ARTICLE CARRIER HAVING REINFORCED BOTTOM WALL
An article carrier comprises upstanding walls adjoining a reinforced bottom wall. The reinforced bottom wall has an arrangement of lesser-reinforced regions. Each lesser-reinforced region may comprise a region of enhanced deformability. The reinforced bottom wall comprises at least a first bottom-wall panel and a second bottom-wall panel disposed in face-contacting relationship with respect to one another. Each lesser-reinforced region may comprise an aperture in one of the first bottom-wall panel and the second bottom-wall panel. Each lesser-reinforced region may comprise an embossment in one of the first bottom-wall panel and the second bottom-wall panel. Each lesser-reinforced region may comprise an embossment in one of the first bottom-wall panel and the second bottom-wall panel and an aperture in another one of the first bottom-wall panel and the second bottom-wall panel in alignment with the embossment.
This application claims priority to U.S. Provisional Application No. 61/025,640 filed Feb. 1, 2008, the entirety of which is incorporated herein by reference.
TECHNICAL FIELDThis invention relates to cartons, and more particularly, the invention relates to a tray-style article carrier having a reinforced bottom wall.
BACKGROUND OF THE INVENTIONArticle carriers are useful for transporting and storing articles. Tray-style article carriers are particularly useful for transporting and storing multiples of articles such as bottles. The designation “tray-style” means that the carrier is open at its top end. Often manufacturers and distributors of bottled products such as beverages have a need to stack tray-style article carriers that are loaded with bottles. The loaded carriers may be stacked for storage at a location such as a warehouse or may be stacked for transport in a stacked configuration, such as a stacked array on a pallet.
A problem in stacking carriers including tray-style article carriers is maintaining stability of the stacked array of carriers. This problem is made worse when the contents of the carriers are weighted articles such as beverage bottles. Instability arises due to at least two causes. One cause of instability is that the weight of loaded carriers can cause the bottom wall of middle-tier or lower-tier loaded carriers in an array to give way under substantial loads. When the bottom wall of a carrier gives way this can cause the loaded carriers and/or their contents to shift position and thereby cause the array to topple. A second cause of instability that can also ultimately result in the toppling of a stacked array is that a loaded carrier stacked on top of another loaded carrier may slide laterally and become vertically displaced unless it is restrained from lateral movement.
The problems described above are particularly applicable to tray-style article carriers that are loaded with articles such as beverage bottles. It is convenient to store, transport and display beverage bottles in tray-style carriers. Because each bottle is individually sealed, it is not necessary to have a fully-closed carrier. Trays constructed of heavy-weight, rigid, durable plastic are often used for packaging bottles for storage, transport and display. The strength of such trays permits loaded trays of this nature to be stacked reliably. However, trays of this type are typically much more expensive than trays that are constructed from less substantial materials such as paper-based materials in general and paper-based and thin-plastic sheet materials in particular. Thus it can be appreciated that manufacturers and distributors often desire to use cartons or carriers made of paperboard or thin-plastic sheets of material in order to reduce packaging costs.
Packaging costs may often be reduced further by using paperboard, corrugated board or other sheet material of as low a caliper (thickness) as possible. Paperboard, corrugated board or other sheet-material packaging also may be more desirable to distributors of bottled beverages than heavier-weight materials because lighter-weight packaging materials produce lighter-weight loaded packages thereby reducing transportation costs and providing a loaded carrier that is easier to handle.
When a carrier or some of its parts are constructed of relatively thin, flexible material such as paperboard, corrugated board or thin plastic sheets, the problem of the bottom wall giving way (as described above) can occur, particularly if the upper ends of bottles of a lower-tier are not optimally aligned with the lower ends of bottles of an upper tier.
Therefore, despite the advantages offered by packaging that is light-weight, the walls of such packaging, particularly the bottom walls of paperboard, corrugated board or thin-sheet plastic material, are inherently weaker than the walls of heavier plastic packaging. Thus, it can be appreciated that there is a need to have an article carrier made of light-weight material that can be stacked reliably when loaded articles such as beverage bottles.
SUMMARY OF THE INVENTIONAn article carrier comprises upstanding walls adjoining a reinforced bottom wall according to exemplary embodiments of the present invention. The reinforced bottom wall has an arrangement of lesser-reinforced regions. Each lesser-reinforced region comprises a region of enhanced deformability, that is, a region that is more susceptible to being deformed than the remainder of the reinforced bottom wall. In accordance with additional exemplary embodiments the reinforced bottom wall comprises at least a first bottom-wall panel and a second bottom-wall panel disposed in face-contacting relationship with respect to one another. In accordance with an aspect of exemplary embodiments, each lesser-reinforced region comprises a predetermined pattern cut into one of said first bottom-wall panel and said second bottom-wall panel. In accordance with another aspect of exemplary embodiments, each lesser-reinforced region comprises an aperture as a predetermined pattern that is cut into in one of the first bottom-wall panel and the second bottom-wall panel. In accordance with a further aspect of the exemplary embodiments each lesser-reinforced region comprises an embossment in one of the first bottom-wall panel and the second bottom-wall panel. In accordance with yet another aspect of the exemplary embodiments each lesser-reinforced region comprises an embossment in one of the first bottom-wall panel and the second bottom-wall panel and an aperture in another one of the first bottom-wall panel and the second bottom-wall panel in alignment with said embossment.
As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of an article carrier having a reinforcing panel with product alignment features.
In the this description of the present invention, various exemplary embodiments of a tray-style article carrier having a reinforcing panel with product alignment features will be described in the context of utilization in the transportation of beverage bottles for retail distribution; however, it is contemplated that such an article carrier can be used for any suitable application. Generally, the article carrier that is illustrated and described is a lighter-weight, lower-cost and potentially disposable alternative to heavy-weight, rigid, reusable plastic trays that are commonly used store, transport and display beverage bottles.
As an overview, the invention provides a carrier having upstanding walls attached to a reinforced bottom wall. The reinforced bottom wall includes an arrangement of regions of lesser reinforcement (or lesser-reinforced regions). The invention further teaches that each region of lesser-reinforcement may comprise a region of enhanced deformability. That is, the material from which the bottom wall is constructed is made to be more susceptible to deformation from perpendicularly-applied forces. For example, paperboard, corrugated board or thin-sheet plastic material sandwiched between two vertically-aligned bottles is subject to deformation. When a region of the bottom wall is effectively weakened in a manner as described herein it is thereby made less reinforced and susceptible to greater deformation than the remainder of the bottom wall. These regions of lesser reinforcement or enhanced deformability are also referred to herein as deformable areas. The invention is particularly useful for packaging PET-type bottles that can withstand substantial axial loads when filled with a liquid.
In exemplary embodiments described herein, the invention contemplates that the reinforced bottom wall comprises a multiple-ply structure of at least two panels, namely, a first bottom wall panel and a second bottom wall panel. As will be described in greater detail herein, each region of lesser reinforcement is created by modifying either or both of the bottom wall panels at a selected location so that its resistance to deformation is lessened at that location.
A tray-style article carrier 100 includes either an apertured reinforcing panel 108 or an embossed reinforcing panel 310, and an apertured tray-style article carrier 300 includes an embossed reinforcing panel 310, that enhances structural integrity and provides carrier and product alignment and locking features, as will be described in more detail below. This basic configuration of an article carrier formable from a blank as taught by the invention is applicable to articles designated by both numerals “100” and “300” in this description and accompanying drawings.
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A reinforcing panel 108 having apertures 110 can be formed from paperboard, cardstock, cardboard, corrugated board, plastic sheet, and the like. The apertured reinforcing panel 108 is aligned with the outer surface of the bottom wall 102 of the article carrier 100. The apertured reinforcing panel 108 is placed on, or attached to, the outer surface of the bottom wall 102, as illustrated in
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An embossed reinforcing panel 310 having a plurality of embossed portions 312 is also illustrated. The embossed reinforcing panel 310 can be formed from paperboard, cardstock, cardboard, plastic sheet, any combination thereof, and the like. The embossed reinforcing panel 310 is in alignment with the outer surface of the bottom wall 302 of the apertured article carrier 300. As illustrated in
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The invention is particularly useful with tray-style article carriers for bottles wherein the upper ends of the bottles extend at least slightly above side and end walls (the upstanding walls) of the carrier in the manner illustrated. The bottles are thus able to serve as the axial load-bearing structures of the invention as well as serve as a nesting component for substantially interlocking vertically-adjacent packages. The regions of lesser reinforcement are disposed to correspond with the overlapping upper ends and lower ends of bottles of respective adjacent tiers of carriers. The interaction between the upper end of a bottle (the bottle top) and the centrally-disposed concavity of the lower end of an adjacent bottle causes the lesser-reinforced carrier material that is sandwiched between the two to be upwardly embossed. This action, in turn promotes nesting (and thereby stabilization) between adjacent tires of loaded, stacked carriers. Thus, the bottom walls of the carriers 100, 300 are reinforced but also promote nesting (and thereby stabilization) when loaded with articles such as bottles.
As described and herein, the invention provides a carrier having a reinforced bottom wall that resists undesirable deformation and degradation when loaded carriers are stacked upon one another. At the same time, the reinforced bottom wall provides “weakened” regions (lesser-reinforced regions or regions of enhanced deformability) that can be made nestable with respect to tops of bottles and the central concavities of PET-type bottles. The nesting promoted by the carriers enables the axial load of a stack of loaded carriers to be distributed along columns of bottles. This weight distribution enhances the strength and stability of a stack or stacked array of loaded carriers that are constructed in accordance with the teachings of the invention. Nesting promoted by the carriers also help inhibit lateral movement of stacked carriers with respect to one another.
Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. For example, although the exemplary article carriers 100, 300 are designed to carry eight bottles 114, as shown in the Figures, it is contemplated that the article carrier can be modified to hold more or fewer bottles 114, or to divide the bottles in to one or more groups. The article carrier may be constructed from disposable material or may be reusable. As an example of an additional variation, the bottom wall may be integrally formed so as to produce the regions of lesser reinforcement or enhanced deformability. All such modifications, combinations, and variations are included herein by the scope of this disclosure and the following claims.
Claims
1. An article carrier comprising:
- a plurality of upstanding walls adjoining a reinforced bottom wall, said reinforced bottom wall having an arrangement of lesser-reinforced regions.
2. The article carrier of claim 1, wherein each said lesser-reinforced region comprises a region of enhanced deformability.
3. The article carrier of claim 1, wherein said reinforced bottom wall comprises at least a first bottom-wall panel and a second bottom-wall panel disposed in face-contacting relationship with respect to one another.
4. The article carrier of claim 3, wherein each said lesser-reinforced region comprises a predetermined pattern cut into one of said first bottom-wall panel and said second bottom-wall panel.
5. The article carrier of claim 4, wherein said predetermined pattern comprises an aperture.
6. The article carrier of claim 3, wherein each said lesser-reinforced region comprises an embossment in one of said first bottom-wall panel and said second bottom-wall panel.
7. The article carrier of claim 3, wherein each said lesser-reinforced region comprises an embossment in one of said first bottom-wall panel and said second bottom-wall panel and an aperture in another of said first bottom-wall panel and said second bottom-wall panel in alignment with said embossment.
8. A tray-style carrier, comprising:
- a bottom wall;
- a pair of opposed side walls hingedly connected to said bottom wall;
- a pair of opposed end walls hingedly connected to said bottom wall and hingedly interconnecting said side walls to form a tubular structure;
- a reinforcing panel disposed against said bottom wall, said reinforcing panel comprising a plurality of first regions that will promote upward deformation of a plurality of second regions of said bottom wall that are in alignment with said plurality of first regions when an upward force is applied in registry with each of said first regions.
9. The tray-style carrier of claim 8, wherein said plurality of first regions comprise a plurality of apertures.
10. The tray-style carrier of claim 9, wherein said reinforcing panel is disposed on an inner surface of said bottom wall.
11. The tray-style carrier of claim 9, wherein said reinforcing panel is disposed on an outer surface of said bottom wall.
12. The tray-style carrier of claim 8, wherein said plurality of first regions comprise a plurality of embossed portions and wherein said reinforcing panel is disposed on an inner surface of said bottom wall such that said plurality of embossed portions extend upwardly with respect to said bottom wall.
13. A tray-style carrier, comprising:
- a bottom wall comprising a plurality of apertures;
- a pair of opposed side walls hingedly connected to said bottom wall;
- a pair of opposed end walls hingedly connected to said bottom wall and hingedly interconnecting said side walls to form a tubular structure; and
- a reinforcing panel disposed against said bottom wall, said reinforcing panel comprising a plurality of embossed portions in substantial alignment with said plurality of apertures wherein said plurality of embossed portions extend upwardly with respect to said bottom wall.
14. The tray-style carrier of claim 13, wherein said reinforcing panel is disposed upon an outer surface of said bottom wall such that said embossed portions extend into said plurality of apertures.
15. The tray-style carrier of claim 13, wherein said reinforcing panel is disposed upon an inner surface of said bottom wall such that said plurality of embossed portions substantially cover said plurality of apertures.
Type: Application
Filed: Feb 2, 2009
Publication Date: Aug 6, 2009
Inventor: Aaron L. Bates (Raleigh, NC)
Application Number: 12/363,888
International Classification: B65D 75/00 (20060101); B65D 6/04 (20060101);