U.S. patent application number 12/913048 was filed with the patent office on 2011-04-28 for carton with differently shaped ends.
This patent application is currently assigned to Graphic Packaging International, Inc.. Invention is credited to Felicia Pinkstone.
Application Number | 20110095075 12/913048 |
Document ID | / |
Family ID | 43897543 |
Filed Date | 2011-04-28 |
United States Patent
Application |
20110095075 |
Kind Code |
A1 |
Pinkstone; Felicia |
April 28, 2011 |
Carton With Differently Shaped Ends
Abstract
A blank is erected into a tubular structure having opposite end
openings. One of the end openings is substantially rectangular. The
other end opening is generally rectangular with substantially
rounded corners. The erected blank includes an end panel that is
substantially rectangular and obstructs the substantially
rectangular end opening. The erected blank includes an end panel
that is generally rectangular with rounded corners. The generally
rectangular end panel with rounded corners obstructs the end
opening that is generally rectangular with rounded corners.
Inventors: |
Pinkstone; Felicia; (Aston,
PA) |
Assignee: |
Graphic Packaging International,
Inc.
Marietta
GA
|
Family ID: |
43897543 |
Appl. No.: |
12/913048 |
Filed: |
October 27, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61255240 |
Oct 27, 2009 |
|
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|
Current U.S.
Class: |
229/117.27 ;
229/162.1; 229/182.1; 229/183; 229/215; 229/5.5 |
Current CPC
Class: |
B65D 5/0209 20130101;
B65D 5/742 20130101; B65D 5/0254 20130101; B65D 5/4204 20130101;
B65D 3/08 20130101; B65D 5/541 20130101; B65D 5/606 20130101 |
Class at
Publication: |
229/117.27 ;
229/162.1; 229/215; 229/182.1; 229/183; 229/5.5 |
International
Class: |
B65D 5/00 20060101
B65D005/00; B65D 5/56 20060101 B65D005/56; B65D 25/54 20060101
B65D025/54; B65D 5/74 20060101 B65D005/74; B65D 5/54 20060101
B65D005/54 |
Claims
1. A carton comprising, a tubular structure having an upper end
defining a substantially closed first shape, and a lower end
defining a substantially closed second shape that is substantially
different from the first shape; the tubular structure having a
shape that transitions from the first shape to the second shape
between the upper and lower ends of the tubular structure; a top
panel connected to the tubular structure and obstructing the upper
end of the tubular structure, wherein the top panel has an outer
periphery that substantially defines the first shape; and a bottom
panel connected to the tubular structure and obstructing the lower
end of the tubular structure, wherein the bottom panel is spaced
apart from and substantially parallel to the top panel, and the
bottom panel has an outer periphery that substantially defines the
second shape.
2. The carton according to claim 1, wherein the top panel includes
an end flap, and the end flap includes a fold line adapted for
allowing the end flap to be formed into a spout.
3. The carton according to claim 1, further comprising a viewing
window within and positioned between the upper and lower ends of
the tubular structure.
4. The carton according to claim 1, further comprising a bag
positioned in the tubular structure, wherein the bag includes a
spout.
5. The carton according to claim 1, wherein: the lower end of the
tubular structure includes a lower edge and a recessed edge; as
compared to the lower edge, the recessed edge is recessed into the
plurality of panels; and the bottom panel is foldably connected to
the recessed edge.
6. The carton according to claim 1, wherein: the first shape
comprises a substantially rectangular shape having corners that
substantially define right angles, and the second shape comprises a
generally rectangular shape having beveled corners.
7. The carton according to claim 6, wherein the beveled corners are
substantially rounded corners:
8. The carton according to claim 1, wherein: the tubular structure
comprises at least one panel that extends around and defines a
longitudinal axis of the carton; the at least one panel includes a
plurality of score lines that extend along the longitudinal axis,
from proximate the upper end of the tubular structure toward the
lower end of the tubular structure.
9. The carton according to claim 8, wherein the plurality of score
lines do not extend to the lower end of the tubular structure.
10. The carton according to claim 1, wherein: the tubular structure
comprises at least one panel that extends around and defines a
longitudinal axis of the carton; the at least one panel includes a
plurality of fold lines that extend along the longitudinal axis,
from proximate the upper end of the tubular structure toward the
lower end of the tubular structure.
11. The carton according to claim 10, wherein the plurality of fold
lines do not extend to the lower end of the tubular structure.
12. A blank for being erected into a carton, the blank comprising:
a plurality of panels that are foldably connected to one another
and are for being formed into a tubular structure, wherein the
plurality of panels includes opposite first and second edges; a
first end flap foldably connected to the first edge for obstructing
an end of the tubular structure, wherein the first end flap has an
outer periphery that defines a first shape; and a second end flap
foldably connected to the second edge for obstructing an end of the
tubular structure, wherein the second end flap has an outer
periphery that defines a second shape that is substantially
different from the first shape.
13. The blank according to claim 12, wherein: the plurality of
panels further includes a third edge that is opposite from the
first edge; the third edge is proximate both the second edge and
the second end flap; and as compared to the third edge, the second
edge is recessed into the plurality of panels.
14. The blank according to claim 12, wherein: the first shape
comprises a substantially rectangular shape having corners that
substantially define right angles, and the second shape comprises a
generally rectangular shape having beveled corners.
15. The blank according to claim 14, wherein the beveled corners
are substantially rounded corners:
16. The blank according to claim 12, wherein: the plurality of
panels is formed into the tubular structure; the ends of the
tubular structure are opposite first and second ends that
respectively include the first and second edges of the plurality of
panels; the first end of the tubular structure is adapted for
substantially defining the first shape when the blank is erected
into the carton; and the second end of the tubular structure is
adapted for substantially defining the second shape when the blank
is erected into the carton.
17. The blank according to claim 16, wherein the plurality of
panels includes a plurality of fold lines that extend from
proximate the first end of the tubular structure toward the second
end of the tubular structure.
18. The blank according to claim 17, wherein the plurality of fold
lines do not extend to the second end of the tubular structure.
19. A method of forming a carton, comprising: forming a tubular
structure from a blank, comprising forming an end of the tubular
structure into a generally rectangular shape having substantially
rounded corners; and obstructing the end with a panel having a
generally rectangular shape with substantially rounded corners,
comprising forming the panel from the blank.
20. The blank according to claim 19, wherein the forming of the
panel from the blank comprises folding a plurality of end flaps
respectively about a plurality of recessed edges of the tubular
structure into an interior of the tubular structure, and fastening
at least some of the end flaps to one another.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/255,240, which was filed on Oct. 27, 2009.
INCORPORATION BY REFERENCE
[0002] The entire disclosure of U.S. Provisional Application No.
61/255,240, which was filed on Oct. 27, 2009, is incorporated
herein by reference.
BACKGROUND
[0003] This disclosure generally relates to packages or cartons for
holding and/or dispensing products.
SUMMARY
[0004] One aspect of this disclosure is the provision of a carton
having a tubular structure with an upper end defining a
substantially closed first shape (e.g., a substantially rectangular
shape/opening), and a lower end defining a substantially closed
second shape (e.g., a shape/opening that is generally rectangular,
with substantially rounded corners) that is substantially different
from the first shape. The shape of the tubular structure
transitions from the first shape to the second shape between the
upper and lower ends of the tubular structure. One or more lines of
disruption (e.g., fold, crease or score lines) may be located at
the upper end of the tubular structure, and the lines of disruption
may extend only partially along the tubular structure so that the
shape of the tubular structure substantially smoothly transitions
between the opposite upper and lower ends.
[0005] The carton may further include a top panel connected to the
tubular structure and obstructing (e.g., closing) the opening at
the upper end of the tubular structure. The top panel may have an
outer periphery that substantially defines the first shape (e.g.,
the substantially rectangular shape). The carton may further
include a bottom panel connected to the tubular structure and
obstructing (e.g., closing) the opening at the lower end of the
tubular structure. The bottom panel may have an outer periphery
that substantially defines the second shape (e.g., the generally
rectangular shape with substantially rounded corners).
[0006] The bottom panel may be formed from bottom end flaps that
are respectively foldably connected to recessed edges proximate the
lower end of the tubular structure. The top panel may be at least
partially formed by an end flap that includes at least one fold
line adapted for allowing the end flap to be formed into a spout.
The carton may contain a bag containing product, and the carton may
include a viewing window so that a user may see the product through
the bag by way of the viewing window.
[0007] In accordance with one aspect of this disclosure, a blank
for being erected into a carton includes: a plurality panels that
are foldably connected to one another and are for being formed into
a tubular structure, wherein the plurality of panels includes
opposite first and second edges; a first end flap foldably
connected to the first edge for obstructing (e.g., closing) an
opening at an end of the tubular structure, wherein the first end
flap has an outer periphery that defines a first shape (e.g., a
substantially rectangular shape); and a second end flap foldably
connected to the second edge (e.g., a recessed edge) for
obstructing (e.g., closing) an opening at another end of the
tubular structure, wherein the second end flap has an outer
periphery that defines a second shape (e.g., a generally
rectangular shape with substantially rounded corners) that is
substantially different from the first shape. The blank may include
one or more of the above-discussed features of the carton and/or
other features.
[0008] In accordance with one aspect of this disclosure, a tubular
structure may be formed from a blank, and the forming of the
tubular structure may include forming an end of the tubular
structure into a generally rectangular opening having substantially
rounded corners. The generally rectangular opening having
substantially rounded corners may be obstructed (e.g., closed) with
a generally rectangular panel that is formed from the blank and has
substantially rounded corners. The generally rectangular panel with
substantially rounded corners may be formed from end flaps
respectively folded about recessed edges of the blank. The forming
of the tubular structure may also include forming and obstructing
(e.g., closing) an end opening that is substantially
rectangular.
[0009] Other aspects of this disclosure will become apparent from
the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Having described some aspects of this disclosure in general
terms, reference will now be made to the accompanying drawings,
which may be schematic, are not necessarily drawn to scale, and
wherein:
[0011] FIG. 1 is a plan view of a flat blank that may be erected
into a carton, in accordance with a first embodiment of this
disclosure.
[0012] FIG. 2 is a front pictorial view of a closed carton erected
from the blank of FIG. 1.
[0013] FIG. 3 is a rear pictorial view of the carton of FIG. 2 with
its upper end open, and a bag within the carton being upwardly open
and extending through the upper, open end of the carton, in
accordance with the first embodiment.
[0014] FIG. 4 is a pictorial view of a closed carton in accordance
with a second embodiment of this disclosure.
[0015] FIG. 5 is a pictorial view of the carton of FIG. 4 with its
upper end open, and a spout formed at one end of the upper
opening.
[0016] FIG. 6 is a pictorial view of the carton of FIGS. 4 and 5
with the spout formed at one end of the upper opening, a bag within
the carton being upwardly open and extending through the upper,
open end of the carton, and the bag being viewable by way of a
viewing window (e.g., hole in the carton) in accordance with the
second embodiment.
[0017] FIG. 7 is a plan view of the flat blank of FIG. 1 with a bag
attached thereto, in accordance with a version of the first
embodiment of this disclosure.
[0018] FIG. 8 illustrates a series of bags that include projecting
spout sections and are connected end-to end, and that are for being
separated from one another for use within the blanks and cartons,
in accordance with various embodiments of this disclosure.
DETAILED DESCRIPTION
[0019] Referring now in greater detail to the drawings, in which
like numerals refer to like parts throughout the several views,
exemplary embodiments of this disclosure are described in the
following. For example, a blank 10 is shown in FIG. 1 and described
in the following, in accordance with a first embodiment of this
disclosure. The blank 10 may be characterized as generally
including an upper end 12 and a lower end 14. The blank 10 includes
main panels 20, 50 connected to one another along a longitudinal
fold line 43, and an attachment panel 60 (e.g., adhesive panel)
connected to the main panel 50 along a longitudinal fold line
93.
[0020] At the upper and lower ends 12, 14 of the blank 10, end
flaps are attached to the main panels 20, 50 by fold lines that are
transverse to the longitudinal fold lines 43, 93. More
specifically, along the upper end 12 of the blank 10, an upper
secondary end flap 22 is attached to an upper edge of the main
panel 20 along a transverse fold line 21, an upper primary end flap
24 is attached to an upper edge of the main panel 20 along a
transverse fold line 31, an upper secondary end flap 40 is attached
to an upper edge of the main panel 20 along a transverse fold line
41, an upper secondary end flap 42 is attached to an upper edge of
the main panel 50 along a transverse fold line 51, an upper primary
end flap 44 is attached to an upper edge of the main panel 50 along
a transverse fold line 61, an upper secondary end flap 46 is
attached to an upper edge of the main panel 50 along a transverse
fold line 71, and an attachment end flap 48 (e.g., adhesive end
flap) is attached to an upper edge of the attachment panel 60 along
a transverse fold line 81. One or more of the transverse fold lines
21, 31, 41, 51, 61, 71, 81 can be collinear with one another such
that the transverse fold lines 21, 31, 41, 51, 61, 71, 81 may be
characterized as being portions of a single transverse fold line 15
that extends all the way between opposite edges of the blank
10.
[0021] The upper primary end flap 24 includes several lines of
disruption, namely transverse tear lines 30, 32, 34 and a series of
cuts (e.g., slits) that form a tuck-in flap or tab 36. The lines of
disruption in the upper primary end flap 24 form a tear strip 28
and another separable portion 26 of the upper primary end flap 24.
The series of slits that form the tuck-in tab 36 are positioned
between and connect inner ends of the tear lines 30, 32. As shown
in FIG. 1, the series of slits that form the tuck-in tab 36 include
oblique slits that respectively extend upwardly from the inner ends
of the tear lines 30, 32, and a transverse slit that connects the
upper ends of the oblique slits. The tear strip 28 is connected to
the inner portion of the upper primary end flap 24 along the tear
lines 30, 32. The tear strip 28 is partially defined by, and
extends along, the tuck-in tab 36 (e.g., the slits that define the
tuck-in tab). The separable portion 26 is connected to the tear
strip 28 by the tear line 34. As will be discussed in greater
detail below, the tear strip 28 is removable from the remainder of
the upper primary end flap 24 by separating the tear strip 28 along
the tear lines 30, 32, 34. Optionally, the separable portion 26 can
be removed together with tear strip 28, if desired.
[0022] For at least one of (e.g., for each of) the upper main end
flaps 24, 44, the end flap has an outer periphery that defines a
substantially rectangular shape having corners that substantially
define right angles, although differently shaped upper main end
flaps are within the scope of this disclosure. More specifically
and as shown in FIG. 1, some of the corners of the substantially
rectangular shapes defined by the outer peripheries of the upper
main end flaps 24, 44 may be slightly rounded. Also as shown in
FIG. 1, the opposite ends of the tear strip 28 may cause the outer
periphery of the upper main end flap 24 not to be perfectly
rectangular. Notwithstanding, whether the outer peripheries of the
upper main end flaps 24, 44 are perfectly rectangular or a little
less than perfectly rectangular, as shown in FIG. 1, the outer
peripheries of the upper main end flaps 24, 44 may be referred to
as being substantially rectangular.
[0023] The upper primary end flap 44 includes a tuck-in slot 38
sized to receive the tuck-in tab 36 after the carton 400 (FIGS. 2
and 3) is formed from the blank 10. As shown in FIG. 1, the tuck-in
slot 38 may be formed by a series of slits that include a
transverse slit and oblique slits that respectively extend upwardly
from the opposite ends of the transverse slit.
[0024] The upper primary end flaps 24, 44 are separated from the
adjacent secondary upper flaps 22, 40, 42, 46 by way of cut outs or
cuts, namely longitudinal slits 54. In contrast, the upper
secondary end flaps 40, 42 are connected to one another by a
longitudinal fold line 53, which is shown to be generally collinear
with the longitudinal fold line 43. Similarly, the upper secondary
end flaps 46, 48 are connected to one another by a longitudinal
fold line 83, which is shown to be generally collinear with the
longitudinal fold line 93. The longitudinal fold lines 53, 83 allow
the end flaps 40, 42 and the end flaps 22, 46, 48 to respectively
be flexed outwardly to form pouring spouts, or the like, (e.g., see
the spout 300' in FIGS. 5 and 6). Alternatively, other arrangements
of flaps may be used for closing the ends of the carton 400 (FIGS.
2 and 3). For example, the longitudinal fold lines 53, 83 may be
replaced with cuts, such as slits.
[0025] The main panels 20, 50 optionally include relatively short
lines of disruption, namely score lines that may be referred to as
longitudinal fold lines 23, 33, 63, 73. The longitudinal fold lines
23, 33, 63, 73 extend transverse to the transverse fold lines 21,
31, 41, 51, 61, 71, 81 for allowing or enhancing flexure of the
main panels 20, 50 along the upper end 12 when the blank 10 is
formed into carton 400 (FIGS. 2 and 3). As shown in FIG. 1, the
longitudinal fold lines 23, 33, 63, 73 are respectively collinear
with the longitudinal slits 54. The longitudinal fold lines 23, 33,
63, 73 extend in the upper end 12 of the blank for facilitating
formation of the upper end 12 into a substantially rectangular
configuration when the blank 10 is formed into carton 400. The
longitudinal fold lines 23, 33, 63, 73 extend only partially toward
the lower end 14 so that, as best understood with reference to
FIGS. 2 and 3, in the downward direction, the carton 400
transitions from the substantially rectangular configuration to a
more rounded configuration (e.g., a substantially rounded side
arrangement) at the lower end 14 of the carton 40.
[0026] At the lower end 14 of the blank 10 as shown in FIG. 1, a
lower main end flap 70 is connected by a transverse fold line 91 to
a recessed edge of the main panel 20, lower secondary end flap 74
is connected by a transverse fold line 101 to a recessed edge of
the main panel 20, lower secondary end flap 76 is connected by a
transverse fold line 111 to a recessed edge of the main panel 50,
lower main end flap 78 is connected by a transverse fold line 121
to a recessed edge of the main panel 50, lower secondary end flap
80 is connected by a transverse fold line 131 to a recessed edge of
the main panel 50, and lower secondary end flap 82 is connected by
a transverse fold line 141 to the attachment panel 60.
[0027] The recessed edges of the panels 20, 50, 60 that are
respectively coextensive with the transverse fold lines 91, 101,
111, 121, 131, 141 are recessed relative to respective lowest edges
of the main panels 20, 50 by virtue of respective cuts (e.g.,
curved slits 104 and longitudinally extending straight slits 105)
that respectively extend downwardly from the recessed
edges/respectively extend inwardly from the lowest edges of the
main panels 20, 50. One or more of the transverse fold lines 91,
101, 111, 121, 131, 141 may be characterized as being portions of
one or more larger fold lines. For example, ends of the transverse
fold lines 101, 111 are contiguous and collinear. Similarly, ends
of the transverse fold lines 131, 141 are contiguous and collinear.
Also, the transverse fold lines 91, 101, 111, 121, 131, 141 may
alternatively be located at lowest edges of the panels 20, 50
rather than being located at the recessed edges.
[0028] Reiterating from above and for example, for each of the
upper main end flaps 24, 44, the end flap has an outer periphery
that defines a substantially rectangular shape having corners that
substantially define right angles. In contrast, for at least one of
(e.g., for each of) the lower main end flaps 70, 78, the flap has
an outer periphery that defines a shape that is substantially
different from the substantially rectangular shape defined by the
outer peripheries of the upper main end flaps 24, 44. More
specifically, for at least one of (e.g., for each of) the lower
main end flaps 70, 78, the flap has an outer periphery that defines
a generally rectangular shape having beveled corners (e.g.,
substantially rounded corners). More specifically and in accordance
with the first embodiment, the main end flaps 24, 44, 70, 78 are
all about the same size, except, for example, that the corners of
the lower main end flaps 70, 78 are substantially more rounded as
compared to the corners of the upper main end flaps 24, 44. For
example, whereas FIG. 1 shows that some of the corners of the upper
main end flaps 24, 44 may be slightly rounded, the corners of the
lower main end flaps 70, 78 are substantially more rounded, such as
by having radiuses of curvature that are at least two times as
large, at least three times as large, at least four times as large,
at least five times as large, or greater than five times as large
as any radius of curvature of the corners of the upper main end
flaps 24, 44. Other configurations and relationships are also
within the scope of this disclosure.
[0029] The lower secondary end flaps 74, 76 are connected to one
another by a longitudinal fold line 103, which is generally
collinear with the longitudinal fold line 43. Similarly, the lower
secondary end flaps 80, 82 are connected to one another by a
longitudinal fold line 113, which is generally collinear with
longitudinal fold line 93. Each of the pair of end flaps 40, 42,
the pair of end flaps 46, 48, the pair of end flaps 74, 76, and the
pair of end flaps 80, 82, may be referred to as a single end flap
that optionally includes and is divided (e.g., bifurcated) by the
respective longitudinal fold line 53, 83, 103, 113 or any other
suitable line of disruption, such as a cut or slit.
[0030] An example of a method of erecting the carton 400 (FIGS. 2
and 3) is described in the following primarily with reference to
FIG. 1, in accordance with the first embodiment of this disclosure.
Either side of the blank 10 may define the exterior of the carton
44. The blank 10 may be folded along the longitudinal fold lines
43, 93. The attachment panel 60 may be attached to the free,
longitudinal marginal edge of the main panel 20, such as by using
adhesive material or any other suitable fastening mechanism(s). As
a result, the blank 10 will be in the form of a flat tubular
structure (e.g., collapsed tubular structure).
[0031] A generally rectangular bottom panel (e.g., composite bottom
panel) with substantially rounded corners is formed from the lower
end flaps 70, 74, 76, 78, 80, 82 for obstructing (e.g., closing)
the opening at the lower end 14 of the carton 400 (FIGS. 2 and 3).
The lower end flap 70 may optionally include, and be bifurcated by,
a transverse fold line 151 so that the carton 400 may be
collapsed/substantially flattened after the bottom panel is at
least partially formed. The end flaps 74, 76, 80, 82, may be
characterized as dust flaps and/or attachment flaps that may
function in combination with the end flaps 70, 78 so that the
bottom panel is a semi-automatic bottom panel. Other bottom panels
are within the scope of this disclosure.
[0032] After the flattened tubular structure is formed from the
blank 10 as discussed above, the tubular structure is "opened"/no
longer collapsed so that at least one panel (e.g., the main panels
20, 50 together) extend around a longitudinal axis and open
interior of the tubular structure. The bottom panel may be formed
while the tubular structure is "opened"/no longer collapsed. The
lower end 14 of the open tubular structure may be manually shaped,
or the lower end 14 of the open tubular structure may be
automatically shaped, such as through the use of an automated
system including mandrel(s) and/or outer forming or supporting
structures, or any other suitable shaping mechanism or process, so
that the opening at the lower end 14 of the open tubular structure
substantially defines the same (albeit slightly larger) generally
rectangular shape having substantially rounded corners as the lower
main end flaps 70, 78. Throughout this Detailed Description section
of this disclosure, the generally rectangular shape having
substantially rounded corners may more generally be referred to in
geometrical terms as a substantially closed shape that is generally
rectangular and has beveled corners.
[0033] While the lower end 14 of the open tubular structure defines
the generally rectangular shape having substantially rounded
corners, first the lower main end flap 78 is folded inwardly about
ninety degrees along the transverse fold line 121/the respective
recessed edge of the main panel 50 so that the lower main end flap
78 is pivoted into the interior of the open tubular structure, then
the lower main end flap 70 is folded inwardly about ninety degrees
along the transverse fold line 91/the respective recessed edge of
the main panel 20 so that the lower main end flap 70 is pivoted
into the interior of the open tubular structure, then the lower
secondary end flaps 74, 76, 80, 82 are folded inwardly about ninety
degrees along the respective transverse fold lines 101, 111, 131,
141/the respective recessed edges of the panels 20, 50, 60 so that
the lower secondary end flaps 74, 76, 80, 82 are pivoted into the
interior of the open tubular structure. The lower secondary end
flaps 74, 76, 80, 82 are attached (using adhesive material or any
other suitable fastening mechanism(s)) to the opposite ends of the
lower main end flap 70 so that the fold lines 103, 113, 151 are
substantially parallel to one another and the fold lines 103, 113
extend along the fold line 151, so that the otherwise open tubular
structure has a closed lower end 14. As a result, the open (e.g.,
upwardly open) tubular structure has a closed lower end 14, and the
lower ends of the main panels 20, 50 define the generally
rectangular shape having substantially rounded corners. As a
result, the carton 400 (FIGS. 2 and 3) may be characterized as
having a distinctive appearance and/or the substantially rounded
corners seek to enhance the ease with which the carton 400 may be
manually grasped.
[0034] The lower secondary end flaps 74, 76, 80, 82 may be
adhesively or otherwise attached to the opposite ends of the lower
main end flap 70 manually or through the use of an automated system
that may include mandrel(s) and/or outer forming or supporting
structures, or any other suitable mechanisms or processes. The
generally rectangular bottom panel with rounded corners may be
formed in a different manner. For example, the lower end flaps 70,
74, 76, 78 80, 82 can be folded and/or attached in another manner
or order without departing from the scope of this disclosure.
[0035] Then, optionally and if desired, and perhaps theoretically
depending upon the rigidity of the material from which the blank 10
is constructed, the tubular structure with the closed lower end 14
may be flattened (e.g., substantially flattened) by having the
lower main end flap 78, which is within the interior of the tubular
structure, in opposing face-to face relation or contact, or the
like, with the main panel 50, and then folding along the fold lines
43, 93, 103, 113, 151. Thereafter at a desired time, the
substantially flattened tubular structure with the closed lower end
14 may be formed into the open tubular structure with the closed
lower end/upwardly open carton 400. Any suitable product (e.g.,
food stuffs) may be disposed within the interior of the carton 400
(FIGS. 2 and 3), such as by passing the product through the open
upper end 12 of the carton.
[0036] When the open tubular structure with the closed lower end
14/upwardly open carton 400 (FIGS. 2 and 3) is formed and
thereafter, the relatively short longitudinal fold lines 23, 33,
63, 73 (FIGS. 1-3) in the upper end of the carton seek to cause
(e.g., substantially cause) the upper end 12 of the carton (e.g.,
the upper opening of the carton) to substantially define the same
substantially rectangular shape as the upper main end flaps 24, 44.
A substantially rectangular top panel 160 (FIG. 2) of the carton
400 is for closing (the opening at) the upper end 12 of the carton
and may help to maintain the substantially rectangular
configuration of the upper end 12 of the carton 400. Throughout
this Detailed Description section of this disclosure, the
substantially rectangular shape may more generally be referred to
in geometrical terms as a substantially closed shape that is
substantially rectangular. When the carton 400 is fully erected and
fully closed, the bottom panel and the top panel 160 are typically
parallel (e.g., substantially parallel) with one another.
[0037] The substantially rectangular top panel 160 (e.g., composite
top panel shown in FIG. 2) for closing the upper end 12 of the
carton 400 is formed from the upper end flaps 22, 24, 40, 42, 44,
46, 46. The top panel 160 may be formed/the opening at the upper
end 12 of the carton 400 may be obstructed (e.g., closed) by
folding the upper secondary end flaps 22, 40, 42, 46, 46 inwardly
about ninety degrees respectively along the transverse fold lines
21, 31, 41, 51, 61, 71, 81, then the upper main end flap 44 is
folded inwardly about ninety degrees along the transverse fold line
61, and then the upper main end flap 24 is folded inwardly about
ninety degrees along the transverse fold line 31. The separable
portion 26 of the upper main end flap 24 is attached (using
adhesive material or any other suitable fastening mechanism(s)) to
the respective portion of the upper main end flap 44, to complete
formation of the substantially rectangular top panel 160.
[0038] As shown in FIGS. 2 and 3, the upper end 12 of the carton
400 is substantially rectangular, whereas the lower end 14 of the
carton 400 generally has rounded or arced sides along the fold
lines 43, 93 proximate the lower end 14 of the carton (e.g., the
lower end is generally rectangular with substantially rounded
corners). Between the upper and lower ends 12, 14 of the carton,
the tubular portion of the carton transitions (e.g., substantially
smoothly transitions) between the contrasting shapes at the
opposite ends 12, 14.
[0039] Referring primarily to FIGS. 2 and 3, the upper end 12 of
the closed carton 400 may be opened by manually tearing away the
optional tear strip 28. As shown in FIG. 3, the tear strip 28 has
been removed along tear the lines 30, 32, 34 (FIG. 1). For example,
FIG. 3 shows the carton 400 in an upwardly open configuration.
Optionally, the carton 400 may be lined with or otherwise contain a
bag B that is shown upwardly open in FIG. 3. After the upper end 12
of the 400 has been opened, it may be closed by the remaining
portion of the substantially rectangular top panel 160 (FIG. 2)/the
remaining portion upper main end flap 24 and the other upper end
flaps 22, 40, 42, 44, 46, 46. The remaining portion of the
substantially rectangular top panel 160 may be releasably secured
by inserting the tuck-in tab 36 into the suck-in slot 38 (FIG.
1).
[0040] A second embodiment of this disclosure is like the first
embodiment, except for variations noted and variations that will be
apparent to one of ordinary skill in the art. For example and
referring to FIGS. 4 and 5, the carton 400' according to the second
embodiment of this disclosure is like the carton 400 of the first
embodiment, except that the upper main end flap 24' of the carton
400' of the second embodiment does not include the separable
portion 26 (FIG. 1) or tear strip 28 (FIG. 1) of the first
embodiment. Notwithstanding, the carton 400' of the second
embodiment typically, although optionally, includes a tuck-in tab
36' adapted for being received in a tuck-in slot 38'.
[0041] FIG. 5 shows the carton 400' with a spout 300' formed at one
side of the upper end 12', although substantially similar spouts
may be formed at either side of the upper end. The spout 300' is
formed by outward flexing (e.g., folding) the upper secondary end
flaps 40', 42' along fold the fold line 53', or outwardly flexing
(e.g., folding) the upper secondary end flaps 22', 46', 48' along
the fold line 83'. In addition to providing a spout 300 in just one
pair or group of end flaps 40', 42' or 22', 46', 48', optionally,
spouts can be formed in both sides of the upper end 12' of carton
400'. The pairs of fold lines 43', 53' and 83', 93' being
respectively aligned seeks to enhance formation of the spouts
300'.
[0042] FIG. 6 shows the carton 400' containing a bag B' that is
upwardly open adjacent the spout 300'. The opened bag B' and the
spout 300' cooperate to enable access to the bagged product in the
carton 400'. The spout 300' may function as a guiding mechanism
that seeks to enhance control over the process of pouring the
product out of the opening in the bag B' while the bag is within
the carton 400'.
[0043] As best understood with reference to FIG. 6, the cartons
400, 400' may optionally include one or more windows 200' that are
typically in the form of holes through the main panel 20' and/or
the main panel 50'. The optional window 200' typically allows for
viewing of product or other materials inside the bags B, B'.
Generally, the window 200' can be formed of any substance that
allows viewing access from the exterior to the interior of the
carton 400', and can enable visual assessment of the type of
ingredients, the quality of ingredients, the level of product
remaining in the carton, or any host of other reasons viewing
access may be desired. The window 200' has an irregular shape in
FIG. 6; however, any other suitable shape (e.g., a rectangular
shape) may be used. The window 200 can be formed in any shape,
size, dimension, and/or at any suitable distance from the upper end
12' or the lower end 14' of the carton 400'. Whereas the inclusion
of a bag B' is optional, the bag B' will typically be present when
one or more windows 200' are included in the carton 400', unless,
for example, the hole that defines the window 200' is separably
covered with a material (e.g., polymer film) that typically may be
seen through.
[0044] When the window 200' and the bag B' are both included in the
carton 400', the bag B' will typically be constructed of a material
(e.g., polymer film) that may be seen through. That is, when the
window 200' and the bag B' are both included, the bag B is
typically formed of a material that allows the product therein to
be viewed therethrough (e.g. the bag B could be formed of a polymer
film or other clear or opaque substances).
[0045] The bags B, B' may be sealed and installed and/or formed in
the cartons 400, 400' in any suitable manner. As schematically
shown in FIG. 6, the upper end of the bag B includes seals 500'
formed by adhesive material or any other suitable form of sealing,
such as through the application of heat, ultrasonic signals, or the
like. The seals 500' are schematically illustrated by parallel
lines in FIG. 6. The seals 500'/sealing lines or the like may
extend transversely where the bag' is opened, and longitudinally
where the bag B' is to remain closed. For example, adhesive
material may be applied in specific/contrasting amounts and/or
patterns in a manner that signals to a user that the bag B is
supposed to be open in a specific (e.g., predetermined) area, as
shown in FIG. 6. There may be a lesser amount or number of the
seals 500'/sealing lines or the like where the bag B' is intended
to be opened.
[0046] In some examples of this disclosure, the bags B, B', which
are optional and may be omitted, are within the cartons 400, 400'
but are not adhered to or otherwise connected to the interior
surface of the cartons 400, 400' containing the bags B, B'.
Alternatively, the bags B, B' may be adhered to or otherwise
connected to the interior surface of the cartons 400, 400'
containing the bags B, B'. For example and as shown in FIG. 7 in
accordance with a version of the first embodiment, the bag B may be
adhered to the blank 10 with patterns of adhesive material 502.
Generally, the bag B, with its lower end sealed, may be adhered to
the blank 10 on the main panel 50 (e.g., the side that does not
include the crease (e.g., transverse fold line 151) at the bottom).
Thus, as shown in FIG. 7, the bag B is adhered to blank 10 by the
adhesive material 502 on the main panel 50. Alternatively or
additionally, adhesive material 502 can be applied onto the main
panel 20, so that the bag B becomes adhered to the main panel 20
when the carton 400 is erected.
[0047] In FIG. 7, the bag B is schematically shown as having closed
bottom formed by a pinch seal 600 or any other suitable seal along
the bottom of the bag B. A fin seal 700 or any other suitable seal
may be used to form the tubular precursor of the bag B. The seals
600, 700 may be conventional and may be any suitable types of seals
that may be adapted to accommodate for a wide variety of possible
needs that may depend upon the size, type, thickness, orientation,
etc. of the bag B. Similarly, the adhesive material 502 (e.g.,
glue) may be applied in different amounts, configurations, and
locations than shown in FIG. 7.
[0048] For each of the cartons 400, 400', any bag therein may
include a spout or spout-like feature adjacent to the carton's
spouts 300' (FIG. 6). For example, each of the above-discussed bags
B, B' may be replaced with one of the bags B'' schematically shown
in FIG. 8. In FIG. 8, a series of the bags B'' are schematically
shown connected end-to end, and the bags B'' to be used within the
cartons 400, 400' may be cut from one another (e.g., slit or torn
from one another, or the like) along a curved line 504'' so as to
include projecting spout sections 506''. The projecting spout
sections 506'' are for being opened to form a spout of the bag B''
for dispensing. The bags B'' would typically be arranged in the
cartons 400, 400' so that the projecting spout sections 506'' would
be adjacent the spouts 300' (FIG. 6). As shown in FIG. 8, the spout
sections include seals 500'' formed by adhesive material or any
other suitable form of sealing, such as through the application of
heat, ultrasonic signals, or the like.
[0049] In FIG. 8, the seals 500'', sealing lines or the like are
schematically illustrated by parallel lines. The seals 500'',
sealing lines or the like in the projecting spout sections 506''
are schematically illustrated as extending transversely. The seals
500'' sealing lines or the like in other than the projecting spout
sections 506'' are schematically illustrated as extending
longitudinally. There may be a lesser amount or number of the seals
500''/sealing lines or the like in the projecting spout sections
506'', so that the projecting spout sections 506'' may be manually
opened more easily that the other sealed sections. For example, the
seals 500'' may be formed in predetermined specific/contrasting
amounts and/or patterns in a manner that signals to a user that the
bag B'' is supposed to be open in the projecting spout section
506''. There may be a lesser amount or number of the seals
500''/sealing lines or the like in the projecting spout section
506''.
[0050] The bags B', B'', B''' may be formed of any material, such
as food-grade polymer film, and the bags may be formed of a
repulpable or other recycled material or materials to function at
least generally as described herein. Generally, the upper ends of
the bags B', B'', B''' are sealed closed after product (e.g., food)
is inserted therein. The bags B', B'', B''' may be sealed liners
that are formed inside the cartons 400, 400' and/or the bags may be
installed into the cartons after the bags are filled in lieu of
being adhered to the blank prior to the blank being formed into a
carton.
[0051] The blanks according to the present disclosure can be, for
example, formed from coated paperboard and similar or any other
suitable materials. For example, the interior and/or exterior sides
of the blanks can be coated with a clay coating. The clay coating
may then be printed over with product, advertising, price coding,
and other information or images. The blanks may then be coated with
a varnish to protect any information printed on the blank. The
blanks may also be coated with, for example, a moisture barrier
layer, on either or both sides of the blank. In accordance with the
above-described embodiments, the blanks may be constructed of
paperboard of a caliper such that it is heavier and more rigid than
ordinary paper. The blanks can also be constructed of other
materials, such as cardboard, hard paper, or any other material
having properties suitable for enabling the carton to function at
least generally as described herein. The blanks can also be
laminated or coated with one or more sheet-like materials at
selected panels or panel sections.
[0052] In accordance with the above-described embodiments of the
present disclosure, a line of disruption in the form of a fold line
can be any substantially linear, although not necessarily straight,
form of weakening that facilitates folding therealong. More
specifically, but not for the purpose of narrowing the scope of the
present disclosure, fold lines include: a score line, such as lines
formed with a blunt scoring knife, or the like, which creates a
crushed portion in the material along the desired line of weakness;
a cut that extends partially into a material along the desired line
of weakness, and/or a series of cuts that extend partially into
and/or completely through the material along the desired line of
weakness; and various combinations of these features. In accordance
with the first embodiment, all of the fold lines 21, 31, 41, 51,
53, 61, 71, 81, 83, 101, 103, 111, 113, 131, 141 may be
score/crease lines, and the fold lines 91, 93, 121, 151 may each be
formed by an alternating series of slits and score/crease
lines.
[0053] As an example, a line of disruption in the form of a tear
line can include: a slit that extends partially into the material
along the desired line of weakness, and/or a series of spaced apart
slits that extend partially into and/or completely through the
material along the desired line of weakness, or various
combinations of these features. As a more specific example, one
type tear line is in the form of a series of spaced apart slits
that extend completely through the material, with adjacent slits
being spaced apart slightly so that a nick (e.g., a small somewhat
bridging-like piece of the material) is defined between the
adjacent slits for typically temporarily connecting the material
across the tear line. The nicks are broken during tearing along the
tear line. The nicks typically are a relatively small percentage of
the tear line, and alternatively the nicks can be omitted from or
torn in a tear line such that the tear line is a continuous cut
line. That is, it is within the scope of the present disclosure for
each of the tear lines to be replaced with a continuous slit, or
the like. For example, a cut line can be a continuous slit or could
be wider than a slit without departing from the present
disclosure.
[0054] Directional references (e.g., top, upper, bottom, lower,
longitudinal, transverse, side, or the like) have been used in this
disclosure for ease of understanding and not for the purpose of
limiting the scope of this disclosure.
[0055] It will be understood by those skilled in the art that while
the present disclosure has been discussed above with reference to
exemplary embodiments, various additions, modifications and changes
can be made thereto without departing from the spirit and scope of
the invention as set forth in the claims.
* * * * *