U.S. patent application number 14/712331 was filed with the patent office on 2015-09-03 for basket carrier including open-top basket and lid.
The applicant listed for this patent is Graphic Packaging International, Inc.. Invention is credited to Paul Bradford, Zoe Claire Wilkins.
Application Number | 20150246762 14/712331 |
Document ID | / |
Family ID | 39636347 |
Filed Date | 2015-09-03 |
United States Patent
Application |
20150246762 |
Kind Code |
A1 |
Wilkins; Zoe Claire ; et
al. |
September 3, 2015 |
Basket Carrier Including Open-Top Basket And Lid
Abstract
A basket carrier is disclosed. The carrier includes an open-top
basket and a lid for the basket. The basket includes a
vertically-extending handle, a pair of side walls foldably
connected to the handle by a plurality of divider walls, a pair of
end walls foldably connected to the side walls and the handle, and
a bottom wall formed by bottom flaps foldably connected to the side
walls. The side walls, end walls, divider walls and handle together
define a plurality of compartments for holding containers, such as
bottles or cans. The handle may include a plurality of handle flaps
that are partially separable from the handle to provide comfortable
gripping surfaces for a user's hand. The lid includes a top panel
for covering a top area of the basket, side panels for covering the
side walls of the basket, and adhesive flaps detachably connected
to the side panels for attaching the lid to the basket. A handle
opening is provided in the top panel, laterally offset from the
handle, to provide access to the handle of the basket. Blanks for
forming the lid basket and lid are also disclosed.
Inventors: |
Wilkins; Zoe Claire;
(Bristol, GB) ; Bradford; Paul; (Bristol,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Graphic Packaging International, Inc. |
Atlanta |
GA |
US |
|
|
Family ID: |
39636347 |
Appl. No.: |
14/712331 |
Filed: |
May 14, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12496682 |
Jul 2, 2009 |
9061809 |
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14712331 |
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PCT/US2008/050971 |
Jan 14, 2008 |
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12496682 |
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60880269 |
Jan 12, 2007 |
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60880202 |
Jan 12, 2007 |
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60880221 |
Jan 12, 2007 |
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Current U.S.
Class: |
229/117.12 ;
229/125.19 |
Current CPC
Class: |
B65D 2571/0079 20130101;
B65D 2571/00388 20130101; B65D 71/0022 20130101; B65D 2571/00666
20130101; B65D 2571/00253 20130101; B65D 2571/00444 20130101; B65D
2571/00728 20130101; B65D 2571/0045 20130101; B65D 2571/00141
20130101; B65D 2571/00487 20130101; B65D 71/38 20130101; B65D
5/46072 20130101; B65D 2571/00277 20130101; B65D 2571/00574
20130101; B65D 2571/00283 20130101 |
International
Class: |
B65D 71/38 20060101
B65D071/38; B65D 5/46 20060101 B65D005/46; B65D 71/58 20060101
B65D071/58 |
Claims
1. A blank for forming a basket suitable for carrying a plurality
of containers, the blank comprising: a first upper panel, wherein
the first upper panel includes a first handle portion; a second
upper panel foldably connected to an inner lateral edge of the
first upper panel along a central fold line, wherein the second
upper panel includes a second handle portion; a side adhesive flap
connected to an outer lateral edge of the first upper panel along a
first longitudinal fold line, wherein the side adhesive flap is
configured to be attached to the second upper panel; a first bottom
closure flap foldably connected to a bottom edge of the first upper
panel along a first lateral fold line; and a second bottom closure
flap foldably connected to a bottom edge of the second upper panel
along a second lateral fold line.
2. The blank of claim 1, wherein: the first handle portion includes
at least one first handle flap that is partially separable from the
first handle portion; the second handle portion includes at least
one second handle flap that is partially separable from the second
handle portion; and the at least one first handle flap and the at
least one second handle flap are each at least partially defined by
a substantially U-shaped cut line.
3. The blank of claim 2, wherein the at least one first handle flap
and the at least one second handle flap are each at least partially
defined by a convex fold line extending between endpoints of the
substantially U-shaped cut line and a concave fold line extending
between the endpoints of the substantially U-shaped cut line below
the convex fold line.
4. The blank of claim 1, wherein: the first upper panel comprises
first substantially diagonally extending cut lines laterally spaced
from each other, and first longitudinally extending interior fold
lines laterally spaced from each other; the second upper panel
comprises second substantially diagonally extending cut lines
laterally spaced from each other, and second longitudinally
extending interior fold lines laterally spaced from each other;
each of the first substantially diagonally extending cut lines
bisects one of the first longitudinally extending interior fold
lines; and each of the second substantially diagonally extending
cut lines bisects one of the second longitudinally extending
interior fold lines.
5. The blank of claim 4, wherein: the first substantially
diagonally extending cut lines and the first longitudinally
extending interior fold lines together at least partially define a
first side wall portion, a first end wall portion, a first end wall
reinforcement portion, the first handle portion and at least one
first divider wall portion; and the second substantially diagonally
extending cut lines and the second longitudinally extending
interior fold lines together at least partially define a second
side wall portion, a second end wall portion, a second end wall
reinforcement portion, the second handle portion and at least one
second divider wall portion.
6. The blank of claim 4, wherein the first substantially diagonally
extending cut lines and the second substantially diagonally
extending cut lines are substantially S-shaped.
7. The blank of claim 4, wherein: the first upper panel includes a
first group of longitudinal slits that partially defines the first
end wall; and the second upper panel includes a second group of
longitudinal slits that partially defines the second end wall.
8. The blank of claim 1, comprising: a first bottom glue flap
connected to the bottom edge of the first upper panel along a third
lateral fold line, and configured to be attached to the second
bottom closure flap; and a second bottom glue flap connected to the
bottom edge of the second upper panel along a fourth lateral fold
line, and configured to be attached to the first bottom closure
flap.
9. The blank of claim 1, wherein the first bottom closure flap and
the second bottom closure flap are configured to engage each other
in an interlocking relationship.
10. A blank for forming a basket lid, comprising: a top wall panel
disposed at a center of the blank; a first side wall panel foldably
connected to a first lateral side of the top wall panel along a
first fold line; a second side wall panel foldably connected to a
second lateral side of the top wall panel along a second fold line;
and a handle opening disposed in the top wall panel and laterally
offset from a central axis of the top wall panel extending parallel
to the first and second fold lines, wherein the handle opening is
configured to receive a person's hand.
11. The blank of claim 10, comprising: a first adhesive flap
detachably connected to the first side wall panel along a first
line of weakness, and a second adhesive flap detachably connected
to the second side wall panel along a second line of weakness.
12. The blank of claim 10, comprising: a first web member foldably
connected to a first end of the top wall panel and connected to the
first and second side wall panels; and a second web member foldably
connected to a second end of the top wall panel and connected to
the first and second side wall panels.
13. The blank of claim 12, wherein the first and second web members
each comprise: a rectangular member foldably connected to the top
wall panel; a first gusset member foldably connected to the
rectangular member and the second side wall panel; and a second
gusset member foldably connected to the rectangular member and the
first side wall panel.
14. The blank of claim 10, comprising: first openings disposed
partially in the first side wall panel and partially in the top
wall panel; and second openings disposed partially in the second
side wall panel and partially in the top wall panel.
15. The blank of claim 14, comprising: first patterns of weakness
positioned to allow enlargement of the first openings; and second
patterns of weakness positioned to allow enlargement of the second
openings.
16. A basket lid comprising: a horizontally extending top wall; a
downwardly extending first side wall foldably connected to a first
lateral side of the top wall along a first fold line; a downwardly
extending second side wall foldably connected to a second lateral
side of the top wall a second fold line; and a handle opening
disposed in the top wall and laterally offset from a central axis
of the top wall extending parallel to the first and second fold
lines, wherein the handle opening is configured to receive a
person's hand.
17. The lid of claim 16, comprising: a first adhesive flap
detachably connected to the first side wall along a first line of
weakness, and a second adhesive flap detachably connected to the
second side wall along a second line of weakness.
18. The lid of claim 16, comprising: a first web member foldably
connected to a first end of the top wall and connected to the first
and second side walls; and a second web member foldably connected
to a second end of the top wall and connected to the first and
second side walls.
19. The lid of claim 18, wherein the first and second web members
each comprise: a rectangular member foldably connected to the top
wall; a first gusset member foldably connected to the rectangular
member and the first side wall; and a second gusset member foldably
connected to the rectangular member and the second side wall.
20. The lid of claim 16, comprising: first openings disposed
partially in the first side wall and partially in the top wall; and
second openings disposed partially in the second side wall and
partially in the top wall.
21. The lid of claim 20, comprising: first weakening patterns
positioned to allow enlargement of the first openings; and second
weakening patterns positioned to allow enlargement of the second
openings.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/496,682, filed Jul. 2, 2009, which is a continuation of
International Application No. PCT/US2008/050971, filed Jan. 14,
2008, entitled "Basket Carrier Including Open-Top Basket," which
designates the United States of America and which claims the
benefit under 35 U.S.C. .sctn.119(e) of U.S. Provisional
Application No. 60/880,269, filed Jan. 12, 2007, U.S. Provisional
Application No. 60/880,202, filed Jan. 12, 2007, and U.S.
Provisional Application No. 60/880,221, filed Jan. 12, 2007.
BACKGROUND
[0002] Conventional open-top, paperboard baskets for carrying
containers such as bottles and cans are often difficult and
uncomfortable to carry. Particularly, the handles of traditional
basket carriers often include thin-walled members with relatively
sharp edges that cause discomfort to a person gripping the handle.
In addition to being uncomfortable to grip, the handles in
traditional basket carriers can often inflict cuts and abrasions on
the hands of people carrying them.
[0003] Conventional open-top baskets typically also leave the
containers held therein largely unprotected, as significant
portions of the containers are not covered by the basket.
[0004] In view of the issues discussed above, it is desirable to
provide a basket carrier including an open-top basket having an
improved handle that is comfortable for gripping. It is also
desirable to provide such a basket carrier with a detachable lid
for covering the basket and protecting the containers held
therein.
SUMMARY
[0005] The entire disclosures of U.S. patent application Ser. No.
12/496,682, International Application No. PCT/US2008/050971, U.S.
Provisional Application No. 60/880,269, U.S. Provisional
Application No. 60/880,202, and U.S. Provisional Application No.
60/880,221 are hereby incorporated by reference in their entirety
as though fully set forth herein.
[0006] A basket carrier for carrying containers, such as bottles or
cans, is disclosed. The basket carrier includes an improved basket
and an improved lid for covering the basket.
[0007] According to one exemplary embodiment, a basket carrier
includes a basket and a lid covering the basket. The basket may
comprise a first basket side wall, a second basket side wall
extending parallel to first basket side wall, a first basket end
wall extending orthogonally between the first and second basket
side walls, a second basket end wall extending between the first
and second basket side walls parallel to the first basket end wall,
a bottom wall extending between the first and second basket side
walls and the first and second basket end walls, container
compartments for holding containers, and a handle extending
parallel to the basket side walls between the first and second
basket end walls. The handle may include one or more grip openings
for gripping the handle. The lid may include a horizontally
extending lid top wall positioned over the handle, a downwardly
extending first lid side wall foldably connected to a first lateral
side of the lid top wall and positioned over the first basket side
wall, a downwardly extending second lid side wall foldably
connected to a second lateral side of the lid top wall and
positioned over the second basket side wall, and a handle opening
disposed in the lid top wall to allow a hand to access the
handle.
[0008] According to another exemplary embodiment, a basket for
carrying containers includes a first side wall, a second side wall
extending parallel to first side wall, a first end wall extending
orthogonally between the first and second side walls, a second end
wall extending between the first and second side walls parallel to
the first end wall, a bottom wall extending between the first and
second side walls and the first and second end walls, a handle
extending parallel to the side walls between the first and second
end walls, first container compartments disposed on a first side of
the basket; and second container compartments disposed on a second
side of the basket. The handle may include a first handle portion
and a second handle portion positioned against each other in
back-to-back relationship. The first handle portion and the second
handle portion may each be formed as a substantially flat panel.
The handle may also include one or more first handle flaps formed
in the first handle portion and one or more second handle flaps
formed in the second handle portion and aligned with the one or
more first handle flaps. The one or more first handle flaps may be
at least partially separable from the first handle portion and the
one or more second handle flaps may be at least partially separable
from the second handle portion to form an opening for gripping the
handle. The one or more first handle flaps and the one or more
second handle flaps may further be foldable to form substantially
flat gripping surfaces extending transversely to the first and
second handle portions.
[0009] According to another exemplary embodiment, a basket lid may
include a horizontally extending top wall, a downwardly extending
first side wall foldably connected to a first lateral side of the
top wall along a first fold line, a downwardly extending second
side wall foldably connected to a second lateral side of the top
wall a second fold line, and a handle opening disposed in the top
wall and laterally offset from a central axis of the top wall
extending parallel to the first and second fold lines, wherein the
handle opening is configured to receive a person's hand.
[0010] Exemplary embodiments of blanks for forming a basket and a
lid according to are also disclosed.
[0011] Other embodiments and aspects will become apparent to those
of ordinary skill in view of the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plan view showing an outer side of a blank from
which a basket of a basket carrier is formed.
[0013] FIGS. 2A and 2B are plan views of the blank of FIG. 1 folded
into a shipping or storage configuration.
[0014] FIGS. 3A and 3B are perspective views of the blank of FIG. 1
folded from the configuration of FIG. 2 into an unfinished basket
configuration.
[0015] FIGS. 4A and 4B are perspective views of a basket erected
from the blank of FIGS. 1-3B.
[0016] FIG. 4C is a bottom view of the basket of FIGS. 4A and
4B.
[0017] FIG. 4D is a perspective view of the basket of FIGS. 4A-4C
loaded with containers.
[0018] FIG. 5 shows a handle of the basket of FIGS. 4A-4D.
[0019] FIG. 6 is a plan view of a blank from which a lid for the
basket carrier is formed.
[0020] FIG. 7 is a perspective view of a lid formed from the blank
of FIG. 6.
[0021] FIGS. 8 and 9 are perspective views of a basket carrier
including the basket of FIGS. 4A-4D and the lid of FIG. 7.
DETAILED DESCRIPTION
[0022] FIGS. 8 and 9 show a basket carrier or carton 400 including
a basket 110 and a lid 300, in accordance with one embodiment of
the present invention. The features of the basket 110, the lid 300
and blanks for forming the basket and the lid are described below
with reference to FIGS. 1-7.
[0023] FIG. 1 shows an outer side of a blank 10 for an open-top
basket 110 (FIGS. 4A-4D) of a basket carrier 400 (FIGS. 8 and 9).
The blank 10 may be constructed, for example, of paperboard or
another suitable material. The blank 10 includes a first upper
panel 20, a second upper panel 40 foldably connected to a first
lateral edge of the first upper panel 20 along a central
longitudinal fold line 34, and a side adhesive flap, or fastening
flap 60 connected to a second lateral edge of the upper panel 20
along a longitudinal fold line 32. The blank 10 further includes a
first bottom closure flap 70 foldably connected to a bottom edge of
the first upper panel 20 along a lateral fold line 73, a first
bottom adhesive flap 80 foldably connected to the bottom edge of
the first upper panel 20 along a lateral fold line 82, a second
bottom closure flap 90 foldably connected to a bottom edge of the
second upper panel 40 along a lateral fold line 93, and a second
bottom adhesive flap 100 foldably connected to the bottom edge of
the upper panel 40 along a fold line 102.
[0024] As shown in FIG. 1, the upper panels 20, 40 are
substantially rectangular and each include: a basket side wall
portion 20a, 40a; a basket end wall portion 20b, 40b disposed
adjacent to the side wall portion 20a, 40a at a right region of the
panel 20, 40; a basket end wall reinforcement portion 20c, 40c
disposed at an upper left region of the panel 20, 40; a basket
handle portion 20d, 40d disposed at a central region of the panel
20, 40 above the side wall portion 20a, 40a; a first transverse
divider wall portion 20e, 40e disposed adjacent to the end wall
reinforcement panel portion 20c, 40c, between the handle portion
20d, 40d and the sidewall portion 20a, 40a; and a second transverse
divider wall portion 20f, 40f disposed adjacent to the first
transverse divider wall portion 20e, 40e, between the handle
portion 20d, 40d and the sidewall portion 20a, 40a. The upper
panels 20, 40 are also shown to have radiused upper corners 20g,
40g, which increase open area in the erected basket 110 and improve
the aesthetics of the basket. It should be understood, however,
that the upper panels 20, 40 may be have a shape that varies from
the substantially rectangular shape shown.
[0025] The handle portions 20d, 40d each optionally include a pair
of adjacent handle grip elements or flaps 28. The handle grip
elements 28 are each formed by a substantially U-shaped cut line 29
having endpoints 29a, 29b, a convex fold line 30 extending between
the endpoints 29a, 29b, and a concave fold line 31 extending
between the endpoints 29a, 29b below convex the fold line 30. As
will be described later, the handle grip elements 28 can be
partially separated from the handle portion 20d and folded to
expose handle openings 172 (FIGS. 4A, 4B and 5) for gripping by a
person's hand.
[0026] The upper panel 20 includes a plurality of laterally-spaced,
diagonally extending container compartment cut lines 21, 22, 23
positioned bellow the handle portion 20d, and a plurality of
laterally-spaced, longitudinally extending interior fold lines 24,
25, 26. The cut lines 21, 22, 23 preferably extend entirely or
substantially entirely through the thickness of the blank 10 such
that the cut lines 21, 22, 23 can be opened to form compartments
190 (FIG. 4A) for bottles, cans or other containers C (FIG. 4D), as
will be described later. Although the cut lines 21, 22, 23 are
shown to be generally S-shaped, they may instead be substantially
straight or have other suitable shapes. The arrangement of the cut
lines 21, 22, 23 and the fold lines 24, 25, 26 is discussed
below.
[0027] The outermost container compartment cut line 21 extends from
a lower end 21a, which intersects the fold line 32, to an upper end
21b. The outermost interior fold line 24 extends from the upper
edge of the panel 20 and is bisected into an upper segment 24a and
a lower segment 24b by the cut line 21. The middle cut line 22
extends from a lower end 22a, which intersects a lower end of the
interior fold line 24, to an upper end 22b. The middle interior
fold line 25 extends from the upper end 21a of the cut line 21 to a
lower end 23a of the innermost container cut line 23. The fold line
25 is bisected into an upper segment 25a and a lower segment 25b by
the cut line 22. The container compartment cut line 23 extends from
its lower end 23a to an upper end 23b. The innermost interior fold
line 26 extends from the upper end 22b of the cut line 22 to the
bottom edge of the panel 20, where it intersects the lateral fold
lines 73, 82. The fold line 26 is bisected into an upper segment
26a and a lower segment 26b by the innermost container compartment
cut line 23.
[0028] The panel 20 also includes a series of longitudinally
extending slits or fold lines 36 extending between the upper end
23b of the cut line 23 and the upper edge 27 of the panel 20. The
slits/fold lines 36 facilitate folding of the end wall portion
20b.
[0029] As can be understood from the foregoing description and FIG.
1, the side wall portion 20a is defined by the area outlined by the
lower portion of the fold line 32, the lower portion of the cut
lines 21, 22, 23 the line segments 24b, 25b, 26b, and the fold line
73. The end wall portion 20b is defined by the area outlined by the
line segment 26b, the upper portion of the cut line 23, the
slits/fold lines 36, the upper edge 27 of the panel 20 the fold
line 34, and the fold line 82. The end wall reinforcement portion
20c is formed in the area outlined by the upper portion of the fold
line 32, the upper edge 27 of the panel 20, the line segment 24a
and the lower portion of the cut line 21. The handle portion 20d is
defined in the area outlined by the line segments 24a, 25a, 26a the
upper edge 27 of the panel 20, the slits/fold lines 36 and the
upper portions of the cut lies 21, 22, 23. The divider panel
portion 20e is formed in the area outlined by the upper portion of
the cut line 21, the lower portion of cut line 22, the line segment
24b and the line segment 25a. The divider panel 20f is defined in
the area surrounded by the upper portion of the cut line 22, the
lower portion of the cut line 23, the line segment 25b and the line
segment 26a.
[0030] Still referring to FIG. 1, the second upper panel 40 is
similar to the first upper panel 20. The upper panel 40 includes a
plurality of laterally-spaced, diagonally extending container
compartment cut lines 41, 42, 43 positioned bellow the handle
portion 40d, and a plurality of laterally-spaced, longitudinally
extending interior fold lines 44, 45, 46. In accordance with the
embodiment shown in the drawings, the cut lines 41, 42, 43 have the
same shape, structure and relative spacing as the cut lines 21, 22,
23 such that the cut lines 41, 42, 43 can be opened to form
compartments 190 (FIG. 4B) for containers C (FIG. 4D).
[0031] The innermost container compartment cut line 41 extends from
a lower end 21a, which intersects the central fold line 34, to an
upper end 41b. The innermost interior fold line 44 extends from the
upper edge of the panel 40 and is bisected into an upper segment
44a and a lower segment 44b by the cut line 41. The middle cut line
42 extends from a lower end 42a, which intersects a lower end of
the interior fold line 44, to an upper end 42b. The middle interior
fold line 45 extends from the upper end of the cut line 21 to a
lower end 43a of the outermost container compartment cut line 43.
The fold line 45 is bisected into an upper segment 45a and a lower
segment 45b by the cut line 42. The outermost container compartment
cut line 43 extends from its lower end 43a to an upper end 43b. The
outermost interior fold line 46 extends from the upper end 42a of
the cut line 42 to the bottom edge of the panel 40, where it
intersects the lateral fold lines 93, 102. The fold line 46 is
bisected into an upper segment 46a and a lower segment 46b by the
outermost container compartment cut line 43.
[0032] The panel 40 also includes a series of longitudinally
extending slits or fold lines 56 (similar to slits/fold lines 36)
extending between the upper end 43b of the cut line 43 and the
upper edge 47 of the panel 40.
[0033] The side wall portion 40a is defined by the area outlined by
the lower portion of the fold line 34, the lower portion of the cut
lines 41, 42, 43 the line segments 44b, 45b, 46b, and the fold line
93. The end wall portion 40b is defined by the area outlined by the
line segment 46b, the upper portion of the cut line 43, the
slits/fold lines 56, the upper edge 47 of the panel 40, the outer
lateral edge 49 of the panel 40 and the fold line 102. The end wall
reinforcement portion 40c is formed in the area outlined by the
upper portion of the fold line 34, the upper edge 47 of the panel
40, the line segment 44a and the lower portion of the cut line 41.
The handle portion 40d is defined in the area outlined by the line
segments 44a, 45a, 46a the upper edge 47 of the panel 40, the
slits/fold lines 56 and the upper portions of the cut lies 41, 42,
43. The divider panel portion 40e is formed in the area outlined by
the upper portion of the cut line 41, the lower portion of cut line
42, the line segment 44b and the line segment 45a. The divider
panel 40f is defined in the area surrounded by the upper portion of
the cut line 42, the lower portion of the cut line 43, the line
segment 45b and the line segment 46a.
[0034] The panel 40 may also be provided with an adhesive in the
schematically illustrated region 48 near the outer lateral edge 49
of the end wall portion 40b for attaching the adhesive flap 60
thereto, as shown in FIG. 2A.
[0035] Due to the arrangement described above, the cut lines 21,
22, 23/41,42,43 and the fold lines 24, 25, 26/44, 45, 46 together
allow folding of the side wall portion 20a/40a, the end wall
portion 20b/40b, the end wall reinforcement portion 20c/40c and the
transverse divider wall portions 20e, 20f/40e, 40f, and allow
partial separation of the side wall portion 20a/40a from the end
wall reinforcement portion 20c/40c, the handle portion 20d/40d and
the transverse divider wall portions 20e, 20f/40e, 40f to form
three container compartments 190 (FIGS. 4A and 4B) on each side of
the basket 110. Thus, the basket 110, as configured, provides six
container compartments 190. However, one of skill in the art will
understand that the number of compartments can be increased or
decreased by increasing or decreasing the number of cut lines 21,
22, 23/41,42,43 and fold lines 24, 25, 26/44, 45, 46.
[0036] Still referring to FIG. 1, the bottom closure flaps 70, 90
each include a major flap member 72, 92 that is generally
trapezoidal in shape, and a generally trapezoidal minor flap member
74, 94 attached to the major flap member along a diagonal fold line
75, 95. Interlocking notches 77, 97 are provided between the major
flap members 72, 92 and the minor flap members 74, 94 in middle
lateral regions of the flaps 70, 90 to facilitate interlocking
locking engagement of the flaps 70, 90 with each other in the
erected basket 110. Clearance notches 76, 96 are also provided
between the major flap members 72, 92 and the minor flap members
74, 94 at lateral edges near the intersection points of the lateral
fold lines 73, 93 and the longitudinal fold lines 32, 34 to provide
clearance during folding of the flaps 70, 90. Zig-zag shaped
portions 73a, 93a may also be provided in the fold lines 73, 93 to
facilitate folding of the flaps 70, 90 during erection of the
basket 110.
[0037] The bottom adhesive flaps 80, 100 may be generally
trapezoidal in shape to provide clearance with respect to the upper
panels 20, 40 during folding of the blank 10 to erect the basket
110. The adhesive flaps 80, 100 may also include schematically
illustrated adhesive regions 84, 104 on their inner surfaces for
securing the bottom closure flaps 70, 80 to the adhesive flaps 80,
100.
[0038] FIGS. 2A and 2B show the blank 10 folded into an example of
what can be referred to as a storage or shipping configuration. In
this configuration, the upper panels 20, 40 are folded together
such that they lie substantially flat with their inside or back
surfaces facing each other (i.e., back-to-back). The handle
portions 20d, 40d may be adhered together to prevent relative
movement between them, and the side adhesive flap 60 is folded
downward about the fold line 32 such that the back side of the side
adhesive flap 60 is adhered to the adhesive region 48 of the end
wall portion 40b. In this configuration, the side wall portions
20a, 40a are laterally offset from each other, the handle portions
20d, 40d are aligned back-to-back with each other, the end wall
portion 40b is aligned back-to-back with the end wall reinforcement
portion 20c, the end wall portion 20b is aligned back-to-back with
the end wall reinforcement portion 40c. From this configuration,
the blank 10 may easily be erected into a basket 110.
[0039] The process of erecting a basket 110 from the blank 10 is
illustrated in FIGS. 3A-4C and will be described in the following,
in accordance with an embodiment of the invention. In a first step
illustrated in FIGS. 3A and 3B, the blank 10 in the shipping
configuration may be folded into the partially erected basket
formation shown in FIG. 3 by, simultaneously: retaining the end
wall reinforcement portion 40c against the end wall portion 20b;
retaining the end wall reinforcement portion 20c against the end
wall portion 40b; forcing the side wall portion 20a to fold
outward, transversely to the lateral and longitudinal directions of
the blank 10, about the lower portion of the fold line 32 and the
lower segment 26b of the fold line 26, such that the sidewall
portion 20a extends substantially parallel to the handle portion
20d; forcing the side wall portion 40a to fold outward,
transversely to the lateral and longitudinal directions of the
blank 10, about the lower portion of the fold line 34 and the lower
segment 46b of the fold line 46, such that the sidewall portion 40a
extends substantially parallel to the side wall portion 46a and the
handle portion 40d; forcing the end wall portion 20b to fold about
the line segment 26b, the slits/fold lines 36, and the fold line 34
such that the end wall portion 20b extends substantially
orthogonally to the side wall portions 20a, 40a; and forcing the
end wall portion 40b to fold about the line segment 46b, the
slits/fold lines 56, and the fold line 32 of the side adhesive flap
60 (which is attached to the end wall portion 40b) such that the
end wall portion 40b extends substantially orthogonally to the side
wall portions 20a, 40a and parallel to the end wall portion 20b.
Folding the blank in this manner causes the transverse divider wall
portions 20e, 20f/40e, 40f to fold so as to extend transversely to
the side wall portions 20a/40a and the handle portions 20d/40d.
Specifically, the divider wall portions 20e, 40e fold about the
lower line segments 24b, 44b of the fold lines 24, 44 and the
respective upper line segments 25a, 45a of the fold lines 25, 45;
while the divider wall portions 201, 40f fold about the respective
lower line segments 25b, 45b of the fold lines 25, 45 and the
respective upper line segments 26a, 46a of the fold lines 26,
46.
[0040] Next, as shown in FIG. 4C, the bottom adhesive flaps 80, 100
in the formation of FIG. 3 are folded inward, and the bottom
closure flaps 70, 90 are folded inward into interlocking engagement
with each other with the minor flap members 74, 94 adhered to the
inner surfaces of the adhesive flaps 100, 80. The bottom closure
flaps 70, 90 are interlocked such that the interlocking notches 77,
97 engage each other, the major flap member 72 lies over the
adhesive flap 80, and the major flap member 92 lies over the
adhesive flap 100. Thus, the closure flaps 70, 90 are secured in a
position substantially orthogonal to the side wall portions 20a,
40a and the end wall portions 20b, 40b, thereby forming a bottom
wall 160, completing the erection of the basket 110. Differently
configured bottom walls may be used.
[0041] As shown in FIGS. 4A-4D, the basket 110 includes: first and
second side walls 20a, 40a; first and second end walls 20b, 40b
extending orthogonally between the side walls 20a, 40a at opposite
ends of the side walls; a bottom wall 160 formed by the bottom
closure flaps 70, 90, which are respectively connected to the first
and second side walls 20a, 40a along the fold lines 73, 93, and the
bottom adhesive flaps 80, 100, which are respectively connected to
the first and second end walls 20b, 40b; a handle 170 formed by
first and second handle portions 20d, 40d in a center region of the
basket 110 and extending between the end walls 20b, 40b above and
parallel to the side walls 20a, 40a; first and second divider walls
20e, 20f extending at an inclined angle from the first side wall
20a to the handle 170; third and fourth divider walls 40e, 40f
extending at an inclined angle from the second side wall 40a to the
handle 170; and a plurality of container compartments 190 defined
on opposing sides of the basket 110.
[0042] The end wall reinforcement portions 20c, 40c form
reinforcing walls disposed parallel to the end walls 40b, 20b in
back-to-back relationship with the end walls 20b, 40b. As can be
seen in FIGS. 4A and 4B, the reinforcement walls 20c, 40c reinforce
the end walls 40b, 20b and support the handle portions 20d,
40d.
[0043] Referring to FIG. 4A, the container compartments 190 on a
first side of the basket 110 are defined by the first side wall
20a, the first handle portion 20d, the first and second end walls
20b, 40b, the first reinforcing wall 20b, and the bottom wall 160.
Turning to FIG. 4B, the container compartments 190 on the second
side of the basket 110 are defined by the second side wall 40a, the
second handle portion 40d, the first and second end walls 20b, 40b,
the second reinforcing wall 40b, and the bottom wall 160.
[0044] The handle 170 is configured such that the handle portions
20d, 40d form substantially flat handle panels aligned in a
back-to-back configuration with the grip elements 28 in the handle
portion 20d being aligned with the grip elements 28 in the handle
portion 40d.
[0045] Referring to FIG. 4A, the first side wall 20a and the first
end wall 20b are connected along the segment 26b of the fold line
26. The first divider wall 20e is connected to the first handle
portion 20d along the segment 25a of the fold line 25 and is
connected to the first side wall 20a along the segment 24b of the
fold line 24. The second divider wall 20f is connected to the first
handle portion 20d along the segment 26a of fold line 26 and is
connected to the first side wall 20a along the segment 25b of the
fold line 25 The first reinforcing wall 20c is connected to the
first handle portion 20d along the segment 24a of the fold line 24.
The first side wall 20a and the first reinforcing wall 20c are
connected to the second end wall 40b by the adhesive flap 60, which
extends parallel to the second end wall 40b and is connected to
first side wall 20a and the first reinforcing wall 20c along the
fold line 32.
[0046] Turning to FIG. 4B, the second side wall 40a and the second
end wall 40b are connected along the segment 46b of the fold line
46. The third divider wall 40e is connected to the second handle
portion 40d along the segment 45a of the fold line 45 and is
connected to the first side wall 40a along the segment 44b of the
fold line 44. The fourth divider wall 40f is connected to the
second handle portion 40d along the segment 46a of the fold line 46
and is connected to the second side wall 40a along the segment 45b
of the fold line 45. The second reinforcing wall 40c is connected
to the second handle portion 40d along the segment 44a of the fold
line 44. The second side wall 40a and the second reinforcing wall
40c are connected to the first end wall 20b along the fold line
34.
[0047] As best shown in FIG. 5, to facilitate carrying the basket
110, each handle grip element 28 can be partially separated from
the respective handle portion 20d, 40d and folded outward about the
fold line 30 to expose a pair of handle openings 172 and to cause
the portion 28b of the grip element 28 between the convex fold line
30 and the concave fold line 31 to extend transversely to the
remainder of the handle 170. Thus, the inner surface of the portion
28b of the grip element 28 forms a lateral gripping surface against
which a person's fingers can rest when the handle 170 is gripped.
The portion 28a of the grip element 28 defined within the fold line
31 and the U-shaped cut line 29 can be folded further upward, in
the direction U, about the fold line 31 such that the inner surface
of the portion 28a forms a substantially vertical gripping surface
for a person's fingers. Thus, the finger grip elements 28 form
large, comfortable surfaces that can be gripped by a person's
fingers while reducing the likelihood that the handle 170 will
injure or irritate a person's hand while carrying the basket
110.
[0048] FIG. 6 shows the outer surface of a blank 200 for forming a
lid 300 of a basket carrier 400 (FIGS. 7A and 7B). The blank 200
includes: a rectangular top wall panel 210 disposed at a center of
the blank; a pair of substantially rectangular side wall panels 220
foldably connected to opposite lateral sides of the top wall panel
210 along longitudinally extending fold lines 212; a pair of
trapezoidal web panels 230 foldably connected to ends of the top
wall panel 210 and foldably connected to the side wall panels 220;
and a pair of adhesive flaps 250 foldably and detachably connected
to the side wall panels 220 along lines of weakness 252 (e.g., tear
lines). The adhesive flaps 250 may include adhesive on their inner
surfaces for attaching the flaps 250 to the basket 110, as will be
described later.
[0049] The web panels 230 each include a rectangular panel member
232 foldably connected to the top wall panel 210 along a laterally
extending fold line 214. Each web panel 230 further includes a pair
of gusset members 234 foldably connected to the rectangular panel
member 232 and one of the side wall panels 220. Each of the gusset
members 234 is connected to a respective one of the panel members
232 along a longitudinal fold line 236, which is collinear with a
respective one of the fold lines 212. Each gusset member 234 is
also connected to a respective one of the side wall panels 220
along a diagonal fold line 222.
[0050] The top wall panel 210 includes a handle opening 216 which
is sized and shaped to expose the handle 170 of the basket 110 and
to accommodate a person's hand when the blank is formed into the
lid 300 on the basket. The handle opening 216 has an oval shape and
extends lengthwise in the longitudinal direction of blank 200. The
opening 216 is laterally offset from a central longitudinal axis Y
(extending parallel to the fold lines 212) of the top wall panel
210 to provide better access to the handle 170, as will be
described in more detail later. A plurality of openings 224 are
provided near laterally inner regions of the side wall panels 220
for receiving the tops of containers C held within the basket 110.
The openings 224 are spaced to correspond to the container
compartments 190 in the basket 110. As shown in FIG. 8, the
openings 224 may partially extend across the fold lines 212 into
the top wall panel 210. Weakening patterns 226 are provided in the
side wall panels 220 laterally adjacent to the openings 224. Each
weakening pattern 226 may include a plurality of lines of weakness
(e.g., slits and/or tear lines), such as a central line of weakness
226a extending laterally from the opening 224 and a pair of
diagonal lines of weakness 226b disposed on opposite sides of the
central line of weakness 226a. it should be understood that,
although any number of openings 224 may be provided, the openings
224 should be equal in number to the container compartments 290 of
the basket 110.
[0051] FIG. 7 shows a lid 300 formed by the blank 200. To form the
lid 300, the side wall panels 220 are folded towards each other
about the fold lines 212 such that the side wall panels 220 and
adhesive flaps 250 extend transversely to the top wall panel 210
and the back sides of the side panels 220 face each other. The
rectangular panel members 232 are folded inward towards each other
about the fold lines 214 such that the rectangular panel members
232 extend and transversely to the side panels 220 and the top wall
panel 210. The gusset members 234 are folded about the fold lines
236, 222 such that the gusset members 234 extend transversely
between the respective side panel 220 and rectangular panel member
232.
[0052] Thus, as indicated in FIG. 7, the lid 300 includes a
substantially horizontal top wall 210, substantially downwardly
extending side walls 220 connected to opposite sides of the top
wall 210 along fold lines 212, a pair of trapezoidal web panels 230
formed foldably connected to opposite ends of the top panel 210 and
to the side panels 220, and a pair of adhesive flaps 250 foldably
and detachably connected to the side walls 220 along the lines of
weakness 252. The lid is configured such that the handle access
opening 216 is laterally offset from the central longitudinal axis
L of the top wall 210. The lid 300 is also configured such that the
container top openings 224 and weakening patterns 226 positioned in
upper portions of the side walls 220, with the openings 224
extending partially into the top wall 210.
[0053] Referring to FIGS. 8 and 9, to form the basket carrier 400,
the lid 300 is first positioned over the basket 110 such that each
of the side walls 220 of the lid 300 is aligned with a side wall
20a/40a of the basket 110, and the top wall 210 of the lid 300 is
positioned over the handle 170. The lid 300 is then attached to
basket by attaching the adhesive flaps 250 to the side walls 20a,
40a.
[0054] Thus, as shown in FIGS. 8 and 9, the carrier 400 is formed
such that the side walls 320 of the lid 300 cover the side walls
20a, 40a and the container compartments 190 of the basket 110, and
the top wall 310 of the lid 300 extends over the handle 170 of the
basket 110 to cover the open top of the basket 110. Each of the
container top openings 224 is aligned with and positioned above one
of the container compartments 190, and the handle access opening
216 is laterally offset from the handle 170, with the handle 170
being positioned beneath the opening 216. Although the handle
access opening 216 is laterally offset from the handle 170, the
handle 170 may be positioned within or close to the perimeter 218
of the opening 216 to provide optimum access to the handle 170.
Therefore, a person can easily grab and carry the carrier 400 by
inserting his hand into the opening 216, inserting his fingers
through the handle openings 172, and gripping the handle 170. The
relative positioning of the handle 170 and the opening 216 provides
generous space for a person's hand and comfortable positioning of
the hand in the carrier 400.
[0055] To remove containers C from the carrier 400 with the lid
installed, the containers C can be pulled through the openings 224.
As containers C are pulled through the openings 224, the weakening
patterns 226 will partially separate from the side walls 320,
thereby expanding the openings 226 to facilitate removal of the
containers.
[0056] Access to the containers C can also be gained by detaching
the side walls 220 from the adhesive flaps 250 along lines of
weakness 252, such that the adhesive flaps 250 remain attached to
the side walls 20a, 40a of the basket 110 and the remainder of the
lid 300 is removed from the basket 110.
[0057] In accordance with the exemplary embodiments, the cartons
(i.e., basket and lid) may be constructed of paperboard, for
example. The paperboard webs used to form the blank may be thicker
and heavier than ordinary paper. The blanks, and thus the carton
and lid, can also be constructed of other materials, such as
cardboard, or any other material having properties suitable for
enabling the cartons to function at least generally as described
above. For example, the blanks may be formed from coated solid
unbleached sulfate (SUS) board. The blanks can also be laminated to
or coated with one or more web-like materials at selected panels or
panel sections.
[0058] One or more panels of the blanks discussed above can be
coated with varnish, clay, or other materials, either alone or in
combination. The coating may then be printed over with product,
advertising, and other information or images. The blanks may also
be coated to protect any information printed on the blank. The
blanks may be coated with, for example, a moisture barrier layer,
on either or both sides of the blanks.
[0059] In accordance with the exemplary embodiments, a fold line or
line of weakness can be any substantially linear, although not
necessarily straight, form of weakening that facilitates folding
therealong. More specifically, but not for the purpose of narrowing
the scope of the present invention, fold lines include: a score
line, such as lines formed with a blunt scoring knife, or the like,
which creates a crushed portion in the material along the desired
line of weakness; a cut that extends partially into a material
along the desired line of weakness, and/or a series of cuts that
extend partially into and/or completely through the material along
the desired line of weakness; and various combinations of these
features. In situations where cutting is used to create a fold
line, typically the cutting will not be overly extensive in a
manner that might cause a reasonable user to incorrectly consider
the fold line to be a tear line. A pattern of weakness can be any
pattern which serves as a form of weakening to facilitate folding
or tearing.
[0060] The term "line" as used herein includes not only straight
lines, but also other types of lines such as curved, curvilinear or
angularly displaced lines.
[0061] In the present specification, a "panel" need not be flat or
otherwise planar. A "panel" can, for example, comprise a plurality
of interconnected generally flat or planar sections.
[0062] In the present specification, reference is made to various
directions, such as "vertical," "lateral," "longitudinal,"
variations thereof. It should be understood that such descriptions
are provided to facilitate understanding of the relative
orientation of various elements described herein, and are not
intended to be limiting.
[0063] The foregoing description of the invention illustrates and
describes the present invention. Additionally, the disclosure shows
and describes only selected embodiments of the invention, but it is
to be understood that the invention is capable of use in various
other combinations, modifications, and environments and is capable
of changes or modifications within the scope of the inventive
concept as expressed herein, commensurate with the above teachings,
and/or within the skill or knowledge of the relevant art.
* * * * *