U.S. patent application number 13/208827 was filed with the patent office on 2013-02-14 for package configuration for disposable absorbent articles.
The applicant listed for this patent is Jack Cheng Chang, Lucio Frias, Richard Shane Mays, Luke Anthony Snider, Todd Jeffrey Vishnauski. Invention is credited to Jack Cheng Chang, Lucio Frias, Richard Shane Mays, Luke Anthony Snider, Todd Jeffrey Vishnauski.
Application Number | 20130037432 13/208827 |
Document ID | / |
Family ID | 46690737 |
Filed Date | 2013-02-14 |
United States Patent
Application |
20130037432 |
Kind Code |
A1 |
Chang; Jack Cheng ; et
al. |
February 14, 2013 |
Package Configuration for Disposable Absorbent Articles
Abstract
A box package containing stacked disposable absorbent articles
is disclosed. The package has a pair of top flaps, and a handle
cutout on each flap. In one embodiment a handle reinforcing
material may be disposed between the handle cutouts. In one
embodiment the handle cutouts may be partial, and attached portions
of material forming residual cutout flaps may remain attached
within the cutouts. Other structural elements may be present to
maximize economy of space while maintaining structural integrity,
conserving materials and providing a package that is convenient for
consumers.
Inventors: |
Chang; Jack Cheng; (Mason,
OH) ; Frias; Lucio; (Cincinnati, OH) ; Mays;
Richard Shane; (Cincinnati, OH) ; Snider; Luke
Anthony; (Cincinnati, OH) ; Vishnauski; Todd
Jeffrey; (Cincinnati, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Chang; Jack Cheng
Frias; Lucio
Mays; Richard Shane
Snider; Luke Anthony
Vishnauski; Todd Jeffrey |
Mason
Cincinnati
Cincinnati
Cincinnati
Cincinnati |
OH
OH
OH
OH
OH |
US
US
US
US
US |
|
|
Family ID: |
46690737 |
Appl. No.: |
13/208827 |
Filed: |
August 12, 2011 |
Current U.S.
Class: |
206/299 ;
220/62.2; 220/626; 220/651; 229/117.15 |
Current CPC
Class: |
B65D 85/07 20180101;
A61F 13/55115 20130101; B65D 5/4608 20130101 |
Class at
Publication: |
206/299 ;
220/62.2; 220/626; 220/651; 229/117.15 |
International
Class: |
B65D 85/18 20060101
B65D085/18; B65D 90/02 20060101 B65D090/02; B65D 5/468 20060101
B65D005/468; B65D 5/42 20060101 B65D005/42 |
Claims
1. A package, comprising: a rectangular box container formed of
corrugated cardboard, the box having a rectangular top panel, a
rectangular bottom panel, a pair of oppositely-disposed rectangular
side panels, a rectangular front panel, and a rectangular back
panel; the top panel being formed at least in part of a pair of
opposing flaps, the flaps being integral with the respective front
and back panels and extending from proximal edges at horizontal
folds in the cardboard defining upper edges of the front and back
and outer edges of the top, and the flaps having distal terminal
edges, wherein each of the pair of opposing flaps has a flap width
measured along a direction parallel to its associated horizontal
fold and a flap length measured along a direction perpendicular to
its associated horizontal fold, and each of the pair of opposing
flaps has a handle cutout therethrough, the handle cutout having a
cutout width and a cutout length and having no sharp inside corner
pointing toward a flap edge, the cutout length being oriented along
and substantially centered along the flap width, the respective
handle cutouts being respectively disposed substantially opposite
each other; wherein the corrugated cardboard comprises a first
layer of linerboard, a second layer of linerboard, and a fluted
medium disposed between the first linerboard and the second
linerboard, the fluted medium being of size C flutes or larger,
with the flutes oriented vertically; wherein the box contains at
least one inner package, the inner package comprising a plurality
of stacked disposable absorbent articles wrapped in a polymeric
film bag; and wherein there is a top clearance TC between the inner
package and the top panel of no more than 1 cm.
2. The package of claim 1 wherein the opposing flaps overlap.
3. The package of claim 1 wherein the opposing flaps do not
overlap, and the package further comprises a handle reinforcing
material attached to each of the side panels and extending across
the top panel, and disposed between the handle cutouts.
4. The package of claim 3 wherein the handle reinforcing material
has a longitudinal tensile strength of at least 20 pounds per inch
width.
5. The package of claim 1 wherein the handle cutout has a profile
of a shape selected from the group consisting of circular,
bean-shaped, peanut-shaped, oval, ovaloid, egg-shaped, elliptical,
rounded rectangle and race-track.
6. The package of claim 5 wherein the handle cutout width is from
15 mm to 35 mm and the handle cutout length is from 80 mm to 100
mm.
7. The package of claim 5 wherein the handle cutout is partial,
having terminal ends, leaving an attached portion of material along
a fold line extending between the terminal ends.
8. The package of claim 7 wherein the handle cutout is continuous
between the terminal ends.
9. The package claim 7 wherein the fold line is substantially
parallel to the flap edge.
10. The package of claim 7 wherein the attached portion of material
forms a residual cutout flap within the handle cutout, and the
residual cutout flap has a Push-In Force of no more than 18
pounds.
11. A package, comprising: a rectangular box container formed of
corrugated cardboard, the box having a rectangular top panel, a
rectangular bottom panel, a pair of oppositely-disposed rectangular
side panels, a rectangular front panel, and a rectangular back
panel; the top panel being formed at least in part of a pair of
opposing flaps, the flaps being integral with the respective front
and back panels and extending from proximal edges at horizontal
folds in the cardboard defining upper edges of the front and back
and outer edges of the top, and the flaps having distal terminal
edges, wherein each of the pair of opposing flaps has a flap width
measured along a direction parallel to its associated horizontal
fold and a flap length measured along a direction perpendicular to
its associated horizontal fold, and each of the pair of opposing
flaps has a handle cutout therethrough, the handle cutout having a
cutout width and a cutout length, the cutout length being oriented
along and substantially centered along the flap width, the
respective handle cutouts being respectively disposed substantially
opposite each other; wherein the corrugated cardboard comprises a
first layer of linerboard, a second layer of linerboard, and a
fluted medium disposed between the first linerboard and the second
linerboard, the fluted medium being of size C flutes or larger,
with the flutes oriented vertically; wherein the box contains at
least one inner package, the inner package comprising a plurality
of stacked disposable absorbent articles wrapped in a polymeric
film bag; wherein there is a top clearance TC between the inner
package and the top panel of no more than 1 cm; wherein the handle
cutout is partial, having terminal ends, leaving an attached
portion of material along a fold line extending between the
terminal ends; and wherein the attached portion of material forms a
residual cutout flap within the handle cutout, and the residual
cutout flap has a Push-In Force of no more than 18 pounds.
Description
BACKGROUND OF THE INVENTION
[0001] Currently, disposable absorbent articles such as diapers and
training pants are packaged in smaller quantities for retail sale
in bags or sealed packages formed of polymeric films, or, in larger
quantities, boxes formed of cardboard. Since diapers and training
pants may be used by a consumer at the rate of up to 6 or more per
day per child, many consumers prefer to purchase such articles in
larger quantities, and therefore, purchase box packages.
[0002] The outer surfaces of such larger-quantity retail box
packages may be somewhat smooth and slippery, as a result of the
manufacturer's desire to provide an attractive print design and
finish. The packages may also be found by consumers to be
relatively large and bulky for purposes of carrying. For example, a
example of a box package containing 124 size 3 disposable diapers
may have outside dimensions of approximately 28 cm high (bottom to
top).times.25 cm deep (front to back).times.41 cm wide (side to
side) (11 in..times.9.8 in..times.16.1 in.). For this reason,
manufacturers of such box packages may provide them with a handle
configuration. In a currently marketed configuration, handle
cutouts are provided at the sides, near the top, to enable
insertion of the fingers of the hands through the side panels at
each side, hooking of the fingers about the upper edges of the
cutouts, and two-handed carry.
[0003] However, it is believed that consumers may prefer to carry
such packages using only one hand. It has been observed that
consumers tend to grasp and lift such a package by grasping it at
only one handle cutout, on one side of the package. The box
material surrounding the cutout may have insufficient strength and
tear resistance to support the weight of the box from just one such
handle cutout, and tearing of the box upwardly from the handle
cutout may result. This may result in a loss of utility of the
handle cutout and/or a negative consumer perception of product
quality. It may also result in a partially opened or defaced and
damaged package of reduced value on a store shelf, in the event a
consumer removes the package from the shelf and then replaces it
after inadvertently tearing it at the handle cutout, perhaps after
examining the package and changing her mind about her
selection.
[0004] The manufacturing of such disposable absorbent articles is
necessarily a relatively capital-intensive, high-volume, low
margin-per-unit business. In order to stay competitive,
manufacturers of such articles must maintain close control over
costs of materials and manufacturing. Incurring additional costs,
or saving costs, of even very small amounts per unit may be very
significant when multiplied by the volumes of sales typically
needed for competitive operation.
[0005] Thus, a need for an improved, cost-effective package and
handle configuration for a diaper package presents itself.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a box package
configuration;
[0007] FIG. 2 is a plan view of a cardboard cutout of a box package
precursor cutout from cardboard stock;
[0008] FIGS. 3A and 3B are plan views of handle cutout alternatives
shown in relation to other box package features;
[0009] FIGS. 3C-3E are plan views of several handle cutout
alternatives;
[0010] FIG. 4 is a partial cross section of a box package
configuration, through a handle cutout having a residual cutout
flap; and
[0011] FIG. 5 is a view of a fixture used in the Push-In Force Test
described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The description herein will identify elements with respect
to the horizontal and vertical, as if the package configuration
described were assembled and resting on a horizontal surface in its
normally upright position.
[0013] FIG. 1 is a perspective view of an assembled box package
configuration 10; and FIG. 2 is a plan view of a cardboard cutout
of a box package precursor cutout from cardboard stock, which may
be folded along the dotted lines shown and glued in suitable
locations to form a closed box package configuration such as shown
in FIG. 1. The configuration has a first pair of opposing vertical
panels 20a, 20b and a second pair of opposing vertical panels 21a,
21b. When the package configuration is assembled, vertical panels
21a and 21b have surfaces that approximately define planes that are
substantially perpendicular to planes approximately defined by
surfaces of vertical panels 20a and 20b. Vertical panels 20a, 20b,
21a and 21b form four vertical containing walls, or sides, of the
package configuration. The configuration also has a pair of
opposing horizontal panels 22a, 22b, forming the top and bottom
containing walls of the package configuration.
[0014] The box described herein is contemplated for use as a box
container of packages of disposable absorbent articles such as
disposable diapers and training pants. Non-limiting examples
include disposable diapers and training pants of the kind marketed
by The Procter & Gamble Company, Cincinnati, Ohio, under the
PAMPERS and LUVS brands. Two or more packages of such articles in
folded stacks wrapped by, or within, a polymer film bag or wrapper,
may be contained within the box described herein. Due to the nature
of the materials of which such articles are made and the manner in
which they are manufactured and packaged, such packages are
typically compressible to varying degrees. The degree of
compressibility may be adjusted by adjusting the degree to which
the articles are compressed when packaged within their film
packages.
[0015] Respective panels 20-22 may be formed of single layers or
several layers of cardboard material, and each layer may be formed
of a single section or multiple sections of cardboard material. In
the example shown, horizontal panel 22b is formed of four sections
which include exterior flaps 22c, 22d, each of which form
approximately half of an outer layer of horizontal panel 22b.
[0016] Each of exterior flaps 22c, 22d may have a handle cutout 30
therein. In the assembled package handle cutouts 30 may be disposed
substantially opposite each other across the respective adjacent
flap edges 23a, 23b. It will be appreciated that a consumer may
lift and carry the package by inserting fingers of one hand through
one of the handle cutouts 30 and curling the fingers under so as to
attain a grasp of the package at the top panel, possibly
supplementing her grasp by inserting the thumb through the other
handle cutout and curling it under, toward the fingers.
[0017] It may be desirable that the package configuration 10 be
stackable (i.e., the package will support the weight of a number of
additional packages stacked on top of it, without crushing or
collapsing) for purposes of efficiency in shipment and storage, and
purposes of maintaining an attractive appearance for presentation
on store shelves. Unlike packages containing relatively hard or
rigid articles such as metal cans or glass bottles which provide
rigid structural support in a stacked configuration, the package
contemplated herein will contain relatively compressible packaged
materials, e.g., disposable absorbent articles, substantially
filling the space within the box structure between the respective
opposing vertical panels and from bottom to top. Thus, it may be
desirable that the box be formed of a cardboard having suitable
rigidity and strength to provide stackability. Accordingly, for the
package weights contemplated herein, it may be deemed important
that the package configuration be formed of a corrugated cardboard
comprising two outer layers of flat linerboard sandwiching an inner
corrugated (fluted) layer, having flutes of size C or larger. In
order for the package to best sustain vertical loads, it may be
desirable that the flutes be oriented in direction FO (flute
orientation), i.e., vertically relative the sides of the assembled
package sitting in its normally upright position on a horizontal
surface. (This means that the flutes form channels within the
cardboard that extend along direction FO, i.e., vertically relative
the sides of the assembled package sitting in its normally upright
position on a horizontal surface.)
[0018] Additionally, while the compressible contents do not provide
rigid structural support, they may be packed into the box with
sufficient compression so as to exert some outward pressure on the
respective panels, thereby providing supplemental support to the
cardboard outer structure. Accordingly, it may be desirable to have
the contained contents substantially fill the box such that they
exert some outward pressure on the panels, particularly the top
panel (horizontal panel 22b), and thereby provide supplemental
structural support. Accordingly, referring to FIG. 1, it may be
desired that the contained articles leave a top clearance TC
between the inside of panel 22b and the top of the contained
articles, of no more than 1 cm and more preferably zero, measured
from the plane defined by the inside top corners of the box to the
top of the contained articles at their highest point, with the
package resting in its normally upright position on a horizontal
surface.
[0019] The handle configuration depicted in FIG. 1, however,
presents some structural concerns. Under certain circumstances
cardboard flute orientation along a particular direction may
provide greater chances for propagation of tears in that direction,
as compared with the direction perpendicular to the flutes. Thus,
with handle cutouts 30 situated as shown, particularly close to
flap edges 23a, 23b as shown, stresses concentrated in the area
between the handle cutout and flap edges may promote tearing at the
handle cutout that may propagate all the way to the flap edges 23a
or 23b, resulting in failure of the handle structure. In order to
minimize the possibility for such tearing or failure, additional
structural features may be included.
[0020] Referring to FIGS. 3A and 3B, in order to provide sufficient
material between the inside edge 30i of the handle cutout 30 and
the flap edge 23a or 23b to avoid an unacceptably high
concentration of stresses in a relatively narrow strip of material
lying between the handle cutout and the flap edge, it may be
desired that the distance D between inside edge 30i and flap edge
23a or 23b be no less than 25 mm, more preferably, no less than 27
mm. (Herein, the "inside edge" of a handle cutout is the edge
closest to a flap edge.)
[0021] In order to provide a reinforced handle structure, it may be
desired that the box be designed and sized such that flaps 22c and
22d overlap when in assembled and closed configuration, thus
providing at least two layers of material between the handle
cutouts, increasing strength and resistance to tearing. This
configuration, however, requires usage of relatively more cardboard
material, and also may create an uneven top surface if the overlap
is only partial, i.e., does not extend across the entire top panel.
Referring again to FIG. 1, in another alternative the package may
be designed such that the flaps 22c and 22d do not overlap when the
box is in assembled and closed configuration. However, the package
may be provided with a strip of handle reinforcing material 24.
Handle reinforcing material 24 may be disposed between the handle
cutouts 30 and may extend across the entire top horizontal panel
22b, and may be attached to the vertical panels 20a, 20b, thereby
providing a strap-like structure to distribute stresses resulting
from lifting the package at the handle cutouts, to the sides of the
package. Handle reinforcing material 24 may be formed of a
supplemental strip of cardboard, paper, polymeric film or other
material adhered and/or otherwise attached to the flaps 22c, 22d
and/or the vertical panels 20a, 20b. In one example, handle
reinforcing material 24 may be a strip of adhesive tape of suitable
tensile strength applied along a substantially straight line across
the top of the package between the handle cutouts and down over
respective vertical panels 20a, 20b. The handle reinforcing
material, if disposed over the surface of horizontal panel 22b, may
be substantially translucent or transparent so that it does not
obscure graphics, indicia, designs or other artwork or commercial
information that may be printed on the top panel; for example, if
the handle reinforcing material is tape, it may be a substantially
translucent or transparent tape. Referring to FIGS. 3A and 3B, to
minimize the possibility for tear propagation, it may be desirable
that edge 24e of handle reinforcing material 24 be substantially
tangent to inside edge 30i of each handle cutout, or at most, a
distance HD of 8 mm from 30i. Accordingly, the handle reinforcing
material 24 should be wide enough and/or the handle cutouts 30
should be suitably located, to provide for such maximum distance HD
for both handle cutouts. Without intending to be bound by theory,
it is believed that most consumers will prefer handle cutouts of
the type described herein to be no more than 65 mm apart for ease
of use and one-handed carry, and more preferably, no more than 60
mm or even no more than 55 mm apart. Accordingly, handle
reinforcing material should be no more than 55 mm wide in an area
of horizontal panel 22b between the handle cutouts.
[0022] For packages of the weights contemplated herein, it may be
desirable that handle reinforcing material 24 is a strip having a
tensile strength measured in the direction of its length of at
least 20 pounds, more preferably at least 25 pounds, and even more
preferably, at least 30 pounds, per inch width, and the strip
should most preferably wide enough to extend width-wise at least 80
percent of the distance between the handle cutouts.
[0023] Additionally, where handle reinforcing material 24 is tape
or other material adhered or attached to the surface of horizontal
panel 22b and/or surfaces of vertical panels 20a, 20b, it may be
desirable that the material have sufficient tensile strength and
adhesion or attachment to the surface of panel 22b such that it may
not be lifted or pulled away from the surface by use of only
mechanical lifting and/or peeling force, without the package
material failing, i.e., the material of which the package is formed
will partially or entirely fail, tear or delaminate before the
attachment between the handle reinforcing material 24 and the
package surface is completely broken by mechanical lifting and/or
peeling force. For example, if handle reinforcing material 24 is
tape, it may be desirable that the tape may not be completely
lifted and/or peeled away from the package surface without tearing
at least a portion of the underlying package material along with
it. This ensures that stresses caused by lifting the package are
distributed broadly to as much material as possible, i.e., beyond
the handle reinforcing material 24 and along and into the top
and/or side panels.
[0024] To further reduce the chances for tear propagation, the
handle cutouts may be designed such that they have profiles having
no sharp inside corners pointing toward the flap edges, or sharp
bends at or proximate their inside edges, at which stress from
lifting the package would tend to concentrate. FIG. 3C depicts one
alternative, an oval- or elliptical-shaped cutout 30. It can be
seen that such a cutout 30 has a profile with only gradually
rounded inside bends proximate its inside edge 30i. The cutout 30
may also be circular, bean-shaped or peanut-shaped, again, with no
sharp inside corners pointing toward the flap edges, or sharp bends
at or proximate their inside edges. (For purposes herein, a "sharp
inside corner pointing toward a flap edge" is a portion of a cut
path forming a macroscopically sharp angle, whereby a line
bisecting the angle and extending along a direction from within the
area circumscribed by the cutout, toward and intersecting the cut
path at the angle vertex, and then extending away from the cutout,
intersects the flap edges.) Thus, the possibility for concentrated
stress and associated tear propagation is reduced. FIG. 3D depicts
another alternative, a cutout defined by a pair of spaced-apart
semicircle sections 30a, 30b of radius r, joined by a pair of
straight sections 30c ("race track" shaped cutout). As with an
oval- or elliptical-shaped cutout, the handle cutout shown in FIG.
3D presents only rounded inside bends proximate its inside edge
30i, or a straight portion. In another alternative, handle cutout
30 may be defined by a rounded rectangle shape, i.e., a rectangle
having its corners rounded. Other suitable shapes for the handle
cutouts may include but not be limited to circular, bean-shaped,
peanut-shaped, oval, ovaloid, egg-shaped, elliptical, rounded
rectangle and race-track shapes.
[0025] In yet another alternative, handle cutout 30 may have a
profile defined by a semicircle or lesser section of a circle
characterized by a straight line segment along one edge and an arc
of a circle along the opposing edge; the areas where the two
geometric components meet may also be rounded. With these latter
two profiles, it may be preferred by consumers that straight
portions of the adjacent cutouts 30 face each other, i.e., are
closest the flap edges. These latter two cutout profiles may not be
quite as effective as an oval- or elliptical profile since stresses
may be more apt to concentrate at the transitions between the
curved sections and the straight sections. However, the greater
stress concentration may be borne and distributed by an adjacent
handle reinforcing material as discussed above. In another
alternative, however, the profile of a handle cutout 30 may be
defined by a semicircle or lesser section of a circle characterized
by a straight line segment along one edge and an arc of a circle
along the opposing edge; and the semicircle or lesser section of a
circle may be disposed closest the flap edge and the straight line
segment may be disposed furthest away from the flap edge.
[0026] In all events, it may be desirable that a top handle cutout
30 be of sufficient size to allow most consumers to conveniently
and comfortably insert at least three and more preferably four
fingers into the opening and curl them under, but not so large as
to have adverse effects on the structural rigidity of the package
configuration, or unacceptably increase the chances that
contaminating dust, dirt or debris will enter the package through
an overly large hole, during shipping and handling. It is believed
that the most acceptable width W (for example, as illustrated in
FIG. 3E) of the handle cutout 30 is in the range of 15 mm to 35 mm,
more preferably 20 mm to 30 mm, and still more preferably 23 mm to
28 mm. It is believed that the most acceptable length L (see FIG.
3D) of the handle cutout 30 is 80 mm to 100 mm, and more preferably
85 mm to 95 mm.
[0027] The material within handle cutouts 30 may be completely
removed during manufacture, such that the cutouts circumscribe
holes through horizontal panel 22b. This may provide for a package
having a neater appearance. Such holes, however, particularly if
made through the top of the package, may allow contaminating dust,
dirt or debris to enter the package during shipping and handling,
and therefore, may be undesirable. Additionally, material
completely removed from within handle cutouts can present
complications during large-scale production manufacturing or
shipping, since efforts must be made and/or systems installed to
collect, remove and dispose of or otherwise process cutout/removed
material.
[0028] Thus, in another alternative, referring to FIGS. 3B and 3E,
cutout 30 may take the form of a partial cut rather than a complete
cutout. The partial cut may be a series of perforations along a cut
path with terminal ends E.sub.C, or alternatively, may be a
continuous cut that follows a path that partially but not
completely circumscribes a cutout or hole through the panel, with
terminal ends E.sub.C. For example, as suggested in FIGS. 3B and
3D, a cut may follow a path that partially circumscribes a race
track cutout. Thus, material within the cutout is left attached
along fold line 31, and this material may stay attached and
substantially in its original position relative the surrounding
material during shipping, thereby avoiding the need to handle
removed cutout material during manufacturing, and avoiding
formation of a hole in the box that may allow contaminants to
enter.
[0029] When a carry handle is needed, e.g., by a consumer, the cut
portion allows separation of material forming residual cutout flap
31f, and the uncut portion of the otherwise circumscribed cutout
profile may form a handle fold line 31, about which material
forming residual cutout flaps 30f within the cutout may fold. It
may be desired that the fold line is substantially parallel to the
flap edge, and/or the fold lines of the respective cutouts are
substantially parallel each other. Thus, a consumer may push
downwardly on material forming a residual cutout flap 30f, causing
cutout flap 30f to disengage the material of panel 22b surrounding
the cutout and rotate downwardly and inwardly (into the package and
toward flap edge 23a or 23b) about handle fold line 31, thereby
forming an opening through which fingers may be inserted and curled
under to grasp the package. As suggested in FIGS. 3B and 3E, it may
be desired that the cut extend around in the area proximate the
flap edge 23a such that both terminal ends E.sub.C of the cut point
more toward each other, rather than more toward the flap edge.
Expressed differently, it may be desired that a line tangent to the
curve or profile defined by the cut, at each terminal end E.sub.C,
forms a smaller angle with a line defined by the flap edge, which
is less than 45 degrees, more preferably less than 30 degrees, and
still more preferably less than 15 degrees. In the examples
illustrated in FIGS. 3B and 3E, that angle is approximately zero,
i.e., such a tangent line L.sub.TC is approximately parallel with a
line defined by the flap edge 23a. This feature may be desired to
reduce the chances of a tear propagating toward the flap edge as a
result of concentration stress at the cut terminal end E.sub.C,
resulting from carrying the package by grasping at the
cutout(s).
[0030] It will be appreciated, however, that this partial cut
configuration may make it more difficult for a consumer to identify
and/or locate a handle cutout, and push it inwardly to create a
handle configuration when, as discussed above, the package has a
minimum or zero top clearance TC within, as discussed above. In
other words, when the contents of the package are close to,
touching, and/or, in some examples, pressing upwardly against the
top horizontal panel 22b, they can obstruct an attempt to push in a
residual cutout flap 30f and fold it under. This is illustrated in
FIG. 4. An inner package of articles 40 may be packaged within
package configuration 10 such as a box having bottom horizontal
panel 22b, vertical panel 21b, and top horizontal panel 22b. The
package configuration 10 may be designed, through a combination of
outer container sizing and compression and sizing of inner package
of articles 40, such that there is zero top clearance TC; and inner
package of articles 40 may even exert upward pressure on top
horizontal panel 22b, for added structural support to the package
configuration as discussed above. It can be appreciated that inner
package of articles 40 would thus obstruct an attempt to push
cutout flap 30f downward into the package, separating it from
cutout 30 edges and folding it about handle fold line 31, toward
flap edge 23a.
[0031] To address the problem of handle identification/location,
the package may be marked on its top surface by printing or other
mechanism to include a handle indicium about or proximate the
handle cutout 30, to provide a visual signal to the consumer of a
location of a handle cutout that may be pushed in to create a
handle.
[0032] To address the problem of obstruction of attempt to push in
cutout flap 30f, it may be desirable that the partial cut not be in
perforations or segments, but rather, a continuous cut between
terminal ends E.sub.C. This maximizes the ease with which the
consumer may separate residual cutout flap 30f from surrounding
material by pushing it. It may further be desired that the pressure
inside the package configuration, between the top horizontal panel
22b, and the contained articles, be controlled via design,
manufacture and/or filling of the package with its contents, so as
not to be so great as to unacceptably frustrate the consumer from
pushing the material forming residual cutout flap 30f inwardly and
folding it around to create a handle configuration. Thus, the
package may be appropriately sized relative the articles it will
contain, and/or, the size(s) and/or degree of compression of the
stacks or bundles within inner packages of articles 40 that will be
packaged will be appropriately determined and effected, such that a
consumer may push residual cutout flap 30f inwardly and fold it
around and under about handle fold line 31 without undue
difficulty. Referring again to FIG. 4, for example, the design may
be such to allow the inner package of articles 40 to compress and
deflect along a deflection profile 32 so as to permit effective
creation of a handle opening. Without intending to be bound by
theory, it is believed that the maximum Push-In Force consumers
will find acceptable for such a handle configuration is 18 pounds
as measured herein. Accordingly, it may be desirable that the
package configuration be designed such that the residual cutout
flap 30f may be pushed inwardly by exerting a Push-In Force of no
more than 18 pounds, more preferably, no more than 15 pounds, and
even more preferably, 13 pounds, as measured by the Push-In Force
Test set forth below.
[0033] Push-In Force Test
[0034] The Flap Push-In Force necessary to push in a handle
residual cutout flap on a box package sample is measured on a twin
screw, constant rate of extension tensile tester with computer
interface (for many boxes a suitable instrument is the MTS Alliance
using Testworks 4.0 Software, as available from MTS Systems Corp.,
Eden Prairie, Minn.) using a load cell for which the forces
measured are within 10% to 90% of the limit of the cell. The lower
fixture to be mounted on the tensile tester is a square platform
(not shown) 38 cm by 38 cm by 1 cm thick and made of aluminum. The
platform is mounted on the tester via a mounting shaft of
appropriate dimensions and configuration suitable to mount the
platform to the stationary base of the tensile tester. When mounted
the platform fits between the screws of the tester, centered on the
stationary base of the tester, and is situated with a square
surface in a horizontal plane perpendicular to the direction of
movement of the crosshead of the tensile tester. The upper fixture
500, as shown in FIG. 5, consists of a shaft 501 (50 mm long by 5
mm in diameter) and presser bar 502 (1.27 mm in diameter and 5.7 cm
in length). The ends of the presser bar 502 are rounded at a radius
of 0.635 mm. A cylindrical housing 503, attaches the presser bar to
the movable crosshead of the tensile tester. The housing is 1.9 cm
in diameter and 8.8 cm long. The housing has a hole 504 (5 mm in
diameter and 25.4 mm deep) drilled axially into the housing, into
which the shaft 501 is inserted. Silicone stopcock grease is
applied to the shaft so that it does not fall out of the hole 504
but can rotate around the shaft's axis. The upper end 505 of
housing is of appropriate dimensions and configuration to mount to
the crosshead of the tensile tester. When mounted, the longitudinal
axis of the housing is parallel to the direction of movement of the
crosshead and perpendicular to the square surface of the
platform.
[0035] Prior to testing, condition the box package sample(s) to be
tested in a room(s) maintained at, first, 40.+-.2.degree. C. and
20.+-.2% relative humidity for 24 hours, and then, second,
23.+-.2.degree. C. and 50.+-.2% relative humidity for another 24
hours, before testing under the second set of environmental
conditions. With a marking pen, draw perpendicular lines on the
cutout flap, dividing its width and length. Place the box package
onto the platform, in its upright position, with either of the
lines drawn on the cutout flap extending forward and backward
relative to the front and rear of the tensile tester. Adjust the
position of the box package on the platform and the presser bar 502
to align the presser bar 502 with its longitudinal axis over and
aligned with the longer line drawn on the cutout flap and the axis
of the shaft 501 centered on the shorter line drawn on the handle
flap.
[0036] Set the gage length (i.e., the distance between the bottom
of the presser bar 502 and the top of the carton) to 25.4 mm. The
tensile tester is programmed to move the crosshead down at 127.0
mm/min. until it moves 50.8 mm. Zero the load cell and cross head
position. Start the tensile tester program and collect data for
force (lbs) as a function of vertical crosshead displacement
(mm).
[0037] Record the maximum peak force (lbs) to the nearest 0.1 lbs.
Repeat the measurement for the handle flaps on 20 cases and report
the average Flap Push-In Force to the nearest 0.1 lbs.
[0038] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0039] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0040] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
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