U.S. patent application number 12/584256 was filed with the patent office on 2011-03-03 for blank for forming a carton and a method of recycling 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 | 20110049227 12/584256 |
Document ID | / |
Family ID | 43623374 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110049227 |
Kind Code |
A1 |
Gretzinger; Gary Patrick ;
et al. |
March 3, 2011 |
Blank for forming a carton and a method of recycling 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
pair of dispensing openings through which the roll products can be
individually removed. The carton also has a pair of openings
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 recycling 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: |
43623374 |
Appl. No.: |
12/584256 |
Filed: |
September 1, 2009 |
Current U.S.
Class: |
229/117.12 ;
229/122; 229/242; 53/473 |
Current CPC
Class: |
B65D 2571/00728
20130101; B65D 5/541 20130101; B65D 5/542 20130101; B65D 2571/00141
20130101; B65D 2571/00574 20130101; B65D 2571/00586 20130101; B65D
2571/0066 20130101; B65D 2209/00 20130101; B65D 71/36 20130101 |
Class at
Publication: |
229/117.12 ;
229/122; 229/242; 53/473 |
International
Class: |
B65D 5/72 20060101
B65D005/72; B65D 5/468 20060101 B65D005/468; B65B 5/00 20060101
B65B005/00 |
Claims
1. A carton formed from cellulose fibers and having a pair of
dispensing openings, said carton capable of housing a plurality of
generally cylindrically shaped products formed from cellulose
fibers, each of said products 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 said front panel and having portions that
extend into each of said top and bottom panels, said first tear
panel defining a first dispensing opening when removed which
provides access to at least one of said products housed within said
carton; f) a second tear panel formed in one of said end walls and
having portions that extend into each of said top and bottom
panels, said second tear panel defining a second dispensing opening
when removed which provides access to at least one of said products
housed within said carton; and g) a pair of third tear panels
formed in said top panel, said pair of third tear panels defining a
pair of third openings when removed which allow an empty hollow
core to be inserted back into said carton once one of said products
has been removed from said carton.
2. The carton of claim 1 wherein one of said pair of third tear
panels is located adjacent to a first corner of said top panel and
said other pair of third tear panels is located adjacent to a
second corner of said top panel, and said first corner is located
diagonally across from said second corner.
3. The carton of claim 2 wherein one of said pair of third tear
panels has a circular configuration with a central axis which is
located with 2 inches of said first tear panel.
4. The carton of claim 3 wherein said other of said pair of third
tear panels has a circular configuration with a central axis which
is located with 2 inches of said second tear panel.
5. The carton of claim 2 wherein each of said pair of third tear
panels has a diameter which is greater than said common diameter of
said empty hollow cores.
6. The carton of claim 1 further comprising a pair of fourth tear
panels formed in said bottom wall, said pair of fourth tear panels
defining a pair of fourth openings when removed which allow an
empty hollow core to be inserted back into said carton once at
least one of said products has been removed from said carton.
7. The carton of claim 6 wherein each of said third and fourth
pairs of tear panels has a central axis and said central axis of
each of said pair of third tear panels is coaxially aligned with a
central axis of each of said pair of fourth tear panels.
8. The carton of claim 1 wherein each of said first, second and
pair of third tear panels includes a plurality of perforations and
a handle is positioned in said top panel.
9. The carton of claim 1 wherein one of said first and second
openings has an edge located flush with an adjacent panel and a
detent is formed along said edge to restrict movement of said
product.
10. A blank for forming a carton having a pair of dispensing
openings, 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 said front panel and having a pair of
portions which extends partially into said top panel and said
bottom panel, and when said first tear panel is removed a first
opening is formed into said carton; and u) a pair of second tear
panels, one of said pair of second tear panels formed in said top
panel top flap and having a portion which partially extends into
said top panel and said other of said pair of second tear panels
formed in said bottom panel top flap and having a portion which
partially extends into said bottom panel, and when said pair of
second perforations is removed a second opening is formed into said
carton.
11. The blank of claim 10 further comprising a pair of third tear
panels formed in said top panel, when at least one of said pair of
third tear panels is removed a third opening is formed into said
carton which allows an empty hollow core to be inserted back into
said carton, and each of said third openings has a diameter which
is at least equal to said common diameter of said empty hollow
core.
12. The blank of claim 11 wherein a pair of third tear panels are
formed in said top panel, each of said pair of third tear panels
has a central axis which is located within about 3 inches of one of
said first and second horizontal fold lines.
13. The blank of claim 10 wherein each of said back panel top flap,
said front panel top flap, said top panel top flap and said bottom
panel top flap has a height, and said height of each of said top
panel top flap and said bottom panel top flap is greater than said
height of each of said back panel top flap and said front panel top
flap.
14. The blank of claim 10 wherein each of said back panel, said
front panel, said top panel and said bottom panel has a width, said
width of said back panel is approximately equal to said width of
said front panel, and said width of said top panel is approximately
equal to said width of said bottom panel, and said width of said
back panel is greater than said width of said top panel.
15. The blank of claim 10 wherein said back panel bottom flap and
said front panel bottom flap are identical in size and
configuration, and said top panel bottom flap and said bottom panel
bottom flap are identical in size and configuration.
16. The blank of claim 10 further comprising a pair of fourth tear
panels formed in said bottom panel, when at least one of said pair
of fourth tear panels is removed a fourth opening is formed into
said carton which allows an empty hollow core to be inserted back
into said carton, and said fourth opening has a diameter which is
at least equal to said common diameter of said empty hollow
core.
17. The blank of claim 16 wherein each of said pair of fourth tear
panels has a central axis which is located within about 3 inches of
one of said first and second horizontal fold lines.
18. A method of recycling empty hollow cores formed from cellulose
fibers which are housed in a carton formed from cellulose fibers,
each of said hollow cores having a product formed from cellulose
fibers 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 said front panel and having portions
that extend into each of said top and bottom panels, said first
tear panel defining a first opening when removed which provides
access to at least one of said products housed within said carton,
a second tear panel formed in one of said pair of end walls and
having portions that extend into each of said top and bottom
panels, said second tear panel defining a second opening when
removed which provides access to at least one of said products
housed within said carton, and a pair of third tear panels formed
in said top panel, said pair of third tear panels defining a pair
of third openings when removed which permits an empty hollow core
to be inserted back into said carton once one of said products has
been removed from said carton; b) removing one of said first and
second tear panels to obtain a dispensing opening into said carton;
c) removing at least one of said third tear panels; 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 one
of said third openings.
19. The method of claim 18 further comprising the step of removing
both of said third tear panels.
20. The method of claim 18 further comprising recycling said carton
containing one or more of said empty hollow cores.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a blank capable of forming a
carton having a pair of dispensing openings therein and a method of
recycling 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 cellulose fibers, and recycling the 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. 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. 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. Some existing
paperboard cartons only contain a single dispensing opening that is
accessed via a removable "tear off" panel through which the roll
products can be removed. Existing paperboard cartons for use with
other kinds of cylindrical shaped products only contain a single
dispensing opening through which roll products could be removed.
Since the cartons tend to have a rectangular cube shape, it is
advantageous to construct the carton to have two dispensing
openings formed therein to allow the consumer to vary the
orientation of the carton as it is being stored on a shelf or in a
closet while still being able to remove the roll products one at a
time, as needed. One drawback with the existing paperboard cartons
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.
[0004] Now a blank capable of forming a paperboard carton having a
pair of dispensing openings formed therein has been invented which
further includes a pair of openings through which hollow cores,
which have had the cellulosic product removed there from and the
removable panel(s), can be inserted back into the original carton
and be recycled. In addition, a method of recycling the hollow
cores and removable panels back into the carton is also
disclosed.
SUMMARY OF THE INVENTION
[0005] Briefly, this invention relates to a blank for forming a
carton having a pair of dispensing openings. 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.
[0006] 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, one of the
pair of second tear panels formed in the top panel top flap and
having a portion which partially extends into the top panel and the
other of the pair of second tear panels formed in the bottom panel
top flap and having a portion which partially extends into the
bottom panel, and when the pair of second perforations is removed a
second opening is formed into the carton formed from the blank.
[0007] This invention also relates to a carton formed from
cellulose fibers and having a pair of dispensing openings 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 the front
panel and having portions that extend into each of the top and
bottom panels. 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 one of the pair of end walls and having portions
that extend into each of the top and bottom panels. The second tear
panel defines a second opening when removed which provides access
to at least one of the roll products housed within the carton. The
carton still further includes a pair of third tear panels formed in
the top panel. The pair of third tear panels defines a pair of
third openings when removed which allows the hollow cores to be
inserted back into the carton through one of the third openings so
that they can be recycled with the carton once one of the roll
products has been removed from the carton.
[0008] 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 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 the front panel and having portions that extend into each
of the top and bottom panels. 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 one of the pair of end walls and having
portions that extend into each of the top and bottom panels. The
second tear panel defines a second opening when removed which
provides access to at least one of the roll products housed within
the carton. The carton still further has a pair of third tear
panels formed in the top panel. The pair of third tear panels
defines a pair of third openings when removed which allow the
hollow cores to be inserted back into the carton through one of the
pair of third tear panels once one of the roll products has been
removed from the carton. The method also includes removing at least
one of the third tear panels. The method further includes removing
the roll product from the hollow core and then inserting the hollow
core back into the carton through one of the pair of third
openings.
[0009] The general object of this invention is to provide a blank
capable of forming a carton having a pair of dispensing openings
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.
[0010] Another object of this invention is to provide a carton
having a first tear panel formed in the front panel and a second
tear panel formed in one of the pair of end walls which allows roll
products housed in the carton to be dispensed at two different
locations.
[0011] Another object of this invention is to provide tear panel
opening of a size and shape that will allow the consumer very easy
access to the open core ends of the roll products for fast, sure
dispensing without damage to the paper towel or bath tissue.
[0012] Another object of this invention is to provide a fifth tear
panel that can be used to view the interior of the paperboard
carton to easily determine the number of un-used paper rolls still
remaining in the carton.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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
[0018] 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.
[0019] FIG. 2 is a top view of the blank shown in FIG. 1 after the
four bottom flaps have been folded inward and the blank has been
folded along the transverse central axis Y-Y.
[0020] FIG. 3 is a perspective view of a carton formed from the
blank shown in FIG. 1.
[0021] FIG. 4 is a perspective view of a carton formed from the
blank shown in FIG. 1 and having the first tear panel removed to
reveal a couple of the roll products housed in the carton.
[0022] FIG. 5 is a top view of a portion of the top panel showing
the semi-circular perforation line.
[0023] FIG. 6 is a top view of a portion of the front panel showing
a perforation line having an alternative arrangement of cuts and
land areas.
[0024] FIG. 7 is a partial cut away perspective view of an empty
carton showing the second tear panel removed to form a second
opening in the carton, and showing a pair of third tear panels
formed in the top panel and a pair of fourth tear panels formed in
the bottom panel with each of the third tear panels being coaxially
aligned with one of the fourth tear panels.
[0025] FIG. 8 is a perspective view of a hollow core formed from
cellulosic fibers.
[0026] FIG. 9 is a perspective view of the carton formed from the
blank shown in FIG. 1 and having the pair of second tear panels
removed to reveal a couple of the roll products housed in the
carton.
[0027] FIG. 10 is a partial perspective of an alternative
embodiment showing the second dispensing opening having an edge
flush with the back panel of the carton and showing the portions of
the pair of second tear panels that extends into the front and
bottom panels form an offset arcuate configuration.
[0028] FIG. 11 is a partial perspective of still another
alternative embodiment showing the second dispensing opening having
a pair of detents positioned along the lower edge of the second
dispensing opening and showing the portions of the pair of second
tear panels that extends into the front and bottom panels form an
angular configuration.
[0029] FIG. 12 is a partial perspective of still another embodiment
showing the second dispensing opening having an edge flush with the
back panel of the carton and having a pair of corner detents.
[0030] FIG. 13 is a flow diagram of a method of recycling empty
hollow cores back into the carton.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to FIGS. 1-4, a blank 10 is shown in FIG. 1 along
with a carton 12 which can be constructed from the blank 10, see
FIGS. 3 and 4. The blank 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.
[0032] Referring to FIGS. 1 and 2, the blank 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 the blank
10, measured perpendicular to the X-X and Y-Y axes, can vary. The
blank 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 blank 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 blank 10. The blank 10 is relatively thin. The
blank 10 can have a thickness of less than about 0.2 inches.
Desirably, the blank 10 has a thickness of less than about 0.1
inches. More desirably, the blank 10 has a thickness of less than
about 0.05 inches. Even more desirably, the blank 10 has a
thickness of less than about 0.03 inches.
[0033] Once the blank 10 is formed to a predetermined shape, it can
be easily configured, folded, constructed or transformed into a
carton 12. The blank 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 can be
folded, bent over, doubled up, joined, taped, interlocked and/or be
sealed or bonded together to form the carton 12, see FIGS. 3 and 4.
Desirably, the blank 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.
[0034] Referring to FIGS. 3 and 4, the carton 12 formed from the
blank 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. The overall size of the carton 12 can
vary.
[0035] The carton 12 can be sized to house or retain a plurality of
roll products 13. The roll products 13 are generally cylindrically
shaped products formed from cellulosic fibers. The roll products 13
can be formed with eco-friendly features. For example, the roll
products 13 can be made from recycled cellulose fibers. The roll
products 13 can be made hypoallergenic. The roll products 13 can be
made with no added dyes or fragrances and can even be whitened
without using chlorine. Such roll products 13 include but are not
limited to: rolls of paper towel, rolls of toilet paper, rolls of
napkins, rolls of paper work-towels, rolls of dry wipes, rolls of
wipers, etc. The size and shape of the roll products 13 can vary.
Each of the roll products 13 is compressible by at least 10 percent
measured perpendicular to its longitudinal central axis
X.sub.1-X.sub.1, see FIG. 4. Each of the roll products 13 may also
exhibit a relatively high coefficient of friction. Normally, the
carton 12 can house from between 2 to 120 similar roll products 13.
An even number or an odd number of roll products 13 can be housed
or retained in the carton 12. Desirably, an even number of similar
roll products 13 are housed in the carton 12. For rolls of paper
towels or rolls of dry wipes, the carton 12 can be sized to house
or retain 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24, etc. rolls of paper towels. For rolls
of toilet paper, the carton 12 can be sized to house or retain 2,
3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37,
38, 39, 40 or more rolls of toilet tissue.
[0036] It should be understood that one could house different types
of roll products 13 with the carton 12, if desired. Desirably, each
carton 12 will retain a plurality of like kind of roll products
13.
[0037] 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 14. The size and shape of the adhesive tab 14 can
vary. The adhesive tab 14 can include a continuous area of adhesive
or glue or multiple intermittent areas of adhesive or glue that
will bond to an adjoining portion of the blank 10 once the blank 10
is folded into the carton. The blank 10 also includes a back panel
16 located adjacent to the adhesive tab 14. The back panel 16 has a
top 18 and a bottom 20. The top and bottom, 18 and 20 respectively,
are measured relative to the transverse central axis Y-Y. The blank
10 also has a first vertical fold line 22 positioned between the
adhesive tab 14 and the back panel 16. The first vertical fold line
22 extends parallel to the transverse central axis Y-Y. The first
vertical fold line 22 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 22 in the blank
10.
[0038] The blank 10 further has a top panel 24 located adjacent to
the back panel 16. The top panel 24 has a top 26 and a bottom 28.
The blank 10 also has a second vertical fold line 30 positioned
between the back panel 16 and the top panel 24. The second vertical
fold line 30 extends parallel to the transverse central axis Y-Y.
The second vertical fold line 30 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 30 in
the blank 10.
[0039] The blank 10 further has a front panel 32 located adjacent
to the top panel 24. The front panel 32 has a top 34 and a bottom
36. The blank 10 also has a third vertical fold line 38 positioned
between the top panel 24 and the front panel 32. The third vertical
fold line 38 extends parallel to the transverse central axis Y-Y.
The third vertical fold line 38 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 38 in
the blank 10.
[0040] The blank 10 further has a bottom panel 40 located adjacent
to the front panel 32. The bottom panel 40 has a top 42 and a
bottom 44. The blank 10 also has a fourth vertical fold line 46
positioned between the front panel 32 and the bottom panel 40. The
fourth vertical fold line 46 extends parallel to the transverse
central axis Y-Y. The fourth vertical fold line 46 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 46 in the blank 10.
[0041] Still referring to FIG. 1, the blank 10 also has a back
panel top flap 48 located adjacent to the top 18 of the back panel
16, a back panel bottom flap 50 located adjacent to the bottom 20
of the back panel 16, a top panel top flap 52 located adjacent to
the top 26 of the top panel 24, a top panel bottom flap 54 located
adjacent to the bottom 28 of the top panel 26, a front panel top
flap 56 located adjacent to the top 34 of the front panel 32, a
front panel bottom flap 58 located adjacent to the bottom 36 of the
front panel 32, a bottom panel top flap 60 located adjacent to the
top 42 of the bottom panel 40, and a bottom panel bottom flap 62
located adjacent to the bottom 44 of the bottom panel 40.
[0042] The back panel top flap 48 has a height h.sub.1 and the
front panel top flap 56 has a height h.sub.3. The height h.sub.1 of
the back panel top flap 48 is approximately equal to the height
h.sub.3 of the front panel top flap 56. Desirably, the height
h.sub.1 of the back panel top flap 48 is equal to the height
h.sub.3 of the front panel top flap 56. The top panel top flap 52
has a height h.sub.2 and the bottom panel top flap 60 has a height
h.sub.4. The height h.sub.2 of the top panel top flap 52 is
approximately equal to the height h.sub.4 of the bottom panel top
flap 60. Desirably, the height h.sub.2 of the top panel top flap 52
is equal to the height h.sub.4 of the bottom panel top flap 60. In
addition, the height h.sub.2 of the top panel top flap 52 as well
as the height h.sub.4 of the bottom panel top flap 60 are each
greater than the height h.sub.1 of each of the back panel top flap
48 and the height h.sub.3 of the front panel top flap 56. 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.
[0043] Each of the back panel 16, the top panel 24, the front panel
32 and the bottom panel 40 has a width, w.sub.1, w.sub.2, w.sub.3
and w.sub.4 respectively. The width w.sub.1 of the back panel 16 is
approximately equal to the width w.sub.3 of the front panel 32.
Desirably, the width w.sub.1 of the back panel 16 is equal to the
width w.sub.3 of the front panel 32. The width w.sub.2 of the top
panel 24 is approximately equal to the width w.sub.4 of the bottom
panel 40. Desirably, the width w.sub.2 of the top panel 24 is equal
to the width w.sub.4 of the bottom panel 40. In addition, the width
w.sub.1 of the back panel 16 is greater than the width w.sub.2 of
the top panel 24, and the width w.sub.3 of the front panel 32 is
greater than the width w.sub.4 of the bottom panel 40.
[0044] Still referring to FIG. 1, the back panel bottom flap 50 and
the front panel bottom flap 58 are identical in size and
configuration. The top panel bottom flap 54 and the bottom panel
bottom flap 62 are identical in size and configuration. However,
the back panel bottom flap 50 can be of a different size and
configuration from the front panel bottom flap 54, if desired. In
addition, each of the back panel bottom flap 50 and the front panel
bottom flap 58 is larger in size than either of the top panel
bottom flap 54 or the bottom panel bottom flap 62. Alternatively,
the back panel bottom flap 50 and the front panel bottom flap 58
can be smaller or of equal size to the top panel bottom flap 54 or
to the bottom panel bottom flap 62.
[0045] The blank 10 further has a first horizontal fold line 64
disposed between the back panel 16 and the back panel top flap 48,
between the top panel 24 and the top panel top flap 52, between the
front panel 32 and the front panel top flap 56, and between the
bottom panel 40 and the bottom panel top flap 60. The blank 10
further has a second horizontal fold line 66 disposed between the
back panel 16 and the back panel bottom flap 50, between the top
panel 24 and the top panel bottom flap 54, between the front panel
32 and the front panel bottom flap 58, and between the bottom panel
40 and the bottom panel bottom flap 62. The first horizontal fold
line 64 is aligned essentially parallel to the second horizontal
fold line 66 and both the first and second horizontal fold line, 64
and 66 respectively, are aligned parallel to the longitudinal
central axis X-X.
[0046] It should be understood that the blank 10 can be configured
and constructed so as to form a hollow sleeve with an auto forming
end or have two oppositely aligned manual or machine formable
ends.
[0047] Still referring to FIG. 1, the back panel bottom flap 50 can
optionally contain a first perforated line 51 formed along the
second horizontal fold line 66 and a second perforated line 53
formed at an acute angle to the first perforated line 51. The
second perforated line 53 intersects the second vertical fold line
30. The top panel bottom flap 54 can optionally contains a
perforated line 55 formed along the second horizontal fold line 66.
The top panel bottom flap 54 also has a spot of an adhesive or glue
57 secured thereto. The front panel bottom flap 58 can optionally
contains a first perforated line 59 formed along the second
horizontal fold line 66 and a second perforated line 61 formed at
an acute angle to the first perforated line 59. The second
perforated line 61 intersects the fourth vertical fold line 46.
Lastly, the bottom panel bottom flap 62 can optionally contains a
perforated line 63 formed along the second horizontal fold line 66.
The bottom panel bottom flap 62 also has a spot of an adhesive or
glue 65 secured thereto. When the perforation lines 51, 53, 55, 59,
61 and 63 are present, they cooperate with the second horizontal
fold line 66 and enable the four bottom flaps 50, 54, 58 and 62 to
be automatically formed into a wall of the carton 12.
[0048] Referring to FIGS. 1 and 2, the blank 10 shown in FIG. 1 can
be folded along the Y-Y axis to form a flat folded carton 12, see
FIG. 2. The flat folded carton 12 can be shipped from the
manufacturer of the blank 10 to the customer who will fill the
carton 12 with roll products 13. In the arrangement illustrated in
FIG. 2, the adhesive tab 14 is already secured to the inside of the
bottom panel 40 to form a flat hollow sleeve. The four bottom flaps
50, 54, 58 and 62 (not visible in FIG. 2) are folded into the flat
hollow sleeve. As the hollow sleeve is manipulated into a four
sided carton 12, the four bottom flaps 50, 54, 58 and 62 will move
outward and interlock with one another to automatically form one
end wall of the carton 12. This is referred to as a "self-forming
end" or an "auto forming end". This action saves time and leaves
one open end into the carton 12. As the four bottom flaps 50, 54,
58 and 62 move outward to form an end wall, the adhesive spot 57
contacts the back panel bottom flap 50 and forms a secure
attachment thereto. Simultaneously, the adhesive spot 65 contacts
the front panel bottom flap 58 and forms a secure attachment
thereto.
[0049] Returning to FIG. 1, the blank 10 further includes a first
tear panel 68 formed in the front panel 32. The first tear panel 68
has a central portion 70 and a pair of end portions 72 and 74 which
extends partially into the top panel 24 and the bottom panel 40,
respectively. The size and shape of the first tear panel 68 can
vary. Desirably, the first tear panel 68 can be of any geometrical
shape. As depicted in FIG. 1, the first tear panel 68 has a
rectangular central portion 70 sandwiched between the two end
portions 72 and 74. The two end portions 72 and 74 are depicted as
semi-circular in configuration although almost any geometrical
configuration can be utilized. The rectangular central portion 70
is aligned along the longitudinal central axis X-X and the two end
portions 72 and 74 are positioned at an end thereof.
[0050] It should be understood that one or more finger holes 75 can
be optionally formed in the first tear panel 68. Each finger hole
75 can vary in size, shape and location. For example, in FIG. 1,
two finger holes 75, 75 are depicted being formed in opposite ends
of the first tear panel 68 approximate the vertical fold lines 38
and 46. Each finger hole 75 can be a closed outer portion of the
carton 12 that is at least partially surrounded by perforations. As
one pokes an index finger into the outer portion, the perforations
break and a hole or opening is formed into the first tear panel 68.
The index finger can then be used to tear or separate the first
tear panel 68 from the carton 12.
[0051] Referring now to FIGS. 1, 5 and 6, the first tear panel 68
has a first perforation segment 76, a second perforation segment
78, a third perforation segment 80 and a fourth perforation segment
82. The four segments 76, 78, 80 and 82 combine to form a
continuous line of perforations. Each of the perforation segments
76, 78, 80 and 82 can consist of a plurality of cuts 84 each
separated by a land area 86. The length of the cuts 84 and the size
of the land areas 86 can vary in dimension and thickness. Likewise,
the cuts 84 and the land areas 86 can vary in geometrical shape. In
FIG. 5, a portion of the top panel 24 is shown with the cuts 84 and
the land areas 86 depicted as being arranged in a semi-circle. The
cuts 84 have a length which range from about 3 to about 4 times the
length of the land areas 86. However, the cuts 84 can have a
smaller length, an equal length or a greater length than the land
areas 86.
[0052] In FIG. 6, a portion of the front panel 32 is shown wherein
the perforation segment 80 is formed by a pair of linear cuts 88
and 90. The cuts 88 and 90 can be aligned at an acute angle to one
another. The cuts 88 and 90 can also contact one another or be
spaced apart from one another. Each of the pair of cuts 88 and 90
is separated by a land area 92. As mentioned with regard to FIG. 5,
the length, thickness and shape of the cuts 88 and 90 and the land
areas 92 can vary.
[0053] Referring again to FIGS. 2 and 3, by tearing or breaking the
perforation segments 76, 78, 80 and 82, the first tear panel 68 can
be completely removed from the carton 12. When the first tear panel
68 is removed, a first dispensing opening 94 is formed in the
carton 12 which is of sufficient size and shape to permit the roll
products 13 housed in the carton 12 to be dispended one at a time.
The lower or bottom row of the roll products 13 is dispensed
through the first dispensing opening 94. The size and shape of the
first dispensing opening 94 prevents the roll products 13 situated
in the adjacent upper row from being dispensed. For example, if the
carton 12 contains six roll products 13 arranged with a bottom row,
a middle row and an upper row, with two roll products 13 in each
row, only a roll product 13 situated in the bottom roll can be
dispensed from the carton 12. When this roll product 13 is removed
from the carton 12, the roll product 13 located immediately above
it will move downward and occupy the empty space left by the roll
product 13 that was removed. This means that there will be only
roll product 13 left in the upper row.
[0054] Referring again to FIGS. 1-4 and 7, the blank 10 further
includes a pair of second tear panels 96 and 98, see FIG. 1. The
pair of second tear panels 96 and 98 is aligned parallel to the
transverse central axis Y-Y of the blank 10. One of the pair of
second tear panels 96 and 98 is formed in the top panel top flap 52
and has an end portion 100 which partially extends into the top
panel 24. In FIGS. 1-4, the end portion 100 is shown having a
semi-circular configuration although any geometrical shape can be
used. The other of the pair of second tear panels 96 and 98 is
formed in the bottom panel top flap 60 and has an end portion 102
which partially extends into the bottom panel 40. In FIG. 1, the
end portion 102 is also shown having a semi-circular configuration
although any geometrical shape can be used. The size and shape of
the pair of second tear panel 96 and 98 can vary. Desirably, the
pair of second tear panels 96 and 98 can be of any geometrical
shape. The pair of second tear panels 96 and 98 is designed to mesh
or mate with one another, see FIG. 4. When the pair of second tear
panels 96 and 98 is removed from the carton 12, in a similar
fashion as was described above with reference to the first tear
panel 68, they form a single, second rectangular opening 104 into
the carton 12, see FIG. 7. The pair of second tear panels 96 and 98
include one or more perforation segments as was described above
with reference to the first tear panel 68. The cuts and land areas
used to form the perforation segments can be similar or different
from those shown in FIGS. 5 and 6. Desirably, the perforation
segments around the pair of second tear panels 96 and 98 are
identical to those used around the first tear panel 68.
[0055] As with the first tear panel 68, one or more finger holes
105 can be optionally formed in each of the pair of second tear
panels 96 and 98. Each finger hole 105 can vary in size, shape and
location. For example, in FIG. 1, a finger hole 105 is formed in
each of the pair of second tear panels 96 and 98 approximate the
horizontal fold line 64. Each finger hole 105 can be a closed outer
portion of the carton 12 that is at least partially surrounded by
perforations. As one pokes an index finger into the outer portion,
the perforations break and a hole or opening is formed into the
second pair of tear panels 96 and 98. The index finger can then be
used to tear or separate the pair of second tear panels 96 and 98
from the carton 12.
[0056] Referring again to FIG. 1, one will notice that the top
panel top flap 52 has a pair of spaced apart notches 97, 97 formed
therein. The pair of notches 97, 97 is located adjacent to the
second tear panel 96. The pair of notches 97, 97 allow adhesive
positioned on the inside surface of the bottom panel top flap 60 to
adhere to the outer surfaces of the back panel top flap 48 and the
front panel top flap 56. This structure will then allow the four
top flaps 48, 52, 56 and 60 to be secured together.
[0057] It should be understood that after the carton 12 is filled
with a predetermined number of roll products 13, the four top flaps
48, 52, 56 and 60 are folded inward. First, the back panel top flap
48 and the front panel top flap 56 are simultaneously or
sequentially folded inward. The top panel top flap 52 is then
folded inward on top of the back panel top flap 48 and the front
panel top flap 56. Two spots of adhesive can be applied to the
inside surface of the bottom panel top flap 60 which will be
aligned with the pair of notches 97, 97. Lastly, the bottom panel
top flap 60 is folded over the top panel top flap 52. All four top
flaps 48, 52, 56 and 60 are secured together, such as by an
adhesive. Desirably, the adhesive is a hot melt adhesive.
Alternatively, the adhesive can be a cold melt adhesive or any
other type of adhesive known to those skilled in the art.
[0058] As depicted in FIGS. 1-4 and 7, when the first tear panel 68
and the combination of the pair of second tear panels 96 and 98 are
removed, two identical sized and shaped first and second dispensing
openings, 94 and 104 respectively, are formed into the carton 12.
The first and second dispensing openings, 94 and 104 respectively,
are sized and located so as to allow a single roll product 13 to be
removed from the bottom row of the carton 12 at a given time. It
should be understood that the carton 12 is designed to have only
one of the first or second openings 94 or 104 being available at
any time.
[0059] The first and second dispensing openings, 94 and 104
respectively, are aligned parallel to the longitudinal central axis
X-X of the carton 12. The first opening 94 will be in a different
panel from the second opening 104. Desirably, the first opening 94
will be located in a panel that is adjacent to or at 90 degrees the
end wall containing the second opening 104 once the carton 12 is
constructed. The first and second dispensing openings, 94 and 104
respectively, allow the carton 12 to be stored in two different
orientations while still allowing the roll products 13 to be
singularly dispended or removed from the carton 12. Typically, only
one of the first and second dispensing openings, 94 and 104
respectively, will be opened at a given time. However, both of the
first and second dispensing openings, 94 and 104 respectively,
could be opened at the same time, if desired.
[0060] Referring again to FIG. 1, the blank 10 further includes a
pair of third tear panels 106 and 108 formed in the top panel 24.
Each of the pair of third tear panels 106 and 108 can be identical,
similar or different in appearance. Each of the pair of third tear
panels 106 and 108 can be formed to any desired geometrical
configuration. In FIG. 1, each of the pair of third tear panels 106
and 108 is circular in configuration and of approximately equal
size. Desirably, each of the pair of third tear panels 106 and 108
are of the same size and configuration. Each of the pair of third
tear panels 106 and 108 contains a circumferential line of
perforations 110. The circumferential line of perforations 110 can
be a continuous line or a non-continuous line. The circumferential
line of perforations 110 can consist of a single line or a
combination of two or more lines. The circumferential line of
perforations 110 can be linear or non-linear in appearance.
Desirably, the circumferential line of perforations 110 is
continuous and contains a plurality of arcuate cuts 112 which
cooperate to form a circular configuration. The circumferential
line of perforations 110 includes a plurality of cuts 112 each
separated by a land area 114. The actual shape, length, thickness,
etc. of the cuts 112 and the land areas 114 can vary as was
explained above relative to the perforation segments 76, 78, 80 and
82. Those skilled in the art will be aware of various ways to
construct a circumferential line of perforations which can be
formed in the blank 10.
[0061] The circumferential line of perforations 110 extends
essentially completely around each of the pair of third tear panels
106 and 108 to form a closed geometrical shape, e.g. a circle. The
circumferential line of perforations 110 can later be completely
punched out by the consumer so that all of the material
circumscribed by the line of perforations 110 is removed.
Alternatively, the circumferential line of perforations 110 does
not have to be continuous and thus when the partially circumscribe
area is punched out, a portion of the third tear panel 106 or 108
remains attached to the top panel 24. The portion of the third tear
panel 106 or 108 that was broken at the circumferential line of
perforations 110 can be folded back out of the way, either into or
out of the carton 12.
[0062] Referring now to FIGS. 7 and 8, when at least one of the
pair of third tear panels 106 and 108 is removed, a third opening
116, see FIG. 7, is formed into the carton 12. It should be
understood that only one of the pair of third tear panels 106 and
108 needs to be removed in order to practice this invention. If
desired, both of the pair of third tear panels 106 and 108 could be
removed from the carton 12. When at least one of the third openings
116 is formed, it allows a person to insert an empty hollow core
118, see FIG. 8, back into the carton 12. Once the roll product 13,
for example, a roll of paper towels or a roll of toilet paper, is
used up, the empty hollow core 118 remains and must be recycled or
discarded. The carton 12 provides an easy mechanism for allowing
one or more of the empty hollow cores 118 to be inserted back into
the paperboard carton 12. By doing so, one can later recycle the
carton 12 as well as one or more of the empty hollow cores 118.
Since the paperboard carton 12 and the hollow cores 118 are each
formed from cellulosic fibers, they can be recycled in a similar
fashion and at the same time.
[0063] In FIG. 8, the empty hollow core 118 is shown as an
elongated cylindrical member having a round or circular
cross-section. However, the empty hollow cores 118 can have any
geometrical cross-sectional shape. Desirably, the cross-section of
each of the empty hollow cores 118 is circular. As depicted, the
empty hollow core 118 has an external or common diameter d, a
thickness t and a length I. All three dimensions can vary.
[0064] For a typical roll of paper towel, the empty hollow core 118
can have an external or common diameter d 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 empty hollow core 118 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 empty hollow core 118
can have a length l that ranges from between about 6 to 18 inches,
desirably from between about 10 to 12 inches, and more desirably
from between about 10.5 to about 11.5 inches.
[0065] For a typical roll of toilet paper, the empty hollow core
118 can have an external or common diameter d 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 empty hollow core 118 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 empty hollow core
118 can have a length l that ranges from between about 3 to 6
inches, desirably from between about 3.5 to 5 inches, and more
desirably from between about 3.75 to about 4.25 inches.
[0066] The external or common diameter d of each of the roll
products 13 should be able to easily pass through either of the
pair of third openings 116. Because of this, each of the pair of
third openings 116 should have an accommodating configuration, i.e.
circular, and have a diameter which is at least equal to the
diameter d of the hollow cores 118 contained in the carton 12.
Desirably, each of the third openings 116 should have a diameter
which is greater than the diameter d of the empty hollow cores 118
which are designed to pass through it. More desirably, each of the
third openings 116 is at least about 0.1 inches larger in diameter
than the diameter d of the empty hollow cores 118 which are
designed to pass through it. Even more desirably, each of the third
openings 116 is at least about 0.2 inches larger in diameter than
the diameter d of the empty hollow cores 118 which are designed to
pass through it. It should be understood that the empty hollow
cores 118 serve the function of allowing multiple sheets of the
roll product 13 to be wound onto the empty hollow core 118 during
manufacturing. During use of the roll product 13, the hollow core
118 can be positioned on a circular shaft or like structure to
facilitate rotary motion so that one or more sheets of the roll
product 13 can be easy removed. Once the roll product 13 is used
up, the empty hollow core 118 is removed from the circular shaft or
like structure and recycled or discarded while another full roll of
product 13 is positioned on the circular shaft or like structure
for future use. Normally, the shaft used to support a roll of paper
towels 13 is horizontally or vertically mounted in a kitchen or
some other room of a house. For toilet paper, the shaft is usually
horizontally mounted in a bathroom.
[0067] Referring again to FIGS. 1 and 7, the pair of third tear
panels 106 and 108 is formed in the top panel 24. Each of the pair
of third tear panels 106 and 108 has a central axis X.sub.2-X.sub.2
which is located within about 3 inches of one of the first and
second horizontal fold lines, 64 and 66 respectively. In addition,
the central axis X.sub.2-X.sub.2 of each of the pair of third tear
panels 106 and 108 is located within about 5 inches of one of the
second and third vertical fold lines, 30 and 38 respectively.
Furthermore, one of the pair of third tear panels 106 and 108 is
located within about 2 inches of the end portion 72 of the first
tear panel 68, see FIG. 1, and the other of the pair of third tear
panels 106 and 108 is located within about 2 inches of the end
portion of the second tear panels 96, see FIG. 1. In other words,
the first 106 of the pair of third tear panels 106 and 108 is
located adjacent to a first corner 120, see FIG. 7, and the second
108 of the pair of third tear panels 106 and 108 is located
adjacent to a second corner 122, see FIG. 7. The corners 120 and
122 are located in the top panel 24 diagonally across from one
another. This position is important because when the carton 12 is
resting on one of its end panels and the first tear panel 68 is
removed, the first roll product 13 can be removed from the carton
12. Once the first roll product 106 is removed, the remaining rolls
of product 13 housed in the carton 12 will move downward and/or
forward toward the first opening 94. This action will create a void
area within the carton 12 located approximate the third tear panel
108 and will provide an empty space to accommodate the insertion of
the empty hollow core 118. The third tear panel 108 is designed to
be opened when the first dispensing openings 68 is torn open and
the other third tear panel 108 is utilized when the second
dispensing opening 96 & 98 is torn open.
[0068] It should be noted that the carton 12 can be tilted forward,
if desired, so as to facilitate movement of the remaining roll
products 13 within the carton 12 so that they move toward the first
or second dispensing openings, 94 and 104 respectively.
[0069] Referring now to FIGS. 1, 7 and 9, the blank 10 can
optionally contain a pair of fourth tear panels 124 and 126 formed
in the bottom panel 40. Each of the pair of fourth tear panels 124
and 126 has a central axis X.sub.3-X.sub.3, see FIG. 7. Each
central axis X.sub.3-X.sub.3 of the pair of fourth tear panels 124
and 126 can be coaxially aligned with one of the central axes
X.sub.2-X.sub.2, X.sub.2-X.sub.2 of the pair of third tear panels
106 and 108, see FIG. 7. The central axis X.sub.3-X.sub.3 of each
of the pair of fourth tear panels 124 and 126 is located within
about 3 inches of one of the first and second horizontal fold
lines, 64 and 66 respectively. In addition, the central axis
X.sub.3-X.sub.3 of each of the pair of fourth tear panels 124 and
126 is located within about 5 inches of one of the first and fourth
vertical fold lines, 22 and 46 respectively, when the carton 12 is
constructed. Furthermore, one of the pair of fourth tear panels 124
and 126 is located within about 2 inches of the end portion 74 of
the first tear panel 68, and the other of the pair of fourth tear
panels 124 and 126 is located within about 2 inches of the end
portion of one of the pair of second tear panels 96 and 98. In
other words, the first of the pair of fourth tear panels 124 and
126 is located adjacent to a first corner 128 and the second of the
pair of fourth tear panels 124 and 126 is located adjacent to a
second corner 130, see FIG. 9. The corners 128 and 130 are located
in the bottom panel 40 across from one another. When at least one
of the pair of fourth tear panels 124 and 126 is removed, a fourth
opening 132, see FIG. 9, is formed into the carton 12. The fourth
opening 132 allows the empty hollow cores 118 to be inserted back
into the carton 12.
[0070] Each of the fourth openings 132 has a diameter which is at
least equal to the external or common diameter d of the empty
hollow cores 118 which are designed to pass through it. Desirably,
each of the fourth openings 132 should have a diameter which is
greater than the diameter d of the empty hollow cores 118 which are
designed to pass through it. More desirably, each of the fourth
openings 132 should have a diameter which is at least about 0.1
inches larger in diameter than the diameter d of the empty hollow
cores 118 which are designed to pass through it. Even more
desirably, each of the fourth openings 132 should have a diameter
which is at least about 0.2 inches larger in diameter than the
diameter d of the empty hollow cores 118 which are designed to pass
through it.
[0071] Still referring to FIG. 9, the location of the pair of
fourth tear panels 124 and 126 is important because when the carton
12 is resting on its back panel 16 and the second tear panels 96
and 98 are removed, the second opening 104 is formed in the carton
12. With the second opening 104 being present, the first roll
product 13 can be removed from the carton 12. Once the first roll
product 13 is removed, the remaining rolls of product 13 housed in
the carton 12 will move downward and/or forward toward the second
opening 104. This action will create a void area in the carton 12
approximate the fourth tear panel 126 and will provide an empty
space to accommodate the insertion of the empty hollow core
118.
[0072] It should be understood that when the first dispensing
opening 68 is torn open, the fourth tear panel 124 can be used to
insert empty hollow cores 118 back into the carton 12 once the
first roll product 13 has been removed via the first dispensing
opening 94.
[0073] Referring again to FIGS. 1-4, the blank 10 further includes
a handle tear panel 134 formed in the top panel 24. The handle tear
panel 134 can vary in size and shape. The handle tear panel 134
includes a perforated segment 136 and a non-perforated segment 138.
By depressing the perforated segment 136, a portion of the handle
tear panel 134 will move downward into the carton 12 and a handle
opening 140 is formed, see FIGS. 3 and 4. The perforated segment
136 can be partially or completely folded under the non-perforated
segment 138. The handle opening 140 is designed to allow a consumer
to insert one, two, three or four fingers through the opening 140
and carry the carton 12 in one hand.
[0074] Referring again to FIGS. 1 and 7, the blank 10 can
optionally includes one or more weakened areas or lines 142 formed
in the first tear panel 68 and/or in the pair of second tear panels
96 and 98. The weakened areas or lines 142 can be aligned parallel
to one another, as depicted, or be aligned at an angle to at least
one other area or line. The weakened areas or lines 142 can vary in
size, shape, thickness, length, etc. Furthermore, a weakened area
or line 142 does not have to be continuous. The weakened areas or
lines 142 can be randomly positioned or be evenly spaced from an
adjacent weakened area or line 142. The weakened areas or lines 142
can include but are not limited to: score lines, fold lines, crease
lines, perforation lines, lines of indentations, grooves, areas of
indentation, thin areas, etc. The purpose of the weakened areas or
lines 142 is to allow the tear panels 68, 96 and 98 to be folded or
rolled up into a smaller member and be inserted back into the
carton 12 through one of the third or fourth openings, 116 and 132
respectively, see FIG. 7. By inserting the tear panels 68, 96 and
98 back into the carton 12, one can later recycle one hundred
percent (100%) of the material used to construct the carton 12. In
addition, one can recycle more than just the carton 12 by inserting
the empty hollow cores 118 back into the carton 12 so that both the
carton 12 and the hollow cores 118 can be recycled. Furthermore, if
one can also recycles the used paper towels, one can obtain one
hundred percent (100%) recycling of the carton 12 and the roll
products 13. This will benefit the environment and reduce the
amount of cellulosic material being deposited into landfills.
[0075] Referring again to FIGS. 2, 3, 7 and 9, this invention also
relates to the carton 12. The carton 12 can be formed from
cellulose fibers. One or more similar or different cellulosic
fibers can be used to construct the carton 12 as was explained
above in reference to the blank 10. The carton 12 is formed by
folding, bending, assembling, and/or sealing, taping or
interlocking various portions of the blank 10. As explained above,
the back panel bottom flap 50, the top panel bottom flap 54, the
front panel bottom flap 58 and the bottom panel bottom flap 62 can
be configured such that as the blank 10 can be folded into a sleeve
and an end wall is automatically formed. This creates a carton 12
which is open at only one end.
[0076] The assembled carton 12 has a pair of possible dispensing
openings 94 and 104. The carton 12 is capable of housing or
temporarily retaining a plurality of generally cylindrically shaped
roll products 13 formed from cellulose fibers. Each of the roll
products 13 is wound upon an empty hollow core 118 during
manufacture. Each of the hollow cores 118 is formed from cellulose
fibers and each has an external or common diameter d. The carton 12
includes a top panel 24, a bottom panel 40 aligned opposite to the
top panel 24, a pair of end walls 144 and 146 each being located
between the top panel 24 and the bottom panel 40. The carton 12
also has a front panel 32 and a back panel 16 each being located
between the top panel 24 and the bottom panel 40 and adjacent to
each of the pair of end walls 144 and 146. A first tear panel 68 is
formed in the front panel 32 of the carton 12. The first tear panel
68 has an end portion 72 which extends into each of the top panel
24 and an end portion 74 which extends into the bottom panel 40.
The first tear panel 68 defines a first dispensing opening 94 when
removed. The first dispensing opening 94 allows access to at least
one of the roll products 13 housed within the carton 12. In other
words, the roll products 13 can be individually dispensed from the
carton 12 thorough the first dispensing opening 94.
[0077] The carton 12 also includes a pair of second tear panels 96
and 98 formed in the top panel top flap 52 and in the bottom panel
top flap 60 of the blank 10. These two flaps 52 and 60 form the end
wall 146 once the carton 12 is constructed. The pair of second tear
panels 96 and 98 cooperates to form a rectangular dispensing
opening of similar size to the first dispensing opening 94. The
pair of second tear panels 96 and 98 has portions that extend into
each of the top and bottom panels, 24 and 40 respectively. The pair
of second tear panels 96 and 98 defines a second dispensing opening
104 into the carton 12 when removed. The second dispensing opening
104 allows access to at least one of the roll products 13 housed
within the carton 12. In other words, the roll products 13 can be
individually dispensed from the carton 12 thorough the second
dispensing opening 104.
[0078] Referring again to FIGS. 3 and 7, the carton 12 further
includes a pair of third tear panels 106 and 108 formed in the top
panel 24. The pair of third tear panels 106 and 108 defines a pair
of third openings 116, 116, see FIG. 7, into the carton 12 when
removed. The empty hollow cores 118 can be inserted back into the
carton 12 through one of the pair of third tear panels 116, 116
once one of the roll products 13 has been removed from the carton
12. As explained above, once one of the roll products 13 has been
removed from the carton 12, a void space will be present in the
carton 12 adjacent to one of the pair of third panels 106 and 108.
This void space will allow an empty hollow core 118 to be inserted
back into the carton 12.
[0079] It should be noted that the integrity of the carton 12 is
not compromised or destroyed when either the first dispensing
opening 94 or the second dispensing opening 104 is formed in the
carton 12. Likewise, the formation of one or both of the pair of
third and pair of fourth openings, 116 and 128 respectively, does
not compromise or destroy the integrity of the carton 12.
[0080] The carton 12 can easily be loaded with roll products 13 by
folding the blank 10 along the four vertical fold lines 22, 30, 38
and 46 and bonding the adhesive tab 14 to the bottom panel 40.
Simultaneously, the end wall 144 can be automatically formed by the
interconnection of the back panel bottom flap 50, the top panel
bottom flap 54, the front panel bottom flap 58 and the bottom panel
bottom flap 62. An adhesive or glue can be added to the end wall
144 to retain its structure. This action creates a sleeve open at
only one end. The roll products 13 can then be inserted into the
open end of the carton 12 before the back panel top flap 48, the
top panel top flap 52, the front panel top flap 56 and the bottom
panel top flap 60 are folded inward and secured together with an
adhesive, a glue or by some other means.
[0081] The filled carton 12 can be shipped to a retailer where it
is made available for sale to the ultimate consumer. The consumer
purchases the carton 12 of roll products 13 and takes it home or to
a place of business. The consumer will orient the carton 12 to best
fit on a shelf, into a closet area, etc. At this time, the consumer
can remove one of the first or second tear panels, 68 or 96 &
98 to form either the first dispensing opening 94 or the second
dispensing opening 104. For most applications, only one of the
first and second dispensing openings, 94 or 104 respectively, need
be formed. The finger holes 75 or 105 can facilitate removal of the
tear panels 68 and 96 & 98 from the carton 12. The first and
second dispensing openings, 94 and 104 respectively, are desirably
of the same size and configuration. The carton 12 should be stored
such that the roll products 13 are horizontally arranged for easy
removal from the first or second dispensing openings, 94 or 104
respectively. The roll products 13 are dispensed from the bottom
row. FIG. 9 shows the roll products 13 oriented in a horizontal
fashion.
[0082] With reference to FIG. 10, one can see that the second
dispensing opening 104 is quite larger. For a carton 12 or 12'
containing six or more rolls of paper towels 13, each having a
diameter of about 4.5 inches, the second dispensing opening 104
should have a width w, measured parallel to the transverse central
axis Y-Y, of at least about 6 inches. Desirably, the width w of the
second dispensing opening 104 is at least about 6.5 inches. More
desirably, the width w of the second dispensing opening 104 is at
least about 7 inches. Even more desirably, the width w of the
second dispensing opening 104 is at least about 7.5 inches. Most
desirably, the width w of the second dispensing opening 104 is at
least about 8 inches. Another way of expressing the width w of the
second dispensing opening 104 is to say that the width w is at
least about 1.35 times the external or common diameter of the roll
product 13. Desirably, the width w of the second dispensing opening
104 is at least about 1.45 times the external or common diameter of
the roll product 13. More desirably, the width w of the second
dispensing opening 104 is at least about 1.55 times the external or
common diameter of the roll product 13. Even more desirably, the
width w of the second dispensing opening 104 is at least about 1.65
times the external or common diameter of the roll product 13. Most
desirably, the width w of the second dispensing opening 104 is at
least about 1.75 times the external or common diameter of the roll
product 13.
[0083] Referring to FIGS. 4 and 9, since each of the roll products
13 has a soft outer surface, is compressible, exhibits a relatively
high coefficient of friction and is relatively light in weight; it
will not tend to roll out of the carton 12 under its own weight
like an aluminum can. An aluminum can has a very smooth outer
circumferential surface with a low coefficient of friction and when
it is filled with a liquid it is relatively heavy compared to a
roll of paper towels. Because of these differences, it is not
necessary to maintain a very high lip 148, or any lip 148, adjacent
to either of the first or second dispensing openings, 94 and 104
respectively.
[0084] Referring to FIG. 10, an alternative embodiment of a carton
12' is shown without rolls products 13 so as to better visualize
the second dispensing opening 104. In the carton 12', the second
dispensing opening 104 is situated with an edge 150 located flush
with an adjacent panel. In FIG. 10, the edge 150 is located flush
with the back panel 16. Although the second dispensing opening 104
is shown, it should be understood that the first dispensing opening
94 can be constructed in a similar fashion and the edge 150 would
be located adjacent to the end wall 144.
[0085] One will also notice in FIG. 10 that the end portions of the
second dispensing opening 104 are not semi-circular in
configuration as depicted in FIG. 1. Instead, each of the end
portions has an arcuate shape that is deepest closer to the back
panel 16. This shape facilitates a consumer reaching into the
second dispensing opening 104 with one or two hands and inserting a
finger into the hollow core 118 of the roll product 13 located
adjacent to the second dispensing opening 104. This enables the
consumer to remove the roll product 13 by grasping a portion of the
hollow core 118. The roll product 13 can be removed using one hand
or two hands, whichever is more convenient for the consumer.
[0086] Referring now to FIG. 11, a carton 12'' is shown which is
similar to the carton 12' shown in FIG. 10 except for two
differences. First, the carton 12'' includes one or more detents
152 positioned along the edge 150. Two detents 152, 152 are
depicted. The detents 152 can be integrally formed with the top
panel top flap 52, with the bottom panel top flap 60 or with the
back panel 16. For example, as the pair of second tear panels 96
and 98 is broken away from the carton 12'', via the perforation
lines surrounding the second opening 104, the detents 152, 152 can
remain. By "detent" it is meant an upstanding member, a tab, a
finger, a shoulder, that will limit, restrict or prevent movement
of a roll product 13.
[0087] In FIG. 11, a pair of spaced apart detents 152, 152 is
depicted. However, any number of detents 152 can be utilized. The
size, shape and location of the detent(s) 152 can vary. For
example, a detent 152 can be spaced apart from an adjacent detent
152 by a desired distance. Desirably, the distance ranges from
between about 1 to 6 inches. More desirably, the detents 152, 152
are spaced at least 2 inches apart from one another. Even more
desirably, the detents 152, 152 are spaced at least 1.5 inches
apart from one another. For example, for a roll product 13 having a
length of from between about 10 to about 12 inches, five or six
detents 152 should be effective in preventing the roll product 13
from accidentally rolling out of the carton 12''. The detent(s) 152
will prevent the roll product 13, located immediately adjacent to
the second opening 104, from being discharged from the carton 12'
without human assistance. Since the roll products 13 have a soft
outer surface which is not exceptionally smooth and therefore has a
higher coefficient of friction than say aluminum can, and since the
roll products 13 are rather light in weight, they do not have a
tendency to roll out of the carton 12, 12' or 12'' under their own
power or initiative.
[0088] Referring now to FIG. 12, still another embodiment of a
carton 12''' is shown where the second dispensing opening 104 is
situated with a majority of its lower edge 150 flush with the back
panel 16. A pair of corner detents 154, 154 is located between the
back panel 16 and each of the upstanding bottom panel 40 and the
upstanding top panel 24. Each pair of corner detents 154, 154 has a
height h.sub.5 which rises above the back panel 16. The size, shape
and location of the pair of corner detents 154, 154 can vary. For
example, each of the pair of corner detents 154, 154 can have a
width w.sub.5, measured along the edge 150, which can range from
between about 0.25 inches to about 3 inches for an opening who's
largest dimension is 16 inches or less. The height h.sub.5 can
range from between about 0.1 inches to about 1 inch. Desirably,
each of the pair of corner detents 154, 154 can have a width
w.sub.5 which is equal to or less than about 2.5 inches and a
height h.sub.5 which is equal to or less than about 0.5 inches.
More desirably, each of the pair of corner detents 154, 154 can
have a width w.sub.5 which is equal to or less than about 2 inches
and a height h.sub.5 which is equal to or less than about 0.4
inches. Even more desirably, each of the pair of corner detents
154, 154 can have a width w.sub.5 which is equal to or less than
about 0.75 inches wide and a height h.sub.5 which is equal to or
less than about 0.3 inches.
[0089] As stated above with reference to FIG. 10, the
characteristics of the second dispensing opening 96 & 98 also
apply to the first dispensing opening 94 in FIGS. 11 and 12.
Method
[0090] A method of recycling empty hollow cores 118 formed from
cellulose fibers back into the original package carton 12, 12' 12''
or 12''' will now be explained with reference to FIG. 13. A
plurality of roll products 13 each formed from cellulosic material
and each being wound upon an empty hollow core 118 are housed or
retained in the carton 12, 12', 12'' or 12'''. The carton 12, 12',
12'' or 12''' is formed also from cellulose fibers. Desirably, the
carton 12, 12', 12'' or 12''' is constructed from paperboard. The
carton 12, 12', 12'' or 12''' can be recycled by itself or in
combination with one or more of the empty hollow cores 118 once the
roll product 13 has been removed from the hollow cores 118. Each of
the hollow cores 118 has a paper product 13, such as paper towels,
toilet paper, dry wipes, etc. wound upon it. The roll product 13
usually includes multiple sheet 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 13 at a given time. When all of the sheets are
removed, an empty hollow core 118 will remain.
[0091] The method includes the steps of inserting a plurality of
the roll products 13 into the carton 12, 12', 12'' or 12''' and
closing and sealing the open end of carton 12, 12', 12'' or 12'''.
The carton 12, 12', 12'' or 12''' can then be shipped to a retailer
or directly to a consumer. The carton 12, 12', 12'' or 12''' has a
top panel 24 and a bottom panel 40 aligned opposite to the top
panel 24. The carton 12, 12', 12'' or 12''' also has a pair of end
walls 144 and 146 each being located between the top panel 24 and
the bottom panel 40. The carton 12, 12', 12'' or 12''' further has
a front panel 32 and a back panel 16, each being located between
the top panel 24 and the bottom panel 40 and adjacent to each of
the pair of end walls 144 and 146. The carton 12, 12', 12'' or
12''' also has a first tear panel 68 formed in the front panel 32.
The first tear panel 68 has portions that extend into each of the
top and bottom panels, 24 and 40 respectively. The first tear panel
68 defines a first opening 94 into the carton 12, 12', 12'' or
12''' when it is removed. The first opening 94 provides access to
at least one of the roll products 13 housed within the carton 12,
12', 12'' or 12'''. The carton 12, 12', 12'' or 12''' also has a
second tear panel (a combination of 96 and 98) formed in the end
walls 146. The second tear panel 96 and 98 has portions that that
extend into each of the top and bottom panels, 24 and 40
respectively. The second tear panel 96 and 98 defines a second
opening 104 into the carton 12, 12', 12'' or 12''' when it is
removed. The second opening 104 provides access to at least one of
the roll products 13 housed within the carton 12, 12', 12'' or
12'''.
[0092] The carton 12, 12', 12'' or 12''' further includes a pair of
third tear panels 106 and 108 formed in the top panel 24. The pair
of third tear panels 106 and 108 defines a pair of third openings
116, 116 into the carton 12, 12', 12'' or 12''' when removed. Each
of the third openings 116, 116 allow an empty hollow core 118 to be
inserted back into the carton 12, 12', 12'' or 12''' after at least
one full roll of product 13 has been removed from the carton 12,
12', 12'' or 12'''. At least one roll of product 13 has to be
removed from the carton 12, 12', 12'' or 12''' to create a void
space within the carton 12, 12', 12'' or 12''' which will
accommodate the insertion of the empty hollow core 118.
[0093] The method also includes removing at least one of the third
tear panels 106 and 108 from the carton 12, 12', 12'' or 12''' to
create a third opening 116. After the roll product 13, i.e. paper
towels, is removed from the hollow core 118, an empty hollow core
118 remains. The empty hollow core 118 is then inserted back into
the carton 12, 12', 12'' or 12''' through one of the third openings
116, 116.
[0094] The method can also include forming a pair of fourth tear
panels 124 and 126 in the bottom panel 40. The pair of fourth tear
panels 124 and 126 defines a pair of fourth openings 128, 128 into
the carton 12, 12', 12'' or 12''' when removed. Each of the fourth
openings 128, 128 allow an empty hollow core 118 to be inserted
back into the carton 12, 12', 12'' or 12''' after at least one full
roll of product 13 has been removed from the carton 12, 12', 12''
or 12'''.
[0095] Alternatively, the method can be carried out by removing
both of the third tear panels 106 and 108 so as to form two
openings 116, 116 into the carton 12, 12', 12'' or 12'''. After one
or more of the empty hollow cores 118 has been inserted back into
the carton 12, 12', 12'' or 12''', both the carton 12, 12', 12'' or
12''' and the empty hollow cores 118 contained therein can be
recycled. The recycling can be accomplished using the standard
practice for paper products known to those skilled in the recycling
art.
[0096] Each roll product 13 can be removed from the carton 12, 12',
12'' or 12''' through one of the first or second dispensing
openings, 94 or 104 respectively, by a consumer using one or two
hands. The consumer can reach into the end portions of one of the
first or second dispensing openings, 94 or 104 respectively, and
physically grab the ends of the roll product 13. Alternatively, the
consumer can place an index finger into the opposite ends of the
hollow core 118 and pull the roll product through the first or
second dispensing openings, 94 or 104 respectively. The roll
product 13 being removed from the carton 12, 12', 12'' or 12'''
will be taken from the bottom row of the roll products 13 contained
in the carton 12, 12', 12'' or 12'''.
[0097] 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.
* * * * *