U.S. patent application number 11/470565 was filed with the patent office on 2007-03-08 for carton with ice retention flaps.
Invention is credited to John M. JR. Holley.
Application Number | 20070051781 11/470565 |
Document ID | / |
Family ID | 37547737 |
Filed Date | 2007-03-08 |
United States Patent
Application |
20070051781 |
Kind Code |
A1 |
Holley; John M. JR. |
March 8, 2007 |
CARTON WITH ICE RETENTION FLAPS
Abstract
A carton for enclosing and dispensing articles that can be
configured to serve as a cooler for articles enclosed within the
carton, such as beverage cans. The carton includes retention panels
that are formed from a top wall of the carton and a pair of top end
flaps that are detachable from end walls of the carton. The
retention panels can be rotated to be coplanar with a respective
side wall and the top end flaps can be elevated with respect to the
end walls such that the retention panels and the top end flaps form
a retaining structure.
Inventors: |
Holley; John M. JR.;
(Lawrenceville, GA) |
Correspondence
Address: |
PARKS KNOWLTON LLC
1117 PERIMETER CENTER WEST
SUITE E402
ATLANTA
GA
30338
US
|
Family ID: |
37547737 |
Appl. No.: |
11/470565 |
Filed: |
September 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60714430 |
Sep 6, 2005 |
|
|
|
Current U.S.
Class: |
229/101 |
Current CPC
Class: |
B65D 5/46008 20130101;
B65D 2571/0045 20130101; B65D 2571/00728 20130101; B65D 71/36
20130101; B65D 2571/00567 20130101; B65D 2571/00141 20130101; B65D
2571/00913 20130101; B65D 5/4279 20130101; B65D 5/542 20130101;
B65D 5/0005 20130101; B65D 2571/00574 20130101; B65D 2571/0066
20130101 |
Class at
Publication: |
229/101 |
International
Class: |
B65D 5/00 20060101
B65D005/00 |
Claims
1. A container configured for enclosing articles and reconfigurable
to expand a volumetric capacity of the container, comprising: a
composite end wall formed at least in part from an inner end flap,
wherein said inner end flap is detachable at least partially from
said container such that said inner end flap is able to translate
to an elevated position with respect to said composite end wall to
at least partially define a retaining structure for expanding the
volumetric capacity of the container.
2. The container of claim 1, further comprising means for slidably
connecting said inner end flap to the container.
3. The container of claim 2, wherein: said container comprises an
adjacent wall to which said composite end wall is hingedly
connected; and said slidably connecting means comprises at least
one connecting strip having first and second opposed ends, said
first end being hingedly connected to said composite end wall, and
said second end being hingedly connected to said adjacent wall.
4. The container of claim 3, wherein said connecting strip is
foldable to form a support structure for maintaining said inner end
flap in said elevated position.
5. The container of claim 2, wherein said inner end flap comprises
a locking tab for engaging an upper edge of said composite end wall
to maintain said inner end flaps in said elevated position.
6. The container of claim 3, wherein at least a portion of said at
least one connecting strip is formed from said inner end flap.
7. The container of claim 3, wherein said at least one connecting
strip includes at least one fold line.
8. The container of claim 1, wherein said inner end flap is secured
to a detachable portion of said composite end wall, wherein said
detachable portion is detachable from said composite end wall so
that said inner end flap is detachable from said composite end
wall.
9. A blank for forming the container of claim 1.
10. A carton for enclosing articles, the carton being expandable to
contain a heat transfer agent, comprising: a pair of side walls; a
top wall having a pair of partially detachable retention panels
defined therein, each of said partially detachable retention panels
being hingedly connected to a respective one of said pair of side
walls; a pair of composite end walls, each of the composite end
walls comprising a detachable top end flap that is connected to
both of the side walls by a pair of connecting strips and that is
detachably connected to both the partially detachable retention
panels; wherein the partially detachable retention panels are
foldable to a generally upright position with respect to the side
walls, and the connecting strips slidably connect the top end flaps
to the side walls such that the top end flaps are slidable with
respect to the composite end walls after the top end flaps are
detached from the partially detachable retention panels.
11. The carton of claim 10, wherein each of the connecting strips
is formed at least in part from a respective one of the top end
flaps, and is hingedly connected to a respective one of the side
walls.
12. The carton of claim 11, wherein said each connecting strip is
further formed at least in part from the top wall.
13. The carton of claim 10, wherein the distal edges of the
partially detachable retention panels are defined by at least one
severance line, and the side edges of the partially detachable
retention panels are defined by severance lines each extending
along a hinged connection between a respective one of the top end
flaps and the top wall.
14. The carton of claim 10, wherein: each composite end wall
further comprises a bottom end flap; and each top end flap is
detachable with respect to the remainder of the composite end wall
by means of a pull tab that is secured in a face contacting
arrangement with a detachable reinforcing tab of a respective one
of the bottom end flaps, said pull tab of said each top end flap
being accessible for breaking a severance line that connects the
detachable reinforcing tab to said respective bottom end flap.
15. The carton of claim 10, wherein each top end flap further
comprises a locking tab formed therein for locking the each top end
flap in a elevated position by engaging a distal edge of the
composite end wall.
16. The carton of claim 10, further comprising: a bottom wall
opposing said top wall and hingedly connected to said side walls
and to said composite end walls; and web panels hingedly connecting
adjacent ones of the side walls and the end walls at the bottom
wall, the web panels being for preventing leakage of liquid from
the carton.
17. A blank for forming the carton of claim 10.
18. A blank for forming a carton for enclosing articles, the carton
being reconfigurable to expand a volumetric capacity of the carton,
the blank comprising: a top panel; a pair of side panels each for
being hingedly connected to opposing sides of the top panel along a
fold line; a pair of slidable end flaps each hingedly connected to
opposing ends of the top panel along a severable connection; a pair
of partially detachable retention panels defined in the top panel,
each of said partially detachable retention panels being defined at
least in part by a severance line extending along the length of the
top panel, by the fold lines, and by each severable connection; a
plurality of connecting strips for connecting each of the slidable
end flaps to side panels, each connecting strip being partially
detachable from a respective one of said slidable end flaps and
defined at least in part by a hinged connection between the each
connecting strip and the respective slidable end flap.
19. The blank of claim 18, further comprising: a bottom panel for
being hingedly connected to each of said side panels; a pair of
bottom end flaps hingedly connected to opposing ends of the bottom
panel; a pull tab formed in each of a pair of slidable end flaps;
and a detachable reinforcing tab formed in each of the bottom end
flaps; wherein the pull tabs are positioned to come into registry
with and be secured to the detachable reinforcing tabs respectively
in the erected carton.
20. The blank of claim 19, further comprising web panels hingedly
connected to each of the bottom end flaps and extending to a
respective one of side end flaps that are hingedly connected to
said side panels respectively.
Description
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/714,430, filed Sep. 6, 2005, the entirety of
which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to cartons, and more particularly to
a carton for multiple articles having a dispenser.
BACKGROUND
[0003] Consumers often purchase beverages in disposable cartons to
facilitate transporting and dispensing the beverages in various
locations, such as parks and campgrounds. It is most convenient for
the user to have the ability to dispose of the primary and
secondary packaging when the beverages have been consumed, to avoid
the need to transport empty containers back home. However, to keep
the beverages cold pending consumption, the consumer must typically
bring a separate cooler to ice the beverages down. Regardless of
whether such coolers are disposable (e.g., STYROFOAM) or reusable,
they create an extra expense and inconveniently must be discarded
or transported home. Cartons have been developed that serve as
containers, carriers, and coolers, but such cartons are typically
expensive to manufacture because superfluous sheet material is
required to accommodate the ice, and linings are needed to prevent
leakage as the ice melts.
[0004] Therefore, a heretofore unaddressed need exists in the
industry to address the aforementioned deficiencies and
inadequacies. What is needed is a carton that is inexpensive to
manufacture and that can be configured to serve as a leak resistant
cooler for containing ice in order to keep the articles contained
within the carton cold.
SUMMARY OF THE INVENTION
[0005] The various embodiments of the present invention overcome
the shortcomings of the prior art by providing a carton or other
container that can be configured to enclose articles, such as
beverage cans, and then to be opened and reconfigured to form a
retaining structure for retaining additional material, such as ice,
above or around the articles that are enclosed within the carton.
The leak resistant carton is advantageously manufactured as a
unitary structure, without requiring substantial expenditures for
additional sheet material.
[0006] Generally described, the retaining structure is formed from
a wall of the carton which is divisible into retaining panels
hingedly connected to opposing vertically disposed walls of the
carton so as to be foldably raised into an upright position along
the hinged connections, as well as from end flaps or panels that
are slidable with respect to other opposed and vertically disposed
walls of the carton. Together, the retaining panels and the
slidable end flaps approximate a chimney-like structure that
effectively extends the height of the peripheral walls of the
carton so that additional material can be poured or otherwise
placed on top of the articles.
[0007] In the exemplary embodiments, the retaining structure is
formed from the top wall of a carton. In this respect, the phrase
"top wall" simply refers to the wall that faces substantially
upward when the carton is opened and the retaining structure is
loaded with additional material, and does not limit the carton to
any particular orientation when the carton is used in any other
manner, such as during carrying or storage. The side and end edges
of the top wall are hingedly connected to the peripheral walls of
the carton, which typically include a pair of opposed side walls
and a pair of opposed end walls, all interconnected to wrap around
a group of articles that rest on a bottom wall that is also
hingedly connected to the peripheral walls. The bottom wall
generally opposes the top wall, although it is contemplated that
the top wall may be vaulted, slanted, curved, gabled, or otherwise
contoured. The top wall is divisible preferably by means of a first
severable seam extending from one end of the top wall to an
opposite end, and by additional second and third severable seams
extending along the hinged connection between the top wall and the
end walls. The first seam, which in the exemplary embodiments is
formed from parallel severance lines to approximate a tear strip,
is broken to define the centermost edges of a pair of retaining
panels. The exemplary second and third seams, each formed from a
severance line extending along the hinged connection, are broken to
define the end edges of the retaining panels as well as the
uppermost edges of a pair of slidable end flaps.
[0008] Each end wall is a composite structure that includes a
bottom end flap that is fixedly connected to the bottom and side
walls of the carton and a top end flap. It is this top end flap
that is slidable with respect to the bottom end flap, which remains
fixedly connected as the remnant of the end wall after the carton
is opened and the retaining structure is formed. Breaking the
second, and third seams frees each of the slidable top end flaps
from connection to the remainder of the carton except for a pair of
connecting strips that foldably connects each slidable top end flap
to an end of each of the side walls and optionally to the retention
panels. These connecting strips facilitate a telescoping sliding
motion upward of the slidable top end flap with respect to the
fixed bottom end flap, in which the top end flap moves from a face
contacting arrangement toward a coplanar, edge to edge arrangement
with respect to the bottom end flap. In this configuration, the
free downward extending edge of the slidable top end flap is moved
into closer proximity to, but may continue to partially overlap,
the distal upward extending edge of the bottom end flap.
[0009] As mentioned above, to form the retention structure, the top
wall is opened to liberate or to create opposing retention panels.
These retention panels form opposite sides of the chimney-like
retaining structure. The periphery of the retaining structure is
completed by raising the slidable top end flaps to form opposing
ends of the retaining structure. The connecting strips support the
slidable top end flaps in the upright position. However, according
to another aspect of certain embodiments, further support may be
provided by a locking tab that is defined by an arcuate or
otherwise suitably contoured severance line formed in each top end
flap, which locking tab comes into registry with a notch formed in
the corresponding bottom end flap. The locking tab is matingly
received in the notch to further reinforce the desired position of
the slidable top end flap.
[0010] With the retention flaps and top end flaps raised, a
material such as ice can be poured on top of the articles still
within the carton, and can be heaped up above the level of the
uppermost ends of the articles, and retained by the retaining
structure. As the ice melts, web panels that join the bottom end
flaps to adjacent side end flaps prevent the liquid from leaking
from the bottom corners of the carton. A convenient, disposable,
and inexpensive cooler is thereby achieved, the cooler having leak
resistant bottom corners.
[0011] It is contemplated that the carton can be usable in a
variety of other applications as well, including where the initial
contents of the carton are frozen and the material disposed on top
heats the contents to form a liquid or slushy consistency that is
retained by the walls of the carton.
[0012] 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 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 FIGURES
[0013] FIG. 1 is a plan view of an exemplary embodiment of a blank
for forming a carton, according to the present invention.
[0014] FIG. 2 is a perspective view of an exemplary embodiment of a
carton formed from the blank of FIG. 1.
[0015] FIGS. 3 and 4 are partial perspective views of the carton of
FIG. 2 showing certain steps of an exemplary method of forming an
end wall.
[0016] FIGS. 5 and 6 are perspective views of the carton of FIG. 2
showing certain steps in an exemplary method of opening a
dispenser.
[0017] FIG. 7 is a perspective view of the carton of FIG. 2, in an
open condition with the retaining structure erected.
[0018] FIGS. 8 and 9 are partial perspective views of the interior
of an end wall of the carton of FIG. 2, illustrating the process of
slidingly raising one of the top end flaps.
DETAILED DESCRIPTION
[0019] 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.
[0020] 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 carton for enclosing and dispensing articles. The carton can
be reconfigured to serve as a cooler for articles enclosed within
the carton, such as beverage cans. Specifically, the carton
includes panels that can be raised to extend the height of the
walls of the carton after it is opened, so that ice or other
material can be retained above and around the articles.
[0021] FIG. 1 shows a blank 100 that can be folded and secured to
form an exemplary carton 200 (shown in FIG. 2). In the illustrated
embodiment, 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, to provide a carton with a dispenser, as
described in further detail below. The blank 100 includes a number
of primary panels that are aligned along the longitudinal axis of
the blank 100 and are hingedly connected one to the next along
transverse fold lines, which are substantially perpendicular to the
longitudinal axis of the blank 100. Specifically, a bottom panel
102 is hingedly connected to a side panel 106 along a fold line
104, and the side panel 106 is hingedly connected to a top panel
110 along a fold line 108. Additionally, the top panel 110 is
hingedly connected to a handle panel 114 along a fold line 112 and
the bottom panel 102 is hingedly connected to a second side panel
116 along a fold line 118. Handle panel 114 is so named because an
optional handle aperture H is disposed therein to create a means
for carrying the carton 200. In alternative embodiments, the handle
H is omitted or disposed in another panel.
[0022] End flaps are hingedly connected to opposite ends of each
primary panel along fold lines that are substantially parallel to
the longitudinal axis of the blank 100. The end flaps at opposite
ends of each primary panel are substantially identical and
therefore like references have been used, with "a" or "b" affixed
to distinguish one end of the carton 200 from the other. As will be
described below, a first end closure structure is formed from end
flaps that are hingedly connected to what is shown in FIG. 1 as the
upper end edges of the primary panels. Specifically, a bottom end
flap 120a is hingedly connected to the upper end edge of the bottom
panel 102 along a fold line 122a, a top end flap 128a is hingedly
connected to the upper end edge of the top panel 110 along fold
lines 130a and along a foldable severance line S, and side end
flaps 124a, 132a, 136a are hingedly connected to panels 106, 114,
116 along respective fold lines 126a, 134a, 138a. It should be
noted that the foldable severance line S extends between the fold
lines 130a.
[0023] Similarly, end flaps are hingedly connected to what is shown
in FIG. 1 as the lower end edges of the primary panels. Again, it
should be understood that end flaps and other elements that have
like references with "a" or "b" affixed are substantially identical
such that a description of an element with "a" affixed sufficiently
describes the like reference with "b" affixed. Thus, for clarity, a
description of one of the like elements with an "a" or "b" affixed
may sufficiently describe all of the like elements unless a
description of each element is necessary for understanding the
invention.
[0024] Web panels 140a, 142a connect the bottom end flap 120a to
the adjacent side end flaps 124a, 136a such that the erected carton
200 can hold at least a certain amount of liquid, as described in
further detail below. Specifically, web panel 140a is hingedly
connected to side end flap 136a along fold line 144a, and is
hingedly connected to bottom end flap 120a along fold line 146a.
Similarly, web panel 142a is hingedly connected to bottom end flap
120a along fold line 148a, and is hingedly connected to side end
flap 124a along fold line 150a. In the embodiment shown, the web
panels 140a, 142a are triangular, although any suitable shape may
be utilized, with additional fold lines subdividing each of the web
panels as needed.
[0025] The blank 100 further includes connecting strips 152a, 154a
that facilitate a telescoping end wall feature, which will be
described in more detail below. As will be described in detail
below, the connecting strips 152a, 154a function to connect the top
end flap 128a to the side panel 106 and to the handle panel 114,
respectively. Each connecting strip 152a, 154a is formed in part
from top end flap 128a and in part from top panel 110. More
specifically, connecting strip 152a is defined by a fold line 162a
in the top end flap 128a that is offset from the fold line 130a, a
portion of a side edge 156a of top end flap 128a that extends
between the outermost ends of fold lines 130a, 162a, a severance
line 158a that is offset from the side edge 156a and extends
between the innermost end of fold line 130a and the innermost end
of fold line 162a, a segment of the fold line 108, and a severance
line 160a that extends diagonally from the intersection of fold
line 130a and severance 158a to or toward fold line 108. Connecting
strip 154a is similarly defined by side edge 164a, severance lines
166a, 168a, and fold lines 112, 170a.
[0026] Each connecting strip 152a, 154a may include a number of
fold lines Fi, Fd that facilitate forming a support structure or a
gusset style arrangement to maintain the top end flap 128a in an
elevated position and facilitate a sliding or telescoping feature
of the top end flap 128a, as described in further detail below. In
the exemplary embodiment, an intermediate fold line Fi is disposed
between and parallel to fold lines 130a, 162a. Further, diagonal
fold lines Fd extend between each of the fold lines 162a, 130a and
the intermediate fold line Fd. In the exemplary embodiment, the
diagonal fold lines Fd are substantially parallel to the severance
line 160a. The pattern of fold lines Fi, Fd that is disposed on
each of the other connecting strips is substantially similar.
[0027] As used herein, the phrase "frangible line" or "severance
line" includes, but is not limited to, perforations, a line of
perforations, a printed "cut here" line, 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.
[0028] The top and bottom end flaps 128a, 120a include features
that are secured together to detachably connect the top and bottom
end flaps 128a, 120a when an end closure structure is formed, as
described in further detail below. A severance line 172a is
disposed in the top end flap 128a near severance line S and is
shaped to define a yieldable pull tab 182a. A severance line 174a
is formed near an outer edge 176a of bottom end flap 120a and is
shaped to define a severable reinforcing tab 184a. The placement of
the severance lines 172a, 174a is selected to bring the pull tab
182a and the reinforcing tab 184a into registry when an end closure
structure of the carton 200 is formed.
[0029] A tear strip T is substantially centered on the top panel
110 and extends across the top panel 110 between the top end flap
128a and the top end flap 128b. The tear strip T is defined by two
substantially parallel severance lines 178, 180. In certain
embodiments, a pull tab (not shown) may be disposed at one end of
the tear strip T as a means for tear initiation. In other
embodiments, one or both ends of the tear strip may be defined by a
segment of the severance line S that extends between the severance
lines 178, 180. In addition, in certain embodiments the severance
lines 160a, 168a, and the severance line S extending therebetween,
form a substantially continuous severance line that extends between
the fold lines 108, 112. In other embodiments, the otherwise
continuous severance line may be interrupted by one or more
frangible connections between the adjacent sections of the blank.
The tear strip T and the severance lines S, 160a, 168a define
separable portions of the top panel 110, as described in further
detail below. It should be understood that, in alternative
embodiments, the tear strip T may be replaced by a single severance
line, a cut line, or any other suitable means for controllably
separating portions of the top panel 110 along an edge.
[0030] It is envisaged that, in any embodiment of the present
invention, the carton can be formed from a blank by a series of
sequential folding and gluing operations, which can be performed by
a straight-line automatic packaging machine so that the carton is
not required to be rotated or inverted to complete its
construction. It is also envisaged that the series of sequential
folding and gluing operations can be manually performed. The
folding process is not limited to that described below and can be
altered according to particular manufacturing or user
requirements.
[0031] According to an exemplary method, the carton 200 can be
partially constructed and preglued or otherwise secured as a
tubular structure which may be collapsed for shipping or for
loading into an automatic packaging machine. To do so, the side
panel 116 is folded inwardly along fold line 118 such that the
inside surface of the side panel 116 is in a face contacting
arrangement with the inside surface of bottom panel 102. Glue, or
other means for securing sheet material, is applied to the outside
surface of the side panel 116 and to the outside surface of each of
the side end flaps 136a, 136b such that, as the blank 100 is folded
inwardly along fold line 108, the inside surface of handle panel
114 is brought into an at least partially overlapping face
contacting arrangement with the outside surface of the side panel
116. Thereby, the side panel 116 and the handle panel 114 are
secured to one another to form a composite side panel 114/116.
Additionally, the inside surfaces of side end flaps 132a, 132b are
also brought into an at least partially overlapping face contacting
arrangement with the outside surfaces of side end flaps 136a, 136b,
thereby forming composite side end flaps 132a/136a, 132b/136b. The
sheet material of the blank 100 can be secured together by any
known or yet to be developed means for securing sheet material
including, but not limited to, glue or other adhesives, staples,
tape, mechanical fasteners, Velcro.RTM., and the like.
[0032] The partially erected carton 200 is now in a flattened
tubular configuration suitable for storage, shipping, and loading
either manually or by means of an automatic packaging machine (not
shown). To erect the flattened carton into a tubular structure
having walls defined by the primary panels, the primary panels are
pulled apart. Accordingly, referring to FIGS. 1 and 2, the bottom
panel 102 defines bottom wall 202, side panel 106 defines side wall
206, top panel 110 defines top wall 210, and composite side panel
114/116 defines side wall 214.
[0033] As best shown in FIGS. 6 and 7, the articles B are arranged
in the carton 200 in a matrix formation with sides thereof
substantially parallel to the side walls 206, 214 and opposite ends
thereof substantially adjacent to the top and bottom walls 210,
202. The matrix consists of several rows and columns of articles B.
The first, or endmost, article B in each row is a member of a first
column of articles, the second article B in each row is a member of
a second column, and so on.
[0034] After the articles are grouped and loaded through either or
both of the open ends of the carton 200 as it is arranged as a
tubular structure, the end flaps are folded and secured together to
form end closure structures at each open end of tubular structure
and thereby define the end walls 204, 208. For clarity, the
formation of only one of the end closure structures is
described.
[0035] Referring to FIG. 3, to form the composite end wall 208
(shown in FIG. 5), the top end flap 128b is folded downward toward
the interior of the carton 200 and adhesive or other means for
securing is then applied to the outside surface of pull tab 182b.
To ensure the ability of the innermost portion of the end wall 208,
top end flap 128b, to move freely with respect to bottom end flap
120b and the side end flaps 124b, 132b/136b, no adhesive is applied
to the remainder of top end flap 128b. Referring to FIG. 4, the
side end flaps 124b, 132b/136b are folded inwardly and adhesive is
applied to the outside surfaces thereof. As the side end flaps
124b, 132b/136b are folded inwardly, the web panels 140b, 142b that
connect the side end flaps 124b, 132b/136b to the bottom end flap
120b cause the bottom end flap 120b to be folded upward or inward
so as to be at an angle with respect to the bottom wall 202. The
bottom end flap 120b is then folded fully upward such that the
inside surface of the bottom end flap 120b overlies the outside
surface of the top end flap 128b and the outside surfaces of the
side end flaps 124b, 132b/136b. Thereby, the bottom end flap 120b
is secured to the side end flaps 124b, 132b/136b and the inside
surface of reinforcing tab 184b is secured to the outside surface
of pull tab 182b to define a composite tab 182b/184b to complete
the end closure structure that defines end wall 208. The end
closure structure that defines end wall 204 is formed in a similar
fashion.
[0036] It should be noted that the web panels 140a, 142a provide
that the corners of the carton adjacent the bottom wall 202 of the
carton are continuous or seamless such that the carton can retain a
certain level of liquid. In other words, liquid is not allowed to
escape between an end wall 204, 208 and an adjacent side wall 206,
214 at or near the bottom wall 202 of the carton 200.
[0037] An exemplary method for opening the carton and forming the
retaining structure R of the carton 200 is now described. With
reference to FIG. 5, a user engages an end of the tear strip T and
tears the tear strip T away from the carton 200 along a first seam
formed by severance lines 178, 180, thereby dividing the top wall
210 and defining the centermost or distal edges of the retention
panels 602, 604, as shown in FIG. 6. The retention panels 602, 604
are further separated from the top wall 210 along second and third
seams as the centermost edge of each of the retention panels 602,
604 is pulled outwardly so as to separate its end edges from the
adjacent end walls 204, 208, and more specifically from the
adjacent top end flap 128a, 128b, along segments of the severance
lines S and along severance lines 160a, 160b, 168a, 168b to
partially detach the respective retention panel 602, 604. The
retention panels 602, 604 then can be folded outwardly along
respective fold lines 108, 112 to a generally upright position
(shown in FIG. 7). For example, the exemplary retention panels 602,
604 are substantially coplanar with a respective side wall 214,
206, although it is contemplated that the retention panels 602, 604
may bow outward or lean inwardly somewhat with respect to the
respective side wall 214, 206.
[0038] The retaining structure R is further erected by pulling the
top end flaps 128a, 128b such that they telescope upward with
respect to the respective end wall 202, 208. To do so, composite
tab 182b/184b is pressed inward (or outward) to break severance
lines 174b and 172b, which are in registry. By doing so,
reinforcing tab 184b, which is secured to pull tab 182b, is
completely detached from bottom end flap 120b and pull tab 182b is
partially detached from top end flap 128b. Then the pull tab 182b
is pulled upward to break the severance lines 158b, 166b while
urging the top end flap 128b to slidingly telescope upward with
respect to the end wall 208 (shown in FIGS. 8 and 9). In certain
alternative embodiments, the severance lines 158b, 166b are
replaced by cut lines.
[0039] Referring to FIGS. 8 and 9, the top end flap 128b can be
easily pulled upward so as to slidingly telescope with respect to
the end wall 208 at least in part because the top end flap 128b is
now only attached to the side walls 206, 214 by the connecting
strips 152b, 154b. Once it reaches the elevated position shown in
FIGS. 7 and 9, the top end flap 128b is retained in the elevated
position by the connecting strips 152b, 154b, as the connecting
strips 152b, 154b are folded to form a structure that is able to
support the top end flap 128b. It should be understood that the top
end flap 128a can be pulled upward to an elevated position in a
similar manner. In certain embodiments, the carton 200 may include
additional features to retain the top end flaps 128a, 128b in
elevated positions, as described in further detail below.
[0040] For example, in the embodiment shown, a locking tab 185a,
185b is defined by a severance line 190a, 190b (shown in FIG. 1) in
each of the top end flaps 128a, 128b. The locking tab 185a, 185b is
an example of a locking means for retaining the top end flap 128a,
128b in the elevated or raised position described above. The
locking feature fixes the amount of extension of the top end flap
128a, 128b above the respective end wall 204, 206 and the angle of
deflection of the top end flap 128a, 128b with respect to the
respective end wall 204, 208, thereby preventing the top end flaps
128a, 128b from failing by sinking back down into the carton 200 or
by deflecting severely so as to allow the ice to tumble out. To use
the locking feature, the severance line 190a, 190b is broken, and
the locking tab 185a, 185b is pushed through the notch 195a (not
shown), 195b (shown in FIG. 7) formed in and integral to the upper
edge 176a, 176b of respective bottom end flap 120a, 120b after the
reinforcing tab 184a, 184b is detached--thereby fixing the elevated
position of the top end flap 128a, 128b in the raised position.
Specifically, the inside surface of the locking tab 185b is
substantially in flat face contact with and locked against the
outside surface of the end wall 208. As an added benefit, the
raised retention panels 602, 604 are less likely to deflect due to
the natural tendency of the side walls 206, 214 to bow outward
somewhat when the carton is loaded.
[0041] As another example, the retention panels 602, 604 and the
top end flaps 128a, 128b can be interlocked to fortify the
retaining structure R. It is contemplated that the side edges of
each of these panels may be contoured to form complementary tabs
and notches that matingly interlock to fix the position of each
flap 602, 604, 128a, 128 relative to its neighboring flaps.
[0042] With retention panels 602, 604 and the top end flaps 128a,
128b disposed in a generally upright condition or otherwise
extending to form a chimney-like retaining structure, the carton
200 can function as a disposable cooler, ice bucket, or ice pail in
that the carton 200 is configured to receive, for example, ice or a
similar coolant, which may be poured over the articles B. The
retention panels 602, 604 and the top end flaps 128a, 128b function
as retaining walls to keep the ice in the container or to otherwise
increase the volumetric capacity of the carton 200. As previously
described, as the ice melts, the web panels 140a, 140b, 142a, 142b
disposed at the bottom four corners of the carton 200 create a
barrier to prevent the water from flowing out through the corners.
Further, in certain embodiments, the carton includes other means
that increase the ability of the carton to withstand water soaking
through the walls of the carton or that otherwise includes features
that preserve the structural integrity of the walls. For example,
inside surface of the blank for forming the carton may be treated
with a water resistant coating. In other embodiments, the carton
may include a film or liner for at least the interior of the
carton. A film or liner can also provide or enhance the water
retaining functionality that is described above with respect to the
web panels.
[0043] 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. 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
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.
[0044] Those skilled in the art will also appreciate that the
carton described represents only one example of the various sizes,
shapes, types and carton configurations that will be suitable for
implementation of the various embodiments of the invention, which
is primarily directed to the end wall structure and opening feature
that yields retaining walls for holding ice in contact with the
articles within the carton.
[0045] All such variations, modifications, and combinations are
included herein by the scope of this disclosure and the following
claims.
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