U.S. patent application number 11/379186 was filed with the patent office on 2006-10-19 for stackable basket-style article carrier with ergonomic side handle.
Invention is credited to JohnM Holley, Jr..
Application Number | 20060231440 11/379186 |
Document ID | / |
Family ID | 36694348 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060231440 |
Kind Code |
A1 |
Holley, Jr.; JohnM |
October 19, 2006 |
STACKABLE BASKET-STYLE ARTICLE CARRIER WITH ERGONOMIC SIDE
HANDLE
Abstract
A basket-style article carrier (200) that is collapsible when
empty, and stackable when loaded with articles (C). A handle (H) is
disposed on the side of the carrier (200) and includes an angled
handle aperture (O). The handle aperture (O) defines a axis of
elongation (Y), which is at an angle (A) with tubular axis (X) of
the basket style carrier (200). The angle of the handle aperture
(O) allows one to hold the basket-style carrier (200) at one's side
with one's arm hanging substantially toward the floor such that the
articles (C) remain in the carrier (200).
Inventors: |
Holley, Jr.; JohnM;
(Lawrenceville, GA) |
Correspondence
Address: |
PARKS KNOWLTON LLC
1117 PERIMETER CENTER WEST
SUITE E402
ATLANTA
GA
30338
US
|
Family ID: |
36694348 |
Appl. No.: |
11/379186 |
Filed: |
April 18, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60672345 |
Apr 18, 2005 |
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Current U.S.
Class: |
206/427 ;
206/162 |
Current CPC
Class: |
B65D 2571/00222
20130101; B65D 2571/00932 20130101; B65D 2571/0045 20130101; B65D
2571/00228 20130101; B65D 2571/00475 20130101; B65D 2571/00654
20130101; B65D 2571/00956 20130101; B65D 2571/00154 20130101; B65D
2571/00382 20130101; B65D 2571/0066 20130101; B65D 2313/02
20130101; B65D 71/0022 20130101; B65D 2571/00141 20130101; B65D
2571/00802 20130101 |
Class at
Publication: |
206/427 ;
206/162 |
International
Class: |
B65D 75/00 20060101
B65D075/00; B65D 65/00 20060101 B65D065/00 |
Claims
1. An ergonomic basket-style article carrier, comprising: a tubular
structure comprising a plurality of walls, the tubular structure
defining a tubular axis; a bottom wall hingedly connected to the
tubular structure so as to enclose the lower end of the tubular
structure; and a handle panel hingedly connected to the tubular
structure and extending outwardly therefrom, the handle panel
comprising an elongate handle aperture having an axis of
elongation, the axis of elongation being angled toward an upper
open end of the tubular structure so as to be disposed at an acute
angle with respect to the tubular axis.
2. The article carrier of claim 1, the plurality of walls
comprising: a first end wall; a first side wall hingedly connected
to one side of the first end wall; a second side wall hingedly
connected to an opposite side of the first end wall; a second end
wall hingedly connected to the first side wall and to the second
side wall; wherein the bottom wall is hingedly connected to the
first and second side walls.
3. The article carrier of claim 2, the second end wall comprising a
first end wall panel and a second end wall panel hingedly connected
to one another, wherein the handle panel is hingedly connected to
the first end wall panel and to the second end wall panel so as to
be connected to the second end wall.
4. The article carrier of claim 1, the axis of elongation of the
handle aperture being defined by a weight bearing edge of the
handle aperture.
5. A blank for forming a basket-style carrier for receiving a
plurality of articles, the blank comprising: an upper transverse
section having a first longitudinal axis along its upper edge, the
upper transverse section having formed therein a plurality of
panels hingedly connected one to another along the first
longitudinal axis, the plurality of panels including an upper
handle panel, the upper handle panel comprising an elongate handle
aperture with an axis of elongation disposed at an acute angle with
respect to the first longitudinal axis.
6. The carrier blank of claim 5, the plurality of panels
comprising: a first upper end wall panel; an upper side panel; and
a second upper end wall panel; wherein the upper side panel is
hingedly connected to the first upper end wall panel, the second
upper end wall panel is hingedly connected to the upper side panel,
and the upper handle panel is hingedly connected to the second
upper end wall panel
7. The carrier blank of claim 5, further comprising: a lower
transverse section disposed alongside and hingedly connected to the
upper transverse section, the lower transverse section having a
second longitudinal axis along its lower edge, the lower transverse
section having formed therein a plurality of panels hingedly
connected one to another along the second longitudinal axis, the
plurality of panels including a lower handle panel, the lower
handle panel comprising an elongate handle aperture with an axis of
elongation disposed at an acute angle with respect to the second
longitudinal axis.
8. The carrier blank of claim 7, the plurality of panels
comprising: a first lower end wall panel; an lower side panel; and
a second lower end wall panel; wherein the lower side panel is
hingedly connected to the first lower end wall panel, the second
lower end wall is hingedly connected to the second lower end wall
panel.
9. The carrier blank of claim 7, wherein the upper and lower handle
panels are hingedly connected to respective upper and lower
reinforcing panels for, when the blank is erected into a finished
carrier, forming a composite handle structure by which said carrier
is lifted.
10. The carrier blank of claim 9, wherein the upper and lower
reinforcing panels are hingedly connected to respective upper and
lower partition wall panels for, when the blank is erected into a
finished carrier, forming a composite partition panel for
subdividing the interior of the carrier.
11. The carrier blank of claim 10, wherein the upper and lower
partition wall panels comprise partially detachable partition flaps
for, when the blank is erected into a finished carrier, forming
additional partitions substantially perpendicular to the composite
partition panel for further subdividing the interior of the
carrier.
12. A package, comprising: a plurality of articles of substantially
uniform height; and a stackable basket-style article carrier for
enclosing the articles, comprising; a first end wall; a first side
wall hingedly connected to one side of the first end wall; a second
side wall hingedly connected to an opposite side of the first end
wall; a second end wall hingedly connected to the first side wall
and to the second side wall, and the second end wall comprising a
first end wall panel and a second end wall panel hingedly connected
to one another; a bottom wall hingedly connected to at least two of
the first and second end walls and the first and second side walls
so as to enclose one end of the article carrier; a partition panel
extending across from the first end wall to the second end wall;
and a handle panel hingedly connected to the first end wall panel
and the second end wall panel so as to be connected to the second
end wall, the handle panel being extendable outwardly with respect
to the second end wall; wherein the maximum height of any one of
the end walls, the side walls, and the partition panel is no
greater than the height of the plurality of articles.
13. The package of claim 12, wherein the handle panel has an
uppermost edge that extends no higher with respect to the bottom
wall than the height of the plurality of articles.
14. The package of claim 12, wherein: the article carrier defines a
tubular axis; and the handle panel comprises an elongate handle
aperture having an axis of elongation, the axis of elongation being
angled toward the open end of the article carrier so as to be
disposed at an acute angle with respect to the tubular axis.
15. A package, comprising: a plurality of articles of substantially
uniform height; and a stackable basket-style article carrier for
enclosing the articles, comprising; a tubular structure comprising
a plurality of walls; a bottom wall hingedly connected to the
tubular structure so as to enclose the lower end of the tubular
structure; and a handle panel hingedly connected to the tubular
structure and extending outwardly therefrom; wherein the maximum
height of any one of the plurality of walls is no greater than the
height of the articles.
16. The package of claim 15, wherein the handle panel has an
uppermost edge that extends no higher with respect to the bottom
wall than the height of the plurality of articles.
17. The package of claim 15, wherein: the tubular structure defines
a tubular axis; and the handle panel comprises an elongate handle
aperture having an axis of elongation, the axis of elongation being
angled toward the upper open end of the tubular structure so as to
be disposed at an acute angle with respect to the tubular axis.
18. A package, comprising: a plurality of articles; and a stackable
basket-style article carrier for enclosing the articles,
comprising; a first end wall; a first side wall hingedly connected
to one side of the first end wall; a second side wall hingedly
connected to an opposite side of the first end wall; a second end
wall hingedly connected to the first side wall and to the second
side wall, and the second end wall comprising a first end wall
panel and a second end wall panel hingedly connected to one
another; a bottom wall hingedly connected to at least two of the
first and second end walls and the first and second side walls so
as to enclose one end of the article carrier; a partition panel
extending across from the first end wall to the second end wall;
and a handle panel hingedly connected to the first end wall panel
and the second end wall panel so as to be connected to the second
end wall, the handle panel being extendable outwardly with respect
to the second end wall; wherein any two of the end walls, the side
walls, and the partition panel have the same maximum height, which
is at least the height of the plurality of articles, and form a
weight bearing structure.
19. The package of claim 18, wherein the handle panel has an
uppermost edge that extends no higher with respect to the bottom
wall than the height of the weight bearing structure.
20. The package of claim 18, wherein: the article carrier defines a
tubular axis; and the handle panel comprises an elongate handle
aperture having an axis of elongation, the axis of elongation being
angled toward the open end of the article carrier so as to be
disposed at an acute angle with respect to the tubular axis.
21. A package, comprising: a plurality of articles of substantially
uniform height; and a stackable basket-style article carrier for
enclosing the articles, comprising; a tubular structure comprising
a plurality of walls; a bottom wall hingedly connected to the
tubular structure so as to enclose the lower end of the tubular
structure; and a handle panel hingedly connected to the tubular
structure and extending outwardly therefrom; wherein any two of the
end walls, the side walls, and the partition panel have the same
maximum height, which is at least the height of the plurality of
articles, and form a weight bearing structure.
22. The package of claim 21, wherein the handle panel has an
uppermost edge that extends no higher with respect to the bottom
wall than the height of the weight bearing structure.
23. The package of claim 21, wherein: the tubular structure defines
a tubular axis; and the handle panel comprises an elongate handle
aperture having an axis of elongation, the axis of elongation being
angled toward the upper end of the tubular structure so as to be
disposed at an acute angle with respect to the tubular axis.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Application No.
60/672,345, filed Apr. 18, 2005, the entirety of which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to basket-style carriers
for packaging and transporting multiple articles, and more
particularly to a stackable basket-style carrier with an ergonomic
side handle.
BACKGROUND OF THE INVENTION
[0003] Basket-style carriers for carrying multiple articles, well
known in the art, are useful for enabling consumers to transport,
store, and access the articles for consumption. These carriers
typically have a handle on top, thereby forming a conventional
basket that typically includes a riser or partition extending
upwardly from the bottom of the carrier from which the handle is
fashioned. Such a handle placement prevents the carriers from being
stackable, making their shipping and storing less efficient than
other cartons. However, consumers appreciate basket-style carriers
for their convenience of carrying. Therefore, there exists a need
for a basket-style carrier that is stackable when loaded and still
convenient for the consumer.
[0004] Article carriers with side handles are known. However,
typical side handles provide a handle aperture that is essentially
vertical, in the manner of the handle of a coffee mug. However, a
basket-style carrier is typically carried by a user in one hand
with the user's arm essentially straight down at his or her side.
Such a carrier having a vertical side handle results in the
basket-style carrier being disposed on its side when carried,
allowing the articles to fall out. Thus, there exists a need for a
stackable basket-style carrier with a side handle that allows a
consumer to easily carry articles in the carrier.
SUMMARY OF THE INVENTION
[0005] The present invention overcomes the shortcomings of the
prior art by providing a basket-style carrier that is stackable
when loaded with articles and easy for the consumer to carry. More
specifically, according to the various embodiments, the invention
provides a collapsible, partitioned, basket-style carrier with a
side handle having an ergonomically angled hand aperture.
[0006] The exemplary carrier is formed of a foldable sheet material
and includes a tubular structure formed from preferably several
walls hingedly connected one to another. The tubular structure may
have any configuration, including but not limited to, a cylindrical
tube, a triangular tube, a rectangular tube, or a tube having a
cross section that is a hybrid of any number of shapes. A bottom
wall encloses one end of the tubular structure and provides a
support surface for the articles enclosed by the carrier. The
tubular structure defines a tubular axis that is normal to the
plane of the bottom wall and extends longitudinally through the
center of the tubular structure. In the exemplary embodiments
described in more detail below, the tubular structure includes
opposing side walls, opposing end walls, and a bottom wall. A
composite handle structure is connected to a wall of the carrier,
and preferably to at least one of the end walls. At least one
partition divides the interior of the carrier into compartments,
each compartment being for enclosing a single article or a group of
articles and for strengthening the weight-bearing capacity of the
carrier.
[0007] The ergonomics of the article carrier are greatly improved,
as compared to prior art efforts, primarily by the inclusion of an
angled handle aperture. The handle structure includes an elongate
handle aperture disposed therethrough, the handle aperture defining
an axis of elongation that is angled toward the open end of the
article carrier so as to be at an acute angle with respect to the
tubular axis of the carrier. Thus, when the carrier is loaded with
articles and carried in a user's hand that is hanging down at the
user's side, a weight bearing edge of the elongate handle aperture
rests across the span of the user's fingers, which are curled or
otherwise disposed through the handle aperture. The acute angle is
calculated to slant the articles in the carrier when the weight
bearing edge of the handle aperture is substantially parallel to
the floor. In this manner, the articles are disposed with bottom
ends lower than top ends on a slope that is sufficient to prevent
the articles from sliding out of the carrier. Thus, the user need
not hold his or her arm at an uncomfortable angle or bend it at the
elbow while carrying the loaded carrier.
[0008] According to one aspect, the exemplary basket-style article
carrier is made vertically stackable when loaded with articles, at
least in part by locating the handle on a side or end of the
carrier rather than the top of the carrier. The stackability of the
package is enhanced by providing carrier walls, panels, and
partitions that are no taller than the height of the articles that
are to be enclosed by the carrier. In other words, the intended
articles, which may be cans, bottles, or the like, are at least as
tall as the walls and partitions of a first carrier such that the
bottom wall of a second carrier stacked on the first carrier will
be supported by the tops of the intended articles. Alternatively,
at least two of the carrier walls and/or partitions are rectangular
and taller than the intended articles such that the upper edges of
at least two of the carrier walls and/or partitions are parallel to
the plane of the bottom wall. These rectangular and relatively
taller walls form the base upon which a second carrier can be
stacked.
[0009] The present invention overcomes the inconvenience of having
a substantially vertical hand aperture by providing a more
ergonomic handle with an angled hand aperture that prevents the
contents of the carrier from sliding out of the carrier. Thus, the
carrier of the present invention includes a handle that allows one
to carry the basket-style carrier at one's side while maintaining
the articles in an essentially upright position in which the upper
end of each article is positioned above the lower end of the
article.
[0010] The height of the carrier, defined as the height of the
tallest of the side walls, end walls, handle panel, and partition
walls, is determined by the height of the intended articles. That
is, to remain stackable, the height of the carrier is preferably
substantially equal to or somewhat less than the height of the
intended articles. In this manner, the intended articles are
actually the weight-bearing support members for stacking additional
carriers vertically. Thus, the carton walls and partitions may be
fashioned from relatively less sturdy materials. Alternatively, the
height of the carrier is defined as the height of the tallest two
or more equally tall walls, panels, and partitions, and is at least
slightly greater than the height of the intended articles.
According to this alternative, the tallest walls and partitions are
sufficiently strong to support the weight of one or more carriers
stacked atop the carrier. In all of the embodiments shown, the
uppermost edge of the handle extends no higher than the uppermost
edge of the tallest portion of the carrier or than the maximum
height of the intended articles, although such embodiments are
contemplated.
[0011] The present invention also provides for a blank for
constructing the exemplary basket-style carrier with side handle.
The blank generally includes multiple panels, tabs, and flaps
hingedly connected to one another such that, in the erected
carrier, the panels form the aforementioned opposed side walls,
opposed end walls, bottom wall, one or more partitions, and
composite handle panel with angled handle aperture. More
specifically, the blank includes an upper and a lower elongate
transverse section having first and second longitudinal axes that
extend along the length of the blank. The first longitudinal axis
extends along the upper edge of the upper transverse section, and
the second longitudinal axis extends along the lower edge of the
lower transverse section. The upper transverse section is
preferably at least somewhat symmetrical to the lower transverse
section, at least part of its lower edge coinciding with an axis of
symmetry that is also at least partly coincident with the upper
edge of the lower transverse section.
[0012] The upper and lower transverse sections each include several
panels hingedly connected to one another along the respective
longitudinal axis, including: a first end wall panel, a side panel
hingedly connected to the first end wall panel, a second end wall
panel hingedly connected to the side panel, and a handle panel
hingedly connected to the second end wall panel. The upper handle
panel includes an elongate handle aperture that has an axis of
elongation disposed at an acute angle with respect to the upper
longitudinal axis. The lower handle panel includes an elongate
handle aperture that has an axis of elongation disposed at an acute
angle with respect to the lower longitudinal axis. The upper and
lower handle panels are hingedly connected to respective upper and
lower reinforcing panels that, when the blank is erected into a
finished carrier, cooperate with the handle panels to form a
composite handle by which the carrier is lifted.
[0013] In certain embodiments, the upper and lower reinforcing
panels are also hingedly connected to respective upper and lower
partition wall panels that are arranged at one end of respective
upper and lower transverse elongate sections that, when the blank
is erected, form a composite partition panel for subdividing the
interior of the carrier. The upper and lower partition wall panels
also include partially detachable partition flaps that form
additional partitions disposed substantially perpendicular to the
composite partition panel for further subdividing the interior of
the carrier. In the exemplary embodiments, the interior of the
erected carrier is halved by the composite partition panel and
quartered by the partition flaps, although various other divisions
are contemplated.
[0014] According to another aspect of the invention, the blank is
composed of a single sheet of foldable sheet material that can be
easily assembled into a basket-style carrier that is preferably
collapsible after assembly for ease of shipping to a loading
facility.
[0015] The foregoing has broadly outlined some of the aspects and
features of the present invention, which should be construed to be
merely illustrative of various potential applications of the
invention. Other beneficial results can be obtained by applying the
disclosed information in a different manner or by combining the
disclosed embodiments. Accordingly, other aspects and a more
comprehensive understanding of the invention may be obtained by
referring to the detailed description of the exemplary embodiments
taken in conjunction with the accompanying drawings, in addition to
the scope of the invention defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a plan view of an exemplary embodiment of a blank
for forming a basket-style carrier of the present invention.
[0017] FIG. 2 is a perspective view of a basket-style article
carrier formed from the blank of FIG. 1, shown in an assembled and
non-collapsed condition.
[0018] FIG. 3 is a side elevation view of the carrier of FIG.
2.
[0019] FIG. 4 is a side elevation view of the carrier of FIG. 2,
shown in an assembled and collapsed condition.
[0020] FIG. 5 is a perspective view of the carrier of FIG. 2, shown
being grasped by a user's hand.
[0021] FIG. 6 is a side elevation view of the carrier of FIG. 2,
shown being held by a user's hand, hanging downward from the user's
arm.
[0022] FIG. 7 is a perspective view of the carrier of FIG. 2, shown
being held by a user's hand, hanging downward from the user's
arm.
[0023] FIG. 8 is a plan view of the blank of FIG. 1, showing the
relationship between the longitudinal axes of the exemplary blank
and the axes of elongation of the handle apertures.
DETAILED DESCRIPTION OF THE INVENTION
[0024] As required, detailed embodiments of the present invention
are disclosed herein. It must be understood that the disclosed
embodiments are merely exemplary of the invention that may be
embodied in various and alternative forms, and combinations
thereof. As used herein, the word "exemplary" is used expansively
to refer to embodiments that serve as illustrations, specimens,
models, or patterns. The figures are not necessarily to scale and
some features may be exaggerated or minimized to show details of
particular components. In other instances, well-known components,
systems, materials, or methods have not been described in detail in
order to avoid obscuring the present invention. Therefore, specific
structural and functional details disclosed herein are not to be
interpreted as limiting, but merely as a basis for the claims and
as a representative basis for teaching one skilled in the art to
variously employ the present invention.
[0025] Referring now to the drawings in which like numerals
indicate like elements throughout the several views, the drawings
illustrate certain of the various aspects of exemplary embodiments
of a basket-style carrier according to the teachings of the present
invention.
[0026] In the exemplary embodiment described herein, the invention
provides a basket-style article carrier that is collapsible when
empty and stackable when loaded. The handle, being on the side of
the carrier rather than the top, allows multiple loaded carriers to
be stacked. The angle of the handle allows one to hold the
basket-style carrier at one's side with one's arm hanging
substantially toward the floor, with the articles remaining in the
carrier.
[0027] Referring to the exemplary embodiment illustrated in FIG. 1,
the basket-style article carrier 200 (best shown in FIG. 2) is
formed from blank 100--which is preferably a single sheet of
suitable substrate. It is to be understood that, as used herein the
term "suitable substrate" includes all manner of foldable sheet
material such as paperboard, corrugated board, plastic, or the
like. The terms "fold line" and "severance line" refer to all
manner of printed lines indicating optimal fold or cut locations,
frangible or otherwise weakened lines, perforations, a line of
perforations, a line of short slits, a line of half-cuts, a single
half-cut, a cut line, scored lines, slits, any combination thereof,
and the like.
[0028] Blank 100 generally includes a plurality of panels, each
hingedly connected to at least one other panel. More specifically,
FIG. 1 is a plan view of the blank 100 for forming an exemplary
basket-style carrier 200, with the inside surface of the blank 100
shown. The opposite side (not shown) of the blank 100 is the
outside surface of the carrier, which may be used as its art side
for printing product information and other decorative and marketing
information, such as logos. For discussion purposes, the blank 100
can be described in terms of respective upper and lower transverse
elongate sections A1 and A2 that are connected to one another in a
side by side arrangement; and in terms of three functional
sections--a carrier section B1, a handle section B2, and a
partition section B3. The carrier section B1 is preferably hingedly
connected to the handle section B2, and the handle section B2 is
optionally hingedly connected to the partition section B3. The
components of the blank 100 are optimally arranged in part to form
a footprint that yields a minimum amount of waste sheet
material.
[0029] Each transverse section A1, A2 has a longitudinal axis that
extends across the blank 100 from the left edge to the right. Upper
transverse section A1 includes an end edge flap 102 hingedly
connected to a first end wall panel 114, which is hingedly
connected to a first side panel 132, which is hingedly connected to
a second end wall panel 146, which is hingedly connected to a
handle panel 150. Handle panel 150 is preferably further hingedly
connected to reinforcing panel 170, which is hingedly connected to
partition wall panel 180. In like fashion, lower transverse section
A2 includes an end edge flap 104 hingedly connected to a first end
wall panel 118, which is hingedly connected to a first side panel
138, which is hingedly connected to a second end wall panel 152,
which is hingedly connected to a handle panel 154. Handle panel 154
is preferably hingedly connected to reinforcing panel 171, which is
hingedly connected to partition wall panel 182.
[0030] At one end of blank 100, end edge flap 102 is hingedly
connected along fold line 103 to end edge flap 104. End edge flap
102 includes a notch 105 along its end edge and a retention tab 107
on its side edge. End edge flap 104 preferably includes a congruent
notch 106 along its end edge and a congruent retention tab 108 on
its side edge. The notches 105, 106 are provided to maximize the
surface area adjacent to the notches 105, 106 available for
securing the end edge flaps 102, 104 to one another while
minimizing the consumption of sheet material. End edge flap 102 and
end edge flap 104 are preferably symmetrical about fold line 103 so
as to conform to one another when folded into a face contacting
configuration. In certain embodiments, a portion of material
proximate to fold line 103 is removed, creating aperture 110, so as
to facilitate folding along fold line 103 while reducing the
thickness and congestion of the resulting fold.
[0031] End edge flap 102 is hingedly connected along fold line 112
to end wall panel 114. Similarly, end edge flap 104 is hingedly
connected along fold line 116 to end wall panel 118. End wall panel
114 is hingedly connected along fold line 120 to side panel 132.
Side panel 132 is hingedly connected along fold line 130 to bottom
panel 128, which is hingedly connected along optional fold line 126
to bottom panel 124. Fold line 126 facilitates collapsing the
assembled carrier 200, and thus may be eliminated if the carrier
200 is not to be collapsed after assembly. A notch 127 between
bottom panels 128, 124 is bisected by fold line 126, and cooperates
with retention tabs 107 and 108 to secure the carrier 200 in an
erected condition. Side panel 132 is hingedly connected along fold
line 134 to end wall panel 146. End edge flap 104 is hingedly
connected along fold line 116 to end wall panel 118. End wall panel
118 is hingedly connected along fold line 122 to side panel 138,
which is hingedly connected along fold line 140 to side edge flap
142. Side panel 138 is hingedly connected along fold line 144 to
end wall panel 152. The inner edges of each of the panels 114, 132,
146, 118, 138, and 152 border aperture 136, and form the upper
edges of the walls of the erected carrier 200.
[0032] The carrier section B1 is hingedly connected along fold
lines 148 and 151 to the handle section B2 of blank 100. More
specifically, end wall panel 146 is hingedly connected along fold
line 148 to handle panel 150. End wall panel 152 is hingedly
connected along fold line 151 to handle panel 154. Handle panel 150
is hingedly connected along fold line 153 to handle panel 154. Each
of the handle panels 150, 154 includes a handle aperture 156, 160,
respectively. The handle apertures 156, 160 can be enlarged and
reinforced by means of respective partially detachable handle flaps
158, 162, which are partially defined by respective fold lines 159,
163. The handle flaps 158, 162 also cushion the user's hand when
folded over the raw edges of the weight bearing portion of each
handle aperture 156, 160 that is gripped by the user's hand. Handle
apertures 156 and 160 are preferably symmetrical and equidistant
from fold line 153, such that when folded toward one another along
fold line 153, the handle apertures 156, 160 are in registry with
one another and create a single handle aperture.
[0033] The structural integrity of handle panels 150, 154 is
reinforced by reinforcing panels 170, 171. Handle panel 150 is
hingedly connected along fold line 164 to reinforcing panel 170.
Handle panel 154 is hingedly connected along fold line 166 to
reinforcing panel 171. Reinforcing panels 170 and 171 include
apertures 172, 176 that are at least as large as handle apertures
156, 160 and align with handle apertures 156, 160 so as not to
obstruct or overlap the perimeter thereof, but are not necessarily
symmetrical. The apertures 172, 176 may in fact be larger than
handle apertures 156, 160 to provide reinforcement, while
minimizing the amount of material consumed as well as the thickness
of the composite handle H (best shown in FIGS. 2-7) that is formed
from the handle panels 150, 154 and the reinforcing panels 170,
171. Reinforcing panel 170 is hingedly connected to reinforcing
panel 171 along fold line 175, a portion of which may be proximate
to or include an aperture 174 that facilitates folding and reduces
the thickness and congestion of material along the fold. The inner
edges of each of the handle panels 150, 154 and the reinforcing
panels 170, 171 border aperture 168, and along with fold lines 164
and 166, form an outer edge of the handle H of the erected carrier
200.
[0034] As mentioned above, the handle section B2 is optionally
hingedly connected to the partition section B3. More specifically,
reinforcing panel 170 is hingedly connected to partition wall panel
180 along line 173, a portion of which may border or be defined by
aperture 172. Similarly, reinforcing panel 171 is hingedly
connected to partition wall panel 182 along line 178. Lines 173 and
178, which border respective pairs of panels 170 and 180 and panels
171 and 182, are not necessarily fold lines, but preferably merely
demarcate the transition between reinforcing panels 170, 171 and
partition wall panels 180 and 182. The width of partition wall
panel 182, being the distance from fold line 192 to the opposite
edge of partition wall panel 182, may approximate the height of
carrier 200, which preferably remains equal or lesser than the
height of intended articles to be carried.
[0035] Partition wall panels 180, 182 include respective partition
flaps 194, 196. Partition flap 194 is partially detachable from
partition wall panel 180, being hingedly connected along fold line
184 and detachable along severance line 198. Partition flap 194
also includes partition tab 191, which is partially detachable from
partition wall panel 180 via severance line 188 and is also
hingedly attached along fold lines 187a and 187b. Partition flap
196 is partially detachable from partition wall panel 182, being
hingedly connected along fold line 186 and detachable along
severance line 199a and 199b. Partition flap 196 also includes
partition tab 193, which is partially detachable from partition
wall panel 182 via severance line 195 and is also hingedly attached
along fold lines 189a and 189b.
[0036] Erecting the basket-style carrier 200 from the blank 100 may
be accomplished with the folding operations as described herein,
the operations being performed by automatic erecting machinery
and/or manually. The method of performing the erecting process is
not limited to the exemplary method described herein, particularly
in that the order of the steps can be altered according to the
particular manufacturing requirements, steps may be added or
omitted, and the means for securing components to one another may
vary.
[0037] Referring particularly to FIGS. 1 and 2, the inside surfaces
of handle panel 150 and reinforcing panel 170 are folded toward one
another along fold line 164 into a face contacting arrangement, and
the surfaces of sheet material may be secured together by suitable
means for securing, such suitable securing means including tape,
staples, interlocking folds, VELCRO.RTM., glue or other adhesives,
and the like. Substantially concurrently, the inside surfaces of
handle panel 154 and reinforcing panel 171 are folded toward one
another along fold line 166 into a face contacting arrangement, and
connected with means for securing. Folding the handle panel 150
into a face contacting arrangement with reinforcing panel 170
places the inside surface of a portion of partition panel 180 in a
face contacting arrangement with the inside surface of end wall
panel 146, and places partition flap 194 in a face contacting
arrangement with side panel 132. Similarly, folding handle panel
154 into a face contacting arrangement with reinforcing panel 171
places the inside surface of a portion of partition panel 182 in a
face contacting arrangement with the inside surface of end wall
panel 152, and places partition flap 196 in a face contacting
arrangement with side panel 138. Handle apertures 156 and 160 and
apertures 172 and 176 all align to form a single handle aperture O
(best shown in FIGS. 3 and 4). Handle flaps 158 and 162 align so
that each can be folded toward one another in an overlapping
fashion or to the side or another along fold lines 159 and 163,
respectively, and placed through the handle opening when in use.
Handle flaps 158 and 162 function to provide a smooth grip area for
the user's hand and fingers by covering the raw edges of the
aperture O in the handle H.
[0038] End wall panel 114 is folded toward side panel 132 along
fold line 120 such that at least a portion of the inside surfaces
of the panels 114, 132 are face to face, and at least a portion of
end edge flap 102 may also overlap a portion of the outside surface
of partition panel 180. Substantially concurrently, end wall panel
118 is folded along fold line 122 toward side panel 138 such that
at least a portion of the respective inside surfaces of the panels
118, 138 are also face to face, and at least a portion of end edge
flap 104 may overlap a portion of the outside surface of partition
panel 182.
[0039] End edge flaps 102 and 104 are folded along fold line 103 so
that the outside surfaces thereof are face to face and retention
tabs 107 and 108 are aligned with one another. The outside surfaces
of the end edge flaps 102, 104 and retention tabs 107, 108 are
secured together by means for securing, thereby creating a
composite partition flap 102/104 (obstructed in FIG. 2) that
protrudes inwardly from composite end wall 202 (best shown in FIG.
2) and, optionally, a composite retention tab 107/108. As mentioned
above, optional aperture 110 may be included along fold line 103 to
increase the flexibility and decrease the congestion of this fold.
Substantially concurrently, the outside surfaces of reinforcing
panels 170, 171 are folded toward one another along fold line 175
and secured, as the inside surfaces of handle panels 150, 154 are
folded toward one another along fold line 153, with reinforcing
panels 170, 171 disposed between handle panels 150, 154. All
surfaces of handle panels 150, 154 and reinforcing panels 170, 171
are adjacent and positioned in a face contacting arrangement with
respect to one another and are preferably secured to one another so
as to form a relatively strong and relatively rigid composite
handle H, which is best shown in FIGS. 2-7. Some material may be
removed creating aperture 174, which reduces the thickness and
congestion of the fold between the handle panels 150, 154 and
reinforcing panels 170, 171.
[0040] With the exception of the respective partition flaps 194,
196 and partition tabs 191, 193, the outside surface of partition
panel 180 is preferably secured to the outside surface of partition
panel 182, thereby creating a composite partition P (best shown in
FIGS. 2 and 4). An uppermost portion adjacent to composite
retention tab 107/108 and a lowermost portion adjacent to fold line
103 of composite partition flap 102/104 are preferably interposed
between or otherwise secured to respective uppermost and lowermost
portions of the panels comprising the composite partition P.
[0041] To square up the carrier portion B1, panels 114, 118 are
rotated outwardly along fold lines 112, 116, 120, and 122,
respectively, to approximately 90 degrees, thereby creating
composite end wall 202 composed of end wall panel 114 and 118.
Panels 134, 144, 146, 152 are likewise rotated outwardly along fold
lines 148 and 151, respectively to approximately 90 degrees,
thereby creating composite end wall 204 (best shown in FIG. 2)
composed of end wall panel 146 and 152. Composite end walls 202 and
204 oppose one another and are perpendicular to resultant side
walls 232 and 238. Thus, the perimeter of the carrier 200 is
defined by composite end wall 202, which is hingedly connected to
side wall 232, which is hingedly connected to composite end wall
204, which is hingedly connected to side wall 238, which is also
hingedly connected to composite end wall 202.
[0042] Partition tab 191 is folded 90 degrees along fold line 187a
and 187b to be perpendicular to partition flap 194, which is folded
90 degrees to be perpendicular to the plane of composite partition
P. In this manner, partition tab 191 is positioned parallel to side
wall 232. The inside or outside surface of partition tab 191 is
secured to the inside surface of side wall 232 so as to fix the
perpendicular alignment of partition flap 194 with respect to side
wall 232 and composite partition P. Similarly, partition tab 193 is
folded 90 degrees along fold line 189a and 189b to be perpendicular
to partition flap 196, which is folded 90 degrees to be
perpendicular to the plane of composite partition P. In this
manner, partition tab 193 is positioned parallel to side wall 238.
The inside or outside surface of partition tab 193 is secured to
the inside surface of side wall 238 so as to fix the perpendicular
alignment of partition flap 196 with respect to side wall 238 and
composite partition P.
[0043] Side edge flap 142 is folded inwardly along fold line 140 to
approximately 90 degrees, and bottom panels 124, 128 are folded
inwardly together along fold line 130 so that a portion of the
inside surface of bottom panel 124 contacts and is secured to the
outside surface of side edge flap 142. Bottom panels 124 and 128
thereby form bottom wall 124/128. By matingly engaging clips 107,
108 with notch 127 between bottom panels 124 and 128, the walls
comprising the perimeter of carrier 200 are secured in squared
arrangement, i.e., with opposing end walls 202, 204 substantially
parallel to one another and substantially perpendicular to opposing
side walls 232, 238, which are substantially parallel to one
another as well. Retention tabs 107, 108 may or may not be secured
to one another, and preferably fold flat against bottom wall
124/128 while engaged with notch 127 so as to enable the bottom
wall 124/128 of carrier 200 to rest on a flat surface.
[0044] By means of composite partition P and of partition flaps 194
and 196, the carrier 200 is effectively quartered to enclose four
articles in a two by two (2.times.2) arrangement. Those skilled in
the art will readily recognize that other arrangements of various
numbers of articles can be achieved, such as by positioning two
partition flaps on each partition panel 180, 182 yielding a
2.times.3 arrangement enclosing six articles. As shown in FIGS. 3
and 5-7, the articles enclosed by the carrier 200 are at least as
tall as the tallest of the carrier walls 202, 204, 232, 238, or
partition P.
[0045] As described above, FIG. 4 demonstrates that optional fold
line 126 can be utilized after carrier 200 is assembled, to enable
basket carrier 200 to be collapsed into a flattened arrangement
such as for shipping. To collapse carrier 200 after it has been at
least partially erected, the retention tabs 107, 108 (not visible)
are disengaged from notch 127, thereby allowing the carrier 200 to
spring back into a collapsed condition. The following panels are
folded onto one another in no particular order: the inside surfaces
of bottom panels 124 and 128 are collapsed together along fold
lines 126, 130, and 140; the outside surface of end wall panel 114
is collapsed along fold lines 112 and 120 onto the outside surface
of end wall panel 118, which is collapsed along fold line 116 and
122; side wall 232 is collapsed onto end wall panel 114 and
partition panel P along fold line 134; side wall 238 is collapsed
onto end wall panel 118 and partition panel P along fold line 144;
partition flaps 194 and 196 are collapsed onto opposite sides of
partition panel P by unfolding fold lines 184 and 186; and end wall
panels 146, 152 are collapsed onto opposite sides of partition
panel P by unfolding respective fold lines 148, 151.
[0046] Referring now to FIG. 3, the orientation of the handle
aperture O is optimized to improve the ergonomics of the carrier
200 such that the carrier 200 can be carried at one's side without
the articles, shown as cans C, falling out. FIG. 3 is a side
elevation view of the erected carrier 200 having been loaded with
cans C. An imaginary line representing the tubular axis X extends
through the center of the tubular structure of the carrier 200 so
as to be equidistant from opposing end walls 202, 204 and
equidistant from opposing side walls 232, 238. A second imaginary
line represents the axis of elongation Y of the elongate handle
aperture O, and coincides with the weight bearing edge of elongate
handle aperture O, the weight bearing edge being defined by fold
lines 159/163, which are substantially aligned with one another. As
previously related, handle flaps 158/162 (not shown) cushion the
weight bearing edge for the comfort of the user. Tubular axis X and
axis of elongation Y intersect, with the resultant angle A between
the two being acute, and calculated to minimize the risk that
articles will fall out of the carrier 200 when carried at the
user's side.
[0047] When the carrier 200 is carried at the user's side with the
user's arm hanging substantially straight down toward the floor (as
shown in FIG. 6), the axis of elongation Y is near horizontal with
respect to the floor. At this position, angle A is calculated as at
least the minimum deflection required to position the top of each
article (can C) at a substantially higher elevation than the bottom
of the article. Thereby, the article is unlikely to fall out of the
carrier 200. Angle A is thus greater than zero, and is preferably
not substantially greater than 90 degrees. Angle A may be more
acute when the coefficient of friction between the surface of an
article and the inside surface of the carrier 200 is greater or
when each article is tightly fitted into the carrier 200. Angle A
may be less acute when the coefficient of friction is lower, that
is, when each article has a tendency to slide with respect to the
inside surface of the carrier, or when each article is loosely
fitted into the carrier 200. In the exemplary embodiment as best
shown in FIGS. 3 and 6, the angle A between the handle aperture and
the axis X is approximately 30 degrees, and preferably ranges from
20 degrees to 45 degrees. Determination of the optimal value for
angle A may further take into account the extent to which a typical
person swings his or her arm backwards when carrying a loaded
carrier at his or her side and walking, the goal being to prevent
the articles from being upended at any point in an imaginary arc
representing the typical arm swing. In certain embodiments, the
elongate handle aperture O is disposed at an angle A or otherwise
designed such that the user does not have to exert or provide a
moment of force on the handle H to carry the carrier 200. Rather,
the user need only provide a lifting force to offset the weight of
the loaded carrier 200.
[0048] Referring to FIG. 8, the advantageous disposition of the
elongate handle aperture is also manifest in the blank 100. The
respective longitudinal axes Z and Z' of each transverse section
A1, A2 are shown in the figure, the longitudinal axes Z, Z'
extending horizontally across the blank 100. Elongate handle
aperture 156 defines an axis of elongation Y that is inclined at an
acute angle B with respect to longitudinal axis Z that is disposed
along the upper longitudinal edge of the blank 100. Elongate handle
aperture 160 defines an axis of elongation Y' that is inclined at
an acute angle B' with respect to longitudinal axis Z' disposed
along a lower respective outer longitudinal edge of the blank 100.
The angles B and B' are preferably equal or are otherwise related
to place the handle aperture 156 and 160 in registry with one
another in forming composite handle H having handle aperture O
disposed therethrough. The apertures 172 and 176 may assume any
configuration or orientation that does not interfere with the
perimeter of aperture O. In the exemplary embodiment, the angle B,
B' between the longitudinal axis Z, Z' and the axis of elongation
Y, Y' is 60 degrees, and preferably ranges from about 45 to 70
degrees.
[0049] In use, the fully erected and loaded carrier 200 is
typically stored on a substantially flat surface, such as a shelf
(not shown), or is stored in a vertically oriented stack with at
least one other carrier 200 place atop or below the first carrier.
As apparent in FIGS. 3 and 5-7, the exemplary carrier 200 has no
wall or partition that extends above the maximum height defined by
the upper edge of the cans C or other articles enclosed by the
carrier. In such embodiments, the carrier 200 is best suited to
enclose articles having uniform height, and preferably each article
has at least a small flat top surface. Suitable articles include,
but are not limited to, cans, tins, bottles, jugs, juice boxes, and
the like. In alternative embodiments, at least two of the walls and
partitions are taller than the articles enclosed so as to provide a
support structure upon which another carrier 200 can rest. For
example, it is contemplated that end wall 202 can be formed from
end wall panels 114 and 118 that are substantially rectangular, and
end wall 204 can be formed from end wall panels 146 and 152 that
are substantially rectangular. These alternative end walls 202 and
204 can have the same height as the partition panel P, which can be
made taller than the intended articles. Thus, a second carrier can
be supported and stabilized by the cooperating end walls 202, 204
and partition P. This alternative embodiment (not shown) of carrier
200 preserves stackability, and is suited to enclose articles
having varying heights, or articles having a uniform height that is
less than the height of the end walls and partition.
[0050] When stacked, the composite handle H preferably extends
toward the user for ease of reach. Alternatively, the composite
handle H may be stowed, that is, folded and/or removably secured
against either end wall panel 146, 152 comprising end wall 204. The
user grasps the uppermost carrier 200 by its composite handle H, as
shown in FIG. 5, and carries the carrier 200 as desired, including
holding the carrier 200 at the user's side as shown in FIGS. 6 and
7, benefiting from the advantage of the angled handle H, which
prevents articles from falling out. This advantage is realized
because in the downward position, the articles are at least
somewhat upright, having upper portions at higher elevations than
lower portions.
[0051] The present invention has been illustrated in relation to
particular embodiments which are intended in all respects to be
illustrative rather than restrictive. Those skilled in the art will
recognize that the present invention is capable of many
modifications and variations without departing from the scope of
the invention. For example, as used herein, directional references
such as "top", "bottom", "end", "side", "inside", "outside",
"upper", "median", "lower", "vertical", and "horizontal" do not
limit the respective walls of the carton to such orientation, but
merely serve to distinguish these walls from one another. Any
reference to hinged connection should not be construed as
necessarily referring to a junction including a single hinge only;
indeed, it is envisaged that hinged connection can be formed from
one or more potentially disparate means for hingedly connecting
materials.
[0052] Those skilled in the art will also appreciate that the
basket-style carrier described represents only one example of the
various carrier types and configurations that will be suitable for
implementation of the various embodiments of the invention. For
example, although the upper edges of the end walls, side walls, and
partition wall are shown as being substantially straight edges,
these upper edges my have any suitable or creative shape, providing
that the highest point along such upper edge has a height less than
or equal to the height of the intended articles. Accordingly, the
scope of the present invention is described by the claims appended
hereto and supported by the foregoing.
* * * * *