U.S. patent application number 11/036620 was filed with the patent office on 2005-08-25 for carton blank and method of forming a carton blank.
Invention is credited to Walsh, Joseph.
Application Number | 20050187087 11/036620 |
Document ID | / |
Family ID | 27556323 |
Filed Date | 2005-08-25 |
United States Patent
Application |
20050187087 |
Kind Code |
A1 |
Walsh, Joseph |
August 25, 2005 |
Carton blank and method of forming a carton blank
Abstract
A carton blank may be formed from a first sheet of relatively
rigid material and a second sheet of relatively flexible fluid
impervious material. The second sheet of relatively flexible fluid
impervious material may cover some but not other portions of the
first sheet of relatively rigid material in order to facilitate
gluing of the other portions of the first sheet of relatively rigid
material when the carton blank is assembled into a carton.
Inventors: |
Walsh, Joseph; (Longmont,
CO) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
P.O. BOX 7037
ATLANTA
GA
30357-0037
US
|
Family ID: |
27556323 |
Appl. No.: |
11/036620 |
Filed: |
January 14, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11036620 |
Jan 14, 2005 |
|
|
|
09864567 |
May 24, 2001 |
|
|
|
6854639 |
|
|
|
|
09864567 |
May 24, 2001 |
|
|
|
09410677 |
Oct 1, 1999 |
|
|
|
6352096 |
|
|
|
|
09410677 |
Oct 1, 1999 |
|
|
|
09037284 |
Mar 6, 1998 |
|
|
|
09037284 |
Mar 6, 1998 |
|
|
|
08587495 |
Jan 17, 1996 |
|
|
|
5783030 |
|
|
|
|
08587495 |
Jan 17, 1996 |
|
|
|
08352526 |
Dec 9, 1994 |
|
|
|
08587495 |
Jan 17, 1996 |
|
|
|
08336982 |
Nov 14, 1994 |
|
|
|
08587495 |
Jan 17, 1996 |
|
|
|
08051628 |
Apr 22, 1993 |
|
|
|
08051628 |
Apr 22, 1993 |
|
|
|
07994132 |
Dec 21, 1992 |
|
|
|
Current U.S.
Class: |
493/96 ;
493/97 |
Current CPC
Class: |
B32B 37/12 20130101;
B32B 37/1292 20130101; B65D 5/563 20130101; Y10T 156/1049 20150115;
B31B 2105/001 20170801 |
Class at
Publication: |
493/096 ;
493/097 |
International
Class: |
B65H 001/08; B31B
007/00 |
Claims
1-24. (canceled)
25. A method of forming carton blanks, comprising: providing a
sheet of first material having a first surface and an oppositely
disposed second surface thereon, said first surface comprising a
first area and a second area; providing a sheet of second material
comprising a first portion and a second portion; causing said first
portion of said sheet of second material to overlie said first area
of said sheet of first material and said second portion of said
sheet of second material to overlie said second area of said sheet
of first material; adhering said first portion of said sheet of
second material to said first area of said sheet of first material;
and exposing said second area of said sheet of first material by
removing said second portion of said sheet of second material.
26. The method of claim 25, wherein said sheet of first material is
a unitary relatively rigid sheet of material.
27. The method of claim 25, wherein said sheet of first material
comprises paperboard
28. The method of claim 25, wherein said sheet of second material
is a sheet of plastic material.
29. The method of claim 28, wherein said sheet of plastic material
is non-compatible with a water based adhesive.
30. The method of claim 25, further comprising separating said
sheet of first material and said sheet of second material into
individual articles.
31. The method of claim 30, further comprising forming fold lines
in the article resulting from said separating in order to form said
blanks, wherein each blank comprises a plurality of side panels and
a closure panel.
32. The method of claim 31, wherein each blank comprises a
plurality of end panels, each end panel being foldably connected to
one of said side panels.
33. The method of claim 25, further comprising superposing
continuous strips of a third material over said sheet of first
material, wherein said strips of said third material are disposed
between said sheets of first and second material after said
adhering step.
34. The method of claim 33, wherein said strips of third material
comprise paper.
35. Carton blanks formed according to the method of claim 25.
36. A method of forming carton blanks, comprising: providing a
sheet of first material having a first surface and an oppositely
disposed second surface thereon, said first surface comprising a
first area and a second area; providing a sheet of second material
comprising a first portion and a second portion; adhering said
first portion of said sheet of second material to said first area
of said sheet of first material so that said sheet of second
material overlies said first area of said sheet of first material
and said second portion of said sheet of second material overlies
said second area of said sheet of first material; removing said
second portion of said sheet of second material; separating said
sheet of first material and said sheet of second material into
individual articles; and forming fold lines in the articles
resulting from said separating in order to form said blanks,
wherein each blank comprises a plurality of side panels.
37. The method of claim 36, wherein said sheet of first material is
a unitary relatively rigid sheet of material.
38. The method of claim 36, wherein said sheet of first material
comprises paperboard.
39. The method of claim 36, wherein said sheet of second material
is a sheet of plastic material.
40. The method of claim 39, wherein said sheet of plastic material
is non-compatible with a water based adhesive.
41. The method of claim 36, wherein each blank comprises a
plurality of end panels, each end panel being foldably connected to
one of said side panels.
42. The method of claim 36, further comprising superposing
continuous strips of a third material over said sheet of first
material, wherein said strips of said third material are disposed
between said sheets of first and second material after said
adhering step.
43. The method of claim 36, wherein said strips of third material
comprise paper.
44. Carton blanks formed according to the method of claim 36.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 09/410,677 filed Oct. 1, 1999, which is a
divisional of U.S. patent application Ser. No. 09/037,284 filed
Mar. 6, 1998 (now abandoned), which is a divisional of U.S. patent
application Ser. No. 08/587,495 filed Jan. 17, 1996 (now U.S. Pat.
No. 5,783,030), which is a continuation-in-part of U.S. patent
application Ser. No. 08/352,526 filed Dec. 9, 1994 (now abandoned),
and U.S. patent application Ser. No. 08/336,982 filed Nov. 14, 1994
(now abandoned), both applications being continuations-in-part of
U.S. patent application Ser. No. 08/051,628 filed Apr. 22, 1993
(now abandoned), which application is a continuation-in-part of
U.S. patent application Ser. No. 07/994,132 filed Dec. 21, 1992
(now abandoned), all of which are hereby specifically incorporated
by reference for all that is disclosed therein.
TECHNICAL FIELD
[0002] The disclosure herein is directed generally to carton blanks
and apparatus and method for forming the carton blanks.
BACKGROUND
[0003] There are many supposedly leakproof cartons on the market
today. These are formed using a variety of methods. Some of the
cartons are designed to hold granular materials while others are
designed to hold liquid materials. While some of these leakproof
cartons have been successful, there is always a need for
improvement.
BRIEF DESCRIPTION
[0004] In a preferred embodiment, a carton blank may include a
unitary sheet of a relatively rigid material having an inner
surface and an oppositely disposed outer surface. The unitary sheet
of a relatively rigid material may further include a plurality of
outer edges defining an outer periphery of the unitary sheet of a
relatively rigid material. The outer surface of the unitary sheet
of a relatively rigid material may have at least a first portion
and a second portion. The carton blank may further include a
unitary sheet of a relatively flexible fluid impervious material
covering the first portion of the outer surface of the unitary
sheet of a relatively rigid material. The second portion of the
outer surface of the unitary sheet of a relatively rigid material
may not be covered by the at least one unitary sheet of relatively
flexible fluid impervious material and no part of the unitary sheet
of a relatively flexible fluid impervious material may extend
beyond the outer periphery of the unitary sheet of a relatively
rigid material.
[0005] In another preferred embodiment, a carton blank may include
a sheet of material having an inner surface and an oppositely
disposed outer surface. The sheet of material may further have a
plurality of outer edges defining an outer periphery of the sheet
of material. The carton blank may further include a sheet of
plastic film covering a portion of the outer surface of the sheet
of material. The sheet of plastic film may cover less than the
entire extent of the outer surface of the sheet of material and no
part of the sheet of plastic film may extend beyond the outer
periphery of the sheet of material.
[0006] In another preferred embodiment, a carton blank may include
a first sheet of material comprising an inner surface and an
oppositely disposed outer surface. The first sheet of material may
have a plurality of outer edges defining an outer periphery of the
first sheet of material. The first sheet of material may have a
length defined between two of the outer edges of the first sheet of
material and a width defined by another two of the outer edges of
the first sheet of material, the width being perpendicular to the
length. The carton blank may further include a second sheet of
plastic material covering a portion of the outer surface of the
first sheet of material. The second sheet of plastic material may
have a plurality of outer edges defining an outer periphery of the
second sheet of plastic material and a length defined between two
of the outer edges of the second sheet of plastic material. The
second sheet of plastic material may have a width defined by
another two of the edges of the second sheet of plastic material,
the width of the second sheet of plastic material being
perpendicular to the length of the second sheet of plastic
material. The length of the first sheet of material may be equal to
the length of the second sheet of plastic material and the width of
the first sheet of material may be greater than the width of the
second sheet of plastic material.
[0007] In another preferred embodiment, a carton blank may be
formed by providing a sheet of first material having a first
surface and an oppositely disposed second surface thereon. The
first surface may include a first area and a second area. A sheet
of a second material may be provided having a first portion and a
second portion. The first portion of the sheet of second material
may be caused to overlie the first area of the sheet of first
material and the second portion of the sheet of second material to
overlie the second area of the sheet of first material. The first
portion of the sheet of second material may be adhered to the first
area of the sheet of first material. Thereafter, the second area of
the sheet of first material may be exposed by removing the second
portion of the sheet of second material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Illustrative and presently preferred embodiments are shown
in the accompanying drawings in which:
[0009] FIG. 1 is a top plan view of the inside portion of a carton
blank of a preferred embodiment;
[0010] FIG. 2 is a perspective view of the carton blank of FIG. 1
slightly enlarged and folded so that desired materials may be
placed therein;
[0011] FIG. 3 is a perspective view of one closure for a sheet of
relatively flexible material;
[0012] FIG. 4 is a perspective view of another closure for the
sheet of relatively flexible material;
[0013] FIG. 5 is a top plan view of a carton blank of another
preferred embodiment;
[0014] FIG. 6 is a top plan view of the carton blank of FIG. 5
after initial operations have been performed thereon;
[0015] FIG. 7 is a schematic illustration of a laminating
process;
[0016] FIG. 8 is a top plan view of a portion of a preferred
laminate formed using the apparatus of FIG. 7;
[0017] FIG. 9 is a cross-sectional view taken on the line 9-9 of
FIG. 8;
[0018] FIG. 10 is a top plan view of a carton blank formed from the
laminate of FIG. 8 as it moves through the formation of the cut and
fold lines for the top and bottom panels;
[0019] FIG. 11 is a cross-sectional view taken on the line 11-11 of
FIG. 10;
[0020] FIG. 12 is a top plan view of a portion of another preferred
laminate formed using the apparatus of FIG. 7;
[0021] FIG. 13 is a cross-sectional view taken on the line 13-13 of
FIG. 12;
[0022] FIG. 14 is a top plan view of a carton blank formed from the
laminate of FIG. 12 as it moves through the formation of the cut
and fold lines for the top and bottom panels;
[0023] FIG. 15 is a cross-sectional view taken on the line 15-15 of
FIG. 14;
[0024] FIG. 16 is a perspective view of another carton;
[0025] FIG. 17 is an end elevational view of FIG. 16;
[0026] FIG. 18 is a top plan view of a portion of another preferred
laminate being formed with the carton blanks to be formed therefrom
illustrated in dashed lines;
[0027] FIG. 19 is a cross-sectional view taken on the line 19-19 of
FIG. 18;
[0028] FIG. 20 is a top plan view of one of the carton blanks
illustrated in FIG. 18;
[0029] FIG. 21 is a cross-sectional view taken on the line 21-21 of
FIG. 20;
[0030] FIG. 22 is a schematic illustration of apparatus forming
another preferred embodiment;
[0031] FIG. 23 is a bottom plan view of FIG. 22;
[0032] FIG. 24 is a top plan view of a carton blank of another
preferred embodiment;
[0033] FIG. 25 is an end elevational view taken from the right side
of FIG. 24;
[0034] FIG. 26 is a schematic illustration of apparatus forming
another preferred embodiment;
[0035] FIGS. 27-29 illustrate various types of adhesive
patterns;
[0036] FIG. 30 is similar to FIG. 22 but includes the feeding of a
plurality of spaced apart, relatively narrow continuous strips of a
relatively flexible material;
[0037] FIG. 31 is similar to FIG. 26 but does not include the
feeding of a plurality of spaced apart continuous strips of a
relatively flexible material;
[0038] FIG. 32 is a partial top plan view of another preferred
embodiment;
[0039] FIG. 33 is an enlarged view of portion of FIG. 32;
[0040] FIG. 34 is a partial top plan view of another preferred
embodiment; and
[0041] FIG. 35 is a view similar to FIG. 34 after one folding
operation.
DETAILED DESCRIPTION
[0042] In FIG. 1, there is illustrated the inner surface of a
carton blank 2 of one preferred embodiment. The carton blank 2 has
a left side edge 4, a right side edge 6, a top edge 8 and a bottom
edge 10 with the left side and right side edges 4 and 6 being
perpendicular to the top and bottom edges 8 and 10. A plurality of
fold lines 12 divide the carton blank 2 into a back panel portion
14, a right side panel portion 16, a front panel portion 18, a left
side panel portion 20 and a glue tab panel portion 22. A plurality
of fold lines 24 and a plurality of cut lines 26 divide carton
blank 2 into a top back panel portion 28, top right side panel
portion 30, top front panel portion 32, and top left side panel
portion 34. A plurality of fold lines 36 and cut lines 38 divide
the carton blank 2 into bottom back panel portion 40, bottom right
side panel portion 42, bottom front panel portion 44 and bottom
left side panel portion 46. It is understood that the carton blank
illustrated in FIGS. 1, 5 and 6 is for illustration purposes only
and that the various concepts described herein can be used with
carton blanks of a variety of configurations.
[0043] A first sheet 50 of a relatively flexible fluid impervious
material having an upper edge 52 and a lower edge 54 overlies the
top back 28, top right side 30, top front 32 and top left side 34
panels portions and portions of the back 14, right side 16, front
18, left side 20 and glue tab 22 panels portions. A portion 56 of
the first sheet 50 of a relatively flexible material between the
fold lines 24 and the lower edge 54 and spaced a slight distance
from the fold lines 24 is secured to the underlying portions of the
back 14, right side 16, front 18, left side 20 and glue tab 22
panels portions so as to form a continuous seal extending from the
left side edge 4 to the right side edge 6.
[0044] A second sheet 60 of a relatively flexible fluid impervious
material having an upper edge 62 and a lower edge 64 overlies the
bottom back 40, bottom right side 42, bottom front 44 and bottom
left side 46 panels portions and portions of the back 14, right
side 16, front 18, left side 20 and glue tab 22 panels portions. A
portion 66 of the second sheet of a relatively flexible material
between the fold lines 36 and the upper edge 62 and spaced a slight
distance from the fold lines 36 is secured to the underlying
portions of the back 14, right side 16, front 18, left side 20 and
glue tab 22 panels portions so as to form a continuous seal
extending from the left side edge 4 to the right side edge 6.
[0045] The first 50 and second 60 sheets of a relatively flexible
material are preferably formed from a fluid impervious material,
such as a paper material coated with a plastic material such as
polyethylene such as that marketed by Eastman Kodak under the trade
designation 808 P having a thickness between about 0.75 and 1.0
mils or other types of material having similar characteristics. The
first 50 and second 60 sheets can be formed from a plastic
material, such as polypropylene, or other materials having similar
characteristics. The portions 56 and 66 are secured using adhesive
or welding or other conventional sealing practices. The carton
blank preferably comprises a unitary sheet of a composite laminate
of layers of materials. The inside layer preferably comprises a
paperboard material such as 0.021 inch DKL (recycled) or other
similar materials such as natural Kraft board. The outside layer
preferably comprises 0.75 mil polypropylene or other similar
materials such as low density polyethylene which may be back
printed to provide a desired appearance. Other thicknesses of the
paperboard and plastic materials may be used. The method of forming
the unitary sheet for forming the carton blank 2 is described in
U.S. Pat. No. 4,254,173 to Peer, Jr., which is hereby incorporated
herein by reference thereto. If the carton is to be used for
holding liquids the inside surface is coated with a suitable
material such a polyethylene or other materials having similar
characteristics. Also, a portion or the glue tab panel portion 22
is skived and hemmed in a conventional manner with the polyethylene
layer being folded over the exposed edge of the paperboard
material.
[0046] In FIG. 2, there is illustrated the outer surface 68 of a
partially formed carton 70 from the carton blank 2 and has an open
top end 72 so that it is ready for filling. The carton 70 is formed
by folding the glue tab panel portion 22 around a fold line 12,
then the left side panel portion 20 is folded around a fold line
12, the front panel portion is folded around a fold line 12, and
then the right side panel portion 16 is folded around a fold line
12 until the glue tab panel portion 22 overlies a portion of the
back panel portion 14. The glue tab panel portion 22 is then
secured to the portion of the back panel portion 14 using any
conventional sealing practice. At the same time, the portions 74 of
the first 50 and second 60 sheets of relatively flexible material
are secured to the portions 76 thereof. The second sheet 60 of
relatively flexible material is then secured together in a
conventional manner as described below. The bottom back panel
portion 40 is folded around a fold line 36, the bottom left side 46
and bottom right side 42 panels portions are folded around fold
lines 36 so that they are in superposed relationship to portions of
the bottom panel portion 40 and the bottom front panel portion 44
is folded around a fold line 36 to a superposed relationship. The
bottom panels portions 40, 42, 46 and 44 are then secured together
using any conventional sealing practice.
[0047] After the carton 70 has been filled, the carton is closed
and sealed using conventional practices such as those illustrated
in FIGS. 3 and 4. In FIG. 3, the portions 78 and 80 are secured
together, then folded over the line 82. The end flaps 84 and 86 are
then folded over to form a leakproof carton. The top panel portions
28, 30 and 32 and 34 are then folded and secured together in the
same manner as that described above in relation to the bottom
panels portions 40, 42 44 and 46.
[0048] In FIG. 4, a gable joint is used to seal the exposed
portions of the first sheet 50 of the relatively flexible material.
The portion of the first sheet 50 of a relatively flexible material
above the left side panel portion is folded inwardly and secured
together to form two end portions 88 and 90. The other end is
formed in the same manner. The central portions 92 are secured
together and they included the innermost portions of the end
portions 88 and 90 to form a leakproof carton.
[0049] In FIGS. 5 and 6, there is illustrated another preferred
embodiment. Since the carton 2 remains the same, it will be
identified with the same reference numerals and the description
remains the same.
[0050] A first sheet 94 of a relatively flexible fluid impervious
material having an upper edge 96 and a lower edge 98 overlies
portions of the back panel portion 14, right side panel portion 16,
front panel portion 18, left side panel portion 20 and glue tab
panel portion 22. A section 100 of the first sheet 94 of a
relatively flexible material is secure to these panels portions at
locations spaced a slight distance from the fold lines 24 by any
conventional practice to form a continuous seal extending between
the right side edge 4 to the left side edge 6.
[0051] A second sheet 102 of a relatively flexible fluid impervious
material having an upper edge 104 and a lower edge 106 overlies
other portions of the back panel portion 14, right side panel
portion 16, front panel portion 18, left side panel portion 20 and
glue tab panel portion 22. A section 108 of the first sheet 94 of a
relatively flexible material is secured to these panels portions at
locations spaced a slight distance from the fold lines 36 by any
conventional practice to form a continuous seal extending between
the right side edge 4 to the left side edge 6.
[0052] The first step in forming a carton from the carton blank 2
of FIG. 5 is illustrated in FIG. 6. The lower edge 98 of the first
sheet 94 of a relatively flexible material is moved toward the top
edge 8 until it is contiguous to the top edge 8 and portions of the
first sheet 94 of a relatively flexible material overlie the
section 100 and the top back panel portion 28, the top right side
panel portion 30, the top front panel portion 32 and the top left
side panel portion 34 and is creased along the line 110 to hold it
in place. The upper edge 104 of the second sheet 102 of a
relatively flexible material is moved toward the bottom edge 10
until it is contiguous to the bottom edge 10 and portions of the
second sheet 102 of a relatively flexible material overlie the
section 108 and the bottom back panel portion 40, the bottom right
side panel portion 42, the bottom front panel portion 44 and the
bottom left side panel portion 46 and is creased along the line 112
to hold it in place. A carton 70 is formed, filled and sealed as
described above in relation to FIGS. 1-4.
[0053] In FIG. 7, there is illustrated conventional laminating
apparatus 120 used for forming laminated products. The laminating
apparatus comprises a pair of rotating rolls 122 and 124 having a
nip portion 126. A continuous strip 128 of a relatively rigid
material, such as a paperboard described in U.S. Pat. No. 4,254,173
dated Mar. 31, 1981 and issued to Peer, Jr., which is incorporated
herein by reference thereto, or a conventional clay coated
paperboard having surface printing thereon is pulled from a roll
(not shown) of such material and fed into the nip portion. At the
same time, a plurality of relatively narrow continuous strips 130
of a relatively flexible material, such as a kraft paper, in spaced
apart relationship, are pulled from rolls (now shown) of such
material and fed into the nip portion 126 to be in spaced apart
superposed relationship on the continuous strip 128. A liquid
plastic material 132, such as polyethylene or other materials
having similar characteristics, or a conventional adhesive material
is sprayed into the nip portion 126 by a nozzle 134. A continuous
film 136 of a relatively flexible fluid impervious plastic
material, such as polypropylene or other materials having similar
characteristics, having oppositely facing surfaces 138 and 140 is
pulled from a roll (not shown) of such material and fed into the
nip portion 126 so that the surface 138 moves into contact with the
liquid plastic material 132. As the laminate passes through the nip
portion 126, the surface 138 is secured to the coated portions of
the continuous strips 130 of a relatively flexible material and the
coated portion of the continuous strip 128 of a relatively rigid
material. The middle continuous strip 130 has a width twice the
width of the end continuous strips 130 so that when forming the
carton blanks, described below, the middle continuous strip will be
cut in half. After the formation of the laminate described above,
the laminate is cut in half along the middle strip 130. Then, the
end continuous strips 130 and the portions of the continuous film
136 of a relatively flexible plastic material are folded back upon
themselves, as illustrated in FIGS. 10 and 11 and passed through a
conventional apparatus for forming cut lines and fold lines to
produce a carton blank illustrated in FIG. 10.
[0054] The carton blank 150 has a left side edge 152, a right side
edge 154, a top edge 156 and a bottom edge 158 with the left side
and right side edges 152 and 154 being perpendicular to the top and
bottom edges 156 and 158. A plurality of fold lines 160 divide the
carton blank 150 into a back panel portion 162, a left side panel
portion 164, a front panel portion 166, a right side panel portion
168 and a glue tab panel portion 170. A plurality of fold lines 172
and a plurality of cut lines 174 divide the carton blank 150 into a
top back panel portion 176, top left side panel portion 178, top
front panel portion 180, and top right side panel portion 182. A
plurality of fold lines 184 and cut lines 186 divide the carton
blank 150 into bottom back panel portion 188, bottom left side
panel portion 190, bottom front panel portion 192 and bottom right
side panel portion 194. It is understood that the carton blank
illustrated in FIGS. 10 and 11 is for illustration purposed only
and that the concepts disclosed herein can be used with carton
blanks of a variety of configurations.
[0055] The upper continuous strip 130 of FIG. 8 is folded over the
fold line 196 and the half of the middle continuous strip 130 has
been folded over the fold line 198. After the continuous strips 130
together with the portions of the film 136 secured thereto have
been folded over, the laminate is passed through a conventional
machine to form the cut and fold lines described above. Prior to
forming a carton from the carton blank 150, the upper continuous
strips 130 is folded back to overlie the top panel portions 176,
178, 180 and 182 and the portions 200, 202, 204 and 206 of the
sidewall panel portions 162, 164, 166 and 168 and the portion 208
of the glue panel portion 170 and the lower continuous strip 130 is
folded back to overlie the bottom panel portions 188, 190, 192 and
194 and the portions 210, 212, 214 and 216 of the sidewall panel
portions 162, 164, 166 and 168 and the portion 218 of the glue
panel portion 170. A carton is then formed and filled as described
above in relation to FIGS. 3 and 4. The inner surface of the carton
will be the film 136 of the relatively flexible plastic material to
form a leakproof carton.
[0056] The laminate illustrated in FIGS. 12 and 13 is formed using
the apparatus of FIG. 7 but does not include the continuous film
136 of a relatively flexible plastic material. A continuous strip
128 of a relatively rigid material, such as paperboard of the type
in the Peer, Jr. patent or a conventional clay-coated paperboard,
is fed into the nip 126 along with the plurality of continuous
strips 130 of a relatively flexible material, such as paper, and a
liquid plastic material, such as polyethylene, is fed into the nip
126 and as these materials pass through the nip 126 a continuous
coating 230 of the fluid impervious plastic material is formed over
the exposed surfaces of the continuous strip 128 and the continuous
strips 130. Also, the laminate is cut in half along the middle
continuous strip 130 and the continuous strips 130 are folded back
as illustrated in FIGS. 14 and 15 so that the cut and fold lines
may be made. The continuous strips 130 are folded back, as
described above, so that the cartons when formed as in FIGS. 3 and
4 will have a continuous inner surface of a plastic coating 230. In
some instances, it may be desirable to use a bead of adhesive to
secure an edge portion of each continuous strip 130 to a portion of
the continuous strip 128. This can be done when the continuous
strips 130 are being superposed over portions of the continuous
strip 128 prior to entering the nip 126.
[0057] In FIGS. 16 and 17, there is illustrated a carton 240 having
a plurality of sidewall panels 242, 244 and 246 and sealed together
end panels 248. As illustrated in FIGS. 16 and 17, the closure
panel 250 and the glue tab panel 252 are in an opened condition so
that packages 254 of cigarettes may be inserted therein. At the
manufacture's plant for making cigarettes, after the packages 254
have been inserted, the closure panel 250 is temporarily sealed to
the glue tab panel 252 and loaded into large boxes for shipment to
distributing centers. During shipment the seal between the closure
panel and the glue tab panel 252 breaks. This is done because at
the distributing centers, it is necessary to apply the state and/or
local tax stamps. After the tax stamps have been applied, the
closure panel 250 is then permanently sealed to the glue tab panel
252. Since there are so many distributing centers, it is common for
them to use conventional apparatus to apply a water base adhesive
to secure the closure panel 250 to the glue tab panel 252. When a
carton is formed from a composite material such as in the Peer, Jr.
patent, glue tab panel 252 has a plastic surface facing the
paperboard surface of the closure panel 250. Therefore, since a
water based adhesive is not compatible to the plastic surface, a
permanent seal cannot be made. Other surface materials may also
result in non-compatible surfaces.
[0058] In FIGS. 18 and 19, there is illustrated a laminate from
which a carton blank can be formed to have a desired reverse
printed plastic film as an outer surface and still have compatible
paperboard to paperboard surfaces on the closure panel 250 and the
glue tab panel 252. The laminate of FIGS. 18 and 19 is formed using
the apparatus in FIG. 7. A continuous strip 128 of a relatively
rigid material, such as paperboard is fed into the nip 126, and two
continuous strips 130 of a relatively flexible material, such as
paper, are superposed over portions of the continuous strip 128 so
that the liquid plastic material 132 contacts only the exposed
surfaces of the continuous strip 128 and the continuous strips 130.
A reverse printed plastic film, such as that illustrated in FIG. 7
as 136, is fed into the nip 126 from the other side so that it can
be coated by the liquid plastic material 132. After this, the
laminate is passed through apparatus, such as a vacuum roll, where
the continuous strips 130 with the portion of the plastic film 136
adhered thereto are pulled away from the laminate to leave a
portion 256 of the continuous strip 128 exposed. The lower
continuous strip 130 has a width that is one-half the width of the
upper continuous strip 130 When the carton blank 258 of FIGS. 20
and 21 is folded around the fold lines, the exposed paperboard
portion 256 will face the paperboard portion of the closure panel
250 so that a water based adhesive may be used to form a permanent
seal between these compatible surfaces. The carton blanks 258 are
illustrated in FIG. 18 only to show that the glue tab panel portion
252 extend in the machine direction.
[0059] The thickness of the various materials such as the
continuous strip 128, the plastic adhesive or coating 132 or 230,
the continuous strip 130 and the plastic film have been exaggerated
for illustration purposes. The continuous strip 128, the plastic
adhesive or coating 132 or 230 and the plastic film would be
similar to the corresponding materials in the Peer, Jr. patent. The
continuous strips 130 may comprise a kraft paper having a thickness
of between about 0.75 and 1.0 mils of other types of materials
having similar characteristics.
[0060] Another preferred embodiment is schematically illustrated in
FIGS. 22 and 23. A roll 270 of a relatively rigid material, such as
that described above, is mounted so that a continuous strip 272 may
be removed therefrom. The continuous strip 272 is fed between a
driven gravure roll 274 and an idler pressure applying roll 276. A
supply tank 278 is mounted at a fixed location and holds a supply
of a suitable adhesive material 280. A transfer roll 282 is
rotatably mounted to pass through the adhesive material 280 and
then to contact the raised surface 284 of the gravure roll 274 to
coat the raised surface 284 with the adhesive material 280 and the
gravure roll 274 then coats the central body portion 286 of the
continuous strip 272 with the adhesive material 280 leaving
opposite edge portions 288 and 290 uncoated. Although a gravure
roll is preferred, it is understood that other types of rolls or
other types of conventional laminating apparatus can be used to
apply the adhesive material to the continuous strip 272.
[0061] A roll 292 of a relatively flexible fluid impervious
material is mounted so that a continuous film 294 may be removed
therefrom. The roll 292 of a relatively flexible fluid impervious
material can comprise a plastic coated paper material, such as that
described above, but preferably comprises a laminated material,
such as a kraft paper and a film of polypropylene or other
materials having similar characteristics laminated thereto or a
film of a fluid impervious plastic material. The continuous strip
272 and the continuous film 294 are moved into conventional
laminating apparatus having a first roll 296 and a second roll 298
to secure the central body portion 300 of the continuous film 294
to the central body portion 286 of the continuous strip 272 leaving
opposite edge portions 302 and 304 unsecured. Either one or both of
the first 296 and second 298 rolls may be driven by conventional
means (not shown). Also, either one or both of the first 296 and
second 298 rolls can have an elastic surface. The continuous strip
272 and the continuous film 294 are then passed through
conventional apparatus 306 to provide the continuous strip 272 with
cut and fold lines. In FIGS. 22 and 23, the continuous strip 272 is
illustrated as being of a width so that only one coating of
adhesive is applied thereto. However, it is understood that the
continuous strip 272 can have a width so that a plurality of spaced
apart adhesive coatings may be applied to the continuous strip 272
so that a continuous film 294 having the same width can also be
secured thereto.
[0062] In FIGS. 24 and 25, there is illustrated a carton blank 308
formed by the process illustrated in FIGS. 22 and 23. The carton
blank 308 has an outer surface 310 and an inner surface 312. The
carton blank 308 is similar to the carton blank 2 of FIGS. 1 and 5
and corresponding parts have been identified with the corresponding
reference numerals. The central body portion 300 of a rectangularly
shaped sheet 314 of the flexible plastic film 294 is adhesively
secured to the central body portion 286 of the relatively rigid
paperboard material so that the opposite edge portions 302 and 304
are unsecured. As illustrated, portions of the edges of the
rectangularly shaped sheet 314 underlie the edges 4, 6, 8 and
10.
[0063] As illustrated in FIG. 24, the central body portions 286 and
300 are secured together between the lines 320 and 322. A cut-out
226 is formed in the upper portion of the glue tab panel portion 22
and extends downwardly to the line 320. Also, a cut-out 231 is
formed in the lower portion of the glue tab panel portion 22 and
extends upwardly to the line 322. Although the cut-outs 226 and 231
are illustrated as v-shaped, it is understood that they can be of
other geometrical configurations. Also, although the cut-outs 226
and 231 are illustrated as extending completely through the glue
tab panel portion 22, it is understood that they can extend only
partially through the glue tab panel portion 22. When a carton is
formed from the carton blank 308 by folding around the fold line
12, a continuous bead of adhesive (not shown) is superposed over
the upper portion of the rectangularly shaped sheet 314, the
cut-out 226, the glue tab panel portion 22, the cut-out 231 and the
lower portion of the rectangularly shaped sheet 314. A carton is
formed from the carton blank 308 by conventionally forming the edge
portion 304, folding and securing the bottom panel portions 40, 42,
44 and 46, filling the carton, conventionally folding the edge
portion 302 and folding and securing the top panel portions 28, 30,
32 and 34.
[0064] Another preferred embodiment is schematically illustrated in
FIG. 26. A continuous strip 330 of a relatively rigid material,
such as paperboard, is pulled from the roll 332. A plurality of
spaced apart, relatively narrow continuous strips 334 of a
relatively flexible material, similar to the strips 130, are pulled
from the rolls 336 and are positioned at spaced apart locations
beneath the continuous strip 330 for movement therewith.
[0065] A continuous film 340 of a relatively flexible fluid
impervious material, such as those described above, is pulled from
the roll 342 and fed into an adhesive coating station 344. The
continuous film 340 moves between a driven gravure roll 346 having
at least one raised surface and an idler pressure applying roll
348. A supply tank 350 is mounted at a fixed location and holds a
supply of a suitable adhesive material 352. A transfer roll 354 is
rotatably mounted to pass through the adhesive material 352 and
then to contact the raised surfaces of the gravure roll 346 to coat
them with the adhesive material 352. The coated continuous film 340
passes over guide rollers 356 and 358. The coated continuous film
340, the strips 334 and the continuous strip 330 pass into
conventional laminating apparatus having a first roll 360 and a
second roll 362, similar to the first 296 and second 298 rolls, to
secure the strips 334 to the coated continuous film 340 and the
portions of the continuous strip 330 of a relatively rigid material
between the strips 334 to the continuous film 340. The laminated
product 364 is then fed into conventional apparatus 366 for further
processing. Although a gravure roll is preferred, it is understood
that other types of rolls can be used to apply the adhesive
material to the continuous film 340.
[0066] If the gravure roll 346 applies a continuous film of the
adhesive material 352 as illustrated in FIG. 27, then the plurality
of strips 334 and the portions of the continuous strip 330 between
the plurality of strips 334 will be adhered to the continuous film
340. If desired, the gravure roll 346 can apply an adhesive pattern
as illustrated in FIG. 28 so that the continuous strip 330 is
adhered to the continuous film 340 at spaced apart intervals 368.
The gravure roll 346 can apply a pattern of adhesive to the
continuous film 340 similar to the pattern illustrated in FIG. 23
to secure the central body portion of the continuous film 340 to
the central body portion of the continuous strip 330 or, as a
modification illustrated in FIG. 29, the pattern will contain
non-adhesive areas 370.
[0067] The apparatus illustrated in FIG. 30 is similar to the
apparatus illustrated in FIG. 22 except that a plurality of spaced
apart rolls 324 of a relatively flexible material, such as kraft
paper, are located so that spaced apart, relatively narrow
continuous strips 326 may be fed into the nip between the gravure
roll 274 and the idler roll 276. The gravure roll 274 has a surface
pattern to apply an adhesive coating material similar to that
illustrated in FIG. 27 or 28.
[0068] The apparatus illustrated in FIG. 31 is similar to the
apparatus illustrated in FIG. 26 except that the spaced apart,
relatively narrow continuous strips 334 of a relatively flexible
material have been excluded. The gravure roll 346 has a surface
pattern to apply an adhesive coating material similar to that
illustrated in FIG. 23 or 29 to produce a product illustrated in
FIG. 25.
[0069] In FIGS. 32 and 33, which are similar to FIG. 24, there is
illustrated another preferred embodiment of the carton blanks
illustrated in FIGS. 10 and 14 and in which corresponding parts are
identified with the same reference numerals. When the continuous
strips 130 of the relatively flexible material are fed into the
apparatus of FIG. 7, there is a maximum tolerance distance that the
lower edge 222 of the upper continuous strip 130 can be spaced from
the fold line 172 and that the upper edge 224 of the lower
continuous strip 130 can be spaced from the fold line 184. A
cut-out 226 is formed in the upper portion of the glue tab panel
portion 170 and extends downwardly from the upper edge 228 for a
distance substantially equal to the maximum tolerance distance.
Also, a cut-out 231 is formed in the lower portion of the glue tab
panel portion 170 and extends upwardly from the lower edge 232 for
a distance substantially equal to the maximum tolerance distance.
Although the cut-outs 226 and 230 are illustrated as V-shaped, it
is understood that they can be of other geometrical configurations.
Also, although the cut-out portions 226 and 231 are illustrated as
extending completely through the glue tab panel portion 170, it is
understood that they can extend only partially through the glue tab
panel portion 170. When a carton is formed from the carton blank of
FIGS. 10, 14 and 22 by folding around the fold lines 160, a
continuous bead 234 of adhesive, such as a hot melt adhesive, is
superposed over the upper continuous strip 130, the cut-out 226,
the glue tab panel portion 170, the cut-out 230 and the lower
continuous strip 130 so that these portions may be secured to
superposed portions of the continuous film 136 of FIG. 10 or the
continuous coating 230 of FIG. 14.
[0070] In FIGS. 34 and 35, there is illustrated another preferred
embodiment of the carton blanks illustrated in FIGS. 10 and 14 and
in which corresponding parts are identified with the same reference
numerals. The glue tab panel portion 171 is wider than the glue tab
panel portion 170 and the upper and lower continuous strips 130 and
the continuous film are wider. Prior to the folding of the carton
blank around the fold lines 160, portions 236 of the upper and
lower continuous strips 130 and the glue tab panel portion 171 and
the adhesively secured portion of the continuous film 136 are
folded back over and secured to adjacent portions of the upper and
lower continuous strips 130 and the glue tab panel portion 171.
When a carton is formed from the carton blank, a bead (not shown)
of adhesive, such as a hot melt adhesive, is superposed over the
edge 238 formed by the folded over portions 236.
[0071] While illustrative and presently preferred embodiments have
been described in detail herein, it is to be understood that the
inventive concepts may be otherwise variously embodied and employed
and that the appended claims are intended to be construed to
include such variations except insofar as limited by the prior
art.
* * * * *