Package for Containers

Abstract

A package is formed from a carton and containers extending through a bottom panel of the carton. First and second struts and brace apertures in the carton sidewalls provide support for the containers accommodated within the carton.

Description

BACKGROUND

1. Technical Field

The technical field relates to cartons for accommodating containers and packages formed therefrom.

2. Related Art

Cartons for engaging and securing upper portions of containers are known. The containers are typically inserted through apertures in a bottom panel of the carton and secured by engaging radially protruding parts of the containers. One such carton is disclosed in U.S. Pat. No. 6,223,892 to Bakx. Conventional cartons, however, may not securely retain the containers, or may fail to satisfy other requirements recognized in the art.

SUMMARY

According to a first aspect of the invention, a package comprises a plurality of containers accommodated in a carton. The carton comprises a top panel, a bottom panel, a first side panel, a second side panel, a plurality of first struts extending from the bottom panel along a first row, a plurality of second struts extending from the bottom panel along a second row, a first row of first container apertures, each first container aperture being adjacent to one of the plurality of first struts, and a second row of second container apertures, each second container aperture being adjacent to one of the plurality of second struts. Each first strut comprises an upper first strut section, a lower first strut section foldably connected to the bottom panel, and a first inner brace aperture. Each second strut comprises an upper second strut section, a lower second strut section foldably connected to the bottom panel, and a second inner brace aperture. The inner brace apertures may include lower brace edges that support flanges of the containers accommodated in the carton.

According to a second aspect of the invention, the side panels of the carton can include outer brace apertures through which portions of the container flanges extend. The outer brace apertures have lower brace edges that support the undersides of the container flanges. During erection of the carton, the carton blank can be tightly wrapped around the upper portions of the containers to securely retain the containers within the carton.

According to the above aspects of the invention and additional aspects described below, the brace apertures and the struts serve to prevent the containers from inadvertently being pulled downward through the container apertures, and also prevent excessive movement or pivoting of the containers.

Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description, taken in conjunction with the drawings and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.

FIG. 1 is a plan view of a blank used to form a package according to a first embodiment of the invention.

FIG. 2 illustrates an erection step for forming the first package embodiment.

FIG. 3 illustrates an erection step for forming the first package embodiment.

FIG. 4 illustrates an erection step for forming the first package embodiment.

FIG. 5 illustrates the first package embodiment.

DETAILED DESCRIPTION

The present embodiments are addressed to cartons for attachment to containers. The cartons engage and secure upper portions of the containers to form a package.

FIG. 1 is a plan view of a blank 8 used to form a carton or carrier 150. The carton 150 is illustrated in its erected state in FIG. 5, in which it is attached to upper portions of containers 170, forming a package 200. As shown in FIG. 1, the blank 8 may be wholly or partially symmetric about a longitudinal centerline CL. Therefore, certain elements in the drawing figures share common reference numerals in order to reflect the whole and/or partial longitudinal symmetry. In this specification, the terms “bottom,” “top,” “lower,” “upper,” and “side” indicate orientations determined in relation to a fully erected carton placed in an upright configuration.

Referring to FIG. 1, the blank 8 comprises a first top panel 10 foldably connected to a first side panel 20 at a first transverse fold line 21, a bottom panel 30 foldably connected to the first side panel 20 at a second transverse fold line 31, a second side panel 40 foldably connected to the bottom panel 30 at a third transverse fold line 41, and a second top panel 50 foldably connected to the second side panel 40 at a fourth transverse fold line 51. An aperture 12 may be formed in the first top panel 10 for allowing a user to grasp and carry the package.

The transverse fold lines 21, 31, 41, 51 in the blank 8 can be more generally referred to as “lines of weakness” or “lines of disruption” in the blank about which the blank is foldable. Each of the transverse fold lines 21, 31, 41, 51 may be interrupted at one or more locations, for example, and need not be continuous across the transverse direction of the blank 8. One or more cuts may be, for example, placed along one or more of the transverse fold lines 21, 31, 41, 51. In the exemplary embodiment illustrated in FIG. 1, the transverse fold lines 21, 31, 41, 51 may be cut/crease lines in which the cuts facilitate folding of the blank 8 at the fold lines. Any number of cuts may be formed along the fold lines 21, 31, 41, 51, and the number and length of the cuts may be selected according to, for example, the gauge and the stiffness of the material used to form the blank 8. The cuts may be partial cuts (e.g. kiss cuts), or 100% cuts extending through the entire thickness of the blank 8.

The bottom panel 30 includes a plurality of first container-receiving patterns 80 and a plurality of second container-receiving patterns 100. The first container-receiving patterns 80 are arranged in a first row, and the second container-receiving patterns 100 are arranged in a second row spaced from the first row. Each container-receiving pattern 80, 100 is shaped and sized to receive an upper portion of a container 170 that is to be held within the erected carton 150. In the exemplary embodiment, two columns of first container-receiving patterns 80 and two columns of second container-receiving patterns 100 are formed in the bottom panel 30 so that four containers 170 can be accommodated in the erected carton 150, forming a 2×2 package. Other package configurations, such as 2×3, 2×4 or 2×5, 3×2, etc. are also within the scope of the present invention.

Each first container-receiving pattern 80 defines a first strut 81. Each second container-receiving pattern 100 defines a second strut 101. Each first strut 81 includes an upper first strut section 84 and a lower first strut section 86 foldably connected to the upper section 84 at a transverse fold line 82. The first lower strut sections 86 are foldably connected to the bottom panel 30 at transverse fold lines 88. Each second strut 101 includes an upper second strut section 104 and a lower second strut section 106 foldably connected to the upper section 104 at a transverse fold line 102. The second lower strut sections 106 are foldably connected to the bottom panel 30 at transverse fold lines 108.

The first struts 81 include first inner brace apertures 90 cut from the lower first strut sections 86. The second struts 101 include second inner brace apertures 110 cut from the lower second strut sections 106. The first inner brace apertures 90 include lower brace edges 92, and the second inner brace apertures 110 include lower brace edges 112. The inner brace apertures 90, 110 are sized to receive a part of a flange of a container 170 in the interior of the erected carton 150 (illustrated in FIG. 5). The upper first strut sections 104 may each have a distal edge 105 that is complementary in shape with recesses 54 cut into the second top panel 50.

The first side panel 20 includes first outer brace apertures 22. The number of first outer brace apertures 22 may correspond to the number of columns of first container-receiving patterns 80 and to the number columns of patterns 100. Referring also to FIG. 3, each first outer brace aperture 22 is adapted to receive a part of an upper flange portion 175 of a container 170 held within an adjacent, aligned first container aperture 85 formed from a corresponding first container-receiving pattern 80. The first outer brace apertures 22 have lower brace edges 24 located at or adjacent to the first transverse fold line 21 and cut from the first side panel 20. The second side panel 40 includes second outer brace apertures 42 adapted to receive upper flange portions 175 of containers 170 received within second container apertures 105 formed from the second container-receiving patterns 100. The number of second outer brace apertures 42 may also correspond to the number of columns of first container-receiving patterns 80 and to the number of columns of patterns 100. The second outer brace apertures 42 have lower brace edges 44 cut from the second side panel 40. The container-receiving patterns 80, 100 and the first and second brace apertures 22, 42 are arranged in two columns in FIG. 1. From right to left, each column in the blank 8 includes an aligned first outer brace aperture 22, a first container-receiving pattern 80, a second container-receiving pattern 100, and a second outer brace aperture 42.

An exemplary method of erection of the carton 150 to form the package 200 is discussed below with reference to FIGS. 2-5.

FIG. 2 is a perspective view of an erection step of the carton 150 and its initial attachment to the containers 170. Top portions of four containers 170, including their flanges 175, are inserted through the first and second container-receiving patterns 80, 100, one container per pattern. In accordance with the exemplary embodiment, the flanges 175 are defined by lids that close the containers 170. Inserting the containers 170 may serve to open up the first and second container apertures 85, 105 at the first and second container-receiving patterns 80, 100, respectively. The container apertures 85, 105 may, for example, have curved or arcuate sidewalls at each end that may generally conform in shape to the exterior profiles of the containers 170. In FIG. 2, the containers 170 push the first and second struts 81, 101 so that they fold about the transverse fold lines 88, 108, respectively, and extend generally upwardly from the bottom panel 30. The flange 175 of each container 170 in a first container aperture 85 extends in part through a corresponding inner brace aperture 90 of an adjacent first strut 81. The flange 175 of each container 170 in a second container aperture 105 extends in part through a corresponding inner brace aperture 110 of an adjacent second strut 101.

Referring to FIG. 3, the first top panel 10 and the first side panel 20 are folded about the transverse fold line 31 so that the panels 10, 20 extend generally upwardly. Folding the first side panel 20 upwardly causes the flange 175 of each container 170 in a first container aperture 85 to extend in part through a corresponding, aligned first outer brace aperture 22. The second side panel 40 and the second top panel 50 are folded about the transverse fold line 41 so that the panels 40, 50 extend generally upwardly. The flange 175 of each container 170 in a second container aperture 105 thus extends in part through a corresponding, aligned second outer brace aperture 42.

Referring to FIG. 4, the upper first strut sections 84 of the first struts 81 are folded over at the fold lines 82 so that each upper first strut section 84 rests on the upper surface of a flange 175 of a container 170. The flange 175 of each container 170 in a first container aperture 85 extends in part through a corresponding, adjacent inner brace aperture 90, with the underside of the flange resting on a brace edge 92. Similarly, the upper second strut sections 104 of the second struts 101 are folded over at the fold lines 102 so that each upper first strut section 104 rests on the upper surface of a flange 175 of a container 170. The flange 175 of each container 170 in a second container aperture 105 extends in part through a corresponding, adjacent inner brace aperture 110, with the underside of the flange resting on a brace edge 112.

The second top panel 50 is folded about the transverse fold line 51 so that it extends over the tops of the containers 170 disposed within the second row of container apertures 105. The upper strut sections 84, 104 now extend generally parallel to the bottom panel 30. The distal edge 105 of each upper first strut section 104 is complementary in shape with one of the adjacent recess 54 formed in the edge of the second top panel 50. The complementary shape of the edges 105 with the recesses 54 allows the upper second strut sections 104 and the second top panel 50 to lay adjacent to one another on the top of an adjacent flange 175 without the upper strut sections 104 overlapping the top panel 50. When the first top panel 10 is folded over the upper strut sections 104 and the second top panel 50 to close the top of the package, the resulting top panel will therefore have a smoother, flatter appearance.

The first top panel 10 is folded about the transverse fold line 21 so that the underside of the first top panel 10 can be adhered or otherwise secured to the upper surface of the second top panel 50, forming a top panel 120, as shown in FIG. 5. If desired, the underside of the first top panel 10 may be adhered to one or more of the upper strut sections 84, 104. The carton 150 is therefore closed about the upper portions of the containers 170 to complete the package 200. When viewed from the end, the carton 150 has a generally tubular shape with open ends. The width of the top panel 120, measured across the open end of the carton 150, is less than the width of the bottom panel 30. The first and second side panels 20, 40 therefore slope inwardly toward the top of the package 200.

When closing the carton 150, the first top panel 10 and the second top panel 50 can be brought together and joined relatively tightly so that the flanges 175 of the containers 170 extend through and are supported in the outer brace apertures 22, 42 in the side panels 20, 40, respectively. At the exterior edge of the carton 150, the undersides of a flange 175 of a container 170 accommodated in a first container aperture 85 is thereby securely engaged with a first brace edge 24, and the underside of a flange of a container accommodated in a second container aperture 105 is securely engaged with a second brace edge 44.

In the interior of the carton, the first struts 81 support the containers 170 accommodated in the first row of container apertures 85, and the second struts 101 support the containers 170 accommodated in the second row of container apertures 105. Referring also to FIG. 4, the flange 175 of each container 170 in a first container aperture 85 extends in part through a corresponding first inner brace aperture 92. The lower brace edge 94 of the brace aperture 92 is positioned to exert an upward force on the underside of the container's flange 175. Similarly, the flange 175 of each container 170 in a second container aperture 105 extends in part through a corresponding second inner brace aperture 112. The lower brace edge 114 of the brace aperture 112 is positioned to exert an upward force on the underside of the container's flange 175.

According to the above embodiment, containers 170 are securely retained by the outer brace apertures 22, 42 in the side panels 20, 40 and by the struts 81, 101 in the carton interior. The containers 170 are thereby secured against being pulled downwardly through the bottom panel 30, and are also secured against excessive translation and/or pivoting within the carton 150.

The exemplary embodiment shown in FIG. 5 illustrates a carton 150 accommodating four containers 170 arranged in two rows and four columns. Additional columns, for example, may be added by increasing the width of the blank 8 (in the transverse direction in FIG. 1) and forming additional opposed container-receiving patterns 80, 100 in the bottom panel 30 and corresponding aligned brace apertures 22, 42 in the side panels 10, 20, respectively.

In this specification, the term “flange” indicates any radially projecting rim, collar, ring, raised portion or protrusion extending from an upper portion of a container.

The blank 8 according to the present invention can be, for example, formed from coated paperboard and similar materials. The blank can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the resultant package to function at least generally as described in this specification.

The interior and/or exterior sides of the blank 8 can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blank may then be coated with a varnish to protect any information printed on the blank. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank, or laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the exemplary embodiment of the present invention, a fold line can be any substantially linear, although not necessarily straight, form of disruption or weakening in the blank 8 that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, fold lines include: score lines; crease lines; a cut 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.

The above embodiments may be described as having one or panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

The description is not intended to limit the invention to the form disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments, not explicitly defined in the detailed description.

Claims

1. A package, comprising:

a carton, comprising: a top panel; a bottom panel; a first side panel; a second side panel; a plurality of first struts extending from the bottom panel along a first row, each first strut comprising an upper first strut section, a lower first strut section foldably connected to the bottom panel, and a first inner brace aperture; a plurality of second struts extending from the bottom panel along a second row, each second strut comprising an upper second strut section, a lower second strut section foldably connected to the bottom panel, and a second inner brace aperture; a first row of first container apertures, each first container aperture being adjacent to one of the plurality of first struts; and a second row of second container apertures spaced from the first row of container apertures, each second container aperture being adjacent to one of the plurality of second struts; and

a plurality of containers, each container being accommodated in one of the container apertures and having a flange with an underside, wherein

the flange of the container in each first container aperture is at least partially accommodated in the first inner brace aperture of the adjacent first strut, and

the flange of the container in each second container aperture is at least partially accommodated in the second inner brace aperture of the adjacent second strut.

2. The package of claim 1, wherein each first inner brace aperture comprises a first lower brace edge, the underside of the flange of the container at least partially accommodated in each first inner brace aperture being supported on the first lower brace edge of the first inner brace aperture.

3. The package of claim 2, wherein the upper first strut section of each first strut lies on a top surface of the container accommodated in the adjacent first container aperture.

4. The package of claim 3, further comprising:

a plurality of first outer brace apertures in the first side panel; and

a plurality of second outer brace apertures in the second side panel, wherein

each container is supported by at least one of the outer brace apertures at the underside of its flange.

5. The package of claim 3, wherein each first strut's upper first strut section is connected to its lower first strut section at a fold line.

6. The package of claim 1, wherein the upper first strut section of each first strut lies on a top surface of the container accommodated in the adjacent first inner container aperture.

7. The package of claim 1, further comprising:

a plurality of first outer brace apertures in the first side panel; and

a plurality of second outer brace apertures in the second side panel, wherein

each container is supported by at least one of the outer brace apertures at the underside of its flange.

8. The package of claim 1, wherein the first and second rows of container apertures are arranged in a plurality of columns.

9. The package of claim 1, wherein the top panel comprises a first top panel and a second top panel, the second top panel having a plurality of recesses, each recess in the second top panel being complementary in shape with a distal edge of an adjacent upper second strut section.

10. The package of claim 1, wherein the lower first strut sections are substantially upright.

11. The package of claim 1, wherein the carton has a substantially tubular shape with open ends.

12. A blank, comprising:

at least one top panel;

a first side panel, the first side panel having at least one first outer brace aperture;

a bottom panel;

a second side panel, the second side panel having at least one second outer brace aperture;

a first row of at least one first container-receiving pattern in the bottom panel, each first container-receiving pattern defining an upper first strut section, a lower first strut section foldably connected to the upper first strut section, and a first inner brace aperture; and

a second row of at least one second container-receiving pattern in the bottom panel, each second container-receiving pattern defining an upper second strut section, a lower second strut section foldably connected to the upper second strut section, and a second inner brace aperture, wherein

each first outer brace aperture is aligned with a first container-receiving pattern.

13. The blank of claim 12, wherein:

each second container-receiving pattern is aligned with a first container-receiving pattern; and

each second outer brace aperture is aligned a first container-receiving pattern.

14. The blank of claim 13, further comprising a second top panel foldably connected to the second side panel.

15. The blank of claim 12, wherein the blank is constructed from paperboard.

16. The blank of claim 12, wherein the at least one first container-receiving pattern comprises a plurality of first container-receiving patterns arranged in a plurality of columns.

17. A method of erecting a package, comprising:

providing a blank comprising: at least one top panel; a first side panel, the first side panel having at least one first outer brace aperture; a bottom panel; a second side panel, the second side panel having at least one second outer brace aperture; a first row of at least one first container-receiving pattern in the bottom panel, each first container-receiving pattern defining an upper first strut section, a lower first strut section foldably connected to the upper first strut section, and a first inner brace aperture; and a second row of at least one second container-receiving pattern in the bottom panel, each second container-receiving pattern defining an upper second strut section, a lower second strut section foldably connected to the upper second strut section, and a second inner brace aperture, wherein each first outer brace aperture is aligned with a first container-receiving pattern;

providing a plurality of containers, each container having an upper portion with a flange;

moving the upper portion of one of the containers through each one of the first container-receiving patterns;

moving the upper portion of one of the containers through each one of the second container-receiving patterns;

for each first container-receiving pattern, folding the upper first strut section over a top of the container moved through the first container-receiving pattern;

for each second container-receiving pattern, folding the upper second strut section over a top of the container moved through the second container-receiving pattern; and

securing the top panel over the containers.

18. The method of claim 17, further comprising moving the flanges of each container through a brace aperture in an adjacent one of the side panels.

19. The method of claim 18, further comprising:

for each first container-receiving pattern, folding the lower first strut section upwardly before folding the upper first strut section; and

for each second container-receiving pattern, folding the lower second strut section upwardly before folding the upper second strut section.

20. A package, comprising:

a carton, comprising: a top panel; a bottom panel; a first side panel; a second side panel; at least one first strut extending from the bottom panel along a first row, each first strut comprising an upper first strut section and a lower first strut section foldably connected to the bottom panel; at least one second strut extending from the bottom panel along a second row, each second strut comprising an upper second strut section and a lower second strut section foldably connected to the bottom panel; at least one first container aperture, each first container aperture being adjacent to one of the at least one first struts; and at least one second container aperture, each second container aperture being adjacent to one of the at least one second struts; and

a plurality of containers, each container being accommodated in one of the container apertures and having a flange with an underside, wherein

the upper first strut section of each first strut lies on a top surface of the container accommodated in the adjacent first container aperture, and

the upper second strut section of each second strut lies on a top surface of the container accommodated in the adjacent second container aperture.

21. The package of claim 20, further comprising:

a plurality of first outer brace apertures in the first side panel; and

a plurality of second outer brace apertures in the second side panel, wherein

each container is supported by at least one of the outer brace apertures at the underside of its flange.

22. The package of claim 21, wherein each first strut comprises a first inner brace aperture, the flange of the container in each first container aperture being at least partially accommodated in the first inner brace aperture of the adjacent first strut.

23. The package of claim 22, wherein each first inner brace aperture comprises a first lower brace edge, the underside of the flange of the container at least partially accommodated in each first inner brace aperture being supported on the first lower brace edge of the first inner brace aperture.

24. The package of claim 20, wherein:

each first strut's upper first strut section is connected to its lower first strut section at a fold line; and

each first strut's lower first strut section is connected to the bottom panel at a fold line.

25. The package of claim 20, wherein the lower first strut sections are substantially upright.

26. The package of claim 20, wherein the carton has a substantially tubular shape with open ends.