CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/123,438, filed November 17, 2014.

INCORPORATION BY REFERENCE

100021 The disclosure of U.S. Provisional Patent Application No. 62/123,438, which was filed on

November 17, 2014, is hereby incorporated by reference for all purposes as if presented herein in its entirely.

BACKGROUND OF THE DISCLOSURE

[0003] The present disclosure generally relates to cartons or carriers for holding beverage containers or other types of articles. More specifically, the present disclosure relates to cartons that include reinforcement features for strengthening the carton.

SUMMARY OF THE DISCLOSURE

[0004] In general, one aspect of the disclosure is directed to a carton for carrying a plurality of articles. The carton comprises at least one top panel, a first side panel, a second side panel, and a bottom panel. A plurality of end flaps is foldably connected to a respective panel to close an end of the carton. The carton includes reinforcement features at the end of the carton to increase the strength of the carton.

[0005] In another aspect, the present disclosure is generally directed to a carton for carrying a plurality of articles. The carton comprising a plurality of panels that extend at least partially around an interior of the carton. The plurality of panels comprising at least one top panel, a first side panel, a second side panel, and bottom panel. A plurality of end flaps are each foldably connected to a respective panel of the plurality of panels for closing an end of the carton. At least one end flap of the plurality of end flaps has reinforcement features for increasing the strength of the carton. The reinforcement features comprising a base portion foldably connected to the first side panel, an intermediate portion foldably connected to the base portion, and a distal portion foldably connected to the intermediate portion. [0006] In another aspect, the present disclosure is generally directed to a blank for forming a carton for carrying a plurality of articles. The blank comprising a plurality of panels comprising at least one top panel, a first side panel, a second side panel, and bottom panel. A plurality of end flaps are each foldably connected to a respective panel of the plurality of panels for closing an end of the carton formed from the blank. At least one end flap of the plurality of end flaps has reinforcement features for increasing the strength of the carton formed from the blank. The reinforcement features comprising a base portion foldably connected to the first side panel, an intermediate portion foldably connected to the base portion, and a distal portion foldably connected to the intermediate portion.

[0007] In another aspect, the present disclosure is generally directed to a method of forming a carton for carrying a plurality of articles. The method comprising obtaining a blank comprising a plurality of panels comprising at least one top panel, a first side panel, a second side panel, and a bottom panel. A plurality of end flaps are each foldably connected to a respective panel of the plurality of panels, wherein at least one end flap of the plurality of end flaps has reinforcement features for increasing the strength of the carton. The reinforcement features comprising a base portion foldably connected to the first side panel, an intermediate portion foldably connected to the base portion, and a distal portion foldably connected to the intermediate portion. The method comprises positioning the plurality of panels to form an interior of the carton, closing an end of the carton by at least partially overlapping the plurality of end flaps, and positioning the reinforcement features to increase the strength of the carton. The positioning the reinforcement features comprising positioning the base portion, intermediate portion, and distal portion to increase the strength of the carton.

[0008] 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.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] 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. [0010] Fig. 1 is an exterior plan view of a carton blank used to form a carton in accordance with an embodiment of the disclosure.

[0011] Fig. 2 is a perspective view of the carton in a partly assembled configuration in accordance with the embodiment of the disclosure.

[0012] Fig. 3 is a perspective view of the carton in a further assembled configuration with articles placed in the interior of the carton in accordance with the embodiment of the disclosure.

[0013] Fig. 4 is a close-up view of an end of the carton having reinforcement features in accordance with the embodiment of the disclosure.

[0014] Fig. 5 is a perspective view of the assembled carton in accordance with the embodiment of this disclosure.

[0015] Fig. 6 is a close-up view of a corner of the assembled carton in accordance with the embodiment of this disclosure.

[0016] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0017] The present disclosure generally relates to cartons that contain articles such as containers, pouches, bottles, cans, boxes, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, flexible pouch material such as laminates including aluminum and synthetic polymer layers; flexible pouch material such as laminates including synthetic polymer layers; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE. HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof.

[0018] Cartons 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 flexible pouches (e.g., j uice pouches) as disposed within the carton embodiments. In this specification, the terms "lower." "bottom," "upper" and "top" indicate orientations determined in relation to fully erected and upright cartons. [0019] Fig. 1 is a plan view of an exterior surface 2 of a blank 3, used to form a carton 5, shown in

Figs. 5-6, according to one embodiment of the disclosure. The carton 5 can be used to house a plurality of articles such as containers C (e.g., see exemplary containers C shown in Fig. 3). In one embodiment, the containers C can be flexible pouches commonly referred to as juice pouches, although the containers can contain fluids other than juice. The containers C can be any suitable beverage container such as any shape, size, and type of containers or any other container containing products such as beverages or products other than beverages without departing from the disclosure.

[0020] In one embodiment, the blank 3 is sized to form a carton 5 that contains ten containers C in two layers with each layer having five containers (e.g., a 2x5 arrangement). But, it is understood that the blank 3 and/or carton 5 may be sized and shaped to hold containers C of a different or same quantity in a single layer or more than two layers and/or in different row/column arrangements (e.g., 1x6, 2x3, 2x4, 2x6, 2x4, 2x2, 2x6x2, 2x4x2, 2x9, etc.). In the illustrated embodiment, the carton 5 has reinforcement features for strengthening the carton to allow stacking of multiple cartons without failure (e.g., crushing) of the carton.

[0021] As shown in Fig. 1 , the blank 3 has a longitudinal axis L I and a lateral axis L2. In the illustrated embodiment, the blank 3 comprises a bottom panel 1 1 foldably connected to a first side panel 13 at a lateral fold line 15, a second side panel 17 foldably connected to the bottom panel at a lateral fold line 19, a first top panel 21 foldably connected to the first side panel 13 at a lateral fold line 23, and a second top panel 25 foldably connected to the second side panel 17 at a lateral fold line 27. In one embodiment, the first top panel 21 includes handle flaps 31 , 33 respectively foldably connected to the first top panel at longitudinal fold lines 35, 37. The handle flaps 31 , 33 could be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure.

1 022] In one embodiment, the panels 1 1 , 13, 17, 21 have respective first end flaps 41 , 43, 45, 47, at a first marginal portion of the blank 3 such that the first end flaps are foldably connected to respective panels to close a first end 49 of the carton 5. The panels 1 1 , 13, 17, 21 have respective second end flaps 51, 53, 55, 57 at a second marginal portion of the blank 3 such that the second end flaps are foldably connected to respective panels to close a second end 59 of the carton. As shown in Fig. 1 , the bottom end flap 41 is foldably connected to the bottom panel 1 1 at a longitudinal fold line 61 , the side end flap 43 is foldably connected to the first side panel 13 at a longitudinal fold line 63, the side end flap 45 is foldably connected to the second side panel 17 at a longitudinal fold line 65, and the top end flap 47 is foldably connected to the first top panel 21 at a longitudinal fold line 67. In one embodiment, the bottom panel 1 1 includes an oblique edge 69 between the fold lines 61 , 63 and a straight edge 71 between the fold lines 61 , 65. Similarly, the first top panel 21 includes an oblique edge 73 between the fold lines 63, 67 and a straight edge between the fold line 67 and the lateral edge connected to the first side panel 13 at fold line 63, an intermediate portion 79 foldably connected to the base portion at a longitudinal fold line 81 , and a distal portion 83 foldably connected to the intermediate portion at a longitudinal fold line 85. In the illustrated embodiment, the second top panel 25 is free from first or second end flaps, but the second top panel could be otherwise shaped, arranged, and/or configured without departing from the disclosure. As shown in Fig. 1 , the second marginal portion of the blank 3 is a mirror image of the first marginal portion so that the second end flaps 51 , 53, 55, 57 are shaped to have identical features as the first end flaps 41 , 43, 45, 47. As such, the second end flaps 51 , 53, 55, 57 are foldably connected to a respective panel 1 1 , 13, 17, 21 at a respective fold line 91 , 93, 95, 97. The bottom panel 1 1 has an oblique edge 99 and straight edge 101 at the second marginal portion of the blank 3, and the first top panel 21 has an oblique edge 103 and a straight edge 105 at the second marginal portion of the blank. The side end flap 53 at the second marginal portion of the blank 3 has a base portion 107 foldably connected to the first side panel 13 at the longitudinal fold line 93, a intermediate portion 109 foldably connected to the base portion at a longitudinal fold line 1 1 1 , and a distal portion 1 13 foldably connected to the intermediate portion 109 at a longitudinal fold line 1 15. The first end flaps 41 , 43, 45, 47 and the second end flaps 51 , 53, 55, 57 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.

Figs. 2-6 show one exemplary method of forming the blank 3 into the carton 5. In one embodiment, the first top panel 21 , the bottom panel 1 1 , and the side end flaps 43, 53 are upwardly folded relative to the first side panel 13 at respective fold lines 15, 23, 63, 93 to form a tray 121. The end flaps 41 , 51 connected to the bottom panel 1 1 are inwardly folded at respective fold lines 61 , 91 and positioned to be in face-to-face contact and adhered to a respective side end flap 43, 53. As shown in Fig. 2, the base portions 77, 107 of respective side end flaps 43, 53 is angled or positioned to be oblique relative to the first side panel 13, with the intermediate portions 79, 109 and distal portions 83, 1 13, positioned to be generally perpendicular to the first side panel 13. As shown in Fig. 2, the end flaps 51 , 57 are adhered in face-to-face contact with the intermediate portion 109 of the end flap 53 and the end flaps 41 , 47 are adhered in face-to-face contact with the intermediate portion 79 of the end flap 43. The oblique base portions 77, 107 of the end flaps 43, 53 conform to respective oblique edges 69, 73, 99, 103 of the bottom panel 1 1 and the first top panel 21 to form respective angled corners 125, 127 at the ends 49, 59 of the carton 5. In one embodiment, the second side panel 17, the second top panel 25, and the end flaps 45, 55 form a lid 123 that is foldably connected to the tray 121 at the fold line 19. As shown in Fig. 3, the containers C are loaded in the interior space 13 1 of the tray 121. In one embodiment, eight containers C are placed in the interior space 131 arranged in two layers of four containers, but other quantities and arrangements of containers can be loaded in the carton 5 without departing from the disclosure. Further, the containers C can be loaded by other methods or steps. After the containers C are loaded in the tray 121 , the distal portions 83, 1 13 of the side end flaps 43, 53 are downwardly folded relative to the intermediate portions 79, 109. As shown in Fig. 4, the lid 123 is downwardly folded relative to the tray 121 at fold line 19 (and in the direction of arrow A l in Fig. 3) so that the second side panel 17 closes the interior space 131 of the tray. In one embodiment, the edge of the distal portions 83. 1 13 engages the second side panel to keep the distal portions at an oblique angle relative to the intermediate portions 79, 109 of the end flaps 43, 53. The end flaps 43, 53 are sized so that the distal portions 83, 1 13 of the end flaps extend far enough into the interior space 131 to be engaged by the second side panel 17 when the lid 123 is downwardly folded so that the distal portions 83, 1 13 are secured in the oblique position relative to the intermediate portions 79, 109. As shown in Figs. 6 and 7, the end flaps 45, 55 are downwardly folded in the direction of arrow A2 (Fig. 4) to overlap the end flaps 43, 43 and close the ends 49, 59 and the second side panel 25 is downwardly folded to overlap the first side panel 21. The end flaps 45, 55 of the lid 123 can be adhesively attached to the intermediate portions 79, 109 of the end flaps 43, 53 by an adhesive such as glue. The second top panel 25 can be secured to the first top panel 21 by glue. The carton 5 could be formed by other steps or forming methods without departing from the disclosure.

In one embodiment, the downwardly folded end flaps 45, 55 form an external corner 135, 137 at a respective end 49, 59 that is square or orthogonal (i.e., the end flaps 45, 55 are positioned at 90 degrees relative to the second side panel 17). Each of the corners 135, 137 includes a respective angle distal portion 83, 1 13 of the end flaps 43 that is oblique relative to the end flaps 45, 55 that are in face-to-face contact with the intermediate portion 79, 109 of a respective end flap 43, 53. In this way, the corners 135, 137 include internal oblique reinforcement portions in the form of the distal portions 83, 1 13 that are not visible from the exterior of the carton. The oblique distal portions 83, 1 13 are the reinforcement features of the carton 5 that provide an internal structural member that increases the strength of the carton and increases the resistance to crushing of the carton when the cartons are stacked on top of each other. Because of the increased strength resulting from the internal structural members 83, 1 13, the carton 5 and blank 3 can be manufactured from lighter or thinner material thus saving manufacturing costs. In one embodiment that the oblique distal portions 83, 1 13 and the oblique base portions 77, 107 of the end flaps 43, 53 cooperate to form the reinforcement features at the ends 49, 59 of the carton 5. The carton 5 could have other features without departing from the scope of the disclosure. [0027] In general, the blanks described herein may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank 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 blank 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.

[0028] As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear l ine is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.

[0029] 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.

[0030] 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 embodiments.

As various changes could be made in the above construction without departing from the 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. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure 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.