Abstract:
A carton blank includes first and second spaced main panels and first and second side flaps abutting first and second side edges, respectively, of the first main panel. Third and fourth side flaps abut first and second side edges, respectively, of the second main panel and an intermediate panel is disposed between first ends of the first and second spaced main panels. A cover flap abuts a second end of the second main panel and a display flap includes first and second portions adjacent to one another wherein the first portion is joined to a second end of the first main panel by a score line and the second portion is joined to the second end of the first main panel by a perforated line collinear with the score line.

Description:
TECHNICAL FIELD 
     The present invention relates to product cartons, and more particularly, to cartons that can be converted from a shippable form to a displayable form. 
     BACKGROUND ART 
     Finished products are typically packed into cartons and shipped to merchants for sale to the general public. The merchants thereafter unpack the finished products and stack them manually on display racks or store shelves in order for consumers to easily locate and pick out products. This process is time consuming and labor intensive. Certain carton designs have attempted to address this problem through the use of convertible designs that allow the merchant to display products in the cartons in which they were shipped. 
     Leftwich et al., U.S. Pat. No. 5,657,872, discloses a storage/display container. The container has two removable sides and a removable top cover that enable a merchant to convert the container from a shipping container to a display container. The sides and top cover are removed from the container by the merchant and the products within the container are exposed with the two remaining sides and lips along the front and rear edges of the container defining the boundaries of the container. The front lip of the container can further be removed by the merchant to allow consumers to slide products out of the container if further containers are stacked on top. 
     Rosenbaum, U.S. Pat. No. 6,158,579, also discloses a storage/display container. The container includes a foldable portion comprised of the top of the container and a portion of the front of the container. A merchant utilizes the foldable portion of the container to create a fold up header at the rear of the container that displays advertising for the products within. After the fold up header is created the front of the container consists of a skirt that defines the front edge of the container and contains the products within. 
     These container designs allow merchants to display products within the cartons that the products were shipped in and can be placed by the merchant on the floor, countertop or shelves for consumers to view. However, placement of the cartons on a shelving unit creates problems in both designs and neither design allows a merchant to effectively choose between a floor/counter display and a shelf display. Specifically, in the case of the Leftwich et al. patent the container is placed on a shelf with the open side facing out. As a result, when the consumer views the container there is little or no surface space on the side of the container nearest the consumer to identify the products within. This problem may be magnified in regard to flat products or in situations where the products are pushed into the back of the container where the consumer cannot easily view the products within to identify them. 
     The Rosenbaum container can also be somewhat problematic for consumers and merchants. The container cannot easily fit in the opening between closely spaced shelves because of the fold up header created when the merchant converts the container into the display form. Furthermore, where the shelf spacing is such that the carton will fit in such opening, the fold up header is disposed in back of the shelf where consumers are unable to see printed material on the header due to obstruction and/or a lack of light. Thus, the consumer encounters the same problem as with the Leftwich et al. container, whereby the consumer is left with little viewable container surface by which to identify the products within. Also, the skirt prevents consumers from easily reaching into the bottom of the container to retrieve flat products and interferes with the ability of the merchant to readily ascertain the number of products remaining in the carton. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, a carton blank includes first and second spaced main panels and first and second side flaps abutting first and second side edges, respectively, of the first main panel. The carton blank further includes third and fourth side flaps abutting first and second side edges, respectively, of the second main panel and an intermediate panel disposed between first ends of the first and second spaced main panels. Also provided is a cover flap abutting a second end of the second main panel and a display flap having first and second portions adjacent to one another wherein the first portion is joined to a second end of the first main panel by a score line and the second portion is joined to the second end of the first main panel by a perforated line collinear with the score line. 
     A further aspect of the present invention comprehends a carton including top and bottom spaced main panels and first and second side flaps abutting first and second side edges, respectively, of the bottom main panel. The carton further includes third and fourth side flaps abutting first and second side edges, respectively, of the top main panel and secured to the first and second side flaps, respectively and an intermediate panel integral with first ends of the top and bottom spaced main panels. A display flap is also provided having first and second portions adjacent to one another wherein the first portion is joined to a second end of the bottom main panel by a score line and the second portion is joined to the second end of the bottom main panel by a perforated line collinear with the score line. A cover flap is joined to a second end of the top main panel and is secured to the display flap. 
     Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view of one side of a carton blank according to the present invention; 
     FIG. 2 is an elevational view of the opposite side of the carton blank of FIG. 1; 
     FIGS. 3-6 are isometric views of a process of erecting the carton blank of FIGS. 1 and 2; 
     FIGS. 7-9 are isometric views steps undertaken to convert the carton of FIG. 6 from a shipping form to a display form; 
     FIGS. 10 and 11 are isometric views of the carton of FIGS. 7-9 showing removal of the second main panel and cover flap to complete the conversion process to a display form according to a first embodiment of the present invention; and 
     FIGS. 12 and 13 are isometric views of the carton of FIGS. 7-9 showing folding of the second main panel and cover flap and tucking of such elements to complete the conversion process to a display form according to a second embodiment of the present invention 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to FIG. 1, a carton blank  20  includes a first side  21  and comprises sections of corrugated cardboard or other paperboard material connected by score lines and/or perforated lines. A first main panel  22  is attached at score lines  24 ,  26  to first and second side flaps  28 ,  30  respectively. The first main panel  22  is also attached to an intermediate panel  32  at a score line  34 . The first main panel  22  is further attached to a front or display flap  36  at a line  38 . 
     The front or display flap  36  includes a first section  40  attached at a perforated line  42  to a second section  44 . The first section  40  of the display flap  36  is further attached to the first main panel  22  at a score line  46  that forms a first part of the line  38 . The second section  44  of the display flap  36  is attached to the first main panel  22  at a scored and perforated line  48 . The scored and perforated line  48  forms a second part of the line  38 . The display flap  36  further includes a third section  50  disposed between the first and second sections  40 ,  44 . The third section  50  is defined by cut lines  52 ,  54  and  56 . 
     First and second tabs  60 ,  62  are attached to opposing ends of the first side flap  28 . The first tab  60  is adjacent to the intermediate panel  32  and is connected to the first side flap  28  at a score line  64 . The second tab  62  is adjacent to the second section  44  of the display flap  36  and is attached to the first side flap  28  at a scored and perforated line  66 . Third and fourth tabs  68 ,  70  are attached to opposing ends of the second side flap  30  at score lines  72 ,  74 , respectively. The third tab  68  is disposed at a location adjacent the intermediate panel  32  whereas the fourth tab  70  is adjacent the first section  40  of the display flap  36 . 
     A second main panel  80  is attached to the intermediate panel  32  at a scored and perforated line  82 . Third and fourth side flaps  84 ,  86  are attached to opposing sides of the second main panel  80  at scored and perforated lines  88 ,  90 , respectively. A cover flap  92  is attached to the second main panel  80  at a score line  94 . Furthermore, as shown in FIG. 2, which illustrates a second side  95  of the blank  20 , the second main panel  80  is comprised of first and second folding panel sections  96 ,  98  respectively. The first folding panel section  96  is attached to the second folding panel section  98  at a score line  100  that extends between the scored and perforated lines  88  and  90  Preferably, although not necessarily, the score line  100  forms 90 degree angles with respect to the scored and perforated lines  88  and  90 . Also preferably, the score line  100  is formed only in the second side  95  and not the first side  21 , although the score line  90  could be formed in both sides  21  and  95 , if desired. 
     Also, in other embodiments any or all of the scored and/or perforated lines could be replaced with other lines of weakness in the corrugated cardboard or other paperboard material used in the carton blank that enable the material to bend or tear as described below. 
     Industrial Applicability 
     The process of erecting the carton blank  20  to obtain an erected carton  110  is illustrated in FIGS. 3-6. Referring first to FIG. 3, the carton blank  10  is oriented by a user with the side  95  having the score line  100  separating the first and second folding panel sections  96 ,  98  facing up. All of the following steps of erecting the carton  110  are preferably undertaken by equipment designed to accomplish such steps but can also be accomplished manually. 
     The first and second side flaps  28 ,  30  are folded up along the score lines  24 ,  26 , respectively, as shown in FIGS. 3 and 4. Before, during or after this folding step the tabs  60 ,  62 ,  68 ,  70  are folded up/in relative to the first and second side flaps  28 ,  30  along the score lines  64 ,  72 ,  74  and along the scored and perforated line  66 . Adhesive of any suitable type is applied to outwardly-directed faces  60   a ,  62   a ,  68   a ,  70   a  (see also FIG. 1) of the tabs  60 ,  62 ,  68 ,  70 , respectively, at any suitable point in the process. Thereafter, the display flap  36  and the intermediate panel  32  are folded upwardly along the lines  38  and  34 , respectively, and adhesively attached to the outwardly-directed faces  60   a ,  62   a ,  68   a ,  70   a  of the tabs  60 ,  62 ,  68 ,  70  (FIG.  5 ). 
     If desired, the foregoing steps can be undertaken in any suitable sequence. For example, one or both of the tabs  60 ,  62  may be folded upwardly relative to the first side flap  28  and the first side flap  28  may thereafter be folded upwardly relative to the first main panel  22 . One or both of the tabs  68 ,  70  can then be folded upwardly relative to the second side flap  30  and the second side flap  30  may thereafter be folded upwardly relative to the first main panel  22 . Adhesive can then be applied to the outwardly-directed faces  60   a ,  62   a ,  68   a ,  70   a  of the tabs  60 ,  62 ,  68 ,  70  and the display flap  36  and the intermediate panel  32  may be folded upwardly in sequence or simultaneously into contact with the outwardly-directed faces  60   a ,  62   a ,  68   a ,  70   a  of the tabs  60 ,  62 ,  68 ,  70 . 
     Referring again to FIGS. 3 and 4, the third and fourth side flaps  84 ,  86  are then folded up along the scored and perforated lines  88 ,  90 , respectively, relative to the second main panel  80 . Before, during or after such folding, adhesive is applied to inner faces  84   a ,  86   a  of the third and fourth side flaps  84 ,  86 . After placing product in the carton, and as seen in FIG. 5, the second main panel  80  is then folded down along the scored and perforated line  82  until the second main panel  80  contacts one or more of upper edges  112 ,  114  of the first and second side flaps  28 ,  30  and an upper edge  116  of the display flap  36 . The third and fourth side flaps  84 ,  86  are then folded down into contact with and adhered to outer surfaces  28   a ,  30   a  (also see FIG. 1) of the first and second side flaps  28 ,  30 . If desired, adhesive may be applied to the outer surfaces  28   a ,  30   a  in addition to or in place of the adhesive on the inner faces  84   a ,  86   a  of the third and fourth side flaps  84 ,  86 . Alternatively or in addition, the third and fourth side flaps  84 ,  86  may be held in place by adhesive tape or any other securing means (not shown). Finally, the cover flap  92  is folded down along the score line  94  and the cover flap  92  is attached to the display flap  36 , preferably by adhesive tape (not shown), so that the carton  110  assumes the erected shipping form shown in FIG.  6 . 
     The process of converting the erected carton  110  into a first display form is shown in FIGS. 7-11. Referring to FIG. 7, the adhesive tape seal is first broken or severed by a user and the cover flap  92  is folded up along the score line  94 . Referring to FIG. 8, the second main panel  80  is then pulled up and torn from the third and fourth side flaps  84 ,  86  along the scored and perforated lines  88  and  90 , respectively. The third and fourth side flaps  84 ,  86  remain secured to the first and second side flaps  28 ,  30  after such tearing. 
     Then, referring to FIG. 9, the third section  50  is punched or knocked out (if it has not already been removed from the first and second sections  40 ,  44 ). The user inserts a finger into the hole left by removal of the third section  50  and grasps and removes the second section  44  of the display flap  36  from the first section  40  and the first main panel  22  by tearing at the perforated lines  42  and  48 . At this time, the second tab  62  is also separated and removed from the first side flap  28  by tearing the scored and perforated line  66 . 
     At this point, the user has the option of converting the carton  110  into one of two display forms. If the carton is to be placed in closely-spaced shelves, the user may elect to remove the second main panel  80  and the attached cover flap  92  from the intermediate panel  32  (and the remainder of the carton  110 ) by tearing along the scored and perforated line  82 , as seen in FIG. 10 to obtain the configuration shown in FIG.  11 . This configuration comprises a first or limited height display form. Once the carton  110  is placed on the merchant&#39;s shelf with the display flap  36  facing outwardly, purchasers can readily observe printed material provided on the first section  40  identifying and/or promoting the product in the carton  110 . 
     In the event that the carton  110  is to be placed at a location where vertical spacing is not a limiting factor, the user may elect to convert the carton from the configuration shown in FIG. 9 to a second display form. Specifically, as seen in FIG. 12, the user folds the second main panel  80  along the score line  100  to place the second folding panel section  98  into face-to-face abutment with the first folding panel section  96 . At this point the user tucks the cover flap  92  into abutment with the tabs  60 ,  68 . The side edges of the cover flap  92  and adjacent portions of the second folding panel section  98  remaining after tearing of the scored and perforated lines  88  and  90  may slightly engage inner surfaces  120 ,  122  of the side flaps  28 ,  30  to maintain the second folding panel section  96  in position against the first folding panel section  98 . Alternatively or in addition, the cover flap  92  may be tucked behind the product in the carton  110  and/or adhesive and/or adhesive tape may be used to maintain the second folding panel section  96  in upstanding position against the first folding panel section  98  as seen in FIG.  13 . Preferably, an outer surface  124  of the second folding panel section  96  includes printed matter thereon identifying and/or promoting the product in the carton  110 . 
     In either form, a purchaser or the merchant can easily observe how much product remains in the carton  110 , due to the removal of the second section  44  of the display flap  36  from the first section  40  down to the level of the first main panel  22 . This feature is particularly useful in the case of flat or small product. Further, the merchant need not unpack product from the carton  110  prior to display thereof. Promotional matter on the carton  110  is readily observed by the customer. 
     As an alternative to the embodiments described above, the cover flap  92  may be secured by any suitable fastening means to the display flap  36  and may further be configured substantially identically to the display flap  36 . In other words, the cover flap  92  may include three sections shaped substantially identically to the sections  40 ,  44  and  50  and which are separated from one another by lines of substantially similar design and shape as the lines  42 ,  52 ,  54  and  56  when the cover flap  92  overlies the display flap  36 . In such an embodiment, the section of the cover flap  92  overlying the section  44  may be secured to the second main panel  80  at a scored and perforated line. During conversion, the sections  50  and  44 , and the sections of the cover flap  92  corresponding thereto may be removed, leaving the section  40  and the section of the cover flap  92  corresponding thereto in place. In this case, the remaining portion of the cover flap  92  may have printed matter thereon describing or referring to the product in the carton. 
     In still another embodiment, all or portions of one or more of the first through fourth side flaps  28 ,  30 ,  84 ,  86 , the intermediate panel  32  and/or the tabs  60 ,  68  and  70  may be removed during the conversion process. This may be accomplished by tearing at one or more additional perforated lines or other line(s) of weakness. This may allow a the user to remove an entire corner of the carton to enhance the visibility of the product in the carton. 
     Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.