U.S. patent application number 11/277076 was filed with the patent office on 2006-11-16 for carton for multiples of tapered containers.
Invention is credited to John W. JR. Cargile.
Application Number | 20060254942 11/277076 |
Document ID | / |
Family ID | 36609417 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060254942 |
Kind Code |
A1 |
Cargile; John W. JR. |
November 16, 2006 |
Carton for Multiples of Tapered Containers
Abstract
A tubular carton is configured to be erected to a first pre-load
height, and then to a second post-load height. This carton
comprises a top wall, a bottom wall, and a pair of opposed side
walls. The walls define a void of a first height for receiving
articles, such as tapered bottles. In addition, this carton
includes a structure that funnels the articles into the void, such
that the articles force the carton to flex along a score line and
at least a portion of one or more walls to retract inwardly,
thereby increasing the height of the void from a first height to a
second greater height. The funneling structure may be connected to
one of the walls and, after loading of the articles, is arranged to
seal the carton.
Inventors: |
Cargile; John W. JR.;
(Decatur, GA) |
Correspondence
Address: |
PARKS KNOWLTON LLC
1117 PERIMETER CENTER WEST
SUITE E402
ATLANTA
GA
30338
US
|
Family ID: |
36609417 |
Appl. No.: |
11/277076 |
Filed: |
March 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60664326 |
Mar 21, 2005 |
|
|
|
Current U.S.
Class: |
206/427 ;
53/456 |
Current CPC
Class: |
B65D 71/36 20130101;
B65D 2571/0066 20130101; B65D 2571/00469 20130101; B65D 2571/00141
20130101; B65D 2571/00549 20130101; B65D 2571/00574 20130101; B65D
2571/0045 20130101; B65D 2571/00913 20130101; B65D 2571/00728
20130101 |
Class at
Publication: |
206/427 ;
053/456 |
International
Class: |
B65D 65/00 20060101
B65D065/00; B65D 75/00 20060101 B65D075/00; B65B 43/08 20060101
B65B043/08 |
Claims
1. A carton configured to be erected to a first pre-load height and
then to a second post-load height; comprising: a first wall
defining opposite edges and opposite ends; a pair of opposed side
walls, defining opposite ends and upper and lower edges, said
opposed side walls connected along said lower edges to respective
edges of said first wall; a second wall defining opposite edges and
opposite ends, comprising at least one score line, said second wall
connected along said edges to respective upper edges of said
opposed side walls, said walls defining a void for receiving
articles, said second wall being spaced apart from said first wall
by said first height; at least one means for funneling said
articles into said void such that said articles apply a force to
said second wall to displace at least a portion of said second wall
such that the portion of said second wall is spaced apart from said
first wall by a second height, said score line for facilitating
said displacement, said means for funneling connected to at least
one of said walls; and, at least one end wall structure comprising
said means for funneling.
2. The carton of claim 1, wherein said second post-load height is
greater than said first pre-load height.
3. The carton of claim 1 wherein at least one of said side walls
includes a fold line for facilitating displacement of said second
wall.
4. The carton of claim 1 wherein said first height is defined by
the height of one of said side walls.
5. The carton of claim 1, wherein said first pre-load height is
greater than said second post-load height.
6. The carton of claim 1, wherein said second wall includes a fold
line for facilitating displacement of said second wall.
7. A carton configured to be erected to a first pre-load height and
then to a second post-load height; comprising: a first wall
defining opposite edges and opposite ends; a pair of opposed side
walls defining opposite ends and upper and lower edges, said side
walls connected along said lower edges to opposite edges of said
first wall and to one another along said respective upper edges to
define a void of a first height for receiving articles; at least
one score line located on at least one of said walls; at least one
means for funneling said articles into said void such that said
articles apply a force to at least one of said walls such that said
at least one score line facilitates a change in the height of said
void from said first height to said second height, said means for
funneling connected to at least one of said walls; and, at least
one end wall structure comprising said means for funneling.
8. A package, comprising: a plurality of containers and a carton
enclosing said containers, the carton comprising: a plurality of
walls, each hingedly connected to at least one other wall, defining
a void of a first configuration to receive said containers; a means
for funneling said containers into said void, said means for
funneling connected to at least one of said walls; wherein said
void is reconfigured in response to receiving said containers; and,
an end wall structure comprising said means for funneling.
9. The package of claim 8, wherein said containers comprise a first
body portion of a first dimension and a second body portion of a
second dimension;
10. A method for loading articles of a first height into a carton
of an initial lesser height, comprising: providing a tubular carton
comprising a first void defined by a plurality of walls and at
least one open end; scoring at least one of said walls; configuring
said open end to form a means for funneling; pushing said articles
through said means for funneling toward said void; directing at
least one of said articles to apply a force to at least one of said
scored walls; and, displacing at least one of said scored walls to
move from a first position to a second position under said force,
thereby converting said first void to a second void.
11. The method of claim 10, further comprising loading said
articles into said second void.
12. The method of claim 10, further comprising reconfiguring said
means for funneling into an end wall structure.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Application No.
60/664,326, filed Mar. 21, 2005, the entirety of which is
incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention taught herein relates generally to cartons for
packaging tapered containers such as bottles or other vessels with
necks, and more particularly, to special shaped cartons formed by
side-loading vertically-oriented articles of a first height into
open-ended tubular cartons of a different initial height.
BACKGROUND OF THE INVENTION
[0003] Utility cartons for encasing and transporting groups of
tapered articles are known. For example tapered articles include
conventional glass or plastic beverage bottles, beverage bottles
with spill-resistant tops, fluid dispensing containers that include
a shoulder area and a neck, and containers of all shapes wherein
the body is wider than an end. The conventional utility carton for
such applications is the ubiquitous square or rectangular cardboard
box used to pack and ship bottles that are loaded from the top
before the top flaps are sealed and the carton is shipped. An
increasingly common utility carton is the side-loaded square or
rectangular paperboard carton, wherein a column or multiple columns
of tapered articles are loaded from the side before the end flaps
are sealed and the carton is shipped.
[0004] The present utility cartons that are used for encasing and
transporting groups of tapered articles share common inadequacies.
For example, because the typical tapered article is narrower at its
top than its bottom, the typical utility carton has, proportionally
speaking, a great deal of air space within the upper portion. That
is, from about the shoulder of an article to its top, the article
is surrounded by substantial volumes of space. This particular
inadequacy yields a number of problems. First, all else being
equal, a carton with substantial volumes of space is a weakened
carton susceptible to damage during transportation. This problem is
apparent by observing cartons with crushed corners or caved top
panel, readily visible in the local grocery or liquor store.
Second, the typical remedy to eliminate wasted volume--filling the
space with packing material in an attempt to strengthen the carton
and prevent damage, wastes material and increases the cost of
manufacturing. Third, a carton with substantial volumes of space
creates an unfavorable impression with potential consumers that
sometimes results in lost sales. For example, a consumer may
falsely assume that articles are damaged because they shift within
the carton. Similarly a consumer may falsely assume the carton is
partially empty of articles when the consumer feels or hears the
looseness of the articles within the carton. Under these and
similar circumstances, the consumer sometimes avoids purchasing
otherwise satisfactory products.
[0005] Solutions have been developed that attempt to overcome the
problems associated with conventional cartons. Frequently attempted
solutions focus on providing extraneous packing material between or
around the articles. Examples of well-known packing material
include saw dust, wood shavings, crumbled paper, cloth, dividers,
foam, packing peanuts, bumpers of various materials and shapes, and
air-filled bladders of various configurations including bubble
wrap. While these solutions attempt to protect the articles and/or
strengthen the carton, the most consistent result appears to be the
increase in cost. For example, the increased cost may include the
cost of the packing materials, the cost of labor to place the
packing material, the cost to ship cartons with additional weight,
and the cost to dispose of the packing material.
[0006] Improved packing materials include thermo-formed stackable
plastic trays. These solutions have found application with
breakable food products such as cookies and soft candies. The
typical manufacturer places fragile products into specially formed
stackable plastic trays that receive and store the individual
products in spaced apart sections. While useful under certain
conditions, such solutions have the same short-comings with regard
to tapered articles as other packing materials.
[0007] Other attempts to solve the problem of shipping tapered
products include eliminating the top portion of a carton and
wrapping a group of articles in layers of plastic film. While this
solution does eliminate the problem of damaged cartons since it
eliminates all but the short base portion of a carton, it creates
its own problems. For example, this solution is generally limited
to plastic articles and is not generally suitable for glass
articles. Further, the articles are no longer protected from damage
as they are when surrounded by the walls and top of a carton. In
addition, the product information space that is available of the
exterior surface of the cartons is eliminated. This is typically
undesirable as most manufacturers rely on that area to provide
point of purchase advertisement.
[0008] A survey of the packaging arts confirms that there remains a
need for an improved apparatus and/or method for encasing and
transporting groups of tapered articles. Such improvements would
provide a stronger carton, reduce or eliminate the need for packing
materials, improve the fit of the articles, improve the feel of the
carton, and improve or at least maintain the advertising space
typically provided on the exterior of utility cartons. In addition,
to the extent the improved carton is of unique shape then the
unique shape may provide the manufacturer or distributor an
opportunity to create brand awareness through the unique packaging
shape.
SUMMARY OF THE INVENTION
[0009] The present invention with its various embodiments overcomes
the shortcomings of the prior art by providing easily constructed
cartons of special shapes. Such cartons require less material to
construct, reduce or eliminate the need for extraneous packing
materials, improve the fit of the articles, improve the feel of the
carton, increase the strength of the package as a whole, and allow
the manufacturer and or distributor a new flexibility with regard
to advertising and branding.
[0010] One embodiment of the present invention includes a blank for
making a carton. The blank includes at least five primary panels: a
bottom panel, a first side panel, a second side panel, a top panel,
and an edge panel. These panels are hingedly connected to one
another. Each of the panels is also hingedly connected to opposing
end flaps or end wall panels. When the carton is erected it takes
the shape of a tubular carton with the end flaps and end wall
panels cooperating to form end walls or end closure structures.
[0011] In this embodiment, the top panel includes scores or score
lines that divide the panel into three sections including two top
panel edge portions and a top panel center portion. The blank
further includes frangible severance lines comprising severance
line segments, which, when the carton is erected, define removable
portions known as tear panels. With regard to the severance lines
in this embodiment, severance line segments extend from one end
wall panel across the side panels and top panel before terminating
at the end of another end wall panel. When the carton is erected,
severance line segments cooperate to form a substantially
continuous frangible severance line.
[0012] Another five panel blank embodiment includes an outer top
panel, a first side panel, a bottom panel, a second side panel, and
an inner top panel that are hingedly connected to one another. Each
of the panels is also hingedly connected to opposing end flaps or
end wall panels. When the carton is erected it takes the shape of a
tubular carton with the top panels attached in an overlapping
fashion to form a composite top wall, and the end flaps and end
wall panels cooperate to form end walls or end closure
structures.
[0013] Other embodiments of blanks include less than five panels.
For example, a tubular carton with a triangular cross-section. In
one embodiment of a triangular carton, the triangular carton does
not have a top panel in the pre-load configuration, but may have a
top panel in the post-load configuration. In another embodiment,
the edge panel is eliminated in favor of a two-pieced bottom
panel.
[0014] Still other embodiments of blanks include five or more
panels, such as those including a compound top panel. A compound
top panel provides for at least a first pre-load height and at
least a second post-load height. In addition, any of the panels may
include scores used to configure the void of a carton to a special
shape.
[0015] In one embodiment, a tubular carton is configured to be
erected to a first pre-load height, and then to a second post-load
height. This embodiment comprises a top wall with at least one
score, opposite edges and opposite ends, and a pair of opposed side
walls. The sidewalls define upper and lower edges and opposite
ends, and are connected along their upper edges to the opposite
edges of the top wall. This embodiment also includes a bottom wall
with opposite edges and opposite ends, connected to the sidewalls
along the lower edges and spaced apart from the top wall. The walls
define a void of a first height for receiving articles, such as
tapered bottles. In addition, this embodiment includes a structure
that funnels the articles into the void such that the articles
force the carton to flex along the score line and at least a
portion of one or more sidewalls to retract inwardly, thereby
increasing the height of the void from a first height to a second
greater height. The funneling structure may be connected to at
least one of the ends of at least one of the walls and, after
loading of the articles, is arranged to seal the carton.
[0016] Exemplary embodiments of the present invention include
packages. One embodiment of a package includes containers and a
carton. The containers are uniformly tapered or have various body
shapes, such as a neck portion that is smaller than the largest
body portion. The carton comprises four walls in the pre-load
configuration, each wall hingedly connected to at least one other
wall. As used herein, the term "wall" will be understood to include
individual panels, parts of individual panels, and configurations
of panels, flaps, or parts thereof that form an exterior surface of
an erected or partially erected carton. That carton further
includes a configuration of end wall flaps and/or panels that
permit funneling of the containers into the void. In this
embodiment, at least one of the walls becomes reconfigured under
the pressure of loading the containers to create a post-load carton
configuration comprising no less than five walls. After
reconfiguring and loading the end wall flaps and panels are closed
to seal the package. Other embodiments comprise post-load carton
profiles of different wall configurations and counts.
[0017] The present invention includes exemplary methods for loading
articles of a first dimension into a carton of a second dimension.
In one embodiment, the method of loading comprises a number of the
following steps: providing a tubular carton that includes a
plurality of walls, includes at least one open end, and defines a
first void; scoring at least one of the walls; configuring the open
end to form a means for funneling; pushing the articles through the
means for funneling toward the void; directing at least one of the
articles to apply a force to the scored wall; displacing the scored
wall to move from a first position to a second position under the
force, thereby converting said first void to a second void; loading
the articles into said second void; and, reconfiguring the funnel
to be an end wall structure.
[0018] The exemplary methods of loading are best performed with
severance lines that do not fail or substantially separate during
loading. Further, the exemplary methods of loading are best
performed with a handle that that does not fail or substantially
separate during loading. Rather, the severance lines flex and
otherwise cooperate with the various fold lines and scores without
failing or substantially separating during the reconfiguration of a
carton from one shape to another.
[0019] 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 embodiments of the invention. Other
beneficial results can be obtained by combining various aspects of
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
[0020] FIG. 1 is a plan view of an embodiment of a blank for
forming an embodiment of a carton, according to the present
invention.
[0021] FIG. 2 is a perspective view of a partially erected carton
formed from the blank of FIG. 1, the carton show in a pre-load
configuration.
[0022] FIG. 3 is an end elevation view of a cross-section of the
partially erected carton of FIG. 2, the carton shown in a pre-load
configuration.
[0023] FIG. 4 is a perspective view of the partially erected carton
of FIG. 2, the carton shown in a post-load configuration.
[0024] FIG. 5 is an end elevation view of a cross-section of the
partially erected carton of FIG. 2, the carton shown in a post-load
configuration.
[0025] FIG. 6 is a perspective view of an embodiment of package
formed from the blank of FIG. 1, according to the present
invention.
[0026] FIGS. 7 and 8 show the pre-load and post-load configurations
of an embodiment of a carton, according to the present
invention.
[0027] FIGS. 9 and 10 show the pre-load and post-load
configurations of an embodiment of a carton, according to the
present invention.
[0028] FIGS. 11 and 12 show the pre-load and post-load
configurations of an embodiment of a carton, according to the
present invention.
[0029] FIG. 13 is a plan view of an alternative embodiment of a
blank for forming an embodiment of a carton, according to the
present invention.
DETAILED DESCRIPTION
[0030] 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 an illustration, specimen,
model or pattern. 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.
[0031] 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 an exemplary
embodiment of a carton according to the present invention. In the
embodiments described herein, the carton of the present invention
is for enclosing, shipping, storing, displaying, carrying, and
dispensing tapered articles, such as conventional beverage bottles.
Generally described, the carton is formed from a foldable sheet
material such as paperboard, corrugated board, plastic,
combinations thereof, and the like.
[0032] FIG. 1 is a plan view of an exemplary embodiment of a blank
100 for forming a carton 200, best shown in FIGS. 2, 3, 4, and 5.
The paperboard blank 100 includes at least four primary panels for
forming the carton 200: a bottom panel 102, a first side panel 104,
a second side panel 106, a top panel 108, and an edge panel 110.
The panels 102, 104, 106, 108, and 110 are hingedly connected to
one another. The bottom panel 102 is hingedly connected to the
first side panel 104 by fold line 112. The first side panel 104 is
hingedly connected to the top panel 108 by fold line 114. The
second side panel 106 is hingedly connected to the top panel 108 by
fold line 116. The edge panel 110 is hingedly connected to the
bottom panel 102 by fold line 118. In the illustrated embodiments,
a unitary blank is used to form a single carton although it should
be recognized that two or more blanks may be employed. For example,
two or more blanks may be employed to provide the structure
described in more detail below.
[0033] The blank 100 includes end flaps or end wall panels that are
hingedly connected to opposite edges of each of the panels 102,
104, 106, and 108 along transverse fold lines. When the carton 200
is erected, the end flaps and end wall panels cooperate to form end
walls or end closure structures (best shown in FIG. 6). In the
embodiment illustrated, each end closure structure is sufficiently
identical that like references have been used, with "a" or "b"
affixed to distinguish one end of the carton from the other. With
continued reference to FIG. 1, bottom panel 102 is hingedly
connected to end flaps 120a, 120b along a fold lines 122a, 122b,
respectively. First side panel 104 is hingedly connected to end
wall panels 124a, 124b along fold lines 126a, 126b, respectively.
Second side panel 106 is hingedly connected to end wall panels
128a, 128b along fold lines 130a, 130b, respectively. Top panel 108
is hingedly connected to end flaps 132a, 132b along fold lines
134a, 134b, respectively.
[0034] In the exemplary embodiment, the top panel 108 includes
scores 136, 138 that divide the top panel 108 into three sections:
top panel edge portions 140, 142 and top panel center portion 144.
End flaps 132a, 132b include recesses 146a, 146b, respectively. The
relationship between the scores 136, 138 and the recesses 146a,
146b are likewise described below with regard to closing the carton
after loading.
[0035] Blank 100 further includes mirror image frangible severance
lines 150. Each frangible severance line 150 includes severance
line segments 152, 154, and 156, which, when the carton is erected,
defines mirror image removable portions shown as tear panels T in
FIGS. 2, 4 and 6. Turning momentarily to FIG. 6, tear panel T
comprises side wall panel sections 160, 162, top panel section 164,
and end wall section 166. Because of the mirror configuration of
the tear panels T, the following description is provided regarding
one tear panel T at one side of the blank 100 only, the other tear
panel T being substantially identical. Of course, as will be
understood by those skilled in the art, in alternative embodiments
the tear panels T are not necessarily mirror configurations but of
any configuration that permits access to the articles within the
carton 200.
[0036] Returning again to FIG. 1 with regard to severance line 150,
the severance line segment 152 extends from the distal edge of end
wall panel 128a, 128b toward and across the second side panel 106
before arching toward fold line 116, where it joins the severance
line segment 154. Severance line segment 154 extends from the fold
line 116, across top panel edge portion 142, and crosses score 136
before passing proximate to a finger access cutout 170 that is
located on the top panel center portion 144. Continuing across top
panel center portion 144 severance line segment 154 crosses score
138 and extends across top panel edge portion 140 toward fold line
114. Severance line segment 156 joins severance line segment 154 at
fold line 114. From that point the line segment 156 extends across
the first side panel 104 and arches toward the end wall panel 124a,
124b before terminating at the distal edge of end wall panel 124a,
124b. When the carton is erected, severance line segments 152, 154,
and 156 cooperate to form continuous frangible severance line 150.
It is contemplated that the frangible severance line 150 includes,
but is not limited to, perforations, a line of perforations, a line
of short slits, a line of half cuts, a single half cut, any
combination of perforations, slits, and half cuts, short score
lines, or the equivalent that separate to facilitate the opening of
the carton.
[0037] The blank 100 may also include a suitable known handle H to
allow the user to carry the carton 200. With regard to the
formation of the illustrated handle H, finger access cutouts 170
having the shape of an ellipse are provided within top panel 108.
Each cutout 170 is proximate to but spaced apart from severance
line segment 154. Handle severance lines 172 extend from the major
axis of each elliptical cutout 170 and may follow the arc of
elliptical cutout 170 before veering toward scores 136, 138 and
terminating at the approximate intersection of severance line
segments 154 and fold lines 114, 116.
[0038] Handle tabs 174 are defined by the severance line segments
154 and the handle severance lines 172. Turning briefly to FIG. 4,
when the carton 200 is erected the handle H is formed by a user
grasping one or both finger cutouts 170 and squeezing with
sufficient pressure to break handle severance lines 172. The
breaking of handle severance lines 172 will allow one or more
handle tabs 174 to fold inwardly to create additional support for
the handle H and comfort for the user.
[0039] Like the severance line 150, the handle severance line 172
includes, but is not limited to, perforations, a line of
perforations, a line of short slits, a line of half cuts, a single
half cut, any combination of perforations, slits, and half cuts,
short score lines, or the equivalent. The exemplary methods of
loading are best performed with severance lines 150, 172 that do
not fail or substantially separate during loading. Further, the
exemplary methods of loading are best performed with a handle H
that that does not fail or substantially separate during loading.
Rather, the severance lines 150, 172 flex or otherwise cooperate
with the various fold lines 114, 116 and scores 136, 138, without
failing or substantially separating during the reconfiguration of a
carton from one shape to another, as will now be described.
[0040] FIG. 2 is a perspective view of a partially erected carton
200 formed from the blank of FIG. 1. To erect the illustrated
carton 200 to a first pre-load height, edge panel 110 is glued or
otherwise secured to second side panel 106 to form the open-end
tubular carton 200. The carton 200 is adapted to hold a group of
similarly dimensioned, preferably tapered, articles. For example,
the group of articles may include cans or bottles with shoulders
arranged in one or more columns. The articles in each column are
disposed vertically on their bottoms, preferably in a side-by-side
parallel fashion. As shown in FIG. 3, side walls 104 and 106 are
disposed along the side walls of the articles of the group.
[0041] When the carton 200 is erected to its pre-load height, a
configuration best shown in FIG. 2, it is understood that this
height is determined by the height of the sidewalls 104, 106. The
configuration of the carton 200 is shown as it may appear when
located on a conveyor immediately prior to being side-loaded with
the articles. FIG. 3 shows the contrast between the initial height
of the carton 200 and the height of articles B to be loaded. As
shown, the articles B are clearly taller than the sidewalls 104,
106 and rise above the height level of the top panel 108.
[0042] FIG. 3 also illustrates the various locations a score, such
as scores 136, 138, may be positioned with relation to the tapered
article B. In some embodiments the score may be proximate to a fold
line 116, 114 or proximate to the articles, as shown with regard to
the dimension W.sub.1. In other embodiments the score may be far
away from a fold line or articles, as shown with regard to
dimension W.sub.2. As used herein, the terms "score", "score line",
and "fold line" may be used interchangeably to reference a line or
line segment about which the plane of a panel or wall is angled.
Accordingly, a carton of a special shape as taught herein that is
constructed of all fold lines is the equivalent of a carton of a
special shape as taught herein with reference to both fold lines
and score lines.
[0043] Before describing one method of side-loading vertically
oriented articles of a first height into an open-ended tubular
container with an initial lesser height, remember that top panel
108 comprises two substantially parallel edge portions 140 and 142
spaced apart by a center portion 144. More specifically, edge
portion 140 is defined longitudinally by fold line 114 and score
138, edge portion 142 is defined longitudinally by fold line 116
and score 136, and center portion 144 is defined longitudinally by
scores 136, 138. One skilled in the art will recognize that
although scores 136, 138 are shown straight and parallel to each
other as well as their respective adjacent fold lines, scores 136,
138 are not limited to such a configuration or number, and may
indeed be of different and differing configurations and numbers as
required to form the special shape desired.
[0044] Those skilled in the art will further recognize that a force
directed to center portion 144 will cause the top panel 108 to fold
along scores 136, 138 as well as adjacent fold lines 114, 116 to
create three walls from the top wall. For example, with regard to
the embodiment illustrated in FIGS. 3, 5 and not by way of
limitation, the vertical force F exerted against the inner or back
surface of center portion 144 will cause top panel 108 to extend
upwardly so that the cross-section of carton 200 reconfigures from
the rectangle shown in FIG. 3 to the polyhedron shown in FIG. 5. A
carton of this configuration may be referred to as a tapered top
carton.
[0045] One embodiment of a tapered top carton may be defined by
exterior walls formed by panels or panel portions 102, 104, 140,
144, 142, and 106. Another embodiment may be defined by exterior
walls formed by panels or panel portions 102, 104, 140, 144, 142,
and 106, wherein side panels 104, 106 include scores S (shown in
FIGS. 3 and 5) that are located proximate to the shoulder of the
tapered article such that a portion of the side 104', 106' panels
may be substantially coplanar with the edge portions 140, 142 when
the carton 200 is configured as a tapered top carton. In some
embodiments, the side panels 104, 106 may bow when the carton 200
is configured as a tapered top carton. For another example,
assuming the top panel 108 is defined by fold lines 114, 116 and
comprises a single score that is parallel and equidistant to the
fold lines, a single vertical force F exerted proximate to the
score from the inner or back side will reconfigure the carton 200
from a rectangular cross-section to that of a pentahedron. A carton
of this configuration may be referred to as a gable top carton.
[0046] Turning now to describe a method of side-loading vertically
oriented articles of a first height into an open-ended tubular
container of an initial lesser second height, reference will be
made to FIGS. 2, 3, 4 and 5. As understood by one skilled in the
art, in preparation of loading articles into the carton 200, the
carton 200 is typically transported through a series of stations
via a conveyor associated with a packaging machine. Articles to be
loaded into the carton 200, such as bottles, are positioned
adjacent to and directed toward the open ends of the carton 200.
The loading direction is represented by the arrows A shown in FIG.
2. In addition, machine guides hold adjacent end wall panels 124a,
128a and 124b, 128b, and end flaps 120a, 132a and 120b, 132b back
or open so that the loading of the articles is not restricted or
otherwise hampered by any parts of the carton structure.
[0047] Further, in conventional side loading procedures where
articles of a first height are directed into a carton of a second
greater height, the articles are directed into the carton using a
means for loading. Means for loading include moving individual or
groups of articles downstream by way of back pressure. That is, the
upstream articles exert a force on the downstream articles thereby
pushing the downstream articles forward and into cartons, as also
represented by the arrows A. Means for loading also include
plungers located behind defined groups of articles pushing those
articles forward into cartons, as also represented by the arrows A.
In whatever manner articles are transported, delivered, pushed, or
otherwise directed toward and into the carton, the articles may be
side-loaded using a means for loading from either or both end
openings.
[0048] In the illustrated embodiments articles of a first height
are directed into a carton of a second lesser height. That is, as
best shown in FIG. 3 the articles B to be loaded are taller than
the height of the plane defined by the top panel 108 and upper
edges of the side walls 104, 106. Methods of loading vertically
oriented articles of a first height into an open-end tubular
container of an initial lesser second height include allowing the
articles to be used as a mandrel. Such methods of loading are
facilitated by scores, such as scores 136, 138. One advantage of
using the articles as mandrels is to create cartons of special
shapes. Cartons of special shapes may be configured to use less
material, reduce interior volume, eliminate extraneous packing
material, provide better protection for the articles, and improve
the performance characteristics of the carton including its tensile
and burst strength. Another advantage of using the articles as
mandrels is to create cartons of special shapes without the use of
special equipment.
[0049] For the purposes of teaching and not limitation, an
exemplary method of loading articles of a first height into a
carton of a second lesser height will now be described. Further,
for purposes of teaching and not limitation, the description is
directed to filled and sealed bottles B to be loaded into a carton
dimensioned for a group of articles arranged in a 2.times.6 array.
It will be understood by those skilled in the art that the
principles taught herein are applicable to tubular cartons of all
dimensions.
[0050] Closure structure elements such as end wall panels 124a,
124b, 128a, 128b and end flaps 120a, 120b, 132a, 132b may be guided
to an open position that creates a funnel. In alternative
embodiments a means for funneling includes both the end wall panels
and end flaps guided to an open position, only the end wall panels
guided to an open position, only the end flaps guided to an open
position, and, some combination of end wall panels and end flaps
guided to an open position.
[0051] Directing the bottles toward the means for funneling will
allow the tops of a first row of bottles B to brush against the
inner surface of an end flap 132a, 132b. In brushing against the
inner surface of the end flap 132a, 132b, the end flap 132a, 132b
lifts sufficiently to allow the tops of the bottles B to forceably
slide toward and under the respective fold line 134a, 134b. In
forceably sliding under the fold lines 134a, 134b, the bottles lift
the leading edge of the top panel 108 sufficiently that the top
panel 108 begins to fold along the scores 136, 138. In folding
along the scores 136,138 the top panel 108 begins its reconfigured
from the rectangular cross-section, best shown in FIG. 3, to the
polyhedron cross-section, best shown in FIG. 5.
[0052] Continuing to direct, load, or otherwise push the bottles
into the carton 200 permits the bottles to exert a force F upwardly
against the back of top panel 108. The magnitude of the force F is
dependant upon a number of factors, including the height
relationship between the bottles and the carton, the coefficient of
friction between the carton and the bottles, the composition of the
carton material, and the position and depth of the scores. In the
illustrated embodiments, the vertical force F is of a magnitude at
least sufficient to push upwardly on top panel center portion 144
so as to fold top panel 108 along scores 136, 138 but not of a
magnitude great enough to overcome the horizontal force of loading.
Stated another way, a sufficient force is that force which is great
enough to permit the bottles to act as moving mandrels to fold or
unfold panels to create a special shape without being wedged in the
carton 200 before reconfiguring and loading is successfully
completed.
[0053] After sliding under the fold lines 134a, 134b and lifting
the top panel center portion 144 such that top panel 108 begins to
unfold along scores 136, 138, the bottles B continue to load into
the carton 200. As the bottles are directed into the carton 200 by
a means for loading, the bottles continue to exert a force F
against top panel center portion 144, which in turn continues to
cause top panel 108 to fold along scores 136, 138. This sequence of
directing the bottles, exerting a force, and folding the carton 200
is one method of loading articles of a first height into a carton
of a lesser second height and in doing so increasing the height of
the carton to at least the first height. One result of this method
is the reconfiguring of a carton of substantially rectangular
cross-section, best shown in FIG. 3, to the special shaped carton
of polyhedron cross-section, best shown in FIG. 5.
[0054] In one embodiment of a method of loading, the width W.sub.1
of the top panel edge portion 140, 142, between fold line 114, 116
and respective score 138, 136, is approximately the same as the
distance from the outside edge of the container top to the furthest
outside edge of the container sidewall along the same transverse
plane. This relationship is best shown in FIG. 3. There each bottle
exerts a force proximate to the scores 136, 138 that causes the
center panel 144 to lift and the top panel edge portion 140, 142 to
rotate or fold about the respective score 136, 138 and fold line
114, 116. This configuration may be used with, by way of example
and not limitation, a container that comprises a shoulder and neck
portion such as conventional beverage bottles, automotive oil
containers with built-in spouts, liquid detergent containers with
built-in pouring features, and decorative jars containing food
products.
[0055] In another embodiment of a method of loading, the width
W.sub.1 of the top panel edge portion 140, 142, from respective
fold line 114, 116 to respective score 138, 136, is approximately
the same as the distance from the center-line of a bottle cap to
the furthest outside edge of the bottle along the same transverse
plane. There, the bottle exerts a force directly under the score
which causes the top panel edge portion to rotate or fold about the
respective score and fold line. This configuration may be used
with, by way of example and not limitation, a container that
comprises a shoulder and neck portion that further includes a
raised or severely tapered top such as the pop-up type dispenser
found on sport drink products or the spray feature found on many
articles.
[0056] Turning to FIG. 6, after the articles are grouped and loaded
through either or both of the open ends of the carton 200, the end
flaps 120a, 132a and end wall panels 124a, 128a are folded and
secured together to form end closure structures 202a, 202b. In the
embodiment shown in FIG. 6, end wall panels 124a and 128a are first
folded inwardly, followed by folding end flap 120a upwardly then
folding end flap 132a downwardly to overlap end flap 120a. End wall
panels 124a, 128a may be secured to one or both of end flaps 120a,
132a and end flaps 120a, 132a may be secured to each other. In
contrast, end wall 202a may be formed by a different sequence of
folding and securing the end wall panels 124a, 128a and end flaps
120a, 132a. The end flaps 120b, 132b and end wall panels 124b, 128b
cooperate similarly to form the opposing end closure structure
202b. Also shown here is the recess 146a, formed to reflect the
profile of the end closure structure. As shown, the recess 146a
reflects the post-load position of top panel edges 140, 142 in
order to form a carton of low profile. Alternatively, the recess
146a, 146b may be configured so that some portion of end flap 132a,
132b protrudes beyond the post-load position as part of a special
shaped carton.
[0057] Other end closure structures and means for structure closure
include partial end wall panels or end flaps that may be secured,
end wall panels or end flaps that do not overlap, end wall panels
or end flaps in the form of hoods or cowlings that may be folded
and locked on themselves or each other, caps--for example, shaped
in the form of the carton profile--that may be fastened to the open
end of the carton, and similar means for closing the carton.
[0058] Cartons of various shapes and configures will be readily
apparent based on the description provided herein, including
multi-faceted cartons with a transverse cross-section of five or
more exterior surfaces. By way of example and not limitation one
pentahedron embodiment includes a bottom panel, two side panels,
and two top panel edge portions, while another polyhedron
embodiment includes a bottom panel, two side panels each bisected
longitudinally by a score, a top panel comprising a plurality of
sets of scores, and a plurality of top panel portions. Those
skilled in the art will understand that various embodiments of
special shaped cartons, including those wherein one or more scores
and or fold lines are on either or both sides of a container top,
are taught and claimed herein.
[0059] The blank 100 preferably includes one or more means for tear
initiation, shown in FIG. 1. The means for tear initiation includes
the combination of the finger access cutout 170, the handle
severance line 172, and the severance line segment 154. FIG. 6 is a
perspective view of an embodiment of a carton after the removal of
one of the detachable tear panels T. Here, by way of example and
not limitation, the removal of tear panel T was initiated by
breaking the handle severance line 172, followed by the breaking of
severance line segments 152, 156, and the removal of the end wall
section 166. Finger access cutout 170 and the panel top section 164
cooperate to create a convenient configuration for a user to grasp
the edge of the tear panel T with one or fingers and begin tearing
the handle severance line 172. After the handle severance line 172
is broken the user may move to breaking severance lines 152, 156.
In the embodiment shown, the finger hole is defined by an
elliptical cutout dimensioned to allow at least one finger to
penetrate the carton 200 and begin breaking the handle severance
line 172. Those skilled in the art will recognize that various
known or yet to be developed means for tear initiation can be
adapted for implementation in conjunction with the embodiments of
the present invention, including but not limited to a push tab,
pull tab, flap, or loop; any combination of tabs, loops, or flaps;
or an equivalent structure for gripping a small detached portion of
a relatively larger attached structure.
[0060] With the panel T removed, a user has access to the articles
contained in carton 200. In the illustrated embodiment of FIG. 6, a
single removed panel T permits access to six bottles B. Naturally,
the remaining six bottles are accessible after the remaining panel
T is removed. As understood by those skilled in the art, other
removable panel configurations are possible as are other removable
panel configurations that provide a special dispenser. By way of
example and not limitation, severance line segments such as 152,
154, 156 may course, undulate, and otherwise meander across some or
all of the panels comprising a carton such as 104, 106, 108, 120,
124, 128, 132, to produce a removal panel or panels T of any
configuration. It is further contemplated that a removal panel may
or may not leave the handle H intact. Accordingly, side wall panel
sections 160, 162 may be of various depths and designs, as may end
wall panel section 166, according to the design considerations of
the special shapes.
[0061] FIGS. 7 and 8 illustrate the pre-load and post-load
configurations of an embodiment of the present invention. Panels
102, 104 and 106 are joined to form a pre-load tubular carton with
a substantially triangular cross-section. Scores 138 define panel
portions 140, 142 and end closure 202a restrains the items, in a
manner similar to that described above. The post-load
configuration, after the items have been inserted and used as
mandrels to reshape the carton, differs from the pre-load
configuration. Here, the items are in two columns, with the
pre-load height being taller than the post-load height.
[0062] FIGS. 9 and 10 illustrate the pre-load and post-load
configurations of an embodiment of the present invention. Panels
102, 104, 106, and 108 are joined to form a pre-load tubular carton
with a square or rectangular cross-section. Scores 138 define panel
portions 140, 142 and end closure 202a restrains the items, in a
manner similar to that described above. The post-load
configuration, after the items have been inserted and used as
mandrels to reshape the carton, differs from the pre-load
configuration. Here, the items are in three columns, with the items
in the center column being taller than the items in the adjacent
side columns.
[0063] FIGS. 11 and 12 illustrate the pre-load and post-load
configurations of an embodiment of the present invention. Panels
102, 104, 106, and 108 are joined to form a pre-load tubular carton
with a square or rectangular cross-section. Scores 138 define panel
portions 140, 142, 164 and end closure 202a restrains the items, in
a manner similar to that described above. The post-load
configuration, after the items have been inserted and used as
mandrels to reshape the carton, differs from the pre-load
configuration. Here, the items are in four columns, with the items
in the two center columns being taller than the items in the
adjacent side columns.
[0064] Turning now to FIG. 13, with an eye toward FIG. 1, we see an
alternative embodiment of a blank 300 for forming a carton
according to the present invention. Aspects of the blank 300 in
FIG. 13, correspond to the blank 100 illustrated in FIG. 1.
Therefore, the majority of elements in FIG. 13 have been identified
with a corresponding number that may be found in a substantially
similar element of FIG. 1, the difference being that the element
prefix number "1" has been substituted for the element prefix
number "3". For example, the bottom panel 102 of FIG. 1 corresponds
to the bottom panel 302 of FIG. 13. Here, the primary distinction
is that rather than forming a tubular carton by attaching the edge
panel 110 to the bottom panel 102 as described with reference to
FIG. 1, with reference to FIG. 13 a tubular carton is formed by
attaching the inner top panel 308a to the outer top panel 308b in
an overlapping manner to form a composite top wall 308. The outer
top wall 308b further includes end panels 333a, 333b. Otherwise, in
the majority of respects, the details of composition and method of
assembly of the second carton 300 are identical to those of the
first carton 100 described above.
[0065] The present invention has been illustrated in relation to
various particular embodiments which is 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 claims. For example, as used herein, directional references
such as "top", "base", "bottom", "end" "side", "inner", "outer",
"upper", "middle", "lower", "front" and "rear" do not limit the
respective panels, walls, or articles to such orientation, but
merely serve to distinguish these elements from one another. Any
reference to hinged connection should not be construed as
necessarily referring to a single fold line or score line only;
indeed, it is envisaged that hinged connection can be formed from
one or more of one of the following, a score line, a frangible line
or a fold line, without departing from the scope of the claims.
Also, the shapes and sizes of the end flaps and end wall panels are
only examples of the various end wall structures that will be
suitable for implementation of the various embodiments of the
invention. For example, the end wall structures may likewise be
tapered and the end wall structures need not entirely seal the open
ends.
[0066] It should be understood that various changes may be made
within the scope of the claims, for example, the size and shape of
the panels and apertures may be adjusted to accommodate articles of
differing size or shape, and alternative end wall structures may be
used. The carton may accommodate more than one article in different
arrangements, and articles of various heights, including a group of
articles in three or more horizontally arranged columns. Although
the severance lines 150 of FIGS. 1 and 4 are shown symmetrically,
the removable panels T and handle H may have any suitable
shape.
[0067] The above-described embodiments are merely exemplary
illustrations of implementations set forth for a clear
understanding of the principles of the invention. Variations,
modifications, and combinations may be made to the above-described
embodiments without departing from the scope of the claims. All
such variations, modifications, and combinations are included
herein by the scope of this disclosure and the following
claims.
* * * * *