US 3638848 A
A protective carton for bulbous articles having substantially parallel end surfaces of polygonal configuration connected by planar rectangular wall portions to form a compact septrahedronal prismatic carton closure.
Description (OCR text may contain errors)
United States Patent Heyworth  CARTON FOR BULBOUS ARTICLES UNITED STATES PATENTS 1,653,914 12/1927 Keppler..................................
Ernest R. Heyworth, Horseheads, N Y. 3,184,146 5/1965 Hurley.. Assrgnec: Corning Glass Works, Corning, N.Y.
 Filed: Feb. 20, 1970 [72} Inventor:
Primary Examiner.lamcs B. Marbert AtlorneyClarence R. Patty, Jr. and Burton R. Turner Appl. No.:
planar rectangular wall portions to form a compact scptrahedronal prismatic carton closure.
2800 20 WN 2 2 2 6 m m 2. 2
 Int.  Field of Search 9 Claims, 8 Drawing Figures References Cited PATENTEU FEB I B72 SHEEY E OF 3 INVENTOR. Ernesf R. Heyworfh ATTORNEY PATENTEUFEB H972 3,638,848 SHEET 20F 3 m R we M Rx Em w H f S E l 4 m H /& MM/ w m 2 ||||||2||||| III 6 2 ATTORNEY PATENTED FEB 1 1972 SHEET 3 [IF 3 IINVENTOR. Ernest R. Heyworfh ATTORNEY CARTON FOR BULBOUS ARTICLES BACKGROUND OF THE INVENTION This invention pertains to the packaging art and more particularly to a specific carton structure for packaging irregular shaped articles with increased shipping density.
In the past it has been customary to package bulbous shaped articles, such as automobile headlamps, in square shaped containers having tediously constructed puckered-in or billowedin top and bottom end closures. Not only did the square construction increase cubage and require substantial material, but also the single-face material utilized in such construction provided minimum protection. The present invention, on the other hand, not only substantially reduces the cubage necessary to package these items, but also materially reduces the square footage of board required to construct the carton, from that utilized in the prior art, while affording increased protection.
SUMMARY OF THE INVENTION A generally rectangular shaped carton blank is provided with a plurality of crease lines and cut lines so as to facilitate the folding of the blank into a prism-shaped carton having a pentagonal cross section parallel to its two opposed planar parallel end surfaces. Both the blank and the carton formed from such blank are symmetrical about a plane extending perpendicularly to and bisecting a centrally disposed panel of the carton structure. The symmetrical construction facilitates ease in loading, assembling and sealing of the carton structure by automatic machinery. The pentagonal cross section construction not only reduces cubage so as to provide increased shipping density, but also provides unique outer surface configurations for facilitating a variety of display orientations.
An object of the present invention has been to provide an improved carton structure for packaging bulbous shaped articles wherein cubage is reduced by forming the carton in a prismatic shape having a pentagonal cross section.
A further object of the invention has been to provide a car ton blank for facilitating automatic loading, forming and sealing of the carton, wherein the carton structure is symmetrical about a central loading panel, which panel may subsequently double as a display panel for the packaged merchandise.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a plan view of an improved blank structure for forming a prismatic carton construction of the present invention.
FIG. 2 is a plan view of the blank in a partially assembled position.
FIG. 3 is a side elevational view of the partially assembled blank shown in FIG. 2.
FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 2, with a packaged headlamp shown in position.
FIG. 5 is a top plan view of an assembled carton construction of the present invention.
FIG. 6 is a side elevational view of the carton shown in FIG.
FIG. 7 is a fragmental plan view ofa further embodiment of a blank for forming a modified carton construction of the present invention.
FIG. 8 is a side elevational view of a modified carton formed from the blank shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, and particularly FIG. I, a blank 10 for forming a preferred embo;iment of the carton design is shown comprising a central panel 12 having a pair of small inner wall panels 14 foldably attached thereto along score or crease lines 16, and a pair of large outer wall panels 18 foldably attached to the inner panels 14 along score or crease lines 20. Central panel 12 has a pair of hexagonally shaped inner end flaps 22 foldably connected to opposite ends thereof along crease lines 24, whereas outer wall panels 18 each have a pair of outer end flaps 26 foldably connected thereto along crease lines 28. The crease lines 24 and 28 on opposite sides of the blank form three pairs of parallel lines which are inwardly offset from the outer edge portions of small wall panels 14, with crease lines 24 being more inwardly offset than lines 28. Short die-cut sections 30, 32 are formed in small inner wall panels 14 for forming end flaps 22 and 26 respectively. For display purposes, a center portion of central panel 12 may be die cut or blanked out if desired to form a window portion 34.
FIGS. 2, 3 and 4 illustrate one method of assembling a carton II from the blank 10. It should be noted that although an article to be packaged, such as a headlamp H, is initially positioned upon central panel 12, for purposes of clarity it has not been shown in FIGS. 2 and 3. Further, although in operation the carton would normally be assembled symmetrically, one half of the carton has been shown in an open position to facilitate an understanding of its construction.
After the article H is positioned upon central panel 12, the inner end flaps 22 are folded upwardly along crease lines 24 to a position substantially perpendicular to the central panel. The small wall panels 14 and large wall panels 18 are then folded upwardly about the outer edges of inner end flaps 22, with small wall panels 14 diverging upwardly and outwardly and large wall panels 18 converging upwardly and inwardly into abutting relation, as particularly shown in FIG. 6. Glue is applied either to the outer surface of inner end flaps 22 or the inner surface of outer end flaps 26, and outer end flaps 26 are then folded downwardly along crease lines 28 so as to overlie and be in sealing engagement with inner end flaps 22, as shown in FIGS. 3 and 6. As shown particularly in FIG. 6, the outer end flaps 26 abut one another within a plane extending normal to and bisecting central panel 12.
The particular order in which the various panels and end flaps are folded into a carton structure may vary with production operations. For example, after an article H is positioned on central panel 12, the inner and outer wall panels 14 and 18 respectively, may be initially folded upwardly about the article to provide the suspending effect, and then inner end flaps 22 may be folded upwardly into position within the assembled inner and outer panels. Finally, outer end flaps 26 would be folded downwardly into a glue-sealing relationship with inner end flaps 22. Alternatively, outer flaps 26 may be taped or sta pled in a closed position. Further, although corrugated fiberboard is shown in the construction, it will be understood that other packaging materials such as folding boxboard, chip material, and paper laminations may be utilized ifdesired.
It should be noted with reference to FIGS. 1 and 2, that crease lines 24 and die-cut sections 30 position the inner end flaps 22 inwardly of the outer edges of small wall panels 14 a sufficient distance so that die-cut sections 32 and crease lines 28 may position the outer surface of outer end flaps 26 in the plane of the outer edges of panels 14, as particularly shown in FIG. 4. Further, when the small inner wall panels 14 are folded upwardly, they contact edge portions of the article H and provide a suspended support thereto so that the central portion of the article is spaced apart from the inner surface of central panel 12, as shown in FIG. 4. As further shown in FIG. 4, the overlapping end flaps 22, '26 provide improved doublecushioning protection about opposite rim edge portions of article H.
During the loading, assembling and sealing operations, central panel 12 is in the down position, and the automatic assembly of the carton is facilitated by the fact that both the carton and the blank structures are symmetrical about a normal plane bisecting central panel 12. However, in order to maximize density and reduce cubage in shipping, it is contemplated that a plurality of cartons II will be positioned on end flaps 26 in staggered rows within a shipping container. Finally, when the carton is positioned on a dealers shelf for display, it may rest on large wall panel 18 so as to aesthetically display the merchandise through window 34.
Referring now to FIGS. 7 and 8, a modified carton blank 10' is shown for forming a further carton embodiment ll. The blank 10 is shown having the outer portions of inner end flaps 22 and outer end flaps 26 removed so as to further conserve board material. in addition, a glue flap 36 may be provided on the outer end of one of the outer wall panels 18'. Blank 10' is assembled in a similar manner as blank 10 so as to form carton 11, however, additional glue is applied to flap 36 so that it may be sealingly attached to the other outer wall panel 18. As noted particularly in FIG. 8, a portion of the inner end flap 22 is exposed due to the removal of outer portions of the outer end flaps 26.
Although I have disclosed the now-preferred embodiments of my invention it will become apparent to those skilled in the art that various changes and modifications may be made thereto without departing from the spirit and scope thereof as defined in the appended claims.
1. A blank for forming a prismatic carton having a pentagonal cross section which comprises, a central panel, a pair of inner wall panels foldably attached to opposite sides of said central panel along score lines, an outer wall panel foldably attached to the outer edge of each of said inner wall panels, a pair of opposed inner end flaps foldably connected to opposite ends of said central panel along substantially paraliel crease lines extending between said inner wall panels, an opposed pair of outer end flaps foldably connected to opposite ends of each of said outer wall panels along substantially parallel crease lines, said blank being substantially symmetrical about a plane extending normal to and bisecting said central panel, said crease lines extending between said central panel and said inner end flaps and the crease lines between said outer wall panels and said outer end flaps being inwardly offset with respect to outer edges of said inner wall panels, and die-cut sections extending from said crease lines to edge portions of said inner wall panels.
2. A blank for forming a prismatic carton having a pentagonal cross section as defined in claim 1 wherein said inner end flaps are formed with a hexagonal configuration.
3. A blank for forming a prismatic carton having a pentagonal cross section as defined in claim I wherein a portion of said central panel is removed to form a window portion.
4. A blank for forming a prismatic carton having a pentagonal cross section as defined in claim 1 wherein a glue flap extends from an outer edge of one of said outer wall panels for cooperative engagement with the other of said outer wall panels.
5. A prismatic carton construction having a pentagonal cross section which comprises, a central panel, a pair of outwardly diverging wall panels extending from opposed sides of said central panel, a pair of converging wall panels with one integrally extending from each of said diverging wall panels and converging in abutting relationship at their outer ends, an inner end flap extending from each end of said central panel substantially normal thereto and having outer edges in abutting relationship with inner surfaces of said diverging and converging wall panels, and a pair of outer end flaps overlying each inner end flap and sealingly closing opposite end portions of said prismatic carton structure.
6. A prismatic carton construction as defined in claim 5 wherein said outer end flaps are foldably attached to said converging wall portions and abut one another along a plane extending normal to and bisecting said central panel.
7. A prismatic carton as defined in claim 5 wherein a glue flap extends from an outer edge of one of said converging wall panels and is secured to an edge portion of the other of said converging wall panels along their line of abutment.
8. A prismatic carton as defined in claim 5 wherein said inner end flaps have a hexagonal configuration which complements and supports adjacent portions of said diverging and converging wall portions.
9. A prismatic carton as defined in claim 5 wherein said inner end flaps are inwardly offset with res ect to said divergmg wall pane s, and the outer surface of sai outer end flaps be substantially within a plane passing through the outer edges of said diverging wall panels.