BOTTLE CARRIER

Abstract

A method of constructing a carrier for bottles (such as two or four craft beer bottles), wherein the layout fits through a digital printer, is disclosed. A flat of beverage board is printed upon (on one side or both, though all exterior surfaces of the finished package are derived from one side of the board) with individualized and/or short-run graphics. The flat is die-cut and folded into a square or rectangle container closed by a tab that is glued on the back of one of side panels, and bottom flaps are folded and glued into place. A riser extends up from each of a pair of opposite sides to support a handle flap that extends across the top of the container, and the handle flaps are glued to the opposite riser and together across the top of the container.

Description

REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent application Ser. No. 15/046,430, filed Feb. 17, 2016, with title BOTTLE CARRIER, which claims priority to U.S. Provisional Application No. 62/117,193, filed Feb. 17, 2015, with title BOTTLE CARRIER, the entire disclosures of which are hereby incorporated by reference.

FIELD

The present invention relates to carriers for carrying bottles. More specifically, the present invention relates to structures and assembly of cartons for carrying bottles, the cartons being made of paper board and the like and having a handle for carrying the same.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a flat that may be formed into a bottle carrier according to a first embodiment.

FIG. 2 is a plan view of a flat that may be formed into a carrier according to a second embodiment.

FIG. 3 is a plan view of a flat that may be formed into a carrier according to a third embodiment.

FIG. 4 is a plan view of a flat that may be formed into a carrier according to a fourth embodiment.

FIG. 5 is an expanded plan view of a detail of the flat of FIG. 4.

FIG. 6 is a flowchart depicting a method of forming a carrier from a flat.

FIG. 7 is a plan view of a flat that may be formed into a carrier according to a fifth embodiment.

FIG. 8 is a top perspective view of a carrier formed by the flat of FIG. 7.

FIG. 9 is a plan view of a flat that may be formed into a carrier according to a sixth embodiment.

FIG. 10 is a top perspective view of a carrier formed by the flat of FIG. 9.

DESCRIPTION

For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the invention as illustrated therein are contemplated as would normally occur to one skilled in the art to which the invention relates.

Generally, one form of the present apparatus is a carrier that holds two bottles, such as those used for craft beer. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles. This embodiment, illustrated in FIG. 1, is a flat form 100 that is die-cut from beverage board (such as that known as “20pt board” available from most paper merchants), though other materials may also be used as will occur to those skilled in the art. FIG. 1 shows one side (e.g., a front) of flat 100, and it will be understood that the opposing side (e.g., the corresponding rear) is essentially a mirror image of the view shown. As discussed in further detail below, form 100 may be assembled or formed into an assembled configuration to form the carrier.

As shown, form 100 includes front panel 110, back panel 120, side panels 130, 135, bottom panels 140, 145, and tab 170 that collectively define a container portion 148. In the embodiment shown, panels 110, 120, 130, 135 define a top edge extending along a line 149. Form 100 further includes risers 150 and handle flaps 160 from which carrying holes 165 are fully or partially cut out, extending substantially from line 149 away from top edge, to define a handle portion 158. In alternative embodiments, portions of handle portion may extend below line 149. For example, segment 180 may extend below line 149, thus causing portions of handle flaps 160 to lie below line 149. It will be understood that in some embodiments, after form 100 is assembled into the assembled configuration, some portions of handle portion 158, such as portions of handle flaps 160, may lie below line 149, due to manufacturing or assembly-related anomalies or inconsistencies. In the embodiment shown, holes 165 are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration.

Container portion 148 includes a plurality of fold lines 10, 12, 14, 16, 18, 20, 22, 24 along which portions of form 100 may be folded in order to form the assembled configuration of form 100. More particularly, fold line 10 extends between panels 135, 110, while fold line 12 extends between panels 110, 130. Fold line 14 extends between panels 130, 120, and fold line 16 extends between panel 160 and flap 170. Fold line 18 extends between panels 120 and the adjacent bottom panel 140, while fold line 20 extends between panel 130 and the adjacent bottom panel 145. Fold line 22 extends between panel 110 the adjacent bottom panel 140, and fold line 24 extends between panel 135 and the adjacent bottom panel 145. Fold lines 190 extend between handle flap 160 and riser 150. In the embodiment shown, fold lines 10, 12, 14, 16, 190 are parallel to one another and perpendicular to fold lines 18, 20, 22, 24. As shown, fold lines 18, 20, 22, 24 are co-linear when form 100 is unassembled. In the embodiment shown, fold lines 10, 12, 14, 16, 18, 20, 22, and 24 represent imaginary lines along which form 100 may be folded to form the carrier. However, in some embodiments, any or all of fold lines 10, 12, 14, 16, 18, 20, 22, 24 may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 100. Edges and/or fold lines shown herein as parallel or perpendicular might be substantially (but not precisely) parallel or perpendicular, or may have other relative orientations as will occur to those skilled in the art.

As form 100 is formed by a die cutting process, for example, handle edge segments 180 are also cut, separating each handle flap 160 from its respective neighboring panel 110 or 120. Moreover, in the embodiment shown, fold lines 190 are scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 100. However, in other embodiments, one or both of fold lines 190 may not include such features such that fold lines 190 represent imaginary lines along which flaps 160 may be folded. Moreover, in other embodiments, segments 180 and creases 190 may be treated before or after form 100 is created through a die cutting process.

After form 100 is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels 135, 110, 130, and 120 are folded at approximately 90-degree angles to form a rectangular shape, in cross section, such as in cross section along line 149 (e.g., block 302 of FIG. 6). Tab 170 is likewise folded to be inside side panel 135 and attached with any suitable glue or other adhesive or bonding agent or non-adhesive technique such as a tab-and-slot configuration (all generically “glued” or “attached” herein) as will occur to those skilled in the art (e.g., block 304 of FIG. 6). More particularly, panel 135 is folded along fold line 10, panel 110 is folded along fold line 12, and panel 120 is folded along fold line 14, such that panels 110, 120 end up being parallel to one another and each end up perpendicular to panels 130, 135. As mentioned above, tab 170 is folded inside panel 135 and bonded thereto, such that a bonding is provided between tab 170 and panel 135 along a third plane that is substantially perpendicular to line 149 and parallel to a second plane (block 306 of FIG. 6). More specifically, in the illustrated embodiment, tab 170 is bonded to the back of panel 135. Thus, panels 110, 120, 130, 135 will remain in the substantially rectangular cross-sectional shape, due at least in part to the bonding between tab 170 and panel 135. As shown, panels 110, 120 define a length of the rectangular cross-sectional shape, and panels 130, 135 define a width of the rectangular cross-sectional shape. In the present embodiment, the length as defined by panels 110, 120 is longer than the width defined by panels 130, 135. However, other suitable relative dimensions of panels 110, 120, 130, 135 and other portions of flat 100 that may be provided in order to accommodate a particular amount and/or size of bottles or articles will be apparent to persons skilled in the art in view of the teachings herein.

In order to form the bottom portion of the expanded carrier configuration of form 100, bottom panels 140 and 145 are folded up along their respective fold lines 18, 20, 22, 24 and glued together. In the embodiment shown, in the assembled configuration, bottom panels 140, 145 lie substantially perpendicularly to each of the panels 110, 120, 130, 135. Thus, in the embodiment shown, panels 110, 120, 130, 135, 140, 145 in the assembled configuration define a single compartment extending substantially from bottom panels 140, 145 to line 149 (e.g., block 302 of FIG. 6). More particularly, panels 110, 120, 130, 135 define sidewalls of a compartment, while bottom panels 140, 145 collectively define a bottom portion or bottom wall of a compartment.

Handle flaps 160 are folded at fold lines 190 so that they extend perpendicular to risers 150 and parallel to side panels 130 and 135 (blocks 308, 310 of FIG. 6). The rear portions of each of handle flaps 160 are glued together such that each of the holes 165 is aligned with the other to form a single opening in handle portion 158, and such that flaps 160 lie substantially along a second plane in order to form a unitary handle of handle portion 158 (blocks 312, 314 of FIG. 6). In the embodiment shown, the second plane essentially bisects container portion 148 such that the handle formed by handle portion 158 lies at the midpoint between panels 130, 135. Thus, in the embodiment shown, handle portion 158 essentially defines two cells above line 149 that are each suitable for holding a bottle. Accordingly, while carton portion 148 defines a single compartment as described above, handle portion 158 allows for an effective separation of bottles or other articles that may be placed in the compartment of carton portion 148.

In some implementations, before or after form 100 is cut out, form 100 may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form 100. In some of these implementations, the text and/or graphics are customized by a third party, automatically computer-generated per a remote customer's request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities and/or digital printing technology. Because of the configuration of form 100 as described herein, text and graphics need only be applied to one side of form 100 in its flattened configuration in order to display such text and/or graphics on the surfaces of form 100 that are on the outside when form 100 is in its expanded, carrier configuration.

FIG. 2 shows another embodiment of a form 200 that may be constructed or formed into an assembled configuration to make a carrier configured to hold four bottles. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles as will occur to those having ordinary skill in the art in view this disclosure. This embodiment, illustrated in FIG. 2, is also a form 200 that is die-cut from beverage board, though other materials may also be used as will occur to those skilled in the art. Form 200 is similar to form 100, except for the differences described below. Moreover, while FIG. 2 shows one side (e.g., a front) of flat 200, it will be understood that the opposing (e.g., rear) side is essentially a mirror image of the view shown in FIG. 2.

Form 200 includes front panel 210, back panel 220, side panels 230, 235, bottom panels 240, 245, and tab 270 that collectively define a container portion 248. In the embodiment shown, panels 210, 220, 230, 235 define a top edge extending along a line 249. Form 200 also includes risers 250a, 250b and handle flaps 260a, 260b extending substantially from line 249 away from top edge, that define a handle portion 258. As shown, handle flap 260a and riser 250a extend from panel 230 such that a portion of flap 260a is outboard of panel 230 and flap 270. Handle flap 260b extends from panels 235, 210, and riser 250b extends from panel 235.

As form 200 goes through the die-cutting process, handle edge segments 280a, 280b are also cut, separating handle flap 260a from panel 230, and separating handle flap 260b from panels 235, 210. In the embodiment shown, fold lines 290 are scored, perforated, or otherwise treated or configured to facilitate later handling or assembly of the form 200 during the die cutting process. However, in other embodiments, one or both of fold lines 290 do not include such features, so fold lines 290 represent imaginary lines along which flaps 260a, 260b may be folded relative to risers 250a, 250b. Moreover, in other embodiments, segments 280a, 280b and fold lines 290 may be treated before or after form 200 is created through a die cutting process. In the embodiment shown, handle flaps 260a, 260b each include carrying holes 265 that are cut out from handle flaps 260a, 260b. As shown in the present embodiment, holes 265 are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration. In the embodiment illustrated in FIG. 2, holes 265 include an obround shape, but in other embodiments may include any other suitable shape as will occur to persons skilled in the art in view of the teachings herein.

In alternative embodiments, portions of handle portion 258 may extend below line 249. For example, segments 280a, 280b may extend below line 249, thus causing portions of handle flaps 260a, 260b to lie below line 249. It will be understood that in some embodiments, after form 200 is formed into the assembled configuration, some portions of handle portion 258, such as portions of handle flaps 260a, 260b, may lie below line 249, due to manufacturing or assembly related anomalies or inconsistencies.

Container portion 248 comprises a plurality of fold lines 26, 28, 30, 32, 34, 36, 38, 40 along which portions of form 200 may be folded in order to form the assembled configuration of form 200. As shown, fold line 26 extends between panels 220, 235, while fold line 28 extends between panels 235, 210. Fold line 30 extends between panels 210, 230, and fold line 32 extends between panel 230 and flap 270. Fold line 32 extends between panel 230 and the adjacent bottom panel 240, while fold line 36 extends between panel 210 and the adjacent bottom panel 245. Fold line 38 extends between panel 235 and the adjacent bottom panel 240, and fold line 40 extends between panel 220 and the adjacent bottom panel 245. Fold lines 290 extend between handle flap 260a, 260b and riser 250a, 250b. In the embodiment shown, fold lines 26, 28, 30, 32, 190 are parallel to one another and perpendicular to fold lines 34, 36, 38, 40. As shown, fold lines 34, 36, 38, 40 are collinear when form 200 is unassembled. In the embodiment shown, fold lines 26, 28, 30, 32, 34, 36, 38, 40 represent imaginary lines along which form 200 may be folded to form the carrier. However, in some embodiments, any or all of fold lines 26, 28, 30, 32, 34, 36, 38, 40 may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 200.

After form 200 is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels 230, 210, 235, and 220 are folded at approximately 90-degree angles with each other to form a rectangle, in cross section, such as in cross section along line 249 (e.g., block 302 of FIG. 6). Tab 270 is likewise folded to be inside side panel 220 such that it is glued to the back of panel 220 (e.g., block 304 of FIG. 6). Accordingly, a bonding or non-bonding attachment (as will occur to those skilled in the art) is provided between tab 270 and panel 220 along a third plane that is substantially perpendicular to line 249 and parallel to a second plane (block 306 of FIG. 6).

In order to form the bottom portion of the expanded carrier configuration of form 100, bottom panels 240 and 245 are folded up along their respective fold lines 34, 36, 38, 40 and glued together. In the embodiment shown, in the assembled configuration, bottom panels 240, 245 lie substantially perpendicularly to each of the panels 210, 220, 230, 235. Thus, in the embodiment shown, panels 210, 220, 230, 235, 240, 245 in the assembled configuration define a single compartment extending substantially from bottom panels 240, 245 to line 249 (block 302 of FIG. 6). More particularly, panels 210, 220, 230, 235 define sidewalls of a compartment while bottom panels 240, 245 collectively define a bottom portion or bottom wall of a compartment.

Handle flaps 260a, 260b are folded at fold lines 290 so that they extend perpendicular to risers 250a, 250b, and parallel to front and rear panels 210, 220 (blocks 308, 310 of FIG. 6). The rear portions of each of handle flaps 260a, 260b are glued together such that each of the holes 265 is aligned with the other to form a single opening in handle portion 258, and such that flaps 260a, 260b lie substantially along a second plane in order to form a unitary handle of handle portion 258 (blocks 312, 314 of FIG. 6). In the embodiment shown, the second plane essentially bisects container portion 248 such that handle of handle portion 258 lies at the midpoint between panels 210, 220. Thus, in the embodiment shown, handle portion 258 essentially defines two cells above line 249 that are each suitable for holding two bottles. Accordingly, while container portion 248 defines a single compartment as described above, handle portion 258 allows for an effective separation of bottles or other articles that may be placed in the compartment of container portion 248.

In some implementations, before or after form 200 is cut out, form 200 may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form 200. In some of these implementations, the text and/or graphics are customized by a third-party, automatically computer-generated per a remote customer's request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities. Due to the configuration of form 200 as described herein, text and graphics need only be applied to one side of form 200 in its flattened configuration in order to display such text and/or graphics on the front or outer portion of form 200 in its expanded, carrier configuration.

FIG. 3 shows another embodiment of a form 300 that may be constructed or formed into an assembled configuration to make a carrier. Form 300 is substantially similar to form 100, discussed above with reference to FIG. 1, except for the differences described below. For that reason, substantially similar or identical structures are not labeled with reference numerals. As shown, form 300 includes exemplary alternative bottom panels 340, 342, 344, 346 that are configured differently than bottom panels 140, 145. As shown, panels 340, 344 include a substantially rectangular shape. Panels 342, 346 include features that allow those panels to lock together as bottom panels 340, 342, 344, and 346 are folded upwardly to form a bottom of carrier. As shown, panel 344 includes dimensions that allow it to substantially cover the surface area of the bottom portion of carrier in the expanded configuration. For example, panel 344 has substantially the same width as panel 110 and a height that substantially matches the width of panel 130 so that panel 344 substantially covers the bottom of the container portion of the carrier when it is assembled. Other suitable configurations (including relative size, shape, and other features) of bottom panels 340, 342, 344, 346 will be apparent to persons skilled in the art in view of the teachings herein.

Form 300 includes an exemplary alternative handle portion 358. Particularly, handle portion 358 includes an alternative segment (cut) 380 that includes a substantially straight, horizontal portion 380a and a curved portion 380b, as seen best in FIG. 5. Thus, segment is cut along horizontal portion 380a and curved portion 380b. Including the curved portion 380b in segment 380 may decrease the tendency of handle portion 358 to tear at the junction between the risers 150 and adjoining panels 110, 120, respectively. Form 300 also includes an alternative fold line 390. Fold line 390 comprises an upper portion 390a, middle portion 390b, and lower portion 390c. As shown, middle portion 390b is scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 300, such as folding of the handle flaps 160. As shown, upper and lower portions 390a, 390c represent imaginary lines along which form 100 may be folded to form the carrier. However, in other embodiments, upper and lower portions 390a, 390c may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 300. In some embodiments, such a configuration may give additional strength to handle portion 358. For example, such a configuration may decrease the tendency of handle portion 358 to tear at the junction between the risers 150 and adjoining panels 110, 120, respectively. Other suitable configurations of handle portion 358 will be apparent to persons skilled in the art in view of the teachings herein.

FIG. 4 shows another embodiment of a form 400 that may be constructed or formed into an assembled configuration to make a carrier. Form 400 is substantially similar to form 200, except for the differences described below. For that reason, substantially similar or identical structures are not labeled with reference numerals. As shown, form 400 includes exemplary alternative bottom panels 440, 442, 444, 446 that are configured differently from bottom panels 240, 245. Panels 442, 446 include features that allow those panels to lock together or be attached more securely to bottom panels 440, 444 as bottom panels 440, 442, 444, and 446 are folded upwardly to form a bottom of carrier. As shown, panel 444 includes dimensions that allow it to substantially cover the surface area of the bottom portion of carrier in the expanded configuration. For example, panel 444 has substantially the same width as panel 235 and a height that substantially matches the width of panel 210. Other suitable configurations of bottom panels 440, 442, 444, 446 will be apparent to persons skilled in the art in view of the teachings herein.

Form 400 includes an exemplary alternative handle portion 458. Particularly, handle portion 458 includes an alternative segment 480 that includes a horizontal portion 480a and a curved portion 480b, as seen best in FIG. 5. It will be understood that although segments 380, 480 and fold lines 390, 490 are different, respectively, the portions shown in the close-up view of FIG. 5 are substantially identical. Thus, FIG. 5 is used to demonstrate and show such structures of form 400 as well.

As shown, segment 480 is cut along horizontal portion 480a and curved portion 480b. Including the radius of curved portion in segment 480 may decrease the tendency of handle portion 458 to tear at the junction between the risers 250a, 250b and adjoining panels 230 and 210, 235, respectively. Form 400 also includes an alternative fold line 490. Fold line 490 comprises an upper portion 490a, middle portion 490b, and lower portion 490c. As shown, middle portion 490b is scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 400, such as folding of the handle flaps 260a, 260b. As shown, upper and lower portions 490a, 490c represent imaginary lines along which form 100 may be folded to form the carrier. However, in other embodiments, upper and lower portions 490a, 490c may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 400. Such a configuration may provide for additional strength of handle portion 458. For example, such a configuration may decrease the tendency of handle portion 458 to tear at the junction between the risers 150 and adjoining panels 110, 120, respectively. Other suitable configurations of handle portion 458 will be apparent to persons skilled in the art in view of the teachings herein.

FIGS. 7-8 show another embodiment of a form 500 that may be constructed or formed into an assembled configuration to make a carrier configured to hold four bottles. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles as will occur to those having ordinary skill in the art in view this disclosure. This embodiment, illustrated in FIG. 7, is also a form 500 that is die-cut from beverage board, though other materials may also be used as will occur to those skilled in the art. Form 500 is similar to form 400, except for the differences described below. Moreover, while FIG. 7 shows one side (e.g., a front) of flat 500, it will be understood that the opposing (e.g., rear) side is essentially a mirror image of the view shown in FIG. 7.

Form 500 includes front panel 530, back panel 535, side panels 510, 520, bottom panels 540, 541, 543, 545, and tab 570 that collectively define a container portion 548. In the embodiment shown, panels 510, 520, 530, 535 define a top edge extending substantially along a line 549. Panels 510, 520, 530, 535 may have a height of about 5 inches and a width of about 4 29/32 inches, though other suitable dimensions may be used. Form 500 also includes risers 550, handle flaps 560, and tabs 562, 564 extending substantially from line 549 away from top edge, that define a handle portion 558. As shown, handle flap 560 and riser 550 extend from panels 510, 520 respectively such that each tab 562, 564 and a portion of each flap 560 is outboard of each panel 510, 520. Each handle flap 560 may have a height of about 3 inches above line 549 and each handle tab 562, 564 may have a width of about 1½ inches, though other suitable dimensions can be used.

As form 500 goes through the die-cutting process, handle edge segments 580, 582, 584, 586, 587, 588 are also cut, separating handle flaps 560 and tabs 562, 564 from panels 510, 520, 530. In the embodiment shown, fold lines 590, 561 are scored, perforated, or otherwise treated or configured to facilitate later handling or assembly of the form 500 during the die cutting process. However, in other embodiments, one or both of fold lines 590, 561 do not include such features, so fold lines 590, 561 represent imaginary lines along which flaps 560 and tabs 562, 564 may be folded relative to risers 550. In the embodiment shown, handle flaps 560 each include carrying holes 565 that are cut out from handle flaps 560. As shown in the present embodiment, holes 565 are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration. In the embodiment illustrated in FIG. 7, holes 565 include an obround shape, but in other embodiments may include any other suitable shape as will occur to persons skilled in the art in view of the teachings herein.

As shown in FIG. 7, portions of handle portion 558 extend below line 549. For example, segments 584, 586, 587, 588 extend below line 549, thus causing portions of handle flaps 560 and tabs 562, 564 to lie below line 549.

Container portion 548 comprises a plurality of fold lines 511, 512, 514, 516, 518, 521, 522, 524, 547 along which portions of form 500 may be folded in order to form the assembled configuration of form 500. As shown, fold line 511 extends between panels 510, 535, while fold line 512 extends between panels 510, 530. Fold line 514 extends between panels 530, 520, and fold line 516 extends between panel 520 and flap 570. Fold line 518 extends between panel 520 and the adjacent bottom panel 540, while fold line 521 extends between panel 530 and the adjacent bottom panel 545. Fold line 522 extends between panel 510 and the adjacent bottom panel 541, and fold line 524 extends between panel 535 and the adjacent bottom panel 545. Fold lines 547 extend diagonally along bottom panels 545 to define flaps 543. In the embodiment shown, fold lines 511, 512, 514, 516, 561, 590 are parallel to one another and perpendicular to fold lines 518, 521, 522, 524. As shown, fold lines 518, 521, 522, 524 are collinear when form 500 is unassembled. In the embodiment shown, fold lines 511, 512, 514, 516, 518, 521, 522, 524, 547 represent imaginary lines along which form 500 may be folded to form the carrier. However, in some embodiments, any or all of fold lines 511, 512, 514, 516, 518, 521, 522, 524, 547 may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 500.

After form 500 is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels 530, 510, 535, and 520 are folded at approximately 90-degree angles with each other to form a square, in cross section, such as in cross section along line 549. Tab 570 is likewise folded to be inside panel 535 such that it is glued to the back of panel 535. Accordingly, a bonding or non-bonding attachment (as will occur to those skilled in the art) is provided between tab 570 and panel 535 along either the front or back of panel 535 near the unattached, straight edge thereof.

In order to form the bottom portion of the expanded carrier configuration of form 500, bottom panels 540, 545, 543, 541 are folded up along their respective fold lines 518, 521, 522, 524, 547 and glued together. In the embodiment shown, in the assembled configuration, bottom panels 540, 545, 543, 541 lie substantially perpendicularly to each of the panels 510, 520, 530, 535. Thus, as shown in FIG. 8, panels 510, 520, 530, 535, 540, 545, 543, 541 in the assembled configuration define a single compartment extending substantially from bottom panels 540, 545, 543, 541 to line 549. More particularly, panels 510, 520, 530, 535 define sidewalls of a compartment while bottom panels 540, 545, 543, 541 collectively define a bottom portion or bottom wall of a compartment.

Handle flaps 560 are folded at fold lines 590 so that they extend perpendicular to risers 550, and parallel to front and rear panels 530, 535. Handle tabs 562, 564 are folded at fold lines 561 so that they extend perpendicular to handle flaps 560. The rear portions of each handle tab 563, 564 are glued to the rear portion of each riser 550 and side panels 510, 520. The rear surfaces of each of handle flaps 560 are glued together such that each of the holes 565 is aligned with the other to form a single opening in handle portion 558, and such that flaps 560 lie substantially along a second plane in order to form a unitary handle of handle portion 558. In the embodiment shown, the second plane essentially bisects container portion 548 such that handle portion 558 lies at the midpoint between panels 530, 535. Thus, in the embodiment shown, handle portion 558 essentially defines two cells above line 549 that are each suitable for holding two bottles. Accordingly, while container portion 548 defines a single compartment as described above, handle portion 558 allows for an effective separation of bottles or other articles that may be placed in the compartment of container portion 548.

As described above, form 500 is substantially similar to form 400, except for the following differences. As shown, form 500 includes an exemplary alternative handle portion 558. Particularly, handle portion 558 includes an alternative handle flap 560 and handle tab 562, 564 that extends below line 549. As shown in FIG. 7, segment 587 is cut horizontally along the bottom of tab 564 and flap 560 below line 549. Segment 588 is cut at a downward angle from line 549 to below line 549 to horizontal segment 586 to form the bottom of tab 562. Each segment 584 is then cut at an upward angle to horizontal segment 580 along the bottom of each flap 560, substantially even with line 549. Accordingly, a top portion of each panel 530, 535 extends below line 549. The additional tabs 562, 564 and the portions of flaps 560 extending below line 549 may reinforce the handle portion 558 and decrease the tendency of handle portion 558 to tear at the junction between the risers 550 and adjoining panels 510, 520. Other suitable configurations of handle portion 558 will be apparent to persons skilled in the art in view of the teachings herein.

In some implementations, before or after form 500 is cut out, form 500 may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form 500. In some of these implementations, the text and/or graphics are customized by a third party, automatically computer-generated per a remote customer's request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities. Due to the configuration of form 500 as described herein, text and graphics need only be applied to one side of form 500 in its flattened configuration in order to display such text and/or graphics on the front or outer portion of form 500 in its expanded, carrier configuration.

FIGS. 9-10 show another embodiment of a form 600 that may be constructed or formed into an assembled configuration to make a carrier. This embodiment, illustrated in FIG. 9, is also a form 600 that is die-cut from beverage board, though other materials may also be used as will occur to those skilled in the art. Form 600 is similar to form 500, except for the differences described below. Moreover, while FIG. 9 shows one side (e.g., a front) of flat 600, it will be understood that the opposing (e.g., rear) side is essentially a mirror image of the view shown in FIG. 9.

Form 600 includes front panel 630, back panel 635, side panels 610, 620, bottom panels 640, 641, 643, 645, and tab 670 that collectively define a container portion 648. In the embodiment shown, panels 610, 620, 630, 635 define a top edge extending substantially along a line 649. Panels 610, 620 may have a width of about 5 15/16 inches and panels 630, 635 may have a width of about 3 inches, though other suitable dimensions may be used. Form 600 also includes risers 650, handle flaps 660, and tabs 664 extending substantially from line 649 away from top edge, that define a handle portion 658. As shown, handle flaps 660 extend from panels 610, 620 respectively such that each tab 664 is outboard of each panel 610, 620. Each handle flap 660 may have a height of about 3¾ inches and each handle tab 664 may have a width of about 1½ inches, though other suitable dimensions can be used.

As form 600 goes through the die-cutting process, handle edge segments 680, 682, 684, 687 are also cut, separating handle flaps 660 and tabs 664 from panels 610, 620, 630. In the embodiment shown, fold lines 690, 661 are scored, perforated, or otherwise treated or configured to facilitate later handling or assembly of the form 600 during the die cutting process. However, in other embodiments, one or both of fold lines 690, 661 do not include such features, so fold lines 690, 661 represent imaginary lines along which flaps 660 and tabs 664 may be folded relative to risers 650. In the embodiment shown, handle flaps 660 each include carrying holes 665 that are cut out from handle flaps 660. As shown in the present embodiment, holes 665 are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration. In the embodiment illustrated in FIG. 9, holes 665 include an obround shape, but in other embodiments may include any other suitable shape as will occur to persons skilled in the art in view of the teachings herein.

As shown in FIG. 9, portions of handle portion 658 extend below line 649. For example, segments 684, 687 extend below line 649, thus causing portions of tabs 664 to lie below line 649.

Container portion 548 comprises a plurality of fold lines 611, 612, 614, 616, 618, 621, 622, 624, 647 along which portions of form 600 may be folded in order to form the assembled configuration of form 600. As shown, fold line 611 extends between panels 610, 635, while fold line 612 extends between panels 610, 630. Fold line 614 extends between panels 630, 620, and fold line 616 extends between panel 620 and flap 670. Fold line 618 extends between panel 620 and the adjacent bottom panel 640, while fold line 621 extends between panel 630 and the adjacent bottom panel 645. Fold line 622 extends between panel 610 and the adjacent bottom panel 641, and fold line 624 extends between panel 635 and the adjacent bottom panel 645. Fold lines 647 extend diagonally along bottom panels 645 to define flaps 643. In the embodiment shown, fold lines 611, 612, 614, 616, 661, 690 are parallel to one another and perpendicular to fold lines 618, 621, 622, 624. As shown, fold lines 618, 621, 622, 624 are collinear when form 600 is unassembled. In the embodiment shown, fold lines 611, 612, 614, 616, 618, 621, 622, 624, 647 represent imaginary lines along which form 600 may be folded to form the carrier. However, in some embodiments, any or all of fold lines 611, 612, 614, 616, 618, 621, 622, 624, 647 may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 600.

After form 600 is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels 630, 610, 635, and 620 are folded at approximately 90-degree angles with each other to form a rectangle, in cross section, such as in cross section along line 649. Tab 670 is likewise folded to be inside side panel 635 such that it is glued to the back of panel 635. Accordingly, a bonding or non-bonding attachment (as will occur to those skilled in the art) is provided between tab 670 and panel 635 along either the front or back of panel 635 near the unattached, straight edge thereof.

In order to form the bottom portion of the expanded carrier configuration of form 600, bottom panels 640, 645, 643, 641 are folded up along their respective fold lines 618, 621, 622, 624, 647 and glued together. In the embodiment shown, in the assembled configuration, bottom panels 640, 645, 643, 641 lie substantially perpendicularly to each of the panels 610, 620, 630, 635. Thus, as shown in FIG. 10, panels 610, 620, 630, 635, 640, 645, 643, 641 in the assembled configuration define a single compartment extending substantially from bottom panels 640, 645, 643, 641 to line 649. More particularly, panels 610, 620, 630, 635 define sidewalls of a compartment while bottom panels 640, 645, 643, 641 collectively define a bottom portion or bottom wall of a compartment.

Handle flaps 660 are folded at fold lines 690 so that they extend perpendicular to risers 650, and parallel to front and rear panels 630, 635. Handle tabs 664 are folded at fold lines 661 so that they extend perpendicular to handle flaps 660. The rear portions of each handle tab 664 are glued to the rear portion of each riser 650 and side panels 610, 620. The rear portions of each of handle flaps 660 are glued together such that each of the holes 665 is aligned with the other to form a single opening in handle portion 658, and such that flaps 660 lie substantially along a second plane in order to form a unitary handle of handle portion 658. In the embodiment shown, the second plane essentially bisects container portion 648 such that handle of handle portion 658 lies at the midpoint between panels 630, 635. Accordingly, while container portion 648 defines a single compartment as described above, handle portion 658 may allow for an effective separation of bottles or other articles that may be placed in the compartment of container portion 648.

As described above, form 600 is substantially similar to form 500, except for the following differences. As shown, form 600 includes an exemplary alternative handle portion 658. Particularly, handle portion 658 includes an alternative handle flap 660 and handle tab 664. As shown in FIG. 9, segments 687 are cut horizontally along the bottom of each tab 664 below line 649. Each segment 684 is then cut at an upward angle to line 649 at fold line 661. Accordingly, a top portion of each panel 630, 635 extends below line 649. Horizontal segment 680 is cut along the bottom of each flap 660, substantially even with line 649. Segment 682 is then cut at an upward angle above line 649. Accordingly, each handle flap 660 is substantially even with line 649. Each handle tab 664 is then positioned to extend beyond panel 610, 620, respectively, and below line 649. For instance, tab 664 may extend to a midpoint of panels 630, one 635. The additional tabs 664 may reinforce the handle portion 658 and decrease the tendency of handle portion 658 to tear at the junction between the risers 650 and adjoining panels 610, 620. Other suitable configurations of handle portion 658 will be apparent to persons skilled in the art in view of the teachings herein.

In some implementations, before or after form 600 is cut out, form 600 may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form 600. In some of these implementations, the text and/or graphics are customized by a third-party, automatically computer-generated per a remote customer's request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities. Due to the configuration of form 600 as described herein, text and graphics need only be applied to one side of form 600 in its flattened configuration in order to display such text and/or graphics on the front or outer portion of form 600 in its expanded, carrier configuration.

All publications, prior applications, and other documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Claims

1. A unitary flat for forming a carrier configured to hold bottles, the flat comprising:

(a) a container portion, comprising: (i) a first side panel; (ii) a front panel adjacent to the first side panel, (iii) a second side panel adjacent to the front panel, (iv) a rear panel adjacent to the second side panel, wherein the first side panel, the front panel, the second side panel, and the rear panel define a top edge, and (v) at least one bottom panel, wherein the front panel, the rear panel, the first and second side panels, and the at least one bottom panel are foldable relative to one another to form the container portion; and

(b) a handle portion extending from the top edge of each of the first and second side panels, each handle portion comprising a riser, a handle flap extending from the riser, and a handle tab extending from the handle flap;

wherein the handle flap of each handle portion is foldable to extend across the container portion, and the handle tab is foldable relative to the handle flap to extend parallel to the riser of the other handle portion; and

wherein the handle portion extending from the top edge of the first side panel extends beyond an end of the container portion along the top edge.

2. The flat of claim 1, wherein a portion of the handle tab extends below the top edge into the container portion.

3. The flat of claim 1, wherein a portion of the handle flap extends beyond the end of the container portion in the direction of the top edge.

4. The flat of claim 3, wherein a portion of the handle flap extends below the top edge and beyond an extent of the container portion.

5. The flat of claim 1, wherein the front and rear panels are substantially the same width.

6. The flat of claim 1, wherein the first and second side panels are substantially the same width.

7. The flat of claim 6, wherein the first and second side panels, the front panel, and the rear panel are substantially the same width.

8. The flat of claim 1, wherein the at least one bottom panel comprises four bottom panels, where each of the side panels, the front panel, and the rear panel has one of the four bottom panels extending therefrom.

9. The flat of claim 8, wherein each of the bottom panels is foldable along an axis that is parallel to the top edge.

10. The flat of claim 1, wherein each of the risers has a generally triangular configuration.

11. The flat of claim 1, wherein the top edge of the first and second side panels extends along a line, wherein a portion of the top edge of the front and rear panels extends below the line.

12. The flat of claim 1, wherein each handle flap is foldable to extend perpendicular to the riser of the same handle portion, and wherein each handle tab is foldable to extend perpendicular to the handle flap of the same handle portion.

13. A carrier configured to hold bottles, the carrier comprising:

(a) a container portion, comprising: (i) a front panel, (ii) a rear panel, (iii) a pair of side panels extending between the front and rear panels, and (iv) at least one bottom panel configured to close a bottom opening of the container portion; and

(b) a handle portion extending from a top edge of the container portion, wherein the handle portion comprises: (i) a first handle comprising a first riser, a first handle flap adjacent to the first riser, and a first handle tab adjacent to the first handle flap, and (ii) a second handle comprising a second riser, a second handle flap adjacent to the second riser, and a second handle tab adjacent to the second handle flap, wherein the second handle tab is positioned to against the first riser, the second handle flap is positioned against the first handle flap, and the second riser is positioned against the first handle tab.

14. The carrier of claim 13, wherein the first riser extends upward from a first side panel, and wherein the second riser extends upward from an opposing, second side panel.

15. The carrier of claim 14, wherein the first riser and the first handle tab are each perpendicular to the first handle flap, and wherein the second riser and the second handle tab are each perpendicular to the second handle flap.

16. A method of forming a flat into a carrier configured to hold bottles, wherein the flat comprises a first side panel, a front panel, a second side panel, and a rear panel; wherein the first side panel, the front panel, the second side panel, and the rear panel define a top edge; a bottom panel; a first handle portion extending from one of the first side panel, the front panel, the second side panel, and the rear panel; and a second handle portion extending from another one of the first side panel, the front panel, the second side panel, and the rear panel; the method comprising:

(a) folding the first side panel, the front panel, the second side panel, the rear panel, and the bottom panel relative to one another to form a container portion;

(b) folding a first flap of the first handle portion along a first fold line such that the first flap is generally perpendicular to another portion of the first handle portion;

(c) folding a first tab of the first handle portion along a second fold line such that the first tab is generally perpendicular to the first flap;

(d) folding a second flap of the second handle portion along a third fold line such that the second flap is positioned generally perpendicular to another portion of the second handle portion;

(e) folding a second tab of the second handle portion along a fourth fold line such that the second tab is positioned generally perpendicular to the second flap; and

(f) attaching the first and second flaps to form a handle.

17. The method of claim 16, further comprising attaching the first tab to the second handle portion and attaching the second tab to the first handle portion.

18. The method of claim 17, wherein the first and second tabs extend into the container portion, wherein the first tab is attached to the second side panel and the second tab is attached to the first side panel.

19. The method of claim 18, wherein the handle extends centrally between the first and second side panels.