Carton, blank, and method of folding

Abstract

A carton defines a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls. The carton is formed from a blank having a first side and a second side disposed opposite said first side. The first side defines the interior surface of the bottom wall and the interior and exterior surfaces of the first and second side walls and the first and second end walls.

What is claimed is: 
     
         1 . A carton for containing a plurality of articles, the carton comprising:
 a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and the first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls;   wherein each of the bottom wall, the first and second side walls, and the first and second end walls define both an interior surface disposed adjacent an interior space defined by the carton and an exterior surface;   wherein the carton is formed from a blank comprising a first surface and a second surface disposed opposed opposite to the first surface;   wherein the interior surface of the bottom wall, and the interior and exterior surfaces of the first and second side walls and first and second end walls are each defined substantially entirely by the first surface; and   wherein the first side wall, second side wall, first end wall, and second end wall define an upper edge opposite the bottom wall, wherein the upper edge defines rectangular portions that follow a rectangle, and wherein the upper edge defines at least one edge portion that is oblique relative to rectangular portions.   
     
     
         2 . The carton as recited in  claim 1 , wherein the blank comprises a plurality of main panels hinged together in a linear series, the plurality of main panels comprising first and second inner side panels, first and second outer side panels, and a bottom panel;
 wherein the first outer side panel is hingedly connected to the first inner side panel, the first inner side panel is hingedly connected to the bottom panel, the bottom panel is hingedly connected to the second inner side panel, and the second inner side panel is hingedly connected to the second outer side panel;   wherein the first outer side panel defines the exterior surface of the first side wall, the first inner side panel defines the interior surface of the first side wall, the bottom panel defines the exterior and interior surfaces of the bottom wall, the second inner side panel defines the interior surface of the second side wall, and the second outer side panel defines the exterior surface of the second side wall; and   wherein the blank further comprises first and second end panels hingedly connected to the bottom panel at respective opposite ends of the bottom panel, wherein the first end panel defines the interior surface of the first end wall and wherein the second end panel defines the interior surface of the second end wall.   
     
     
         3 . The carton as recited in  claim 2 , wherein the blank further comprises first and second inner end flaps hingedly connected to the first inner side panel at respective opposite ends of the first inner side panel;
 wherein the blank further comprises third and fourth inner end flaps hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel;   wherein the blank further comprises first and second outer end flaps hingedly connected to the first outer side panel at respective opposite ends of the first outer side panel; and   wherein the blank further comprises third and fourth outer end flaps hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel.   
     
     
         4 . The carton as recited in  claim 3 , wherein the first and third outer end flaps define the exterior surface of the first end wall along a first perimeter length of the upper edge; and
 wherein the first end panel is adjacent the first and third inner end flaps and defines a second length along the upper edge that is greater than the first length so that the first end panel bows inward to define the at least one edge portion that is oblique relative to rectangular portions.   
     
     
         5 . The carton as recited in  claim 3 , wherein the first inner end flap is connected to the first inner side panel by first oblique corner panel; and
 wherein the third inner end flap is connected to the second inner side panel through a second oblique corner panel, wherein the first and second oblique corner panels define the at least one edge portion that is oblique relative to the rectangular portions.   
     
     
         6 . The carton as recited in  claim 5 , wherein the first outer end flap is foldably connected directly to the first outer side panel by a fold line without an intervening oblique corner panel, wherein the first oblique corner panel, first outer side panel, and first outer end flap surround a first triangular corner pocket; and
 wherein the third outer end flap is connected directly to the second outer side panel by a fold line without an intervening corner panel, wherein the second oblique corner panel, the second outer side panel, and the third outer end flap surround a second triangular corner pocket.   
     
     
         7 . The carton as recited in  claim 6 , wherein the first and second triangular corner pockets form a first pair of pockets at a first end of the interior space; and
 wherein the interior space has a second end opposite the first end, wherein the second end includes a second pair of pockets mirroring the first pair of pockets.   
     
     
         8 . The carton as recited in  claim 5 ,
 wherein the first outer end flap is connected to the first outer side panel by a third oblique corner panel that overlies the first oblique corner panel and forms a portion of the exterior surface; and   wherein the third outer end flap is connected to the second outer side panel by a fourth oblique corner panel that overlies the second oblique corner panel and forms a portion of the exterior surface.   
     
     
         9 . The carton as recited in  claim 8 , wherein the first, second, third, and forth oblique corner panels form a first pair of oblique corners of the interior and exterior surfaces at a first end of the interior space; and
 wherein the interior space has a second end opposite the first end which includes a second pair of oblique corners mirroring the first pair of oblique corners.   
     
     
         10 . A blank for forming a carton, the blank comprising:
 a first surface;   a second surface disposed opposite to the first surface, and a plurality of panels and flaps, the plurality of panels and flaps configured to form a set-up carton defining a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and the first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls;   wherein each of the bottom wall, the first and second side walls, and the first and second end walls define both an interior surface disposed adjacent an interior space defined by the set-up carton and an exterior surface;   wherein the interior surface of the bottom wall, and the interior and exterior surfaces of the first and second side walls and first and second end walls are each defined substantially entirely by the first surface; and   wherein the first side wall, second side wall, first end wall, and second end wall define an upper edge opposite the bottom wall, wherein the upper edge defines rectangular portions that follow a rectangle, and wherein the upper edge defines at least one edge portion that is oblique relative to rectangular portions.   
     
     
         11 . The blank as recited in  claim 10 , wherein the blank comprises a plurality of main panels hinged together in a linear series, the plurality of main panels comprising first and second inner side panels, first and second outer side panels, and a bottom panel;
 wherein the first outer side panel is hingedly connected to the first inner side panel, the first inner side panel is hingedly connected to the bottom panel, the bottom panel is hingedly connected to the second inner side panel, and the second inner side panel is hingedly connected to the second outer side panel;   wherein the first outer side panel defines the exterior surface of the first side wall, the first inner side panel defines the interior surface of the first side wall, the bottom panel defines the exterior and interior surfaces of the bottom wall, the second inner side panel defines the interior surface of the second side wall, and the second outer side panel defines the exterior surface of the second side wall; and   wherein the blank further comprises first and second end panels hingedly connected to the bottom panel at respective opposite ends of the bottom panel, wherein the first end panel defines the interior surface of the first end wall and wherein the second end panel defines the interior surface of the second end wall.   
     
     
         12 . The blank as recited in  claim 11 , wherein the blank further comprises first and second inner end flaps hingedly connected to the first inner side panel at respective opposite ends of the first inner side panel;
 wherein the blank further comprises third and fourth inner end flaps hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel;   wherein the blank further comprises first and second outer end flaps hingedly connected to the first outer side panel at respective opposite ends of the first outer side panel; and   wherein the blank further comprises third and fourth outer end flaps hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel.   
     
     
         13 . The blank as recited in  claim 12 , wherein the first and third outer end flaps define the exterior surface of the first end wall along a first perimeter length of the upper edge; and
 wherein the first end panel is adjacent the first and third inner end flaps and defines a second length along the upper edge that is greater than the first length so that the first end panel bows inward to define the at least one edge portion that is oblique relative to rectangular portions.   
     
     
         14 . The blank as recited in  claim 12 , wherein the first inner end flap is connected to the first inner side panel by first oblique corner panel; and
 wherein the third inner end flap is connected to the second inner side panel through a second oblique corner panel, wherein the first and second oblique corner panels define the at least one edge portion that is oblique relative to the rectangular portions.   
     
     
         15 . The blank as recited in  claim 14 , wherein the first outer end flap is foldably connected directly to the first outer side panel by a fold line without an intervening oblique corner panel, wherein the first oblique corner panel, first outer side panel, and first outer end flap surround a first triangular corner pocket; and
 wherein the third outer end flap is connected directly to the second outer side panel by a fold line without an intervening corner panel, wherein the second oblique corner panel, the second outer side panel, and the third outer end flap surround a second triangular corner pocket.   
     
     
         16 . The blank as recited in  claim 15 , wherein the first and second triangular corner pockets form a first pair of pockets at a first end of the interior space; and
 wherein the interior space has a second end opposite the first end, wherein the second end includes a second pair of pockets mirroring the first pair of pockets.   
     
     
         17 . The blank as recited in  claim 14 ,
 wherein the first outer end flap is connected to the first inner side panel by a third oblique corner panel that overlies the first oblique corner panel and forms a portion of the exterior surface; and   wherein the third inner end flap is connected to the second inner side panel by a fourth oblique corner panel that overlies the second oblique corner panel and forms a portion of the exterior surface.   
     
     
         18 . The blank as recited in  claim 17 , wherein the first, second, third, and forth oblique corner panels form a first pair of oblique corners of the interior and exterior surfaces at a first end of the interior space; and
 wherein the interior space has a second end opposite the first end which includes a second pair of oblique corners mirroring the first pair of oblique corners.   
     
     
         19 . A method of forming a carton comprising:
 providing a blank having a first blank side and a second blank side disposed opposite the first blank side, the blank comprising a plurality of main panels hinged together in a linear series, the plurality of main panels comprising a bottom panel, first and second inner side panels, and first and second outer side panels, wherein the first outer side panel is hingedly connected to the first inner side panel, the first inner side panel is hingedly connected to the bottom panel, the bottom panel is hingedly connected to the second inner side panel, and the second inner side panel is hingedly connected to the second outer side panel, the blank further comprising first and second end panels, first, second, third, and fourth inner end flaps, and first, second, third, and fourth outer end flaps, wherein the first and second end panels are hingedly connected to the bottom panel at respective opposite ends of the bottom panel, the first and second outer end flaps are hingedly connected to the first outer side panel at respective opposite ends of the first outer side panel, the third and fourth outer end flaps are hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel, the first and second inner end flaps are hingedly connected to the first inner side panel at respective opposite ends of the first inner side panel, and the third and fourth inner end flaps are hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel;   folding the first outer side panel back onto the first inner side panel and securing it thereto such that second blank side surfaces of the first outer side panel and the first inner side panel are coupled together in a face-contacting relationship;   folding the second outer side panel back onto the first inner side panel and securing it thereto such that second blank side surfaces of the second outer side panel and the second inner side panel are coupled together in a face-contacting relationship;   folding the first outer side panel and the first inner side panel about the bottom panel so as to form a first side wall of the carton, an exterior surface of the first side wall being defined by a first blank side surface of the first outer side panel and an interior surface of the first side wall being defined by a first blank side surface of the first inner side panel, a first blank side surface of the bottom panel defining an interior surface of a bottom wall of the carton;   folding the second outer side panel and the second inner side panel about the bottom panel so as to form a second side wall of the carton, an exterior surface of the second side wall being defined by a first blank side surface of the second outer side panel and an interior surface of the second side wall being defined by a first blank side surface of the second inner side panel;   folding the first and second end panels about the bottom panel to form respective first and second end walls of the carton, a first blank side surface of the first end panel defining an interior surface of the first end wall, a first blank side surface of the second end panel defining an interior surface of the second end wall; and   folding the first and third inner end flaps and the first and third outer end flaps into an overlapping arrangement with a second blank side of the first end panel and securing them thereto, a first blank side surface of the first and third outer end flaps defining an exterior surface of the first end wall;   folding the second and fourth inner end flaps and the second and fourth outer end flaps into an overlapping arrangement with a second blank side of the second end panel and securing them thereto, a first blank side surface of the second and fourth outer end flaps defining an exterior surface of the second end wall,   wherein the first side wall, second side wall, first end wall, and second end wall define an upper edge opposite the bottom wall, wherein the upper edge defines rectangular portions that follow a rectangle, and wherein the upper edge defines at least one edge portion that is oblique relative to rectangular portions.   
     
     
         20 . The method as recited in  claim 19 , wherein folding the first, second, third, and fourth inner end flaps and folding the first, second, third, and forth outer end flaps includes bowing the first end panel inward to define the at least one edge portion that is oblique relative to the rectangular portions. 
     
     
         21 . The method as recited in  claim 19 , wherein folding the first, second, third, and fourth inner end flaps and folding the first, second, third, and forth outer end flaps includes forming a first triangular corner pocket wherein the first oblique corner panel, first outer side panel, and first outer end flap surround a first triangular corner pocket; and
 forming a second triangular pocket wherein the second oblique corner panel, the second outer side panel, and the third outer end flap surround a second triangular corner pocket.   
     
     
         22 . The method as recited in  claim 19 ,
 wherein folding the first, second, third, and fourth inner end flaps and folding the first, second, third, and forth outer end flaps includes folding the first outer end flap, wherein the first outer end flap is connected to the first outer side panel by a third oblique corner panel that overlies a first oblique corner panel and forms a portion of the exterior surface; and   folding the third outer end flap wherein the third outer end flap is connected to the second outer side panel by a fourth oblique corner panel that overlies a second oblique corner panel and forms a portion of the exterior surface.