Three piece beverage carrier

[0001] This non-provisional patent application claims priority to the provisional application having Ser. No. 60/563,641, which was filed on Apr. 20, 2004 and to the design patent application having Ser. No. 29/200,049, which was filed on Feb. 18, 2004.

[0002] The three piece beverage carrier relates to beverage packages in general and more specifically to the divided open top containers for long neck beer bottles. Interlocking longitudinal and transverse partitions become a grid-like divider with the edges of the partitions folded and glued for stiffness. The partitions, when placed in an expanded condition within a carton, receive and separate the bottles from contact with each other.

[0003] Basket carriers have had much use carrying bottles of soda, beer, and other beverages. Prior art basket carriers start from a single blank of material. The four walls and the bottom of the carrier, and the partition assembly start as separate flat blanks later folded and formed into a basket for carrying beverages. Complicated machinery performs the intricate folding and gluing that forms a blank into a carrier. Made from a single blank, the carriers do not nest together. Further, printing must be applied to the prior art blanks before assembly of the carriers, adding a step and cost to the production process.

[0004] Generally, the present invention provides a three piece beverage carrier. The carrier comprises an outer ply, a box, and a partition assembly. The partition assembly secures within the box to divide the box into a plurality of bottle receiving cells. The outer ply receives printing and folds over a portion of the partition assembly. The box has two sidewalls, two endwalls, and a bottom. The bottom takes form from folding inward two side flaps and two end flaps that depend from the sidewalls and endwalls respectively. The end flaps parallel the transverse axis of the present invention and fold towards the center of the bottom. The side flaps fold over the end flaps again towards the center of the bottom but cover the end flaps. A line of glue secures one side flap upon the other side flap. When secured, the joint between the sideflaps is offset from the center of the bottom. Preferably, one side flap has a square edge and the other side flap has a tab substantially along the length of the other side flap. The glued bottom and tab lowers the chance of the carrier bottom sagging under the weight of transported bottles therein. In currently available carriers, a center fold increases the sag. Opposite the sideflaps and the endflaps, the sidewalls and the endwalls have linear upper edges. The upper edges can be shaped for different marketing campaigns.

[0005] Then the partition assembly has at least one transverse, or cross, partition having a length substantially equal to the distance between the carrier box endwalls and at least one cross partition having a length substantially equal to the distance between the carrier box sidewalls. Each of the partitions has glue tabs along side edges of the partitions that adhere to the inner surface of the carrier box to secure the partition assembly within the carrier box. Formed from a one piece blank, the partition assembly includes a first body section, a second body section, and a handle section. The first and second body sections are hingedly connected to each other at the top of the partition in the handle section and form the transverse divider of the partition. The handle section has a hinged connection to the top of the first and second body sections. The first and second body sections each include at least one fold-out section to define the at least one cross partition. Preferably, the first and second body sections each include two fold out sections to form four dividers, or cross partitions, which go on to define six cells for bottles.

[0006] Upon folding the first body portion onto the second body portion, the partition assembly has a handle section. The handle section extends away from the body portions. During assembly, the outer ply is folded lengthwise and placed upon the handle section. The outer ply has two lines of glue to secure the outer ply to the handle section. The outer ply has preprinted indicia placed by the carrier manufacturer or others.

[0007] Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiment of the present invention when taken in conjunction with the accompanying drawings. Before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0008] One object of the present invention is to provide a new and improved beverage carrier from separate pieces.

[0009] Another object is to provide such a carrier that is easy to assemble.

[0010] Another object is to provide such a carrier that is formed from a carrier blank, a partition blank, and an outer ply blank.

[0011] Another object is to provide such a carrier with a carrier blank, a partition blank, and an outer ply blank made from different materials and having different coatings to minimize cost.

[0012] Another object is to provide such a carrier which has a squared and flatter bottom for sharper appearance.

[0013] Another object is to provide an outer ply suitable for inking and laminating an unfinished partition assembly that minimizes decoration of the carrier in hidden portions.

[0014] These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.

[0023] The same reference numerals refer to the same parts throughout the various figures.

[0024] The present art overcomes the prior art limitations by providing separate pieces for printing and assembly. Beginning on FIG. 1, the preferred embodiment of the three piece beverage carrier 1 has an outer ply 2, a partition assembly 3, and a box 4. The outer ply 2 folds upon and joins a handle section 5 of the partition assembly 3. The outer ply 2 has a generally rectangular scored slot 6 that opens through the handle section 5 through which a person grasps the carrier 1. The partition assembly 3 divides the interior space 7 of the box 4 into a plurality of cells 8, six cells 8 for bottles in the present invention 1. The cells 8 receive and protect individual beverage bottles during shipping. The partition assembly 3 extends for the full height of the present invention 1 and lacks openings of sufficient size for bottles in adjacent cells 8 to contact each other. During movement, the present invention 1 prevents the bottles from damaging each other. The box 4 has two mutually parallel and spaced apart sidewalls 9a, b generally parallel to the longitudinal axis of the carrier 1, and two mutually parallel and spaced apart endwalls 10a, b generally perpendicular to the longitudinal axis of the carrier 1. The end walls 10a, b and the sidewalls 9a, b have a generally rectangular shape and beneath, the box 4 has a bottom 11 for the carrier 1.

[0025] Turning to FIG. 2, the outer ply 2 has a generally rectangular shape with a center fold 12. The center fold 12 is parallel to the longitudinal axis of the outer ply 2 and the carrier 1. Each half of the outer ply 2 has a scored flap 13 that partially detaches from the outer ply 2, forms a slot 14, and bends to admit a person's fingers. The slot 14 has a generally rectangular shape with rounded ends 15.

[0026] Then the partition assembly 3 has a generally rectangular shape with a handle section 5 and cross partitions 16 beneath the handle section 5. The cross partitions 16 extend between the sidewalls 9a, b of the box 4. The handle section 5 has a shape similar to the folded outer ply 2, and a scored slot 6 that partially detaches from the outer ply 2 that bends to admit fingers. The slot 6 has a generally rectangular shape slightly larger than that in the outer ply 2. The cross partitions 16 fold out from a longitudinal divider 18 and perpendicular to the partition assembly 3 with at least one partition 16 on each side of the handle section 5. Folding out the partitions 16 creates an opening 19 whereby the two middle cells 8 communicate with each other. Between the outer pairs of cells 8, the partition assembly 3 creates a solid wall 20. Opposite the handle section 5, the cross-partitions 16e, f have a glue tab 21d, e folded perpendicular to the cross-partition 16e, f. And opposite the first cross-partition 16e, each side of the partition assembly 3 has a glue tab 22 folded perpendicular to the handle section 5. The partition assembly 3 glue tabs 22 are diagonally opposed on each side of the partition assembly 3.

[0027] Beneath the partition assembly 3, the box 4 has mutually parallel and spaced apart sidewalls 9a, b and mutually parallel and spaced apart endwalls 10a, b. The end walls 10a, b are perpendicular to the sidewalls 9a, b. Beneath the box 4 formed by the sidewalls 9a, b and end walls 10a, b, the box 4 has a bottom 11. Sideflaps 24a, 24b folded upon endflaps 24c, 24d form the bottom 11 that supports the bottles in the cells 8. The sideflaps 24a, 24b and end flaps 24c, 24d depend from their respective sidewalls 9a, b and endwalls 10a, b. Each flap 24a, b, c has a hinged connection to each respective wall 9a, b, 10a, b.

[0028] Moving to FIG. 3, the present invention 1 starts as three blanks of paperboard in flat form, though other materials may be used. The outer ply 2 has a generally rectangular shape with a center fold 12 parallel to the longitudinal axis of the outer ply 2. Symmetric about the center fold 12, two slots 14 appear in the outer ply 2. A partially attached flap 13 occupies each slot 14. The slot 14 has a generally rectangular shape with rounded ends and each flap 13 has a rectangular shape with one longitudinal edge of the flap 13 connected to the outer ply 2.

[0029] Next the partition assembly 3 has a single blank with the cross partitions 16 and glue tabs 21, 22 punched into paperboard. The punching pattern is a mirror image upon a center fold 25 between the upper and the lower halves of the partition assembly 3.

[0030] In flat form, the box 4 starts as a single blank and forms a long rectangular shape. The blank divides into four sections 26a, b, c, d that correspond to the left and right sides 9a, b and the front and back ends 10a, b, respectively of the present invention 1. The four sections 26a, b, c, d join together as hinges upon fold lines 27a, b, c. The rectangular shape has breaks from punching for alternating sidewalls 9a, b and end walls 10a, b with appended side flaps 24a, b and end flaps 24c, d. The side flaps 24a, b and the end flaps 24c, d form the bottom 11 of the box 4 upon folding. The side flaps 24a, b and the end flaps 24c, d join the sidewalls 9a, b and end walls 10a, b as hinges upon fold lines 28a, b, c, d. Upon the left sidewall 9a, a glue tab 22a extends outward from a hinged connection upon a fold line 27d. The side flaps 24a, b have a generally square end 29 opposite the hinged connection with the sidewall 9a, b. The end flaps 24c, d though have a tapered end 30 opposite the hinged connection with their respective endwalls 10a, b. Preferably, a series of elongated scores as the fold line 27a, b, c, d, 28a, b, c, d ease folding of the blank into the box 4.

[0031] Over in FIG. 4, the outer ply 2 has a flat rectangular form with a center fold 12 upon the center longitudinal axis. Centered and flanking the fold line 12, two flaps 13 fold beneath the outer ply 2 and towards the center axis of the outer ply 2. The flaps 13 partially attach upon one side of each slot 6 with both flaps 13 attaching towards the center of the outer ply 2. The slots 6 have a generally rectangular shape with rounded ends 15. Lettering and other indicia can be printed upon the outer ply 2 before folding and placement upon the partition assembly 3.

[0032] In blank flat form shown in FIG. 5, the partition assembly 3 begins as a single piece of paperboard from which the longitudinal divider 18 and the cross partitions 16 take form. The blank divides into four sections 23a, b, c, d separated by the center fold 25 and slices 16c, d: the first body 23a, the first handle section 23b, the second handle section 23c, and the second body 23d. The first body 23a joins by the first handle section 23b to the second handle section 23c then to the second body 23d. The second body 23d is the mirror image of the first body 23a.

[0033] The first body 23a and the second body 23d have substantial similarities and form the longitudinal divider 18 and the cross partitions 16 that divide the box 4 into cells 8. The first body 23a and the second body 23d each have a portion that forms the longitudinal divider 18. Glue tabs 22 locate upon the sides of the body sections 23a, c and an adhesive strip 22a occupies each tab 22. A middle portion 26e in the center of the first body 23a and the second body 23d is defined by a slice 16d. The middle sections 26e fold about a fold line 16b and upon folding, become the second cross-partitions 16f. The middle sections 26e each have a tab 21c with an adhesive strip 21e. Slices 16c define the form of the first cross-partitions 16e that fold out from a fold line 16a. These slices 16c are parallel with the longitudinal divider 18 and perpendicular to the fold line 16a that defines the first cross partition 16e.

[0034] The first body 23a has a generally rectangular shape with a glue tab 22a upon one end. The glue tab 22 width is the same as the height of the box 4. Upon a pre-scored line 21a, the glue tab 22 folds beneath the first body 23a and opposite to the cross partitions 16e, f. Then glue tabs 21b, c form at the ends of the partitions 16e, f dividers opposite the divider's 18 glue tabs 22. The glue tabs 21b, c have an adhesive strip 21d, e that can be a continuation of the adhesive strip 21d, e applied upon an opposite glue tab 21b, c. Opposite from the glue tab 22, the first body 23a has the first partition 16e. The first partition 16e has a generally rectangular shape attached on one side 16a adjacent to the first body 23a. The first partition 16e has one side 16c cut from the first body 23a perpendicular to the fold line 16a and adjacent to the first handle section 23b. The first partition 16e separates from the first body 23a and folds until perpendicular to the first body 23a where the first partition glue tab 21b folds parallel to the second partition glue tab 21c. Opposite the glue tab 21b, the second partition 16f has a polygonal shape with one side 16b partially attached to the first body 23a and the remaining sides scored to detach from the first body 23a at a slice 16d. Opposite the attachment side 16b and the glue tab 22a of the first body 23a, the second partition 16f has a glue tab 21c. Upon a pre-scored slice 16d, the second partition 16f separates from the first body 23a and folds until perpendicular to the first body 23a where the second partition glue tab 21c folds parallel to the sidewall 9a, b. The second body 23d has partitions 16e, f and glue tabs 21b, c in a mirror image to the first body 23a and the first body 23a descriptions of cross partitions 16e, f apply to the second body 23d in mirror image.

[0035] The first and second handle sections 23b, c span between the first body 23a and the second body 23d. Each handle section 23b, c has a generally rectangular shape akin to the outer ply 2. A center fold 25 parallel to the length of the carrier 1 hingedly connects the first handle section 23b to the second handle section 23c. A centered slot 17 has rounded ends within each handle section 23b, c. After the first body 23a folds upon the second body 23d, the slots 17 accept the flaps 13 from the outer ply 2.

[0036] FIG. 6 shows the box 4 in flat blank form prior to folding. The blank divides into four sections that correspond to the front 10a, back 10b, and the sides 9a, 9b of the present invention 1. The four sections connect as hinges at fold lines 27a, b, c. A glue tab 22 extends across the finished height of the box 4 upon one sidewall. Behind the glue tab 22, sidewalls 9a, b and endwalls 10a, b alternate position at hinged connections, starting with a sidewall 9a. The sidewalls 9a, b and endwalls 10a, b have generally rectangular shapes with the length of the sidewalls 9a, b exceeding that of the endwalls 10a, b. Depending from the sidewalls 9a, b and the endwalls 10a, b, side flaps 24a, b and end flaps 24c, d respectively fold upon a fold line 28a, b, c parallel to the longitudinal axis of the box 4. Preferably, a series of elongated scores as the fold lines 28a, b, c ease folding of the blank into the box 4. The side flaps 24a, b have a tapered trapezoidal shape with the wider base nearer the box 4. The end flaps 24c, d have a rectangular shape with the corners beveled opposite the box 4. The sideflap 24b further from the glue tab 22 has a glue strip 29a parallel to the longitudinal axis of the box 4 and opposite from fold line 28c.

[0037] Prior to folding the carrier 1 into a familiar box like shape, machinery applies a series of parallel lines of glue 22a, 21f, g, and 18a upon the box 4. The glue tabs 21b, c adhere to the sidewalls 9a, b forming the cross-partitions 16e, f by the glue lines 21f, g. The glue lines 21f, g extend from close to the top of sections 26a, b, c, and d and extend nearly to the bottom 11 of the carrier 1. The glue lines 21f, g, 18a serve to glue the partition assembly 3 into the box 4 as will be described below.

[0038] With the box 4 remaining flat, FIG. 7 shows the initial assembly of the three piece beverage carrier 1. Rotating the box 4 from FIG. 6, the partition assembly 3 folds upon the box 4. The first body 23a folds over the second body 23d with the resulting handle sections 23b, c positioned away from the box 4. The partition assembly 3 centers upon the sidewall 9b further from the glue tab 22a. The partition assembly 3 glues into place with glue tabs 21b, c upon the inner, or unprinted, surface of the box 4. The cross partitions 16e, f remain flat in this figure. The glue tab 22 of the partition 3 adheres to the endwall 10a nearer to the glue tab 22a of the box 4 and the glue tabs 21b, c depending from the cross partitions 16e, f adhere to the sidewall 9b further from the glue tab 22a. These glue tabs 22, 21b, c adhere one edge of the longitudinal divider 18 to one end of the box 4 and the cross partitions 16e, f to a side of the box 4. With the handle sections 23b, c in position upon the box 4, the outer ply 2 is folded along its fold line 12 and moved towards the handle sections 23b, c. Next in FIG. 8, the outer ply 2 folds upon the handle 5 with the flaps 13 of the outer ply 2 extending into the slots 17 of the handle 5.

[0039] Then in FIG. 9, the box 4 is folded along the fold line 27b as the partition assembly 3 is brought over and upon the endwall 10b and sidewall 9a closer to the glue tab 22a. The endwall 10a formerly further from the glue tab 22a receives the glue tab 22a and joins the sidewall 9a to the second endwall 10a. This adheres the longitudinal divider 18 to the endwall 10a and the cross partitions 16e, f to the other sidewall 9a of the box 4. Folding the glue tab 22a on fold line 27d and the fold lines 27a, b, c between the sidewalls 9a, b and the endwalls 10a, b rotates the box 4 into a rectangular configuration. Upon gluing of the tabs 22, 22a, 21b, c to the endwalls 10a, b and sidewalls 9a, b respectively, the carrier 1 achieves an assembled, but flattened state. The beverage carrier 1 stores and ships flat prior to forming the bottom 11 of the beverage carrier 1 at the bottler.

[0040] FIG. 10 has the box 4 in a rectangular configuration wherein the cross partitions 16e, f unfold. The cross partitions 16e, f are perpendicular to the sidewalls 10a, b while the glue tab 21b, c of each cross partition 16e, f adheres parallel to a sidewall 10a, b. At each end of the partition assembly 3, a glue tab 22 adheres the first body 23a and the second body 23d, and to the endwalls 10a, b of the box 4. To form the carrier 1, the box 4 expands from the flattened state shown in FIG. 9. The unfolded cross partitions 16e, f form cells 8 suitable for bottles. With the partition assembly 3 joined to the box 4, the bottom 11 of the carrier 1 forms by folding the end flaps 24c, d towards the center of the carrier 1 and upon the partition assembly 3. Then the sideflaps 24a, b fold upon the end flaps 24c, d with the sideflap 24a folding first and the other sideflap 24b securing to the glue strip 29a. The glue strip 29a holds the bottom 11 together. With the bottom 11 formed a bottler inserts bottles into the carrier 1 and ships the loaded carrier 1 to market.

[0041] From the aforementioned description, a three piece beverage carrier has been described. The three piece beverage carrier is uniquely capable of receiving printing in separate pieces before assembly of the carrier. The three piece beverage carrier and its various components may be manufactured from many materials including but not limited to paperboard, cardboard, chip board, polymers, high density polyethylene HDPE, polypropylene PP, polyethylene terephalate ethylene PETE, polyvinyl chloride PVC, polystyrene PS, nylon, ferrous and non-ferrous metal foils, their alloys, and composites.

[0042] The phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Therefore, the claims include such equivalent constructions insofar as they do not depart from the spirit and the scope of the present invention.