U.S. patent application number 13/230592 was filed with the patent office on 2012-03-15 for carton with improved strength sidewall panels.
This patent application is currently assigned to ORANGE COUNTY CONTAINER GROUP LLC. Invention is credited to Gregory Vorce Hall, Rafael Gonzalez Rosas.
Application Number | 20120061456 13/230592 |
Document ID | / |
Family ID | 45805680 |
Filed Date | 2012-03-15 |
United States Patent
Application |
20120061456 |
Kind Code |
A1 |
Rosas; Rafael Gonzalez ; et
al. |
March 15, 2012 |
CARTON WITH IMPROVED STRENGTH SIDEWALL PANELS
Abstract
A carton formed from a blank of foldable corrugated sheet
material having two pairs of upstanding generally parallel sidewall
panels and a pair of first flaps hingedly foldably connected to the
upper and lower edges of each sidewall panel along a fold line, the
flaps configured to form a panel for covering the bottom and top of
the carton when the carton is assembled and wherein cuts for
support tabs are made into the corrugated material along the fold
lines such that when the cover-forming flaps are folded 90 degrees
to form the bottom cover of the carton, the support tabs remain
oriented in the planes of the sidewall panels. The carton may
further comprise cuts for corner support tabs made into the
corrugated material at each of the locations where the fold lines
overlap adjacent sidewall panels, such that when the cover-forming
flaps are folded 90 degrees to form the bottom or top cover of the
carton, the corner support tabs remain oriented in the planes of
the sidewall panels.
Inventors: |
Rosas; Rafael Gonzalez;
(Playas de Rosarito, MX) ; Hall; Gregory Vorce;
(La Mesa, CA) |
Assignee: |
ORANGE COUNTY CONTAINER GROUP
LLC
City of Industry
CA
|
Family ID: |
45805680 |
Appl. No.: |
13/230592 |
Filed: |
September 12, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61381610 |
Sep 10, 2010 |
|
|
|
Current U.S.
Class: |
229/117.01 |
Current CPC
Class: |
B65D 5/443 20130101;
B65D 5/0227 20130101 |
Class at
Publication: |
229/117.01 |
International
Class: |
B65D 5/36 20060101
B65D005/36 |
Claims
1. A carton formed from a blank of foldable corrugated sheet
material comprising: two pairs of upstanding, generally parallel
sidewall panels; a pair of first flaps hingedly foldably connected
to each of the first pair of said parallel sidewall panels along a
fold line, the flaps configured to form a panel for covering the
bottom of the carton when the carton is assembled, and wherein cuts
for support tabs are made into the corrugated material along the
fold lines such that when the cover-forming flaps are folded 90
degrees to form the bottom cover of the carton, the support tabs
remain oriented in the plane of the respective sidewall panel.
2. The carton according to claim 1 further comprising a pair of
second flaps hingedly foldably connected to each of the first pair
of said parallel sidewall panels along a fold line, the flaps
configured to form a panel for covering the top of the carton when
the carton is assembled, and wherein cuts for support tabs are made
into the corrugated material along the fold lines such that when
the cover-forming flaps are folded 90 degrees to form the top cover
of the carton, the support tabs remain oriented in the plane of the
respective sidewall panel.
3. The carton according to claim 1 further comprising a pair of
second flaps hingedly foldably connected to each of the second pair
of said parallel sidewall panels along a fold line, the flaps
configured to form a portion of a panel for covering the bottom of
the carton when the carton is assembled, and wherein cuts for
corner support tabs are made into the corrugated material at each
of the four locations where the fold lines extend across adjacent
sidewall panels such that when the cover-forming flaps are folded
90 degrees to form the bottom cover of the carton, the corner
support tabs remain oriented in the planes of the sidewall
panels.
4. A carton formed from a blank of foldable corrugated sheet
material comprising: two pairs of upstanding, generally parallel
sidewall panels; a pair of first flaps hingedly foldably connected
to each pair of said parallel sidewall panels along a fold line,
the flaps configured to form a panel for covering the bottom of the
carton when the carton is assembled, and wherein cuts for corner
support tabs are made into the corrugated material at each of the
four locations where the fold lines extend across adjacent sidewall
panels such that when the cover-forming flaps are folded 90 degrees
to form the bottom cover of the carton, the corner support tabs
remain oriented in the planes of the sidewall panels.
5. The carton according to claim 4 further comprising a pair of
second flaps hingedly foldably connected to each pair of said
parallel sidewall panels along a fold line, the flaps configured to
form a panel for covering the top of the carton when the carton is
assembled, and wherein cuts for corner support tabs are made into
the corrugated material at each of the four locations where the
fold lines extend across adjacent sidewall panels such that when
the cover-forming flaps are folded 90 degrees to form the top cover
of the carton, the corner support tabs remain oriented in the
planes of the sidewall panels.
6. A carton formed from a blank of foldable corrugated sheet
material comprising: at least three upstanding sidewall panels; a
flap hingedly foldably connected to each of at least two of said
sidewall panels along a fold line, the flaps configured to form a
panel for covering the bottom of the carton when the carton is
assembled, and wherein cuts for support tabs are made into the
corrugated material along the fold lines such that when the
cover-forming flaps are folded 90 degrees to form the bottom cover
of the carton, the support tabs remain oriented in the plane of the
respective sidewall panel.
7. The carton according to claim 6 further comprising a flap
hingedly foldably connected to each of at least two of said
sidewall panels along a fold line, the flaps configured to form a
panel for covering the top of the carton when the carton is
assembled, and wherein cuts for support tabs are made into the
corrugated material along the fold lines such that when the
cover-forming flaps are folded 90 degrees to form the top cover of
the carton, the support tabs remain oriented in the plane of the
respective sidewall panel.
8. The carton according to claim 6 wherein the carton comprises
three sidewall panels and wherein cuts for corner support tabs are
made into the corrugated material at each of at least three
locations where the fold lines extend across adjacent sidewall
panels such that when the cover-forming flaps are folded 90 degrees
to form the top cover of the carton, the corner support tabs remain
oriented in the planes of the sidewall panels.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of priority under 35 U.S.C.
Section 119(e) to U.S. Provisional application Ser. No. 61/381610,
filed Sep. 10, 2010, entitled "Carton With Angled Corner Panels,"
which is hereby incorporated herein by reference.
Field of the Invention
[0002] The present invention relates to cartons with sidewall
panels having improved resistance to distortion from vertical
loads.
BACKGROUND OF THE INVENTION
[0003] Many cartons containing products are stored or transported
under conditions in which vertical pressures are imposed upon the
cartons from applied loads such as in multiple layer stacked
configurations. Accordingly, to provide protection for the
products, cartons must have substantial vertical strength to
prevent buckling and deformation.
SUMMARY OF PARTICULAR EMBODIMENTS OF THE INVENTION
[0004] The present invention, in one embodiment, provides a carton
formed from a single sheet of corrugated material, having three or
more sidewall panels and one or more foldable flaps at the upper
and lower edges of the sidewall panels. These flaps may form the
bottom and top panels of the carton. These cover-forming flaps may
have tab-shaped cuts in the corrugated material along the fold line
to form support tabs along the upper and lower edges of the
sidewall panels, when the cover-forming flaps are folded 90 degrees
to form the cover of the carton. The top surfaces of these support
tabs are formed by cuts in the corrugated material along a plane
orthogonal to the vertically-oriented flutes of the corrugated
material, and parallel to the bottom and top panels of the carton.
These support tabs form portions of the upper and lower edges of
the sidewall panels, which are cut, as opposed to folded, such that
the upper and lower surfaces of the vertically-oriented corrugated
material of the support tabs maintains the open flute
configuration. This open flute configuration of the upper tab
surface provides a substantially flat and wider load-bearing
surface with greater resistance to buckling and distortion than
folded edges, which necessarily crimp the flutes in the corrugated
material. This support tab configuration at the top and bottom
edges of the wall panels also provides wall panels which are strong
and prevent crushing of the container during storage or handling
operations. The support tabs are preferably dimensioned to extend
slightly above the bottom and top panels of the carton, which are
formed by the folding of the flaps at the upper and lower edges of
the sidewall panels. Thus, the carton will rest on top of a
supporting surface by contact with the lower surfaces of the
vertically-oriented corrugated material of the support tabs on the
lower edges of the sidewall panels. The support tabs provide
support along the outer perimeter of the bottom panel of the
carton, much like the legs of a table, resulting in improved
stability, particularly when compared to conventional cartons with
folded bottom panels, which may tend to bulge or bow towards the
center. By the use of support tabs along the folds between the
sidewalls and the bottom and top panels of the carton, this
configuration provides a more stable top and bottom surface for
resting on a flat supporting surface and for stacking of cartons in
multiple layers.
[0005] Additionally, because the portions of the upper and lower
edges of the sidewall panels where the support tabs are formed are
cut rather than folded, the edges formed along the folded corners
between the sidewalls and the bottom and top panels of the carton
are more nearly perpendicular, thus reducing or eliminating the
bulging that may result in the sidewall and top and bottom panels
of the carton. By allowing a more nearly perpendicular fold between
the sidewalls and the bottom and top panels of the carton, this
configuration provides a more stable top and bottom surface for
resting on a flat supporting surface and for stacking of cartons in
multiple layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The above mentioned and other features and objects of this
invention and the manner of attaining them will become more
apparent and the invention itself will be better understood by
reference to the following description of an embodiment of the
invention taken in conjunction with the accompanying drawings.
[0007] FIG. 1 is a perspective view of the assembled carton
according to the present invention illustrating the support tabs
cuts along the fold line between the flaps and the upper and lower
edges of the sidewall panels and the resulting fluted bearing
surfaces at the corners and around the perimeters of the bottom and
top panels of the carton.
[0008] FIG. 2 is a plan view of the interior face of an unjoined,
unfolded blank for the carton of FIG. 1.
[0009] FIG. 3 is a plan view of a joined, unfolded blank of FIG.
2.
[0010] FIG. 4 is a perspective view of a portion of the assembled
carton of FIG. 1 illustrating the orthogonal cuts along the fold
line between the flaps and the upper and lower edges of the
sidewall panels and the resulting fluted bearing surfaces at the
corners and around the perimeters of the bottom and top panels of
the carton.
[0011] FIG. 5 is a perspective view of the assembled carton
according to another embodiment of the present invention
illustrating the support tabs cuts along the fold line between the
flaps and the upper and lower edges of the sidewall panels and the
resulting fluted bearing surfaces at the corners of the bottom and
top panels of the carton.
[0012] FIG. 6 is a plan view of the interior face of an unjoined,
unfolded blank for the carton of FIG. 5.
[0013] FIG. 7 is a plan view of a joined, unfolded blank of FIG.
6.
[0014] FIG. 8 is a perspective view of a portion of the assembled
carton of FIG. 5 illustrating the orthogonal cuts along the fold
line between the flaps and the upper and lower edges of the
sidewall panels and the resulting fluted bearing surfaces at the
corners of the bottom and top panels of the carton.
[0015] Corresponding reference characters indicate corresponding
parts throughout the several views of the drawings.
[0016] The drawings illustrate, among other things, various
examples of embodiments of the invention, and certain examples of
characteristics thereof. Other embodiments may differ. Different
embodiments of the invention include various combinations of
elements or acts shown in the drawings, described herein, known in
the art, or a combination thereof, for instance.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0017] Referring to FIGS. 1 and 2, according to one embodiment of
the present invention, there is shown a carton 10 which is formed
of a sheet blank 12 of corrugated material, such as cardboard or
the like. As shown in FIG. 2, the unitary blank 12 includes
sidewall panels 14, 16, 18 and 20. In this preferred embodiment,
sidewall panels 14 and 18 constitute one pair of parallel sidewall
panels, and sidewall panels 16 and 20 constitute another pair of
parallel sidewall panels.
[0018] As shown in FIG. 2, cuts for the support tabs 22 are made
into the corrugated material along the horizontal fold lines 50.
These cuts form the support tabs 22 along the upper and lower edges
of the sidewall panels when the cover-forming flaps 30, 32, 38 and
40 are folded 90 degrees along the horizontal fold lines 50 to form
the top and bottom covers of the carton 46 and 48 (not visible), as
shown in FIG. 1.
[0019] Also as shown in FIG. 2, cuts for corner support tabs 24 may
also be made into the corrugated material along the horizontal fold
lines 50 where they extends across adjacent sidewall panels such
as, for example, across adjacent sidewall panels 14 and 16, or
across adjacent sidewall panels 18 and 20. These cuts for corner
support tabs 24 will form the 90 degree corner support tabs 24
along the upper and lower edges of the sidewall panels when the
adjacent sidewall panels 14, 16, 18 and 20 of the unfolded blank 12
are folded 90 degrees from one another to form the two pairs of
parallel side panels of a four-sided carton, and the cover-forming
flaps 30, 32, 38 and 40 are folded 90 degrees along the horizontal
fold lines 50 to form the top and bottom covers of the carton 46
and 48, as shown in FIG. 1.
[0020] It should be noted that FIG. 2 illustrates the interior face
of the blank 12, and the dotted lines 26 are vertical fold lines
between adjacent sidewall panels 14, 16, 18 and 20 along which
blank 12 is folded inwardly toward the viewer in order to form the
wall panels thereof as further described hereinafter. Similarly,
the dotted lines 50 are the horizontal fold lines along which the
cover-forming flaps 30, 32, 38 and 40 are folded 90 degrees
inwardly toward the viewer from the sidewall panels 14, 16, 18 and
20 in order to form the top and bottom covers of the carton 46 and
48, as shown in FIG. 1.
[0021] An overlap portion 28 adjoins sidewall 20 whereby, when
blank 12 is joined, overlap portion 28 may be secured to sidewall
14 such as by means of an adhesive.
[0022] FIG. 3 illustrates a blank 12 in a joined configuration,
such that overlap portion 28 has been secured to sidewall 14, such
as by means of an adhesive.
[0023] As shown in FIGS. 1 and 2, a top flap 30 adjoins sidewall 14
at the top and bottom flap 38 adjoins sidewall 14 from the bottom.
Similarly, top flap 32 adjoins sidewall 18 at the top, and bottom
flap 40 adjoins sidewall 18 at the bottom.
[0024] Also as shown in FIGS. 1 and 2, a top flap 34 also adjoins
sidewall 16 at the top and bottom flap 42 adjoins sidewall 16 from
the bottom. Similarly, top flap 36 adjoins sidewall 20 at the top,
and bottom flap 44 adjoins sidewall 20 at the bottom.
[0025] Also as shown in FIGS. 1, and 4, in a preferred embodiment
of the present invention, the top flaps 30, 32, 34 and 36 of the
respective upstanding sidewall panels 14, 18, 16 and 20 are folded
and sealed to form the top panel 46 of the carton 10. Similarly,
bottom flaps 38, 40, 42 and 44 of the respective upstanding
sidewall panels 14, 18, 16 and 20 are folded and sealed to form the
bottom panel 48 of the carton 10.
[0026] As shown in FIGS. 1 and 4, when the cover-forming flaps are
folded 90 degrees to form the cover of the carton, the cuts along
the horizontal fold lines 50 form the support tabs 22 along the
upper and lower edges of the sidewall panels and the 90 degree
corner support tabs 24 at the upper and lower corners of the
sidewall panels.
[0027] As shown in FIGS. 1 and 4 the upper surfaces of the support
tabs 22 and the 90 degree corner support tabs 24 are cut such that
the vertically-oriented corrugated material of the tabs maintains
the open flute configuration, thus providing a substantially flat
and wider load-bearing surface with greater resistance to buckling
and distortion than folded edges, which necessarily crimp the
flutes in the corrugated material. This support tab and corner
support tab configuration at the top and bottom edges of the wall
panels also provides wall panels which are strong and prevent
crushing of the container during storage or handling
operations.
[0028] Also as shown in FIGS. 1 and 4, the support tabs 22 and
corner support tabs 24 are preferably dimensioned to extend
slightly above the bottom and top panels of the carton formed by
the folding of the flaps at the upper and lower edges of the
sidewall panels. Thus, the carton will rest on top of a supporting
surface by contact with the lower surfaces of the
vertically-oriented corrugated material of the support tabs 22 and
corner support tabs 24 on the lower edges and corners of the
sidewall panels.
[0029] Alternatively, the support tabs 22 and corner support tabs
24 may be dimensioned to extend at or near the upper and lower
surfaces of the top panel 46 and bottom panel 48 of the carton 10
formed by the folding of the flaps at the upper and lower edges of
the sidewall panels. By selectively dimensioning the support tabs
22 and corner support tabs 24, the bearing load may be distributed
as desired between the support tabs 22 and corner support tabs 24,
and the upper and lower surfaces of the top panel 46 and bottom
panel 48 of the carton 10.
[0030] Also as shown in FIGS. 1 and 4, the corner support tabs 24
form a 90 degree self-reinforcing structure having substantial
strength, rigidity, and resistance to crushing or deformation.
[0031] FIGS. 5-8 depict another embodiment of the present invention
illustrating the corner support tabs 24 cuts along the horizontal
fold lines 50 between the flaps and the upper and lower edges of
the sidewall panels and the resulting fluted bearing surfaces at
the corners of the bottom and top panels of the carton.
[0032] As shown in FIGS. 5, and 8, in this preferred embodiment of
the present invention, the top flaps 30, 32, 34 and 36 of the
respective upstanding sidewall panels 14, 18, 16 and 20 are folded
and sealed to form the top panel 46 of the carton 10. Similarly,
bottom flaps 38, 40, 42 and 44 of the respective upstanding
sidewall panels 14, 18, 16 and 20 are folded and sealed to form the
bottom panel 48 (not shown) of the carton 10.
[0033] Also as shown in FIGS. 5 and 8, when the cover-forming flaps
are folded 90 degrees to form the cover of the carton, the cuts
along the horizontal fold lines 50 form the 90 degree corner
support tabs 24 at the upper and lower corners of the sidewall
panels.
[0034] As shown in FIG. 6, cuts for corner support tabs 24 are made
into the corrugated material along the horizontal fold lines 50
where they extends across adjacent sidewall panels such as, for
example, across adjacent sidewall panels 14 and 16, or across
adjacent sidewall panels 18 and 20. These cuts for corner support
tabs 24 will form the 90 degree corner support tabs 24 along the
upper and lower edges of the sidewall panels when the adjacent
sidewall panels 14, 16, 18 and 20 of the unfolded blank 12 are
folded 90 degrees from one another to form the two pairs of
parallel side panels of a four-sided carton, and the cover-forming
flaps 30, 32, 38 and 40 are folded 90 degrees along the horizontal
fold lines 50 to form the top and bottom covers of the carton 46
and 48, as shown in FIG. 5.
[0035] As shown in FIGS. 5 and 8, the corner support tabs 24 are
preferably dimensioned to extend slightly above the bottom and top
panels of the carton formed by the folding of the flaps at the
upper and lower edges of the sidewall panels. Thus, the carton will
rest on top of a supporting surface by contact with the lower
surfaces of the vertically-oriented corrugated material of the
corner support tabs 24 on the lower edges and corners of the
sidewall panels.
[0036] Alternatively, the corner support tabs 24 may be dimensioned
to extend at or near the upper and lower surfaces of the top panel
46 and bottom panel 48 of the carton 10 formed by the folding of
the flaps at the upper and lower edges of the sidewall panels. By
selectively dimensioning the corner support tabs 24, the bearing
load may be distributed as desired between the corner support tabs
24 and the upper and lower surfaces of the top panel 46 and bottom
panel 48 of the carton 10.
[0037] Also as shown in FIGS. 5 and 8, the corner support tabs 24
form a 90 degree self-reinforcing structure having substantial
strength, rigidity, and resistance to crushing or deformation.
[0038] Although the foregoing described embodiments relate to
four-sided cartons, the present invention also encompasses
embodiments of cartons with three or more sidewall panels,
including, for example, a triangular or hexagonal cartons with
sidewall support tabs and/or corner support tabs.
[0039] In essence, in one embodiment the present invention
comprises a carton formed from a blank of foldable corrugated sheet
material having two pairs of upstanding, generally parallel
sidewall panels, pairs of first flaps hingedly foldably connected
to each of the first pair of said parallel sidewall panels along
fold lines, the flaps configured to form panels for covering the
top and bottom of the carton when the carton is assembled, and
wherein cuts for support tabs are made into the corrugated material
along the fold lines such that when the cover-forming flaps are
folded 90 degrees to form the bottom cover of the carton, the
support tabs remain oriented in the plane of the respective
sidewall panel.
[0040] In essence, in another embodiment the present invention
comprises a carton formed from a blank of foldable corrugated sheet
material having two pairs of upstanding, generally parallel
sidewall panels, a pair of first flaps hingedly foldably connected
to each pair of said parallel sidewall panels along a fold line,
the flaps configured to form a panel for covering the top or bottom
of the carton when the carton is assembled, and wherein cuts for
corner support tabs are made into the corrugated material at each
of the four locations where the fold lines extend across adjacent
sidewall panels such that when the cover-forming flaps are folded
90 degrees to form the top or bottom cover of the carton, the
corner support tabs remain oriented in the planes of the sidewall
panels.
[0041] In essence, in another embodiment the present invention
comprises a carton formed from a blank of foldable corrugated sheet
material having at least three upstanding sidewall panels, flaps
hingedly foldably connected to each of at least two of said
sidewall panels along the fold lines, the flaps configured to form
panels for covering the top and bottom of the carton when the
carton is assembled, and wherein cuts for support tabs are made
into the corrugated material along the fold lines and cuts for
corner support tabs are made into the corrugated material at each
of at least three locations where the fold lines extend across
adjacent sidewall panels such that when the cover-forming flaps are
folded 90 degrees to form the top and bottom cover of the carton,
the support tabs and corner support tabs remain oriented in the
plane of the respective sidewall panel.
[0042] While this invention has been described as having preferred
designs, it will be understood that it is capable of further
modification. This application is therefore intended to cover any
variations, uses or adaptations of the invention following the
general principles thereof and including such departures from the
present disclosure as come within known or customary practice in
the art to which this invention pertains and fall within the limits
of the appended claims.
* * * * *