U.S. patent number 3,927,821 [Application Number 05/509,847] was granted by the patent office on 1975-12-23 for lined carton.
This patent grant is currently assigned to Hoerner Waldorf Corporation. Invention is credited to Robert M. Dunning.
United States Patent |
3,927,821 |
Dunning |
December 23, 1975 |
Lined carton
Abstract
A paperboard carton is provided including a bottom panel, and
side and end walls hinged thereto and corner flaps on certain of
the walls overlapping portions of the adjoining walls to form areas
of double thickness. A lining film of plastic or the like is
adhered to the inner surface of the paperboard. One or more
apertures are provided in the inner layer of the double thickness
areas. The lining film extends through these apertures and is
secured to the outer layer, thus securing the corner flaps in
place.
Inventors: |
Dunning; Robert M. (St. Paul,
MN) |
Assignee: |
Hoerner Waldorf Corporation
(St. Paul, MN)
|
Family
ID: |
24028324 |
Appl.
No.: |
05/509,847 |
Filed: |
September 27, 1974 |
Current U.S.
Class: |
229/164.2;
229/5.84; 229/198; 229/198.2 |
Current CPC
Class: |
B65D
5/56 (20130101) |
Current International
Class: |
B65D
5/56 (20060101); B65D 005/56 () |
Field of
Search: |
;229/14BL,48T,32,14R,14BA,14BE,3.1,48SA ;206/461 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Dixson, Jr.; William T.
Assistant Examiner: Garbe; Stephen P.
Attorney, Agent or Firm: Best; Jerry F.
Claims
I claim:
1. A paperboard carton corner in combination with a carton having a
base panel, a pair of walls hinged to the base panel, and a corner
flap hinged to one wall and overlapping the other wall to form an
area of double thickness, the inner layer of the double thickness
area having an aperture therethrough, and a plastic liner film
attached to the inner surface of said paperboard, said film
extending through said aperture and secured to the outer layer of
said double thickness area to hold the overlapping portions in
overlapping relation.
2. The structure of claim 1 and in which said inner layer includes
a plurality of apertures through which said film extends.
3. The structure of claim 1 and in which said corner flap comprises
the outer layer of said double thickness area.
4. A carton of paperboard and the like including a rectangular
bottom panel, side and end wall panels hingedly secured thereto,
and corner flaps secured to two opposed of said walls overlapping
the adjoining walls to form areas of double thickness,
the inner layer of said double thickness areas having at least one
aperture therein,
a liner of plastic film secured to the wall panels and bottom
panel,
portions of said liner extending through said apertures and secured
to the outer layer to secure said double thickness areas in
overlapping relation.
5. The structure of claim 4 and in which said corner flaps form the
outer layer of said double thickness area.
6. The structure of claim 4 and in which said inner layer of said
double thickness area includes a plurality of apertures in each
double thickness area.
Description
This invention relates to a lined carton and method of making the
same and deals particularly with a simple carton having a liner
film adhered to the inner surface thereof. The liner acts to hold
the carton in its formed condition.
BACKGROUND OF THE INVENTION
In an application being simultaneously filed in the name of
Lawrence Knoell a lining film is applied over the upper surface of
the tray shaped carton, and suction is applied to the external
walls of the tray, to draw the film into the tray and in close
contact with the bottom and side walls thereof. This film may
either be extruded directly over the cartons, or a plastic film may
be heated while over the trays and drawn into the trays by suction
applied to the outer surface of the various walls so as to form a
continuous liner adhered to the porous paperboard to make the tray
waterproof. The tray may or may not be provided with a hinged cover
to which the partially molten film is secured.
Trays of this type are usually connected by corner flaps adhered or
otherwise secured to opposed walls of the tray, forming areas of
double thickness. While paperboard is normally porous to some
extent, it is obviously more difficult to draw the film against the
inner surface of the tray at the double thickness areas than
through the remaining single thickness of the remainder of the
tray. Usually, the trays are preformed, with the corner flaps
hinged to the ends of two opposed walls and folded into surface
contact with the remaining walls of the tray. It has been shown
that if sufficient suction is applied to the exterior of the walls,
the liner will conform very closely to the inner surfaces of the
walls and be adhered thereto while the film is in its partially
molten form.
SUMMARY OF THE INVENTION
It has been found that the operation of forming the tray can be
simplified by merely plunging the flat blank into pockets on a
conveyor, suitable means being provided for swinging the corner
flaps on the two opposed walls against the other two walls. Then by
providing apertures in the walls of the tray or corner flaps in the
double thickness areas, the film will be drawn through the
apertures, securing the corner flaps to the walls against which
they lie.
Under normal conditions, the corner flaps on the two opposed walls
are folded outwardly of the remaining opposed walls to provide a
stronger corner structure. In such an event, the apertures are
provided in the portions of the walls over which the corner flaps
extend. As a result, the vacuum applied to the exterior walls must
pass through only one layer of paperboard in the area outwardly of
the apertures so that the film is drawn through the apertures and
against the outer layer of the double thickness area. Obviously, if
the corner flaps are folded inwardly of the walls, the apertures
are formed in the corner flaps, and are drawn against the opposed
container walls in the areas of double thickness formed by the
corner flaps.
These and other objects and novel features of the present invention
will be more clearly and fully set forth in the following
specification and claims .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the lined tray.
FIG. 2 is a sectional view through a section of the apertures in
the double thickness area, the position of the section being
indicated by the line 2--2 of FIG. 1.
FIG. 3 is a sectional view through one of the double thickness
areas showing the manner in which the lining film is drawn through
the apertures, the position of the section being indicated by the
line 3--3 of FIG. 2.
FIG. 4 is a diagrammatic view of the blank from which the tray is
formed.
FIG. 5 is a diagrammatic view showing the manner in which the film
is drawn by suction into the container for lining the same.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the carton is formed as an open-top tray in order
to show the simplest form of construction. Obviously, a cover may
be hingedly connected to one of the walls, and flanges may be
hingedly secured to others of the walls if it is so desired.
Furthermore, while a particular arrangement of apertures is
illustrated, this specific arrangement is merely a matter of
choice, it only being necessary that the apertures extend through
the double thickness areas of the tray formed by the corner flaps.
Also, while the tray is illustrated as having vertical walls, it
should be understood that trays having upwardly and outwardly
inclined walls could also be used by modifying the shape of the
walls and the corner flaps.
The tray A is formed of the blank illustrated in FIG. 4 of the
drawings. As indicated, it includes a generally rectangular bottom
panel 11 which is foldably connected along parallel fold lines 12
to side walls 13. The bottom panel 11 is also connected along fold
lines 14 which are at right angles to the fold lines 12 to end
walls 15. The side walls 13 are hingedly connected at their ends by
fold lines 16 to corner flaps 17.
In the normal formation of the carton, the side and end walls 13
and 15 are folded upwardly to right angular relation with the
bottom panel 10, and the corner flaps 17 are folded outwardly of
the end walls 15, as is indicated in FIG. 1 of the drawings. As
previously stated, the tray like carton may also include a cover
hingedly connected to one of the side walls 13, and may include
flanges hingedly connected to the upper edges of certain of the
walls, such as the end walls 15.
In the arrangement illustrated, a series of three apertures 19
extend through the end walls 15 in the area which will be normally
covered by the corner flaps 17. Also in the arrangement
illustrated, the apertures are arranged with two of the three
apertures at each corner positioned near the end of the double
thickness area and a third aperture near the side extremity of the
end walls. Obviously, the shape of the apertures may be varied, and
the apertures may be square or any other desired shape.
Furthermore, in place of having three apertures, a single larger
area may be provided if desired.
In the application being simultaneously filed in the name of
Lawrence Knoell, a carton is disclosed having a liner formed of
plastic film or the like which may be heated to partially molten
form, and drawn into the carton to line the entire interior
thereof. As a result, the liner is continuous, and the carton is
capable of holding water or other liquid without leaking. In this
previous structure, the cartons are usually preformed by adhering
or otherwise securing the corner flaps to the adjoining walls. I
have found that this preforming operation may be avoided by drawing
portions of the resilient film through the apertures and into
contact with the surface of the outer layer of the double thickness
area. The film has a tendency to adhere to the surface of the
paperboard, and by drawing the film through the apertures and
against the inner surface of the outer layer of the double
thickness area, the corner flaps may be held in place so that the
carton remains in erected form once the film has been drawn into
the open topped carton. FIG. 2 shows the wall 13 and bottom wall 11
of the carton which is formed of paperboard. Paperboard is always
somewhat porous unless it is specifically formulated so as to avoid
being porous. In other words, the form of paperboard normally used
to produce folding cartons and the like is not air tight, and air
may be drawn through the fibrous board unless it is coated with an
air pervious material. Accordingly, if vacuum is applied to the
outer surfaces of the wall panels, a suction may be created within
the open topped carton which will draw a partially molten plastic
film against the inner surface of the carton wall as indicated in
FIG. 2. The film acting as the carton liner is indicated by the
numeral 20.
FIG. 3 of the drawings is a sectional view through the double
thickness area of the carton and through two of the spaced
apertures 19. As indicated, portions 21 of the liner have been
drawn through the apertures 19 and into contact with the inner
surface of the corner flaps 17 so as to secure the corner flaps to
the wall 15.
This step saves the separate operation of gluing or otherwise
securing the corner flaps in face contact with two opposed walls of
the carton.
FIG. 5 is a very diagrammatic view showing the manner in which this
may be accomplished. The numeral 22 indicates a portion of the
upper reach of an endless conveyor belt having a series of
foraminous pockets in spaced relation supported by the belt 22. As
the conveyor belt 22 moves in the direction of the arrow 24, it
passes beneath a suitable hopper 25 which includes some sort of
means for depositing a carton blank upon the conveyor belt 12
overlying each pocket 23. As the pocket 23 moves to the right, a
plunger 26 supported by a reciprocable plunger arm 27 forms the
flat blank into the foraminous pocket 23, there being means on the
belt 22 to fold the corner flaps 17 into surface contact with the
end walls 15. Such a means is not indicated in the drawings, but is
well known in the art. One such carton forming means capable of
erecting the side and end walls from the bottom panel, and folding
the corner flaps into right angular relation to the walls from
which they are hinged is shown in U.S. Pat. No. 2,516,624 issued
July 27, 1950 to Reynolds Guyer.
As the conveyor belt 22 keeps moving to the right, the film F moves
into overlying relation with the cartons in the pockets 23. The
film F may be extruded directly over the cartons as indicated in
the Knoell application above referred to, or may be drawn from a
supply roll, and heated by heating means indicated at 29. The
foraminous pockets 23 move through a vacuum chamber 30 which
applies vacuum to the outer surfaces of the open topped carton, and
draws the film into the cartons to adhere to the various walls
thereof and form a unitary liner.
During the movement of the carton through the vacuum chamber 30,
the vacuum draws air through the single thickness portions of the
carton more readily than the portions which are of double
thickness, as will be obvious. Accordingly, by providing the
apertures 17 in the inner layer of the double thickness areas, the
vacuum will be drawn through the outer layer in the areas outwardly
of the apertures. As a result, the film will adhere to the corner
flaps 17 and attach them to the end walls 15 virtually as
effectively as the corner flaps would be adhered by use of an
adhesive. Thus the step of separately erecting and gluing the
corner flaps in place is eliminated, and the corner flaps are
attached to the end walls at the same time the film is attached to
the interior of the carton.
This system also has the effect of better securing the lining film
to the entire inner surface of the carton. In following the method
described in the co-pending application above referred to, it has
been found that the film sometimes will not adhere to the inner
surface of the double thickness areas of the carton. Such double
thickness areas are virtually essential if the corners are to be
formed by corner flaps. By providing apertures in the double
thickness areas, the film is drawn more closely to the surface of
the double thickness areas, and a more complete adhesion of the
film to the interior of the carton is likely to result.
In accordance with the Patent Statutes, I have described the
principles of construction and operation of my improvement in LINED
CARTON; and while I have endeavored to set forth the best
embodiment thereof, I desire to have it understood that obvious
changes may be made within the scope of the following claims
without departing from the spirit of my invention.
* * * * *