Triangular carton, blank, and method
A carton for carrying a plurality of like-sized objects of generally circular cross-sectional shape includes a generally triangular first panel forming a carton base bounded by three sides. Each side is connected to an adjacent side by a rounded corner having a radius of curvature approximately equal to that of curvature of the objects. A generally triangular second panel is coextensive with and spaced from the base panel in aligned facing relation. A one-piece peripheral sidewall secured to and extending between the first and second panels has a cross-sectional shape coextensive with the first and second panels. The peripheral sidewall has three planar sides, each connected to an adjacent planar side through a non-folded corner having a radius of curvature which is approximately equal to a radius of curvature of the objects to be carried. In further aspects, a carton blank and method of carton assembly are also provided.
The present invention relates generally to cartons or containers and, more particularly, to improved containers having a three-piece, generally triangular prismatic construction. It is particularly advantageous for use in connection with objects having at least a portion which is generally in circular cross-sectional shape, such as cans, bottles, balls, rolls, tubes, and the like.
Traditionally, cartons or containers for multi-packs of beverage containers, such as six-pack or twelve-pack cartons for beer, soft drinks, and the like have been formed by folding and securing from one-piece blanks of paper board sheet material. Often, it is desired to employ a paper board sheet material that is laminated with a decorative plastic, foil, and/or printed layer to increase attractiveness to the consumer. Such laminates must be formed prior to forming the blank and add significantly to the cost of the sheet material, particularly where laminate includes a metallized or holographic layer. Thus, a drawback of using a one-piece carton is that the tops and bottoms of the carton are also, necessarily, formed of the expensive laminate sheet material. This adds to the cost of the carton, while adding little or no additional value to the carton since, generally, only the side of the carton is viewed by the purchaser, i.e., when it is stacked on a shelf or display, e.g., at a place of purchase.
Another drawback of the conventional one-piece carton designs is the large amount of waste typically generated when the blanks are stamped or die cut. This likewise adds to the cost of the carton, particularly when an expensive laminated paperboard sheet material is used, again, since any decorative laminates must be applied prior to cutting the blank.
The present invention provides a new and improved carton, blank, and method that overcome the above-referenced problems and others.
SUMMARY OF THE INVENTIONIn one aspect, a carton for carrying a plurality of like objects having a generally circular cross-sectional shape includes a generally triangular first panel forming a base of the carton having first, second, and third sides and a generally triangular second panel coextensive with the base panel and opposing the base panel in aligned facing relation. A one-piece peripheral sidewall is secured to and extends between the first and second panels and has a cross-sectional shape coextensive with the first and second panels. The peripheral sidewall has three planar sides, each of which is connected to an adjacent planar side through a non-folded corner having a radius of curvature which is approximately equal to a radius of curvature of the objects to be carried.
In another aspect, a carton sidewall blank is formed of a sheet material being cut and scored and adapted to be assembled to define a tubular carton sidewall having generally triangular cross-sectional shape. The blank is further adapted to be combined with at least one separately formed, generally triangular end closure panel to define a generally triangular prismatic carton, the triangular prismatic carton being adapted to carry a plurality of like objects having a generally circular cross-sectional shape. The blank includes a generally rectangular main portion for forming the tubular sidewall and a first fold line parallel to a first edge of the main portion defining a first folding strip along the first edge. A second fold line runs parallel to a second edge of the main portion opposite the first edge and defines a second folding strip along the second edge. A plurality of score lines within the folding strips run perpendicular to the first and second fold lines and are arranged to facilitate bending the sidewall blank to form the tubular carton sidewall wherein the tubular carton sidewall has three planar sidewall surfaces wherein each planar sidewall surface is adjoined to an adjacent planar sidewall surface via a curved sidewall surface having a radius of curvature approximately equal to a radius of curvature of the objects to be carried.
In yet another aspect of the present invention, a method of forming a generally triangular prismatic carton adapted to carry a plurality of like objects having a generally circular cross-sectional shape is provided. The method comprises forming sidewall blank from a sheet of material comprising a generally rectangular main portion for forming the tubular sidewall and scoring a first fold line on the main portion parallel to a first edge of the main portion, the fold line defining a first folding strip along the first edge. A plurality of score lines are scored within the first folding strip running perpendicular to the first and second fold lines. The sidewall blank is bent to form a tubular carton sidewall having three planar sidewall surfaces wherein each planar sidewall surfaces is adjoined to an adjacent planar sidewall surface via a curved sidewall surface having a radius of curvature approximately equal to a radius of curvature of the objects to be carried, wherein the plurality of score lines arranged to facilitate the bending. An end of the tubular carton sidewall is closed by attaching a separately formed, generally triangular panel.
One advantage of the present invention resides in the provision of a triangular carton which uses less sheet material than the conventional rectangular cartons, thereby reducing its cost.
Another advantage of the present invention resides in the provision of a three-piece carton construction which does not require the base and top portion to be formed from the same sheet material as the sidewall portion. As such, the cost of the components is reduced even more since expensive printed and/or laminated materials such as a sheet material having lithographic, foil, or holographic laminate layers can be reserved for the sidewall, and wherein an inexpensive undecorated sheet material may be used for the base and/or cover portions.
Yet another advantage of the present invention resides in the fact that its manufacture may be adapted to existing assembly equipment.
Yet another advantage resides in a the provision of a prismatic carton system allowing cylindrical, spherical, or other objects having a generally circular cross-sectional shape to be packaged in less space, thereby reducing space requirements and/or storage costs for the packaged goods.
Still further benefits and advantages of the invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGSThe following detailed description may be best understood when read in reference to the accompanying drawings wherein:
Referring to
The carton 10 preferably includes a structurally reinforced upper rim 18. This may be formed, for example, by folding or rolling the upper edge of the sidewall panel 12. In a preferred embodiment, the upper rim 18 is formed by folding the upper edge of the sidewall panel 12 toward the interior facing surface thereof. In another preferred embodiment, the upper rim 18 is formed by rolling the upper edge of the sidewall panel 12 toward the exterior facing surface thereof.
The carton 10 is depicted in
Referring now to
Alternatively, the upper portion 24 of the lid 22 may be moveable with respect to or separable from the base portion 26. For example, the base portion 26 may attach to the rim 18 of the sidewall 12 with the upper portion 24 being removably and/or moveably mounted on the base portion 26 of the cover 22. For example, the base portion 26 may be secured to the rim 18, e.g., via an adhesive, mechanical fastener, or the like. The upper portion 24, in turn, is movably or removably secured to the base portion 26, e.g., via a frictional fit, snap fit, or other retention means. In an especially preferred embodiment, the upper portion 24 is secured to the base portion 26 via a hinge 28 (shown in phantom) wherein it may pivotally be opened to a position 29 (shown in phantom) and may be secured in the depicted closed position at the opposite corner via a fastener 30 (shown in phantom), e.g., a snap-fit type fastener or the like. For example, fastener 30 may be comprise a protrusion formed on one of the members 24 and 26 engaging a complimentary depression or receptacle formed on the other.
Referring now to
Horizontal scoring lines 42 may be formed parallel to transversely extending edges 44 for folding therealong, e.g., toward an unprinted surface 40 of the sidewall 12. Alternatively, the upper edge may be reinforced by rolling, e.g., toward the printed side of the sidewall blank 12 opposite the unprinted side 40.
During construction of the carton 10, the optional handle portion 20 is folded along the line 32, toward the unprinted side 40. The folding of the handle 20 provides additional strength to prevent tearing. However, a non-folded, single-ply handle is also contemplated, e.g., wherein the sheet material forming the sidewall and handle is of sufficient strength to allow the unit to be carried without tearing.
The edges 44 may be folded or rolled as described above. The sidewall blank 12 is then bent or shaped about a mandrel, which may be facilitated by vertical scoring lines 46 preformed in the regions of the blank 12 corresponding to the rounded corners 48 (see
The blank 12 is sized so that the axially extending ends 49 (i.e., extending parallel to the axis of the formed tubular sidewall 12) form an axially extending overlap or seam 51 (see
In the depicted embodiments of
Referring now to
With reference now to
With continued reference to
With reference to
Referring now to
Referring now to
A lid or cover 72 includes a plurality of apertures 74 arranged and adapted to receive the bottlenecks 64 when the lid 72 is placed on the sidewall 62 such that at least a portion of the bottleneck 64 protrudes therethrough, and preferably resting on the shoulders 65. A plurality of slits 76 are spaced about and extend radially from the apertures 74. The paperboard or other sheet material forming the lid 72 is sufficiently rigid or stiff so as to stabilize the bottles 16 within the container 60 and provide positive retention of the bottles 16 therein during transport, handling, and when the container 60 is carried by the handle 20.
Although the material forming the lid 72 has sufficient stiffness to retain the bottles, the material forming the lid 72 is also sufficiently flexible or
Although the material forming the lid 72 has sufficient stiffness to retain the bottles, the material forming the lid 72 is also sufficiently flexible or deformable such that the radial tabs 77 defined by the slits 76 and openings 74 will give way so to allow a bottle 16 to be removed from the carton when desired by grasping the protruding portion of the bottleneck 66 and pulling the bottle 16 upward and through the opening 74, without it being necessary to remove or detach the lid 72 from the carton 60. The slits 76 may be precut or, alternatively, may comprise perforated lines, partially cut lines, or otherwise weakened regions, which allows the slits 76 to be readily broken when a bottle 16 is removed from the container 60.
The lid 72 may be fastened to the upper rim 68 of the sidewall 62 via any number of methods. For example, a mechanical or adhesive type of fastener may be employed or, in the case a carton formed of a plastic or plastic laminate sheet material, the lid 72 may be bonded or fused to the sidewall 62 through the application of heat and pressure as described above. In the embodiment depicted, the peripheral edge 78 of the lid 72 is folded (both upwardly and downwardly folded edges are contemplated) to provide a vertically aligned surface for bonding or fastening to the rim 68 of the sidewall 62 (fastening to an interior or exterior facing surface of the sidewall 62 is contemplated). Alternatively the lid 72 may be fastened to the sidewall 62 through the use of clips, a snap-fit or interlocking engagement between the upper rim 68 of the sidewall 62 and the peripheral edge 78 of the lid 72, or other mechanical faster.
With reference to
Referring now to
With reference to
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. The forms hereinbefore described being merely explanatory and exemplary, it is intended that the invention be construed as including all such modifications and alterations.
Claims
1. A carton for carrying a plurality of like-sized objects having at least a portion having a generally circular cross-sectional shape:
- a generally triangular first panel forming a base of the carton, said first panel bounded three sides, wherein each of said three sides is connected to an adjacent side by a rounded corner having a radius of curvature which is approximately equal to a radius of curvature of said objects to be carried;
- a generally triangular second panel coextensive with the base panel and spaced apart from the base panel in aligned facing relation;
- a one-piece peripheral sidewall secured to and extending between the first and second panels, said peripheral sidewall having a cross-sectional shape coextensive with the first and second panels;
- said peripheral sidewall having three generally planar sides, each of said generally planar sides connected to an adjacent generally planar side through a non-folded corner having a radius of curvature approximately equal to a radius of curvature of the objects to be carried.
2. The carton of claim 1, wherein the objects to be carried are cylindrical in shape.
3. The carton of claim 1, wherein the objects to be carried are beverage containers.
4. The carton of claim 1, wherein the objects to be carried are cans.
5. The carton of claim 1, wherein the objects to be carried are selected from beer cans, beer bottles, soft drink cans, and soft drink bottles.
6. The carton of claim 1, further comprising a handle for carrying the container.
7. The carton of claim 6, wherein said handle is integral with said peripheral sidewall.
8. The carton of claim 1, wherein the peripheral sidewall includes overlapping first and second ends which are secured together to form a seam.
9. The carton of claim 8, wherein the first and second ends are secured via thermosealing the mutually facing surfaces of said seam.
10. The carton of claim 8, wherein the seam is formed along one of said generally planar sides.
11. The carton of claim 8, wherein the seam is formed along one of said non-folded corners.
12. The carton of claim 8, wherein one of said first and second ends comprises a handle.
13. The carton of claim 12, wherein the handle is integral with the peripheral sidewall.
14. The carton of claim 13, wherein the handle is formed from a single layer of material.
15. The carton of claim 13, wherein said handle includes first and second handle panels folded about a fold line therebetween, each of said first and second panels having first and second apertures, respectively, said first and second apertures being aligned when said first and second panels are folded about said fold line to form a handle opening adapted to receive fingers of a user for carrying the container.
16. The carton of claim 15, wherein the handle is swingably movable between a first storage position in which the handle lies flat against said peripheral sidewall and a second carrying position in which the handle extends perpendicularly from said sidewall.
17. The carton of claim 15, further comprising handle reinforcement members foldably moveable between a first position within said apertures and a second position adjacent to and reinforcing said handle.
18. The carton of claim 1, wherein the first panel and said sidewall are formed of a paperboard material.
19. The carton of claim 1, wherein said sidewall is formed from a first sheet material having decorative indicia applied to a surface thereof and said first panel is formed from a second sheet material not having a decorative indicia applied to a surface thereof.
20. The carton of claim 1, wherein said objects to be carried are beverage bottles, each having a cylindrical main body portion depending coaxially from a narrowed neck.
21. The carton of claim 20, wherein the second panel includes a plurality of openings for receiving said at least a portion of the necks therethrough.
22. The carton of claim 21, wherein the second panel further comprises a plurality of slits extending radially outwardly from said openings and adapted to allow said cylindrical portion of said bottles to pass through the second panel.
23. The carton of claim 22, wherein said slits are selected from cuts which pass completely through the second panel, cuts which pass partially through the second panel, and perforated lines.
24. The carton of claim 22, wherein the carton is adapted to hold six beverage bottles.
25. The carton of claim 1, wherein the carton is adapted to hold N number of objects, wherein N is selected from 3, 6, 10, 15, 21, 28, and 36.
26. The carton of claim 1, wherein the carton is adapted to hold six objects.
27. The carton of claim 1, wherein the second panel is removably attached to said sidewall.
28. The carton of claim 1, wherein the sidewall further comprises a reinforced rim.
29. The carton of claim 28, wherein the reinforced rim is selected from a rolled edge of sidewall and a folded edge of said sidewall.
30. The carton of claim 1, wherein said second panel includes:
- a peripheral engaging portion affixed to a rim portion of the sidewall defined peripherally about an opening provided on the carton; and
- a closure portion swingably attached to the peripheral engaging portion, said closure portion movable between a closed position covering said opening and an open position allowing access through said opening.
31. The carton of claim 1, wherein said objects are spherical.
32. The carton of claim 31, wherein said objects are balls.
33. A carton sidewall blank formed of a sheet of material being cut and scored and adapted to be assembled to define a tubular carton sidewall having generally triangular cross-sectional shape, and further adapted to be combined with at least one separately formed, generally triangular end closure panel to define a generally triangular prismatic carton, the triangular prismatic carton being adapted to carry a plurality of like objects having a generally circular cross-sectional shape, the blank comprising:
- a generally rectangular main portion for forming the tubular sidewall;
- a first fold line parallel to a first edge of the main portion defining a first folding strip along said first edge;
- a plurality of score lines within said first folding strip running perpendicular to said first and second fold lines;
- said plurality of score lines arranged to facilitate bending said sidewall blank to form said tubular carton sidewall wherein said tubular carton sidewall has three planar sidewall surfaces wherein each planar sidewall surfaces is adjoined to an adjacent planar sidewall surface via a curved sidewall surface having a radius of curvature approximately equal to a radius of curvature of said objects to be carried.
34. The blank of claim 33, further comprising a second fold line parallel to a second edge of the main portion opposite said first edge defining a second folding strip along said second edge.
35. The blank of claim 33, further comprising a handle portion integrally formed with said main portion and extending from a third edge of said main portion perpendicular to said first and second edges, said handle portion comprising a handle fold line defining a proximal handle panel and a distal handle panel, each of said distal and proximal handle portions having an aperture formed therein, said apertures spaced so as to be aligned when said distal handle portion is folded along said fold line back onto proximal handle portion, and further wherein said distal handle portion is sized to overlap with said main body portion when said distal handle portion is folded along said fold line back onto proximal handle portion.
36. A method of forming a generally triangular prismatic carton adapted to carry a plurality of like objects having a generally circular cross-sectional shape, the method comprising:
- forming sidewall blank from a sheet of material comprising a generally rectangular main portion for forming the tubular sidewall;
- scoring a first fold line on the main portion parallel to a first edge of the main portion, the fold line defining a first folding strip along said first edge; and
- scoring a plurality of score lines within said first folding strip running perpendicular to said first and second fold lines;
- bending said sidewall blank into a tubular carton sidewall having three planar sidewall surfaces wherein each planar sidewall surfaces is adjoined to an adjacent planar sidewall surface via a curved sidewall surface having a radius of curvature approximately equal to a radius of curvature of said objects to be carried;
- said plurality of score lines arranged to facilitate said bending;
- closing an end of said tubular carton sidewall by attaching a separately formed, generally triangular panel.
Type: Application
Filed: Jul 2, 2003
Publication Date: Jan 6, 2005
Inventor: John Cahill (North Hampton, NH)
Application Number: 10/612,740