a bottom
wall of the resulting carton. Major end flaps are foldably joined
to an end of each of the sidewalls and minor end flaps are likewise
foldably coupled to an end of the top wall or bottom wall panels.
When the carton is erected, the major and minor end flaps are
folded relative to the respective side, top and bottom walls to
form end walls of the carton. A plurality of gussets are each
foldably joined to one of the major end flaps and an adjacent one
of the minor end flaps. The gussets foldably interconnect the major
and minor end flaps and are tucked in between those end flaps when
the carton is formed. A preferably rectangular bevel panel is
formed between the minor end flaps and the associated top and
bottom wall adjacent to the gussets. The bevel panel is supported
by the adjacent beverage cans when the carton is filled and
therefor contributes to the tightness of the carton and the
prevention of undesirable crushing of the corners of the
carton.
[0013] Advantageously, gusset holes which are formed at a juncture
of the top or bottom walls and the adjacent sidewalls in part
define the gussets. The gusset holes are preferably generally
trapezoidal-shaped to provide for increased surface area of the
gusset hole relative to prior art configurations. The
trapezoidal-shaped larger gusset holes provide for a more
consistent and reliable removal of the carton material scrap from
the gusset hole during production of the blank. The
trapezoidal-shaped gusset holes are on the average 27 percent
larger than triangular-shaped apertures in prior art carton blanks
thereby providing for an increased area for the stripper pins on
the stripper drums to puncture the scrap material in the gusset
hole for removal. As such, even if the paperboard web is not
precisely aligned with the location of the stripper pins on the
stripper drum, the web can be processed at or near maximum speeds
in the production facility because the stripper pin reliably and
consistently removes the scrap from the gusset holes, unlike prior
art carton blank designs.
[0014] Therefore, the advantages and benefits of certain known wrap
around or sleeve style tubular cartons can be achieved with the
carton blank, tubular carton sleeve and associated beverage carton
of this invention while still allowing for maximum production
efficiencies and process rates by avoiding the need for manual
removal of the scrap from apertures, gusset holes or the like in
the carton blank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The objectives and features of the invention will become
more readily apparent from the following detailed description taken
in conjunction with the accompanying drawings in which:
[0016] FIG. 1 is a plan view of a prior art carton blank;
[0017] FIG. 2 is a plan view of a carton blank according to a
presently preferred embodiment of this invention;
[0018] FIG. 3 is a perspective view of a stripper pin on a stripper
drum rotating to intersect the scrap material in a gusset hole of a
carton blank according to one presently preferred embodiment of
this invention;
[0019] FIGS. 4A and 4B are sequential views of the stripper pin
removing scrap from the gusset hole of the carton blank in FIG.
3;
[0020] FIG. 5 is a perspective view of a tubular carton sleeve
formed from the carton blank of FIG. 2;
[0021] FIG. 6 is a partially broken away perspective view of one
end of the tubular carton sleeve of FIG. 5 being folded into an end
wall of the carton;
[0022] FIGS. 7A and 7B are enlarged partial plan views of
trapezoidal-shaped gusset holes from a carton blank according to
one presently preferred embodiment of this invention; and
[0023] FIG. 8 is a view similar to FIGS. 7A and 7B of a
triangular-shaped aperture in a prior art carton blank.
DETAILED DESCRIPTION OF THE INVENTION
[0024] A presently preferred embodiment of a carton blank 10
according to the present invention is shown in FIG. 2 and includes
a top wall 12. Sidewalls 14, 14 are foldably joined to the side
edges of the top wall 12 along fold lines 16, 16. Bottom lap panels
18, 18 are foldably joined respectively to the sidewalls 14, 14
along fold lines 20, 20. A carrying handle 22 is provided for the
carton and includes a pair of flaps 24, 24. The details of such a
carrying handle 22 are disclosed for example in U.S. Pat. No.
5,106,014 issued Apr. 21, 1992, which is hereby incorporated by
reference.
[0025] Major end flaps 26, 28 are foldably joined to the end edges
of sidewalls 14, 14 along fold lines 30, 32, respectively. Minor
end flaps 34, 34 are foldably coupled respectively to bevel panels
36, 36 at the end edges of the top wall 12 along fold lines 38, 38
and 40, 40. Likewise, partial minor end flaps 42, 42, 42, 42 are
foldably joined respectively to partial bevel panels 44, 44, 44, 44
at the end edges of the bottom lap panels 18,18 along fold lines
46, 46, 46, 46, and 48, 48, 48, 48.
[0026] Gussets 50 interconnect the adjacent end flaps 26 and 34; 28
and 34; 26 and 42 as well as 28 and 42. Since all of the gussets 50
are virtually identical, only the specific features of the gusset
50 will be described here in detail. With particular reference to
FIGS. 2 and 5, the gusset 50 is foldably joined to the minor end
flaps 42, 34 along a fold line 52. The opposite end of the gusset
50 is foldably joined to the major end flaps 26, 28 along a fold
line 54.
[0027] A rectangular bevel panel 36, 44 is defined between the fold
lines 46, 48, and 38, 40 respectively. Bevel panel 36 is foldably
joined to the top wall 12 and to the minor end flap 34. Likewise,
bevel panel 44 is foldably joined to the bottom lap panels 18 and
to the partial minor end flaps 42.
[0028] Specifically, in one presently preferred embodiment the
carton blank 10 includes gusset holes 74 that are trapezoidal in
shape and likewise provide an increased surface area relative to
the prior art blank 11 having triangular apertures 13 (FIG. 1) for
more reliable removal of scrap 72 (FIGS. 4A and 4B) from the gusset
hole 74 during production of the carton blank 10. In one presently
preferred embodiment, the gusset hole 74 is trapezoidal-shaped and
the gusset holes 74a in the carton blank 10 proximate the top wall
12 include first and second edges 76, 78 that are each generally
parallel to one another and third and fourth edges 80, 82 that are
obliquely oriented relative to each other and relative to the first
and second edges 76, 78. These gusset holes 74a in one presently
preferred embodiment have a surface area of about 0.4554 square
inches. Additionally, in another presently preferred embodiment the
gusset holes 74b proximate the bottom lap panels 18 of the carton
blank 10 have first and second edges 84, 86 that are generally
parallel to one another and a third edge 88 is generally
perpendicular to the first and second edges 84, 86 and a fourth
edge 90 is obliquely oriented relative to the first, second and
third edges 84, 86, 88. The gusset holes 74b proximate the bottom
lap panels 18 have a surface area of approximately 0.4293 square
inches. The trapezoidal-shaped gusset holes 74a, 74b according to
this invention are advantageously larger than the triangular-shaped
apertures 13 in the prior art carton blank 11 of FIG. 1. More
specifically, the triangular-shaped prior art aperture 13 of FIG. 8
has a surface area of approximately 0.3487 square inches. As such,
the gusset hole 74b of FIG. 7A is approximately 23 percent greater
than that of the prior art triangular-shaped apertures 13 of FIG.
8; whereas, the trapezoidal-shaped gusset hole 74a of FIG. 7B is 31
percent larger than the triangular-shaped aperture 13 of the prior
art in FIG. 8. On the average, the gusset holes 74a, 74b of FIGS.
7A and 7B of this invention are 27 percent larger than the prior
art aperture 13 of FIG. 8. While the gusset holes 74a, 74b are
shown as being different trapezoidal shapes and sizes, the gusset
holes 74 may be the same configuration and size and preferably
trapezoidal and as large as practically possible to increase the
likelihood of removing the scrap. The advantageous size and
configuration of the gusset holes 74a, 74b result in an increase in
production because the web 10a moves at a rate of approximately 625
feet per minute which is a 30 percent or greater increase relative
to production rates for the prior art carton blank 11 of FIG. 1. As
such, the carton blank 10 configuration according to this invention
and shown in FIG. 2 provides a significant increase in production
rate and advantage over known prior art designs due in large part
to the configuration of the gusset holes 74a, 74b.
[0029] To complete the basic elements of the carton, one or more
outlet ports 56 are each defined by severance lines 58 as shown in
FIG. 2. The severance lines 58 are formed in at least one of the
sidewalls 14. The outlet port(s) 56 provide(s) a dispensing means
for dispensing the beverage cans from the carton. A preferred
embodiment in the outlet port 56 is disclosed U.S. Pat. No.
5,249,681, issued Oct. 5, 1993 and hereby incorporated by
reference.
[0030] To form a tubular carton sleeve 60 from the carton blank 10,
the bottom lap panels 18, 18 are partially overlapped onto one
another and glued together, typically on a folder-gluer machine as
is well known in the art. The sleeve 60 can then be collapsed about
fold lines 16 and 20 for storage and/or shipping.
[0031] To form the carton from the sleeve 60, the minor end flaps
34, 42, as viewed in FIGS. 5 and 6, are pivoted and folded into the
positions shown in FIG. 6. This action causes the bevel panels 36,
44 to swing inwardly together with each gusset 50 into the
respective positions as shown in FIGS. 5 and 6. Following this, the
major end flap 26 is folded inwardly along the fold line 30 and
major end flap 28 is then folded inwardly along fold line 32 until
the major end flaps 26, 28 overlap and are glued together to form
end walls. Once this is completed on both ends of the sleeve 60,
the carton is formed. The articles are loaded into the carton
through the open end or ends of the carton.
[0032] It should be recognized that as used herein, the terms
"top", "bottom" and "side" with respect to the various carton walls
or components are relative terms, and that the carton and/or its
contents may be re-oriented as necessary or as desired. Further,
rather than the bottom wall being formed from separate lap panels
18, 18, it will be recognized that the carton blank 10 may be
rearranged whereby some other panel is formed as a composite from
lap panels.
[0033] One advantage of this invention is that the end walls of the
completed carton have large flat surfaces and that the carton still
maintains adequate integrity due to the bevel panels 36, 44 at the
ends of the top wall 12 and bottom wall. The endwall enlarged flat
surfaces are useful as space for carrying printing such as an
advertisement, trademark, and other information.
[0034] A principal advantage of this invention is demonstrated in
FIGS. 3, 4A, 4B, 7A, 7B and 8. Once a web of paperboard 10a is die
cut, it commonly passes between various counter rotating rollers
and drums. One such drum is a stripper drum 62 having a number of
stripper pin assemblies 64 with pins 66 projecting from the outer
circumference of the drum 62. Each stripper pin is mounted to the
drum 62 on a base 68 and a movable sleeve 70 surrounds the pin
66.
[0035] Referring to FIGS. 3, 4A and 4B, as the die cut paperboard
web 10a passes in the direction of arrow A past the stripper drum
62 rotating in the direction of arrow B, the stripper pins 66 are
spaced and configured on the stripper drum 62 so that one of the
pins 66 puncture the scrap portion 72 of the paperboard 10a formed
in the gusset hole 74. Once the stripper pin 66 punctures the scrap
72 as shown in FIG. 4A, continued movement of the paperboard web
10a and the stripper drum 62 separates the scrap 72 and pin 66 from
the paperboard web 10a thereby exposing the gusset hole 74 as shown
in FIG. 4B. Due to the centrifugal forces of the rotating stripper
drum 62, the movable sleeve 70 slides along the stripper pin 66 to
project in the direction of arrow C and thereby dislodge the scrap
72 from the pin 66 for disposal. As such, upon subsequent rotation
of the stripper drum 62, the stripper pin 66 is free to puncture
scrap 72 in a subsequent die cut portion of the paperboard web
10a.
[0036] The above-described removal process for scrap 72 from die
cut holes or apertures in the carton blank 10 is generally the
desired objective of many carton blank production facilities and
paperboard converters. However, because of the design of prior art
carton blanks 11 such as those shown in FIG. 1, frequently the
stripper pin does not puncture the scrap portions of the die cut
blank and, consequently, does not remove the scrap from die cut
holes or apertures in the paperboard web. As a result, the process
must be halted or interrupted so that an operator manually
punctures the scrap from the die cut holes with a screw driver or
the like. The misalignment of the stripper pin 66 relative to the
scrap may be the result of a number of factors including
misalignment of the web relative to the stripper drum 62,
inaccurate placement of the stripper pin assemblies 64 on the
stripper drum 62 for a given die cut configuration or the like.
Additionally, wobble or loosely mounted stripper pins 66 are
commonly utilized so that dust or other foreign matter can be
easily and/or automatically ejected from the stripper pin assembly
64 to prevent clogging, jamming or the like. Such inherent movement
in the stripper pin 66 may also create inaccuracies in the
puncturing of the paperboard web.
[0037] Nevertheless, the carton blank 10 according to one
embodiment of this invention overcomes these problems and allows
for maximum or near peak production rates because scrap 72 in
particular apertures in the gusset hole 74 is consistently and
reliably punctured by the stripper pins 66 for removal thereby
alleviating the requirement for interruption of the process or
manual removal of the scrap.
[0038] From the above disclosure of the general principles of the
present invention and the preceding detailed description of at
least one preferred embodiment, those skilled in the art will
readily comprehend the various modifications to which this
invention is susceptible. Therefore, I desire to be limited only by
the scope of the following claims and equivalents thereof.
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