Title: Film multipackage
Abstract: This invention relates to a single-piece carrier for unitizing a plurality of containers with a retainer sheet integrated with a carrier sleeve. The retainer sheet comprises a plurality of container receiving openings for engaging a top portion of each container while the carrier sleeve surrounds the plurality of containers. Packages preferably comprise two or more layers of containers within the carrier sleeve separated by a divider.
Patent Number: 6,935,491 Issued on 08/30/2005 to Marco
| Inventors:
|
Marco; Leslie S. (Bloomingdale, IL)
|
| Assignee:
|
Illinois Tool Works Inc. (Glenview, IL)
|
| Appl. No.:
|
417684 |
| Filed:
|
April 17, 2003 |
| Current U.S. Class: |
206/150; 206/151 |
| Intern'l Class: |
B65D 075/00 |
| Field of Search: |
206/139,140,147,148,150,151,162,427,432,434,497
|
References Cited [Referenced By]
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| 3198327 | Aug., 1965 | Boehling et al.
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| 3200944 | Aug., 1965 | Rapata.
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| 3214016 | Oct., 1965 | Stephan.
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| 3217874 | Nov., 1965 | Potter.
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| 3325004 | Jun., 1967 | Wanderer.
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| 3410596 | Nov., 1968 | Slevin, Jr.
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| 3460863 | Aug., 1969 | Schaich.
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| 3509684 | May., 1970 | Hohl.
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| 3570746 | Mar., 1971 | Wood.
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| 3700275 | Oct., 1972 | Deasy.
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| 3899076 | Aug., 1975 | Florian.
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| 4121401 | Oct., 1978 | Duerr et al.
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| 4378879 | Apr., 1983 | Killy.
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| 4403689 | Sep., 1983 | Wood.
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| 4471870 | Sep., 1984 | Uhlig.
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| 4523676 | Jun., 1985 | Barrash.
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| 4560064 | Dec., 1985 | Peterson et al.
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| 4637515 | Jan., 1987 | Wilson et al.
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| 4779731 | Oct., 1988 | Fujio.
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| 4807751 | Feb., 1989 | Klygis et al.
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| 4828110 | May., 1989 | Lems.
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| 4893712 | Jan., 1990 | Allen et al.
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| 4919265 | Apr., 1990 | Lems et al.
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| 4932528 | Jun., 1990 | Benno.
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| 5305877 | Apr., 1994 | Olsen.
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| 5311984 | May., 1994 | Harris.
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| 5328024 | Jul., 1994 | Sutherland.
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| 5360104 | Nov., 1994 | Sutherland.
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| 5390784 | Feb., 1995 | Sutherland.
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| 5425446 | Jun., 1995 | Weaver et al.
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| 5437370 | Aug., 1995 | Marco.
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| 5487463 | Jan., 1996 | Harris.
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| 5538133 | Jul., 1996 | Campbell et al.
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| 5582289 | Dec., 1996 | Wright.
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| 5590776 | Jan., 1997 | Galbierz et al.
| |
| 5653334 | Aug., 1997 | Marco.
| |
| 5701994 | Dec., 1997 | Marsh.
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| 5765684 | Jun., 1998 | Van Dore et al.
| |
| 6145656 | Nov., 2000 | Marco.
| |
| Foreign Patent Documents |
| 1 013 564 | Jun., 2000 | EP.
| |
| 2 015 754 | Apr., 1970 | FR.
| |
| 2 169 442 | Sep., 1973 | FR.
| |
| 93/14992 | Aug., 1993 | WO.
| |
Primary Examiner: Foster; Jim
Attorney, Agent or Firm: Pauley Petersen & Erickson
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No.
09/777,628, filed 06 Feb. 2001 now U.S. Pat. No. 6,564,530, which is a continuation-in-part
application Ser. No. 09/220,428 filed Dec. 24, 1998 now U.S. Pat. No. 6,213,293,
which issued on 10 Apr. 2001.
Claims
1. A package for carrying a plurality of containers, the package comprising:
a carrier including a retainer sheet portion having a plurality of container
receiving openings for stretchingly engaging the plurality of containers and a
stretchable carrier sleeve portion integrated with at least two side edges of the
retainer sheet portion;
a plurality of containers arranged in an upper level and a lower level, each
container receiving opening of the plurality of container receiving openings engaged
with a container in the upper level of the plurality of containers;
a divider positioned between the upper level and the lower level of containers;
and
a handle integrated with the retainer sheet portion and extending over a top
of the package.
2. The package of claim 1 further comprising:
a seam formed between the carrier sleeve portion and the retainer sheet portion.
3. The package of claim 2 wherein the seam is positioned along an overlapping
area between the carrier sleeve portion and the retainer sheet portion.
4. The package of claim 1 further comprising a pull tab positioned in the carrier
sleeve portion, the pull tab connecting a tear strip extending around at least
a portion of the perimeter of the package.
5. The package of claim 4 wherein the tear strip is formed on each side of a
seam extending between the carrier sleeve portion and the retainer sheet portion.
6. The package of claim 1 wherein the divider comprises a paperboard sheet having
a footprint approximately corresponding with a footprint of the package.
7. A package of a plurality of containers, the package comprising:
a carrier including a retainer sheet portion and a carrier sleeve portion, the
retainer sheet portion having a plurality of container receiving openings arranged
in longitudinal rows;
a seam extending between the retainer sheet portion and the carrier sleeve portion;
a plurality of containers arranged in an upper level and a lower level, each
container receiving opening of the plurality of container receiving openings engaged
with a container in the upper level of the plurality of containers, the carrier
sleeve portion positioned around the plurality of containers;
a divider positioned inside of the carrier sleeve portion and extending between
the upper level of the plurality of containers and the lower level of the plurality
of containers; and
a handle positioned over a top of the package.
8. The package of claim 7 wherein the carrier sleeve portion surrounds each side
and a bottom of the package of the plurality of containers.
9. The package of claim 7 wherein the handle is formed from a double layer of
the retainer sheet portion.
10. The package of claim 7 further comprising a tear strip positioned in the
carrier sleeve for disassociating one or more containers in the upper level of
the plurality of containers from the package.
11. The package of claim 10 wherein the tear strip disassociates all containers
in the upper level of the plurality of containers from the package.
12. A package of a plurality of containers, the package comprising:
a carrier including a retainer sheet portion and a carrier sleeve portion, each
of the retainer sheet portion and the carrier sleeve portion formed of a stretchable
material, the retainer sheet portion having a plurality of container receiving
openings;
a seam extending within overlapping portions of the retainer sheet portion and
the carrier sleeve portion along a longitudinal edge of the package;
a plurality of containers arranged in an upper level and a lower level, each
container receiving opening of the plurality of container receiving openings engaged
with a container in the upper level of the plurality of containers, the carrier
sleeve portion positioned around both the upper level and the lower level of the
plurality of containers;
a divider positioned inside of the carrier sleeve portion and extending between
the upper level of the plurality of containers and the lower level of the plurality
of containers.
13. The package of claim 12 further comprising:
a handle positioned over a top of the package.
14. The package of claim 13 wherein the handle comprises two thicknesses of the
retainer sheet portion fastened together with a seal.
15. The package of claim 12 further comprising:
a tear strip positioned along the longitudinal edge of the package, the tear
strip tearable to disassociate all containers in the upper level of the plurality
of containers from the package.
16. The package of claim 12 wherein the divider comprises a paperboard sheet.
17. The package of claim 12 wherein the stretchable material is different for
each of the carrier sleeve portion and the retainer sheet portion.
18. The package of claim 12 wherein the retainer sheet portion comprises a thicker
stretchable material than the carrier sleeve portion.
19. The package of claim 12 wherein the carrier sleeve portion surrounds the
plurality of containers on five sides.
20. A package for carrying a plurality of containers, the package comprising:
a carrier including a retainer sheet portion having a plurality of container
receiving openings for stretchingly engaging the plurality of containers and a
stretchable carrier sleeve portion integrated with at least two side edges of the
retainer sheet portion;
a plurality of containers arranged in an upper level and a lower level, each
container receiving opening of the plurality of container receiving openings engaged
with a container in the upper level of the plurality of containers;
a divider positioned between the upper level and the lower level of containers;
and
a pull tab positioned in the carrier sleeve portion, the pull tab connecting
a tear strip extending around at least a portion of the perimeter of the package.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device and method of manufacture of the device for
unitizing a plurality of containers, the carrier having a retainer sheet for engaging
a top portion of the containers integrated with a film sleeve for surrounding the containers.
2. Description of Prior Art
Conventional container carriers are often used to unitize a plurality
of similarly sized containers, such as cans, bottles, jars and boxes, although
other packages or containers may be unitized. Plastic ring carriers and box carriers
are two such conventional container carriers.
The plastic ring carrier produces a unitized package for containers using little
material. However, the plastic ring carrier, when used alone in most instances,
has little or no advertising or promotional printing space. Conversely, the box
carrier generally has a relatively large amount of area for promotional graphics.
Disadvantageously, the box carrier requires a relatively large amount of material,
may permit containers to fall out if it is not maintained in an upright position,
and usually shrouds most or all of the actual containers. Therefore, there is a
need for a package that incorporates the stability and economy of a ring carrier
and the promotional area of a box carrier.
SUMMARY OF THE INVENTION
It is one object of this invention to provide a container carrier that unitizes
a plurality of containers into a tight, solid package.
It is another object of this invention to provide a container carrier that provides
a prominent billboard space for merchandising information.
It is still another object of this invention to provide a container carrier which
restricts lateral and vertical movement of the containers with respect to one another.
It is yet another object of this invention to provide a container carrier that
incorporates the stability and economy of a ring carrier and the promotional area
of a box carrier.
It is still another object of this invention to provide a container carrier that
utilizes a film sleeve to maintain a tight configuration of unitized containers.
A carrier according to this invention carries a plurality of containers such
as
cans or bottles. The carrier unitizes a plurality of containers to create a package.
The carrier is a single-piece device comprising a retainer sheet integrated with
a film sleeve, each preferably constructed from a flexible, resilient material
such as plastic. The retainer sheet preferably has a first thickness different
from and thicker than a second thickness of the film sleeve.
The retainer sheet is formed with a plurality of container receiving openings
the number of which depends upon the intended size of the package. The retainer
sheet is integrated with the film sleeve preferably along longitudinal sides of
the retainer sheet.
The film sleeve may be designed to create a package open at a bottom of the package
or along a lower edge of the carrier. The film sleeve may further include a bottom
along a portion of the lower edge of the film sleeve. Each side edge of the film
sleeve is preferably bound with a seal. The carrier when formed is preferably generally
symmetrical around fold lines of the carrier.
Containers are inserted within the carrier so that the containers are
surrounded by between five and six sides of the package. Each container receiving
opening in the retainer sheet preferably engages a container around an upper portion
of the container. The rigidity and elasticity of the retainer sheet thereby supports
each container.
The film sleeve is positioned around the plurality of containers, preferably
in a stretching engagement with the containers. The film sleeve is preferably printed
with graphics, promotional and/or other information related to contents and/or
ingredients of package. Therefore, the film sleeve serves both to unitize the plurality
of containers and to advertise the nature of the contents of the containers.
The carrier is preferably manufactured according to one of several preferred
methods wherein a generally continuous length of carriers is formed. In summary,
a film substrate and/or film sleeve material is printed with desired graphics and
other merchandising information. A retainer sheet material is next joined to the
film substrate and/or film sleeve material by heat sealing, extrusion coating,
laminating, profile extrusion or glueing the retainer sheet material to the film
substrate and/or film sleeve material. The joined retainer sheet material and film
substrate and/or film sleeve material are next either folded along a fold line
to create a symmetrical double layer or laminated to an identical section of joined
retainer sheet material and film substrate and/or film sleeve material thereby
creating a carrier blank. Seams are next added by heat sealing or laminating the
symmetrical double layer of retainer sheet material and film substrate and/or film
sleeve material together. Finally, the carrier is formed by die cutting the double
layer of retainer sheet material and film substrate to create container receiving
openings and to define a film sleeve and a retainer sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and objects of this invention will be
better understood from the following detailed description taken in conjunction
with the drawings wherein:
FIG. 1 is a top view of a carrier for holding a plurality of containers according
to one preferred embodiment of this invention;
FIG. 2 is a top view of a carrier for holding a plurality of containers according
to another preferred embodiment of this invention;
FIG. 3 is a perspective view of a package of containers, using a carrier similar
to the carrier shown in FIG. 2, according to one preferred embodiment of this invention;
FIG. 4 is a top view of a carrier for holding a plurality of containers according
to another preferred embodiment of this invention;
FIG. 5 is a perspective view of a package of containers, using a carrier similar
to the carrier shown in FIG. 4, according to one preferred embodiment of this invention;
FIG. 6 is a schematic of a method for making a carrier for holding a plurality
of containers according to one preferred embodiment of this invention;
FIG. 7 is a schematic of a method for making a carrier, similar to the carriers
shown in FIGS. 2 and 3, for holding a plurality of containers according to another
preferred embodiment of this invention;
FIG. 8 is a schematic of a method for making a carrier for holding a plurality
of containers according to yet another preferred embodiment of this invention;
FIG. 9 is a schematic of a method for making a carrier for holding a plurality
of containers according to yet another preferred embodiment of this invention;
FIG. 10 is a schematic of a method for making a carrier for holding a plurality
of containers according to yet another preferred embodiment of this invention; and
FIG. 11 is a perspective view of a package of containers according to one preferred
embodiment of this invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1-11 show carriers
10 for carrying a plurality of containers
5.
Containers
5 as shown in FIGS. 3 and 4 are preferably cans. Although cans
are shown in FIGS. 3 and 4, bottles or any other commonly unitized container
5
may be used with carrier
10 according to this invention. Containers
5
are preferably like-sized within a single carrier
10.
Carrier
10 unitizes a plurality of containers
5 to create package
1, such as package
1 shown in FIGS. 3 and 5. Carrier
10 is
preferably a single-piece device comprising retainer sheet
15 integrated
with film sleeve
30, each preferably constructed from a flexible, resilient
material such as plastic. For the purposes of this specification and claims, a
sleeve is defined as a tubelike component capable of fitting over or around a plurality
of containers
5.
In one preferred embodiment of this invention, retainer sheet
15 is made
from low density polyethylene. In other embodiments, a higher density polyethylene
is preferable having a different thickness. Retainer sheet
15 preferably
has a first thickness, such as between 0.008-0.020", possibly thinner than the
thickness of traditional plastic ring carriers. As discussed in additional detail
below, retainer sheet
15 is preferably cut, using means known to those skilled
in the art such as a stamping die, to form a plurality of container receiving openings
20 in retainer sheet
15. Two or more container receiving openings
20 are formed in retainer sheet
15 in longitudinal rows and one or
more transverse ranks. In one preferred embodiment of this invention shown in FIGS.
2-5, container receiving openings
20 are configured in two rows of three
ranks. Retainer sheet
15 may include other configurations of container receiving
openings
20 depending on the size of package
1 desired.
Retainer sheet
15 is integrated with film sleeve
30 to form
a single-piece carrier
10, as described in detail below. According to one
preferred embodiment of this invention, film sleeve
30 has a second thickness
that is thinner than the first thickness of retainer sheet
15, such as 0.004"
to 0.006". The total thickness of retainer sheet
15 may range between approximately
0.008-0.026" according to one preferred embodiment of this invention. Film sleeve
30 may exhibit different elasticity and different rigidity than retainer
sheet
15. Film sleeve
30 may comprise a stretchable low density polyethylene
(LDPE) film or similar material known to those having ordinary skill in the art.
In one preferred embodiment of this invention, shown in FIGS. 6,
8,
9
and
10, handle
50 is integrated within retainer sheet
15.
Handle
50 preferably has a same or similar thickness as retainer sheet
15.
In one preferred embodiment of this invention, shown in FIGS. 6 and 8, handle
50
is integrated between longitudinal rows of container receiving openings
20.
Alternatively, package
1 may be carried using bands
55 formed between
container receiving openings
20 as shown in FIGS. 3 and 5.
Film sleeve
30 is preferably integrated with retainer sheet
15
along longitudinal sides
17 of retainer sheet
15. In one preferred
embodiment of this invention, film sleeve
30 is not connected along two
lateral edges
18 of retainer sheet
15. Film sleeve
30 is preferably
printed with, on one or both sides, UPC and proof of purchase labels, graphics,
and promotional and/or other information related to contents and/or ingredients
of package
1. Film sleeve
30 may additionally be at least partially
transparent to effectively display the nature of containers
5. Therefore,
film sleeve
30 serves the dual purposes of retaining containers
5
within a tightly assembled package
1 and advertising marketable features
of the containers
5 and/or package
1.
In one preferred embodiment of this invention shown in FIG. 2, film sleeve
30
is open along lower edge
33 of carrier
10. As shown in FIG. 1, lower
edge
33 of carrier
10 may further include bottom
35 of film
sleeve
30. Each side edge
37 of film sleeve
30 is preferably
bound with seal
40. Therefore, film sleeve
30 extends from openable
lower edge
33 of carrier to seals
40 on either side edge
37
of film sleeve to retainer sheet
15 at a top portion of carrier
10.
As shown in FIGS. 1 and 2, carrier
10 is preferably generally symmetrical
around fold lines
25. As discussed in detail below, carrier
10 is
manufactured so that retainer sheet
15 and film sleeve
30 are each
preferably symmetrical around fold lines
25.
Carrier
10 is applied to a plurality of containers
5 to form
package
1, shown in FIGS. 3 and 5. Containers
5 are inserted within
carrier
10 which bounds containers
5 around between five and six
sides of package
1. Each container receiving opening
20 preferably
engages container
5, preferably around chime
7 or similar upper portion
of container
5. The rigidity and elasticity of retainer sheet
15
supports container
5 within container receiving opening
20. A top
portion of package
1 is therefore at least partially covered by retainer
sheet
15.
As shown in FIGS. 3 and 5, film sleeve
30 is positioned around the plurality
of containers
5. Preferably, film sleeve
30 is stretchingly engaged
with containers
5 and the combination of container receiving openings
20
and sleeve
30 prevents skewing or lateral movement of containers
5
with respect to each other. In one preferred embodiment of this invention, shown
in FIGS. 2 and 3, film sleeve
30 covers at least a portion of four horizontal
sides of package
1.
Containers
5 are positioned within package
1 so that film
sleeve
30 is flat and tight with respect to containers
5 and prominent
with respect to package
1. Film sleeve
30 is preferably sized to
stretch when slid over a plurality of containers
5. Such a configuration
of film sleeve
30 results in package
1 having a prominent display
area or "billboard" for advertising, information, graphics and other marketing material.
In another preferred embodiment of this invention, shown in FIGS. 1,
4
and
5, film sleeve
30 covers at least a portion of a bottom of package
1. Film sleeve
30 preferably covers at least a portion of the bottom
of package
1 when one or more containers
5 are not engaged with container
receiving openings
20. For instance, carrier
10 shown in FIG. 1 requires
bottom
35 because retainer sheet
15 includes only two container receiving
openings
20 in carrier
10 that holds more than two containers
5.
Carrier
10 shown in FIG. 5 also requires bottom
35 because, of the
twelve containers
5 in package
10, the lower six containers
5′
in package
1 are not supported around chime
7 by retainer sheet
15.
Therefore, bottom
35 provides support for those containers
5 not
supported within container receiving openings
20.
As shown in FIGS. 3-5, package
1 may additionally contain pull tab
45
and/or line of perforation
47 positioned within film sleeve
30. Using
an arrangement such as shown in FIGS. 3-5, package
1 may be opened by pulling
pull tab
45 across longitudinal side
17 of package
1 thereby
tearing line of perforation
47 to access containers
5.
A package according to FIGS. 4 and 5 will have the novel characteristic of having
an upper level of containers
5 removable from a lower level of container
5′ while keeping the upper level of containers
5 integrated
as a sub-package and permitting the lower level of containers
5′
to be freely removable for individual consumption or storage.
According to one preferred embodiment of this invention, perforated removal
strip
49 facilitates the efficient removal of the upper level of containers
5 and retainer sheet
15 from the lower level of containers
5
and sleeve
30. Perforated removal strip
49 is designed so a single
pulling action of tab
45 circumferentially around package
1 will
disassociate retainer sheet
15 and upper level of containers
5′
from sleeve
30. Tabs
45 at an end panel of package
1 permit
such single pulling action removal from either side of package
1. FIG. 6
shows carrier
10 according to this preferred embodiment, which is contemplated
to be manufactured similar to FIG. 7, described below.
FIGS. 6-10 show methods for manufacturing carrier
10 according to three
preferred methods of this invention. The methods shown in FIGS. 6-10 demonstrate
from right to left the assembly of various components of carrier
10, each
step in the method designated by a letter of the alphabet. Each step of each method
of manufacture includes two carriers
10 to demonstrate a representative
segment of carriers
10 that are typically formed in a generally continuous length.
FIG. 6 shows a method for manufacturing carrier
10 according to one preferred
embodiment of this invention. In step [A] film substrate
28 is printed with
desired graphics and other merchandising information. In step [B] retainer sheet
material
13 is joined to film substrate
28 by glueing or otherwise
attaching retainer sheet material
13 to film substrate
28. In step
[C] retainer sheet material
13 and film substrate
28 are folded along
fold line
25 to create a symmetrical double layer. In step [D] seams
40
are added by heat sealing or laminating the symmetrical double layer of retainer
sheet material
13 and film substrate
28 together. In step [E] carrier
10 is formed by cutting, such as in a punch press, the double layer of retainer
sheet material
13 and film substrate
28 to define film sleeve
30
and retainer sheet
15. Step [F] (not shown) preferably comprises accumulating
the continuous strip of carriers
10 by fan folding or rolling about a core.
Carriers
10 according to this invention, regardless of the method of manufacture,
are not conducive to winding on reels because of the variable thickness between
film sleeve
30 and retainer sheet
15.
FIG. 7 shows a method for manufacturing carrier
10 according to another
preferred embodiment of this invention. In step [A] film substrate
28 is
printed with desired graphics and other merchandising information. In step [B]
retainer sheet material
13 is joined to film substrate
28 by extrusion
coating, laminating, profile extrusion, or glueing retainer sheet material
13
to film substrate
28. In step [C] retainer sheet material
13 and
film substrate
28 are folded along fold line
25 to create a symmetrical
double layer and seams
40 are added by heat sealing or laminating the symmetrical
double layer of retainer sheet material
13 and film substrate
28
together. In step [D] carrier
10 is formed by cutting, such as in a punch
press, the double layer of retainer sheet material
13 and film substrate
28 to define film sleeve
30 and retainer sheet
15. Step [E]
(not shown) preferably comprises accumulating the continuous strip of carriers
10 by fan folding or rolling about a core.
FIG. 8 shows a method for manufacturing carrier
10 according to yet another
preferred embodiment of this invention. In step [A] film substrate
28 is
printed with desired graphics and other merchandising information. In step [B]
retainer sheet material
13 is joined to film substrate
28 by extrusion
coating or laminating retainer sheet material
13 to film substrate
28.
In step [C] two identical sheets of retainer sheet material
13 and film
substrate
28 are laminated together along lamination lines
42. Step
[C] requires careful registration to align two identical portions of joined retainer
sheet material
13 and film substrate
28 prior to lamination. In step
[D] seams
40 are added by heat sealing or laminating the two identical sheets
of retainer sheet material
13 and film substrate
28 together. In
step [E] carrier
10 is formed by cutting, such as in a punch press, the
two sheets of retainer sheet material
13 and film substrate
28 to
define film sleeve
30 and retainer sheet
15. Step [F] (not shown)
preferably comprises accumulating the continuous strip of carriers
10 by
fan folding or rolling about a core.
Another method for manufacturing carrier
10 for carrying a plurality
of containers is shown in FIG.
9. As shown in step [A], film sleeve material
32 is preprinted with appropriate graphics and/or product information. Step
[B] shows retainer sheet material
13 provided for incorporation with film
sleeve material
32. Retainer sheet material
13 is either folded and/or
comprises a pair of sheets laid on top of each other and then may be laminated
and/or sealed prior to incorporation with film sleeve material
32. Step
[C] shows retainer sheet material
13 folded over and connected with respect
to film sleeve material
32, such as with a heat seal
41, preferably
near a periphery of two opposed edges
60 of retainer sheet material
32.
As a result of the above-described steps, retainer sheet material
13 and
film sleeve material
32 maybe manufactured, printed and shipped separately,
i.e. on separate rolls or coils, prior to completion of final carrier
10.
As further shown in steps [C] and [D] of FIG. 9, retainer sheet material
13
is further attached with respect to film sleeve material
32 along a pair
of opposed edges
60 along an open end
62 of the folded retainer sheet
material
13 and a pair of opposed edges
70 along an open end
72
of the folded film sleeve material
32 to form carrier blank
80. According
to a preferred embodiment of this invention, carrier
10 is preferably symmetrically
formed about at least one fold line
25. Pair of opposed edges
60
of retainer sheet material
13 may be sealed, joined, bonded, adhered or
any other attachment method known to those having ordinary skill in the art, to
pair of opposed edges
70 of film sleeve material. Step [D] additionally
shows the attachment of side edges
37 with respect to each other with welds
and/or heat seals.
In steps [E] and [F], additional features of carrier
10 are formed including
perforations defining removal strip
49 and the plurality of container receiving
openings
20 to complete carrier
10. Step [F] also may require cutting
lower fold line
25 so as to create open end
33 in carrier
10.
As a result, carrier
10 includes an open end
33 sufficiently large
to allow film sleeve
30 to be slid over at least a pair of containers
5.
Another method for manufacturing carrier
10 for carrying a plurality
of containers is shown in FIG.
10. As shown in step [A] film sleeve material
32 is preprinted with appropriate graphics and/or product information. Step
[B] shows film sleeve material
32 cut into two discrete sections. Alternatively,
this method may start with step [B] wherein two separate sheets and/or coils of
film sleeve material
32 are provided for incorporation into carrier
10.
Step [C] shows retainer sheet material
13 provided for incorporation with
film sleeve material
32. Retainer sheet material
13 is either folded
and/or comprises a pair of sheets laid on top of each other and then may be laminated
and/or sealed prior to incorporation with film sleeve material
32. Step
[D] shows retainer sheet material
13 connected with respect to the two discrete
sections of film sleeve material
32 along two sides of retainer sheet material
13, such as with seals
41, thereby forming one or more carrier blanks
80. Like the method shown in FIG. 9, this method permits retainer sheet
material
13 and film sleeve material
32 to be manufactured, printed
and shipped separately, i.e. on separate rolls, prior to completion of final carrier
10.
As further shown in step [E] of FIG. 10, according to a preferred embodiment
of
this invention, carrier blank
80 is preferably symmetrically formed about
at least one fold line
25 or comprises two or more sheets welded and/or
laminated with respect to each other. Step [F] additionally shows the placement
of laminations or longitudinal seals
42 to create a spine for retainer sheet
15. Steps [G], [H] and [I] further show the attachment of sealed side edges
37 with respect to each other with welds and/or heat seals as well as additional
features of carrier
10 including perforations defining removal strip
49
and the plurality of container receiving openings
20 to complete carrier
10. As shown in step [H], tear or removal strip
49 is positioned
below seal
41. According to one preferred embodiment of this invention,
handle
50 is also formed in carrier
10.
As described in the various embodiments of this invention, retainer sheet material
13 and/or retainer sheet
15 may have a first thickness and film sleeve
material
32 and/or film sleeve
30 may have a second thickness thinner
than the first thickness. Alternatively, the first thickness and the second thickness
maybe the same. Finally, regardless of the relative thicknesses, retainer sheet
material
13 and film sleeve material
32 may have different rigidities
and/or elasticities.
Also as described in the various embodiments of this invention, retainer sheet
material
13, retainer sheet
15, film sleeve material
32 and/or
film sleeve
30 may be shipped on a single coil of material, on separate
coils between retainer sheet material
13 and film sleeve material
32
or each on multiple coils for incorporation into carrier
10.
According to one preferred embodiment of this invention shown in FIG. 11,
package
101 is assembled for carrying a plurality of containers
5
in an upper level and a plurality of containers
5′ in a lower level.
Package
101 is assembled with a carrier
110 including retainer sheet
portion
115 having a plurality of container receiving openings
120
for stretchingly engaging the plurality of containers
5 and a stretchable
carrier sleeve portion
130 integrated with at least two side edges of retainer
sheet portion
115. The stretchable material may be the same or different
for each of carrier sleeve portion
130 and retainer sheet portion
115.
Container receiving openings
120 are preferably engaged with a plurality
of containers
5 arranged in the upper level wherein each container receiving
opening
120 is engaged with a container
5 in the upper level. A lower
level of containers
5′ is additionally positioned below the upper
level and within stretchable carrier sleeve portion
130. Additionally, divider
160 is positioned between the upper level of containers
5 and the
lower level of containers
5′ within package
101.
During manufacture as described above, seam
140 may be formed to
5
join carrier sleeve portion
130 and retainer sheet portion
115. According
to one preferred embodiment of this invention, seam
140 is positioned along
an overlapping area between carrier sleeve portion
130 and retainer sheet
portion
115. Seam
140 preferably extends longitudinally along each
side of package
101. Seam
140 may be added in a manner similar to
the method described above and shown in FIG. 10 by heat sealing, laminating or
otherwise attaching carrier sleeve portion
130 and retainer sheet portion
115 to each other. Additionally, cutouts
170 may be formed in each
transverse end of carrier
110 to facilitate sealing carrier sleeve portion
130 to retainer sheet portion
115, thereby preventing seam
140
from extending entirely around the perimeter of package
101.
Package
101 may be separated into a separately portable upper level
of containers
5 and lower level of containers
5′. To facilitate
such separation, package
101 may further comprise pull tab
145 positioned
in carrier sleeve portion
130. Pull tab
145 preferably connects tear
strip
149 extending around at least a portion of the perimeter of package
101. Tear strip
149 may be formed on each side of seam
140
extending between carrier sleeve portion
130 and retainer sheet portion
115. As such, tear strip
149 may be positioned in carrier sleeve
portion
130 for disassociating containers
5 in the upper level from
package
101 from containers
5′ in the lower level of package
101. Because carrier sleeve portion
130 preferably surrounds each
side and a bottom of the lower level of containers
5′, the remaining
package, essentially a group of loose containers in a bag-like carrier formed by
at least a portion of carrier sleeve portion
130, may be separately portable
following disassociation of the upper level of containers
5.
According to one preferred embodiment of this invention, divider
160
comprises a paperboard sheet having a footprint approximately corresponding with
a footprint of package
101. As such, divider
160 preferably extends
inside of carrier sleeve portion
130 and entirely between the upper level
of containers
5 and the lower level of containers
5′. Accordingly,
divider
160 prevents metal to metal contact between the upper level of containers
5 and the lower level of containers
5′ thereby preventing
can abrasion and unwanted nesting between containers in the upper and lower levels.
In addition, divider
160 may include marketing and promotional information,
including game pieces, coupons, instructions and similar space for product-related
promotions and descriptions.
As in the embodiments described above, a handle may be integrated with retainer
sheet portion
115 and extend over a top of package
101. The handle
may be formed from a double layer of retainer sheet portion
115. As shown
in FIG. 11, the handle may comprise finger loops
155 for grasping package
101.
While in the foregoing specification this invention has been described in relation
to certain preferred embodiments thereof, and many details have been set forth
for purpose of illustration, it will be apparent to those skilled in the art that
the carrier and package are susceptible to additional embodiments and that certain
of the details described herein can be varied considerably without departing from
the basic principles of the invention.
*
