Front-opening Carton With Unique End Flap Arrangement

Abstract

A front-opening, rectangular paperboard carton including top, bottom, front wall, rear wall and end walls, together defining an enclosure and provided with a unique end flap arrangement which facilitates reclosure. An upstanding divider separating the enclosure into a plurality of compartments is also disclosed. At least one compartment may be provided with a removable cover panel, if desired.

Description

BACKGROUND OF THE INVENTION

This invention relates to cartons, and more particularly, to improved cartons for packaging foodstuffs such as ice cream.

Paperboard cartons are a widely accepted means for packaging various materials including foodstuffs. Such cartons usually are erected and filled with the normal access opening or cover means in a sealed condition. Typical such cartons are shown in U.S. Pat. Nos. 3,361,328 and 3,410,476.

While it is desirable for aesthetical and space-saving reasons to have a carton having a flat, square end, with the heretofore known reclosable paperboard cartons the cover or top panel end flaps still project outwardly to a greater or lesser extent once the carton is opened and then reclosed.

Also, in the case of foodstuffs, often the content of a particular carton is not used up immediately upon opening but is permitted to stand with the attendant result that the foodstuff contained therein oxidizes and/or discolors.

The carton design of the present invention obviates the foregoing drawbacks and provides several advantages with a unique end flap arrangement. Also in one embodiment a compartmentalized container whereby foodstuffs contained in a particular compartment remain fresh until desired for use, notwithstanding the fact the carton itself has been opened and another compartment emptied prior to that time, is provided.

Moreover, in the case of ice cream, several different flavors can be advantageously provided in separate compartments of the same container.

Another advantage that is derived from the carton design of the present invention is that the present design permits the use of a lower caliper paperboard for construction purposes inasmuch as a divider or bridge within the carton lends substantial structural rigidity thereto.

A still further advantage is that the present design, incorporating a vertical divider, provides a backstop for the innermost end flaps of a carton which provision not only dimensionally stabilizes the carton but also results in a better sealing of the carton ends.

Thus it is an object of the present invention to provide a carton for the packaging of foodstuffs which has a unique end flap arrangement and which can be subdivided into several compartments so that the contents of one compartment can be consumed while another compartment remains substantially sealed. Another object of the present invention is to provide a carton design which permits the use of a relatively lower caliper paperboard without sacrificing the structural rigidity of the carton.

Still other objects will readily present themselves to one skilled in the art upon reference to the ensuing specification, drawings, and the claims.

SUMMARY OF THE INVENTION

The carton of the present invention can be defined as a front-opening carton having a bottom panel; a front wall hingedly connected to one edge of the bottom panel; a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel; a top panel hingedly connected to the opposite edge of the rear panel; a front panel hingedly connected to the top panel and overlapping the front wall; bottom panel end flaps hingedly connected to the bottom panel and constituting one layer of carton end walls; top panel end flaps hingedly connected to the top panel and overlapping the bottom panel end flaps at each end; rear wall end flaps and front wall end flaps hingedly connected to rear wall and front wall, respectively, provided with a tearout section in each flap adhesively affixed to a top panel end flap, and overlapping the bottom panel end flaps and the top panel end flaps. Optionally, an upstanding divider is provided within the carton separating the carton enclosure into a plurality of compartments, and a removable cover panel for at least one of the compartments can be secured between the divider means and the front wall or rear wall of the carton. Detachable carton opening means adhesively affixes the front panel to the front wall.

In another embodiment the present invention contemplates a front-opening carton having an upstanding divider means secured to a bottom panel of the carton and dividing the enclosure defined by the carton into a plurality of compartments. Furthermore, a removable cover panel hingedly connected to the divider means and affixed to carton front wall or rear wall is provided. The removable cover panel can have lines of weakening which define a removable portion thereof. A tear strip adapted to facilitate the removal of the cover panel can also be provided.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings,

FIG. 1 is a plan view of an integral carton blank cut and scored so as to provide a carton of this invention;

FIG. 2 is a plan view of a separate divider means which can be used with the carton of this invention;

FIG. 3 is a plan view of a carton blank and an integral divider and cover panel combination which, when assembled, provides a carton of this invention;

FIG. 4 is a plan view of the blank shown in FIG. 3 with one portion thereof folded over prior to gluing;

FIG. 5 is a plan view of the blank shown in FIG. 3 completely folded and ready for gluing and subsequent erection;

FIG. 6 is a perspective view of a carton of this invention with the end flaps folded over in a sealing position;

FIG. 7 is an elevational view of a section taken along line VII -- VII of FIG. 6;

FIG. 8 is a top perspective view of a carton of this invention showing the carton with one internal compartment open;

FIG. 9 is a top perspective view of a carton of this invention showing the carton with both internal compartments open;

FIG. 10 is a top perspective view of the carton shown in FIGS. 8 and 9 in reclosed condition;

FIGS. 11 and 12 are plan views of integral carton blanks embodying the present invention; and

FIG. 13 is a top perspective view showing an opened carton erected from the blank of FIG. 12.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the accompanying drawings all parts are numbered and the same numbers are used to identify the same parts in the several FIGURES. Additionally, areas having an adhesive applied thereon are indicated by stippled shading, and areas that are embossed are indicated by a series of horizontal lines. The term "embossed" is used with reference to the outer surface of the carton as constructed.

Referring to FIG. 1, carton blank 10 comprises bottom panel 11, and front wall 12 and rear wall 13 both hingedly connected to bottom panel 11. Top panel 14 is hingedly connected to rear wall 13 and front panel 15 is hingedly connected to top panel 14 and adapted to overlap front wall 12 when the carton is erected.

Bottom panel 11 is provided with bottom panel end flaps 16 and 17 hingedly connected thereto which constitute one layer of end walls for the erected carton. Similarly front wall 12 is provided with front wall end flaps 18 and 19 hingedly connected thereto and adapted to overlap bottom panel end flaps 16 and 17, respectively, when the carton is erected. By the same token, rear wall 13 is provided with rear wall end flaps 20 and 21 hingedly connected thereto and also adapted to overlap bottom panel end flaps 16 and 17, respectively, when the carton is erected.

Top panel 14 is provided with top panel end flaps 22 and 23 which are hingedly connected thereto and which overlap bottom panel end flaps 16 and 17, respectively. Front wall end flaps 18 and 19 and rear wall end flaps 20 and 21 overlap top panel end flaps 22 and 23.

Detachable carton opening means are provided in front panel 15 and comprise tear strip 32 and adhesive region 31 which is adapted for adhesive affixation to front wall 12. In lieu of tear strip 32 a peel strip having an adhesive region thereon can also be used, if desired. Reclosure tab 33 in front panel 15 is adapted to be exposed when tear strip 32 is removed. Reclosure slot 34 in front wall 12 is adapted to receive tab 33.

The end flap arrangement shown in the FIGURES is the essential feature of the present invention. This particular arrangement provides an effective end closure for the carton having a flat, square appearance. In the embodiment shown in FIG. 1, main sections 42 and 41 of front wall end flaps 18 and 19 have embossments or embossed sections 36 and 35, respectively, which terminate in respective cut-out portions 38 and 37. Main sections 48 and 47 of rear wall end flaps 20 and 21 are also provided with embossments or embossed sections 44 and 43, respectively, which terminate in cut-out portions 46 and 45, respectively.

Main sections 42 and 48 of flaps 18 and 20, respectively, are adapted for affixation to bottom panel end flap 16 and main sections 41 and 47 of flaps 19 and 21, respectively, are adapted for adhesive affixation to bottom panel end flap 17. Inasmuch as top panel end flaps 22 and 23 also overlap end flaps 16 and 17, respectively, tear-out sections 40 and 50 are adapted for adhesive affixation to end flap 22 and tear-out sections 39 and 49 are adapted for adhesive affixation to end flap 23. Cut-out portions 38 and 46 cooperate to provide a convenient finger insert means 55 on one side of the carton for opening the same (FIG. 6). In the same manner cut-out portions 37 and 45 provide a finger insert means on the other side of the carton.

In front wall end flaps 18 and 19 and in rear wall end flaps 20 and 21, tear-out sections 39, 40, 49 and 50 of the end flaps are delineated from the respective embossed sections 35, 36, 43 and 44 by severance lines 51, 52, 53 and 54, respectively. When an erected and glued carton is subsequently opened, these lines are severed and the tear-out sections 39, 40, 49 and 50 remain permanently attached to the respective top panel end flaps 22 and 23. A pocket suitable for the insertion of top panel end flap 22 upon carton reclosure is formed through cooperation of embossed sections 38 and 46. Similarly, a pocket for top panel end flap 23 is formed by cooperating embossed sections 35 and 43. Insertion of flaps 22 and 23 in the aforesaid pockets can be further facilitated, if desired, by providing crease scores or lines of weakening at the outer corners thereof such as perforated lines 56, 57, 58 and 59 shown in FIG. 1.

FIG. 2 shows a separate cover panel and divider means combination which can be conveniently secured to either front wall 12 or rear wall 13 by means of cover panel attachment strips 62 and 63. The aforesaid combination comprises upstanding vertical divider means 60 and removable cover means 61 hingedly connected thereto preferably by means of a line of weakening such as perforated line 27. Divider means 60 is adapted for adhesive affixation to bottom panel 11 by means of attachment strip or glue flap 30 defined by a crease score or line of weakening such as perforated line 64. Removal of cover panel 61 is facilitated by provision of tear strip 29 therein.

In another embodiment of this invention, shown in FIG. 3, an integral divider and removable cover means is contemplated. In FIG. 3 and subsequent FIGURES, the parts assigned a number followed by the designation a, b, or c are identical to parts having the corresponding number in FIGS. 1 and 2 and cooperate in the same manner. Thus a detailed description of these identical parts shown in FIG. 3 et seq. will be omitted. In this embodiment upstanding divider means 24 is adapted for adhesive attachment to bottom panel 11a at adhesive region 25 by means of attachment strip 30a and is hingedly connected to removable cover panel 26, preferably by means of a line of weakening such as perforated line 27a. Removable cover panel 26, in turn, is connected to front wall 12a at score 28a which also can be a line of weakening. Removal of cover panel 26 is facilitated by the provision of tear strip 29a therein.

In still another variant of this invention (not shown in the FIGURES) a pair of upstanding divider means, each connected to a removable cover panel, can be used to divide the carton enclosure into three separate compartments, two of which are covered, with one cover panel attached to a front wall and the other attached to a rear wall of the carton. Moreover, the upstanding divider means and the adjacent cover panels can be made integral with the carton blank, if desired, hingedly connected to the respective front wall and rear wall thereof, and the top panel and front panel, together with their attendant end flaps supplied as a separate member which is then adhesively attached to the rear wall of the carton in any suitable manner. In addition, an upstanding divider means adhesively attached to bottom panel 11 and top panel 14 can be provided.

Upon assembly of a carton from blank 10a shown in FIG. 3, blank 10a is folded over as shown in FIG. 4 with divider attachment strip 30a superimposed over adhesive region 25a so that divider means 24 can be adhesively attached to bottom panel 11a. Thereafter front wall 12a and bottom panel 11a are folded over as shown in FIG. 5 and front panel 15a folded over front wall 12a so that adhesive region 31a (FIG. 3) can be adhesively attached thereto. After front panel 15a is attached to front wall 12a the result is a folded tube with divider means 24 secured in place. The thus obtained folded tube can be waxed or otherwise suitably treated at this stage of construction, if desired. Blank 10 is assembled in a similar manner but, of course, omitting the folding over of a divider means, if no divider is contemplated.

To erect a carton so constructed for filling, the folded tube-like blank is squared up on a conventional squaring machine or the like, and one end of the carton closed by first folding bottom panel end flap such as flap 16a. Top panel end flap 22a is then folded over flap 16a, and subsequently front wall and rear wall end flaps 18a and 20a, respectively, folded thereover. To facilitate squaring of the carton and subsequent filling, cover panel 26 and top panel 14a may be attached together by means of one or more isolated adhesive areas in the form of ovals, circles, or the like.

If heat-activatable adhesive is applied on the indicated adhesive regions, affixation of the several flaps is accomplished by heating these regions and then suitably pressing down the flaps. In the alternative, a hot melt adhesive may be applied on the aforesaid areas at the machine erecting the cartons so as to accomplish the same result as with a pre-applied, heat-activated adhesive. When using a hot melt adhesive, the need for heat activating machinery is, of course, obviated.

The erected carton can now be filled through the remaining open end in the usual manner and the open end of the filled carton subsequently closed in a sequence substantially as hereinbefore described. That is, referring to FIGS. 4 and 5, bottom panel end flap 17a is folded over the carton end opening, top panel end flap 23a is then folded over flap 17a and thereafter front wall and rear wall end flaps 19a and 21a, respectively, folded thereover. Alternatively, the first-mentioned carton end may be closed and/or tacked, as with glue, but not sealed, and then both carton ends sealed simultaneously after filling.

A sealed carton is shown in FIG. 6 and an elevational view thereof in section taken along line VII--VII is shown in FIG. 7.

The sealed carton may be opened first as shown in FIG. 8 by detaching tear strip 32a, severing lines 52a and 54a (FIG. 6), as well as lines 51a and 53a (FIG. 3), and lifting up top panel 14a to expose one portion of container contents. Another portion of container contents is exposed by detaching tear strip 29a and lifting up and/or detaching removable cover panel 26 along perforated line 27a as shown in FIG. 9.

Reclosure of the opened carton can be accomplished by returning top panel 14a to its original position, tucking in protruding portions of top panel flaps such as flap 22a in the pocket provided therefor, i.e., between embossed sections 36a and 44a on one hand and bottom panel end flap 16a on the other, and by engaging reclosure tab 33a with reclosure slot 34a. A reclosed carton is shown in FIG. 10.

Once the contents of one of the carton compartments has been consumed or removed therefrom, upstanding divider means 24 can be detached from bottom panel 11a in any convenient manner, for example by severing attachment strip 30a from divider means 24 along a suitable line of weakening such as perforated line 64a.

While embossments such as 35, 36, 43 and 44 as shown in FIG. 1 are preferred, they are not essential for the proper functioning of the end closure arrangement of this invention. In lieu thereof a crease score across the flaps can be provided approximately delineating that portion of main sections 41, 42, 47, and 48 which overlaps the corresponding top panel end flap. When main sections 41, 42, 47, and 48 are adhesively affixed to the respective bottom panel end flaps 16 and 17, and tear-out sections 39, 40, 49, and 50 are removed upon opening the carton, the crease score will tend to spread the upper portion of main sections 41, 42, 47, and 48 apart, away from the corresponding bottom panel end flaps, and thereby will facilitate the insertion of top panel end flaps 22 and 23 into their respective pockets formed between the rear and front wall end flaps and the bottom panel end flaps.

In yet another preferred embodiment of this invention, shown in FIG. 11, front wall end flaps 18b and 19b as well as rear wall end flaps 20b and 21b are formed without any embossments or crease scores. Top panel end flaps 22b and 23b are provided with lift tabs 66 and 67, respectively, and the configuration of tear-out sections 39b, 40b, 49b, and 50b is such that portions thereof overlap also lift tabs 66 and 67. These tear-out sections are adhesively attached to end flaps 22b and 23b and to lift tabs 66 and 67, thereby providing reinforcement for the lift tabs.

A still further preferred embodiment of this invention is shown in FIGS. 12 and 13 wherein top panel end flaps 22c and 23c are provided with lift tabs 68 and 69, where cut-out portions are omitted from rear wall end flaps 20c and 21c, and where front wall end flaps 18c and 19c are provided with somewhat larger cut-out portions 70 and 71, respectively. The configuration of tear-out sections 39c and 40c is such that portions thereof overlap also lift tabs 69 and 68, respectively, and are adhesively attached thereto so as to provide reinforcement for the tabs. By moving lift tabs 68 and 69 more toward the center of top panel end flaps 22c and 23c, respectively, the carton can be opened more easily. Besides, erection of the carton on certain types of automatic equipment is facilitated because additional area for the placement of vacuum suction cups for opening the folded carton tube is made available.

An opened carton, erected from the blank shown in FIG. 12 is shown in FIG. 13. Finger insert means such as opening 72 formed by the cooperation of end flaps 18c and 20c can be of any convenient size which facilitates the insertion of a finger under lift tab 68 as shown in FIG. 13 or under a top panel end flap, whatever the case may be. In this manner, as the lift tab or top panel end flap is pulled upwardly, tear-out sections such as 40c and 50c (FIG. 12) are readily severed from end flaps such as 18c and 20c.

The foregoing embodiments of the present invention are intended as illustrative but are not to be construed as limiting. Still other variations within the spirit and scope of this invention will readily present themselves to one skilled in the art.

Claims

We claim:

1. A front-opening paperboard carton having

a bottom panel;

a front wall hingedly connected to one edge of the bottom panel;

a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel;

a top panel hingedly connected to the opposite edge of the rear wall;

a front panel hingedly connected to the top panel and overlapping the front wall;

detachable carton opening means adhesively affixing the front panel to the front wall;

rear wall end flaps hingedly connected to the rear wall and comprising a main section and a tear-out section;

front wall end flaps hingedly connected to the front wall and comprising a main section and a tear-out section;

top panel end flaps hingedly connected to the top panel;

bottom panel end flaps hingedly connected to the bottom panel and constituting one layer of end walls for the carton;

said top panel end flaps overlapping the bottom panel end flaps; and

said front wall end flaps and rear wall end flaps overlapping the bottom panel end flaps and the top panel end flaps, and the main section thereof being adhesively attached to a bottom panel end flap and the tear-out section thereof being adhesively attached to a top panel end flap.

2. The front-opening paperboard carton of claim 1 wherein each top panel end flap is provided with a lift tab, wherein one of the front wall end flaps or one of the rear wall end flaps overlies each lift tab, and wherein the end flaps overlying the lift tab have a cut-out portion providing a finger insert means under the lift tab.

3. The front-opening paperboard carton of claim 1 wherein each top panel end flap is provided with a lift tab, wherein embossments are provided in the main sections of the rear wall end flaps and the front wall end flaps adjacent to the tear-out sections of said flaps, wherein one of the rear wall end flap embossments or one of the front wall end flap embossments overlies each lift tab, and wherein the embossment overlying the lift tab has a cut-out portion providing a finger insert means under the lift tab.

4. The front-opening paperboard carton of claim 1 wherein embossments are provided in the main sections of the rear wall end flaps and the front wall end flaps adjacent to the tear-out sections of the flaps.

5. The front-opening paperboard carton of claim 4 wherein the embossments of the front wall end flaps each have a cut-out portion providing a finger insert means under the corresponding top panel end flap for opening the carton.

6. The front-opening paperboard carton of claim 4 wherein the embossments of the rear wall end flaps and the front wall end flaps each have a cut-out portion providing a finger insert means under the underlying top panel end flap for opening the carton.

7. The front-opening paperboard carton of claim 1 wherein rear and front wall end flaps overlapping the top panel end flap have a cut-out portion providing a finger insert means under the top panel end flap.

8. The front-opening paperboard carton of claim 1 having an upstanding divider means in said carton spaced from the front wall and the rear wall, adhesively attached to the bottom panel, and dividing enclosure defined by said walls and said panels into a plurality of compartments.

9. The front-opening paperboard carton of claim 1 having an upstanding divider means in said carton spaced from the front wall and the rear wall, adhesively attached to the bottom panel, and dividing enclosure defined by said walls and said panels into a plurality of compartments; and

a removable cover panel for at least one of the compartments hingedly connected to the free edge of the divider means and affixed to the front wall or the rear wall of the carton.

10. The front-opening paperboard carton of claim 9 wherein the removable cover panel is adhesively attached to the front wall or rear wall of the carton.

11. The front-opening paperboard carton of claim 9 wherein the removable cover panel is hingedly connected to the front wall or rear wall of the carton.

12. The front-opening paperboard carton of claim 9 wherein the removable cover panel is provided with lines of weakening defining a removable portion thereof.

13. The front-opening paperboard carton of claim 9 wherein the removable cover panel is provided with a tear strip adapted to facilitate the removal thereof.

14. The front-opening paperboard carton of claim 1 wherein a portion of the top panel end flap protrudes beyond a tear-out section of overlapping front wall end flap or rear wall end flap and the protruding portion is received in a pocket defined by the front wall and rear wall end flaps and by the bottom panel end flap.

15. The front-opening paperboard carton of claim 14 wherein a line of weakening is provided in the protruding portion so as to facilitate insertion thereof in said pocket.

16. The front-opening paperboard carton of claim 1 wherein each top panel end flap is provided with a lift-tab, and wherein the front wall end flaps overlie the lift tabs and have cut-out portions therein which provide a finger insert means under the lift tabs.

17. An integral paperboard blank for forming a front-opening carton cut and scored to provide

a bottom panel;

a front wall hingedly connected to one edge of the bottom panel;

a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel;

a top panel hingedly connected to the opposite edge of the rear wall;

a front panel hingedly connected to the top panel and adapted to overlap the front wall;

detachable carton opening means in the front panel adapted for adhesive affixation of the front panel to the front wall;

bottom panel end flaps hingedly connected to the bottom panel and adapted to constitute one layer of end walls for the carton;

rear wall end flaps hingedly connected to the rear wall and comprising a main section and a tear-out section;

front wall end flaps hingedly connected to the front wall and comprising a main section and a tear-out section;

top panel end flaps hingedly connected to the top panel and adapted to overlap the bottom panel end flaps; and

said front wall end flaps and rear wall end flaps being adapted to overlap the bottom panel end flaps and the top panel end flaps and the main section thereof being adapted for adhesive affixation to a bottom panel end flap and the tear-out section thereof being adapted for adhesive affixation to a top panel end flap.

18. The integral paperboard blank of claim 17 wherein each top panel end flap is provided with a lift tab, wherein one of the front wall end flaps or one of the rear wall end flaps is adapted to overlie each lift tab, and the front wall end flaps or rear wall end flaps adapted to overlie the lift tab have a cut-out portion adapted to provide a finger insert means under the lift tab.

19. The integral paperboard blank of claim 17 wherein each top panel end flap is provided with a lift tab, wherein embossments are provided in the main sections of the rear wall end flaps adjacent to the tear-out sections of said flaps, wherein one of the rear wall end flap embossments or one of the front wall end flap embossments is adapted to overlie each lift tab, and wherein the embossment adapted to overlie the lift tab has a cut-out portion adapted to provide a finger insert means under the lift tab.

20. The integral paperboard blank of claim 17 wherein embossments are provided in the main sections of the rear wall end flaps and the front wall end flaps adjacent to the tear-out sections of the flaps.

21. The integral paperboard blank of claim 20 wherein the embossments of the front wall end flaps each have a cut-out portion adapted to provide a finger insert means under the corresponding top panel end flap.

22. The integral paperboard blank of claim 17 wherein the embossments of the rear wall end flaps and the front wall end flaps each have a cut-out portion adapted to provide a finger insert means under the corresponding top panel end flap for opening the carton.

23. The integral paperboard blank of claim 17 wherein rear and front wall end flaps overlapping the top panel end flap have a cut-out portion adapted to provide a finger insert means under the top panel end flap.

24. The integral paperboard blank of claim 17 additionally having a cover panel hingedly connected to the front wall and a divider means hingedly connected to the cover panel and adapted for adhesive affixation to the bottom panel.

25. The integral paperboard blank of claim 24 wherein lines of weakening are provided in the cover panel defining a removable portion thereof.

26. The integral paperboard blank of claim 24 wherein a tear strip is provided in the cover panel.

27. The integral paperboard blank of claim 17 wherein the detachable opening means is a tear strip provided in the front panel.

28. The integral paperboard blank of claim 17 wherein a portion of the top panel end flap is adapted to protrude beyond a tear-out section of overlapping front wall end flap or rear wall end flap and the protruding portion of the top panel end flap is adapted to be received in a pocket defined by the front wall and rear wall end flaps and by the bottom panel end flap.

29. The integral paperboard blank of claim 28 wherein a line of weakening is provided in each protruding portion and is adapted to facilitate the insertion thereof in said pocket.

30. The integral paperboard blank of claim 17 wherein each top panel end flap is provided with a lift tab, and wherein the front wall end flaps are adapted to overlie the lift tabs and are provided with cut-out portions providing a finger insert means under the lift tabs.