U.S. patent application number 12/584255 was filed with the patent office on 2011-03-03 for blank for forming a carton and a method of inserting empty hollow cores back into the carton.
This patent application is currently assigned to Green Bay Converting, Inc.. Invention is credited to Gary Patrick Gretzinger, Lee Thomas Luft.
Application Number | 20110048993 12/584255 |
Document ID | / |
Family ID | 43623258 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110048993 |
Kind Code |
A1 |
Gretzinger; Gary Patrick ;
et al. |
March 3, 2011 |
Blank for Forming a Carton and a Method of Inserting Empty Hollow
Cores Back into the Carton
Abstract
A blank formed from cellulosic fibers is disclosed which is
capable of being constructed into a carton. The carton is capable
of housing a plurality of roll products, such as rolls of paper
towels or rolls of toilet paper. Each of the roll products is wound
onto a hollow core made from cellulosic fibers. The carton has a
dispensing opening through which the roll products can be
individually removed. The carton also has an empty hollow core
insertion opening through which an empty hollow core can be
inserted back into the carton for the purpose of being recycled
along with the empty carton. A method of inserting the empty hollow
cores back into the carton is also disclosed.
Inventors: |
Gretzinger; Gary Patrick;
(Green Bay, WI) ; Luft; Lee Thomas; (Kewaunee,
WI) |
Assignee: |
Green Bay Converting, Inc.
Green Bay
WI
|
Family ID: |
43623258 |
Appl. No.: |
12/584255 |
Filed: |
September 1, 2009 |
Current U.S.
Class: |
206/391 ;
229/117.13; 229/122; 53/467 |
Current CPC
Class: |
B65D 5/10 20130101; B65D
5/0227 20130101; B65D 5/541 20130101; B65D 85/672 20130101; B65D
2209/00 20130101 |
Class at
Publication: |
206/391 ;
229/122; 229/117.13; 53/467 |
International
Class: |
B65D 85/02 20060101
B65D085/02; B65D 5/54 20060101 B65D005/54; B65D 5/468 20060101
B65D005/468; B65D 5/72 20060101 B65D005/72 |
Claims
1. A blank for forming a carton having a dispensing opening and an
empty hollow core insertion opening, comprising: a) an adhesive
tab; b) a back panel located adjacent to said adhesive tab and
having a top and a bottom; c) a first vertical fold line positioned
between said adhesive tab and said back panel; d) a top panel
located adjacent to said back panel and having a top and a bottom;
e) a second vertical fold line positioned between said back panel
and said top panel; f) a front panel located adjacent to said top
panel and having a top and a bottom; g) a third vertical fold line
positioned between said top panel and said front panel; h) a bottom
panel located adjacent to said front panel and having a top and a
bottom; i) a fourth vertical fold line positioned between said
front panel and said bottom panel; j) a back panel top flap located
adjacent to said top of said back panel; k) a back panel bottom
flap located adjacent to said bottom of said back panel; l) a top
panel top flap located adjacent to said top of said top panel; m) a
top panel bottom flap located adjacent to said bottom of said top
panel; n) a front panel top flap located adjacent to said top of
said front panel; o) a front panel bottom flap located adjacent to
said bottom of said front panel; p) a bottom panel top flap located
adjacent to said top of said bottom panel; q) a bottom panel bottom
flap located adjacent to said bottom of said bottom panel; r) a
first horizontal fold line disposed between said back panel and
said back panel top flap, between said top panel and said top panel
top flap, between said front panel and said front panel top flap,
and between said bottom panel and said bottom panel top flap; s) a
second horizontal fold line disposed between said back panel and
said back panel bottom flap, between said top panel and said top
panel bottom flap, between said front panel and said front panel
bottom flap, and between said bottom panel and said bottom panel
bottom flap; t) a first tear panel formed in both said back panel
top flap and in said front panel top flap, said first tear panel
having a pair of portions which extends partially into said back
panel and partially into said front panel, said first tear panel
intersecting said first horizontal fold line, and when said first
tear panel is removed a dispensing opening is formed into said
carton; and u) a second tear panel formed in said back panel and
aligned adjacent to said second horizontal fold line, said second
tear panel having a central axis aligned perpendicular to said back
panel, and when said second tear panel is removed an empty hollow
core insertion opening is formed into said carton.
2. The blank of claim 1 further comprising a third tear panel
formed in said front panel and aligned adjacent to said second
horizontal fold line, said third tear panel having a central axis
aligned perpendicular to said front panel, and when said third tear
panel is removed another insertion opening is formed into said
carton through which an empty hollow core can be inserted.
3. The blank of claim 2 wherein said central axes of said second
and third tear panels are coaxially aligned.
4. The blank of claim 1 wherein said empty hollow core has a
diameter and said second tear panel has a circular configuration
with a diameter at least equal to said diameter of said empty
hollow core.
5. The blank of claim 3 wherein said second tear panel has a
diameter of at least 1.5 inches and said second tear panel is
circumscribed by a perforation line.
6. The blank of claim 1 wherein said blank is folded and assembled
into a six sided enclosed carton capable of housing a plurality of
roll products, and each of said roll products has a hollow core
upon which multiple sheets of said roll product are wound.
7. The blank of claim 6 further comprising a fourth tear panel
formed in said top panel, said fourth tear panel having a central
axis aligned perpendicular to said top panel, and when said fourth
tear panel is removed a viewing opening is formed into said carton
through which a consumer can view the roll products housed in said
carton.
8. The blank of claim 7 further comprising a fifth tear panel
formed in said top panel, said fifth tear panel having a central
axis aligned perpendicular to said top panel, and when said fifth
tear panel is removed a handle opening is formed which allows a
consumer to carry said carton.
9. The blank of claim 6 wherein said top panel top flap has a pair
of spaced apart slits formed therein which create a pivotable
flap.
10. A carton formed from cellulose fibers and having a dispensing
opening and an empty hollow core insertion opening, said carton
capable of housing a plurality of generally cylindrically shaped
products formed from cellulose fibers, each of said products being
wound upon a hollow core formed from cellulose fibers and having a
common diameter, said carton comprising: a) a top panel; b) a
bottom panel aligned opposite to said top panel; c) a pair of end
walls each being located between said top panel and said bottom
panel; d) a front panel and a back panel each being located between
said top panel and said bottom panel and adjacent to each of said
pair of end walls; e) a first tear panel formed in one of said pair
of end walls and having a pair of portions which extend partially
into said back panel and partially into said front panel, and when
said first tear panel is removed a dispensing opening is formed
into said carton; and f) a second tear panel formed in said back
panel, said second tear panel having a diameter at least equal to
said common diameter of each of said hollow cores, and when said
second tear panel is removed an empty hollow core insertion opening
is formed into said carton which allow an empty hollow core to be
inserted back into said carton once one of said products has been
removed from said carton.
11. The carton of claim 10 wherein said second tear panel has a
diameter which is greater than said common diameter of each of said
hollow cores.
12. The carton of claim 10 wherein said second tear panel has a
circular configuration with a central axis which is located within
about 3 inches of said top tear panel and diagonally away from said
dispensing opening.
13. The carton of claim 12 wherein said second tear panel is
located at a greater distance from said bottom panel than said
dispensing opening when said carton is resting on said bottom
panel.
14. The carton of claim 10 further comprising a third tear panel
formed in said front panel, said third tear panel having a diameter
which is equal to said diameter of said second tear panel.
15. The carton of claim 10 further comprising an inspection opening
formed in said top panel which is sized to allow a person to insert
at least one finger through said opening and touch an adjacent roll
product housed in said carton, said opening being covered by a
flap, and said flap being releasably secured to said top panel by
an adhesive.
16. The carton of claim 10 further comprising a fourth tear panel
formed in said top panel, and when said fourth tear panel is
removed a viewing opening is formed into said carton through which
a consumer can view said products housed in said carton.
17. The carton of claim 10 further comprising a fifth tear panel
formed in said top panel, and when said fifth tear panel is removed
a handle opening is formed which allows a consumer to carry said
carton.
18. The carton of claim 10 wherein one of said pair of end walls
contains a rotatable flap having a free end that can be rotated to
expose an opening into said carton through which a person can
insert a thumb and index finger so as to physically touch at least
one of said roll products housed in said carton, and said flap can
be rotated back to a closed position wherein said free end is
inserted into a slit to reclose said carton.
19. A method of inserting an empty hollow core having a common
diameter back into a carton, each of said hollow cores having a
product wound upon it, said method comprising the steps of: a)
inserting a plurality of said products into said carton and sealing
said carton, said carton having a top panel, a bottom panel aligned
opposite to said top panel, a pair of end walls each being located
between said top panel and said bottom panel, a front panel and a
back panel each being located between said top panel and said
bottom panel and adjacent to each of said pair of end walls, a
first tear panel formed in one of said pair of end walls and having
a pair of portions which extend partially into said back panel and
partially into said front panel, and when said first tear panel is
removed a dispensing opening is formed into said carton which
provides access to at least one of said products housed within said
carton, and a second tear panel formed in one of said front and
back panels, said second tear panel having a diameter at least
equal to said common diameter of each of said hollow cores, and
when said second tear panel is removed an empty hollow core
insertion opening is formed into said carton which allow an empty
hollow core to be inserted back into said carton once one of said
products has been removed from said carton; b) removing said first
tear panel to obtain a dispensing opening into said carton; c)
removing said second tear panel to obtain an insertion opening; d)
removing one of said products from said carton; e) removing said
product wound upon said hollow core to obtain an empty hollow core;
and f) inserting said empty hollow core back into said carton
through said insertion opening.
20. The method of claim 19 wherein said carton and each of said
hollow cores is formed from cellulose fibers, and said method
further comprises recycling said carton containing one or more of
said empty hollow cores.
21. The method of claim 19 further comprising forming said second
tear panel in said back panel and forming a third tear panel in
said front panel, said third tear panel having a diameter at least
equal to said common diameter of each of said hollow cores, and
when said third tear panel is removed, another empty hollow core
insertion opening is formed into said carton which allows an empty
hollow core to be inserted back into said carton once one of said
products has been removed from said carton.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a blank capable of forming a
carton and a method of inserting empty hollow cores back into the
carton. More particularly, this invention relates to a paperboard
carton capable of housing a plurality of roll products, such as
rolls of paper towels, rolls of toilet paper, rolls of dry wipes,
etc., which are wound onto a hollow core formed from cellulosic
fibers, and recycling the empty hollow cores back into the
carton.
BACKGROUND OF THE INVENTION
[0002] Today, many consumers desire to purchase products that
utilize recycled materials and additionally can be recycled so as
to benefit the environment. Some paper products, especially paper
towel and toilet paper are manufactured from cellulose fibers that
have been recovered and recycled and this is considered a superior
and much more sustainable approach to disposable paper product
manufacturing utilizing virgin wood (cellulose) fibers. However, up
until now, it has been difficult to recycle the materials used to
package and dispense these disposable paper products. Most paper
towels and toilet paper is wound onto a hollow, paper or cardboard
core during manufacture for easy dispensing. These products are
typically referred to as roll products and have a generally
cylindrical shape and contain multiple sheets of paper towels or
toilet paper. A plurality of these roll products is then typically
wrapped in plastic in multiples of 4, 6, 8, 12, 24 rolls and then
packed into corrugated fiberboard cartons for easy shipment to a
retailer for ultimate sale to consumers.
[0003] It has been found that the plastic wrap or sheeting used to
form the commonly used wrappers cannot be easily collected and
recycled. Therefore, this plastic wrap is often discarded and
eventually the plastic wrap is landfilled where it is slow to break
down. Even in communities where consumers take the extra time to
collect and recycle the plastic film, it is difficult for some
recyclers to know the specific plastic from which the wrap was
produced and therefore it may still be difficult to properly
segregated and successfully recycled the plastic wrap. In addition,
consumers who wish to recycle the plastic wrap and the empty paper
cores must first separate the paper or cellulosic based hollow
cores from the plastic wrap during the recycling process. For this
reason, many consumers who desire green (recyclable/sustainable)
products wish to purchase paper towels and toilet paper in
paper-based (paperboard) packaging/cartons. At present, there is no
known commercial use of a paperboard carton to house, transport and
display (retail applications) disposable paper products such as
paper towel and bathroom tissue.
[0004] There are commercially available paperboard cartons for use
with other kinds of cylindrical shaped products, i.e. aluminum
cans. However, such paperboard cartons do not contain a separate
opening to allow for the recapture of recyclable materials. One
drawback with the existing plastic packaging for kitchen roll
towels or bathroom tissue is that, up until now, there was no easy
way to recycle the empty hollow cores and/or the removable panel
covering the dispensing opening back into the carton once the
sheets of paper towels or sheets of toilet paper were removed from
the hollow cores. Many consumers were forced to discard the empty
hollow cores and the removable cover panels in their garbage
receptacles. By providing an easy to use recycling alternative, the
consumer will now be able to dispose of the empty hollow cores and
the removable cover panels and recycle them along with the original
paperboard carton. No further segregation of materials is
required.
[0005] Now a blank capable of forming a paperboard carton having a
dispensing opening and an empty hollow core insertion opening has
been invented. The blank is capable of being formed into a carton
capable of holding a plurality of roll products. The carton has a
specific opening into which empty hollow cores can be inserted back
into the carton once the cellulosic product has been removed there
from. In addition, a method of inserting the hollow cores back into
the carton is also disclosed.
SUMMARY OF THE INVENTION
[0006] Briefly, this invention relates to a blank for forming a
carton having more than one opening to facilitate both the
dispensing of carton contents as well as to recapture recyclable
materials that are currently most often discarded. The blank
includes an adhesive tab and a back panel located adjacent to the
adhesive tab. The back panel has a top and a bottom. The blank also
has a first vertical fold line positioned between the adhesive tab
and the back panel. The blank further has a top panel located
adjacent to the back panel. The top panel has a top and a bottom.
The blank also has a second vertical fold line positioned between
the back panel and the top panel. The blank further has a front
panel located adjacent to the top panel. The front panel has a top
and a bottom. The blank also has a third vertical fold line
positioned between the top panel and the front panel. The blank
further has a bottom panel located adjacent to the front panel. The
bottom panel has a top and a bottom. The blank also has a fourth
vertical fold line positioned between the front panel and the
bottom panel. The blank also has a back panel top flap located
adjacent to the top of the back panel, a back panel bottom flap
located adjacent to the bottom of the back panel, a top panel top
flap located adjacent to the top of the top panel, a top panel
bottom flap located adjacent to the bottom of the top panel, a
front panel top flap located adjacent to the top of the front
panel, a front panel bottom flap located adjacent to the bottom of
the front panel, a bottom panel top flap located adjacent to the
top of the bottom panel, and a bottom panel bottom flap located
adjacent to the bottom of the bottom panel.
[0007] The blank further has a first horizontal fold line disposed
between the back panel and the back panel top flap, between the top
panel and the top panel top flap, between the front panel and the
front panel top flap, and between the bottom panel and the bottom
panel top flap. The blank further has a second horizontal fold line
disposed between the back panel and the back panel bottom flap,
between the top panel and the top panel bottom flap, between the
front panel and the front panel bottom flap, and between the bottom
panel and the bottom panel bottom flap. The blank still further
includes a first tear panel formed in the front panel and having a
pair of portions which extends partially into the top panel and the
bottom panel, and when the first tear panel is removed a first
opening is formed into the carton formed from the blank. The blank
still further includes a pair of second tear panels that can be
opened to allow recapture of the recyclable core materials and the
previously removed roll-dispensing tear panel.
[0008] This invention also relates to a carton formed from
cellulose fibers and having a pair of openings for dispensing and
re-insertion of recyclable materials formed therein. The carton is
capable of housing a plurality of generally cylindrically shaped
products formed from cellulose fibers. Each of the products is
wound upon a hollow core formed from cellulose fibers and having a
common diameter. The carton includes a top panel, a bottom panel
aligned opposite to the top panel, a pair of end walls each being
located between the top and bottom panels, and a front panel and a
back panel each being located between the top panel and the bottom
panel and adjacent to each of the pair of end walls. The carton
also has a first tear panel formed in one of the pair of end walls
and having a pair of portions which extend partially into the back
panel and partially into the front panel. The first tear panel
defines a first opening when removed which provides access to at
least one of the roll products housed within the carton. The carton
further has a second tear panel formed in the back panel. The
second tear panel has a diameter at least equal to the common
diameter of each of the hollow cores. When the second tear panel is
removed, an empty hollow core insertion opening is formed into the
carton which allows a empty hollow core to be inserted back into
the carton once one or more of the products has been removed from
the carton.
[0009] Still further, this invention relates to a method of
recycling hollow cores formed from cellulose fibers which are
housed in a carton formed from cellulose fibers. Each of the hollow
cores has a roll product formed from cellulose fibers wound upon
it. The method includes the steps of inserting a plurality of the
roll products, each having a hollow core, into the carton and
sealing the carton. The carton has a top panel, a bottom panel
aligned opposite to the top panel, a pair of end walls each being
located between the top panel and the bottom panel, a front panel
and a back panel each being located between the top panel and the
bottom panel and adjacent to each of the pair of end walls. The
carton also has a first tear panel formed in one of the pair of end
walls and has a pair of portions which extend partially into the
back panel and partially into the front panel. When the first tear
panel is removed, a dispensing opening is formed into the carton
which provides access to at least one of the products housed within
the carton. The carton also has a second tear panel formed in one
of the front and back panels. The second tear panel has a diameter
at least equal to the common diameter of each of the hollow cores.
When the second tear panel is removed, an empty hollow core
insertion opening is formed into the carton which allows an empty
hollow core to be inserted back into the carton once one of the
products has been removed from the carton.
[0010] The method also includes removing the first tear panel to
obtain a dispensing opening into the carton. The second tear panel
is also removed to obtain an insertion opening. The method further
includes removing at least one of the products from the carton and
removing, such as by using the product, the product wound upon the
hollow core to obtain an empty hollow core. This empty hollow core
is then inserted back into the carton through the insertion
opening.
[0011] The general object of this invention is to provide a blank
capable of forming a carton and a method of recycling hollow cores
and tear panels back into the original carton. A more specific
object of this invention is to provide a paperboard carton capable
of housing a plurality of roll products, such as rolls of paper
towels or rolls of toilet paper, which are wound onto a hollow core
formed from cellulose fibers, and recycling the hollow cores back
into the original carton.
[0012] Another object of this invention is to provide a dispensing
opening of a size and shape that will allow a consumer to easily
grasp a roll product approximate its opposite ends and remove the
roll product from the carton.
[0013] Another object of this invention is to provide a paperboard
carton capable of housing a plurality of generally cylindrically
shaped roll products and having an easy to open flap that is
recloseable and which can be opened so that a potential consumer
can reach in with his or her fingers and feel the product prior to
purchase of the paperboard carton.
[0014] A further object of this invention is to provide a
paperboard carton capable of housing a plurality of generally
cylindrically shaped roll products each wound onto a hollow core
formed from paper or cardboard, and providing an opening through
which the hollow cores can be inserted back into the original
carton so that both can be recycled together.
[0015] Still another object of this invention is to provide a
method for recycling hollow cores formed from cellulose fibers
which are housed in a carton formed from cellulose fibers.
[0016] Still further, an object of this invention is to provide a
method for inserting an empty hollow core back into the original
carton once the first roll product is removed from the carton.
[0017] Still further, an object of this invention is to provide a
method for recycling the carton having at least one empty hollow
core positioned therein.
[0018] Other objects and advantages of the present invention will
become more apparent to those skilled in the art in view of the
following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a top view of a blank formed from cellulosic
fibers into a paper, paperboard or cardboard blank that can be
configured into a carton.
[0020] FIG. 2 is a partial view of an embodiment of a blank wherein
the four bottom flaps are designed to automatically intermesh as a
blank is assembled into a sleeve forming a closed end wall.
[0021] FIG. 3 is a perspective view of a carton formed from the
blank shown in FIG. 1.
[0022] FIG. 4 is another perspective view of the carton formed from
the blank shown in FIG. 1 showing the opposite end of the carton
and having the first tear panel removed to reveal the dispensing
opening and the second tear panel removed to reveal the empty
hollow core insertion opening.
[0023] FIG. 5 is an end view of a carton having a self forming end
wall formed from the blank shown in FIG. 2.
[0024] FIG. 6 is a plane view of the front panel showing another
empty hollow core insertion opening.
[0025] FIG. 7 is a plane view of the back panel partially broken
away to reveal twelve roll products housed in the carton.
[0026] FIG. 8 is a perspective view of a roll product wound upon a
hollow core.
[0027] FIG. 9 is a perspective view of an empty hollow core after
the roll product has been removed.
[0028] FIG. 10 is an enlarged top view of a fourth tear panel which
covers a viewing opening and having a finger opening formed
therein.
[0029] FIG. 11 is a cross-sectional view of the fourth tear panel
after the finger opening flap has been pushed downward and the
third tear panel has been removed from the top panel of the
carton.
[0030] FIG. 12 is a top view of the carton shown in FIG. 1 showing
a viewing opening and a handle opening.
[0031] FIG. 13 is a front view of a plurality of cartons stacked on
a cardboard pallet and held in position by four L-shaped corner
posts and a top cap.
[0032] FIG. 14 is a perspective view of an L-shaped corner
post.
[0033] FIG. 15 is a view of an easy to open flap that is
recloseable over a reach in window.
[0034] FIG. 16 is a partial cross-sectional view taken along line
16-16 showing the easy to open flap.
[0035] FIG. 17 is a partial cross-sectional view showing an
alternative embodiment of the flap covered by a recloseable
label.
[0036] FIG. 18 is an end view of the carton depicting another
embodiment containing a partially separable flap and showing a
first portion before it is sealed by an adhesive to an oppositely
aligned second portion, and the partially separable flap capable of
being separated from the first portion and being rotated to an open
position so that a consumer can reach into the carton and
physically feel the roll product and then the partially separable
flap can be securely closed by tucking its free end into a slit
formed in the second portion.
[0037] FIG. 19 is an end view of the carton shown in FIG. 18 when
the end wall is closed.
[0038] FIG. 20 is an end view of the carton shown in FIG. 19 when
the partially separable flap is rotated to its open position
revealing at least one of the roll products contained in the
carton.
[0039] FIG. 21 is an end view of the carton shown in FIG. 20 when
the partially separable flap is rotated back against the end wall
and its free end is tucked into a slit formed in the second
portion.
[0040] FIG. 22 is a flow diagram of a method of inserting an empty
hollow core back into the carton.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Referring to FIGS. 1-4, a blank 10 and 10' are shown each of
which can be assembled into a carton 12, see FIGS. 3 and 4. The
blanks 10 and 10' can be formed from any cellulosic material. One
or more different cellulosic fibers can be used to construct the
cellulosic material. The cellulosic material can be paper,
paperboard, cardboard or the like which is constructed from a
plurality of cellulosic fibers. Desirably, the blank 10 is formed
from paperboard. The material forming the blank 10 can be easily
recycled or composted.
[0042] In FIG. 2, the blank 10' has four bottom flaps that are
designed to automatically intermesh as the blank 10' is assembled
into a sleeve forming a closed end wall.
[0043] Each of the blanks 10 and 10' can be a generally rectangular
or elongated member having a longitudinal central axis X-X and a
transverse central axis Y-Y. The thickness of each of the blanks 10
and 10', measured perpendicular to the X-X and Y-Y axes, can vary.
Each of the blanks 10 and 10' can consist of one or more layers
secured together. When two or more layers are present, each layer
can have a similar or a different thickness. Desirably, when two or
more layers are present, they are secured together such as by an
adhesive. Alternatively, the two or more layers can be secured
together by using heat, pressure, heat and pressure or by other
mechanisms known to those skilled in the art. The one or more
layers forming the blanks 10 or 10' can be flat or planar layers or
at least one of the layers can be corrugated or have some other
configuration that adds thickness to the blanks 10 or 10'. Each of
the blanks 10 and 10' is relatively thin. Each of the blanks 10 and
10' can have a thickness of less than about 0.2 inches. Desirably,
each of the blanks 10 and 10' has a thickness of less than about
0.1 inches. More desirably, each of the blanks 10 and 10' has a
thickness of less than about 0.05 inches. Even more desirably, each
of the blanks 10 and 10' has a thickness of less than about 0.03
inches.
[0044] Referring to FIGS. 1-4, once the blank 10 or 10' is formed
to a predetermined shape, it can be easily configured, folded,
constructed, assembled or transformed into the carton 12. The blank
10 or 10' can contain one or more fold lines, score lines, crease
lines, adhesive lines, etc. to facilitate folding and bending
various portions and/or sealing or interlocking various portions
together. The various portions of the blank 10 or 10' can be
folded, bent over, doubled up, joined, taped, interlocked and/or be
sealed or bonded together to form the carton 12. Desirably, the
blank 10 or 10' is configured such that it can be folded at several
locations upon itself and be sealed or bonded at least one location
to form the carton 12. Adhesive or glue is normally used to seal
the carton 12.
[0045] The carton 12 formed from the blank 10 or 10' has a
longitudinal central axis X-X, a transverse central axis Y-Y, and a
vertical central axis Z-Z. The carton 12 can vary in size and
shape. Desirably, the carton 12 is a rectangular cube having six
sides with at least two of the sides having a rectangular face.
Alternatively, the carton 12 can be a cube having six congruent
square faces. Still another alternative is to form a carton having
more than six faces, such as a hexagon shape, along with a top and
a bottom.
[0046] Referring to FIGS. 4, 7 and 8, the carton 12 can be sized to
house or retain a plurality of roll products 14. The roll products
14 are generally cylindrically shaped products formed from
cellulosic fibers. The roll products 14 can be formed with
eco-friendly features. For example, the roll products 14 can be
made from recycled cellulose fibers. The roll products 14 can be
made hypoallergenic. The roll products 14 can be made with no added
dyes or fragrances and can even be whitened without using chlorine.
Such roll products 14 can be rolls of paper tissue, rolls of toilet
paper or rolls of some other kind of paper product. Desirably, the
roll products 14 are rolls of toilet paper or toilet tissue. The
size and shape of the roll products 14 can vary.
[0047] Referring to FIGS. 8 and 9, each of the roll products 14 has
a longitudinal central axis X.sub.1-X.sub.1 and a transverse
central axis Y.sub.1-Y.sub.1. Each of the roll products 14 is an
elongated rectangular sheet containing multiple weakened lines (not
shown) where it can be easily and cleanly separated from the
remaining sheet. The weakened lines can be in the form of score
lines, perforation lines, tear lines, etc. The elongated sheet is
radially wound onto a hollow core 16 to form a roll product 14, see
FIG. 8. The roll product 14 has a height h and an outside diameter
d. The height h and the diameter d can vary. For a typical roll of
toilet paper 14, the height h can range from between about 3.5
inches to about 5 inches. Desirably, the height h can range from
between about 3.75 inches to about 4.5 inches. More desirably, the
height h can range from between about 4 inches to about 4.4 inches.
Even more desirably, the height h can range from between about 3.8
inches to about 4.25 inches.
[0048] The roll product 14 is compressible by at least 10 percent
measured perpendicular to its longitudinal central axis
X.sub.1-X.sub.1, see FIG. 8. Desirably, each roll product 14 is
compressible by at least 15 percent measured perpendicular to its
longitudinal central axis X.sub.1-X.sub.1. More desirably, each
roll product 14 is compressible by at least 20 percent measured
perpendicular to its longitudinal central axis X.sub.1-X.sub.1.
Each of the roll products 14 may also exhibit a relatively high
coefficient of friction. Normally, the carton 12 can house from
between 2 to 120 similar roll products 14. An even number or an odd
number of roll products 14 can be housed or retained in the carton
12. Desirably, an even number of similar roll products 14 are
housed in the carton 12. For rolls of toilet paper, the carton 12
can be sized to house or retain 2, 4, 6, 8, 10, 12, 14, 16, 18, 20,
22, 24, 26, 28, 30, 32, 34, 36, 38, 40 or more rolls of toilet
paper.
[0049] It should be understood that one could house different types
of roll products with a single carton 12, if desired. Desirably,
each carton 12 will retain a plurality of like kind of roll
products 14.
[0050] Referring to FIG. 9, the hollow core 16 is shown as an
elongated cylindrical member having a round or circular
cross-section. However, the hollow core 16 can have any geometrical
cross-sectional shape. Desirably, the cross-section of each of the
hollow cores 16 is circular. The hollow core 16 has a longitudinal
central axis X.sub.1-X.sub.1 and a transverse central axis
Y.sub.1-Y.sub.1. As depicted, the hollow core 16 has an external or
common diameter d.sub.1, a thickness t and a length l. All three
dimensions can vary. For a typical roll of toilet paper, the hollow
core 16 can have an external or common diameter d.sub.1 that ranges
from between about 1 to about 3 inches, desirably, from about 1.5
to about 2.5 inches, and more desirably, from between about 1.6 to
about 2 inches. The hollow core 16 can have a thickness t that
ranges from between about 0.01 to about 0.2 inches, desirably, from
between about 0.02 to about 0.15 inches, and more desirably, from
between about 0.05 to about 0.1 inches. The hollow core 16 can have
a length l that ranges from between about 3 to about 6 inches,
desirably from between about 3.5 to about 5 inches, and more
desirably from between about 3.75 to about 4.25 inches.
[0051] Referring again to FIG. 1, the blank 10 will be described
from left to right and from top to bottom. The blank 10 includes an
adhesive tab 18. The adhesive tab 18 can be a thin strip of
adhesive or glue that will bond to an adjoining portion of the
blank 10 once it is pressed and/or heated. The adhesive tab 18 can
contain a continuous area of adhesive or glue or two or more
intermittent areas of adhesive or glue. The blank 10 also includes
a back panel 20 located adjacent to the adhesive tab 18. The back
panel 20 has a top 22 and a bottom 24. The top and bottom, 22 and
24 respectively, are measured relative to the transverse central
axis Y-Y. The blank 10 also has a first vertical fold line 26
positioned between the adhesive tab 18 and the back panel 20. The
first vertical fold line 26 extends parallel to the transverse
central axis Y-Y. The first vertical fold line 26 can be a score, a
crease, a groove, an indentation, a line of weakness, etc. that
extends into a portion of the thickness of the blank 10. Those
skilled in the art are well aware of how to form the first vertical
fold line 26 in the blank 10.
[0052] The blank 10 further has a top panel 28 located adjacent to
the back panel 20. The top panel 28 has a top 30 and a bottom 32.
The blank 10 also has a second vertical fold line 34 positioned
between the back panel 20 and the top panel 28. The second vertical
fold line 34 extends parallel to the transverse central axis Y-Y.
The second vertical fold line 34 can be a score, a crease, a
groove, an indentation a line of weakness, etc. that extends into a
portion of the thickness of the blank 10. Those skilled in the art
are well aware of how to form the second vertical fold line 34 in
the blank 10.
[0053] The blank 10 further has a front panel 36 located adjacent
to the top panel 28. The front panel 36 has a top 38 and a bottom
40. The blank 10 also has a third vertical fold line 42 positioned
between the top panel 28 and the front panel 36. The third vertical
fold line 42 extends parallel to the transverse central axis Y-Y.
The third vertical fold line 42 can be a score, a crease, a groove,
an indentation, a line of weakness, etc. that extends into a
portion of the thickness of the blank 10. Those skilled in the art
are well aware of how to form the third vertical fold line 42 in
the blank 10.
[0054] The blank 10 further has a bottom panel 44 located adjacent
to the front panel 36. The bottom panel 44 has a top 46 and a
bottom 48. The blank 10 also has a fourth vertical fold line 50
positioned between the front panel 36 and the bottom panel 44. The
fourth vertical fold line 50 extends parallel to the transverse
central axis Y-Y. The fourth vertical fold line 50 can be a score,
a crease, a groove, an indentation, a line of weakness, etc. that
extends into a portion of the thickness of the blank 10. Those
skilled in the art are well aware of how to form the fourth
vertical fold line 50 in the blank 10.
[0055] Still referring to FIG. 1, the blank 10 also has a back
panel top flap 52 located adjacent to the top 22 of the back panel
20, a back panel bottom flap 54 located adjacent to the bottom 24
of the back panel 20, a top panel bottom flap 56 located adjacent
to the top 30 of the top panel 28, a top panel bottom flap 58
located adjacent to the bottom 32 of the top panel 28, a front
panel top flap 60 located adjacent to the top 40 of the front panel
38, a front panel bottom flap 60 located adjacent to the bottom 42
of the front panel 38, a bottom panel top flap 64 located adjacent
to the top 46 of the bottom panel 44, and a bottom panel bottom
flap 66 located adjacent to the bottom 48 of the bottom panel
44.
[0056] The back panel top flap 52 has a height h.sub.1 and the
front panel top flap 60 has a height h.sub.3. The height h.sub.1 of
the back panel top flap 52 is approximately equal to the height
h.sub.3 of the front panel top flap 60. Desirably, the height
h.sub.1 of the back panel top flap 52 is equal to the height
h.sub.3 of the front panel top flap 60. The top panel top flap 56
has a height h.sub.2 and the bottom panel top flap 64 has a height
h.sub.4. The height h.sub.2 of the top panel top flap 56 is greater
than the height h.sub.4 of the bottom panel top flap 64. The height
h.sub.2 of the top panel top flap 56 can be approximately equal to
the height h.sub.1 of the back panel top flap 52 and approximately
equal to the height h.sub.3 of the front panel top flap 60.
Furthermore, the height h.sub.4 of the bottom panel top flap 64 is
less than the height h.sub.1 of each of the back panel top flap 52
and is also less than the height h.sub.3 of the front panel top
flap 60. The exact dimension of the heights h.sub.1, h.sub.2,
h.sub.3 and h.sub.4 will vary depending upon the size of the carton
12.
[0057] The top panel top flap 56 can optionally contain a pair of
spaced apart slits 57, 57. The pair of spaced apart slits 57, 57
can be aligned parallel to one another or be aligned at an angle
relative to one another. Desirably, the pair of slits 57, 57 is
aligned parallel to one another. The pair of spaced apart slits 57,
57 defines a flap 59 therebetween. The flap 59 will be explained in
more detail later.
[0058] The adhesive tab 18 has a width w. The width w of the
adhesive tab 18 can range from between about 0.25 inches to about 1
inch. Each of the back panel 20, the top panel 28, the front panel
38 and the bottom panel 44 has a width, w.sub.1, w.sub.2, w.sub.3
and w.sub.4 respectively. These widths w.sub.1, w.sub.2, w.sub.3
and w.sub.4 can vary depending on the size of the carton 12. The
width w.sub.1 of the back panel 20 is approximately equal to the
width w.sub.3 of the front panel 38. Desirably, the width w.sub.1
of the back panel 20 is equal to the width w.sub.3 of the front
panel 38. The width w.sub.2 of the top panel 28 is approximately
equal to the width w.sub.4 of the bottom panel 44. Desirably, the
width w.sub.2 of the top panel 28 is equal to the width w.sub.4 of
the bottom panel 44. In addition, the width w.sub.1 of the back
panel 20 is greater than the width w.sub.2 of the top panel 28, and
the width w.sub.3 of the front panel 38 is greater than the width
w.sub.4 of the bottom panel 44.
[0059] The above height and width dimensions apply to a carton
sized to house twelve rolls of toilet paper. The dimensions of the
blanks 10 and 10' can be changed to produce a carton 12 that can
hold various amounts of roll products 14.
[0060] Still referring to FIG. 1, the back panel bottom flap 54 and
the front panel bottom flap 62 are identical in size and
configuration. The top panel bottom flap 58 and the bottom panel
bottom flap 66 are identical in size and configuration. In
addition, each of the back panel bottom flap 54 and the front panel
bottom flap 62 is larger in size than either of the top panel
bottom flap 58 or the bottom panel bottom flap 66.
[0061] The blank 10 also has a first horizontal fold line 68
disposed between the back panel 20 and the back panel top flap 52,
between the top panel 28 and the top panel top flap 56, between the
front panel 38 and the front panel top flap 60, and between the
bottom panel 44 and the bottom panel top flap 64. The blank 10
further has a second horizontal fold line 70 disposed between the
back panel 20 and the back panel bottom flap 54, between the top
panel 28 and the top panel bottom flap 58, between the front panel
38 and the front panel bottom flap 62, and between the bottom panel
44 and the bottom panel bottom flap 66. The first horizontal fold
line 68 is aligned essentially parallel to the second horizontal
fold line 70 and both the first and second horizontal fold line, 68
and 70 respectively, are aligned parallel to the longitudinal
central axis X-X. The first and second horizontal fold lines, 68
and 70 respectively, can optionally contain perforations, 72 and 74
respectively, which can facilitate folding and forming the blank 10
into the carton 12.
[0062] Referring now to FIG. 2, a blank 10' is depicted which is
similar to the blank 10 except that it has a back panel bottom flap
54', a top panel bottom flap 58', a front panel bottom flap 62' and
a bottom panel bottom flap 66' that have a slightly different
configuration. The back panel bottom flap 54' is identical to the
front panel bottom flap 62' and the top panel bottom flap 58' is
identical to the bottom panel bottom flap 66'. The back panel
bottom flap 54' contains a perforation line 76 which angles and
intersects with the second vertical fold line 34. Likewise, the
front panel bottom flap 62' contains a perforation line 78 which
angles and intersects with the fourth vertical fold line 50. The
top panel bottom flap 58' contains a spot of an adhesive or glue 80
and the bottom panel bottom flap 66' also contains a spot of an
adhesive or glue 82. The adhesive or glue 80 is designed to secure
the top panel bottom flap 58' to the inside surface of the smaller
portion of the back panel bottom flap 54'. Likewise, the adhesive
or glue 82 is designed to secure the bottom panel bottom flap 66'
to the inside surface of the smaller portion of the front panel
bottom flap 62'. The blank 10' is then folded at the four vertical
fold lines 26, 34, 42 and 50 and the adhesive tab 18 is secured to
the bottom panel 44 to form a hollow sleeve, not shown.
[0063] The second horizontal fold line 70 still contains the
perforations 74 to facilitate folding and forming the blank 10'
into the carton 12. The four bottom flaps 54', 58', 62' and 66' are
then folded inward into the sleeve and the two spots of adhesive 80
and 82 will bond the top panel bottom flap 58' to the back panel
bottom flap 54' and the bottom panel bottom flap 66' to the front
panel bottom flap 62' respectively. The sleeve is then flattened
for storage and/or shipment. At the manufacturing plant, the flat
sleeve can be again opened into a sleeve. This action will cause
the four bottom flaps 54', 58', 62' and 66' to intermesh and form
one end wall of the carton 12. This is referred to as a
"self-forming end" or an "auto forming end".
[0064] Referring again to FIGS. 1, 3 and 6, the blank 10 also
includes a first tear panel 84 formed in both the back panel top
flap 52 and the front panel top flap 60. The first tear panel 84
has a central portion 86 and a pair of end portions 88 and 90 which
extends partially into the back panel 20 and into the front panel
38, respectively. The size and shape of the first tear panel 84 can
vary. Desirably, the first tear panel 84 can be of any geometrical
shape. As depicted in FIG. 1, the first tear panel 84 has a
rectangular central portion 86 sandwiched between the two irregular
shaped end portions, 88 and 90 respectively. However, almost any
geometrical configuration can be utilized. The rectangular central
portion 86 is aligned perpendicular to the longitudinal central
axis X-X of the carton 12. The two end portions 88 and 90 are
positioned at opposite ends of the central portion 86. The end
portions 88 and 90 are arranged at 90 degrees to the central
portion 86.
[0065] The end portions 88 and 90 can be constructed so that each
extends a sufficient distance into each of the back and front
panels, 20 and 38 respectively. When the end portions 88 and 90
extend to a distance that a major portion of the hollow core 16 is
visible, it enables a consumer to reach in and grasp the roll
product with one or both hands. Alternatively, the consumer can
place his or her index finger in the hollow core 16 and extract the
roll product from the carton 12 by pulling outward on the hollow
core 16. Desirably, one or both of the end portions 88 and 90
should extend at least about 1.5 inches inward into the back and/or
front panels, 20 and 38 respectively, for a roll product 14 having
a diameter d of about 4 inches. More desirably, one or both of the
end portions 88 and 90 should extend at least about 2 inches inward
into the back and/or front panels, 20 and 38 respectively, for a
roll product 14 having a diameter d of about 4 inches. Even more
desirably, one or both of the end portions 88 and 90 should extend
at least about 2.5 inches inward into the back and/or front panels,
20 and 38 respectively, for a roll product 14 having a diameter d
of about 4 inches.
[0066] The actual shape of the end portions 88 and 90 can vary. In
addition, the end portion 88 can be identical or different in
configuration from the other end portion 90. One will notice in
FIG. 1 that the end portion 88 is different in size and shape from
the other end portion 90.
[0067] It should be understood that one or more finger holes 92 can
be optionally formed in the first tear panel 84. Each finger hole
92 can vary in size, shape and location. For example, in FIG. 1,
two finger holes 92, 92 are depicted being formed in the first tear
panel 84 approximate the first horizontal fold line 68.
[0068] Referring now to FIG. 3, the first tear panel 84 is
circumscribed by a continuous perforation line 94. The perforation
line 94 contains a plurality of cuts 96 each separated by a land
area 98. The length of the cuts 96 and the size of the land areas
98 can vary in dimension and thickness. Likewise, the cuts 96 and
the land areas 98 can vary in geometrical shape. Various portions
of the perforation line 94 can be linear or non-linear. Some
portions of the perforation line 94 can be arcuate or curved in
configuration. The cuts 96 have a length which range from about 1
to 4 times the length of the land areas 98. However, the cuts 96
can have a smaller length, an equal length or a greater length than
the land areas 98.
[0069] Referring again to FIGS. 3 and 4, by tearing or breaking the
perforation line 94, the first tear panel 84 can be completely
removed from the carton 12. When the first tear panel 84 is
removed, a dispensing opening 100 is formed in the carton 12 which
is of sufficient size and shape to permit the roll products 14,
housed in the carton 12, to be dispended one at a time. The lower
or bottom row of roll products 14 is dispensed through the
dispensing opening 100, see FIG. 4. The size and shape of the
dispensing opening 100 prevents the roll products 14 situated in
the adjacent upper row from being dispensed.
[0070] Referring to FIG. 7, one can see that the carton 12 contains
three horizontal rows of the roll products 14. The three rows
include a bottom row, a middle row and an upper row, with four of
the roll products 14 positioned in each of the horizontal rows.
Only the roll product 14 situated in the bottom roll and adjacent
to the dispensing opening 100 can be initially dispensed from the
carton 12. The size and shape of the dispensing opening 100
prevents the roll product 14 located directly above the left most
roll product 14 in the lower row from being withdrawn from the
carton 12 without deforming it. During the removal of the first
roll product 14 from the carton 12, the roll product 14 located
immediately above it will move downward and occupy the empty space
left by the withdrawn roll product 14. The left most roll product
located in the upper row will also simultaneously move downward to
the middle row. This means that there will be only three roll
products 14 left in the upper row.
[0071] Still referring to FIG. 7, the size and shape of the
dispensing opening 100 is designed to permit only one of the roll
products 14 to be withdrawn from the carton 12 at a time. One can
see that the dispensing opening 100 is quite larger. For a carton
12 containing twelve or more rolls of toilet paper 14, each having
a diameter of about 4.25 inches, the dispensing opening 100 should
have a height h.sub.5, measured parallel to the transverse central
axis Y-Y, of at least about 6 inches. Desirably, the height h.sub.5
of the dispensing opening 100 is at least about 6.5 inches. More
desirably, the height h.sub.5 of the dispensing opening 100 is at
least about 7 inches. Even more desirably, the height h.sub.5 of
the dispensing opening 100 is at least about 7.5 inches. Most
desirably, the height h.sub.5 of the dispensing opening 100 is at
least about 8 inches. Another way of expressing the height h.sub.5
of the dispensing opening 100 is to say that the height h.sub.5 is
at least about 1.35 times the external or common diameter of the
roll product 14. Desirably, the height h.sub.5 of the dispensing
opening 100 is at least about 1.45 times the external or common
diameter of the roll product 14. More desirably, the height h.sub.5
of the dispensing opening 100 is at least about 1.55 times the
external or common diameter of the roll product 14. Even more
desirably, the height h.sub.5 of the dispensing opening 100 is at
least about 1.65 times the external or common diameter of the roll
product 14. Most desirably, the height h.sub.5 of the dispensing
opening 100 is at least about 1.75 times the external or common
diameter of the roll product 14.
[0072] Still referring to FIG. 7, the carton 12 contains a lip 102
which is situated between the bottom panel 44 and the lower edge of
the first tear panel 84. The lip 102 has a height h.sub.6 which can
vary in dimension. Desirably, the height h.sub.6 of the lip 102 can
range from between about 0.1 inches to about 2 inches. More
desirably, the height h.sub.6 of the lip 102 can range from between
about 0.2 inches to about 1 inch. Even more desirably, the height
h.sub.6 of the lip 102 can range from between about 0.25 inches to
about 0.75 inches. The width of the lip 102 can extend between the
back panel 20 and the front panel 38 or be less than this
dimension.
[0073] Referring again to FIGS. 1 and 3, the blank 12 also includes
a second tear panel 104 formed in the back panel 20 and aligned
adjacent to the second horizontal fold line 70. The second tear
panel 104 can have any configuration but desirably is circular. The
second tear panel 104 has a central axis 106 aligned perpendicular
to the back panel 20. The second tear panel 104 includes a
perforation line 108 which circumscribes a defined area. The
perforation line 108 can consist or two or more cuts separated by
land areas as was explained above with reference to the first and
second horizontal fold lines, 68 and 70 respectively. The
perforation line 108 can be continuous and extend 360 degrees
around the defined area. Alternatively, the perforation line 108
can be non-continuous but the perforation line 108 should still
extend about 300 degrees around the defined area. If a
non-continuous perforation line is utilized, when the land areas of
the perforations are broken, the remaining attached portion can be
folded into the carton 12 so that it does not obstruct the
insertion of an empty hollow core 16.
[0074] Referring to FIG. 3, the second tear panel 104 is located
about 4 inches below the top panel 28. Desirably, the second tear
panel 104 is located below or within about 3 inches of the top
panel 28. The second tear panel 104 is also positioned diagonally
away from the dispensing opening 100. Depending upon the physical
dimensions of the carton 12, the second tear panel 104 is
positioned at least about 8 inches away from the dispensing opening
100. Desirably, the second tear panel 104 is positioned at least
about 10 inches away from the dispensing opening 100. Furthermore,
the central axis 106 of the second tear panel 104 is located at a
distance b from the bottom panel 44. The top of the first tear
panel 84 is located at a distance b.sub.1 from the bottom panel 44.
The distance b is greater than the distance b.sub.1. Desirably, the
distance b is greater than the distance ID, by at least about 2
inches. More desirably, the distance b is greater than the distance
ID, by at least about 3 inches.
[0075] Referring to FIGS. 4 and 7, when the second tear panel 104
is removed, an empty hollow core insertion opening 110 is formed
into the carton 12. The insertion opening 110 can vary in size and
have any desired geometrical shape. Desirably, the insertion
opening 110 is circular in configuration and has a diameter d.sub.2
which is equal to or larger than the external or common diameter
d.sub.1 of the empty hollow cores 16. More desirably, the diameter
d.sub.2 of the insertion opening 110 is at least about 0.1 inches
larger than the external or common diameter d.sub.1 of the empty
hollow cores 16. Even more desirably, the diameter d.sub.2 of the
insertion opening 110 is at least about 0.25 inches larger than the
external or common diameter d.sub.1 of the empty hollow cores 16.
Most desirably, the diameter d.sub.2 of the insertion opening 110
ranges from between about 0.1 inches to about 1 inch larger than
the external or common diameter d.sub.1 of the empty hollow cores
16.
[0076] The diameter d.sub.2 of the insertion opening 110 can range
from between about 1 inch to about 3 inches. Desirably, the
diameter d.sub.2 of the insertion opening 110 is at least about 1.5
inches. More desirably, the diameter d.sub.2 of the insertion
opening 110 is at least about 1.75 inches. Even more desirably, the
diameter d.sub.2 of the insertion opening 110 is at least about 2
inches.
[0077] Referring again to FIG. 1, a third tear panel 112 is formed
in the front panel 38 and is aligned adjacent to the second
horizontal fold line 70. The third tear panel 112 has a central
axis 114 aligned perpendicular to the front panel 38. The central
axis of the third tear panel 112 can be coaxially aligned with the
central axis 106 of the second tear panel 104.
[0078] The third tear panel 112 can be identical in size and shape
to the second tear panel 104. Alternatively, the third tear panel
112 can be different in size and/or shape to the second tear panel
104. Desirably, the second and third tear panels, 104 and 112 are
identical in size and shape. The third tear panel 112 includes a
perforation line 116 which circumscribes a defined area. The
perforation line 116 can consist or two or more cuts separated by
land areas as was explained above with reference to the perforation
line 108. The perforation line 116 can be continuous and extend 360
degrees around the defined area. Alternatively, the perforation
line 116 can be non-continuous but the perforation line 116 should
still extend about 300 degrees around the defined area. If a
non-continuous perforation line is utilized, when the land areas of
the perforations are broken, the remaining attached portion can be
folded into the carton 12 so that it does not obstruct the
insertion of an empty hollow core 16.
[0079] Referring now to FIG. 6, when the third tear panel 112 is
removed, another empty hollow core insertion opening 118 is formed
into the carton 12 through which an empty hollow core 16 can be
inserted. The insertion opening 118 can vary in size and have any
desired geometrical shape. Desirably, the insertion opening 118 is
circular in configuration and has a diameter d.sub.3 which is equal
to or larger than the external or common diameter d.sub.1 of the
empty hollow cores 16. More desirably, the diameter d.sub.3 of the
insertion opening 118 is at least about 0.1 inches larger than the
external or common diameter d.sub.1 of the empty hollow cores 16.
Even more desirably, the diameter d.sub.3 of the insertion opening
118 is at least about 0.25 inches larger than the external or
common diameter d.sub.1 of the empty hollow cores 16. Most
desirably, the diameter d.sub.3 of the insertion opening 118 ranges
from between about 0.1 inches to about 1 inch larger than the
external or common diameter d.sub.1 of the empty hollow cores
16.
[0080] As mentioned above, the diameter d.sub.2 of the insertion
opening 108 is desirably equal to the diameter d.sub.3 of the
insertion opening 118. The diameter d.sub.3 of the insertion
opening 118 can range from between about 1 inch to about 3 inches.
Desirably, the diameter d.sub.3 of the insertion opening 118 is at
least about 1.5 inches. More desirably, the diameter d.sub.3 of the
insertion opening 118 is at least about 1.75 inches. Even more
desirably, the diameter d.sub.3 of the insertion opening 118 is at
least about 2 inches.
[0081] Referring again to FIGS. 1, 3 and 4, a fourth tear panel 120
is formed in the top panel 28. The fourth tear panel 120 has a
central axis 122 aligned perpendicular to the top panel 28. The
fourth tear panel 120 includes a perforation line 124 which
circumscribes a defined area. The perforation line 124 can consist
or two or more cuts separated by land areas as was explained above
with reference to the second tear panel 104. The perforation line
124 can be continuous and extend 360 degrees around the defined
area. Alternatively, the perforation line 124 can be non-continuous
but the perforation line 124 should still extend about 300 degrees
around the defined area. If a non-continuous perforation line is
utilized, when the land areas of the perforations are broken, the
remaining attached portion can be folded into the carton 12.
[0082] Referring to FIGS. 1, 10 and 11, a finger aperture 126 can
optionally be formed in the fourth tear panel 120. The finger
aperture 126 can be formed by surrounding a small area of the
fourth tear panel 120 with cuts or perforations each separated by a
narrow land area. When a person presses down on the small area, the
land areas break and the finger aperture 126 is formed into the
carton 12. The finger opening 126 is sized to allow a person to
insert his or her index finger therein and pull up thereby
separating the fourth tear panel 120 from the top panel 28 of the
carton 12.
[0083] Referring now to FIG. 12, when the fourth tear panel 120 is
removed, a viewing opening or window 128 is formed into the carton
12 through which a consumer can view the roll products 14. The
viewing opening or window 128 can vary in size and shape. As shown,
the viewing opening or window 128 has a generally tear drop shape
or other aesthetically pleasing shape. The viewing opening or
window 128 is located adjacent to the top 30 of the top panel 28.
Desirably, the viewing opening or window 128 is located from
between about 1 inch to about 6 inches of the top 30 of the top
panel 28. The viewing opening or window 128 can be aligned along
the longitudinal central axis X-X, as shown in FIG. 12, or be
offset therefrom. The viewing opening or window 128 can expose an
area of at least about 1 square inch. Desirably, viewing opening or
window 128 could expose an area of at least about 2 square inches.
More desirably, the viewing opening or window 128 could expose an
area of at least about 3 square inches.
[0084] Referring again to FIGS. 1, 3 and 4, a fifth tear panel 130
is formed in the top panel 28. The fifth tear panel 130 has a
central axis 132 aligned perpendicular to the top panel 28. The
central axes 122 and 132 of the fourth and fifth tear panels, 120
and 130 respectively, can be aligned along a common central axis,
such as the longitudinal central axis X-X, see FIGS. 3 and 4. The
fifth tear panel 130 includes a perforation line 134 and a
non-perforated portion 136. The perforation line 134 and the
non-perforated portion 136 cooperate to circumscribe a defined
area. The perforation line 134 can consist of two or more cuts
separated by land areas as was explained above with reference to
the second tear panel 104. The land areas of the perforation line
134 can be easily broken while the non-perforated portion 136
remains attached to the top 28 of the carton 12. This creates a
flap 138 that can pivot, fold or bend along the non-perforated
portion 136.
[0085] Referring again to FIG. 12, when the flap 138 of the fifth
tear panel 130 is pushed downward into the carton 12, a handle
opening 140 is formed which allows a consumer to insert one, two
three or four fingers of one hand and easily carry the carton 12.
The handle opening 140 should have its maximum dimension aligned
parallel to the longitudinal central axis Z-Z. By orienting the
handle opening 140 in this fashion, the back or front panels, 20 or
38 respectively, can be positioned adjacent to a leg of the person
who is carrying the carton 12. This will facilitate a comfortable
way to carry the carton 12.
[0086] Referring again to FIGS. 3-7, the carton 12 is formed from
the blank 10. The carton 12 is capable of housing a plurality of
generally cylindrically shaped products 14 formed from cellulose
fibers. Each of the products 14 is wound upon a hollow core 16
formed from cellulose fibers. Each hollow core 16 has a common
diameter d.sub.1. The carton 12 includes a top panel 28 and a
bottom panel 44 aligned opposite to the top panel 28. The carton 12
also has a pair of end walls 142 and 144 each being located between
the top panel 28 and the bottom panel 44. The carton 12 further has
a front panel 38 and a back panel 20 each being located between the
top panel 28 and the bottom panel 44 and adjacent to each of the
pair of end walls 142 and 144. A first tear panel 84 is formed in
one of the pair of end walls 142 and 144. The first tear panel 84
has a pair of portions 88 and 90, one of which extends partially
into the back panel 20 and the other which extends partially into
the front panel 38. When the first tear panel 84 is removed, a
dispensing opening 100 is formed into the carton 12. A second tear
panel 104 is formed in the back panel 20. The second tear panel 104
has a diameter d.sub.2 which is at least equal to the external or
common diameter d.sub.1 of each of the hollow cores 16. When the
second tear panel 104 is removed, an empty hollow core insertion
opening 110 is formed into the carton 12. The insertion opening 110
allows an empty hollow core 16 to be inserted back into the carton
12 once one of the products 14 has been removed from the carton
12.
[0087] Referring to FIG. 5, an end wall 144' is shown which is
constructed from the four bottom flaps 54', 58', 62' and 66'
depicted in FIG. 2. The end wall 144' is a self forming end wall
that is created when the folded flat blank 10 is opened in to a
hollow sleeve.
[0088] Referring now to FIG. 13, a plurality of cartons 12 is
stacked on a movable pallet 146. The number of cartons 12 stacked
on the pallet 146 can vary. For example, 20 or more cartons 12 can
form a shipping quantity 148. The actual number of cartons 12
making up the stack will vary depending upon the size of each
carton 12. In FIG. 13, thirty cartons 12 are shown making up one
row of cartons 12. The pallet 146 can be sized to accommodate three
rows which means ninety cartons 12 can be assembled into the
stack.
[0089] The shipping quantity 148 has a longitudinal central axis
X.sub.2-X.sub.2 and a transverse central axis Y.sub.2-Y.sub.2. The
size, height, weight, etc. of the shipping quantity 148 can vary.
The pallet 146 can be formed from a heavy grade of cardboard. The
thickness of the cardboard forming the pallet 146 can range from
between about 0.2 inches to about 0.8 inches. The pallet 146 can
vary in shape and size. Desirably, the pallet 146 has a rectangular
or square configuration. The pallet 146 has a height h.sub.7 which
can range from between about 4 inches to about 10 inches.
Desirably, the pallet 146 has a height h.sub.7 of less than about 8
inches. The pallet 146 can contain two or more fork lift channels
150, 150. Two channels 150, 150 are depicted in FIG. 13. The two
channels 150, 150 are sized, configured and spaced apart so as to
receive the protruding forks on a fork lift truck. The channels
150, 150 can be located in the bottom of the pallet 146 or near the
bottom of the pallet 146.
[0090] Referring to FIGS. 13 and 14, the stack of cartons 12 is
held vertically upright by four corner post 152, two of which are
depicted in FIG. 13. Each of the four corner posts 152 is formed
from paperboard or cardboard. Each of the corner posts 152 can vary
in length. Typically, all four corner posts 152 have the same
length. Each of the four corner posts 152 has a pair of sides 154
and 156 which are aligned at an angle theta (.theta.). The angle
.theta. can range from between about 85 degrees to about 95 degrees
to form an approximately L-shape. Desirably, the angle .theta. is
approximately 90 degree. More desirably, the angle .theta. is 90
degree.
[0091] A top cap 158 having a downwardly extending peripheral lip
160 is placed on top of the stack of cartons 12. The top cap 158 is
also formed from paperboard or cardboard. The top cap 158
cooperates with the four L-shaped corner posts 152 and the pallet
146 to provide support to the cartons 12. A thin flexible wrap, not
shown, which can be formed from a starch material, a thermoplastic
material, a plastic material, or any other material known to those
in the packaging art, can be wrapped around the perimeter of the
stack to form the integral shipping quantity 148.
[0092] One should recognize that the cardboard cartons 12, the
empty hollow cores 16, the pallet 146, the four corner posts 152,
the top cap 158 are all constructed from cellulose fibers and can
be recycled or composed thereby alleviating disposal in a landfill.
In addition, the thin flexible wrap can also be recycled if it is
made from a starch based product.
[0093] Referring now to FIGS. 1, 15 and 16, one can see that the
flap 59 is folded upward along the first horizontal fold line 68
and is folded, bent or overlapped upon itself. In other words, the
flap 59 is rotated 180 degrees from its position in the blank 10,
see FIG. 1. Furthermore, the flap 59 will be positioned
approximately 270 degrees from the remaining two portions of the
top panel top flap 56 when the carton 12 is fully assembled from
the blank 10. The flap 59 is designed to pivot or rotate about the
first horizontal fold line 68 so that it can be oriented at 90
degrees or more relative to the upper surface of the top panel 28.
The flap 59 can be moved from a closed position, where it is
horizontally aligned adjacent to the top panel 28, to an open
position where it is aligned at an angle of 90 degrees or more
relative to the top panel 28. In other words, the flap 59 can be
pivoted so as to be aligned perpendicular to the top panel 28. In
the closed position, the flap 59 lies essentially parallel to the
top panel 28. In the open position, the flap 59 is rotated or
pivoted to expose an opening 162. The opening 162 is formed in the
top panel 28 and extends completely through the thickness of the
top panel 28. When the flap 59 is in the open position, a viewing
and reach-in window is created into the carton 12.
[0094] The flap 59 is sized and configured to completely cover the
opening 162. The opening 162 can vary in size and configuration.
Desirably, the opening 162 has a surface area of at least about one
square inch. More desirably, the opening has a surface area of at
least about 1.5 square inches. Most desirably, the opening 162 has
a surface area of 2 or more square inches. The opening 162 can be
located where the fourth tear panel 120 is located. Alternatively,
the opening 162 can be located between the fourth tear panel 120
and the first horizontal fold line 68. Still alternatively, the
opening 162 can be made to overlap a portion of the fourth tear
panel 120. The opening 162 functions as an inspection window
wherein a potential customer can pull and pivot the flap 59 upward
and backward and visually look through the opening 162 to see the
roll products 14 housed in the carton 12. In addition, the
potential customer can insert one or more fingers and/or his or her
thumb through the opening 162 so as to actually touch and feel the
softness and/or texture of the roll product 14 located adjacent to
the opening 162. Some customers like to be able to feel the
softness of toilet paper they are contemplating purchasing to make
sure the toilet paper is of a softness which suits them. Since
toilet paper is a product that will actually contact the human
body, some customers require that it is be very soft so as not to
be abrasive against their skin during use. Toilet paper is sold in
different grades of softness.
[0095] Referring to FIG. 16, an adhesive 164 is present between the
top panel 28 and the lower surface of the flap 59. By "adhesive" it
is meant a sticky, gummed substance, such as paste, glue, cement,
etc., that provides adhesion. The adhesive 164 can be a hot melt
adhesive, a cold melt adhesive, a co-adhesive, etc. The composition
of the adhesive 164 can vary. The adhesive 164 should have a peel
strength that will allow the flap 59 to be easily separated from
the top panel 28 and allow the flap 59 to be easily reapplied to
the top panel 28 more than once. The adhesive 164 should be made
such that the flap 59 can be released from the top panel 28 and be
resealed against the top panel 28 multiple times. One skilled in
the adhesive arts will be able to select an adhesive 164 which is
capable of performing this function.
[0096] It should be understood that when the flap 59 is adhesively
secured to the top panel 28, the opening 162 will be completely
closed. With the flap 59 closes the opening 162, a person looking
at the carton 12 will not view the carton 12 as being violated in
any way. The carton 12 will be a closed carton 12 and completely
enclose any roll products 14 contained therein.
[0097] Referring now to FIG. 17, an alternative embodiment is shown
wherein a label 166 having a lower adhesive surface 168 covers at
least a portion of the flap 59 and is secured to a portion of the
top panel 28. Desirably, the label 166 completely covers the flap
59 and is secured to a portion of the top panel 28.
[0098] The lower adhesive surface 168 contains an adhesive that is
releasable and resealable. The lower adhesive surface 168 can be
separated from and be reattached to the top panel 28 and/or to the
flap 59 multiple times. The label 166 functions to temporarily
secure the flap 59 to the top panel 28. The label 166 can be
released or separated from the top panel 28 so that the flap 59 can
be pivoted upward and backward away from the opening 162.
Alternatively, the label 166 can be released or separated from the
flap 59 so that the flap 59 can be pivoted upward and backward away
from the opening 162.
[0099] The label 166 can be constructed from various materials. For
example, the label 166 can be constructed from cellulosic fibers,
from a film material, from a thermoplastic, from plastic, from a
composite material, from a combination of two or more materials,
etc. Desirably, the label 166 is formed from a recyclable or
compostable material. By "recyclable" it is meant to reprocess from
waste for reuse, to use again, to reclaim for a new use or
function. By "compostable" it is meant to convert to compost.
[0100] Referring now to FIGS. 18-21, another embodiment a carton
12' is depicted. The carton 12' has an end wall 144'' containing a
first portion 170, a second portion 172, a third portion 174 and a
fourth portion 176. The third and fourth portions, 174 and 176
respectively, are first folded and then the second portion 172 is
folded at least partially over them. Lastly, the first portion 170
is folded so as to partially overlap the second portion 172 and can
be secured thereto by one or more spots of adhesive, not shown.
[0101] In FIG. 18, the first portion 170 is depicted in an open
positioned before it is folded over and partially overlaps the
second portion 172. One can see that the carton 12' contains three
rows of roll products 14. The rows can be arranged in a vertical
fashion. The first portion 170 contains a partially separable flap
178. The flap 178 can be formed from the same material which forms
the remainder of the first portion 170. Alternatively, the flap 178
can be formed from a different material. The flap 178 can be
initially secured to the remainder of the first portion by a pair
of perforation lines 180 and 182. Alternatively, the pair of
perforation lines 180 and 182 can be lines of weakness, score
lines, etc. as is known to those skilled in the art. The pair of
perforation lines 180 and 182 is designed to be broken so that at
least a portion of the flap 178 can be separated from the first
portion 170. The pair of perforation lines 180 and 182 can be
aligned parallel to one another or be aligned at an angle to one
another. The pair of perforation lines 180 and 182 can extend
toward, up to or into the back panel 20. Desirably, the pair of
perforation lines 180 and 182 extends up to the back panel 20.
Another way of expressing this is to say that the pair of
perforation lines 180 and 182 extends across the width of the first
portion 170. The size and shape of the flap 178 can vary to suit
one's needs. Desirably, the flap 178 has a generally rectangular
shape. The flap 178 has a free end 184 which can contain a pair of
bevel edges 186 and 188. The bevel edges 186 and 188 visually
differentiate the free end 184 of the flap 178 from the remainder
of the first portion 170. This feature makes it easy for a consumer
to readily locate the flap 178. Although, a pair of bevel edges 186
and 188 is shown, the free end 184 of the flap 178 can be cut
and/or shaped into any desired geometrical pattern or shape. For
example, the free end 184 of the flap 178 can be rounded, have an
arcuate shape, contain notches, be sinusoidal, have a finger tab
extending outward therefrom, etc. If a finger tab is utilized, it
can have a width which is less than the width of the flap 178.
[0102] The flap 178 also has an opposite end 190, see FIGS. 19 and
21, which is connected to the back panel 20. The flap 178 can
rotate or move around the opposite end 190. For example, the flap
178 can rotate, from its initial closed position, wherein it is
aligned flush with the first portion 170, to an open position once
the pair of perforation lines 180 and 182 is broken. The flap 178
can rotate through an angle up to about 270 degrees. Desirably, the
flap 178 can rotate through an angle of from between about 30
degrees to about 180 degrees. More desirably, the flap 178 can
rotate through an angle of from between about 45 degrees to about
90 degrees.
[0103] The carton 12' is packaged and shipped from the manufacturer
to the retailer with the flap 178 being in the closed position as
shown in FIG. 19. At the retailer, if a consumer desired to feel
the softness or texture of the roll products 14 housed in the
carton 12', he or she can pull the flap 178 outward, away from the
end wall 144'', thereby causing the pair of perforation lines 180
and 182 to break. This action separates the flap 178 from the
remainder of the first portion 170 although the flap 178 is always
connected at its opposite end 190. An opening 192 occurs as the
flap 178 is rotated away from the first portion 170. The opening
192 should be of sufficient size and shape to allow a consumer to
easily insert his or her thumb as well as an index finger
therethrough. Alternatively, the opening 192 should be of
sufficient size to allow a consumer to insert two or more fingers
through the opening 192. The opening 192 allows the consumer to
reach into the carton 12' and physically touch and feel at least
one of the roll products 14. This will allow a consumer to satisfy
themselves that the roll products 14 housed in the carton 12' are
of sufficient softness, or texture, or possesses the quality that
they are looking for. After the physical inspection has taken
place, the flap 178 can be rotated back to a closed position. A
slit 194, see FIGS. 20 and 21, is formed in the second portion 172.
The slit 194 can be aligned parallel to the longitudinal central
axis X-X or be aligned at an angle thereto. The slit 194 is of
sufficient length to allow the free end 184 of the flap 178 to be
tucked or inserted therethrough. Alternatively, the slit 194 is of
sufficient length to allow the finger tab to be inserted therein or
to engage therewith. The free end 184 of the flap 178, or the
finger tab when it is present, should be able to be inserted at
least 0.1 inches inward through the slit 194. Desirably, the free
end 184 of the flap 178, or the finger tab when it is present,
should be able to be inserted at least 0.2 inches inward through
the slit 194. More desirably, the free end 184 of the flap 178, or
the finger tab when it is present, should be able to be inserted at
least 0.3 inches inward through the slit 194. This will create a
secure attachment of the flap 178 with the remaining first portion
170 of the end wall 144''.
[0104] It should be noted that the consumer, a store employee or
someone else can return the flap 178, or the finger tab when it is
present, from its open position to the closed position where the
free end 184 is tucked or inserted through the slit 194. When the
flap 178, or the finger tab when it is present, is tucked into the
slit 194, the carton 12' will appear to be similar to an unopened
carton 12'.
Method
[0105] A method of recycling empty hollow cores 16 formed from
cellulose fibers back into the original package carton 12 will now
be explained with reference to FIG. 22. A plurality of roll
products 14, each formed from cellulosic material and each being
wound upon an empty hollow core 16, are housed or retained in the
carton 12. The carton 12 is formed also from cellulose fibers.
Desirably, the carton 12 is constructed from paperboard. The carton
12 can be recycled or composed by itself or in combination with one
or more of the empty hollow cores 16 once the roll product 14 has
been removed from the respective hollow core 16. Each of the hollow
cores 16 has a paper product 14, such as toilet paper, wound upon
it. The roll product 14 usually includes multiple sheets of
cellulosic material each separated by a weakened line, such as a
perforation line or score line, so that one or more of the sheets
can be removed from the roll product 14 at a given time. When all
of the sheets are removed, an empty hollow core 16 will remain.
[0106] The method includes the steps of inserting a plurality of
the roll products 14 into the carton 12 and closing and sealing the
open end of the carton 12. The carton 12 can then be shipped to a
retailer or directly to a consumer. The carton 12 has a top panel
28 and a bottom panel 44 aligned opposite to the top panel 28. The
carton 12 also has a pair of end walls 142 and 144 each being
located between the top panel 28 and the bottom panel 44. The
carton 12 further has a front panel 38 and a back panel 20, each
being located between the top panel 28 and the bottom panel 44 and
adjacent to each of the pair of end walls 142 and 144. The carton
12 also has a first tear panel 84 formed in one of the pair of end
walls 142 and 144 and has an end portion 88 which extends partially
into the back panel 20 and another end portion 90 which extends
partially into the front panel 38. When the first tear panel 84 is
removed, a dispensing opening 100 is formed into the carton 12. The
dispensing opening 100 provides access to at least one of the
products 14 housed within the carton 14. A roll product situated in
the bottom row or adjacent to the bottom panel 44 can be withdrawn
from the dispensing opening 100.
[0107] A second tear panel 104 is formed in either the back panel
20 or in the front panel 38. The second tear panel 104 has a
diameter d.sub.2 which is at least equal to the external or common
diameter d.sub.1 of each of the hollow cores. When the second tear
panel 104 is removed, an empty hollow core insertion opening 110 is
formed into the carton 12. The insertion opening 110 allows an
empty hollow core 16 to be inserted back into the carton 12 once
one of the products 14 has been removed from the carton 12. One of
the products 14 has to be first removed from the carton 12 in order
to form a void space before the empty hollow core 16 can be
inserted back into the carton 12.
[0108] The method also includes removing the first tear panel 84 to
obtain the dispensing opening 100 into the carton 12. The second
tear panel 104 is also removed to obtain the insertion opening 110.
One of the products 14 is then removed from the carton 12 and the
product which is wound upon the hollow core 16 is used up to obtain
an empty hollow core 16. The method further includes inserting the
empty hollow core 16 back into the carton 12 through the insertion
opening 110.
[0109] The method can also includes recycling or composting the
carton 12 after it has been filled with one or more empty hollow
cores 16.
[0110] The method further includes forming the second tear panel
104 in the back panel 20 and forming a third tear panel 112 in the
front panel 38. The third tear panel 112 has a diameter d.sub.3
which is at least equal to the external or common diameter d.sub.1
of each of the hollow cores 16. When the third tear panel 112 is
removed, another empty hollow core insertion opening 118 is formed
into the carton 12. The insertion opening 118 provides another
opening so that an empty hollow core 16 can be inserted back into
the carton 12 once one of the products 14 has been removed from the
carton 12. With the presence of both of the empty hollow core
insertion openings 110 and 118, one can insert an empty hollow core
16 back into the carton 12 from either the back or front panels, 20
and 38 respectively.
[0111] While the invention has been described in conjunction with
several specific embodiments, it is to be understood that many
alternatives, modifications and variations will be apparent to
those skilled in the art in light of the foregoing description.
Accordingly, this invention is intended to embrace all such
alternatives, modifications and variations which fall within the
spirit and scope of the appended claims.
* * * * *