Package including carton with insert

Description

BACKGROUND OF THE DISCLOSURE

[0001] The present invention generally relates to packages with cartons having at least one insert.

[0002] Document US1821692A discloses a package, a combination and a method forming the basis of the preamble of claims 1, 7 and 11 respectively.SUMMARY OF THE DISCLOSURE

[0003] According to one aspect of the invention, a package for holding at least one product comprises a carton and at least one insert as per claim 1.

[0004] According to another aspect of the invention, a combination comprises a carton blank and at least one insert blank for forming a package for holding at least one product as per claim 7.

[0005] According to another aspect, the subject invention is also directed towards a method of forming a package from a carton blank and at least one insert blank as per claim 11.

[0006] The dependent claims are directed towards advantageous embodiments of the subject invention.

[0007] 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.

[0008] 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 disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Fig. 1 is a plan view of a blank for forming a carton according to exemplary embodiments of the invention. Fig. 2 is a plan view of an insert for being disposed in the carton formed from the blank of Fig. 1 to form a package according to an exemplary embodiment of the invention. Fig. 3 is a perspective view of two inserts of Fig. 2 disposed in a partially erected carton formed from the blank of Fig. 1 according to the exemplary embodiment of the disclosure. Fig. 4 is a perspective view, shown partially in hidden lines, of the package according to the exemplary embodiment of the disclosure.

[0010] Corresponding parts may be designated by corresponding reference numbers throughout the drawings.DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0011] The present disclosure generally relates to package including a carton that may contain products such as flowable materials or food products (e.g., cereal) or any other flowable material (e.g., powder-type mixes, granular materials, salts or other crystallines, detergents, etc.). The cartons described herein can include a liner or bag in the carton interior. The liner can be used to protect and store product in the carton. The liner can be made from materials suitable in composition for packaging the particular product, and the materials include, but are not limited to, plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; metals; papers; and the like, or any combination thereof. Alternatively, the liner can be omitted. In one or more embodiments, in this specification, the terms "inner," "interior," "outer," "exterior," "front," "back," "lower," "bottom," "upper" and "top" indicate orientations determined in relation to fully erected and upright packages and / or cartons.

[0012] Fig. 1 is a plan view of the exterior side 1 of a blank, generally indicated at 3, used to form a carton 5 (Fig. 4) according to exemplary embodiments of the disclosure. The carton 5 can be used to house a flowable material (e.g., a food product such as cereal; not shown) or other products. The carton 5 can have a top closed end 7 and a bottom closed end 9 (Fig. 4). Two inserts 13 (Figs. 2) can be disposed within the carton 5 to form a package 15 (Fig. 4). The package 15 can also include a liner or bag (not shown) disposed within the carton 5.

[0013] As shown in Fig. 1, the blank 3 has a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiment, the blank 3 includes a first end panel 21 foldably connected to a first side panel 23 at a first lateral fold line 25, a second end panel 27 foldably connected to the first side panel 23 at a second lateral fold line 29, and a second side panel 31 foldably connected to the second end panel 27 at a third lateral fold line 33. In the illustrated embodiment, the blank 3 includes an attachment flap 35 foldably connected to the second side panel 31 at a fourth lateral fold line 37. Alternatively, the attachment flap 35 could be foldably connected to the first end panel 21 or could be omitted without departing from the invention as defined by the claims.

[0014] In the illustrated embodiment, a first end top flap 39 and a first end bottom flap 41 are foldably connected to the first end panel 21. As shown, a first side top flap 43 and a first side bottom flap 45 are foldably connected to the first side panel 23. A second end top flap 47 and a second end bottom flap 49 are foldably connected to the second end panel 27, as shown. A second side top flap 51 and a second side bottom flap 53 are foldably connected to the second side panel 31. The top flaps 39, 43, 47, and 51 extend along a first or top marginal area of the blank 3. The first end top flap 39 is foldably connected to the first end panel 21, the first side top flap 43 is foldably connected to the first side panel 23, the second end top flap 47 is foldably connected to the second end panel 27, and the second side top flap 51 is foldably connected to the second side panel 31 along a first longitudinal extending fold line 62 that extends along the length of the blank 3. The bottom flaps 41, 45, 49, 53 extend along a second or bottom marginal area of the blank 3. The bottom flaps 41, 45, 49, 53 are foldably connected to the respective panels 21, 23, 27, 31 along a second longitudinally extending fold line 64 that extends along the length of the blank 3. In one embodiment, the longitudinal fold lines 62, 64 may be, for example, substantially straight, or offset at one or more locations to account for the thickness of the blank 3 or for other factors. When the carton 5 (Fig. 4) is erected, the top end flaps 39, 43, 47, 51 can at least partially close the top end 7 of the carton 5, and the bottom end flaps 41, 45, 49, 53 can at least partially close the bottom end 9 of the carton 5. The blank 3 could be otherwise shaped, arranged, positioned, and / or configured, without departing from the scope of the invention as defined by the claims.

[0015] Fig. 2 illustrates the insert 13 for use in the carton 5 (Figs. 4) according to the first exemplary embodiment of the disclosure. In the illustrated embodiment, two of the inserts 13 are provided for assembly with the carton 5, as described herein. The insert 13 can be formed from any suitable material (e.g., corrugated cardboard, paperboard, and / or other materials). In one embodiment, the insert 13 can be formed from a different material than the blank 3. For example, the material of the insert 13 could be uncoated, unprinted paperboard, and the material of the blank 3 could be a paperboard that is coated and / or printed on at least one side. The material of the insert 13 and the material of the blank 3 could be other suitable materials. Additionally, the material of the insert 13 and the material of the blank 3 could be the same material.

[0016] As shown in Fig. 2, the insert 13 includes a first panel 81, a second panel 83, and an intermediate portion or intermediate panel 85 between the first panel 81 and the second panel 83. The first panel 81 is foldably connected to the intermediate portion 85 along a fold line 87, and the second panel 83 is foldably connected to the intermediate portion 85 along a fold line 89. The intermediate panel 85 includes a plurality of fold lines 91 extending laterally along the insert 13 (e.g., parallel to the fold lines 87, 89) to at least partially define a plurality of sections 92 that are movable relative to one another. The fold line 87 may be a fold line of the plurality of fold lines 91. As shown, the plurality of fold lines 91 may extend substantially along the entire length of the insert 13, or, in other embodiments, may extend along less than the entire length of the insert 13. As also shown, each fold line 91 may be provided as a continuously extending lateral fold line, or, in other embodiments, one or more of the fold lines 91 may be provided with one or more discontinuities. The insert 13 could be otherwise shaped, arranged, positioned, and / or configured, without departing from the scope of the invention as defined by the claims.

[0017] Referring to Fig. 1 and Fig. 3, according to one exemplary method of construction, an open-ended sleeve 40 may be erected by folding the blank 3 about the lateral fold lines 25, 29, 33, 37 so that the attachment flap 35 is adhesively secured to or otherwise attached to the first end panel 21 (e.g., by an adhesive), and the blank 3 is formed into a generally open-ended sleeve 40 with an interior 93. As described herein, the sleeve 40 is an open-ended configuration of the carton 5 (Fig. 4), and the interior 93 of the sleeve 40 will form the interior 93 of the carton 5. In the illustrated embodiment, two inserts 13 can be attached to the blank 3 or, as shown in Fig. 3, to the interior 89 of the sleeve 40 (the partially erected carton 5). In one embodiment, the first panels 81 of the respective inserts 13 can be attached (e.g., adhered such as by gluing) to the respective end panels 21, 27 and the second panels 83 of the respective inserts 13 can be attached (e.g., glued) to the respective side panels 31, 23 so that the intermediate portions 85 extend in opposite corners C1, C2 of the sleeve 40. In the illustrated embodiment, the plurality of sections 92 of the respective intermediate portions 85 are free from direct attachment to the panels 31, 27, 23, 21 and the attachment flap 35, e.g., devoid of foldable or adhesive connection to the panels 31, 27, 23, 21, and can fold along fold lines 87, 89, 91 to extend into the interior 93 of the sleeve 40 at the respective corners C1, C2 of the sleeve 40. As described herein, the corners C1, C2, C3, C4 of the sleeve 40 will form corners of the carton 5 (Fig. 4). In this regard, and as illustrated, the plurality of sections 92 of the intermediate portion 85 together form respective protrusions 94 that extend away from the respective corners C1, C2 into the interior 89 of the sleeve 40. The protrusions 94, as shown, may have an at least partially curved or arched configuration. In embodiments, the respective first panels 81 and second panels 83 of the respective inserts 13 may be disposed in relation to one another to urge the respective protrusions 94 into the curved or arched configuration shown. In embodiments, the inserts 13 may be disposed along different portions of the sleeve 40, such that the protrusions 94 are disposed near different opposing corners C3, C4 of the sleeve 40. In embodiments, a single insert 13 or more than two inserts 13 may be provided in the sleeve 40, for example, such that protrusions 94 are disposed along all four corners C1, C2, C3, C4 of the sleeve 40. The inserts 13 could be otherwise attached to the blank 3 and / or the sleeve 40 without departing from the invention as defined by the claims.

[0018] In one embodiment, the open bottom end of the sleeve 40 can be closed by folding the bottom flaps 41, 45, 49, 53 inwardly, to at least partially overlap the bottom end flaps 41, 45, 49, 53 and close the bottom end 9 of the carton 5 (Fig. 4). Similarly, the open top end of the sleeve 40 can be closed by folding and at least partially overlapping the top flaps 39, 43, 47, 51. In one embodiment, the overlapped bottom flaps 41, 45, 49, 53 can be at least partially glued together and / or the overlapped top flaps 39, 43, 47, 51 can be at least partially glued together. In other embodiments, two or more of the bottom flaps 41, 45, 49, 53 and / or two or more of the top flaps 39, 43, 47, 51 can be interengaged (e.g., in a tab-and slot configuration) to close the open top end and / or the open bottom end of the sleeve 40 to form the carton 5. The erected carton 5 is shown in Fig. 4 as part of the package 15. The carton 5 could be otherwise formed without departing from the invention as defined by the claims.

[0019] Referring to Figs. 1 and 4, in one embodiment, the inserts 13 may have a height H1 that generally the same as a height H2 of the carton 5 (e.g., the inserts 13 can extend substantially along the length from the closed bottom end 9 of the carton 5 to the closed top end 7 of the carton 5). Accordingly, the inserts 13 can reinforce the carton 5 at least for increased compression strength (e.g., to provide resistive forces R against compressive forces F exerted against the top end 7 and / or the bottom end 9 of the carton 5). In embodiments, the presence of the inserts 13 in the carton 5 can provide resistive forces against bending or crushing along lateral portions of the carton 5, e.g., resistance against compressive forces exerted against one or more of panels 31, 27, 23, 21. Such resistance against compression, bending, and / or crushing of portions of the carton 5 is provided by the configuration of the protrusions 94 of the inserts 13. For example, the curved configuration of the protrusions 94 may have a higher area moment of inertia as compared to the square corners C1, C2 of the carton 5 such that increased strength of the carton 5, e.g., resistance against compression, bending, and / or crushing, is provided by the inserts 13. Such configuration of the carton 5 can, for example, allow for direct stacking of multiple packages 15 and / or for allow for use of a lighter material for carton 5. Accordingly, in one embodiment, packages 15 can be stacked upon one another, for example, on a pallet or other storage or transportation medium without requiring reinforcement, for example, corrugated outers as in conventional cartons. In one embodiment, the clearance provided by the inwardly extending protrusions 94 of the inserts 13 can assist in maintaining a desired shape of the package 15, for example, to help avoid unwanted bulging and / or cracking of the inserts 13 and / or the carton 5. In addition, the inserts 13 can be configured and positioned to accommodate product filling in the interior 93 of the carton 15, for example, to reduce empty space, to influence a desired distribution of product, or to avoid interfering with product filling into the carton 5.

[0020] In an alternative embodiment, one of the inserts 13 could be incorporated into the blank 3 (Fig. 1) and the carton 5. For example, the second panel 83 of the insert 13 could be omitted and the intermediate portion 85 of the insert 13 could be foldably connected to the second side panel 31 at the fold line 37 in place of the attachment flap 35. In such a configuration, the first panel 81 of the insert 13 could be glued to the first end panel 21 to form an open-ended sleeve with the intermediate portion 85 of the insert 13 forming a protrusion that can extend into the interior 93 of the carton 5 in a configuration similar to that shown in Fig. 4.

[0021] Different insert configurations may be provided to form different package configurations without departing from the invention as defined by the claims. For example, inserts may be provided with a greater or fewer number of foldably-connected panels than those described, and different numbers of inserts may be provided than those described, without departing from the invention as defined by the claims. In embodiments, inserts may be provided as integrally formed (e.g., foldably connected) along a portion of blanks for forming cartons without departing from the invention as defined by the claims.

[0022] Any of the features of the embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of the invention as defined by the claims. Further, the panels, flaps, and / or other features shown and described in conjunction with the blanks, the cartons, and / or the packages of the above embodiments are included by way of example. The inserts and / or other features of the disclosure can alternatively be associated with any suitable carton or blank having any panel and flap configuration.

[0023] The cartons according to the present disclosure can be, for example, formed from blanks of coated paperboard and similar materials. For example, the interior and / or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.

[0024] In accordance with the above-described embodiments of the present disclosure, 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 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.

[0025] 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 line 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.

[0026] The above embodiments may be described as having one or more panels, flaps, or features, 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.

[0027] 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 invention as defined by the claims, 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 that are within the scope of the claims. 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 defined by the claims, 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.

Claims

1. A package (15) for holding at least one product, comprising: a carton (5) comprising a plurality of panels (21, 23, 27, 31) extending at least partially around an interior (93) of the carton (5), the plurality of panels (21, 23, 27, 31) forming at least one corner (C1, C2, C3, C4) of the carton (5); and at least one insert (13) at least partially disposed in the interior (93) of the carton (5) adjacent the at least one corner (C1, C2, C3, C4) to reinforce the carton (5), the at least one insert (13) comprising a first panel (81, 83), a second panel (81, 83), and an intermediate portion (85) between the first panel (81, 83) and the second panel (81, 83), the intermediate portion (85) is foldably connected to the first panel (81, 83) at a first fold line (87, 89) and the intermediate portion (85) is foldably connected to the second panel (81, 83) at a second fold line (87, 89), each of the first panel (81, 83) and the second panel (81, 83) is attached to a respective panel of the plurality of panels (21, 23, 27, 31) and the intermediate portion (85) is free from attachment to the plurality of panels (21, 23, 27, 31), the intermediate portion (85) comprises a plurality of sections (92) defined by a respective plurality of fold lines (91), each section of the plurality of sections (92) is movable relative to an adjacent section of the plurality of sections (92); said package (15) being characterized in that the plurality of sections (92) together form a protrusion (94) having a curved configuration extending into the interior (93) of the carton (5), the protrusion (94) extending from the first fold line (87, 89) to the second fold line (87, 89).

2. The package (15) of claim 1, wherein the at least one insert (13) is devoid of foldable connection to the plurality of panels (21, 23, 27, 31).

3. The package (15) of claim 1, wherein the intermediate portion (85) is spaced from the at least one corner (C1, C2, C3, C4).

4. The package (15) of claim 3, wherein the intermediate portion (85) has a moment of inertia that is greater than a moment of inertia of the at least one corner (C1, C2, C3, C4).

5. The package (15) of claim 1, wherein the at least one insert (13) has a length (H1) that is substantially the same as a length (H2) of the carton (5).

6. The package (15) of claim 1, wherein the at least one corner (C1, C2, C3, C4) comprises a first corner (C1, C2, C3, C4) and a second corner (C1, C2, C3, C4), and the at least one insert (13) comprises a first insert (13) having a respective intermediate portion (85) spanning the first corner (C1, C2, C3, C4) and a second insert (13) having a respective intermediate portion (85) spanning the second corner (C1, C2, C3, C4), the first corner (C1, C2, C3, C4) and the second corner (C1, C2, C3, C4) are diagonally opposed across the interior (93) of the carton (5).

7. In combination, a carton blank (3) and at least one insert blank (13) for forming a package (15) for holding at least one product, comprising: the carton blank (3) for forming a carton (5) and comprising a plurality of panels (21, 23, 27, 31) for extending at least partially around an interior (93) of the carton (5), the plurality of panels (21, 23, 27, 31) for forming at least one corner (C1, C2, C3, C4) of the carton (5) when the carton (5) is formed from the carton blank (3); and the at least one insert blank (13) for forming at least one insert (13) for being at least partially disposed in the interior (93) of the carton (5) adjacent the at least one corner (C1, C2, C3, C4) to reinforce the carton (5) when the package (15) is formed, the at least one insert blank (13) comprising a first panel (81, 83), a second panel (81, 83), and an intermediate portion (85) between the first panel (81, 83) and the second panel (81, 83), the intermediate portion (85) is foldably connected to the first panel (81, 83) at a first fold line (87, 89) and the intermediate portion (85) is foldably connected to the second panel (81, 83) at a second fold line (87, 89), each of the first panel (81, 83) and the second panel (81, 83) is for being attached to a respective panel of the plurality of panels (21, 23, 27, 31) and the intermediate portion (85) is for being free from attachment to the plurality of panels (21, 23, 27, 31) when the package (15) is formed, the intermediate portion (85) comprises a plurality of sections (92) defined by a respective plurality of fold lines (91), each section of the plurality of sections (92) is movable relative to an adjacent section of the plurality of sections (92); said combination being characterized in that when the package (15) is formed, the plurality of sections (92) together form a protrusion (94) having a curved configuration extending into the interior (93) of the carton (5) and extending from the first fold line (87, 89) to the second fold line (87, 89).

8. The combination of claim 7, wherein the at least one insert blank (13) is devoid of foldable connection to the plurality of panels (21, 23, 27, 31).

9. The combination of claim 7, wherein the intermediate portion (85) is spaced from the at least one corner (C1, C2, C3, C4) when the package (15) is formed.

10. The combination of claim 9, wherein the intermediate portion (85) has a moment of inertia that is greater than a moment of inertia of the at least one corner (C1, C2, C3, C4) when the package (15) is formed.

11. A method of forming a package (15) from a carton blank (3) and at least one insert blank (13), comprising: obtaining a carton blank (3) comprising a plurality of panels (21, 23, 27, 31); obtaining at least one insert blank (13) comprising a first panel (81, 83), a second panel (81, 83), and an intermediate portion (85) between the first panel (81, 83) and the second panel (81, 83), the intermediate portion (85) is foldably connected to the first panel (81, 83) at a first fold line (87, 89) and the intermediate portion (85) is foldably connected to the second panel (81, 83) at a second fold line (87, 89), the intermediate portion (85) comprises a plurality of sections (92) defined by a respective plurality of fold lines (91), each section of the plurality of sections (92) is movable relative to an adjacent section of the plurality of sections (92); forming the at least one insert (13) by attaching the at least one insert blank (13) to the carton blank (3); forming the carton (5) by folding the plurality of panels (21, 23, 27, 31) of the carton blank (3) to extend at least partially around an interior (93) of the carton (5) and forming at least one corner (C1, C2, C3, C4) of the carton (5); and disposing the at least one insert (13) at least partially in the interior (93) of the carton (5) adjacent the at least one corner (C1, C2, C3, C4) such that each of the first panel (81, 83) and the second panel (81, 83) is attached to a respective panel of the plurality of panels (21, 23, 27, 31) and the intermediate portion (85) is free from attachment to the plurality of panels (21, 23, 27, 31); said method being characterized by depositing the at least one insert (13) such that the plurality of sections (92) together form a protrusion (94) having a curved configuration extending into the interior (93) of the carton (5), the protrusion (94) extending from the first fold line (87, 89) to the second fold line (87, 89).

12. The method of claim 11, wherein the at least one insert (13) is devoid of foldable connection to the plurality of panels (21, 23, 27, 31) when the at least one insert (13) is at least partially disposed in the interior (93) of the carton (5).

13. The method of claim 11, wherein the intermediate portion (85) is spaced from the at least one corner (C1, C2, C3, C4), the intermediate portion (85) has a moment of inertia that is greater than a moment of inertia of the at least one corner (C1, C2, C3, C4) when the at least one insert (13) is at least partially disposed in the interior (93) of the carton (5).

14. The method of claim 11, wherein the intermediate portion (85) comprises a plurality of intermediate panels, each panel of the plurality of intermediate panels being foldably connected to one another, the plurality of intermediate panels comprises a first intermediate panel foldably connected to the first panel (81, 83) and a second intermediate panel foldably connected to the first intermediate panel and the second panel (81, 83).

15. The method of claim 11, wherein the at least one insert (13) has a length (H1) that is substantially the same as a length (H2) of the carton (5) when the carton (5) is formed.

16. The method of claim 11, wherein the at least one corner (C1, C2, C3, C4) comprises a first corner (C1, C2, C3, C4) and a second corner (C1, C2, C3, C4) when the carton (5) is formed, and the at least one insert (13) comprises a first insert (13) having a respective intermediate portion (85) spanning the first corner (C1, C2, C3, C4) and a second insert (13) having a respective intermediate portion (85) spanning the second corner (C1, C2, C3, C4) when the at least one insert (13) is at least partially disposed in the interior (93) of the carton (5), the first corner (C1, C2, C3, C4) and the second corner (C1, C2, C3, C4) are diagonally opposed across the interior (93) of the carton (5) when the carton (5) is formed.