Blank and an open-top carton constructed therefrom

Abstract

A container comprises a bottom ball, opposite pair of end walls, and opposite pair of side walls. The opposite pair of the end walls foldably joined to opposite ends of the bottom wall and the opposite pair of side walls foldably joined to opposite sides of the bottom wall. The pair of side walls and the pair of end walls cooperating with one another to form an open-top tray. Each of the pair of side walls comprising at least one locking tab integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to paperboard cartons and more particularly, to a die cut blank and an open-top carton tray assembled therefrom.

Conventional foldable cartons are well known and are used in a variety of applications. For example, the packaging industry utilizes a vast number of cartons in which numerous products are packaged for subsequent shipment. Current frame-vue tray cartons used for packaging golf ball require forming machinery that has expensive tooling that must be changed for each size package. Also, the short side walls of conventional packages can be pushed into the frame by the weight of the golf balls, resulting in creases and tears to the package.

SUMMARY OF THE INVENTION

The present invention relates to a package comprising an open-top tray, a plurality of sleeve boxes, and a cover to fit over the open-top carton tray to thereby enclosing the sleeve boxes therein for shipping, storing and sale.

Accordingly, one aspect of the present invention relates to a container comprises a bottom ball, opposite pair of end walls, and opposite pair of side walls. The opposite pair of the end walls are foldably joined to opposite ends of the bottom wall and the opposite pair of side walls are foldably joined to opposite sides of the bottom wall. The pair of side walls and the pair of end walls are cooperating with one another to form an open-top tray. Each of the pair of side walls comprises at least one locking tab that is integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another.

Another aspect of the present invention relates to a paperboard blank for making a container having a bottom wall, opposite end walls, and opposite side walls. A central panel comprises opposite side edges and opposite end edges, and which forms the bottom wall of the container. A side panel is foldably joined to each of the side edges of the central panel. An end panel is foldably joined to each of the end edges of the central panel. The side panels and the end panels are configured to form respective side walls and end walls in a container made from the blank. Each of the side walls comprises at least one locking tab that is integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another.

A further aspect of the present invention relates to a container comprising a bottom ball, opposite end walls being defined by inner and outer end walls, and opposite side walls being defined by inner and outer side walls. The end walls are foldably joined to opposite ends of the bottom wall and the side walls are foldably joined to opposite sides of the bottom wall. The side walls and the end walls are cooperating with one another to form an open-top tray. Each of the side walls having at least one locking tab is integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another. At least one locking tab inhibits deflection of the inner end wall relative to the outer end wall.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

FIG. 1 is an exploded perspective view of a package including a cover, an open-top carton tray and a plurality of sleeve boxes positionable within the open-top carton tray in accordance to a preferred embodiment of the present invention;

FIG. 2 is a top view of a blank used to construct the open-top carton tray of FIG. 1;

FIG. 3 is a close-up view of a portion of a side wall of the open-top carton tray shown in FIG. 2;

FIG. 4 is a close-up view of a portion of an end wall of the open-top carton tray shown in FIG. 2;

FIGS. 5A-5D illustrate the steps in constructing the open-top carton tray from the blank in FIG. 2 in accordance with the preferred embodiment of the present invention.

DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a package 10 in accordance with one embodiment of the present invention, wherein the package 10 comprises an open-top carton tray 12 and a plurality of sleeve boxes 14 configured to be positioned within the open-top carton tray 12. A cover 16 may be used to fit over the open-top carton tray 12, thereby enclosing the sleeve boxes 14 therein for transporting the package 10.

The cover 16 includes a top panel 11 having a pair of side panels 13a,13b and a pair of end panels 15a, 15b extending from the top panel 11 at generally right angles to form an interior space 17. The side panels 13a, 13b and the end panels 15a, 15b may have equal heights with one another and in turn, correspond to the height of the open-top carton tray 12.

The open-top carton tray 12 includes an interior space 18, into which the plurality of sleeve boxes 14 may be positioned. Each of the plurality of sleeve boxes 14 contains a number of golf balls (not shown) or other items, although any item may be used in connection with the package 10 according to the present invention without departing from the scope of the invention. For example, FIG. 1 illustrates five sleeve boxes 14 configured to be placed within the interior space 18 of the open-top carton tray 12, but depending on the size and shape of the open-top carton tray 12, any number of sleeve boxes 14 may be disposed in the interior space 18 and that the sleeve boxes 14 do not move about within the interior space 18 during shipping. The plurality of sleeve boxes 14 are sized and shaped such that a maximum number of these sleeve boxes 14 can be placed in the interior space 18. As an example shown in FIG. 1, the plurality of sleeve boxes 14 are rectangular in shape, but other shapes may be used as well. The package 10 is generally rectangular in shape; however, other geometrical shapes may be used accordingly.

The open-top carton tray 12 is preferably constructed from a flat sheet of heat-resistant laminated linerboard or corrugated paperboard having a laminated linerboard, although any foldable material may be used. The open-top carton tray 12 is formed from a blank 20 (shown in FIG. 2) which is scored and cut to define a series of foldably interconnected walls and panels as hereinafter described. It is well within the scope of this invention to use any suitable material well known or later developed in the art such as, for example, plastic, foil or the like.

FIG. 2 is a top view of the blank 20 used to construct the open-top carton tray 12. The blank 20 is divided into three major sections by two substantially parallel longitudinal fold lines 22, 24 and further divided into three minor segments by two substantially parallel transverse fold lines 26, 28. Bottom panel 30 is formed by the intersection of the respective two transverse fold lines 26, 28 and respective longitudinal fold lines 22, 24. End panels 32a, 32b are formed by respective transverse fold lines 26, 28 and are generally opposite-hand to one another along an imaginary transverse centerline (not shown) at the bottom panel 30.

When the blank 20 is formed into the open-top carton tray 12 as shown in FIG. 1, each of the end panel 32a, 32b is formed into respective end walls 34a, 34b and 34c, 34d, and respective landing surface 36a, 36b. The end walls 34a, 34b are spaced apart from one another by the landing surface 36a and the end walls 34c, 34d are spaced apart from one another by the landing surface 36b. The landing surface 36a is formed by two parallel fold lines 38a, 40a and the landing surface 36b is formed by two parallel fold lines 38b, 40b. The end walls 34a, 34c define outer walls and the end walls 34b and 34d define inner walls. Slots 35a, 35b, 35c, 35d are formed into the respective landing surfaces 36a, 36b and the respective inner walls 34b, 34d. For example, and only for illustrative purpose, FIG. 4 depicts the detail of the slot 35a with respect to inner end wall 34b and landing surface 36a. The detail of other slots 35b, 35c, and 35d are identical to that of FIG. 4 and as such, a detailed View of each of the slots 35b, 35c, and 35d will be omitted to avoid redundancy. Each of the respective end panels 32a, 32b includes a respective glue flap 42a, 42b that is defined by respective creased lines 44a, 44b. The glue flaps 42a, 42b project outwardly from the walls 34b, 34d and each is provided with a quantity of adhesive thereon for properly securing the identical end panels 32a, 32b to the bottom wall 30. Alternative forms of securing end panels 32a, 32b to the bottom wall 30 may be used such as by staple, slots and tabs, etc.

Similarly, side panels 46a, 46b are formed by fold lines 22, 24, respectively. When the blank 20 is formed into the open-top carton tray as shown in FIG. 1, the side panel 46a is formed into walls 48a, 48b and the side panel 46b is formed into walls 48c, 48d. The walls 48a, 48b are spaced apart by a landing surface 50a and the walls 48c, 48d are spaced apart by a landing surface 50b. The walls 48a, 48c define respective outer walls and the walls 48b, 48d define respective inner walls. Each of the identical side panels 46a, 46b includes a respective glue flap 47a, 47b that are defined by respective creased lines 49a, 49b. Each glue flap 47a, 47b projects outwardly from its respective walls 48b, 48d and each glue flap 47a, 47b is provided with a quantity of adhesive thereon for properly securing the respective side panel 46a, 46b to the bottom wall 30. Alternative forms of securing side panel 46a, 46b to the bottom wall 30 may be used such as by staple, slots and tabs, etc.

The walls 48a, 48c are spaced apart from one another by the landing surface 50a and the walls 48b, 58d are spaced apart from one another by the landing surface 50b. The landing surface 50a is defined by two parallel fold lines 52a, 54a and the landing surface 50b is defined by two parallel fold lines 52b, 54b.

Each of the respective side panels 42a, 42b includes two pair of respective locking tabs 56a, 56b, 56c, and 56d that extend from respective ends of the landing surfaces 50a, 50b. Although the present invention discloses a pair of locking tabs 56a, 56b on the side panel 42a and a pair of locking tabs 56d 56c on the side panel 42b, only one locking tab on each side panels 42a, 42b (depending on the design) may be used. The locking tabs 56a, 56b extend from the opposed ends of the fold line 52a and the locking tabs 56c, 56d extend from opposed ends of the fold line 52c. In addition, the locking tabs 56a, 56b and 56c, 56d are formed and die cut into the respective side panels 46a, 46b and are substantially similar with one another. The respective locking tabs 56a, 56b form respective cut outs 58a, 58b and respective slots 60a, 60b with the inner side wall 48b. Similarly, the respective locking tabs 56c, 56d each form respective cut outs 58c, 58d and respective slots 60c, 60d with the inner side wall 48d.

For illustrative purpose, FIG. 3 depicts the details of cut out 58a and slot 60a with respect to the inner side wall 48b. When the blank 20 is folded to form the open-top tray 12 as depicted in FIG. 1, the respective slots 60a, 60b and 60c, 60d on the respective side panels 46a, 46b are intimately engaged with the corresponding slots 35a, 35b and 35c, 35d on the end panels 32a, 32b and the locking tabs 56a, 56b and 56c, 56d are concealed under the respective landing surface 36a, 36b. Each of the locking tabs 56a, 56b and 56c, 56d provides additional support to the inner walls 34b, 34c by securely holding the inner walls 34b, 34c of the end panel 32a, 32b in the vertical position and preventing the inner walls 34b, 34c from deflecting outwardly from the bottom wall 30.

For illustrative purpose, FIG. 5D depicts a partially cut out view of two corners of the open-top tray 12. The other two corner of the open-top tray 12 are exactly the same and the locking tabs 56b and 56c are concealed each corner of the tray 12. Each of the locking tabs 56a, 56b, 56c, and 56d has a length (L) that permits maximum support for the inner walls 34b, 34d when the locking tabs 56a, 56b and 56c, 56d are in locking positions. As the free body diagram illustrates, there are generally three major forces, namely, glue force F_g, tear force F_t, and locking tab force F_l. The glue force F_g acts downwardly to hold in place the end panel 32b (as shown in FIG. 2) and in turn, the inner wall 34d, to the bottom wall 30. The locking tab force F_l acts as an I-beam structure to stiffen the inner wall 34d in the vertical position. The tear force F_t is caused by the sleeve boxes 14 which act against the end panel 32b in vertical position, to tear the inner wall 34d from the bottom wall 30 when the sleeve boxes 14 are tightly fit inside the open-top carton tray 12. Each of the locking tabs 56a, 56b and 56c, 56d lies in a plane that is substantially perpendicular to a vertical plane in which the outer wall 34c lies and also substantially perpendicular to a vertical plane in which the inner wall 34d lies. As such, each of the locking tabs 56a, 56b and 56c, 56d provides an I-beam-like structure wherein the tab 56d functions like a web portion of an I-beam to stiffen the inner wall 34d, thereby inhibiting deflection of the inner wall 34d relative to the outer wall 34c. This is particularly important in a certain region of the inner wall 34d, where deflection of the inner wall 34d is not resisted by either the landing surface 36b of the outer wall 34c or by the flap 42b, which is glued directly to the bottom wall 30. It should be noted that the magnitude of two locking tab force F_l plus the glue force F_g is much greater than the magnitude of the tear force F_t and thus the present invention produces a sturdy open-top carton tray 12. The locking tabs 56a, 56b and 56c, 56d of the present invention are exemplary and thus, other design of the locking tabs with various lengths and shapes may be used as well.

FIGS. 5A-5D illustrate the steps of constructing the blank 20 to form the open-top carton tray 12 as described hereinabove with respect to FIG. 2. Manual set-up of the open-top carton tray 12 is easily accomplished. First, as shown in FIG. 5A, the respective side panels 46a, 46b and end panels 32a, 32b are folded inwardly or toward the bottom wall 30 (as shown in FIG. 2) at the respective fold lines 52a, 52c and 40a, 40b and the respective flaps 47a, 47b and 42a, 42b are preferably glued to inside of the bottom wall 30. Depending on the alternative design, the flaps 42a, 42b may be tucked or stapled or slided into a jacket within the bottom wall 30.

Next, in FIG. 5B, the end walls 34a, 34b, 34c, 34d are folded at substantially 90 degrees with respect to the bottom wall 30. While in an upright position, the end walls 34a, 34b, 34c, 34d are substantially parallel with one another.

Referring now to FIG. 5C, one side panel 46a is folded inwardly at substantially 90 degrees with respect to the bottom wall 30 at the fold lines 22 and the other side panel 46b is folded inwardly at substantially 90 degrees with respect to the bottom wall 30 at the fold lines 24. In an upright position, the side walls 48a, 48b and 48c, 48d are substantially parallel with one another and the locking tabs 56a, 56b and 56c, 56d and the corresponding slots 60a, 60b and 60c, 60d are intimately engaged with the end walls 34a, 34b, 34c, and 34d as best depicted in FIG. 5D. The locking tabs 56a, 56b and 56c, 56d are concealed under their respective landing surface 36a, 36b. Finally, the plurality of sleeve boxes 14 are tightly placed in the interior space 18 in a manner that the length of the each sleeve box 14 corresponds to the width of the open-top tray 12.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A container comprising a bottom ball, opposite pair of end walls, and opposite pair of side walls, the opposite pair of the end walls foldably joined to opposite ends of the bottom wall and the opposite pair of side walls foldably joined to opposite sides of the bottom wall, the pair of side walls and the pair of end walls cooperating with one another to form an open-top tray and wherein each of the pair of side walls comprising at least one locking tab integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another.

2. The container of claim 1 wherein each of the side walls comprises two locking tabs integrally formed on opposed ends of the each side walls.

3. The container of claim 1 wherein each of the locking tabs is die cut into the side walls by forming a cut out and a slot therein.

4. The container of claim 1 wherein the at least one locking tab support the pair of the side walls when the at least one locking tab is in a locking position.

5. The container of claim 4 wherein the locking position is defined by frictionally engaging the at least one locking tab with a slot formed between inner and outer end wall panels.

6. The container of claim 1 wherein each of the locking tab functions like a web portion of an I-beam to stiffen the pair of the side walls.

7. The container of claim 1 wherein the side walls are defined by inner and outer wall panels and wherein the locking tab inhibits deflection of the inner wall panel relative to the outer wall panel.

8. The container of claim 1 wherein the side wall panels are spaced apart by a landing surface.

9. The container of claim 8 wherein the landing surface is defined by two parallel fold lines.

10. The container of claim 1 further comprising a plurality of sleeve boxes positioned within the open-top tray.

11. The container of claim 1 further comprising a cover fit over the open-top tray.

12. A paperboard blank for making a container having a bottom wall, opposite end walls, and opposite side walls, comprising:

a central panel having opposite side edges and opposite end edges, and which forms the bottom wall of the container; a side panel foldably joined to each of the side edges of the central panel; an end panel foldably joined to each of the end edges of the central panel, the side panels and the end panels configured to form respective side walls and end walls in a container made from the blank and wherein each of the side walls comprising at least one locking tab integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another.

13. The paperboard blank of claim 12 wherein the side walls are defined by inner and outer wall panels wherein the inner and outer wall panels are positioned at substantially right angle with respect to the bottom wall.

14. The paperboard blank of claim 12 wherein the inner and outer wall panels are spaced apart from one another by a landing surface.

15. The paperboard blank of claim 13 wherein the landing surface is formed by a pair of parallel fold lines.

16. The paperboard blank of claim 12 each of the locking tabs is die cut into the side panels by forming a cut out and a slot therein.

17. A container comprising a bottom ball, opposite end walls being defined by inner and outer end walls, and opposite side walls being defined by inner and outer sides walls; the end walls foldably joined to opposite ends of the bottom wall and the side walls foldably joined to opposite sides of the bottom wall, the side walls and the end walls cooperating with one another to form an open-top tray, each of the side walls having at least one locking tab integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another and wherein the at least one locking tab inhibits deflection of the inner end wall relative to the outer end wall.

18. The container of claim 17 wherein the at least one locking tab lies in a plane that is substantially perpendicular to a vertical plane in which the outer end wall panel lies and wherein the at least one locking tab substantially perpendicular to a vertical plane in which the inner end wall panel lies.