US2367717A - Carton - Google Patents

Description

B. J. DAVIDSON Jan. 23, 1945.

CARTON Filed March 14, 1942 3 Sheets-Sheet 1 INVENTOR BRUCE J; DAV/050A! BY Aorm Jan. 23, 1945- B; J. DAVIDSON CARTON Filed March 14, 1942 3 Sheets-Sheet 2 INVENTOR B. J. DAVIDSON Jan. 23, 1945 CARTON 3 Sheets-Sheet 3 INVEN QR BRUCE Ll. DAV/0S0 Filed March 14, 1942 Patented Jan. 23, 1945 Bruce J. Davidson, Manhasset, N. Y., 'asslgnor to National Biscuit Company, New York, N. Y., a

corporation of New Jersey Application March 14, 1942, Serial No. 434,719

6 Claims.

My invention pertains to cartons and has for its principal object to reduce to a minimum the amount of material needed to make a carton of given size, and not decrease its strength or case of fabrication, and yet produce a carton that-can be made on existing machines with only slight or no adjustments or alterations and by well known methods.

Another object is to produce cartons, from heavy material such as corrugated board and the like, suitable for use as shipping containers, and from light material such as chipboard, suitable for small packages, that will use a minimum of material, yet retain all the advantages of. the common forms of cartons that use more material.

Another object is to produce an easy opening and re-closable carton using a minimum of material.

Another object is to form and proportion the closing flaps on carton blanks so that they will interlock with flaps of adjacent blanks and eliminate substantially all waste and can be cut from a continuous sheet or roll or material.

The above and other objects and advantages are attained by my invention, attention being directed to the accompanying drawings wherein I have illustrated how it may be adapted to containers of different kinds.

Fig. 1 is a plan view of a sheet of material, as

corrugated or heavy board, from which blanks for two cartons or containers may be out without waste and with a minimum 01' material.

Fig. 2 shows an empty carton, open at both ends, formed from one of the blanks of Fig. 1.

Fig. 3 shows the carton filled and closed.

Fig. 4 is similar to Fig. 1 showing a carton in which the top closing flaps are stepped and wide enough to provide a center overlap when the carton is closed.

Fig. 5 shows an empty carton formed from a blank of Fig. 4.

Fig. 6 shows the carton filled and sealed.

that may be cut from a continuous roll or sheet of material.

Fig. 13 shows an empty carton, open at both ends, formed from a blank of Fig. 12.

Fig. 14 shows the carton of Fig. 13 filled and sealed.

Fig. 15 shows the carton of Fig. 14 after it has been opened and reclosed.

Figs. 16 and 17 show a carton made ironi s. single piece blank having another form of top closing flaps made according to my invention.

In Fig. 1, I have shown a rectangular sheet of cardboard, corrugated board or other similar material, which is scored and cut to form two identical carton blanks. In making cartons from material of this kind, the sheets are made of such size as to enable 2, 3, 4, or more blanks to be cut therefrom without excessive waste, that is,

so that the four edges of the sheet rorm edges of the carton blanks.

Heretoi'ore, carton blanks cut from these sheets have had all the closing flapsrectangular, with the outer closing flaps, both top and bottom, of

a width equal to one-half the width of the carton when the edges of the flaps are to abut or meet at the center, and this width plus one-half the over-lap when the flaps are to be overlapped in the closed carton. In such cases, the inner end closing flaps are made the same width as the outer closing flaps because the size of the sheet would not he reduced by cutting them of! shorter. Such a carton blank is shown, by way of comparison in Fig. 11.

In Fig. 1, each carton blank has two side panels 20, 2|, and two end panels 22, 23, which are Joined by score lines 24, 25, 26, along which the material Fig. 7 shows how the carton blanks may interlock and be cut from a continuous sheet or roll without substantial waste.

Fig.8 shows an empty carton formed from a blank of Fig. 7.

Fig. 9 shows a carton of Fig. 8 filled and sealed. Fig. 10 shows the carton re'closed after having been opened. 5

'Fig. 11 shows by way of compariso'n how carton blanks were out prior to the present invention.

Fig. 12 shows another'blank for forming a reclosable carton, embodying the present invention.

is folded to form the carton. The meeting edges 21, 28 are secured as by a tape 29, Fig. 2.

A longitudinal score line 30, defines one edge of the side and end closing flaps 3|, 32, 33, 34, which are rectangular and or a width equal to one-half the width oi. the end panels 22, 23. This is the construction usually used prior tothe present invention. These rectangular-flaps could be cut: the same shape as those on'the opposite side of the panels but to do so would not save any usable material, because the material cut off would be useful only as scrap and the total size or area or the sheet would not be reduced. This is true only when the closing flaps come to the.

naps of two blanks can abut or interlock within I I the area or the sheet, then a saving in material is effected. 4

A longitudinal score line 35, along the opposite edges of the side and end panels defines one edge of the closing flaps 36, 31, 38, 39, which are trapezoids, the widest dimension X of which is a function of the .length and width of the carton and the minimum allowable width of the inner closing flaps.

The flaps 31, 39 are the inner or end closing flaps because they are turned in first and then the outer or side flaps 36, 38 are turned down and secured over them. The narrowest or minimum allowable width Q of these inner flaps is one of the i actors or variables which governs the greatest width X of the outer flaps 36, 38.

When the flaps 36, 38 are to meet or abut at the center, as shown in Fig. 3, then their width at the center equals where W equals the width of the end panels. If L equals the length of the carton, or side panels, then the maximum width X of the top closing becomes a function of W, L and Q, and may be expressed by the equation X=F (WL-Q) Usually W, L and Q will be known for any specified container. Thus, a corrugated container for holding 6 No. 10 cans of biscuit, fruit, paint or other merchandise, would be 12 /2 in. wide,

18%; in. long and 'l in high, i. e., W=12 and 'L=l8 The width of the inner flap at its narrow end is governed by the nature of the material. With corrugated board, or other board suitable for shipping containers, this dimension Q is 1% in.

Knowing these factors, L, W and Q, it becomes a simple mathematical problem to determine the maximum width X of the outer flaps and hence the minimum amount of material to be used per carton.

Referring now to Fig. 1, the line a, b, is drawn parallel to the bases of the flaps 36, 31. This divides the two flaps into two similar triangles abc and ade and a rectangle abfg.

In the triangles Since the triangles are similar From which The value of X may also be determined graphically. Knowing the values of W, L and Q, the perpendicular lines do and of may be laid 01! equal to Q and L-i-W, respectively, and the point e determined by erecting the pe pendicular de, equal to at a distance equal to from point i. Then, a line drawn through a and e will intersect the perpendicular fc at a point such that is will equal X. This graphic method usually will be used in laying out the cartons and locating the positions of the cutters. However, the mathematical determination is useful in calculating the saving in material. Thus, in the layout shown in Fig. 1, the saving in material for each container is the difierence between the areas of the flaps 3|, 32, 33, 34 and the flaps 36, 31, 38, 39. If the material be such that the cartons can be cut from a continuous sheet, then.

the saving is doubled.

Considering again the carton for 6 No. 10 cans, the area of the flaps 3|, 32, 33, 34 is Now in the case of flaps 36, 31, 38, 39, their area=(X+Q) (L-l-W) =(8.25+1.5) 31=302.87.

Thus, the saving per carton, when only one end is provided with the diagonal closing flaps is 387.5-302.87=84.63 sq. in. or 21.8% of the usual flap area. If the cartons can be cut from a continuous sheet so that both ends may have my improved flaps, then double the area is saved.

When the carton flaps have anoverlap, instead of abutting as shown in Figs. 1 and 3, then the width of the outer flaps 36, 38 is increased by an average of one-half of the overlap, but the minimum width Q of the inner flaps is not changed. Thus, if the overlap is 1 inches, then the average increased width of the outer flaps will be /4 inch. The total saving in square inches of material will be approximately the same as with abutting flaps.

In Figs. 4 to 6, I have shown my present invention embodied in the same size carton as in Figs. 1 to 3, but with the top closing flaps wide enough so that they overlap at their free edges, yet without increasing the width Q of the inner end closing flaps beyond the allowable minimum.

In Fig. 4, the sheet of material as corrugated board, sufiicient to form two blanks, is cut and scored to form the side panels 40, 4| and end panels 42, 43 with the usual rectangular closing flaps 44, 45, 46, 41 on one side and polygonal closing flaps 48, 49, 50, 5! on the other side. The minimum width Q of the inner closing flaps 49, 5| is retained at 1 /2 inches, the same as in Fig. 1 for a carton of the same dimensions, but the maximum width X of the outer closing flaps 43, 50 is increased enough to give an overlap of 1 inches, but this dimension X in Fig. 4, is somewhat less than dimension X in Fig. 1 plus onehalf of the overlap. Thus, the lay-out of Fig. 4 saves more material, with or without an overlap, than does the lay-out of Fig. 1, with the same or no overlap.

The width of the flaps 44, 45, 4B, 41 is equal to one-half the width of the carton plus one-half the overlap.

In Figs. 4 and 6, L, W and Q equal the length and width of the carton and minimum allowable width of inner flaps, the same as in Fig. 1. X equals the maximum width and Y the minimum width of the outer closing flaps, and P equals the overlap of the top flaps. In all cases, L, W, Q and P will be known and usually Q and P will be equal or 1 inches in the example chosen. As seen in Fig. 6, X+Y=W+P. From Fig. 4, X+Q=2Y, or

X+Q Y 2 From this,

X X+ Q W P, clearing of fractions From this it is seen that X is a function of W and Q, or W and P.

X+ Y: W+ P= W+ Q, substituting the value of X,

Consider now a carton of the dimensions previ- *ously considered, that is 12 /2 x 18 /2 inches, with a minimum flap width of 1 /2 inches and an overlap of 1 /2 inches, then the area of flaps 48, 49, 60, 56 is (l2.5+l8.5) =10.333X 31=320.3 3

square inches. The area of the rectangular flaps is The saving per carton, when the flaps on one only are made according to this form of my invention is 434-320.3=113..7 sq. in. This is a saving of 26.2% of the material that heretofore has gone into the closing flaps.

The small triangular pieces 52, Fig. 4, may be of therectangular part of width Y is L-W, and

1 I prefer to make the length of the rectangular when the blank is folded to form a carton,

the meeting edges of the panels 40, 43 may be secured by a tape, or metal clip 54 or other suitable means. When the cartons are made from suitable material, the free edge of either of the panels 48, or 43, may have a glue strip formed integral therewith which will be glued or stapled to the free edge of the adjoining panel when the carton is formed.

In Figs. '7 to '10, I have illustrated a reclosable carton made according to the present invention that maye be out from a continuous sheet or'roll of chip board, or other suitable material, and effect a saving in material similar to the two forms previously described.

- In Fig. '7 I show part of a continuous sheet or roll of material from which the carton blanks are being cut out. Two full carton blanks and parts of two adjoining blanks are shown. Each blank has twoside panels 55, 56 and two end panels 51, 58 joined together along the usual score lines. A glue strip 59 is formed on one blank attached to the free edge of end panel 58. On the adjacent blank, this strip is attached to side panel 55. This is done so that all glue strips are cut from the same edge of the material and the only waste is the narrow strips 60 between adjacent glue strips 59. When the blanks are cut from a continuous sheet or roll, as here shown, both top and bottom closing flaps can be cut so as to eifect double the saving in material over Figs. 1 and 4.

The side panels 55, 56, have top closing flaps 6|, 62 and bottom closing flaps 63, 64, respectively, joined to them along the usual score or fold lines. These closing flaps are of Stepped formation similar to those of Fig. 4, except that the corners of the Wide part of the flaps, correspondcut out and discarded, in which case the inner ing to triangles 52, are out off only on the flap, as 62 or 64, that is last to be folded down when the carton is closed at top or bottom. Each end panel 51, 58, has top. and bottom inner flaps- 65, 65, 61 and 68, all of which are of the same size and shape.

The flaps 62, 64, are closed last at the top and bottom respectively, of the carton. These flaps are wide enough to overlap the flaps 6|, 63 and be glued to them, as shown in Fig. 9. In order to avoid having a square corner on the flap in the middle of the top and bottom, which would be adapt to catchon similar corners of stacked cartons, I cut off the comers of these flaps, as shown at 68. This leaves the triangles 10 that could be left attached to the inner flaps 65, 61, but I prefer to cut them off as scrap and leave all the inner flaps identical. The top closing flap 6| has a short slit 1| which receives and forms a lock with the diagonal edge 69 of the opposite flap 62, when the carton is reclosed, as shown in Fig. 10.

In forming a carton from a blank of Fig. 7, the blank is folded along the score lines so that the free edges of panels 55 and 58 are brought together and secured by the strip 59, which will be glued or otherwise fastened to the face, inner or outer, of the adjacent panel. In Fig. 8, I show a carton partly, formed with the strip 59 integral with panel 58 and glued to the inner face of panel 55. The next operation is to turn in the two inner bottom flaps 61, 68. The flap 63 is next turned down and glued to flaps 81, 68. Flap 64,

which may have a clipped corner 69, is then turned down and glued to flaps 83, 61 and 68. Flap 64 overlaps flap 63 an amount sufiicient to make a secure joint.

After the carton is filled, the flaps 65, 66 and 6|, 62, are turned down and sealed in the same manner. The flap 82 overlaps the flap 6|, as shown in Fig. 9 which illustrates the carton filled and sealed ready for shipment.

The carton of Fig. 9 may be opened and reclosed as shown in Fig. 10. To open the carton, the point of a kitchen knife or other flat instrument may be inserted at the diagonal edge 88 between the fiaps 6|, 62 and pushed along, each way, to break the seal between them. The seal between the top flaps and the inner flaps 65, 66 may be similarly broken. This releases all flaps without destroying any of them, and the carton can be opened to give access to its contents by turning the flaps up to vertical position.

To reclose the carton, the overlap or lip 12 of flap 62 is tucked under flap 6| so that the inclined edge 69 enters into the slit H as shown in Fig. 10. This holds the carton closed until the consumer again wishes to use some of its contents. When reclosed, the edge of the wide part of each flap lies under the narrow part of the opposite flap.

In Fig. 12, I show another blank for a reclosable carton embodying my invention that may be cut from a continuous sheet of material, the flaps of adjacent blanks interlocking and one corner of the outer or free edge of each flap being cut away so that they will not overlap at the edges and the filled carton will stand firmly on a sealed end.

I show one complete blank and part of an adjoining one with their flaps interlocking. Each blank has formed thereon two end panels 12, 13, which alternate with two side panels H, I5, separated by score lines 16, I1, 18, on which the material is folded to form the carton. A glue strip 18 is attached to the free edge of one of the end or side panels along a score line 80, and is adapted to secure the meeting edges of the panels 12 and 15. v

At the top of the respective panels are end or inner sealing flaps 8|, 82 and side or outer sealing flaps 83. 84, the flap 83 having a slit 85 similar to the slit H in Figs. 7 to 10. The corner 86 of the wide end of flap. may be cut away found desirable. However, one reclosable end usually is'sufiicient.

The flaps 33, 84 add 89, 9|), like the flaps in Figs. 4 and 7 are wider at one end than the other and are wide enough to overlap at their inner edges. As shown in Fig. 6 where these flaps overlap at 9|, 9| at the ends of the carton, and in Fig. 9 at 82, 92' there are three thicknesses of. material which form somewhat of a ridge at this point. This is not objectionable when the on end. In order to make this sealed end flat and avoid this triple thickness, I cut out the free corners of the narrow ends of the outer flaps at 93, 94 and 95, 96, so that when the carton is sealed, as in Fig. 14, the edges of these out out portions will abut the edge of the wide parts of the opposed closing flaps and not overlap it. Thus, over the greater part of the width of the flaps 8|, 82 and 81, 88 and close to the end panels where the sealed top is rigid, it is smooth, and the carton when stood on end has a firm bearing throughout this area. This feature or advantage is equally applicable to the cartons of Figs. 4 to 6 and 7 to 10, and to the cartons of Figs. 1 to 3, if it has overlapping flaps. The carton of Fig. 15 may be opened and reclosed in the same way as in Fig. 10.

When carton blanks are to be made, as in Fig. 4. but without overlap of the flaps 48, 50, then When cartons are to be made as in Figs. 1 to 3, but with the flaps 33, 38 overlapping, then the point C or dimension X will be determined by increasing the dimension by one-half of the overlap, that is the point e will be raised by The dimension Q and the point a will remain the same. A line drawn from a through the new position of e will determine the length of X at the point where it intersects the line 10.

In Fig. 11, I have shown a sheet just large enough to out two cartons according to the best practice prior to my invention, the cartons being identical in siz with those shown in Fig. 1. In Fig. 11, I have marked the several parts with the same relative reference numbers for easy comparison with Fig. 1 and their description need not be repeated. In this figure, W and L are identical with the same dimensions in Fig. 1. and the flaps 3| to 34' on the two edges of the sheets are the same as flaps 3| to 34, the width of each being cartons are relatively wide and not very tall. But when the cartons are relatively tall and narrow as in Figs. 12 to 15, this ridge would make them unstable and prevent their being stacked This is according to the most economical and best practice prior to my present invention; The length of the total sheet in Fig. 11' is identical with the length of the sheet in Figs. 1 and 4, but the width is greater. This shows graphically the saving ,in material accomplished by my invention, even though the flaps on only one end of the carton be made according thereto. On Fig. 11, the material below the dotted line A-B is in excess of the material required to make cartons of identical dimensions in Fig. 1. If the cartons can be out continuously from along sheet or roll, as in Figs. 7 and 12. the saving is double this amount, and when the closing flaps are of the shape shown in Figs. 7, 12 and 16, the saving is'even greater.

In Figs. 16 and 17, I show a carton made from a blank similar to Fig. 4, except that the outer closing flaps overlap for only a ,part of their length. The blank is folded to bringits two edges together when they are secured as by a tape 91. The lower end of the carton may beclosed by the usual rectangular closing flaps, of which only two 98, 99 are visible, but these flaps may be cut the same as those at the top, if desired, or if the size of the sheet from which the blanks are cut is large enough to let the flaps on adjacent blanks interlock, as in Figs. 7 and 12. q

At the top, the inner fiaps i011, ,IOI are cut rectangular, and the widths of the outer closing flaps I02, 13 is such that they abut, or substantially abut, at their two ends, but have an overlap I04 between ends or at or near the center of the top. The flaps I02, I03 may be secured to the inner flaps 590, l ill by stapling, gluing or other suitable means. The overlapping parts I04 may be secured together similarly. This form of the invention provides a carton having a top that is smooth at the ends so the cartons can be stacked and can be used in all cases where the carton does not have to be sealed tightly. By securing the flaps together at H04, it is not necessary to use tape to close the joint and hold the flaps I02, I03 together at the center.

Many other variations, adaptations and modifications of my invention can be made, but the foregoing illustrations seem to be sufiicient to indicate its scope and not to limit it.

While I have shown the cut-out corners 93, 94

only in Figs. 12 to 15, this same principle or element is equally adapted to flaps as shown in the other figures when an overlap is not desired at the edges of the carton. I have shown cartons that are adapted to be closed by taping, gluing, or

- stapling, but it is within the contemplation of my invention that the outer closing flaps may be provided with interlocking tongues and slits. Also any of the cartons illustrated may be secured together by tapes 29, 56, as shown in Figs. 2, 5 and 16, or by stapling or glue strips 59, 19, as shown in Figs. 8 and. 13.

In all of the embodiments of my invention illustrated the saving in material is substantially the same as in Figs. 1 and 4, and may be determined by similar formulae and computations. The cartons of Figs. 7 to 15 are adapted to be made from thin chipboard and used for packaging light materials, as cereals, crackers, and the like. When so made and used, the width Q of the inner flaps may be from %-to 1 inch. In all forms of the invention, the closing flaps on adjacently formed blanks interlock or interfit without waste of material, although the small triangles52, l0 and the like, may be. out 01f as scrap.

In describing my invention, the terms side and side panel are used to designate the area having the longer horizontal dimension of the carton, whilethe terms end and end panel designate the area having the shorter horizontal dimension. Therefore the length of the carton refers to its longer horizontal dimension and the width of the carton is its shorter-horizontal dimension, except in those cases where the two are equal.

panels and two side panels formed alternately thereon adapted to form the four sides of the-carton, closing flaps attached to the top edges of said panels, the flaps attached to the side panels being wider than the flaps attached to the end panels and adapted to overlie the latter when the carton is formed and closed, said side closing flaps being wider at one end than the other, the free edges of the wider and narrower parts being parallel to the opposite edge that is attached to the side panel, said flaps on adjacently formed blanksinterfitting without waste of material with the narrow part of a side closing flap abutting the narrow part of a side closing flap on an adjacent blank and the wide part of a side closing flap abutting an end panel flap on the adjacent blank.

2. A carton having two opposite end panels and two opposite side panels, and flaps attached to the top edges of the end panels and outer closing flaps attached to top edges of the side panels, the end flaps being narrower than the outer closing flaps and lying within the latter when the carton is closed, the said outer closing flaps being of different widths at their two .ends and overlapping at their free edges when the carton is closed with the wideend of each flap opposite the narrow end of the other, one of said closing flaps having a slit extending from its part of less width into its part of greater width into which the edge of the widest part of the opposite flap may be inserted when the carton is reclosed In Fig. 1,'the triangular or sloping part of the end flaps 311, 39 may be cut ofi so that these flaps will be rectangular and of uniform width Q, the

same as the triangular pieces 52, Fig. 4. In referring to the width Q of the inner flaps, this minimum width is intended.

What I claim is:

1. A blank for forming a carton having two end after having been opened.

3. A carton having two opposite end panels and two opposite side panels, end flaps attached to the top edges of the end panels and outer closing flaps attached to top edges of the side panels, the end flaps being narrower than the outer closing flaps and lying within the latter when the carton is closed, the said outer closing flaps being of difierent widths at their two ends and overlapping at their free edges when the carton is closed with the wide end of each flap opposite the narrow end of the other, a notch substantially equal to the overlap being cut in the outer edge of the narrow end of each outer flap where it overlies the end flap, whereby the outer flaps will abut at the edges of the carton.

4. A carton having two opposite end panels and two opposite side panels, end flaps attached to the top edges of the end panels and outer closing flaps attached to top edges of the side panels,

the end flaps being narrower than the outer closing flaps and lying within the latter when they carton is closed, the said outer closing flaps being of different widths at their two ends and overlapping at their free edges when the carton is closed with the wide end of each flap opposite the narrow end of the other, the overlap being cut away at the ends of the outer flaps, whereby these flaps will abut the edges of the carton.

5. A carton formed from a blank having two side panels and two end panels formed alternately thereon, a glue strip formed integral with the free edge of one side panel and secured to the free edge of an adjacent end panel, end flaps attached to the top edges of the end panels and outer closing flaps attached to the top edges of the side panels, the end flaps being narrower than the outer closing flaps and lying under the latter in the closed carton, the said outer closin flaps being ofdifierent widths at their two ends and overlapping at their free edges with the wide end of each flap opposite the narrow end of the other, the overlap being cut away. at the ends of the outer flap by a notch formed in the edge 'of the narrow end of each flap of a width equal to said glue strip and the part so cut out to form the notch forming an integral part of the wide end of anouter flap on an adjacently formed blank.

6. A carton that is out and scored to form alternately two side and two end panels, the side panels being longer than the end panels, closing flaps attached to the top edges of said side CERTIFICATE OF CORRECTION.

Patent No. 2,567,717.

January 5, 9 5- BRUCE J. DAVIDSON.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 5, second column, line 60, claiml after "abut" insert the word --at--; page 6, first column, line 6 claim 6, after "carton" insert --blank---; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 5th'da of June, A. D. 19L 5.

Leslie Frazer dieting Commissioner of Patents.

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