United States Patent 1)
`Bannister
`
`[11] Patent Number:
`[45] Date of Patent:
`
`4,911,355
`Mar. 27, 1990
`
`[54] FOLDABLE CARTON
`James Bannister, R.R. 2, Oliver,
`British Columbia, VOH 1T0, Canada
`
`Inventor:
`
`[76]
`
`[21] Appl. No.: 367,592
`[22] Filed:
`Jun. 19, 1989
`[S21] Unt, Chet oe ceccsesesessseesceseeessseenenenenese B6SD 5/22
`[52] US. C1, oes eeecesesseneceeeeesssneteneees 229/143; 229/150;
`229/178; 229/919; 229/DIG.11
`[58] Field of Search............... 229/143, 149, 150, 151,
`229/178, 915, 919, DIG. 11, 172, 173
`
`[56]
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`3,157,346 11/1964 Hamilton ......csccrcscssosesenssess 229/915
`3,756,499 9/1973 Giebeletal. ....
`« 229/173
`
`3,820,706 6/1974 Gibsonetal....
`. 229/172
`
`3,973,723
`8/1976 Owens........
`. 229/178
`
`4,101,048
`7/1978 Riebonetal. ..
`. 229/919
`
`4,151,948
`5/1979 de la Fuente, Jr.
`» 229/178
`4,770,339
`9/1988 Weiner ......sssssccsssersesrseesreee 229/178
`
`Primary Examiner—Gary Elkins
`Attorney, Agent, or Firm—Fetherstonhaugh & Co.
`[57]
`ABSTRACT
`A foldable carton particularly useful for packaging
`produce. The carton includesa central panel and a pair
`
`of opposedexterior end panels and a pair of interior end
`panels affixed to the exterior end panels. A pair of sup-
`plementary interior end panels are affixed to each of the
`interior end panels and a supplementary interior end
`panelflap is affixed to each supplementary interior end
`panels.. The carton has a pair of opposed side panels
`affixed to the central panel formed with a plurality of
`spaced apart side panel ventilation holes. A pair of side
`panelflaps are affixed to each end the side panels and a
`pair of opposed cover panels with ventilation holes are
`also affixed to the side panels. Forming the foldable
`carton involves folding the supplementary interior end
`panel flaps to overlie the supplementary interior end
`panels, folding the supplementary interior end panels to
`overlie the interior end panels and foldingthe side panel
`flaps to overlie each other. The interior end panels are
`then folded over the exterior end panel to enclose the
`supplementary interior end panel flaps, the supplemen-
`tary interior end panelsand theside panel flaps between
`the interior and exterior end panels to form a carton end
`wall construction that includes five overlapping layers
`sandwiched between the interior and exterior end pan-
`els.
`
`10 Claims, 5 Drawing Sheets
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`US. Patent—Mar. 27, 1990 Sheet 1 of 5 4,911,355
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`US. Patent—Mar. 27, 1990 Sheet 20f5
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`US. Patent—Mar. 27, 1990 Sheet 3 of 5
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`US. Patent—Mar. 27, 1990 Sheet 4 of 5 4,911,355
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`US. Patent—Mar. 27, 1990 Sheet 5 of 5 4,911,355
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`1
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`FOLDABLE CARTON
`
`FIELD OF THE INVENTION
`
`The present invention relates to a foldable carton for
`use typically in the package and storage offruit.
`BACKGROUND OF THE INVENTION
`
`Fooditemssuch as fruit, particularly soft fruits, enjoy
`only a limited life after being picked. For example, such
`fruits as peaches and plums may havea shelflife of only
`up to two weeks after being picked depending upon the
`temperature and other storage conditions. In order to
`maximize thelife of such fruit during storage,it is essen-
`tial to provide for air circulation through thefruitin its
`stored condition in order to maintain a cooling air flow
`over the fruit’s surface and thereby help to inhibit the
`formation and heat build-up associated with bacteria.
`Over the years various types of cartons have been
`used to store fruit in the fruit industry. Such cartons
`have exhibited problems ofinadequate ventilation of the
`produce contained in these boxes together with inade-
`quate strength and limited stackability due to not only
`limited strength but also the tendency of the cartons to
`slip one over the other. Also,it is desirable to dimension
`the cartons so that when they are positioned on a pallet
`they are compatible with the dimensions of the pallet.
`Some boxes in the fruit industry are dimensioned so that
`when they are stacked side by side and end to end they
`do not fit within the overall dimensions of a standard
`sized pallet so that stacking ontothepalletis relatively
`inefficient.
`As‘a result of the foregoing problemsthefruit indus-
`try began fabricating cardboard boxes using glue in
`order to realize greater strength through a more rigid
`structure as well as reduction in the amountof material
`used to make each carton. Because it is not practical to
`transport boxes once they are glued,it is necessary to
`carry out the gluing operations at the same location
`where the boxes are to be used. The need to locate the
`gluing operation adjacent the packaging operation has
`imposed a severe limitation on the acceptability of
`glued boxes other than for very large packing plant
`operations.
`Prior art examples of cardboard containers that use
`glue or staples in their construction and are used for
`storage of assorted materials are shown in U.S. Pat.
`Nos. 2,950,850 to Corcoran and 2,572,610 to Gilbert.
`Other foldable cardboard containers have been de-
`veloped for storing fruit produce and other perishable
`materials that avoid the problemsof gluing and stapling.
`These cartons rely on arrangements ofinterlocking tabs
`for their structural rigidity. Examples of such contain-
`ers are disclosed in the following patents:
`U.S. Pat. No. 1,894,226 to Ross
`U.S. Pat. No. 2,105,057 to Sharpe
`U.S. Pat. No. 2,811,298 to Jones
`U.S. Pat. No. 3,108,569 to Kundikoff
`U.S. Pat. No. 3,756,499 to Giebel
`U.S. Pat. No. 3,973,723 to Owens
`U.S. Pat. No. 3,820,706 to Gibson et al.
`U.S. Pat. No. 4,101,048 to Rieben et al.
`U.S. Pat. No. 4,304,353 to Stollberg
`UK Patent No. 2,043,596 to Scotcheret al.
`French Patent No 2240156
`French Patent No. 2299226
`French Patent No. 2363489; and
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`4,911,355
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`Italian Patent No. 0678940
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`SUMMARYOF THE INVENTION
`
`According to the present invention there is provided
`a foldable carton comprising:
`a central panel;
`a pair of opposed exterior end panels affixed to said
`central panel and foldable about respective central-end
`panel edges;
`a pair of interior end panels affixed to said exterior
`end panels by and foldable about a top end edge;
`a pair of supplementary interior end panels affixed to
`each ofsaid interior end panels by and foldable about an
`interior end panel edge;
`a supplementary interior end panel flap affixed to
`each of said supplementary interior end panels by and
`foldable about a supplementary flap edge;
`a pair of opposed side panels affixed to said central
`panel and foldable about respective central-side panel
`edges havinga plurality of spaced apart side panel ven-
`tilation holes therein;
`a pairofside panelflapsaffixed to each end of each of
`said side panels and foldable with respect thereto about
`respective flap edges;
`a pair of opposed cover panels affixed to respective
`side panels and foldable about respective cover side
`panel edges and removably engageable with said end
`panels, said cover panels having cover ventilation holes
`along the cover side panel edges;
`said interior end panel having means for removable
`locking engagement with said central panel upon being
`folded over said exterior end panel;
`whereby forming said foldable carton includes fold-
`ing said supplementary interior end panel flaps to over-
`lie said supplementary interior end panels, folding said
`supplementary interior end panels to overlie said inte-
`rior end panels, folding said side panel flaps to overlie
`each other, and folding said interior end panels over
`said exterior end panels about said top end edge to
`enclose said supplementary interior end panelflaps, said
`supplementary interior end panels and said side panel
`flaps between said interior and exterior end panels
`thereby forming a carton end wail construction that
`includes five overlapping layers sandwiched between
`said interior and exterior end panels.
`It is the end wall construction comprising a total of
`seven separate layers of material that give the carton of
`the present invention a rigidity and stacking ability not
`found in the priorart patents. This rigidity is achieved
`by the compact folding arrangement of the supplemen-
`tary end panel flaps and the supplementary end panels.
`The foldable carton of the present invention can be
`formed with side panels that are inclined outwardly
`from the vertical. The provision of an inclined pair of
`outwardly extending side panels provides a plenum
`between two adjacent cartons stacked side by side
`which allowsair to flow parallel to the side panels along
`a stacked array of such cartons.
`Unlike prior art cartons, the design of the present
`carton is such that in its laid out or blank form it is
`substantially rectangular in shape. Thus, in dye-cutting
`such cartons from sheets of material, a minimum of
`waste is incurred. The carton, moreover, can beeasily
`and securely assembledin a folded position without the
`need to use fasteners such as staples or other materials
`such as glue.
`.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`Embodiments of the foldable carton are illustrated,
`merely by way of example, in the accompanying draw-
`ings in which:
`FIG. 1 is a plan view of a first embodiment of the
`carton having inclined sides in unfolded form;
`FIG.2 is a perspective view of the carton of FIG. 1
`showing how the end of the carton is folded;
`FIG..3 is a perspective view of the carton of FIG. 1
`in folded form with one cover panel opened;
`FIG.4 is aplan view of a second embodimentof the
`carton having vertical sides in unfolded form; and
`FIG.5 is a perspective view of the carton of FIG. 4
`in folded form.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`
`In the Figures of the various embodiments,like refer-
`ence numbersrefer to like parts. Moreover, in the fol-
`lowing description, words such as “upper”, “top”, and
`“bottom”are used in‘a relative sense only and notin an
`absolute sense.
`A first embodiment of the carton 10 of the present
`invention is shown in FIG. 1 in unfolded form and
`includes a rectangular central panel 12 which forms the
`base of a folded carton. This central panel is joined by
`meansof respective opposed central-side panel edges 30
`to a pair of opposed rectangular side panels 16, and by
`respective opposed central-end panel edges 32 to a pair
`of opposed exterior end panels 14.
`In all embodiments of the present invention, the car-
`ton material is typically made of corrugated cardboard
`or of some other suitable resilient material which per-
`mits one section of the carton to be folded relative to the
`other.
`Affixed to each side panel 16 along a cover-side panel
`edge 34 is a cover panel 18. Perforated in each of the
`side panels 16 are a plurality of elongated spaced-apart
`ventilation holes 17 formed therein.
`The cover panel 18 also has a plurality of spaced-
`apart ventilation holes 19 formed along the cover-side
`panel edge 34 in alignment with corresponding ventila-
`tion holes 17 on side panel 16. On either end of cover
`panel 18 there is a cover tab 28 projecting outwardly
`therefrom. Cover tab 28 is foldable about a cover tab
`folding edge 23. At either end of said panel 16 there are
`side panelflaps 20 foldable about.a flap edge 36. Each of
`side panel flaps 20 has formed therein an elongated
`opening 44 which is located so as to overlap with han-
`dle cutout 38 in exterior end panel 14 when in a folded
`position. Flap 45 is formed in one elongated opening 44
`of each pair of openings.
`Side panels flaps 20 have top and bottom edges 42 and
`48, respectively, that are at an angle with respect to
`central-side panel and cover-side panel edges 30 and 34,
`respectively. Preferably, side panel flaps 20 extend from
`side panels 16 at an angle of approximately four degrees
`with respect to central-side panel edge 30. Necessarily,
`exterior end panel 14 has inwardly converging edges
`that it shares with side panel flaps 20. Top edge 42 of
`side panels flaps 20 are formed with cutouts 56 and 58.
`Adjacent top end edge 57of theinterior end panelflap,
`the inwardly converging edges widen at 94 to join the
`top end edge. Adjacent the central-end panel edge 32
`are a pair of spaced-apart central panel cutouts 51 and
`52. Along top end edge 57, there are also two top end
`edge cutouts 60 and 62. Top end edge 57 is formed
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`between twofolding lines 53 and 54 adjacentto exterior
`end panel 14 and an interior end panel 22.
`Onthe outer edge 26 of each interior end panel 22 are
`formed two spaced tabs 80.and 82. Interior end panel 22
`has interior end panel edges 61 and 63 on either side
`thereof extending partially across the end panel. Each
`of edges 61 and 63 is formed between a pair of folding
`lines. Edge 63 is wider than edge 61. Interior end panel
`edges 61 and 63 mergeinto interior end panel side edges
`84 that extend outwardly to form ears 93. Interior end
`panel side edges 84 are inclined to central-side planel
`edges 30 and are at substantially the same angle thereto
`as are flap bottom edges 48.
`Attached to interior end panels 22 by meansofinte-
`rior end panel edges 61 and 63 are supplementaryinte-
`rior end panels 24a and 24b. The supplementaryinterior
`end panels 24a and 24b have edges 87 substantially
`perpendicular to panel contacting edges 73 and adjacent
`angled edges 88 formed at the same angle as corre-
`sponding interior end panel side edges 84.
`Supplementary interior end panel flaps 100a and 100b
`are attached to supplementary interior end panel flaps
`24a and 24b respectively along an outer portion of top
`edge 85 at supplementary flap edge 102. Flaps 100¢ and
`100d are located adjacent side panel flaps 20 and extend
`toward cover panels 18. Like top end edge 57 and inte-
`rior end panel edges 61 and 63, supplementary flap
`edges 102 have twofold lines 104 and 106 to render flap
`edge 102 sufficiently wide to accommodate folding of
`the cardboard carton.
`In the following description of forming the blank of
`FIG.1 into a carton reference should be made to FIG.
`2. In forming a folded carton from the cutout illustrated
`in FIG. 1, side panel flaps 20 are folded inwardly about
`flap edges 36 and side panels 16 are folded about cen-
`tral-side panel edges 30 such that the side panel flaps
`overlie each other. In the embodiment of FIG.1, side
`panels 16 are inclined at an angle slightly larger that
`ninety degrees to the plane of central panel 12 when
`side panel flap bottom edge 48 lies along central-end
`panel edge 32 due to the angled attachmentofthe side
`flaps to side panel 16. Flap 45 in one of the openings 44
`is folded into the corresponding opening of the adjacent
`side panel flap 20 to lock the two side panel flaps to-
`gether.
`Supplementary interior end panel flap 100a is folded
`downwardly out of the plane of the sheet of FIG. 1
`about flap edge 102 to overlie supplementary interior
`end panel 24a. Supplementary interior end panel flap
`1006 is folded upwardly out of the plane of the sheet of
`FIG. 1 about flap edge 102 to overlie supplementary
`interior end panel 24). Supplementary interior end pan-
`els 24a is then folded about edge 61 to overlie interior
`end panel 22. Supplementary interior end panel 246 is
`folded aboutinterior end panel edge 63 to lie flat against
`the previously folded supplementary interior end panel
`24a. Edge 63 is widened to accommodate the extra
`thickness of material over which panel 245 must be
`folded. In this position, supplementary interior end
`panels 100¢ and 1006 are sandwiched between supple-
`mentary end panels 24a and 240 atop interior end panel
`22 and edge 102 of the flaps 10@ and 1005 are adjacent
`top end edge 57. The angled edge 88 of supplementary
`interior end panels 24¢@ and 245 overlies andis substan-
`tially parallel to respective interior end panel side edge
`84.
`Interior end panel 22 is folded about folding edges 53
`and 54 over side panel flaps 20. Top end edge 57 is
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`sufficiently wide to accommodate the side panel flaps,
`and the supplementary interior end panels and associ-
`ated flaps over which edge 57 is folded.
`On completion ofthe latter folding operation, tabs 80
`and 82 are locked into central panel cutouts 51 and 52,
`respectively. Cover panels 18 are folded about cover
`side panel edge 34 and tab 28 is folded about cover tab
`edge 23 such that tab 28 enters into an associated top
`end edge cutout 60 and 62. Tabs 28 are retained in cut-
`outs 56 and 58in side panel flaps 20 which align beneath
`cutouts 60 and 62 whenthe cartonis folded.
`The fully assembled carton of FIG. 1 is shown in
`FIG. 3. Whenin folded position, side panels 16 form a
`slight outwardly inclined angle from the perpendicular
`with respect to the vertical and the ventilation holes 17
`are oriented substantially vertically in transverse align-
`ment with corresponding associated ventilation holes
`19. Preferably, the corrugations in the cardboard mate-
`rial are oriented to run parallel to central-side panel
`edges 30 providing maximum strength against compres-
`sion in interior and exterior end panels 14 and 22.
`With twocartons 10 side by side, the space between
`the side panels 16 of adjacent cartons 10 forms a plenum
`of triangular cross section running along the length of |
`25
`the carton 10 which permits air to run along the sides of
`the carton 10 and enterinto the latter through elongated
`ventilation holes 17. Air then circulates through the
`contents contained in the carton 10 and exits out
`through cover panel ventilation holes 19. By arranging
`for the latter holes to be located directly above the side
`panel ventilation holes 17, exit holes are provided in the
`vertical path of air entering into the side panel ventila-
`tion holes that are not covered by the central panel 12 of
`an overlying stacked carton 10 as the outwardly in-
`clined side panels make the top of the carton wider than
`the central panel 12.
`While the embodiment of FIG. 1 has been shown
`with inclined side panels 16,it is understood that a simi-
`lar carton can also be constructed having verticalsides.
`Such a carton is shown in FIGS. 4 and 5 in which side
`panelflaps 20 are formed with edgesthat extendparallel
`to central-side panel edge 30 and cover-side panel edge
`34. In this second embodimentof the present invention,
`all parts which are analogous to the parts of the first
`embodiment are identically numbered.
`Both embodiments of the present invention create a
`seven ply end wall construction resulting in an ex-
`tremely rigid carton able to withstand heavy stacking
`loads.
`,
`In both embodiments of the present invention, cover
`panels 18 can be dimensioned so that they do not meet
`whenthey are folded into a covering position atop the
`carton. The gap left between the cover panels in such an
`arrangement defines a central ventilation opening for
`increasing cooling of the producein the cartons.
`Althoughthe present invention has been described in
`some detail by way of example for purposes ofclarity
`and understanding,
`it will be apparent
`that certain
`changes and modifications may be practiced within the
`scope of the appended claims.
`I claim:
`1. A foldable carton comprising:
`a central panel;
`a pair of opposed exterior end panels affixed to said
`central panel and foldable about respective central-
`end panel edges;
`a pair of interior end panels affixed to said exterior
`end panels by and foldable about a top end edge;
`
`40
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`a pair of supplementaryinterior end panels affixed to
`each of said interior end panels by and foldable
`about an interior end panel edge;
`a supplementary interior end panel flap affixed to
`each of said supplementary interior end panels by
`and foldable about a supplementary flap edge;
`a pair of opposed side panels affixed to said central
`panel and foldable about respective central-side
`panel edges having a plurality of spaced apart side
`panel ventilation holes therein;
`a pair ofside panelflapsaffixed to each end of each of
`said side panels and foldable with respect thereto
`about respective flap edges;
`a pair of opposed cover panels affixed to respective
`side panels and foldable about respective cover side
`panel edges and removably engageable with said
`end panels, said cover panels having cover ventila-
`tion holes along the cover side panel edges;
`said interior end panel having means for removable
`locking engagement with said central panel upon
`being folded over said exterior end panels;
`whereby forming said foldable carton includes fold-
`ing said supplementary interior end panel flaps to
`overlie said supplementary interior end panels,
`folding said supplementary interior end panels to
`overlie said interior end panels, folding said side
`panel flaps to overlie each other, and folding said
`interior end panels over said exterior end panels
`about said top end edge to enclose said supplemen-
`tary interior end panel flaps, said supplementary
`interior end panels and said side panel flaps be-
`tweensaid interior and exterior end panels thereby
`forming a carton end wall construction that in-
`cludes five overlapping layers sandwiched be-
`tween said interior and exterior end panels.
`2. A foldable carton as claimed in claim 1 in which
`said means for removable locking engagement with said
`central panel comprises a pair of spaced tabs formed
`along an outer edge of said interior end panel aligned
`with and insertable into a corresponding pair of spaced
`cutoutsin said central panel proximate said central end
`panel edge upon folding of said interior end panel.
`3. A foldable carton as claimed in claim 1 in which
`said carton is cut from corrugated cardboard with cor-
`rugations thereof running along the length of said cen-
`tral panel such that the corrugations of said end panels
`and said end panels flaps are substantially perpendicular
`to said central panel.
`4. A foldable carton as claimed in claim 1 in which
`each of said cover panels has a cover tab on opposed
`ends foldable and insertable into corresponding top end
`edge cutouts.
`5. A foldable carton as claimed in claim 4 in which
`said side panel flaps have cutouts in a top edge thereof
`alignabie upon folding with corresponding top end edge
`cutouts to create a cavity for insertion of said cover
`tabs.
`6. A foldable carton as claimed in claim 1 in which
`eachofsaid side panels and cover panels has a plurality
`of spaced ventilation holes such that when folded the
`cover ventilation holes are aligned with said side panel
`ventilation holes along the length thereof and thelatter
`holes are proximate the cover side panel edges.
`7. A foldable carton as claimed in 6 in which said
`cover panels are dimensioned to extend only partially
`across the open top ofsaid carton when folded thereby
`defining a central ventilation opening between said
`cover panels.
`.
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`8. A foldable carton as claimed in claim 1in which
`said side panel flaps have parallel top and bottom edges
`that extend from said side panels at an angle to said flap
`edge such that said side panels are inclined upwardly
`and outwardly from said central panel when said side
`panels are folded inwardly to overlie each other.
`9. A foldable carton as claimed in claim 8 in which
`said side panel flaps extend from said side panels at an
`
`8
`angle of approximately four degrees with respect to said
`central-side panel edges.
`10. A foldable carton as claimed in claim 8 in which
`said exterior end panel has inwardly converging edges
`to accommodate said bottom edges ofsaid side- panel
`flaps extending from said bottom end panel edge to
`adjacent said top end edge where said inwardly con-
`verging edges widen to join said top end edge.
`*
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