Abstract:
A package includes a plurality of upright bottles arranged in at least one row, and a carton for enclosing the bottles. The carton includes a top wall disposed over tops of the bottles and at least one cushioning flap hingedly connected to the top wall along a fold line. A portion of the cushioning flap is defined at least in part by a tear line such that the cushioning flap is separable from the top wall along the tear line and is inwardly foldable along the fold line so as to provide in the top wall an aperture for receiving fingers of a user&#39;s hand and a cushioned edge that can be gripped for engaging the carton. The cushioning flap is concavely contoured along the tear line such that the cushioning flap can be folded inwardly with a portion of the cushioning flap passing over at least one of the bottles without being obstructed by said at least one bottle and with extended distal ends of the cushioning flap passing on either side of said at least one bottle.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims priority to U.S. Provisional Application No. 60/827,197, filed Sep. 27, 2006, the entirety of which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates generally to cartons and, more specifically, to cartons having an improved tear initiation feature.  
       BACKGROUND OF THE INVENTION  
       [0003]     A tool box style carton typically includes two detachable portions which are separable to define a strap handle for carrying the carton. The detachable portions are relatively large in order to expose all or most of the articles in the carton, while preserving the ability to transport the articles in the opened carton by means of the strap handle. Because the detachable portions are so large, the severance lines that define the detachable portions typically should not be easily breakable in order to prevent the tool box carton from being inadvertently opened. Thus, it would be desirable for the tool box style carton to include a tear initiation feature to facilitate separation of the detachable portions from the tool box carton.  
         [0004]     One problem with the known tear initiation features is that they are difficult to operate and do not allow a user to get a firm grip of the detachable portion to steer and control the tearing of the severance lines. The tear initiation features are otherwise uncomfortable or difficult to use to remove the detachable portions.  
         [0005]     Since the tool box style carton is commonly used to carry a full load of glass bottles after the detachable portions have been removed, it is important that the strap which is defined by removing the detachable portions from the tool box carton be strong and comfortable for a user to grasp as well. Thus, it is also desirable to cushion the user&#39;s hand from the raw edges that remain after formation of the strap handle.  
         [0006]     Therefore, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies. What is needed is a tear initiation feature that is ergonomically designed to be engaged by a user&#39;s hand to facilitate controlled separation of a detachable portion. Further, it is desired that removal of the detachable portion defines an ergonomic strap handle.  
       SUMMARY OF THE INVENTION  
       [0007]     The various embodiments of the present invention overcome the shortcomings of the prior art by providing a carton for enclosing and transporting a plurality of articles that are arranged in rows, such as glass or plastic bottles having elongated necks. The carton includes an improved tear initiation feature for controlling the separation of one or more large detachable portions of the carton. Each of the detachable portions is defined by a substantially continuous severance line. The detachable portion can be separated from the carton along the severance line to define an opening for exposing articles in the carton.  
         [0008]     The tear initiation feature includes a cushioning flap that is hingedly connected to the detachable portion of the carton along a fold line. The cushioning flap is further defined by a segment of the severance line that defines the detachable portion and by severance lines that extend between the segment of the severance line and the fold line. Thereby, the cushioning flap is separable along the severance lines and foldable along the fold line to provide an aperture for receiving the fingers of a user&#39;s hand and a cushioned edge that can be gripped or engaged to control separation of the detachable portion.  
         [0009]     A portion of the segment of the severance line is contoured and the cushioning flap is dimensioned and positioned in accordance with the relative positions of an arrangement of articles. In the exemplary embodiment, the cushioning flap is dimensioned and positioned to fold inwardly into the carton so as to be disposed in the space defined by the sides or necks of articles between a first row and a second row. The contoured portion of the segment of the severance line forks from a proximal point that is located substantially between two centermost bottles in adjacent rows to distal points that are located between bottles in the second row, for example, on either side of the center bottle in the second row. Thereby, the bottles in the second row do not obstruct the cushioning flaps as it is folded inwardly. Further, in certain embodiments that include multiple detachable portions that define a strap handle, the contoured portion of the segment of the severance line for each detachable portion defines a handle flap to provide a cushioned edge for the strap handle.  
         [0010]     The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  is a plan view of a blank incorporating an exemplary embodiment of a tear initiation feature according to the present invention.  
         [0012]      FIG. 2  is a perspective view of a carton formed from the blank of  FIG. 1 .  
         [0013]      FIGS. 3-5  are perspective views of the carton of  FIG. 2  illustrating steps in an exemplary method of removing a detachable portion from the carton.  
         [0014]      FIG. 6  is a plan view of the carton of  FIG. 2  illustrating the relationship between a tear initiation feature and an arrangement of articles in the carton.  
         [0015]      FIG. 7  is a partial plan view showing an alternative embodiment of a tear initiation feature according to the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0016]     As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.  
         [0017]     Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton. Generally described, the carton includes a substantially continuous severance line that defines a detachable portion of the carton and a tear initiation feature that facilitates separating the detachable portion of the carton from the rest of the carton along the severance line, as described in further detail below.  
         [0018]     Referring to the exemplary embodiment illustrated in  FIGS. 1-6 , a carton  200  (shown in  FIG. 2 ) is formed from a blank  100  (the inside surface of which is shown in  FIG. 1 ). The blank is preferably a single sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. In the exemplary embodiment, the blank is dimensioned for packaging an arrangement of bottles. It is envisaged that other articles and/or different arrangements of articles may be contained within the carton and that the blank and carton can be sized accordingly.  
         [0019]     As used herein, the terms “fold line” and “severance line” refer to all manner of printed lines indicating optimal fold or cut locations, frangible or otherwise weakened lines, perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, scored lines, slits, any combination thereof, and the like.  
         [0020]     Referring to  FIG. 1 , the blank  100  includes a series of primary panels which define the walls of a tubular structure portion of the carton  200 . Specifically, the blank  100  includes a first side panel  110 , a top panel  112 , a second side panel  114 , and a bottom panel  116 . The primary panels are hingedly connected one to the next along fold lines. First side panel  110  is hingedly connected to the top panel  112  along fold line  120 , the top panel  112  is hingedly connected to the second side panel  114  along fold line  122 , and the second side panel  114  is hingedly connected to the bottom panel  116  along fold line  124 . In addition, an edge flap  118  is hingedly connected to the bottom panel  116  along fold line  126 .  
         [0021]     The blank  100  includes end flaps that are hingedly connected to opposite ends of each primary panel along fold lines. The end flaps can be folded and secured to form end closure structures at respective open ends of the tubular structure portion of the carton  200  and thereby to define the end walls of the carton  200 . The blank  100  is substantially symmetric such that the end flaps that are hingedly connected to opposite ends of each primary panel are substantially similar. In addition, certain other elements of the blank  100  are substantially similar. Accordingly, the end closure structures of the carton  200  are substantially identical and like references have been used with a suffix “a” or “b” affixed to distinguish one end of the carton from the other. Thus, the description of an element or group of elements having a suffix “a” is suitable for a like-numbered element or group of elements having a suffix “b”. In certain instances, for clarity, only one of the like elements is described unless a description of the other or both of the like elements is useful for understanding the invention.  
         [0022]     A first side end flap  130   a  is hingedly connected to first side panel  110  along fold line  140   a , a top end flap  132   a  is hingedly connected to top panel  112  along fold line  142   a , a second side end flap  134   a  is hingedly connected to second side panel  114  along fold line  144   a , and a bottom end flap  136   a  is hingedly connected to bottom panel  116  along fold line  146   a.    
         [0023]     The blank  100  further includes substantially continuous severance lines  150   a ,  150   b . The severance line  150   a  extends from the distal end of the first side end flap  130   a  across the first side end flap  130   a  to the fold line  140   a , from the fold line  140   a  across the first side panel  110  to the fold line  120 , from the fold line  120  transversely across the top panel  112  to the fold line  122 , from the fold line  122  across the second side panel  114  to the fold line  144   a , and from the fold line  144   a  across the second side end flap  134   a  to the distal end of the second side end flap  134   a.    
         [0024]     A segment  152   a  of the severance line  150   a  extends partially across the top panel  112  to partially define a tear initiation feature T that facilitates breaking the severance line  150   a . In the exemplary embodiment, the tear initiation feature T includes a cushioning flap  160   a  that is defined along its distal edge by the segment  152   a  and along its proximal edge by a fold line  154   a  that is offset from the severance line  150   a . The fold line  154   a  hingedly connects the cushioning flap  160  to a detachable portion  250   a , as will be described in detail below. The cushioning flap  160   a  is further defined by severance lines  156   a ,  158   a  that extend between the segment  152   a  of the severance line  150   a  and the fold line  154   a . Further, in the exemplary embodiment, the cushioning flap  160   a  includes an extensively weakened or precut slit  166   a  that extends from the segment  152   a  of the severance line  150   a  toward the fold line  154   a.    
         [0025]     The segment  152   a  of the severance line  150   a  is contoured or curved to at least partially define extended distal ends  162   a ,  164   a  of the cushioning flap  160   a  and to at least partially define a handle flap  170   a  to cushion the edge of a strap handle  230  of the carton  200 , as described in further detail below. In the embodiment shown, the handle flap  170   a  is substantially semicircular such that the segment  152   a  includes a section that is concave from the perspective of the handle. The handle flap  170   a  is further defined by a fold line  172   a . In the exemplary embodiment, the fold line  172   a  is aligned with a substantially linear portion of the severance line  150   a  that extends across the top panel  112 . The ends of the fold line  172   a  intersect the ends of the contoured portion of the segment  152   a  of the severance line  150   a.    
         [0026]     Referring momentarily to  FIG. 6 , the dimensions and position of the tear initiation feature T is further described. The fold line  154   a  has a length L 1  that is substantially equal to the width of a user&#39;s hand. The fold line  154   a  is offset from the fold line  172   a  by a distance L 2  which, in the exemplary embodiment, defines the maximum length of the cushion flap  160   a . The maximum distance L 3  between the segment  152   a  of the severance line  150   a  and the fold line  172   a  defines the length of the handle flap  170   a . The fold line  172   a  has a length L 4  that is ideally substantially equal to the width of a typical user&#39;s hand. In the exemplary embodiment, the fold line  172   a  defines the maximum width of the handle flap  170   a . The cushioning flaps  160   a ,  160   b  are positioned and dimensioned relative to an arrangement of articles that are enclosed in the carton  200 , as described in further detail below.  
         [0027]     Referring to  FIG. 1 , the side end flaps  130   a ,  134   a  include a portion of a handle opening such as cutouts  180   a ,  182   a  that combine to define a handle opening as the end closure structure is formed. The top end flap  132   a  includes an endless edged handle opening  184   a . The cutouts  180   a ,  182   a  are dimensioned and positioned to be in registry with the handle opening  184   a  as the end closure structure is formed.  
         [0028]     Erecting the carton  200  from the blank  100  may be accomplished with the folding operations as described herein. The operations can be performed by automatic erecting machinery and/or manually. The erecting process is not limited to the exemplary method described herein. Particularly, the order of the steps can be altered according to manufacturing requirements, steps may be added or omitted, and the means for securing components to one another may vary. The surfaces of sheet material may be secured together by suitable means for securing including tape, staples, interlocking folds, VELCRO®, glue or other adhesives, mechanical fasteners, chemical bonding, combinations thereof, and the like.  
         [0029]     The blank  100  is folded along the fold line  124  such that the inside surface of the bottom panel  116  is in a face contacting arrangement with the inside surface of the second side panel  114 . Glue or other adhesive is applied to the outside surface of the edge flap  118  and blank is folded along the fold line  120  such that the inside surface of the first side panel  110  is in a face contacting relationship with the inside surface of the top panel  112 . Thereby, the inside surface of the first side panel  110  overlaps and is secured to the edge flap  118  and the blank  100  forms a collapsed tubular structure. For clarity, it should be noted that the outside surface of the blank  100  is shown in  FIG. 1 .  
         [0030]     The collapsed tubular structure (not shown) can be erected to form the tubular structure portion of the carton  200  by pulling the panels that are in a face contacting arrangement away from one another. Articles can be easily loaded through one or both open ends (not shown) of tubular structure portion of the carton  200 . It should be understood that the exemplary carton  200  is adapted to hold a group of similarly dimensioned, preferably cylindrical articles such as bottles B.  
         [0031]     Referring to  FIGS. 1 and 2 , the end closure structures of the carton  200  are formed by folding the end flaps as described herein. First and second side end flaps  130   a ,  134   a  are folded toward the open end of the tubular structure portion of the carton  200  along fold lines  140   a ,  144   a  so as to be substantially coplanar with one another and such that the ends of the severance line  150   a  are abutting or overlapping and are substantially aligned. The top and bottom end flaps  132   a ,  136   a  are folded toward and secured to the side end flaps  130   a ,  134   a . Thereby, the end closure structures of the carton  200  are formed, as shown in  FIG. 2 , and the carton  200  is fully erected. As the carton  200  is erected, the primary panels and the end closure structures define the walls of the carton  200 . The top panel  112  defines a top wail  212 , the side panels  110 ,  114  define side walls  210 ,  214 , the bottom panel  116  defines a bottom wall  216 , and the end closure structures define end walls  218 ,  220 , respectively.  
         [0032]     Referring to  FIG. 2 , the top wall  212  of the carton  200  includes elements of the tear initiation features that facilitate separation of severance line  150   a  to detach each of the detachable portions  250   a ,  250   b  of the carton  200 . The top wall  212  includes the cushioning flap  160   a  that facilitates removing the detachable portion  250   a  by breaking the severance line  150   a . The severance line  150   a  extends substantially transversely across the top wall  212 , substantially diagonally across each of the side walls  210 ,  214 , and transversely across the end wall  218  such that the detachable portion  250   a  includes at least a portion of the top wall  212 , the side walls  210 ,  214 , and the end wall  218 .  
         [0033]     Referring to  FIGS. 2, 3 , and  6 , the exemplary carton  200  includes an arrangement of bottles B, although any compatible article or group of articles can be accommodated. In the exemplary embodiment, the bottles B include tapered necks and are arranged in a matrix configuration or otherwise in several rows R with multiple bottles B in each row. For clarity, certain of the rows R are numbered in the figures beginning with the endmost row R 1 , the second endmost row R 2 , and so on. In the exemplary embodiment, the carton  200  is dimensioned to enclose four rows of three bottles B. However, in alternative embodiments, the carton can be configured to enclose a different number of articles and/or to enclose articles that are arranged in a different configuration.  
         [0034]     Referring again to  FIG. 6 , the tear initiation feature T is further described as it relates to the arrangement of bottles B. The fold line  154   a  is disposed between adjacent first and second rows R 1 , R 2  of bottles B. Specifically, the fold line  154   a  is aligned with and disposed above the space between a centermost bottle B in the first row R 1  and a centermost bottle B in the second row R 2 . The ends of the fold line  172   a  intersect the contoured portion of the segment  152   a  of the severance line  150   a  at points P 1  and the slit  166   a  intersects the contoured portion of the segment  152   a  at a point P 2  such that the slit  166   a  substantially bisects the contoured portion of the segment  152   a . The point P 2  is disposed between the centermost bottles B in the first and second rows R 1 , R 2  and the points P 1  are disposed substantially between two adjacent bottles B in the second row R 2 .  
         [0035]     The contoured portion Q of the segment  152   a  of the severance line  150   a  extends between the linear portions D of the segment  152   a  of the severance line  150   a  but curves or otherwise diverts to avoid being disposed over the cap C of the centermost bottle B in the second row R 2 . More specifically, the contoured portion Q of the segment  152   a  of the severance line  150   a  extends from the point P 2  that lies above the space between the first and second rows R 1 , R 2  of bottles B to points P 1  that each lie above the spaces between two adjacent bottles B in the second row R 2 . In other words, the segment  152   a  of the severance line  150   a  curvingly or directly diverges or otherwise extends in different directions from the slit  166   a , or from the point P 1 , to the points P 2  that are on opposite sides of the centermost bottle B in the second row R 2 .  
         [0036]     In the exemplary embodiment, the points P 1  are disposed on opposite sides of the centermost bottle B in the second row R 2 . The points P 1  are adjacent to the innermost side of the necks of bottles B in the row R 2  and the point P 2  is adjacent to the outermost side of the neck of the center bottle B in the row R 2 . Further, the contoured portion Q of the segment  152   a  curves or arcs toward the fold line  154   a  such that the fold line  172   a  and the contoured portion Q of the segment  152   a  are disposed on opposite sides of the centermost bottle B in the second row R 2 . In this manner, the ends of the contoured portion Q of the segment  152   a  extend to the strap handle  230  and the middle of the contoured portion Q of the segment bends around the cap C of the center bottle B, so that the cushioning flap defines handle flap  170   a  while being contoured so as to clear the cap C of the centermost bottle B as the carton  200  is opened.  
         [0037]     The severance lines  156   a ,  158   a  extend from ends of the fold line  154   a  and substantially above spaces between the caps C of bottles B in the row R 2  to intersect the severance line  150   a  at points P 3 . Substantially linear portions D of the segment  152   a  of the severance line  150   a  are substantially aligned with the fold line  172   a  so as to be disposed above the spaces between two adjacent bottles B in the second row R 2 . Each of the linear portions D of the segment  152   a  of the severance line  150   a  extends between points P 1 , P 3  and defines a distal edge of the cushioning flap  160   a.    
         [0038]     Referring to  FIGS. 2-5 , the tear initiation feature T facilitates removing the detachable portion  250   a  or otherwise at least partially separating the detachable portion  250   a  from the main portion of the carton  200  along the severance line  150   a . The slit  166   a  is provided to initiate the separation of the cushioning flap  160   a  from the carton  200  along the segment  152   a  of the severance line  150   a . In an exemplary method of removing the detachable portion  250   a , pressure is applied to the area of the carton  200  where the slit  166   a  intersects the segment  152   a  of the severance line  150   a  such the segment  152   a  of the severance line  150   a  is broken and is then torn until it is intersected by the severance lines  156   a ,  158   a . The severance lines  156   a ,  158   a  are then broken such that the cushioning flap  160   a  can be folded along the fold line  154   a  so as to be disposed in the carton  200  to provide an aperture A for receiving at least some of the fingers of a user&#39;s hand, and convenient hand hold area along a cushioned edge E 1  for grasping the detachable portion  250   a  to continue tearing the severance line  150   a . The hand hold area is cushioned as the cushioning flap  160   a  covers the raw edges of the detachable portion  250   a.    
         [0039]     The cushioning flap  160   a  can be folded along the fold line  154   a  to be substantially perpendicular to the top wall  212  of the carton  200 , as shown in  FIG. 2 . Thereby, the distal ends  162   a ,  164   a  of the cushioning flap  160   a  are disposed in open spaces between the sides of adjacent bottles B and the central portion of the cushioning flap  160   a  is disposed in the space between the necks of the center bottles in the rows R 1 , R 2 . In alternative embodiments, or depending on the relative configuration of the neck and shoulder of each bottle B, the cushioning flap  160   a  can be folded into the carton  200  along the fold line  154   a  to be in a face contacting arrangement with the inside surface of the top wall  212 . In such embodiments, the cushioning flap  160   a  is dimensioned and positioned such that, as the cushioning flap  160   a  folded, the cushioning flap  160   a  is not obstructed by the bottles B.  
         [0040]     The distance L 2  between the distal ends  162   a ,  164   a  of the cushioning flap  160   a  and the fold line  154   a  relates to the length of the necks of the bottles B such that, as the cushioning flap  160   a  is folded, the distal ends  162   a ,  164   a  avoid the base portions of the bottles B. The curved portion of the segment  152   a  of the severance line  150   a  defines the central portion of the cushioning flap  160   a  such that, as the cushioning flap  160   a  is folded along the fold line  154   a , central portion of the cushioning flap  160   a  avoids or is otherwise not obstructed by the upper end and neck of the center bottle B in the row R 2 . Further described, the segment  152   a  of the severance line  150   a  is curved so as not to extend across the upper end of the center bottle B in the row R 2 .  
         [0041]     As the cushioning flap  160   a  is folded into the carton  200 , the fold line  154   a  provides a cushioned edge H that can be engaged by a user to pull the detachable portion  250   a  from the carton. The cushioned edge H is engaged and pulled to break the severance line  150   a  such that the detachable portion  250   a  can be at least partially separated from the carton  200  to provide an opening O that is defined by a substantially continuous edge E. A portion of certain of the bottles B is thereby exposed and can be dispensed through the opening O. It should be understood that the cushioned edge H is easily grasped such that the user can better control tearing of the severance line  150   a  to remove the detachable portion  250   a.    
         [0042]     Referring to  FIGS. 4 and 5 , the carton  200  includes two detachable portions  250   a ,  250   b  each of which can be removed to form an opening O that exposes the bottles B, to define the tool box shape of the carton  200 , and to define the strap handle  230  that can be used to carry the carton  200 . The strap handle  230  is defined by the severance lines  150   a ,  150   b  and includes the handle flaps  170   a ,  170   b  which are defined by the segments  152   a ,  152   b  of the severance lines  150   a ,  150   b . The handle flaps  170   a ,  170   b  can be folded along the fold lines  172   a ,  172   b  as the strap handle  230  is grasped to provide a cushioned edge E 2  of the strap handle  230 . The cushioned edge E 2  is particularly advantageous for carrying heavier loads, such as a full complement of glass bottles.  
         [0043]     In an alternative embodiment of the tear initiation feature T, shown in  FIG. 7 , a severance line that extends between the segment  152   a  of the severance line  150   a  and the fold line  154   a  is substituted for the slit  166   a  so as to define two separate cushioning flaps. In other embodiments where a severance line is substituted for the slit  166   a , a severance line is substituted for the fold line  154   a  and fold lines are substituted for the severance lines  156   a ,  158   a  to provide an alternative arrangement of cushioning flaps.  
         [0044]     The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.