U.S. patent application number 12/975508 was filed with the patent office on 2012-06-28 for carton with opposing wave-shaped panel and squared panel and blanks for constructing same.
Invention is credited to Raymond Fisher, Stephen Koven, Nancy Miiller, Ashley Wilkum.
Application Number | 20120160905 12/975508 |
Document ID | / |
Family ID | 46315447 |
Filed Date | 2012-06-28 |
United States Patent
Application |
20120160905 |
Kind Code |
A1 |
Wilkum; Ashley ; et
al. |
June 28, 2012 |
CARTON WITH OPPOSING WAVE-SHAPED PANEL AND SQUARED PANEL AND BLANKS
FOR CONSTRUCTING SAME
Abstract
A carton is described that comprises opposing wave-shaped and
squared panels wherein the two opposing panels preferably comprise
a wave-shaped front panel and a squared back panel. Also disclosed
are single, flat die-cut blanks that may be used to form the
present carton. The carton comprises a wave-shaped front panel
further comprising two opposing wave-shaped fold lines that
approximate single sine waves having a frequency equal to the
height of the carton and two opposing straight fold lines that are
the top and bottom edges to the front panel. The present carton may
optionally comprise a hinging cup-shaped lid in hinging arrangement
with the front panel to open forward toward the consumer, or may
optionally comprise four top flaps resembling a cereal box top
closure.
Inventors: |
Wilkum; Ashley; (Phoenix,
AZ) ; Miiller; Nancy; (Scottsdale, AZ) ;
Fisher; Raymond; (St. Augustine, FL) ; Koven;
Stephen; (Scottsdale, AZ) |
Family ID: |
46315447 |
Appl. No.: |
12/975508 |
Filed: |
December 22, 2010 |
Current U.S.
Class: |
229/116.1 ;
229/147 |
Current CPC
Class: |
B65D 5/6685 20130101;
B65D 5/18 20130101 |
Class at
Publication: |
229/116.1 ;
229/147 |
International
Class: |
B65D 5/42 20060101
B65D005/42 |
Claims
1. A blank for forming a six-sided carton having a height, a width
and a depth, comprising: a square or rectangular rear panel 50; a
second left-side panel 55 foldably connected to the rear panel at a
straight fold line 51; a second right-side panel 60 foldably
connected to the rear panel at a straight fold line 53, said fold
lines 51 and 53 substantially parallel and equal in length to the
height of the carton; a square or rectangular bottom panel 70
foldably connected to the rear panel at a straight fold line 52,
said fold line 52 perpendicular to both fold lines 51 and 53; a
left bottom glue flap 65 foldably connected to the bottom panel at
a straight fold line 67, said fold line 67 perpendicular to fold
line 52; a right bottom glue flap 75 foldably connected to the
bottom panel at a straight fold line 71, said fold line 71 parallel
to fold line 67 and perpendicular to fold line 52; a wave-shaped
front panel 10 foldably connected to the bottom panel at a straight
fold line 13, said fold line 13 parallel to fold line 52 and
perpendicular to both fold lines 67 and 71; a first left-side panel
5 foldably connected to the front panel at a wave-shaped fold line
9, said fold line 9 comprising the approximate shape of a single
sine wave with frequency equal to the height of the carton; a first
right-side panel 14 foldably connected to the front panel at a
wave-shaped fold line 12, said fold line 12 comprising the
approximate shape of a single sine wave with frequency equal to the
height of the carton, said wave-shaped fold line 12 curving in
parallel with wave-shaped fold line 9; a square or rectangular top
panel 24 foldably connected to the front panel at a straight fold
line 11, said fold line 11 parallel to fold line 13, and fold lines
9, 11, 12, and 13 comprising the contiguous boundary around said
front panel 10; a rear glue flap 35 foldably connected to the top
panel at a straight fold line 25, said fold line 25 substantially
parallel to fold line 11; a left side glue flap 20 foldably
connected to the top panel at a straight fold line 23, said fold
line 23 perpendicular to said fold lines 25 and 11; a right side
glue flap 27 foldably connected to the top panel at a straight fold
line 26, said fold line 26 substantially parallel to fold line 23
and perpendicular to both fold lines 25 and 11; a left lid glue
flap 30 foldably connected to said rear glue flap at straight fold
line 34, said fold line 34 perpendicular to fold line 25; and, a
right lid glue flap 37 foldably connected to said rear glue flap at
straight fold line 39, said fold line 39 substantially parallel to
fold line 34 and perpendicular fold line 25, and wherein top panel
24, left side glue flap 20, right side glue flap 27, rear glue flap
35, left lid flap 30, and right lid glue flap 37 collectively
comprise a hinging cup-shaped lid hingeably connected to the front
panel by straight fold line 11.
2. The blank of claim 1, wherein said wave-shaped fold line 9 and
said wave-shaped fold line 12 comprise identical and superimposable
single sine waves.
3. The blank of claim 1, wherein said second left-side panel 55
further comprises: a wave-shaped cut edge 57 opposite and
substantially parallel to fold line 51; a straight cut edge 56 of
approximate length equal to the depth of the carton and
substantially perpendicular to fold line 51; a straight cut edge 58
of approximate length equal to the depth of the carton, parallel to
cut edge 56 and substantially perpendicular to fold line 51;
wherein said wave-shaped cut edge 57 approximates the shape of a
single sine wave with frequency equal to the height of the carton,
and wherein wave-shaped cut edge 57, straight cut edge 56, straight
fold line 51, and straight cut edge 58 comprise the contiguous
boundary of said second left-side panel 55.
4. The blank of claim 3, wherein said second right-side panel 60
further comprises: a wave-shaped cut edge 62 opposite and
substantially parallel to fold line 53; a straight cut edge 61 of
approximate length equal to the depth of the carton and
substantially perpendicular to fold line 53; a straight cut edge 63
of approximate length equal to the depth of the carton, parallel to
cut edge 61 and substantially perpendicular to fold line 53;
wherein said wave-shaped cut edge 62 approximates the shape of a
single sine wave with frequency equal to the height of the carton,
and wherein wave-shaped cut edge 62, straight cut edge 63, straight
fold line 53, and straight cut edge 61 comprise the contiguous
boundary of said second right-side panel 60.
5. The blank of claim 4, wherein said first left-side panel 5
further comprises: a straight cut edge 7 of approximate length
equal to the height of the carton, opposite and substantially
parallel to wave-shaped fold line 9; a straight cut edge 6 of
approximate length equal to the depth of the carton and
substantially perpendicular to cut edge 7; a straight cut edge 8 of
approximate length equal to the depth of the carton, parallel to
cut edge 6 and substantially perpendicular to cut edge 7; wherein
said wave-shaped fold line 9, straight cut edge 8, straight cut
edge 7, and straight cut edge 6 comprise the contiguous boundary of
said first left-side panel 5, and wherein said first left-side
panel 5 and said second left-side panel 55 substantially overlap
with wave-shaped cut line 57 in registration with wave-shaped fold
line 9 when the carton is formed from the blank.
6. The blank of claim 5, wherein said first right-side panel 14
further comprises: a straight cut edge 16 of approximate length
equal to the height of the carton, opposite and substantially
parallel to wave-shaped fold line 12; a straight cut edge 15 of
approximate length equal to the depth of the carton and
substantially perpendicular to cut edge 16; a straight cut edge 17
of approximate length equal to the depth of the carton, parallel to
cut edge 15 and substantially perpendicular to cut edge 16; wherein
said wave-shaped fold line 12, straight cut edge 15, straight cut
edge 16, and straight cut edge 17 comprise the contiguous boundary
of said first right-side panel 14, and wherein said first
right-side panel 14 and said second right-side panel 60
substantially overlap with wave-shaped cut line 62 in registration
with wave-shaped fold line 12 when the carton is formed from the
blank.
7. The blank of claim 6, wherein the wave-shaped fold line 9, the
wave-shaped fold line 12, the wave-shaped cut edge 57, and the
wave-shaped cut edge 62 comprise identical, superimposable single
sine waves of frequency equal to the height of the carton, when the
carton is formed from the blank.
8. A blank for forming a six-sided carton having a height, a width
and a depth, comprising: a square or rectangular rear panel 50'; a
square or rectangular rearward top panel 35' foldably connected to
the rear panel at a straight fold line 54'; a second left-side
panel 55' foldably connected to the rear panel at a straight fold
line 51', said fold line 51' substantially perpendicular to fold
line 54'; a second right-side panel 60' foldably connected to the
rear panel at a straight fold line 53', said fold lines 51' and 53'
substantially parallel and equal in length to the height of the
carton and substantially perpendicular to fold line 54'; a square
or rectangular bottom panel 70' foldably connected to the rear
panel at a straight fold line 52', said fold line 52' substantially
parallel to fold line 54' and perpendicular to both fold lines 51'
and 53'; a left bottom glue flap 65' foldably connected to the
bottom panel at a straight fold line 67', said fold line 67'
perpendicular to fold line 52'; a right bottom glue flap 75'
foldably connected to the bottom panel at a straight fold line 71',
said fold line 71' parallel to fold line 67' and perpendicular to
fold line 52'; a wave-shaped front panel 10' foldably connected to
the bottom panel at a straight fold line 13', said fold line 13'
parallel to fold line 52' and perpendicular to both fold lines 67'
and 71'; a first left-side panel 5' foldably connected to the front
panel at a wave-shaped fold line 9', said fold line 9' comprising
the approximate shape of a single sine wave with frequency equal to
the height of the carton; a first right-side panel 14' foldably
connected to the front panel at a wave-shaped fold line 12', said
fold line 12' comprising the approximate shape of a single sine
wave with frequency equal to the height of the carton, said
wave-shaped fold line 12' curving in parallel with wave-shaped fold
line 9'; a square or rectangular forward top panel 24' foldably
connected to the front panel at a straight fold line 11', said fold
line 11' parallel to fold line 13', fold lines 9', 11', 12', and
13' comprising the contiguous boundary around said front panel 10';
a left top flap 20' foldably connected to the first left-side panel
5' at a straight fold line 6', said fold line 6' comprising a
substantially collinear extension of fold line 11'; a right top
flap 27' foldably connected to the first right-side panel 14' at a
straight fold line 15', said fold line 15' comprising a
substantially collinear extension of fold line 11'; and wherein,
left top flap 20', right top flap 27', forward top panel 24', and
rearward top panel 35' collectively comprise a top closure to the
carton, when the carton is formed from the blank.
9. The blank of claim 8, wherein said wave-shaped fold line 9' and
said wave-shaped fold line 12' comprise identical and
superimposable single sine waves.
10. The blank of claim 8, wherein said second left-side panel 55'
further comprises: a wave-shaped cut edge 57' opposite and
substantially parallel to fold line 51'; a straight cut edge 56' of
approximate length equal to the depth of the carton and
substantially perpendicular to fold line 51'; a straight cut edge
58' of approximate length equal to the depth of the carton,
parallel to cut edge 56' and substantially perpendicular to fold
line 51'; wherein said wave-shaped cut edge 57' approximates the
shape of a single sine wave with frequency equal to the height of
the carton, and wherein wave-shaped cut edge 57', straight cut edge
56', straight fold line 51', and straight cut edge 58' comprise the
contiguous boundary of said second left-side panel 55'.
11. The blank of claim 10, wherein said second right-side panel 60'
further comprises: a wave-shaped cut edge 62' opposite and
substantially parallel to fold line 53'; a straight cut edge 61' of
approximate length equal to the depth of the carton and
substantially perpendicular to fold line 53'; a straight cut edge
63' of approximate length equal to the depth of the carton,
parallel to cut edge 61' and substantially perpendicular to fold
line 53'; wherein said wave-shaped cut edge 62' approximates the
shape of a single sine wave with frequency equal to the height of
the carton, and wherein wave-shaped cut edge 62', straight cut edge
63', straight fold line 53', and straight cut edge 61' comprise the
contiguous boundary of said second right-side panel 60'.
12. The blank of claim 11, wherein said first left-side panel 5'
further comprises: a straight cut edge 7' of approximate length
equal to the height of the carton, said cut edge 7' opposite and
substantially parallel to wave-shaped fold line 9' and
substantially perpendicular to fold line 6'; a straight cut edge 8'
of approximate length equal to the depth of the carton, said cut
edge 8' substantially parallel to fold line 6' and substantially
perpendicular to cut edge 7'; wherein said wave-shaped fold line
9', straight cut edge 8', straight cut edge 7', and straight fold
line 6' comprise the contiguous boundary of said first left-side
panel 5', and wherein said first left-side panel 5' and said second
left-side panel 55' substantially overlap with wave-shaped cut line
57' in registration with wave-shaped fold line 9', when the carton
is formed from the blank.
13. The blank of claim 12, wherein said first right-side panel 14'
further comprises; a straight cut edge 16' of approximate length
equal to the height of the carton, said cut edge 16' opposite and
substantially parallel to wave-shaped fold line 12' and
substantially perpendicular to fold line 15'; a straight cut edge
17' of approximate length equal to the depth of the carton, said
cut edge 17' substantially parallel to fold line 15' and
substantially perpendicular to cut edge 16'; wherein said
wave-shaped fold line 12', straight fold line 15', straight cut
edge 16', and straight cut edge 17' comprise the contiguous
boundary of said first right-side panel 14', and wherein said first
right-side panel 14' and said second right-side panel 60'
substantially overlap with wave-shaped cut line 62' in registration
with wave-shaped fold line 12', when the carton is formed from the
blank.
14. The blank of claim 13, wherein the wave-shaped fold line 9',
the wave-shaped fold line 12', the wave-shaped cut edge 57', and
the wave-shaped cut edge 62' comprise identical, superimposable
single sine waves of frequency equal to the height of the carton,
when the carton is formed from the blank.
15. In combination, a carton formed from the blank of claim 1 and
at least one wave-shaped article enclosed within the carton.
16. In combination, a carton formed from the blank of claim 7 and
at least one wave-shaped article enclosed within the carton.
17. In combination, a carton formed from the blank of claim 8 and
at least one wave-shaped article enclosed within the carton.
18. In combination, a carton formed from the blank of claim 14 and
at least one wave-shaped article enclosed within the carton.
19. A six-sided carton having a front, a back, a left-side, a
right-side, a top, and a bottom, and having a height, a width, a
depth, an outer surface, and an inner surface, comprising: a
wave-shaped front panel; a left-side panel adjacent and foldably
connected to the front panel at a first wave-shaped fold line
approximating a single sine wave with frequency equal to the height
of the carton; a right-side panel adjacent and foldably connected
to the front panel at a second wave-shaped fold line approximating
a single sine wave with frequency equal to the height of the
carton, said second wave-shaped fold line curving in parallel with
said first wave-shaped fold line; a square or rectangular bottom
panel adjacent and foldably connected to the front panel at a
straight front bottom fold line; a square or rectangular back panel
adjacent and foldably connected to the bottom panel at a straight
rear bottom fold line; and a hinging cup-shape lid enclosing the
top of the carton, said lid in hinging attachment to the front
panel at a straight lid hinging line, said lid further comprising a
top panel and at least one glue flap overlapping a portion of the
outer surface of at least one of said left-side panel, said
right-side panel, or said back panel.
20. A six-sided carton having a front, a back, a left-side, a
right-side, a top, and a bottom, and having a height, a width, a
depth, an outer surface, and an inner surface, comprising: a
wave-shaped front panel; a left-side panel adjacent and foldably
connected to the front panel at a left wave-shaped fold line
approximating a single sine wave with frequency equal to the height
of the carton; a right-side panel adjacent and foldably connected
to the front panel at a right wave-shaped fold line approximating a
single sine wave with frequency equal to the height of the carton,
said right wave-shaped fold line curving in parallel with said left
wave-shaped fold line; a square or rectangular bottom panel
adjacent and foldably connected to the front panel at a straight
front bottom fold line; a square or rectangular back panel adjacent
and foldably connected to the bottom panel at a straight rear
bottom fold line; a top panel further comprising a forward top
panel and a rearward top panel, said forward top panel enclosing
approximately half of the top of the carton, said forward top panel
adjacent and foldably connected to said front panel at a straight
front lid hinge line, said rearward top panel enclosing
approximately half of the top of the carton, said rearward top
panel adjacent and foldably connected to said back panel at a
straight rear lid hinge line, said rear lid hinge line
substantially parallel to said front lid hinge line.
Description
FIELD OF INVENTION
[0001] The present invention relates to paperboard packages, boxes,
or cartons, and in particular to a paperboard blank and a carton
comprising a wave-shaped panel opposite a squared panel made from
the blank.
BACKGROUND
[0002] Cartons having one or more curved panels are found in retail
packaging and in the patent literature. Most of these cartons
comprise one or more panels that are fully concave or convex. Such
cartons are commonly seen in food and sporting goods packaging.
Curved panel cartons may have functional attributes simply by
having an overall shape that accommodates the shape of the contents
therein. Other cartons with curved panels may have ornamental
attributes yet still require imaginative design of a single die-cut
blank that can be easily erected to form the ornamental carton.
[0003] For example, U.S. Pat. No. 3,078,989 (Curran, et al.) claims
a carton with a contour design erected from a single die-cut blank.
The blank comprises a top panel with bifurcated end flaps that can
arcuately bend inwardly. The result when erected is a carton with a
concave top and convex ends.
[0004] U.S. Pat. No. 3,270,868 (Pantalone) claims a carton similar
to the Curran carton ('989) except that the carton also comprises
curved front panel display windows. When erected, the carton
comprises a concave front panel that includes the display openings,
convex side panels, and a flat rear wall panel.
[0005] U.S. Pat. No. 3,815,735 (Cucuo) claims a carton for
merchandizing a sports ball, e.g. a soccer or basketball. The
carton comprises two opposing convex side walls with the distance
between them about the same as the diameter of the ball to be
merchandized. The other two opposing side walls are concave and
contain centrally located openings of elliptical configuration
through which the ball can project. The blank that can be erected
to make this carton comprises front, rear, and side panels having
at least one arched cut or fold line. In that way, two opposing
panels have a round shape with flat top and bottom whereas the
other two opposing panels have an hourglass shape.
[0006] U.S. Pat. No. 4,191,323 (Webinger) claims a carton having a
tapered and sculptured appearance made possible by erecting a blank
that has a combination of rectangular panels and panels with one
arched cut or fold line.
[0007] U.S. Pat. No. 5,725,147 (Ljungstrom, et al.) claims a gable
top carton with curved side creases. Such a carton may be
constructed from a blank that has curved score lines dividing one
or more side panels from the top gabled structure. The curved side
crease allows clearance when reaching under the gable to push open
the fin flaps, which is important for very small gabled cartons in
the food industry.
[0008] U.S. Pat. No. 7,665,653 (Fitzwater) claims a twisted carton
made possible by incorporating a plurality of panel strips defined
by oblique fold lines extending along the height of the carton.
When the blank is erected, these panel strips provide the carton
with a twisted shape.
[0009] Cartons having more intricately curved panels instead of
just concave or convex panels are scarcely seen. This is presumably
because of the difficulty in devising a single die-cut blank that
can be erected and glued to create a carton comprised of
intricately curved panels. The balance between aesthetics and the
ease in erecting the carton has not been achieved for all
conceivable types of packaging designs, in spite of decades of
innovation in this area of packaging. Cartons with curved panels
may be required to mechanically protect and merchandize a product
that has a particular shape, and to convey that product shape to
consumers who view only the exterior of the carton at retail.
Therefore, there is a continual need to design new cartons having
shapes that are both functional and aesthetically appealing, and to
devise imaginative designs for a single blank that may be used to
easily erect such a newly shaped carton.
SUMMARY OF THE INVENTION
[0010] The present invention is a new and novel carton comprising
opposing wave-shaped panel and squared panel, and in particular
comprising a wave-shaped front panel, a squared back panel, and
opposing side panels, each bound by three contiguous straight cut
edges and one wave-shaped fold line, and wherein either of the
opposing side panels may be superimposed onto the other by a
180.degree. rotation around a central axis.
[0011] In accordance with an exemplary embodiment of the present
invention, a carton with wave-shaped front panel and squared back
panel is erected from a blank comprising in combination: (1) a
front panel joined to a substantially rectangular top panel and to
a substantially rectangular bottom panel by straight fold lines,
and foldably joined to a first set of side panels by wave-shaped
fold lines that are, or resemble, single sine waves; and, (2) a
rear panel foldably joined to a bottom panel and to a second set of
opposing side panels by straight fold lines, and having a straight
cut edge that forms an uppermost edge of a substantially square or
rectangular opening in the top of the erected carton.
[0012] In accordance with another exemplary embodiment of the
present invention, a new and novel carton comprises a wave-shaped
front panel, a squared back panel, and two sets of overlapping
opposing side panels, and a cup-shaped lid, where the lid is in
hinging arrangement to the front panel such that the carton lid
opens forward toward the consumer.
[0013] In accordance with another exemplary embodiment of the
present invention, a new and novel carton comprises a wave-shaped
front panel, a squared back panel, and two sets of overlapping
opposing side panels, and a four (4) flap cereal box closure
arrangement at the top of the carton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a plan view of a first embodiment of a blank from
which a carton of the present invention may be formed.
[0015] FIG. 2 is a plan view of a second embodiment of a blank from
which a carton of the present invention may be formed.
[0016] FIG. 3 is a front perspective view of another embodiment of
a carton of the present invention in the fully erected condition,
with the optional flip-open lid shown in the open position.
[0017] FIG. 4 is a front perspective view of another embodiment of
a carton of the present invention in the fully erected condition,
with the optional flip-lid shown in the closed position.
[0018] FIG. 5 is a rear perspective view of another embodiment of a
carton of the present invention in the fully erected condition,
with the optional flip-open lid shown in the closed position.
[0019] FIG. 6 is a front perspective view of another embodiment of
a carton of the present invention in the fully erected condition,
with the optional top forward and rearward panels and glue flaps
that comprise a top closure shown in the closed position.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following description is of exemplary embodiments only
and is not intended to limit the scope, applicability or
configuration of the invention in any way. Rather, the following
description provides a convenient illustration for implementing
exemplary embodiments of the invention. Various changes to the
described embodiments may be made in the function and arrangement
of the elements described without departing from the scope of the
invention as set forth in the appended claims. For example, the
present carton may close at the top by a conventional arrangement
of four glue flaps, such as found on most cereal boxes, rather than
a closure comprising a hinging lid. Additionally, though described
herein in general terms of a carton assembled from a single blank,
additional cardboard, paperboard or corrugate board inserts or
layers such as dividers or strengtheners may be envisioned in or on
the present carton. Most importantly, the present carton is not
limited to any particular size. It may be very small, e.g. even
smaller than a cigarette package, to merchandise small items for
sale at a checkout isle, or it may be huge, such as to merchandise
very large items for sale. Ideally, the cartons of the present
invention may be from about 5-6 inches in width, from about 1-4
inches in depth, and from about 6-10 inches in height. The
dimensions may be adjusted to accommodate various size products
and/or influence the perception on a store shelf.
[0021] A "carton" (or a "box") herein refers to a paperboard or
cardboard container having, in combination, (and distinguishable),
a top, a bottom, left and right sides, a front, and a rear that
collectively enclose and protect an interior space that is usable
for packing, storing, shipping, and/or merchandizing a particular
product. For the carton disclosed herein, and for most cartons in
general, the bottom is recognized as the side of the carton that is
logically placed on a surface when the carton is to remain
stationary (e.g. by paying attention to "this end up" or other
printed information, or logically oriented the carton to place the
opening at the top, and/or because of the dimensions/balance of the
carton), and the top side to the carton is the location of an
opening/access to the carton. For purposes of the present
invention, the opening to the carton may be resealable/reclosable
or the top of the carton may simply rip open to irreversibly
provide access to the interior space of the carton.
[0022] A carton for purposes herein will have six discernable
"sides" (front, left, right, top, bottom, rear) and will be
box-like or cuboid in overall shape, in spite of some curved panel
edges. The spatial orientation used herein is such that the "front"
of the fully erected carton refers to that panel of the carton that
has a substantially "wave-shaped" appearance. The "bottom" of the
present carton refers to the panel that will be in contact with
some stationary surface for most of the life of the carton, such as
when the carton sits on a store shelf or on a shelf in a consumer's
home. Correspondingly, the "top" of the present carton refers to
the uppermost panel of the carton when the carton is standing
upright with the bottom on a horizontal stationary surface, and is
the panel of the carton where an access to the interior of the
carton exists. "Rear" and "back" are terms that may be used
interchangeably to refer to that panel of the box opposite the
front panel and not visible when the carton is viewed at the front
plan. When viewing the front plan of the erected carton (i.e.
viewing the carton face-on), the side to the right is herein
designated the "right side panel" and the side to the left is
herein designated the "left side panel." "Panel" and "flap" are
meant interchangeably as primarily flat, rigid, structural elements
that are mutually contiguous and that collectively form the overall
cuboid structure of the carton when the carton is erected, although
where possible, panel refers to a larger and substantially visible
portion of the carton and flap (or "glue flap") to a smaller
functional portion such as a narrow glue flap that will likely not
be visible from the exterior of the carton once erected. Any side
to the erected carton (e.g. "top", "left side", "right side",
"front," "rear," or "bottom") may be comprised of multiple separate
panels and/or flaps, (i.e. any side to the present erected carton
may be comprised of overlapping layers of panels for added strength
and/or ease in gluing). For example, two longer panels and two
shorter end flaps may be folded up and glued or stapled to one
another to create the "top" or "bottom" of an erected box.
Likewise, sets of side panels may be overlapped to partial or even
full extent and glued to form double-thickness sides to a
carton.
[0023] The nature of the product that may be contained within the
carton of the present invention is immaterial to the scope of the
present invention, although it is preferred that the present carton
be used to contain a stack of flat, wave-shaped articles such as
the laundry sheets having the ornamental design disclosed in U.S.
Pat. No. D623422 (Williams, et al.) incorporated herein by
reference. In this way, the carton of the present invention, with
its wave-shaped front, projects the shape of the contents within to
consumers who may only see the exterior of the carton on the store
shelf and not appreciate the shape of the product inside.
[0024] The term "blank" used herein is a term of art in the
packaging industry that refers to a flat board/sheet that is cut to
a pattern that may be erected into a carton structure. A "blank"
may be a flat piece of corrugated board that has various cut lines
and fold lines such that a machine (called a conversion machine or
a carton erector) can build it into a 3-dimensional carton. Such
blanks may also be cut with perforated lines that may outline
locations where the erected box can be opened at a future time.
Perforated lines may allow removal of a flap, the opening of a
handle or grasping aperture, or may define a tear strip to open a
sealed carton. Alternatively, perforations may outline entire
sections of a box intended to be fully removed at some point, and
may even run the length of the blank (and hence, circumscribe the
entire erected box) so that the entire box can be separated into
portions along that perforated line. Perforations in general allow
for the ripping, tearing or breaking of the corrugated or paper
board along the line that is comprised of perforations.
Perforations may be small notches, small cuts, or holes, or
combinations thereof, and may be pierced or cut through one side or
both sides of the corrugated board. For example, a perforated line
that may be torn may comprise a series of small linear cuts lined
up end to end with a particular spacing between the cuts.
[0025] Blanks represent a convenient and collapsed form of a box
that may be stacked, bundled and shipped to the manufacturer of the
product that is to be placed therein for storing, shipping and
merchandising. A die-cut machine cuts card or paperboard or
corrugated board into a blank that has a pattern such that the
manufacturer can fold it up and glue it into the box shape,
readying it for filling with product. Such processes and machines
used for cutting, scoring and perforating card, paperboard and
corrugate board into intricate blanks for box construction is amply
disclosed in U.S. Pat. Nos. 2,195,819 (Kurtzeborn); 2,313,801
(Corll); 2,390,072 (Beaton); 2,821,871 (Sarno); 2,860,555
(Williamson); 2,939,358 (Pearson); 3,020,809 (Guyer); 3,142,233
(Downie); 3,170,342 (Downie); 3,292,513 (Palmer); 3,485,146
(Sarka); 3,786,732 (Forbes); 3,869,949 (Dolle); 3,929,059 (Gendro);
3,982,458 (Terasake); 5,140,872 (Holliday); and, 6,203,482
(Sandford), each of which are incorporated herein in their
entireties.
[0026] In regards to the materials of construction, the carton of
the present invention may be constructed of various paperboard,
cardboard, corrugated board, sheet metal, or wood paneling, or
combinations of these materials, with relatively thin paperboard or
cardboard being preferred over corrugate. The blanks that will be
described below are preferably manufactured from white cardboard.
Corrugated board may be constructed by sandwiching and gluing
fluted corrugating medium between layers of white, mottled-white or
brown paper liner or paperboard. The choice of white,
mottled-white, or brown paper for the corrugated board depends on
what the carton is to be used for. The present carton may be
constructed of post-consumer waste/recycled materials or new
materials as desired, with varying thicknesses depending on cost,
desired weight and strength, balanced with environmental
responsibility.
[0027] Affixation refers to the attachment of flaps and panels to
one another for the purpose of erecting a flat blank into a final
carton. Affixation and "gluing" are used interchangeably herein,
but it must be understood that throughout the packaging industry
cartons may be secured in their erected shape by glue, staples, or
tape, or combinations thereof. In this regard, where "glue" or
"gluing" is stated herein, other substitute/additional means of
affixing flaps and panels to one another, (such as stapling and
taping), is within the scope of the invention. Likewise a "glue
flap" may be secured to another panel by staples or tape rather
than glue.
[0028] Lastly, the present carton is distinguished from the prior
art cartons in that it comprises opposing "wave-shaped" and
"squared" panels. "Wave-shaped" for purposes herein, refers to a
substantially flat panel circumscribed/bounded by a total of four
edges, where the four edges comprise alternating curved and
straight edges (two opposing straight edges and two opposing curved
edges in alternating arrangement), and where each of the two
opposing curved edges have a pattern that approximates a single
sine wave. For a definition of "wave-shaped" herein, the two
opposing curved edges, each approximating a sine wave, curve in
parallel to one another (i.e., the curves are not mirror images of
one another and may even be identical, superimposable curves), and
the remaining two opposing edges of wave-shaped are flat/straight.
As examples of "wave-shaped," reference is again made to the
ornamental design of a wave-shaped laundry sheet, U.S. Pat. No.
D623422 (Williams, et al.) referenced above, and also to an
ornamental design for a wave-shaped scouring sponge disclosed in
U.S. Pat. No. D556966 (Herbrand, et al.), incorporated herein by
reference, regardless if these inventors refer to their ornamental
designs as wave-shaped, these designs are wave-shaped in accordance
with the definition being set forth herein for purposes of the
present invention. Both the Williams sheet for laundry use and the
Herbrand sponge reflect what is meant herein by "wave-shaped," and
aid in defining this term for the present invention. That is, in
each of these ornamental designs, a substantially flat surface is
outlined by four edges, two opposing straight/flat edges and two
opposing curved edges, wherein the two curved edges each have a
wave pattern approximating, or identical to, a single sine wave,
and where the two opposing curved edges curve in parallel to one
another, making them either substantially similar to one another or
even identical and superimposable.
[0029] In the carton of the present invention, the front of the
carton comprises the wave-shaped panel, and therefore the opposing
squared panel must be the back/rear of the carton. This assignment
is not entirely arbitrary because it is desirable to direct the
wave-shaped panel toward the front of a retail store shelf and at
the consumer, in order to convey the shape of the product contained
therein to the consumer. The wave-shaped front of the carton may
convey branding or trade-dress to a consumer and therefore it is
important to position this panel so it directly faces the consumer.
The squared back of the carton simplifies erecting and gluing of
the carton and it will be orientated out of view on the store
shelf. However, if the present carton were entirely devoid of any
branding or other labeling whatsoever, and/or devoid of any
significance as to trade-dress, then the assignment of the
wave-shaped panel as the front of the carton and the opposing
squared panel as the rear of the carton may be more arbitrary than
functional.
[0030] For a carton to comprise a "wave-shaped front," the carton
necessarily has a substantially flat wave-shaped front panel, where
"wave-shape" is defined above. In orientating the wave-shaped front
panel, one of the straight edges of the wave-shaped panel becomes a
top edge of the front of the carton, and the other opposing
straight edge becomes a bottom edge of the front of the carton.
Likewise, the opposing curved edges of the wave-shaped front panel
become the right and left edges of the front of the carton. A sine
wave by definition has both amplitude and wavelength. For
discussion purposes herein, each of the curved front side edges of
the present carton approximate a single sine wave, meaning that the
wavelength of the single sine wave is precisely the height of the
carton. That is, each curved edge approximates a single wave. The
amplitude of the sine wave defines the side-to-side undulation in
the look of the front of the carton. However, it must be stressed
that the present carton comprises a front panel having left and
right side edges that each only need to approximate a single sine
wave. By only approximating, the scope of the present invention
includes the possibility that the two half waves of either of the
single sine waves do not possess identical amplitude, and the
independent possibility that each half wave may not be truly half
the wavelength of the single wave. That is, the half wave point
(where a sine wave by definition has zero amplitude) does not have
to fall precisely at half the height of the present carton. In
order to measure amplitude in the curved edges of the present
carton, an imaginary straight line is drawn thought the approximate
sine wave edge such that two corners of the carton are connected.
For example, in the present carton the front panel necessarily has
foldable edge to the left of the front panel that approximates a
sine wave. In order to describe the dimensions of the wave-shaped
fold line, an imaginary straight line is drawn from the bottom left
corner of the front panel of the carton up to the upper left corner
of the carton. This line represents what would be the fold line if
the fold line were perfectly straight rather than wave-shaped. Now
with reference to the imaginary line, the single wave can be
described by the amplitude of each of the half-wave segments of the
single wave, one amplitude being the distance from the imaginary
straight line to the point of maximum curvature of the half-wave
segment to the right of the straight line, and the distance from
the imaginary straight line to the point of maximum curvature of
the other half-wave segment to the left of the straight line. Of
course, if that wave-shaped fold line is a true sine wave, then the
undulation to the left and to the right, the half-wave amplitudes,
will be identical.
[0031] A "squared" panel refers to a substantially flat panel
circumscribed by four straight line edges, where each edge forms a
right angle to its two adjacent edges. As such, a "squared" panel
must be either square or rectangular. It is important to note that
in the scope of the present invention, "squared rear panel"
includes the possibility of a rectangular panel.
[0032] That being said, an exemplary embodiment of the present
invention is a carton with an opposing wave-shaped panel and
squared panel, and more particularly a wave-shaped front panel and
squared back panel, erected from a blank comprising in combination:
(1) a front panel foldably joined to a substantially rectangular
top panel and to a substantially rectangular bottom panel by
straight fold lines, and foldably joined to a first set of opposing
side panels by wave-shaped fold lines; and, (2) a rear panel
foldably joined to a bottom panel and to a second set of opposing
side panels by straight fold lines, and having a straight cut edge
that forms an uppermost edge of an opening in the top of the
erected carton.
[0033] In accordance with another exemplary embodiment of the
present invention, a new and novel carton comprises a wave-shaped
front panel, a squared back panel, two opposing side panels, and a
cup-shaped lid, where the lid is in hinging arrangement with the
front panel by virtue of a foldable connection between the front
panel and a top panel of the cup-shaped lid, such that the carton
lid opens forward toward the consumer facing the front of the
carton.
[0034] In accordance with another exemplary embodiment of the
present invention, a new and novel carton comprises a single
thickness wave-shaped front, a single thickness squared back, and
double-thickness opposing sides, where each double-thickness side
is formed by the complete overlap of two identically shaped sets of
opposing side panels.
[0035] In accordance with another exemplary embodiment of the
present invention, the top closure of the carton comprising
wave-shaped front panel and squared rear panel comprises a four (4)
flap/panel cereal box top arrangement for closing off the top of
the carton.
[0036] These general comments and preferred embodiments are more
easily understood through a discussion of the drawing figures and
the numbered elements therein.
[0037] Referring first to FIG. 3, the completely erected carton 1
of the present invention comprises: wave-shaped front panel 10;
squared back panel 3; optional cup-shaped flip lid 2; and, an
opening at the top of the carton with rectangular dimension defined
by the front panel top edge 11, the overlapped left side panel top
edges 6/56, the rear panel top edge 54, and the overlapped right
side panel top edges 15/61. The overlapping edges 6/56 and 15/61
are the result of completely overlapping the side panels present on
the carton blank that formed the carton, resulting in
double-thickness for the left- and right-sides of the carton,
(explained below). The optional cup-shaped lid 2 is similar to
flip-open carton lids found in cigarette packaging, for example as
seen in U.S. Pat. No. 7,845,491 (Pollonia, et al.), incorporated by
reference in its entirety. As shown in FIG. 3, the cup-shaped lid 2
of the present carton, if utilized, is preferably hinged to the
front panel 10 of the carton through straight fold line 11 that by
nature of its folding also provides a hinge. Absent a flip-lid, the
opening at the top of the present carton may be closable by a
series of flaps e.g. found on a cereal box, or with a fold over top
panel that tucks either behind the rear panel or around and into a
slit in the back panel. Exemplary alternative carton closure
designs are found in U.S. Pat. Nos. 2,809,777 (Davidson) and
1,152,355 (Sutton), each incorporated herein by reference. Also
visible in the embodiment illustrated in FIG. 3 is one of a pair of
opposing side panels, the first right-side panel 14. The first
right-side panel 14 is seen to be outlined by a single wave-shaped
edge at the front of the carton and three straight edges at the
top, rear, and bottom of the carton.
[0038] Referring now to FIG. 4, a front perspective view of an
exemplary embodiment of the carton 1 is shown with optional
flip-lid 2 in the closed configuration. The carton 1 comprises a
wave-shaped front panel 10, an optional flip-lid 2 (shown closed),
and a first right-side panel 14 that shares a wave-shaped fold line
12 with the front panel 10. The optional flip-lid 2 comprises top
panel 24 (the top panel of the carton), and a right-side glue flap
27 that overlaps, and that may be glued to, right-side panel
14.
[0039] Referring now to FIG. 5, a rear perspective view of an
exemplary embodiment of the carton 1 is shown with optional
flip-lid 2 in the closed configuration. The carton 1 comprises a
squared back panel 50 and left-side panel 5. The optional flip-lid
2 comprises a rear glue flap 35 that may be glued to the rear panel
50, a top panel 24, and a left-side glue flap 20. The particular
embodiment of the rear glue flap 35 depicted comprises an arched
lower edge 36 although this flap could just as well comprise a
straight edge or any other shape for the cut bottom edge instead of
an arch, (straight, zigzag, sine wave, or any other shape that may
draw attention to the fact that the carton is opened by prying up
this flap 35).
[0040] FIG. 1 depicts a plan view of a preferred embodiment of a
blank 4 which forms a carton 1 in accordance with the present
invention. Blank 4 has an outer surface that is seen in this plan
view that may be preprinted with product branding or other
identifying and promotional information, and an inner surface
underneath that is not visible in this plan view. The blank 4
comprises fifteen (15) distinguishable and contiguous panels and
flaps (elements 30, 35, 37, 20, 24, 27, 5, 10, 14, 65, 70, 75, 55,
50, and 60), each having at least one fold line across which each
panel can be bent to an angle of approximately 90.degree. from the
adjacent panel. Fold lines are identified in FIG. 1 by thin solid
lines whereas die-cut lines (the entire outline of the die-cut
blank and including where the panels are physically cut from each
other where necessary) are identified by heavy solid lines. The
blank 4 comprises a squared rear panel 50 that, per the definition
set forth above, is either square or rectangular in shape. Rear
panel 50 is bounded by one die-cut line and three fold lines. The
single straight cut edge 54 of rear panel 50 becomes the rear upper
edge of the rectangular or square top opening in one embodiment of
the erected carton (best seen in FIG. 3). Rear panel 50 is foldably
connected to second left-side panel 55 through straight fold line
51, and similarly, rear panel 50 is foldably connected to second
right-side panel 60 through straight fold line 53. As will become
clearer below, a "first" and "second" designation is used for the
sets of side panels (in addition to right and left designation)
because there are two sets of side panels (one set attached to the
front panel and another set attached to the rear panel) that will
overlap in the finished carton. Still referring to FIG. 1, second
left-side panel 55 and second right-side panel 60 each comprise
three die-cut edges, one of which is wave-shaped and three of which
are straight. Second left-side panel 55 is bounded by cut edge 58,
which becomes a left upper edge of the rectangular/square open top
of the erected carton (best seen in FIG. 3), straight cut edge 56,
and a wave-shaped cut edge 57. Wave-shaped cut edge 57 approximates
one sine wave, wherein each "half wave" is designated as curve 57a
and curve 57b. To disclose the shape of this wave, an imaginary
straight line is drawn through the curve from the corner of panel
55 defined by the point where die-cut curve 57 and die-cut edge 58
meet, up to the corner of panel 55 where die-cut curve 57 and
die-cut edge 56 meet. This imaginary line would be (and may be in
another viable embodiment) a die-cut straight edge to panel 55 if
that were so desired. Distances are then indicated from this
imaginary line to the furthest points of the curves (the point of
each wave that is closest to the rear panel 50 and furthest from
the rear panel 50). A sine wave by mathematical definition has both
amplitude and wavelength, and so herein per a mathematical sine
wave, distance "g" and distance "i" represent the amplitude of the
sine wave approximated by the wave 57, and the wavelength of that
sine wave is the height of the carton (i.e., the length of line 51
or 53). As discussed above, this wave-shaped curve 57 (or any of
the other wave-shaped fold lines or die-cut lines in the present
invention) need only approximate a single sine wave. With that in
mind, distance "g" does not necessarily need to be identical to
distance "i", as would be the case if curve 57 is a mathematically
precise single sine wave. Similarly, the midpoint "k" of panel 55
(determined by bisecting straight line 51 or 53 in half and
following that midpoint along an imaginary line running parallel
with straight cut edge 58 until it crosses curve 57) does not need
to precisely line up with the half-wave point of the sine wave
curve (i.e., where the amplitude "g" and "i" of the sine wave are
zero). All that said, the curved line 57 shown in FIG. 1 may
approximate a sine wave or it may be precisely a sine wave where
"g"="i" and where the half height of the carton point "k" falls at
the half-wave (zero amplitude) point of the sine wave. As will be
explained below, regardless if curve 57 is a true sine wave or only
a close approximation thereof, it is preferred that all four of the
wave-shaped fold and cut lines (57, 9, 12, and 62) are identical,
or at least that adjacent sets be identical and in inverted
relationship (as to amplitude of the half-wave segments) with the
other set of adjacent waves. It is preferred that the wavelength of
the single sine wave curves (i.e. the height of the carton, which
is the length of lines 51 or 53 in FIG. 1) be from about 6 to about
10 inches, and most preferred that this height be from about 7 to
about 8 inches. With this preferred carton height, the amplitudes
of each half wave, (i.e. the measured distances "g" and "i"), may
be from about 1/16 inch to about 1/2 inch. Less than about 1/16
inch eave undulation for a wave-shaped carton with height around 7
inches probably won't result in much of a visible wave shape to the
front of the carton. It is also expected that if the wave is too
great in undulation, e.g. the half-wave amplitudes are greater than
3/4 inch or so, the front and side panels may have to "pucker" to
such an extent that one or more of these panels may crease rather
than just bow.
[0041] Still referring to FIG. 1, the blank 4 further comprises a
second right-side panel 60 foldably connected to rear panel 50 by
straight fold line 53. Second right-side panel 60 is bounded by two
die-cut straight edges 61 and 63, one wave-shaped die-cut edge 62,
and one straight fold line 53 that foldably connects panels 50 and
60. Second right-side panel 60 is bounded in part by cut edge 63,
an edge that becomes a right upper edge of the rectangular/square
open top of one embodiment of the erected carton (best seen in FIG.
3). Similar to cut edge 57, wave-shaped cut edge 62 approximates
one sine wave, wherein each "half wave" is designated as curve 62a
and curve 62b. The curved die-cut edge 62 is preferably
substantially similar to die-cut wave-shaped curve 57, and it is
most preferred that these curves are identical in all respects such
that may be superimposed. A sine wave has both amplitude and
wavelength as discussed above, and so herein per a sine wave,
distance "h" and distance "j" represent the amplitude of the sine
wave approximation of curve 62, and the wavelength of that sine
wave is the height of the carton (i.e., the length of line 53 or
51). Similar to 57, and keeping in line with the relative
dimensions depicted in the blank 4 in FIG. 1, the amplitudes "h"
and "j" are preferably from about 1/16 inch to about 1/2 inch when
the height of the carton (i.e. the length of fold line 53) is from
about 6 to about 10 inches. The distances "h" and "j" are measured
from an imaginary line running between two corners of panel 60, the
corner where edge 61 meets edge 62 and the corner where edge 62
meets edge 63, to positions on each half-wave segment 62a and 62b
farthest from rear panel 50 (distance "h") and closest to rear
panel 50 (distance "j"), as shown in the drawing figure. As
discussed above, this wave-shaped curve 62 (or any of the other
wave-shaped die-cut or fold lines in the present invention) need
only approximate a single sine wave. With that in mind, distance
"h" does not necessarily need to be identical to distance "j", as
would be the case if curve 62 is a mathematically precise single
sine wave. Similarly, the midpoint "1" of panel 60 (determined by
bisecting straight line 53 or 51 in half and following that
midpoint along an imaginary line running parallel with straight cut
edge 63 until it crosses curve 62) does not need to precisely line
up with the half-wave point of the sine wave curve (i.e., where the
amplitude "h" and "j" of the sine wave are zero). All that said,
the curved line 62 shown in FIG. 1 may approximate a sine wave or
it may be precisely a mathematical sine wave with "h"="j" and "l"
falling at the half-wave (zero amplitude) point of the wave. It is
more preferred that curves 62 and 57 be substantially similar in
shape. Most preferred, and regardless if curves 62 and 57 are true
sine waves or only close approximations thereof, it is preferred
that wave-shaped cut edges 57 and 62 are identical.
[0042] Still referring to FIG. 1, it is less preferred, (although
still within the scope of the present invention), that the panels
55 and 60 comprise only narrow rectangular or square glue flaps,
rather than wider panels each comprising an exterior die-cut
wave-shaped edge. This embodiment is anticipated, because when the
present carton is fully erected and glued, it is preferred that
vertical exposed edges 7 and 16 end up at the back of the carton,
out of sight when the carton is on a retail store shelf. Since the
front of the carton has been identified as panel 10, (with the
wave-shaped panel carrying the branding/trade logos/trade-dress and
aimed directly at the consumer to communicate the wave-shaped
product therein), folding second left-side panel 55 behind first
left-side panel 5, and similarly folding second right-side panel 60
behind first right-side panel 14, places the visible and viewable
cut edges 7 and 16 at the rear of the finished carton, rather than
the alternate configuration of placing die-cut wave-shaped edges 57
and 62 visibly exposed at the front of the carton where the
consumer will see them. With that in mind, there is no reason that
the second set of side panels 55 and 60 need to be as wide as to
fully overlap with their first counterpart set of panels 5 and 14,
other than for added strength in the finished carton. However, it
is preferred that they do overlap completely and that the sets of
side panels 5, 14, 55, and 60 be relatively similar in size to
maximize the strength of the erected carton.
[0043] Still referring to the embodiment of the carton blank 4
illustrated in FIG. 1, rear panel 50 is also foldably connected to
a rectangular or square shaped bottom panel 70 by straight fold
line 52. Straight fold line 52 is also herein referred to as the
rear bottom fold line when describing the fully erected carton.
Bottom panel 70 is also foldably connected to left bottom glue flap
65 by straight fold line 67 and to right bottom glue flap 75 by
straight fold line 71. When the carton is folded, erected and
glued, the outer surface of left bottom glue flap 65 may be glued
to the inner surface of panel 5 or to the inner surface of panel
55. In other words, glue flap 65 may be sandwiched in between
panels 5 and 55 when the carton is erected, in which case the outer
surface of glue flap 65 is glued to the inner surface of panel 5.
Alternatively, the outer surface of panel 55 may be first glued to
the inner surface of panel 5, and then the outer surface of glue
flap 65 may be glued to the inner surface of panel 55. There is an
advantage to the former configuration over the latter. Sandwiching
the small glue flap 65 between the panels 5 and 55 removes it from
interfering with the loading of product into the completed carton,
and from interfering with the consumer moving product in and out of
the packaging (e.g. taking more product out than needed and trying
to fit some product back in). Also, it is simpler to erect the
carton in the former sequence. Therefore, it is preferred that the
left bottom glue flap 65 end up sandwiched in between the first
left-side panel 5 and the second left-side panel 55 in the fully
erected carton.
[0044] The right bottom glue flap 75 may be described in the same
way as the left bottom glue flap 65, and flap 75 may be of similar
or identical shape as flap 65, but need not be even close to the
same shape. Glue flap 75 is foldably attached to bottom panel 70 by
the straight fold line 71. The shape and size of these glue flaps
65 and 71 are not critical since they only need to be shaped and
sized such that they can be secured to the side panels as discussed
(e.g. providing sufficient surface areas for gluing). However, each
glue flap needs to have substantially the same width as the bottom
panel 70 and need to be tapered slightly to facilitate folding of
the blank and ability to overlap with the side panels. Being sized
and shaped as indicated by the relative dimensions shown in FIG. 1
is appropriate for their folding and gluing to the side panels.
[0045] Continuing further with FIG. 1, the blank 4 also comprises
wave-shaped front panel 10 foldably connected to bottom panel 70 by
straight fold line 13. Straight fold line 13 is also herein
referred to as the front bottom fold line when describing the
erected carton. Front panel 10 is also foldably connected to top
panel 24 by straight fold line 11. Also and most importantly, front
panel 10 is foldably connected to first left-side panel 5 through a
wave-shaped fold line 9 (also referred to herein as a first
wave-shaped fold line when describing the erected carton), and is
foldably connected to a first right-side panel 14 by wave-shaped
fold line 12 (also referred to herein as a second wave-shaped fold
line when describing the erected carton). As discussed above,
wave-shaped fold lines 9 and 12 are preferably substantially
similar, and that the wave-shaped die-cut edges 57 and 60 are
substantially similar, and it is most preferred that all four of
the wave-shaped fold and die-cut lines be identical, superimposable
mathematical sine waves. This embodiment is preferred because as
mentioned above, it is most desirable to fully overlap the first
set of side panels 5 and 14 with their similarly dimensioned second
set counterparts 55 and 60 such that curves 9 and 57 come close to
registration (i.e. dovetailing) with one another, and such that
curves 12 and 62 also come close to registration, in order to
achieve maximum strength in the fully erected carton. For full
overlap, the first set of side panels need to be identical, or at
least close, in shape and size to the second set of side panels. As
with all the wave-shaped fold lines or die-cut lines in the present
invention, wave-shaped fold lines 9 and 12 should approximate a
single full sine wave each. That being said, amplitude "a" of
half-wave segment 9a may be similar or identical to amplitude "c"
of half-wave segment 9b. Likewise, amplitude "b" of half-wave
segment 12a may be close to or identical to the amplitude "d" of
half-wave segment 12b. Also, as discussed above for the second set
of side panels, midpoint "e," struck at half the height of the
carton, (i.e., a point where straight edge 7 is bisected), may or
may not represent the half-wave point of the wave-shaped curve 9,
and likewise, midpoint "f," struck at half the height of the
carton, (i.e., a point that bisects straight edge 16), may or may
not represent the precise half-wave point of the wave-shaped curve
12. Most preferred, for both ease in folding up the carton blank
and to avoid errant wrinkles in the finished carton, wave-shaped
fold line 9 should be identical in shape and dimension to
wave-shaped fold line 12. That is, it is most preferred that fold
line 9 and fold line 12 be superimposable. If the four (4)
wave-shaped fold and die-cut lines 9, 12, 57, and 62 of the carton
are not all perfect single sine waves and all superimposable, then
it is important not only that wave-shaped fold line 9 be identical
to wave-shaped fold line 12, and that 57 be identical to 62, but
also that half-wave segment 9a be identical in shape and amplitude
to half-wave segment 57b, half-wave segment 9b be identical in
shape and amplitude to half-wave segment 57a, half-wave segment 12a
be identical in shape and amplitude to half-wave segment 62b, and
half-wave segment 12b be identical to half-wave segment 62a. All of
these conditions are necessary for the complete overlap of the
corresponding sets of side panels to be successful and for the
curved die-cut edges to dovetail in the curved fold lines, as
explained above. It is important to note that the set of
wave-shaped die-cut edges 57 and 62 on the second set of side
panels dovetail into the wave-shaped fold lines 9 and 12 present on
the first set of side panels when the second set of curves is
inverted, which is precisely what happens when the rear panel 50 is
folded up behind the front panel 10 by folding 90.degree. bends
into fold lines 52 and 13 in the process of erecting the carton
from the blank. Since panel 10 has been established to be the front
panel of the carton, it is important that wave-shaped fold lines 9
and 12 be substantially similar, if not identical, because they set
out the look of the front of the carton for the consumer. As
mentioned, the preferred height of the carton (which is the
distance between the parallel straight fold lines 11 and 13 in the
carton blank) is from about 6 to about 10 inches. Also with that
preferred height established, the undulations in the waves on the
front panel, (i.e. the distances "a", "b", "c", and "d") are from
about 1/16 inch to about 1/2 inch.
[0046] Continuing with the blank 4 depicted in FIG. 1, the blank 4
further comprises a top panel 24 foldably connected to front panel
10 by straight fold line 11. Top panel 24 is also foldably
connected to left side glue flap 20 by straight fold line 23 and to
right side glue flap 27 by straight fold line 26. Top panel 24 is
also foldably connected to rear glue flap 35 by straight fold line
25. As mentioned, this particular embodiment of the present
invention shown in FIG. 1 comprises a carton blank 4 that, when
erected, forms a carton having a front hinging flip down lid. Fold
line 11 is that hinge for the hinging cup-shaped lid and is
referred to herein as the lid hinging line when describing the
erected carton. Rear glue flap 35 is foldably connected to left lid
glue flap 30 by straight fold line 34 and is foldably connected to
right lid glue flap 37 by straight fold line 39. In this way, top
panel 24 and each of the five glue flaps 20, 27, 30, 35, and 37,
together comprise the cup-shaped hinging lid.
[0047] Referring now to each of the drawing FIGS. 1, 3, 4, and 5
together for clarity, it should be appreciated that both the left
side glue flap 20 and the right side glue flap 27 remain exposed on
portions of the exterior of the carton when the carton is fully
erected and glued. For example, exposed right side glue flap 27 is
seen flush and against an upper portion of right side panel 14 in
FIG. 4, (a front view of the carton), and exposed left side glue
flap 20 is seen flush and against an upper portion of side panel 5
in FIG. 5, (a rear view of the carton). Also when the lid is
closed, the rear glue flap 35 is against the rear panel 50 as seen
in FIG. 5. All that is minimally required in the present carton is
that one of the glue flaps of the cup-shaped lid attach to a
portion of an outer surface of any one of the side panels or the
rear panel.
[0048] To erect the cup-shaped lid portion 2 of the present carton
1 (as illustrated in FIG. 3), left side and right side glue flaps
20 and 27 are each folded back by 90.degree. relative to the top
panel 24. Rear glue flap 35 is folded back 90.degree. relative to
the top panel 24. Left lid and right lid glue flaps 30 and 37 are
also folded 90.degree. from the rear glue flap 35. The outer
surface of 30 is glued to the inner surface of 20. Similarly, the
outer surface of 37 is glued to the inner surface of 27. Then once
the carton body is erected and filled with product, this cup-shaped
lid may then be closed over the opening of the carton (by folding
along the hinge/fold line 11) and the inner surfaces of glued and
overlapping flaps 30 and 20 may then be glued to an upper portion
of the outer surface of left side panel 5. Similarly, the inner
surfaces of the glued and overlapping flaps 37 and 27 may be glued
to the outer surface of an upper portion of the right side panel
14. Finally, the inner surface of rear glue flap 35 is glued onto
an upper portion of the outer surface of rear panel 50. In this way
it can be appreciated that the left side and right side glue flaps
20 and 27, and the rear glue flap 35, all remain exposed on the
fully erected glued and sealed carton because the cup-shaped lid
encases the open top of the carton body. Therefore, some decorative
design elements may be instilled into these three flaps, such as
the arched edges 21, 28 and 36 in the particular embodiment of FIG.
1. Certainly any or all of the arched edges 21, 28, and 36 could
just as well be straight edges and the cup-shaped lid could be
squared and box-like (as per any cigarette box with a flip open
lid). As mentioned above, the cup-shaped lid comprising the top
panel 24 and all the glue flaps 20, 27, 30, 35, and 37 is optional
to the present carton, and any other configuration of flaps/panels
to close the open top of the present carton is within the scope of
the present invention. For example, another embodiment comprising a
four (4) flap cereal box top closure instead of a hinging cup-shape
lid will be disclosed below.
[0049] FIG. 2 depicts another embodiment of a die-cut blank 4'
which forms a carton within the scope of the present invention.
This particular blank forms a carton that comprises a four (4) flap
fold-up box top similar to countless cereal boxes. As in the
previous blank, blank 4' comprises a square or rectangular shaped
rear panel 50' foldably connected to a second left-side panel 55'
by a straight fold line 51' and foldably connected to a second
right-side panel 60' by a straight fold line 53'. Both 51' and 53'
are of identical length, represent the height of the carton, and
are from about 6 to about 10 inches. The second set of side panels
55' and 60' each may comprise a wave-shaped die-cut edge, 57' and
62' respectively. These two wave-shaped edges are in all regards
identical in shape and size to the edges 57 and 62 in blank 4 (FIG.
1), discussed thoroughly above. As such, that discussion is applied
here and is not repeated. As with blank 4, the panels 55' and 60'
need not comprise wave-shaped cut edges 57' and 62' because the
second set of panels hide behind the first set of side panels and
these edges are not visible in the completed carton. The cut edges
57' and 62' may be just straight cut edges parallel to 51' and 53'
and the panels 55' and 60' could be narrow rectangular panels. As
in the previous blank 4, rear panel 50' is foldably connected to a
bottom panel 70' by a straight fold line 52'. Line 52' is the width
of the carton, as is preferably from about 5 to about 6 inches.
[0050] Still referring to FIG. 2, the blank 4' further comprises a
left bottom glue flap 65' and a right bottom glue flap 75', each
foldably connected to bottom panel 70' by opposing straight fold
lines 67' and 71' respectively. Flaps 65' and 75' are in every way
identical to flaps 65 and 75 in the previous blank 4 (FIG. 1), and
therefore the previous description applies here. Their precise
shape and size is highly variable as these are structural elements
that are not visible on the exterior of the finished carton. The
bottom panel 70' is foldably connected to the wave-shaped front
panel 10' by a straight fold line 13'. Front panel 10' is foldably
connected to a first left-side panel 5' by a wave-shaped fold line
9', and foldably connected to a first right-side panel 14' by a
wave-shaped fold line 12'. The wave-shaped fold lines 9' and 12'
are also referred to herein as the left wave-shaped fold line and
the right wave-shaped fold line, respectively, when discussing a
carton erected from the blank 4'. These three panels 5', 10', and
14' and the two wave-shaped fold lines 9' and 12' connecting them
are in every regard identical to the embodiment of FIG. 1, and
therefore their description need not be repeated. As mentioned, for
a box having height from about 6 to about 10 inches, (the length of
panels 51' or 53'), the preferred undulations in the wave-shaped
fold lines 9' and 12' are from about 1/16 to about 1/2 inch, and it
is preferred that fold lines 9' and 12' be identical and
superimposable to maximize the aesthetics of the front of the
carton and to avoid creases. As with the previous blank, if
wave-shaped die-cut lines 57' and 62' are incorporated on the
second set of side panels with the intent that the second set of
side panels fully overlap with the first set of side panels, then
it is most preferred that all four wave-shaped curves and cut lines
9', 12', 57', and 62' are identical and can be superimposed. Less
preferred, yet fully acceptable, is where 9' is identical in
size/shape to 12', 57' is identical in size/shape to 62', provided
57' dovetails into the fold line 9' when inverted, and 62'
dovetails into the fold line 12' when inverted. Even less preferred
is where the second set of side panels 55' and 60' are narrower
rectangular panels with the intent that they will not fully overlap
with the first set of side panels 5' and 14', in which case the
only two curves present in the embodiment, namely 9' and 12', need
to be at least substantially similar to one another, or
superimposable.
[0051] The variations between embodiment 4 and 4' in the present
invention are the top portion of the carton and the portions of the
blank 4' that form the top of the carton. Still referring to the
blank 4' in FIG. 2, and unlike the previous blank 4 (FIG. 1), the
blank 4' features a rearward top panel 35' foldably connected to
rear panel 50' by straight fold line 54'. The fold line 54' is also
referred to herein as the rear lid hinge line when discussing
another embodiment of the erected carton. Therefore, rear panel 50'
is surrounded on all four sides by panels, namely second left-side
panel 55', bottom panel 70', second right-side panel 60', and
rearward top panel 35', all through straight fold lines 51', 52',
53', and 54' respectively. Rearward top panel 35' may also include
a small slit 350 that may be used to close the carton, and it may
be appropriately dimensioned to accept a tab or tongue from an
adjacent top panel (discussed below). The rearward top panel should
have the same width as the carton (i.e. fold line 54' should be the
width of the carton, and the width of the panel should be half the
depth of the carton. Also differing from the prior embodiment,
blank 4' further comprises a forward top panel 24' foldably
connected to the front panel 10' by straight fold line 11'. The
fold line 11' is also referred to herein as the front lid hinge
line when discussing another embodiment of the erected carton. Fold
line 11' is substantially parallel to fold line 13' and forms the
top front edge of the erected carton. The forward top panel 24' may
also comprise an integral tab or tongue feature 240 that may be
dimensioned to fit into slit 350 when resealing a previously opened
carton.
[0052] Referring again to FIG. 2, the first left-side panel 5' is
foldably connected to a left top flap 20' by a straight fold line
6'. The left top flap 20' is bound by die-cut edges on its
remaining three edges. Straight fold line 6' is essentially a
collinear extension of straight fold line 11'. The length of fold
line 6' may be close to the depth to the carton (about 1 to about 4
inches preferred) and the length of die-cut edge 21' may be close
to half the width of the carton (up to about one half of the 5 to
about 6 inches preferred width of the carton). Similarly, the first
right-side panel 14' is foldably connected to a right top flap 27'
by a straight fold line 15'. Also, straight fold line 15' is a
collinear extension of straight fold line 11' such that the three
fold lines 6', 11', and 15' form essentially one straight line. The
sizes of the flaps 20' and 27' are variable and only need to be of
sufficient size to support the top of the carton (e.g., to provide
support and a sufficient glue surface for panels 24' and 35' that
will rest on them, as discussed below), and they don't need to be
of identical size and shape. As mentioned, such side flaps used for
forming the top closure of a carton usually have a depth the same
as the depth of the carton and occupy up to half the width of the
carton, but usually only about 1-2 inches for a carton having about
6 inches width. The relative size of these flaps 20' and 27' as
depicted in the blank 4' are of sufficient size and shape to
support the top of the carton. Wave-shaped front panel 10' is
foldably connected to a substantially square or rectangular forward
top panel 24' by a straight fold line 11'. Since the three fold
lines 6', 11', and 15' form essentially one straight line as
mentioned above, the flaps 20', 27' and the forward top panel 24'
all line up in a row of sorts with their fold lines collinear.
[0053] Lastly and still referring to FIG. 2, left top flap 20',
right top flap 27', rearward top panel 35' and forward top panel
24' comprise a four (4) panel closure for the top of the carton of
the present invention. As mentioned, a tab or tongue 240 may be
configured on forward top panel 24' to fit inside the slit 350 to
close a resealable carton. This arrangement of two relatively
longer panels (24', 35') and two relatively shorter flaps (20',
27'), and the presence of appropriately sized tab 240 and slit 350
for a resealing option, is common to many (if not most) cereal
boxes.
[0054] Referring now to FIG. 6, another embodiment of the complete
carton 1' of the present invention is depicted. The carton 1' may
be formed by folding, erecting, and gluing the carton blank 4'
shown in FIG. 2. The finished carton 1' comprises wave-shaped front
panel 10' foldably connected to first right-side panel 14' by the
wave-shaped fold line 12'. The wave-shaped fold line 12' is seen to
approximate a sine wave and for a carton with height of from about
6 to about 10 inches, the wave undulations are preferably from
about 1/16 inch to about 1/2 inch. The top of the carton is seen to
comprise both a forward top panel 24' and a rearward top panel 35'.
Underneath these top panels are the right top flap and the left top
flap. These flaps are not visible in the completed carton because
the panels 24' and 35' are folded last and glued onto them, (see
the carton blank 4' in FIG. 2). The tab 240 that is an integral
part of the die-cut forward top panel 24' may be glued over the top
of the slit 350 and thus obscure it from view, consistent with the
drawing. As with countless cereal boxes, access to the contents of
the carton involve prying up panels 24' and 35' from the glue flaps
underneath. Reclosing the carton is achieved by bending the panels
24' and 35' back in place and on top of flaps 20' and 27' to cover
the opening of the carton, while slipping the tab 240 into the slit
350.
[0055] We have thus described a carton comprising opposing
wave-shaped and squared panels wherein the opposing panels
preferably comprise a wave-shaped front panel and a squared back
panel. Such a carton is readily formed from a single die-cut blank.
The carton features two opposing wave-shaped edges on the front
panel wherein each wave approximates a single sine wave with
frequency equal to the height of the carton. The present carton may
have a flip open cup-shaped lid or a four flap cereal box
closure.
* * * * *