US20070251982A1 - Gusseted Carton - Google Patents

Abstract

A carton is formed from a major blank that may be reinforced at selected locations to increase the strength of the carton. The carton includes gusseted corners that in part form an interior carton volume. The interior volume of the carton can be varied by placing the carton in an expanded configuration.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims the benefit of U.S. Provisional Application No. 60/796,566, filed May 1, 2006, which is hereby incorporated by reference in its entirety.
RELATED APPLICATION
• This application is related to U.S. application Ser. No. 11/345,185, entitled “GUSSETED CARTON,” filed on Feb. 1, 2006, the contents of which are hereby incorporated by reference in their entirety as if presented herein.
BACKGROUND
• Dispensing cartons are known. Conventional dispensing cartons may have a top panel with a dispensing feature formed therein. Such cartons may be used to contain articles such as beverage containers, for example, that are dispensable through the top panel or through another panel when the carton is opened. Typically, conventional cartons must be refrigerated in order to keep the enclosed containers cool. When the cartons are no longer refrigerated, such as when the carton is removed from the refrigerator to dispense the containers, the containers may become undesirably warm. The containers must then be refrigerated again or otherwise cooled. Further, the dispensing features included in conventional cartons may render the cartons incapable of being securely reclosed once opened. Articles retained within the carton may therefore inadvertently fall out of the carton once the carton has been opened.
• Conventional cartons are typically formed from a single ply of paperboard or similar material. Carrying handles may be formed in one or more panels of the carton and used to carry the carton. Because cartons are often used to carry relatively heavy articles, such as beverage containers, the strength of the handles or other sections of the cartons must be increased in order to accommodate the carton load. A conventional method for increasing the load-bearing capacity of a paperboard carton is to produce the carton from a blank of a different, stronger paperboard material, or to produce the blank from the same carton material but having greater thickness or caliper. Such conventional methods typically increase the costs associated with manufacturing the carton, with the material costs of manufacture generally increasing according to the cost of increasing the strength and/or thickness of the entire blank. Some sections of the blank, however, may not be load-bearing, and the additional costs associated with increasing the strength of non-load bearing sections of the blank are wasted.
SUMMARY
• According to a first embodiment of the invention, a carton is formed from at least a major blank and a minor blank joined to the major blank. The carton comprises a first side panel, a bottom panel, a second side panel, a first end panel, a second end panel, and a plurality of gussets. One gusset is located at each corner of the bottom panel and is disposed between and foldably connected to an adjacent side panel and end panel so as to seal or close off the corners of the carton.
• The minor blank may be configured to render the carton multi-ply at selected sections. According to the first embodiment, the first side panel, the second side panel and the plurality of gussets are formed from at least the major blank, and the bottom panel and the first and second end panels are formed from overlapping sections of the major and minor blanks. According to one aspect of the first embodiment, the minor blank reinforces the major blank so as to increase the strength and load-bearing capacity of the multi-ply carton. The minor blank can be configured to reinforce the major blank at any number of desired locations. Selected reinforcement of specific areas of the major blank can produce a high strength carton having a high load-bearing capacity while using relatively small amounts of board.
• According to an aspect of the first embodiment, a top closure of the of the carton can be opened and ice, cold water, additional containers, and/or other articles can be placed in the carton through the opened top end. The interior volume of the carton can be used to retain liquids, such as water resulting from melting ice, condensation, other liquids, and articles such as, for example, refuse, particulate matter, etc.
• According to another aspect of the invention, the carton can include top side panels foldably connected to the side panels. The carton can be placed in an expanded configuration in which the top side panels extend generally upwardly to in part define an increased interior volume of the carton. Closure panels can be foldably connected to the top side panels. The closure panels and top side panels close a top of the carton prior to placing the carton in the expanded configuration. The closure panels alone can be used to close the top of the carton when the carton is in its expanded configuration.
• According to yet another aspect of the invention, the carton can include handle panels that in part define the interior carton volume when the carton is in its expanded configuration. The handle panels can be used to carry the carton before opening of the carton, when the carton is in the expanded configuration with the top of the carton open, and when the carton is in the expanded configuration with the top closed.
• According to yet another aspect of the first embodiment, a bottom receptacle of the carton can be constructed to have a height that extends above the bottom panel of the carton below which there are no seams sealed by glue or other adhesives. The bottom receptacle may therefore be liquid-tight.
• 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 multi-ply blank used to form a carton according to a first embodiment of the invention.
• FIG. 2A is a plan view of a major blank of the multi-ply blank illustrated inFIG. 1.
• FIG. 2B is a plan view of a minor blank of the multi-ply blank illustrated inFIG. 1.
• FIG. 3 illustrates an erection step in which the multi-ply blank ofFIG. 1 is formed into the carton according to the first embodiment of the invention.
• FIG. 4 illustrates an erection step of the blank ofFIG. 1.
• FIG. 5 illustrates an erection step of the blank ofFIG. 1.
• FIG. 6 illustrates an erection step of the blank ofFIG. 1.
• FIG. 7 illustrates an erection step of the blank ofFIG. 1.
• FIG. 8 illustrates an erection step of the blank ofFIG. 1.
• FIG. 9 illustrates an erection step of the blank ofFIG. 1.
• FIG. 10 illustrates an erection step of the blank ofFIG. 1.
• FIG. 11 illustrates the erected carton according to the first embodiment with containers accommodated therein.
• FIG. 12 illustrates the carton in an expanded configuration with the top opened and with ice poured over the carton contents.
• FIG. 13 illustrates the carton after reclosing the top of the carton while the carton is in its expanded configuration.
DETAILED DESCRIPTION
• The first embodiment of the present invention generally relates to a carton suitable for storing and dispensing articles such as, for example, beverage containers. The carton provides a bottom receptacle suitable for accommodating, for example, liquids, ice, or other coolants in the carton bottom. In one exemplary embodiment, ice can be added to the opened top of the carton to cool beverage containers held within the carton. As the ice melts, all or a part of the resultant runoff water may be held within the bottom receptacle. The carton can also include a reclosure feature in which closure panels can be engaged with one another to close the opened top of the carton. A reinforcing minor blank can extend across the bottom of the carton and upwardly into handles of the carton to increase the load-bearing capacity of the carton.
• Articles accommodated within the present carton embodiments can include containers such as, for example, petaloid bottle beverage containers, metallic beverage cans, glass or plastic bottles, or other containers such as, for example, those used in packaging foodstuffs and other products. For the purposes of illustration and not for the purpose of limiting the scope of the invention, the following detailed description describes generally cylindrical metallic beverage containers as disposed within the carton. In this specification, the terms “side,” “end,” “bottom,” “lower,” “upper” and “top” indicate orientations determined in relation to fully erected, upright cartons.
• FIG. 1 is a plan view of a multi-ply blank8 used to form a carton160 (illustrated inFIG. 11) according to the first embodiment of the invention. The blank8 is formed from a major blank5 and a reinforcing, minor blank6 adhered, laminated or otherwise joined to the major blank5. The interior or underside surface of the major blank5 is visible inFIG. 1. In the illustrated embodiment, the minor blank6 is adhered to the interior side of the major blank5, although it may be adhered to the exterior side.
• The multi-ply blank8 is “multi-ply” in that the joined minor and majorblank plies6 and5 comprising the multi-ply blank8 include substantial overlapping portions. Also, a majority of the overlapping surfaces of the minor and majorblank plies6,5 may be adhered adjacent to one another. For example, theblanks5 and6 have different perimeters or “footprints” and need not overlap at all points, but at least substantially all of the surface of the minor blank6 may be adjacent and/or adhered to the interior side of the major blank5.
• As shown inFIG. 1, the blank8 may be symmetric or nearly symmetric about a transverse centerline C_Tand a longitudinal centerline C_L. The major blank5 and the minor blank6 may also be symmetric about the transverse centerline C_Tand the longitudinal centerline C_L. Therefore, certain elements in the drawing figures may be indicated by identical or similar reference numerals in order to reflect the partial or complete symmetries in the blank8.
• FIG. 2A is a plan view of the major blank5, andFIG. 2B is a plan view of the reinforcing minor blank6. Referring toFIG. 2A, the major blank5 comprises abottom panel10, first andsecond side panels20 foldably connected to each side of thebottom panel10 attransverse fold lines21, respectively, a first sidetop panel32 foldably connected to thefirst side panel20 at atransverse fold line31, a firsttop closure panel42 foldably connected to the first sidetop panel32 at atransverse fold line41, a second sidetop panel34 foldably connected to thesecond side panel20 at atransverse fold line33, and a secondtop closure panel44 foldably connected to the second sidetop panel34 at atransverse fold line43. Anend panel60 is foldably connected to each end of thebottom panel10 at alongitudinal fold line62. Ahandle panel70 is foldably connected to a distal end of eachend panel60 at alongitudinal fold line71. Aracetrack handle feature75 may be formed in eachhandle panel70. Other handle features may be incorporated into thehandle panels70. In this specification, the terms “end” and “side” are used for ease of reference, and do not imply relative sizes of thepanels20,60.
• Acorner gusset80 is located at each corner of thebottom panel10, extending between anadjacent side panel20 andend panel60. Eachcorner gusset80 comprises afirst gusset panel82 foldably connected to anend panel60 at atransverse fold line21, asecond gusset panel86 foldably connected to thefirst gusset panel82 at anoblique fold line84, athird gusset panel90 foldably connected to thesecond gusset panel86 at atransverse fold line31 or33, and afourth gusset panel94 foldably connected to thethird gusset panel90 at anoblique fold line92. The first andsecond gusset panels82,86 can be defined at their edges, for example, by an arcuate orcurved edge96.
• Thefirst closure panel42 may have aclosure aperture48 formed therein. Theclosure aperture48 can be defined by, for example, a knockout section in the major blank5, a cutout section, a slit, or by other breachable lines of disruption in the blank5. Thesecond closure panel44 may have a closure panel orflap50 defined at a distal end of thesecond closure panel44 by a pair oftransverse fold lines51 and acurved cut54 extending between the fold lines51. Thecurved cut54 defines aclosure projection56 struck from thesecond closure panel44. Theclosure aperture48 in thefirst closure panel42 is sized to receive theclosure projection56 in the erected carton160 (FIG. 13).
• Longitudinally-extending handle-receivingapertures46 may be formed in thepanels32,42, and in thepanels34,44. The handle-receivingapertures46 are sized to receive handle flaps from handles of the erected carton160 (FIG. 11). The handle-receivingapertures46 can be defined by, for example, knockout sections in the blank5, cutout sections, slits, or by other breachable lines of disruption in the major blank5.
• Referring toFIG. 2B, the inner, reinforcing minor blank6 is configured to overlay and/or to reinforce one or more selected portions of the major blank5. The minor blank6 may have, for example, symmetry about the centerlines C_L, C_T. The minor blank6 comprises a minorbottom panel102 that may be, for example, of the same size or slightly smaller than thebottom panel10 of the major blank5 (FIG. 2A). First and secondminor end panels104 are foldably connected to each end of the minorbottom panel102 atlongitudinal fold lines103, andminor handle panels106 are foldably connected to distal ends of eachminor end panel104 at longitudinal fold lines105. Referring also toFIG. 2A, eachminor end panel104 may generally correspond in size and shape to theend panels60 of the major blank5, and theminor handle panels106 may generally correspond in size and shape to thehandle panels70. Eachminor handle panel106 may have aminor handle feature108 that generally corresponds in shape and function to ahandle feature75 in an overlappinghandle panel70. The handle features75,108 overlap and cooperate to form two-ply handles144 in the erected carton160 (illustrated inFIG. 11).
• Referring toFIGS. 1, 2A and2B, the multi-ply blank8 may be formed by adhering the minor blank6 to the interior side of the major blank5. Each of thepanels106,104,102,104,106 of the minor blank6 may be adhered tocorresponding panels70,60,10,60,70, respectively, of the major blank5. Glue strips, applied hot melt glue, or other adhesives and means can be used to adhere the major andminor blanks5,6 together. Thelongitudinal fold lines105,103,103,105 in the minor blank6 will generally coincide with thelongitudinal fold lines71,62,62,71 in the major blank5 so that the multi-ply blank8 can be folded along the overlapping fold lines.
• An exemplary method of erection of the multi-ply blank8 into thecarton160 and loading of thecarton160 with articles will now be discussed with reference toFIGS. 1-11.
• FIG. 3 illustrates an initial erection step in which the blank8 is formed into thecarton160. Referring also toFIG. 2A, thepanels34,44,50 are folded back about thetransverse fold line33 in the direction of the curved arrow A. Thepanels32,42 are folded back about the transverse fold line31 (not visible inFIG. 3). The first andsecond side panels20 are folded inwardly along thetransverse fold lines21 in the direction of the curved arrows B. The undersides of thefirst gusset panels82 are thereby brought into contact with and adhered to theminor end panels104 of theminor blank6. Thegusset panels82 can be adhered to facing surfaces of theminor end panels104 by, for example, applied glue, glue strips, other adhesives or other means. The fold steps at the fold lines21,31,33 can occur as discrete steps, or the folds at the fold lines31,33 can be carried out concurrently with the folds at the transverse fold lines21.
• Referring toFIG. 4, the blank8 is folded in the direction of the curved arrow C about thelongitudinal fold lines62 in the major blank5 and the corresponding longitudinal fold lines103 (not visible inFIG. 4) in theminor blank6.FIG. 4 illustrates this folding operation at one end of the blank8. The fold will be performed at each end of the blank8 in order to pre-break the blank8 at thelongitudinal fold lines62,103.
• Referring toFIG. 5, the partially erected multi-ply blank8 is opened up by pulling the side panels20 (not visible inFIG. 5) upwardly and pivoting them about thetransverse fold lines21 in the direction of the curved arrows D. Theside panels20 and the attachedpanels32,42 and34,44 are also pivoted upwardly about the fold lines21 so that they extend generally vertically or upright with respect to thebottom panel10. The general vertical orientation of thepanels32,42 and34,44 is shown inFIG. 6.
• Referring toFIG. 6, one end of the blank8 is shown folded about thelongitudinal fold lines62 in the major blank5 and thelongitudinal fold lines103 in the minor blank6 in the direction of the curved arrow E. The overlappedend panels60,104 and the overlappedhandle panels70,106 stand upright or generally upright. The opposite end of the blank8 will be similarly folded. InFIG. 6, thebottom panel10 and theend panel60 of the major blank5 are covered by thepanels102,104 of the minor blank6, respectively, and thereference numbers10,60 are therefore placed within parentheses. As shown inFIG. 6,free portions83 of thegusset panels82 that are adjacent to theoblique fold lines84 may remain unadhered to theminor end panel104 and may bend away from thepanel104. With theend panels60,104 upright, the partially erected carton is a substantially parallelepipedal form with an open top that can be loaded with articles.
• Referring toFIG. 7, the partially erected carton may be loaded with articles. In the illustrated embodiment, the partially erected carton is loaded with eighteen generally cylindrical twelve-ounce beverage containers C disposed in a 3×6×1 configuration. Theoverlapped end panels60,104 (shown inFIGS. 2A, 2B, respectively) of the major andminor blanks5,6 form reinforced two-ply first andsecond end panels110 at each end of the carton, and the overlappedbottom panels10,102 (FIGS. 2A, 2B, respectively) form a reinforced two-ply bottom panel120. The overlappedhandle panels70,106 form reinforced two-ply handle panels140. The overlapping handle features75,108 (FIGS. 2A, 2B, respectively) in the respective overlappedhandle panels70,106 are aligned with one another and may be adhered together form two-ply handles144 in eachhandle panel140.
• Referring toFIG. 8, one end of the partially erected carton is shown with the second sidetop panel34, and the attachedpanels44,50, folded over the open top of the carton about thetransverse fold line33 in the direction of the curved arrow F. The first sidetop panel32 and thefirst closure panel42 are then folded over about thetransverse fold line31 so that they overlap thepanels34,44. Alternatively, the first sidetop panel32 may be folded over about thefold line31, followed by the second sidetop panel34 being folded over about thefold line33. As thepanels32,34 are folded inwardly, thegusset panels90,94 are folded toward one another about the oblique fold lines92. The opposite end of the partially erected carton is similarly folded.
• Referring toFIG. 9, one end of the partially erected carton is shown with thethird gusset panels90 and the fourth gusset panels94 (shown inFIG. 8) folded about thelongitudinal fold line62 in the direction of the curved arrows G. The opposite end of the partially erected carton is similarly folded. At this time, one or both of the firsttop side panel32 and thefirst closure panel42 can be adhered to one or both of the second sidetop panel34 and thesecond closure panel44. Thepanels32,34,42,44 close a top portion of the carton.
• Referring toFIG. 10, one end of the partially erected carton is shown with the two-ply handle panel140 folded over about the overlappingfold lines71 and105 in the direction of the curved arrow H. Referring also toFIG. 9, the inwardly facing surfaces of thehandle panels140 are thereby brought into contact with thegusset panels90. Glue or other adhesive may be applied to thegusset panels90 so that thehandle panels140 are adhered thereto. The opposite end of the carton is similarly folded and glued to form the generallyparallelepipedal carton160 accommodating containers C illustrated inFIG. 11.
• Referring toFIG. 11, the firsttop side panel32 and thefirst closure panel42 overlay the secondtop side panel34 and thesecond closure panel44, although this orientation may be reversed. Thepanels32,42,34,44 can be secured together by adhesives such as, for example, glue, to form atop closure150. The top of thecarton160 is thereby closed or substantially closed. As shown inFIG. 11, thehandle panels140 extend in a carrying position, generally upwardly, from theend panels110. Thecarton160 can be carried using the reinforced multi-ply handles144 defined in thehandle panels140.
• Thepanels32,42,34,44 comprising thetop closure150 can be alternatively or in addition held in place over the open carton top by pivoting thehandle panels140 in the direction of the arrows H, and tuckinghandle flaps146 of thehandles144 into thehandle apertures46 at each end of thecarton160. In this configuration, thepanels32,42,34,44 may be substantially flat across the top of thecarton160, forming thetop closure150. The handle flaps146 tucked into thehandle apertures46 may, for example, serve to maintain the top andclosure panels32,42,34,44 in a closed position over the carton top such that adhesives are not necessary to secure thepanels32,42,34,44 in place.
• FIG. 12 illustrates thecarton160 in its expanded configuration, with thetop closure150 opened and with ice poured over the carton contents and accommodated in aninterior volume163 of the carton. Thecarton160 may be opened, for example, by pulling thefirst closure panel42 so that thepanels32,42 are pulled upwardly and outwardly in the direction of the arrow J. Thepanels34,44 may then be pulled back in the direction of the other arrow J. Referring also toFIG. 8, as thepanels32,34 are folded outwardly about the fold lines31,33, respectively, thegusset panels94 fold outwardly with respect to the gusset panels90 (which are adhered to handle panels106) about oblique fold lines92.
• As shown inFIG. 12, with the carton top opened, ice, cool water, or other coolant means, for example, may be introduced into theinterior volume163 of thecarton160 so that it contacts the containers C. A first height H_C1of theclosed carton160 is shown inFIG. 12 as generally conforming to the height of theside panels20. The height H_C1corresponds to the carton height when the carton is closed by thepanels32,42,34,44 as shown inFIG. 11. A second height H_C2indicates the height of the interior volume of thecarton160 when thepanels32,42,34,44 extend upwardly as shown inFIG. 12. Thepanels32,34,82,86,90,94,140 define an upper portion of theinterior volume163, with thegussets80 at each corner of thecarton160 serving to substantially seal the corners of the carton from thebottom panel10 up to the second, expanded height H_C2. The capacity of the expandedcarton160 is therefore increased by opening thetop closure150 and extending thepanels140,32,34,90,94 upwardly.
• Thecarton160 can be carried using the reinforced multi-ply handles144 defined in thehandle panels140 when the carton is in the opened and expanded configuration shown inFIG. 12. Added ice or other coolants, in addition to the containers C, may constitute a significant weight to be borne by thecarton160. The two-ply section of thecarton160 comprising the sections where the minor blank6 overlaps the major blank5 adds significant strength to the carton to enable relatively heavy loads to be carried in thecarton160. The reinforcement provided by the minor blank6 may be specifically targeted, for example, for regions of thecarton160 that require reinforcement, so that little board is wasted in forming the carton. In the illustrated embodiment, thepanels106,104,102,104,106 of the minor blank6 (FIG. 2B) extend from onehandle panel140, down oneend panel110, across thebottom panel120, and through theopposite end panel110 and handlepanel140. Therefore, when a user carries the carton using thehandle144, the reinforcing blank6 is arranged to bear a significant portion of the load.
• FIG. 13 illustrates thecarton160 in its expanded configuration with the top of the carton closed by thepanels42,44,50. In this configuration, thepanels32,34 extend generally upright so that the height of the interior volume of thecarton160 is H_C3. The third height H_C3may be slightly less than the second height H_C2. The top of thecarton160 is closed by folding the first and secondtop closure panels42,44 about the fold lines41,43 over the open top of the carton, respectively, in the direction of the arrows K. Theclosure flap50 section of thetop closure panel44 is bent back about the fold lines51 in the direction of the arrow L so that theclosure projection56 extends generally downwardly. Theclosure projection56 is moved downwardly and pressed into theclosure aperture48 in thefirst closure panel42. The engagement of theclosure projection56 in theclosure aperture48 holds thetop closure panels42,44 in place across the top of thecarton160. Thecarton160 can be carried using the reinforced multi-ply handles144 defined in thehandle panels140 when the carton is in the expanded and closed configuration illustrated inFIG. 13. The top of thecarton160 is closed, which reduces the likelihood that articles will inadvertently fall out of the carton.
• According to one aspect of the present invention, the added interior volume afforded by increasing the carton height to the second height H_C2and the third height H_C3can be used to accommodate a significant volume of cooling media such as, for example, ice, or even additional containers or other articles that may require cooling, for example. In addition to having an expanded interior volume, thecarton160 can still be carried by thehandle panels140 in the open expanded configuration shown inFIG. 12 and in the closed expanded configuration shown inFIG. 13.
• According to one embodiment of the present invention, the height of the interior volume of thecarton160 increases by at least 10% when changed from the closed configuration illustrated inFIG. 11, having height H_C1, to the open and expanded configuration shown inFIG. 12, having height H_C2. The height H_C3of the interior volume of thecarton160 in the expanded and closed configuration shown inFIG. 13 can also be at least 10% greater than the first height H_C1of the carton in the closed configuration, with a corresponding increase in interior carton volume. According to another embodiment of the invention, the heights H_C2and H_C3are at least 25% greater than the first height H_C1.
• Referring back toFIG. 12, according to one exemplary aspect of the invention, thegussets80 may define in part an at least partially liquid-tight bottom receptacle165 in the erectedcarton160. The top edge or upper border of thebottom receptacle165 is indicated by dashed lines inFIG. 12, and represents a portion of the bottom of thecarton160 below which no glued seals or seams are formed through which water or other liquid might leak. That is, in accordance with the first embodiment, no adhesive seal or other joinder of material where fluid might escape thecarton160 is located in the carton at a position below the top edge of thebottom receptacle165. Referring also toFIGS. 1 and 2A, thebottom receptacle165 may therefore be formed from a continuous section of folded material of the blank8. The height of the liquid-tight portion of thereceptacle165 below which there are no glued seams is indicated as a height H_RinFIG. 12. Referring toFIG. 2A, the height H_Rmay generally coincide with an uppermost point where thegusset panels82 are foldably connected to thegusset panels84, along the curved edges96.
• The height H_Rmay be, for example, defined as a function of a height of thecarton160. For example, referring toFIGS. 12 and 13, thebottom receptacle165 may define a liquid-tight portion having a height H_Rthat is at least about 15% of a height H_C1of thecarton160. In another embodiment, thereceptacle165 height H_Rmay be at least about 40% of a height H_C1of thecarton160. The receptacle height H_Rmay be increased or decreased by varying the geometry of thegussets82,86, for example, to accommodate larger or smaller anticipated liquid volumes in thecarton160.
• If desired, additional articles may be placed in thecarton160 after opening. For example, if the containers C are beverage containers, ice may be placed over the containers C and held within the carton interior to cool the containers. As the ice melts, thereceptacle165 at the bottom of thecarton160 serves to retain all or a portion of the water runoff from the melting ice. Thereceptacle165 may also serve, for example, to house fine particulate matter that might otherwise escape through a glued seam. If one or more containers C is damaged during shipping or storage of thecarton160, thebottom receptacle165 can serve to retain all or a portion of the contents of the broken container.
• The blank8 can, for example, be constructed of water resistant material to any degree desired so that liquid in the bottom of thecarton160 remains in thebottom receptacle165 for a selected amount of time. Thecarton160 can therefore be constructed so that liquid retained in thebottom receptacle165 initially remains in thecarton160 at least until it reached the height H_R.
• Cartons according to the principles of the present invention may be formed from materials such as, for example, paperboard. Therefore, if exposed to water or other liquids for extended periods of time, the carton may allow for the passage of liquid through the wetted carton surfaces due to partial permeability of the carton material. In this specification, the term “liquid-tight” is generally used to define a section of a carton that is formed from a continuous section of material or of a section without any glued seams through which liquid or fine particulate matter might leak, and the term “liquid-tight” therefore encompasses cartons that may become partially water permeable over time due to prolonged exposure to water or other liquids.
• In the above embodiments, thecarton160 is described as accommodating eighteen 12-ounce cans containers C in 3×6×1 configuration. Other arrangements of containers, packages, articles, and other items, however, can be accommodated within a carton constructed according to the principles of the present invention. For example, a carton constructed according to the principles of the present invention would also work satisfactorily if the carton were sized and shaped to hold articles in other configurations, such as 3×4×1, 4×3×1, 3×6×1, 2×4×1, 2×5×1, 2×6×1, 4×6×1, etc., and multi-tier variations of the aforementioned configurations. The dimensions of the blank8 may also be altered, for example, to accommodate various container forms. For example, 16-ounce petaloid bottles may be accommodated within a carton constructed according to the principles of the present invention.
• In the exemplary embodiments discussed above, the major and minor blanks may be formed from, for example, clay coated newsprint (CCN), solid unbleached sulfate board (SUS), and other materials. In general, the blanks may be constructed from paperboard having a caliper of at least about 14, for example, so that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above.
• The blanks can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
• The above embodiments may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place.
• The term “line” as used herein includes not only straight lines, but also other types of lines such as, for example, curved, curvilinear or angularly displaced or interrupted lines.
• 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 blanks that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, examples of 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 a desired line of weakness; and various sequential and/or overlapping combinations of these exemplary features.
• In the illustrated embodiments, selected fold lines are shown as including spaced cuts to facilitate folding along the lines. If the cuts are below or adjacent to the bottom receptacle portion of the carton, less than 100% cuts may be used to prevent leakage along the fold lines. Alternatively, cuts or scores may be omitted within or near the receptacle portion.
• In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections.
• For purposes of the description presented herein, the term “line of disruption” can be used to generally refer to, for example, a cut line, a score line, a crease line, a tear line, or a fold line (or various sequential and/or overlapping combinations thereof) formed in a blank. A “breachable” line of disruption is a line of disruption that is intended to be breached during ordinary use of the carton. An example of a breachable line of disruption is a tear line.
• In accordance with a second embodiment of the invention, a tray, or other construct, is formed. As one example and referring toFIG. 1, the blank8 can be modified by omitting certain elements, such as thepanels32,34,42,44 in order to form an open tray type carton.
• It will be understood by those skilled in the art that while the present invention has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention as set forth in the following claims.

Claims (44)

1. A carton formed from at least a major blank and a minor blank joined to the major blank, the carton comprising:

a bottom panel;

a first side panel;

a second side panel;

a first end panel;

a second end panel;

a plurality of gussets, one gusset being located at each corner of the bottom panel and disposed between and foldably connected to an adjacent side panel and end panel, wherein

the first side panel, the second side panel and the plurality of gussets are formed from at least the major blank, and

the bottom panel and the first and second end panels are formed from at least the major and minor blanks.

2. The carton ofclaim 1, further comprising:

a first handle panel foldably connected to the first end panel; and

a second handle panel foldably connected to the second end panel, wherein the first and second handle panels are formed from at least the major and minor blanks.

3. The carton ofclaim 2, further comprising:

a first handle feature formed in the first handle panel; and

a second handle feature formed in the second handle panel.

4. The carton ofclaim 2, further comprising:

a first side top panel foldably connected to the first side panel; and

a first closure panel foldably connected to the first side top panel.

5. The carton ofclaim 4, further comprising:

a second side top panel foldably connected to the second side panel;

a second closure panel foldably connected to the second side top panel; and

a closure flap foldably connected to the second closure panel.

6. The carton ofclaim 1, further comprising:

a first side top panel foldably connected to the first side panel, wherein each end of the first side top panel is foldably connected to one of the gussets; and

a first closure panel foldably connected to a distal edge of the first side top panel.

7. The carton ofclaim 6, further comprising:

a second side top panel foldably connected to the second side panel, wherein each end of the second side top panel is foldably connected to one of the gussets;

a second closure panel foldably connected to the second side top panel; and

a closure flap foldably connected to the second closure panel.

8. The carton ofclaim 1, wherein each gusset comprises at least two foldably connected gusset panels.

9. The carton ofclaim 8, wherein each gusset comprises at least four foldably connected gusset panels.

10. The carton ofclaim 1, wherein the carton is substantially parallelepipedal.

11. A carton, comprising:

a bottom panel;

a first side panel foldably connected to the bottom panel;

a second side panel foldably connected to the bottom panel;

a first end panel foldably connected to the bottom panel;

a second end panel foldably connected to the bottom panel;

a first side top panel foldably connected to the first side panel;

a first closure panel foldably connected to the first side top panel and extending across a top of the carton;

a closure aperture in the first closure panel;

a second side top panel foldably connected to the second side panel;

a second closure panel foldably connected to the second side top panel and extending across the top of the carton; and

a closure flap foldably connected to the second closure panel, the closure flap including a closure projection sized to be received in the closure aperture in the first closure panel.

12. The carton ofclaim 11, further comprising:

a plurality of gussets, one gusset being located at each corner of the bottom panel and disposed between and foldably connected to an adjacent side panel and end panel.

13. The carton ofclaim 12, further comprising:

a first handle panel foldably connected to the first end panel; and

a second handle panel foldably connected to the second end panel.

14. The carton ofclaim 13, further comprising:

a first handle feature formed in the first handle panel; and

a second handle feature formed in the second handle panel.

15. The carton ofclaim 14, further comprising:

at least one handle receiving aperture formed at least partially in the first closure panel.

16. The carton ofclaim 13, wherein each handle panel is adhered to at least two of the gussets.

17. The carton ofclaim 11, wherein the first side top panel and the second side top panel extend across the top of the carton.

18. The carton ofclaim 11, wherein each gusset comprises at least two foldably connected gusset panels.

19. The carton ofclaim 11, wherein a liquid-tight bottom receptacle is defined in a bottom portion of the carton.

20. The carton ofclaim 11, wherein the carton is substantially parallelepipedal.

21. A carton blank formed from a major blank and a minor blank joined to the major blank, comprising:

a bottom panel;

a first side panel foldably connected to a first side of the bottom panel;

a second side panel foldably connected to a second side of the bottom panel;

a first end panel foldably connected to a first end of the bottom panel;

a second end panel foldably connected to a second end of the bottom panel;

a first side top panel foldably connected to the first side panel;

a second side top panel foldably connected to the second side panel; and

a plurality of gussets, one gusset being located at each corner of the bottom panel and disposed between and foldably connected to an adjacent side panel and end panel, wherein

the first side panel, the second side panel and the plurality of gussets are formed from at least the major blank, and

the bottom panel and the first and second end panels are formed from at least the major and minor blanks.

22. The blank ofclaim 21, further comprising:

a first closure panel foldably connected to the first side top panel;

a closure aperture in the first closure panel;

a second closure panel foldably connected to the second side top panel; and

a closure flap foldably connected to the second closure panel, the closure flap including a closure projection sized to be received in the closure aperture in the first closure panel.

23. The blank ofclaim 21, further comprising:

a first handle panel foldably connected to the first end panel; and

a second handle panel foldably connected to the second end panel, wherein handle panels are formed from at least the major and minor blanks.

24. The blank ofclaim 23, further comprising:

a first handle feature formed in the first handle panel; and

a second handle feature formed in the second handle panel.

25. The blank ofclaim 23, wherein each gusset comprises at least two foldably connected gusset panels, at least one of the gusset panels being foldably connected to one of the top side panels.

26. A carton blank, comprising:

a bottom panel;

a first side panel foldably connected to the bottom panel;

a second side panel foldably connected to the bottom panel;

a first end panel foldably connected to the bottom panel;

a second end panel foldably connected to the bottom panel;

a first side top panel foldably connected to the first side panel;

a second side top panel foldably connected to the second side panel;

a plurality of gussets, one gusset being located at each corner of the bottom panel and disposed between and foldably connected to an adjacent side panel and end panel;

a first closure panel foldably connected to the first side top panel;

a closure aperture in the first closure panel;

a second closure panel foldably connected to the second side top panel; and

a closure flap foldably connected to the second closure panel, the closure flap including a closure projection sized to be received in the closure aperture in the first closure panel.

27. The blank ofclaim 26, further comprising:

a first handle panel foldably connected to the first end panel; and

a second handle panel foldably connected to the second end panel.

28. The blank ofclaim 27, further comprising:

a first handle feature formed in the first handle panel; and

a second handle feature formed in the second handle panel.

29. The blank ofclaim 26, wherein each gusset comprises at least two foldably connected gusset panels, and wherein each gusset is foldably connected to one of the end panels, to one of the side panels, and to one of the top side panels.

30. A method of erecting a carton, comprising:

providing a carton blank, comprising:

a bottom panel;

a first side panel;

a second side panel;

a first end panel foldably connected to the bottom panel;

a first handle panel foldably connected to the first end panel;

a second end panel foldably connected to the bottom panel;

a second handle panel foldably connected to the second end panel;

a first side top panel foldably connected to the first side panel;

a second side top panel foldably connected to the second side panel;

a plurality of gussets, one gusset being located at each corner of the bottom panel and disposed between and foldably connected to an adjacent side panel and end panel;

a first closure panel foldably connected to the first side top panel; and

a second closure panel foldably connected to the second side top panel;

forming a substantially parallepipedal open top form from the blank;

loading articles into the substantially parallepipedal open top form; and

adhering at least a portion of at least one of the gussets to the first handle panel; and

forming a top closure from at least the first and second closure panels.

31. The method ofclaim 30, further comprising adhering at least a portion of at least one of the gussets to the second handle panel.

32. The method ofclaim 30, wherein the top closure comprises the first and second top side panels and the first and second closure panels.

33. The method ofclaim 30, further comprising folding the first handle panel about a fold line connecting the first handle panel to the first end panel to bring the first handle panel into contact with portions of two of the gussets.

34. The method ofclaim 33, wherein at least one of the gussets is connected to an adjacent top side panel at a fold line that is folded as the first handle panel is folded about a fold line connecting the first handle panel to the first end panel.

35. The method ofclaim 30, further comprising adhering at least a portion of each of the gussets to one of the end panels.

36. The method ofclaim 30, wherein forming a top closure comprises engaging a closure projection with a closure aperture formed in a first closure panel.

37. The method ofclaim 30, wherein each gusset comprises at least two foldably connected gusset panels, and wherein each gusset is foldably connected to one of the end panels, to one of the side panels, and to one of the top side panels.

38. A method of utilizing a carton, comprising:

providing a carton comprising:

a bottom panel;

a first side panel;

a second side panel;

a first end panel;

a second end panel;

a plurality of gussets, one gusset being located at each corner of the bottom panel and disposed between and foldably connected to an adjacent side panel and end panel; and

a top closure extending across a top of the carton, the top closure initially comprising a first side top panel foldably connected to the first side panel and a second side top panel foldably connected to the second side panel;

opening the top closure;

extending the first side top panel generally upwardly and extending the second side top panel generally upwardly to place the carton in an expanded configuration, wherein at least the first side top panel, the second side top panel, and the gussets are connected to define an upper portion of an expanded interior volume of the carton.

39. The method ofclaim 38, further comprising closing the top of the carton after opening the top closure.

40. The methodclaim 39, wherein the carton has a first height before opening the carton and a second height after opening the top closure, the second height being greater than the first height.

41. The method ofclaim 40, wherein the second height is at least 10% greater than the first height.

42. The method ofclaim 39, wherein the top closure further comprises a closure flap and a closure aperture, wherein closing the top of the carton comprises engaging the closure flap with the closure aperture.

43. The method ofclaim 38, wherein the carton further comprises a first handle panel connected to the first end panel and a second handle panel connected to the second end panel, the method further comprising carrying the carton by the first and second handle panels.

44. The method ofclaim 38, wherein each gusset comprises at least two foldably connected gusset panels, and wherein each gusset is foldably connected to one of the end panels, to one of the side panels, and to one of the top side panels.

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