U.S. patent application number 11/735371 was filed with the patent office on 2008-01-31 for carton with article dispenser formed in a composite wall.
Invention is credited to John M. Holley, Jr..
Application Number | 20080023535 11/735371 |
Document ID | / |
Family ID | 38985165 |
Filed Date | 2008-01-31 |
United States Patent
Application |
20080023535 |
Kind Code |
A1 |
Holley, Jr.; John M. |
January 31, 2008 |
CARTON WITH ARTICLE DISPENSER FORMED IN A COMPOSITE WALL
Abstract
A carton (200) includes a composite wall (108/152) with an
article dispenser (140/174) formed in the composite wall (108/152).
The article dispenser (140/174) includes a pair of composite tear
flaps (F1/F2) that are separable from the composite wall (108/152).
The composite tear flaps (F1/F2) are defined by frangible lines in
the layers of the composite wall. The frangible lines in the layers
are strategically misaligned at least in part so as to be arranged
to cooperate to facilitate separation of the composite tear flaps
from the composite wall and to prevent inadvertent operation of the
article dispenser.
Inventors: |
Holley, Jr.; John M.;
(Lawrenceville, GA) |
Correspondence
Address: |
PARKS KNOWLTON LLC
1117 PERIMETER CENTER WEST
SUITE E402
ATLANTA
GA
30338
US
|
Family ID: |
38985165 |
Appl. No.: |
11/735371 |
Filed: |
April 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60744824 |
Apr 13, 2006 |
|
|
|
Current U.S.
Class: |
229/244 |
Current CPC
Class: |
B65D 2571/00592
20130101; B65D 2571/00141 20130101; B65D 2571/00814 20130101; B65D
2571/00524 20130101; B65D 71/36 20130101; B65D 2571/00728 20130101;
B65D 2571/00666 20130101; B65D 2571/0066 20130101; B65D 2571/0045
20130101 |
Class at
Publication: |
229/244 |
International
Class: |
B65D 17/28 20060101
B65D017/28 |
Claims
1. A carton, comprising: a composite wall, defined at least in part
by an outer panel and an inner panel; a pair of composite tear
flaps that are each formed in said composite wall and separable
from said composite wall to form an article dispenser; and a first
inner frangible line formed in said inner panel and a first outer
frangible line formed in said outer panel that are cooperatively
aligned at least in part to at least partially define each of said
pair of composite tear flaps; wherein at least a medial segment of
said first outer frangible line is horizontally spaced apart from a
medial segment of said first inner frangible line to prevent
inadvertent separation of said composite tear flaps from said
composite wall.
2. The carton of claim 1, further comprising a second inner
frangible line formed in said inner panel and a second outer
frangible line formed in said outer panel that are cooperatively
aligned at least in part; wherein said second inner frangible line
intersects said first inner frangible line to at least partially
define a corner of each of said pair of composite tear flaps, and
said medial segment of said first outer frangible line defines a
tab formed from said outer panel such that said tab overlies both
said corners.
3. A carton, comprising: a composite wall, including an outer panel
and an inner panel; an article dispenser formed in said composite
wall, said article dispenser comprising a pair of composite tear
flaps that are separable from said composite wall, said composite
tear flaps including a pair of outer tear flaps that are separable
from said outer panel and a pair of inner tear flaps that are
separable from said inner panel; wherein said outer tear flaps are
defined at least in part by an outer transverse frangible line
having a distal end that intersects an outer longitudinal frangible
line at a first intersection point; and wherein said inner tear
flaps are defined at least in part by an inner transverse frangible
line having a distal end that intersects an inner longitudinal
frangible line at a second intersection point, said inner
transverse frangible line being at least partially substantially
aligned with said outer transverse frangible line and said inner
longitudinal frangible line being at least partially substantially
aligned with said outer longitudinal frangible line to facilitate
separating said composite tear flaps from said composite wall, said
first and second intersection points being spaced apart from one
another.
4. The carton of claim 3, wherein said outer longitudinal frangible
line comprises an outer longitudinal medial segment along which
said first intersection point is disposed; wherein said outer
longitudinal medial segment is substantially nonlinear so as to
define a push tab.
5. The carton of claim 4, wherein said outer longitudinal medial
segment is horizontally spaced apart at least in part from an inner
longitudinal medial segment of said first inner longitudinal
frangible line.
6. The carton of claim 5, wherein said inner longitudinal frangible
line includes a pair of inner longitudinal distal segments on each
side of said inner longitudinal medial segment; wherein said outer
longitudinal frangible line includes a pair of outer longitudinal
distal segments on each side of said outer longitudinal medial
segment; and wherein said inner longitudinal distal segments are
substantially overlappingly aligned with respective ones of said
outer longitudinal distal segments.
7. The carton of claim 3, wherein an inner transverse medial
segment of said inner transverse frangible line is substantially
aligned with said outer transverse frangible line.
8. The carton of claim 4, wherein said tab overlies an inner distal
transverse segment of said inner transverse frangible line and an
inner longitudinal medial segment of said inner longitudinal
frangible line.
9. The carton of claim 6, wherein said outer longitudinal distal
segments are generally perpendicular to said outer transverse
frangible line; and wherein said inner longitudinal frangible line
is generally perpendicular to said inner transverse frangible
line.
10. The carton of claim 3, wherein adjacent corners of said inner
tear flaps are defined by the intersection of said inner transverse
frangible line and said inner longitudinal frangible line.
11. The carton of claim 10, wherein fold lines extend between said
inner transverse frangible line and said inner longitudinal
frangible line to facilitate folding said corners of said inner
tear flaps.
12. The carton of claim 3, wherein said pair of outer tear flaps is
further defined at least in part by a second outer longitudinal
frangible line that is intersected at a third intersection point by
a second distal end of said outer transverse frangible line;
wherein said pair of inner tear flaps is further defined at least
in part by a second inner longitudinal frangible line that is
intersected at a fourth intersection point by a second distal end
of said inner transverse frangible line, said second inner
longitudinal frangible line being at least partially substantially
aligned with said second outer longitudinal frangible line to
facilitate separating said composite tear flaps from said composite
wall, said third and fourth intersection points being spaced apart
from one another.
13. The carton of claim 1, wherein said composite wall is formed
from a unitary blank that includes said inner panel and said outer
panel.
14. The carton of claim 1, wherein said composite wall is formed
from separate blanks that each include one of said inner panel and
said outer panel.
15. The carton of claim 3, wherein said composite wall is formed
from a unitary blank that includes said inner panel and said outer
panel.
16. The carton of claim 3, wherein said composite wall is formed
from separate blanks that each include one of said inner panel and
said outer panel.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/744,824, filed Apr. 13, 2006, the entirety of
which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates generally to cartons, and
particularly, to a carton having an article dispenser formed in a
composite wall.
BACKGROUND OF THE INVENTION
[0003] Cartons with composite walls have improved structural
strength that is useful for packaging heavy articles. These cartons
can include an article dispenser disposed in the composite wall
where frangible lines that are defined in one layer of the carton
directly overlie and are aligned with frangible lines in the
reinforcing layer of the carton. The overlying and aligned
frangible lines facilitate operating the article dispenser in the
composite wall.
[0004] However, the overlying and aligned frangible lines of the
article dispenser may be inadvertently or prematurely broken, for
example, as the handles of the carton are engaged by a user.
Specifically, a user may apply a force with his or her thumb to the
composite wall of the carton when engaging a handle of the carton
that is disposed in an adjacent wall of the carton and thereby
inadvertently operate the article dispenser. For example, a user
may apply a force with a thumb to gain a stronger grip such that
the user is able to carry the carton with one hand. What is needed
is a carton with a article dispenser that does not inadvertently
break upon application of such an outside force.
SUMMARY OF THE INVENTION
[0005] The various embodiments of the present invention overcome
the shortcomings of the prior art by providing a carton with a
reinforced or composite wall that includes a article dispenser
which can be readily operated to open the carton, but resists
inadvertent operation in normal use. The composite carton wall
includes first and second layers. In certain embodiments, one of
the layers is provided by an insert. The layers of the composite
carton wall each include frangible lines which correspond to one
another and which define the article dispenser. Specifically, when
the first layer is secured to the second layer, certain of the
corresponding segments of the frangible lines generally overlie and
align, while certain other corresponding segments of the frangible
lines are spaced apart from one another or are strategically
misaligned, so as to cooperate without directly overlyingly
aligning. This strategic misalignment is employed in varying
degrees particularly in areas where the frangible lines in each
layer intersect or otherwise in areas where an outside force is
typically applied during normal use.
[0006] In an exemplary embodiment, a carton includes a composite
wall that is defined at least in part by an outer panel and an
inner panel. An article dispenser is formed in the composite wall.
The article dispenser includes a pair of composite tear flaps that
are separable from the composite wall. The composite tear flaps
include a pair of outer tear flaps that are separable from the
outer panel and a pair of inner tear flaps that are separable from
the inner panel. The pair of outer tear flaps is defined at least
in part by an outer transverse frangible line that has a distal end
that intersects an outer longitudinal frangible line at a first
intersection point. Similarly, the pair of inner tear flaps is
defined at least in part by an inner transverse frangible line that
has a distal end that intersects an inner longitudinal frangible
line at a second intersection point. The inner transverse frangible
line is at least partially substantially overlyingly aligned with
the outer transverse frangible line and the inner longitudinal
frangible line is at least partially substantially overlyingly
aligned with the outer longitudinal frangible line to facilitate
separating the composite tear flaps from the composite wall. The
first and second intersection points are spaced apart from one
another to prevent inadvertent operation of the composite article
dispenser in the areas surrounding the intersection points.
[0007] In the exemplary embodiment, each of the inner and outer
longitudinal frangible lines includes longitudinal medial segments
and longitudinal distal segments. The outer longitudinal frangible
line includes an outer longitudinal medial segment along which the
outer transverse frangible line intersects the outer longitudinal
frangible line at the first intersection point. The outer
longitudinal medial segment is substantially nonlinear so as to
define a push tab. Further, the outer longitudinal medial segment
is spaced apart from an inner longitudinal medial segment of the
first inner longitudinal frangible line.
[0008] Each of the inner and outer longitudinal frangible lines
includes a pair of longitudinal distal segments on each end of its
respective inner and outer longitudinal medial segment. The inner
longitudinal distal segments are substantially overlyingly aligned
with respective ones of the outer longitudinal distal segments to
facilitate separation of the composite tear flaps therealong.
However, in certain embodiments, the respective inner and outer
longitudinal distal segments are parallel to one another but are
slightly offset from one another to prevent inadvertent operation
of the composite article dispenser. In the exemplary embodiment,
the outer longitudinal distal segments are substantially
perpendicular to the outer transverse frangible line and the inner
longitudinal frangible line is substantially perpendicular to the
inner transverse frangible line.
[0009] The inner transverse frangible line includes an inner
transverse medial segment that is substantially overlyingly aligned
with the outer transverse frangible line to facilitate separation
of the composite tear flaps therealong. The inner transverse
frangible line also includes an inner transverse distal segment
that is overlapped by the tab. The tab also overlaps the inner
longitudinal medial segment.
[0010] The intersection of the inner transverse frangible line and
the inner longitudinal frangible line defines adjacent corners of
the inner tear flaps. In the exemplary embodiment, fold lines
extend between the inner transverse frangible line and the inner
longitudinal frangible line to facilitate folding the corners of
the inner tear flaps.
[0011] In certain embodiments, the pair of outer tear flaps is
further defined at least in part by a second outer longitudinal
frangible line that is intersected at a third intersection point by
a second distal end of the outer transverse frangible line.
Further, the pair of inner tear flaps is further defined at least
in part by a second inner longitudinal frangible line that is
intersected at a fourth intersection point by a second distal end
of the inner transverse frangible line. The second inner
longitudinal frangible line is at least partially substantially
overlyingly aligned with the second outer longitudinal frangible
line to facilitate separating the composite tear flaps from the
composite wall. The third and fourth intersection points are spaced
apart from one another to prevent the composite article dispenser
from being inadvertently operated.
[0012] The foregoing has broadly outlined some of the aspects and
features of the present invention, which should be construed to be
merely illustrative of various potential applications of the
invention. Other beneficial results can be obtained by applying the
disclosed information in a different manner or by combining various
aspects of the disclosed embodiments. Accordingly, other aspects
and a more comprehensive understanding of the invention may be
obtained by referring to the detailed description of the exemplary
embodiments taken in conjunction with the accompanying drawings, in
addition to the scope of the invention defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a plan view of an exemplary embodiment of both a
blank for forming a carton and a blank for forming an insert,
according to the present invention.
[0014] FIG. 2 is a plan view of the carton blank and the insert
blank of FIG. 1, the insert blank being operatively positioned with
respect to the carton blank.
[0015] FIG. 3 is a partial plan view of an area of the operatively
positioned carton blank and insert blank of FIG. 2.
[0016] FIG. 4 is a perspective view of a carton formed from the
carton blank and the insert blank of FIG. 1.
[0017] FIG. 5 is a perspective view of the carton of FIG. 4 showing
a first step in operating the article dispenser.
[0018] FIG. 6 is a partial perspective view of the carton of FIG. 4
showing a second step in operating the article dispenser.
[0019] FIG. 7 is a partial perspective view of the carton of FIG. 4
showing a third step in operating the article dispenser.
[0020] FIG. 8 is a perspective view of the carton of FIG. 4 showing
a fourth step in operating the article dispenser.
[0021] FIG. 9 is a plan view of an alternative exemplary embodiment
of a blank for forming a carton with a composite wall, according to
the present invention.
DETAILED DESCRIPTION
[0022] As required, detailed embodiments of the present invention
are disclosed herein. It must be understood that the disclosed
embodiments are merely exemplary of the invention that may be
embodied in various and alternative forms, and combinations
thereof. As used herein, the word exemplary is used expansively to
refer to embodiments that serve as illustrations, specimens,
models, or patterns. The figures are not necessarily to scale and
some features may be exaggerated or minimized to show details of
particular components. In other instances, well-known components,
systems, materials, or methods have not been described in detail in
order to avoid obscuring the present invention. Therefore, specific
structural and functional details disclosed herein are not to be
interpreted as limiting, but merely as a basis for the claims and
as a representative basis for teaching one skilled in the art to
variously employ the present invention.
[0023] With regard to the drawings, wherein like numerals indicate
like elements throughout the several views, the drawings illustrate
an exemplary embodiment of a carton that is particularly useful for
enclosing and carrying relatively heavy articles such as large
glass bottles. The carton includes a composite wall formed from a
plurality of layers. One of the layers can be provided by an insert
or other reinforcing panel. The composite wall includes an article
dispenser that is defined by frangible lines that are formed in the
layers of the composite wall. Certain segments of the frangible
lines disposed in the layers of the composite wall overlyingly
align with one another to facilitate operation of the article
dispenser and certain segments are strategically misaligned or
spaced apart from one another such that the article dispenser is
not inadvertently operated.
[0024] Referring now to FIG. 1, there is shown an embodiment of a
carton blank 100 and an insert blank 150, according to the present
invention. Each of the blanks 100, 150 is preferably a single sheet
of suitable substrate. It should be understood that, as used
herein, the term suitable substrate includes all manner of foldable
sheet material such as paperboard, corrugated board, cardboard,
plastic, combinations thereof, and the like.
[0025] In the exemplary embodiment, the carton blank 100 is a
unitary blank that is used to form a carton, although it should be
recognized that two or more blanks may be employed, for example, to
provide the carton formed by the unitary carton blank 100. Further,
in the exemplary embodiment, the insert blank 150 is initially
separate from the carton blank 100. However, in alternative
embodiments, the insert blank 150 can be attached or integral to
the carton blank 100.
[0026] In the exemplary embodiment, the blanks 100, 150 are
designed to form a carton for packaging an exemplary arrangement of
exemplary articles. It is envisaged that each of the blanks can be
sized to form a carton for packaging other articles and/or for
packaging different arrangements of articles.
[0027] As used herein, the term fold line refers to all manner of
lines that define the hinge features of the blank, facilitate
folding portions of the blank with respect to one another, or
otherwise indicate optimal folding locations for the blank. A fold
line is typically a scored line, an embossed line, or a debossed
line.
[0028] As used herein, the terms frangible line, tear line, and
severance line refer to all manner of lines that facilitate
separating portions of the substrate from one another or that
indicate optimal separation locations. For example, severance lines
may be weakened lines, cut lines, or slits.
[0029] It should be understood that frangible lines, tear lines,
severance lines, and fold lines can each include elements that are
formed in the substrate of the blank including perforations, a line
of perforations, a line of short slits, a line of half-cuts, a
single half-cut, a cut line, an interrupted cut line, slits,
scores, combinations thereof, and the like. The elements can be
dimensioned and arranged to provide the desired functionality. For
example, a line of perforations can be dimensioned or designed with
various degrees of weakness so as to define a fold line and/or a
frangible line. The line of perforations can be designed to
facilitate folding and resist breaking, to facilitate folding and
facilitate breaking with more effort, or to facilitate breaking
with little effort.
[0030] Referring to FIG. 1, the carton blank 100 includes a
plurality of primary panels for forming the walls of a tubular
structure of a carton 200 shown in FIG. 4. The primary panels of
the carton blank 100 are aligned along a longitudinal axis of the
blank 100 and include a bottom panel 104, a first side panel 106,
an outer top panel 108, and a second side panel 110. The primary
panels 104, 106, 108, 110 are hingedly connected one to the next
along transverse fold lines. Specifically, the bottom panel 104 is
hingedly connected to the first side panel 106 along a fold line
114, the first side panel 106 is hingedly connected to the outer
top panel 108 along a fold line 116, and the outer top panel 108 is
hingedly connected to the second side panel 110 along a fold line
118.
[0031] In the exemplary embodiment, the blank 100 includes an edge
flap 102 that facilitates securing the endmost primary panels 104,
110 to one another. The edge flap 102 is hingedly connected to the
bottom panel 104 along a fold line 112.
[0032] End flaps are hingedly connected to opposite ends of each of
the primary panels 104, 106, 108, 110 along longitudinal fold
lines. The end flaps can be folded and secured to form end closure
structures at respective open ends of the tubular structure of the
carton 200 and thereby define the end walls of the carton 200.
[0033] The blank 100 is substantially symmetric such that the end
flaps that are hingedly connected to the opposite ends of each
primary panel are substantially similar. Accordingly, the end
closure structures of the carton 200 are substantially identical
and like references have been used with a suffix "a" or "b" affixed
to distinguish one end of the carton 200 from the other. Thus, the
description of an element or group of elements having a suffix "a"
is suitable for a like-numbered element or group of elements having
a suffix "b". In certain instances, for clarity, only one of the
like referenced elements may be described unless a description of
the other or both of the like referenced elements is useful for
teaching purposes.
[0034] A bottom end flap 120a is hingedly connected to the bottom
panel 104 along a fold line 130a, a first side end flap 122a is
hingedly connected to the first side panel 106 along a fold line
132a, an outer top end flap 124a is hingedly connected to the outer
top panel 108 along a fold line 134a, and a second side end flap
126a is hingedly connected to the second side panel 110 along a
fold line 136a.
[0035] The blank 100 further includes an outer article dispenser
140 and means for tear initiation 142. The outer article dispenser
140 includes multiple frangible lines that are arranged to define
tear flaps that facilitate access to articles B (shown in FIG. 8)
in the carton 200. The illustrated path of each of the frangible
lines and the illustrated arrangement of the frangible lines of the
outer article dispenser 140 are for purposes of teaching and are
not limiting. In the exemplary embodiment, the frangible lines of
the outer article dispenser 140 are arranged to generally form an
"H", thereby defining two outer tear flaps F1. Specifically, the
outer article dispenser 140 includes an outer transverse frangible
line 144 and a pair of outer longitudinal frangible lines 146a,
146b. Each of the outer longitudinal frangible lines 146a, 146b is
substantially parallel to the other and the outer transverse
frangible line 144 is substantially perpendicular to each of the
outer longitudinal frangible lines 146a, 146b. The outer transverse
frangible line 144 extends between the outer longitudinal frangible
lines 146a, 146b such that the distal ends of the outer transverse
frangible line 144 intersect respective ones of the outer
longitudinal frangible lines 146a, 146b at points P1.
[0036] The outer longitudinal frangible lines 146a, 146b each
include an inwardly curved outer longitudinal medial segment C1
such that the corners of the outer tear flaps F1 are beveled or
rounded. Further, the curved outer longitudinal medial segments C1
define tabs T that project toward each other. The outer transverse
frangible line 144 intersects the outer longitudinal medial
segments C1 of the outer longitudinal frangible lines 146a, 146b
such that the points P1 are located along the length of the outer
longitudinal medial segments C1. Outer longitudinal distal segments
C2 of the outer longitudinal frangible lines 146a, 146b are
disposed on both sides of the outer longitudinal medial segments
C1. In the exemplary embodiment, respective outer longitudinal
distal segments C2 are collinear or coaxial and each of the points
P1 is spaced apart from the line or axis that is defined by
adjacent collinear ones of the outer longitudinal distal segments
C2 by a distance D1.
[0037] In the exemplary embodiment, tear initiation means 142 is an
aperture that interrupts the outer transverse frangible line 144
and is substantially centered on the outer top panel 108. In
alternative embodiments, tear initiation means can include a push
tab, a slit, a detachable portion, combinations thereof, and the
like.
[0038] The outer top end flap 124a includes a handle aperture N1
and a handle edge flap N2, which is hingedly connected along the
edge of the handle aperture N1, that partially define a handle
structure H of the carton 200. Here, the handle aperture N1
illustrated has a sinuous shape, believed to be comfortable to the
user, but all handle aperture shapes are contemplated and included
in the scope of the claims. Further, the side end panels 122a, 126a
include cutouts N3 such that, when each end closure of the carton
200 is formed, at least the weight bearing portion of the handle
aperture N1 is reinforced. Handle flaps 123a are hingedly connected
to each of the side end panels 122a, 126a along fold lines 125a.
The handle flaps 123a are further defined by cut lines 127a which
separate the handle flaps 123a from the outer top end flap 124a and
apertures S. The handle flaps 123a are foldable to additionally
reinforce the weight bearing portion of the handle aperture N1. It
should be noted that, once the end closures of the carton 200 are
formed, the handle aperture N1 in the outer top end flap 124a,
cutouts N3 in the side end panels 122a, 126a, handle flaps 123a,
and inner top end flaps 154a of the insert blank 150 combine to
form a 4-ply reinforced handle structure H.
[0039] Continuing with reference to FIG. 1, an embodiment of an
insert blank 150 is shown according to the present invention. The
illustrated insert blank 150 includes elements for forming,
together with the carton blank 100, the carton 200. The insert
blank 150 includes an inner top panel 152 and a pair of inner top
end flaps 154a, 154b. Similar to the carton blank 100 described
herein, the illustrated insert blank 150 is substantially symmetric
and the opposite ends thereof are substantially identical.
Accordingly, substantially identical elements are designated "a" or
"b" and the present description will generally only be of the
elements designated "a."
[0040] The inner top end flap 154a is hingedly connected to the
inner top panel 152 along fold lines 172a, which are interrupted by
fold apertures 170a. The fold apertures 170a and the fold lines
172a facilitate folding the inner top end flap 154a with respect to
the inner top panel 152 when the insert blank 150 is operatively
positioned with respect to and secured to the carton blank 100 to
form a composite blank for forming the carton 200. The fold
apertures 170a reduce the amount of material at a fold location of
the composite blank. Multiple fold lines 172a increase the ease of
folding the composite blank.
[0041] The insert blank 150 further includes an inner article
dispenser 174 that is defined by an arrangement of frangible lines.
In the exemplary embodiment, the frangible lines are arranged to
generally form an "H" thereby defining two inner tear flaps F2.
Specifically, the inner article dispenser 174 includes an inner
transverse frangible line 178 and a pair of inner longitudinal
frangible lines 180a, 180b. Each of the inner longitudinal
frangible lines 180a, 180b is substantially parallel to the other
and the inner transverse frangible line 178 is substantially
perpendicular to each of the inner longitudinal frangible lines
180a, 180b. The inner transverse frangible line 178 extends between
the longitudinal frangible lines 180a, 180b such that the distal
ends of the inner transverse frangible line 178 intersect
respective ones of the longitudinal frangible lines 180a, 180b at
points P2.
[0042] Adjacent to the points P2, the inner transverse frangible
line 178 and the inner longitudinal frangible lines 180a, 180b
define corners 190 of the inner tear flaps F2. Fold lines 182
extend between one of points P3, each of which is located on the
inner transverse frangible line 178, and one of points P4, each of
which is located on each of the inner longitudinal frangible lines
180a, 180b, to additionally define each of the corners 190.
Referring to FIG. 1, each of the points P3 is spaced apart from a
respective one of the points P2 in the transverse direction by a
distance D2 and each of the points P4 is spaced apart from a
respective one of the points P2 in the longitudinal direction by a
distance D3. Each of the segments of the transverse frangible line
178 that extend between one of the points P2 and an adjacent one of
the points P3 can be weakened to a relatively lesser degree or can
otherwise be a different type of frangible line so as to require a
greater force to break than the rest of the inner transverse
frangible line 178.
[0043] As used herein, the phrases "overlyingly aligned" and
"overlappingly aligned" are used to describe frangible lines or
segments of frangible lines that are disposed in overlapping layers
of a composite wall. Generally described, a frangible line in one
layer of the composite wall is overlyingly aligned with a frangible
line in an overlapping layer of the composite wall where the
frangible lines or relevant sections thereof lie in substantially
the same vertical plane relative to a horizontal plane defined by
the composite wall and extend along substantially the same length
so as to directly overlie or overlap one another. However, to
promote relatively more controlled and selective separation along
frangible lines or segments thereof in layers of a composite wall,
certain of the frangible lines are overlyingly aligned such that
the frangible lines or relevant sections thereof lie in vertical
planes that are at least slightly offset from one another and
generally substantially parallel to one another. Thus, overlyingly
aligned and overlappingly aligned frangible lines are
"cooperatively aligned" to enable separation of adjacent sheet
material when and in the manner desired.
[0044] It should be understood that overlyingly aligned and
overlappingly aligned frangible lines are different from frangible
lines or relevant sections thereof that are described as
strategically misaligned. Overlyingly and overlappingly aligned
frangible lines can generally be broken as a force vertical force
is applied to an area near the frangible lines. However, frangible
lines that are strategically misaligned are generally not broken as
a vertical force is applied to an area near the frangible
lines.
[0045] The inner article dispenser 174 is designed to cooperate
with the outer article dispenser 140 when the carton blank 100 is
operatively positioned with respect to the insert blank 150.
Referring to FIGS. 2 and 3, the insert blank 150 is operatively
positioned with respect to the carton blank 100 such that the inner
article dispenser 174 is positioned with respect to the outer
article dispenser 140. Thus, segments of the outer transverse
frangible line 144 overlyingly align with segments of the inner
transverse frangible line 178 and segments of the outer
longitudinal frangible lines 146a, 146b overlyingly align with
segments of the inner longitudinal frangible lines 180a, 180b.
Specifically, the outer transverse frangible line 144 is
overlyingly aligned with an inner transverse medial segment C3 of
the inner transverse frangible line 178. In the exemplary
embodiment, the outer transverse frangible line 144 and the inner
transverse frangible line 178 are slightly offset from one another
to prevent these segments from inadvertently breaking or otherwise
merely so that each of the frangible lines is visible. The inner
transverse medial segment C3 is defined between the projection of
the points P1 onto the inner transverse frangible line 178 (best
shown in FIG. 3). Since the ends of the inner transverse frangible
line 178 extend beyond of the ends of the outer transverse
frangible line 144, inner transverse distal segments C4 of the
inner transverse frangible line 178 are not overlyingly aligned
with the outer transverse frangible line 144. The inner transverse
distal segments C4 are defined between each point P2 and the
projection of a respective one of the points P1 onto the inner
transverse frangible line 178.
[0046] Similarly, segments of the inner longitudinal frangible
lines 180a, 180b overlyingly align with segments of the outer
longitudinal frangible lines 146a, 146b. Each of the inner
longitudinal frangible lines 180a, 180b includes an inner
longitudinal medial segment C5 and inner longitudinal distal
segments C6 disposed on both sides of the inner longitudinal medial
segment C5. The inner longitudinal medial segment C5 is defined
between points P5, which are defined where the inner longitudinal
distal segments C6 cease to overlyingly align with outer
longitudinal distal segments C2. In the exemplary embodiment, the
inner and outer longitudinal distal segments C2, C6 are slightly
offset from one another to prevent these segments from
inadvertently breaking or otherwise merely so that each of the
segments is visible. That is, the outer longitudinal distal
segments C2 does not directly overlie the inner longitudinal distal
segment C6.
[0047] The areas of each of the outer and inner top panels 108, 152
which generally surround the intersection points P1, P2 will be
referred to herein as intersection areas A. Referring to FIGS. 2
and 3, when the outer and inner top panels 108, 152 are operatively
positioned with respect to one another in an overlapping fashion,
in the corresponding intersection areas A of the outer and inner
top panels 108, 152, segments of the frangible lines of the inner
article dispenser 174 are spaced apart from or are otherwise
strategically substantially misaligned with segments of the
frangible lines of the outer article dispenser 140. Referring to
FIG. 3, it should be noted that, for clarity, only one of
operatively positioned intersection areas A is described. The outer
longitudinal medial segment C1 and the inner longitudinal segment
C5 are spaced apart from one another or are otherwise misaligned to
prevent these segments from inadvertently breaking. Accordingly,
since the intersection points P1, P2 are disposed along the outer
and inner longitudinal medial segments C1, C5, respectively, the
intersection point P1 is spaced apart from the intersection point
P2.
[0048] Importantly, the tab T at least partially overlaps or
overlies the corner portions 190 when the outer and inner top
panels 108, 152 are operatively positioned with respect to one
another. Thus, the tab T at least partially overlaps the inner
transverse distal segment C4 and the inner longitudinal medial
segment C5. Also, the corners 190 are overlapped by the outer
longitudinal medial segment C1. In the exemplary embodiment, the
fold lines 182 are spaced apart from outer longitudinal medial
segment C1 such that the tab T does not overlap the fold lines
182.
[0049] Erecting the carton 200 from the carton blank 100 and the
insert blank 150 may be accomplished with the folding operations as
described herein. The operations can be performed by automatic
erecting machinery and/or manually. The method of performing the
erecting process is not limited to the exemplary method described
herein. Particularly, the order of the steps can be altered
according to manufacturing requirements, steps may be added or
omitted, and the means for securing components to one another may
vary. The surfaces of sheet material may be secured together by
means for securing including tape, staples, interlocking folds,
VELCRO.RTM., glue or other adhesives, combinations thereof, and the
like.
[0050] With reference now to FIGS. 1, 2 and 4, an exemplary method
of erecting the illustrated carton 200 is described. The insert
blank 150 is operatively positioned with respect to the carton
blank 100 as described above and secured thereto. In securing the
outside surface of the inner top panel 152 to the inside surface of
the outer top panel 108, a composite article dispenser 140/174 is
formed such that composite tear flaps F1/F2 are defined by
substantially aligned transverse frangible lines 144/178 and by
substantially aligned longitudinal frangible lines 146a/180a,
146b/180b. Alternatively, the insert blank 150 may be attached to
the top panel 108 at different times during an alternative method
of erecting the carton.
[0051] The carton blank 100 can be folded and secured to form a
collapsed tubular structure by folding the edge flap 102 along the
fold line 112 such that the inside surface of the edge flap 102 is
in flat face contact with the inside surface of the bottom panel
104, applying glue or other adhesive to the outside surface of the
edge flap 102, and folding the carton blank 100 along the fold line
116 such that the inside surface of the second side panel 110 is in
flat face contact with, and thereby secured to, the outside surface
of the edge flap 102.
[0052] The tubular structure can thereafter be erected from the
collapsed tubular structure such that the primary panels form the
walls of the tubular structure. The bottom panel 104 forms a bottom
wall 104, the first side panel 106 forms a first side wall 106, the
outer and inner top panels 108, 152 form a composite top wall
108/152, and the second side panel 110 forms a second side wall
110. The tubular structure includes open ends through which
articles can be loaded. It should be understood that the end flaps
can be folded outwardly or otherwise so as not to obstruct articles
as they are loaded through one or both of the open ends.
[0053] Once the tubular structure is loaded with articles, such as
bottles B, the end panels at each open end of the tubular structure
are folded and secured to form end closure structures. The end
closure structures of the carton 200 are formed by folding the end
flaps as described herein. The handle flaps 123a are folded along
the fold lines 125a to be in flat face contact with the first and
second side end flaps 122a, 126a. The first and second side end
flaps 122a, 126a are folded inwardly toward to the open end of the
tubular structure along fold lines 132a, 136a to be substantially
coplanar with one another. Top and bottom end flaps 124a, 120a are
then folded inwardly toward the open end of the tubular structure
along fold lines 134a, 130a so as to be substantially coplanar with
one another and so as to overlap the first and second side end
flaps 122a, 126a and overlap one another. Glue or other adhesive is
applied to the overlapping portions of the end flaps, which are
thereby secured together such that the end flaps form the end
closure structure 202. The fully erected carton 200 is shown in
FIG. 4.
[0054] Referring to FIGS. 5-8, a non-limiting method of accessing
the articles B in the loaded carton 200 or otherwise operating the
composite article dispenser 140/174 is disclosed. Referring to FIG.
5, tear initiation means is engaged as a user inserts one or more
fingers into the aperture 142/176 and pulls outwardly on one of the
composite tear flaps F1/F2 to initiate a tear along the transverse
frangible line 144/178. Referring to FIG. 6, the transverse
frangible line 144/178 is broken and the tear continues to
propagate along the longitudinal frangible lines 146a/180a,
146b/180b. At substantially the same time, the corner portions 190
pull away with the composite tear flap F1/F2 and are obstructed or
contacted by a respective one of the tabs T. As the corner portions
190 are contacted by a respective tab T, the corner portions 190
fold along the fold line 182 such that the corner portions 190
cease to be obstructed by a respective one of the tabs T. Referring
to FIGS. 7 and 8, the composite tear flap F1/F2 is completely
detached from the composite top wall 108/152 to facilitate access
to the articles B in the carton 200. The other tear flap F1/F2 can
be similarly detached by pulling the tear flap F1/F2 to break the
unbroken segments of the longitudinal frangible lines 146a/180a,
146b/180b.
[0055] As described above, certain corresponding segments of the
frangible lines of the article dispensers 140, 174 are
strategically misaligned or spaced apart from one another such that
the composite article dispenser 140/174 of the assembled carton 200
is not inadvertently operated. For example, a user pressing down on
the composite top wall 108/152, in the general vicinity of one or
both intersection areas A, will not inadvertently operate the
composite article dispenser 140/174 or break through the composite
top wall 108/152. H is foreseeable that, as a user engages the
handle structure H, the user's thumb presses down on one of the
tabs T. Since the segments of the frangible lines of the outer and
inner article dispensers 140, 174 are strategically misaligned in
this area A, the user's thumb does not encounter an overlappingly
or overlyingly aligned set of frangible line segments. Thus, in
this area, the outer top panel 108 supports the frangible line
segments in the inner top panel 152 and the frangible line segments
in the outer top panel 108 are supported by the inner top panel
152.
[0056] Variations and modifications to the embodiment described
above are envisaged. For example, substantial portions of the
transverse frangible lines 144, 178 are described above as directly
aligned, although it is contemplated that frangible lines 144, 178
may alternatively be at least slightly aligned. Similarly,
alternative embodiments of the distal sections C2, C6 of the
longitudinal frangible lines 146a, 180a may be directly aligned
rather than at least slightly aligned. In any event, the outer
longitudinal medial segment C1 is strategically misaligned with the
inner longitudinal medial segment C5 and defines the tab T which
protects the corners 190. All such variations, modifications, and
combinations are included herein by the scope of this disclosure
and the following claims.
[0057] Referring to FIG. 9, an alternative embodiment of a blank
900 is shown. The blank 900 includes certain of the elements of the
blanks 100, 150, which are alternatively arranged. It should be
noted that the blank 900 is a unitary blank for forming a carton
(not shown) with a reinforced or composite wall. In general,
elements of the blank 900 that are substantially similar to the
elements of the blanks 100, 150 are referenced with similar
numbers. However, to distinguish the blanks from one another, the
reference numbers for elements of the blank 900 that are similar to
elements of the blanks 100, 150 are determined by adding eight
hundred to the numbers of the elements of the blanks 100, 150.
Since these elements have been described in detail above, the
description focuses on the arrangement of the blank 900 and an
exemplary method of forming a carton from the blank 900.
[0058] The blank 900 includes primary panels, which form a tubular
structure when the carton is partially erected. The primary panels
are hingedly connected along transverse fold lines. Specifically,
the primary panels include an inner top panel 952, a first side
panel 910, a bottom panel 904, a second side panel 906, and an
outer top panel 908. The inner top panel is hingedly connected to
the first side panel along a fold line 918, the first side panel
910 is hingedly connected to the bottom panel 904 along a fold line
912, the bottom panel 904 is hingedly connected to the second side
panel 906 along a fold line 914, and the second side panel 906 is
hingedly connected to the outer top panel 908 along a fold line
916. Each of the inner and outer top panels 908, 952 include tear
features 940, 974 which cooperate as described above.
[0059] The blank 900 is arranged to form a tubular structure by
folding the blank 900 along the transverse fold lines such that the
outside surface of the inner top panel 952 is in flat face contact
with the inside surface of the outer top panel 908. The inner top
panel 952 is secured to the outer top panel 908 as described above
to form a composite tear feature 940/974.
[0060] It must be emphasized that the above-described embodiments
are merely exemplary illustrations of implementations set forth for
a clear understanding of the principles of the invention.
Variations, modifications, and combinations may be made to the
above-described embodiments without departing from the scope of the
claims.
* * * * *