Carton with retention features

This application claims the benefit of U.S. Provisional Patent Application No. 61/961,882, filed Oct. 25, 2013.

The disclosure of U.S. Provisional Patent Application No. 61/961,882, which was filed on Oct. 25, 2013, is hereby incorporated by reference for all purposes as if presented herein in its entirety.

The present disclosure generally relates to carriers and cartons for holding and dispensing product containers or other types of articles.

In general, one aspect of the disclosure is directed to a carton for carrying a plurality of articles. The carton comprises at least one retention tab for engaging at least a portion of an article of the plurality of articles and at least one corner flap. Each of the at least one retention tab and the at least one corner flap is disposed adjacent at least one corner opening in the carton.

In another aspect, the disclosure is generally directed to a carton for carrying a plurality of articles. The carton can comprise a plurality of panels at least partially extending around an interior of the carton. The plurality of panels can comprise a top panel, at least one side panel, and at least one bottom panel. At least one retention tab can be foldably connected to the at least one bottom panel. The at least one retention tab can be for engaging at least a portion of an article of the plurality of articles. At least one corner flap can be foldably connected to the at least one side panel. Each of the at least one retention tab and the at least one corner flap can be disposed adjacent to at least one corner opening in the carton.

In another aspect, the disclosure is generally directed to a blank for forming a carton for holding a plurality of articles. The blank can comprise a plurality of panels comprising a top panel, at least one side panel, and at least one bottom panel. At least one retention tab can be foldably connected to the at least one bottom panel. At least one corner flap can be foldably connected to the at least one side panel. The at least one retention tab can be at least partially separable from the at least one corner flap along at least one cut line for forming at least one corner opening in the carton formed from the blank.

In another aspect, the disclosure is directed to a method of forming a carton for holding a plurality of articles. The method can comprise obtaining a blank comprising a plurality of panels comprising a top panel, at least one side panel, and at least one bottom panel, at least one retention tab foldably connected to the at least one bottom panel, and at least one corner flap foldably connected to the at least one side panel. The at least one retention tab can be at least partially separable from the at least one corner flap along at least one cut line. The method further can comprise forming an interior of the carton at least partially defined by the plurality of panels. The forming the interior can comprise folding the at least one bottom panel with respect to the at least one side panel. The method also can comprise at least partially engaging the at least one retention tab with a bottom portion of an article of the plurality of articles. The engaging the at least one retention tab can at least partially form a corner opening in the carton.

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

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. Further, 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 disclosure.

FIG. 1 is a plan view of an exterior surface of a blank used to form a carton according to an exemplary embodiment of the disclosure.

FIGS. 2A, 2B, and 3 are plan views of respective portions of the blank of FIG. 1 .

FIGS. 4-6 are perspective bottom views of a partially-assembled carton according to the exemplary embodiment showing the engagement of a plurality of retention tabs with a plurality of articles in the carton.

FIG. 7 is a perspective bottom view of the carton showing the bottom panels folded over the bottom of the carton according to the exemplary embodiment.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

The present disclosure generally relates to various features for cartons or carriers that contain articles such as containers, bottles, cans, etc. The articles can be used for personal care or food products, for example. The articles can be made from materials suitable in composition for packaging the product, and the materials include, but are not limited to, aluminum and/or other metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof.

Cartons or carriers according to the present disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes product containers (e.g., plastic personal care containers) as disposed within the carrier embodiments. In this specification, the terms “inner,” “interior,” “outer,” “exterior,” “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright cartons.

FIG. 1 is a plan view of an exterior surface 2 of a blank 3 , used to form a carton 5 ( FIG. 7 ) according to an exemplary embodiment of the disclosure. The carton 5 can be used to house a plurality of articles such as containers C ( FIG. 4-7 ). In the illustrated embodiment, the containers C are product containers (e.g., deodorant containers, and/or other suitable articles) and the carton 5 is sized to house 12 containers C in a single layer in a 1×12 arrangement, but it is understood that the carton 5 may be sized and shaped to hold containers C of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 1×6, 2×3, 2×6, 2×4, 2×2, 2×6×2, 2×4×2, 2×9, etc.). In the illustrated embodiment, the carton 5 can include bottom retention features 9 for engaging the bottom portions B of the containers C and top retention features 11 for engaging the top portions (not shown) of the containers C.

In the illustrated embodiment, the blank 3 has ends 6 , 8 that can form at least partially closed ends (not shown) in the carton 5 , and the carton can wrap around the containers C (e.g., the carton 5 may be referred to as a wrap-around carton). The carton 5 could be otherwise shaped and arranged such the ends 6 , 8 are generally open or fully closed such as by end flaps or other closing mechanisms.

The blank 3 has a longitudinal axis L 1 and a lateral axis L 2 . In the illustrated embodiment, the blank 3 comprises a top panel 20 foldably connected to a first side panel 22 at a first longitudinal fold line 24 , a first bottom panel 26 foldably connected to the first side panel 22 at a second longitudinal fold line 28 , a second side panel 30 foldably connected to the top panel 20 at a third longitudinal fold line 32 , and a second bottom panel 34 foldably connected to the second side panel 30 at a fourth longitudinal fold line 36 . In the illustrated embodiment, the first side panel 22 includes a first bottom corner panel 38 defined by longitudinal fold lines 28 and 40 . The second side panel 30 includes a second bottom corner panel 42 defined by longitudinal fold lines 36 and 44 . Additionally, the first side panel 22 can include a first top corner panel 46 defined by longitudinal fold lines 24 and 48 , and the second side panel 30 can include a second top corner panel 50 defined by longitudinal fold lines 32 and 52 .

The first bottom panel 26 , which is the inner bottom panel flap in the assembled carton 5 , includes cutouts forming primary female locking edges 53 that are shaped and positioned to engage primary male locking tab projections 54 on the second bottom panel 34 . The first bottom panel 26 also includes asymmetric slits 56 a and generally symmetric slits 56 b shaped and positioned to receive respective outer secondary locking tab projections 58 a , 58 b of the second bottom panel 34 . The secondary locking tab projections 58 a can be asymmetric to correspond with the asymmetric slits 56 a , and the secondary locking tab projections 58 b can be generally symmetric to correspond with the symmetric slits 56 b . Accordingly, the asymmetric secondary locking tabs 58 a can have a single prong 59 a ( FIG. 2B ), and the asymmetric slits 56 a can have a single side cut 57 a ( FIG. 2A ) for receiving the single prong 59 a of a respective asymmetric secondary locking tab 58 a . The symmetric secondary locking tabs 58 b can have two prongs 59 b ( FIG. 2B ), and the symmetric slits 56 b can have two side cuts 57 b ( FIG. 2A ) for receiving the respective prongs 59 b of a respective symmetric secondary locking tab 58 b.

In the illustrated embodiment, the side cuts 57 a , 57 b of the respective asymmetric slits 56 a and symmetric slits 56 b can be curved and can at least partially define a respective locking flap 61 ( FIG. 2A ). As shown in FIGS. 1 and 2A , each of the locking flaps 61 can be foldably connected to the first bottom panel 26 along a respective longitudinal fold line 63 and can be at least partially separable from the first bottom panel 26 along a respective longitudinal cut 65 . Accordingly, the locking flaps 61 can be folded inwardly with respect to the first bottom panel 26 and engage the respective secondary locking tabs 58 a , 58 b when the secondary locking tabs are received in the respective slits 56 a , 56 b.

In one embodiment, the second bottom panel 34 , which is the outer bottom panel in the completed carton 5 , includes a longitudinal fold line 60 , which is interrupted by slits 55 that at least partially define the primary male locking tab projections 54 ( FIG. 2B ). In addition, each of the secondary locking tab projections 58 a , 58 b can include a longitudinal fold line 62 . Although the locking elements of the blank 3 are illustrated to demonstrate a particular bottom panel locking arrangement suitable for use with the carton 5 , it is understood that any alternative form of bottom panel locking structure may be employed without departing from the disclosure. For example, all of the slits 56 a , 56 b and/or all of the secondary locking projections 58 a , 58 b can be symmetric or asymmetric.

As shown in FIGS. 1-2B , the bottom retention features 9 can include a row of first retention features 64 extending in the first bottom corner panel 38 and a row of second retention features 66 extending in the second bottom corner panel 42 . As shown in FIG. 2A , each of the first retention features 64 includes a retention tab 68 adjacent to two corner flaps 70 . In the illustrated embodiment, the retention tab 68 in each of the first retention features 64 can be foldably connected to the first bottom panel 26 along a fold line 72 (e.g., an arcuate fold line) and the corner flaps 70 in each of the first retention features 64 can be foldably connected to the first side panel 22 along a fold line 74 . In one embodiment, the fold lines 72 , 74 can be offset from the respective fold lines 28 , 40 so that the retention tabs 68 interrupt the fold line 28 and the corner flaps 70 interrupt the fold line 40 . Alternatively, the fold lines 72 , 74 could be collinear with the respective fold lines 28 , 40 , or could be otherwise configured. As shown in FIGS. 1 and 2A , each of the retention tabs 68 is separable from the first bottom panel 26 and the first bottom corner panel 38 along curved cut lines 75 and is separable from the adjacent corner flaps 70 along a cut line 76 . The corner flaps 70 of each of the first retention features 64 are separable from one another along a cut line 78 . In an alternative embodiment, the cut lines 76 , 78 could be replaced by tear lines, openings, or other suitable features. As shown in FIG. 2A , the corner flaps 70 are separable from the first side panel 22 and the first bottom corner panel 38 along respective cut lines 80 and are connected to the first bottom corner panel 38 at a respective nick 82 , which interrupts the respective cut line 80 . In an alternative embodiment, the corner flaps 70 could be otherwise foldably connected and/or separable from the first bottom corner panel 38 (e.g., along a fold line, a tear line, or other suitable feature).

As shown in FIG. 2B , each of the second retention features 66 includes a retention tab 84 adjacent to two corner flaps 86 . In the illustrated embodiment, the retention tab 84 in each of the second retention features 66 can be foldably connected to the second bottom panel 34 along a fold line 88 and the corner flaps 86 in each of the second retention features 66 can be foldably connected to the second side panel 30 along a fold line 90 . In one embodiment, the fold lines 88 , 90 can be offset from the respective fold lines 36 , 44 so that the retention tabs 84 interrupt the fold line 36 and the corner flaps 86 interrupt the fold line 44 . Alternatively, the fold lines 88 , 90 could be collinear with the respective fold lines 36 , 44 , or could be otherwise configured. As shown in FIGS. 1 and 2B , each of the retention tabs 84 is separable from the second bottom panel 34 and the second bottom corner panel 42 along curved cut lines 91 and is separable from the adjacent corner flaps 86 along a cut line 92 . The corner flaps 86 of each of the second retention features 66 are separable from one another along a cut line 94 . In an alternative embodiment, the cut lines 92 , 94 could be replaced by tear lines, openings, or other suitable features. As shown in FIG. 2B , the corner flaps 86 are separable from the second side panel 30 and the second bottom corner panel 42 along respective cut lines 96 and are connected to the second bottom corner panel 42 at a respective nick 98 , which interrupts the respective cut line 96 . In an alternative embodiment, the corner flaps 86 could be otherwise foldably connected and/or separable from the second bottom corner panel 42 (e.g., along a fold line, a tear line, or other suitable feature).

In the illustrated embodiment, each of the retention tabs 68 , 84 is positioned to engage at least a portion of a recess R at the bottom B of a respective container C ( FIGS. 4-7 ). One or more of the first bottom corner features 64 and/or the second bottom corner features 66 could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

As shown in FIGS. 1 and 3 , the top retention features 11 include a row of retention features 100 in the first top corner panel 46 and a row of retention features 102 in the second top corner panel 50 . Each of the retention features 100 can include two corner flaps 104 adjacent an opening 106 , and each of the retention features 102 can include two corner flaps 108 adjacent an opening 110 . The corner flaps 104 can be foldably connected to the first top corner panel 46 along respective fold lines 112 , and the corner flaps 108 can be foldably connected to the second top corner panel 50 along respective fold lines 114 . In the illustrated embodiment, the corner flaps 104 can be separable from the first side panel 22 along a cut line 116 and from one another along a cut line 118 , and the corner flaps 108 can be separable from the second side panel 30 along a cut line 120 and from one another along a cut line 122 . In one embodiment, projections 124 can extend from the top panel 20 adjacent the openings 106 , 110 . As shown in FIGS. 1 and 3 , the projections 124 can interrupt the fold lines 24 , 32 , the corner flaps 104 can interrupt the fold line 48 , and the corner flaps 108 can interrupt the fold line 52 . One or more of the retention features 100 , 102 could be omitted or could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

In one embodiment, the first side panel 22 is foldably connected to a first side end flap 126 and a second side end flap 128 , and the second side panel 30 is foldably connected to a first side end flap 130 and a second side end flap 132 . When the carton 5 is erected, the side end flaps 126 , 130 close the first end 6 of the carton, and the side end flaps 128 , 132 close the second end 8 of the carton. In accordance with an alternative embodiment of the present disclosure, different flap arrangements can be used for closing the ends 6 , 8 of the carton.

As shown in FIG. 1 , the end flaps 126 , 130 extend along a first marginal area of the blank 3 , and can be foldably connected at a first lateral fold line 134 that extends along the width of the blank. The end flaps 128 , 132 extend along a second marginal area of the blank 3 , and can be foldably connected at a second lateral fold line 136 that also extends along the width of the blank. The lateral fold lines 134 , 136 may be, for example, substantially straight or offset at one or more locations to account for blank thickness or for other factors. The blank 3 could have other end flap arrangements without departing from the disclosure.

In the illustrated embodiment, the blank 3 can include a transverse tear line 138 extending along a centerline of the blank. Accordingly, the lateral tear line 138 can be actuated to separate the erected carton 5 into two portions. The tear line 138 could be omitted or could be otherwise positioned, shaped, and/or arranged without departing from the disclosure. For example, the tear line 138 could be offset from the centerline of the blank 3 . In one alternative embodiment, the blank 3 could include dispenser features for accessing the containers C in the carton 5 .

As shown in FIGS. 4-7 , the carton 5 can be erected by wrapping the blank 3 around the containers C and interlocking the first and second bottom panels 26 , 34 with the bottom retention features 9 actuated to engage the recess features R of the containers C. As shown in FIG. 4 , the containers C are arranged in a row on the top panel 20 so that the tops (not shown) of the containers C are aligned with the top retention features 11 . The side panels 22 , 30 can be folded upwardly along respective fold lines 24 , 32 so that the tops of the containers C contact the corner flaps 104 , 108 and are received in the openings 106 , 110 (not shown). As the side panels 22 , 30 are folded, the bottom panels 26 , 34 can be folded outwardly along the respective fold lines 28 , 36 . As shown in FIG. 4 , the outwardly folding of the bottom panels can cause the retention tabs 68 , 84 to separate from the respective bottom corner panels 38 , 42 , folding along respective fold lines 72 , 88 . Accordingly, the retention tabs 68 , 84 can be aligned with the recesses R of the containers C when the side panels 22 , 30 are brought into contact with the sides of the containers. In one embodiment, the retention tabs 68 , 84 can separate from the respective corner panels 38 , 42 during folding without being pushed by a tool, for example. Alternatively, the retention tabs could be forced to separate from the respective corner panels with a suitable tool, for example.

As shown in FIGS. 5 and 6 , the first bottom panel 26 can be folded over the bottoms B of the containers C, and the retention tabs 68 can be pushed down into the respective recesses R of the respective containers. In one embodiment, the retention tabs 68 can rotate into the recesses R of the containers when the bottom panel 26 is folded over the bottom of the carton 5 along fold line 28 . Alternatively, the retention tabs 68 can be forced into the recesses R by a suitable tool, for example. In the illustrated embodiment, the corner flaps 70 can be folded outwardly about fold lines 74 and at nicks 82 by contact with the bottoms B of the respective containers C. Accordingly, the bottoms B of the containers C can extend into respective openings 142 formed in the respective first retention features 64 .

Similarly, as shown in FIG. 7 , the second bottom panel 34 can be folded over the bottoms B of the containers C and the first bottom panel 26 , and the retention tabs 84 can be pushed down into the respective recesses R of the respective containers. In one embodiment, the retention tabs 84 can rotate into the recesses R of the containers when the bottom panel 34 is folded over the bottom of the carton 5 along fold line 36 . Alternatively, the retention tabs 84 can be forced into the recesses R by a suitable tool, for example. In the illustrated embodiment, the corner flaps 86 can be folded outwardly about fold lines 90 and at nicks 98 by contact with the bottoms B of the respective containers C. Accordingly, the bottoms B of the containers C can extend into respective openings 144 formed in the respective second retention features 66 .

In one embodiment, the second bottom panel 34 is secured to the first bottom panel 26 by first respectively engaging primary male locking tabs 54 with the primary female locking edges 53 . The primary male locking tabs 54 can be separated from the second bottom panel 34 by folding the second bottom panel along the fold line 60 so that the secondary male locking flaps 58 a , 58 b extend generally upwardly. Once the primary male locking flaps 54 are engaged with the female locking edges 53 , the secondary male locking flaps 58 a , 58 b are respectively inserted through, and cooperatively interact with, the respective slits 56 a , 56 b to further secure the second bottom panel 34 to the first bottom panel 26 . The interlocked bottom panels 26 , 34 cooperate to form a bottom panel 140 of the carrier 5 .

The ends 6 , 8 of the carton 5 can be closed (not shown) by overlapping the end flaps 126 , 130 at the first end 6 and adhering the end flap 130 to the end flap 126 (e.g., at glue lines, glue tabs, or other suitable features), and by overlapping the end flaps 128 , 132 at the second end 8 and adhering the end flap 132 to the end flap 128 (e.g., at glue lines, glue tabs, or other suitable features). The carton 5 could be formed with alternative forming steps without departing form the disclosure.

In the illustrated embodiment, the engagement of the folded retention tabs 68 , 84 with the recesses R of the containers C can help prevent movement of the containers C within the carton 5 and can help prevent the containers C from being forced out of the carton 5 . In addition, or alternatively, the engagement of the folded retention tabs 68 , 84 with the recesses R of the containers C can help reduce damage to the carton 5 due to outside forced on the carton. The carton 5 could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

In general, the blanks according to the present disclosure can be constructed from paperboard having a caliper 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.

In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.

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

The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.