Carton with Integral Cover System

A carton can be initially opened by pulling a gripping tab of a tear strip to detach of cover from the remaining body of the carton except along a hinge body portion on one side of the carton. With this arrangement, the carton can be opened by folding the cover back relative to the front panel along a hinge axis. Closing of the carton is performed by initially pivoting the cover such that a front portion of the cover extends about and overlaps a front panel portion of the carton. Then, the cover is pushed down, causing a portion of the hinge-defining strip to fold and the cover to shift downward so as to extend about and overlap portions of each of the sides of the carton.

FIELD OF THE INVENTION

The invention generally pertains to packaging products, particular food products, in cartons and, more specifically, to a carton incorporating a cover system enabling the carton to not only be easy to initially open, but readily and repeatedly opened and closed in a convenient and effective manner throughout its useful life.

BACKGROUND OF THE INVENTION

In connection with shipping products, such as food products, from a manufacturer to a retail establishment, it is known to package the products in a carton, seal the carton, and ship the carton for delivery to a designated retail establishment. Although various materials could be used in making the cartons, the most common material employed is paperboard. In general, the paperboard is provided in the form of a blank which can be conveniently stored in a flat configuration but easily erected through a simple folding operation to establish an open-ended carton which can be filled and sealed, typically in an automated process. These cartons are not only lightweight and quite strong, but the paperboard is advantageously recyclable.

In some situations, the cartons are designed with a closure system which enables the carton to be opened and closed numerous times prior to depleting the product therein. For example, it is widely known to package cereal and other food products in end load cartons and to provide the cartons with closure systems operating between upper and lower flaps of top portions of the cartons. In addition to end load cartons, top load cartons are popular for foods and other products. For example, donuts and other food products are often packaged in top load cartons, each including a cover which extends across an entire open top of the carton, with the cover being hinged to enable selective, repeated access to a product storage region of the carton.

Each of these known carton types has been employed in connection with storing and dispensing of animal food. Actually, there is a trend in the case of at least dry dog and cat foods to shift away from the large bags of food still found in many retail feed and grocery stores to carton containers. By way of example, it has previously been proposed to provide a carton with a reclosable top which can be opened to expose an internal bag within which dry pet food is stored. These storage cartons have many advantages over large bags of the food. In particular, with both the internal reclosing of the bag and the external closure of the carton, the ability to contain the odor of the food from exiting the carton and effectively keep animals out of the food between feedings are greatly enhanced. The cartons also advantageously provide storing advantages over large food bags as the cartons can be readily stacked with similar cartons or other packaged products, whereas the large pet food bags do not afford this benefit.

Even with the advantages mentioned above, there are certain drawbacks from known carton designs employed in the industry. For instance, the mechanisms employed for opening such cartons can be difficult to start. By way of example, it is known to provide a tear strip for use in at least partially detaching the cover of the carton. However, known tear strip arrangements, if not clearly marked, can be overlooked by consumers, resulting in the carton being opened in another manner with loss of the reclosing feature. In addition, even using the tear strip often leads to a carton being damaged to an extend which limits the ability to adequately cover the open portion of the carton between uses. If the damage includes larger strips of the carton being torn off, handles provided in sidewalls of the carton for carrying the same can be compromised. In any case, it is considered desirable to provide a food packaging and storing carton which addresses these and other drawbacks, particularly by providing an enhanced tear strip arrangement which is at least significantly less prone to tearing, avoids damage to any carton handles, and can be readily identified to assure the proper opening of the carton. In particular, it would be desirable to employ the tear strip to establish a cover for a carton wherein the cover can assume a closed position overlapping all side walls of the carton, thereby providing an enhanced closure arrangement. Furthermore, it is desired to provide a carton which is easy to breakdown after final use for recycling purposes.

SUMMARY OF THE INVENTION

The invention is directed to a carton including a tear strip having opposing starter strip portions, each located in an upper rear panel portion of the carton and extending along perforated lines from the rear panel through side, front and opposing side panels of the carton. Once the tear strip is removed, a cover or lid is established which is only connected to the remainder of the carton through a hinge-defining strip extending along the rear panel of the carton. Given the positioning and size of the starter strip portions, the carton is torn around more than three sides, with the hinge-defining strip having a length less than the width of the rear panel. With this arrangement, the carton can be opened by folding the cover back relative to the front panel, with the initial folding establishing a flexible hinge axis. Closing of the carton is performed by initially pivoting the cover such that a front portion of the cover extends over and overlaps a front panel of the carton. Then, the cover is pushed down, causing a portion of the hinge-defining strip to fold and the cover to shift downward so as to extend about and overlap each of the sides of the carton.

Additional structural features are preferably provided to further enhance the closing operation. For instance, at front and/or rear corners of the carton, short vertical slits or cut-outs can be provided, starting from the tear line. With this enhancement, portions of the carton will readily deflect inward when the cover is extended over the panels and pushed downward. In establishing the hinge-defining strip, it has been found advantageous to provide the rear panel with at least one a line of perforations extending across the hinge-defining strip to enhance the establishment of the hinge axis. Furthermore, the hinge-defining strip is also preferably pre-formed with at least an intermediate fold line which aids in folding of the hinge-defining strip inward during the stage when the cover is pushed down.

As the invention is particularly designed for use in storing and dispensing of dry pet food, the carton also preferably incorporates other enhancements. For instance, the carton can include an internal bag in which the dry pet food is directly stored. The internal bag can be opening along a top seam and wrapped or otherwise sealed closed between uses to further prevent pet food odors emanating from the carton. In addition, one or more side carton handles can be provided to assist in carrying the carton, with each handle being formed as a full cut-out or by partially perforating a side portion of the carton which can be pivoted inward to enable fingers of the user to be inserted for lifting the carton. When provided, each handle is spaced well below the tear strip to ensure the integrity of the handle for selective use even after the carton is opened. Furthermore, the cover can itself include structure to support a removable utensil that can be conveniently used to scoop out measured portions of the dry pet food from within the bag housed in the carton.

Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.

DETAILED DESCRIPTION OF INVENTION

With initial reference toFIGS.1and2, a carton constructed in accordance with the present invention is generally indicated at5. Carton5includes a top10, a front15, sides18and19, back21and a bottom22. To assist in carrying carton5, side18is formed with a cutout24defining a handle. As best shown inFIG.1, top10is formed from an upper flap26which is adhesively secured to a lower flap27. On the other hand, with particular reference toFIG.2, bottom22includes in-folded side flaps31and32, as well as interlocking main flaps34and35. As will be detailed more fully below, main flap34includes a tongue member37which is received in a recessed portion38of main flap35. As also shown, main flap35is provided with an enlarged opening41which, as will also be described more fully below, is provided to assist in readily breaking down carton5for recycling purposes. Carton5is also shown to include, spaced below top10, a tear strip45. In particular, tear strip45includes starter strip portions47and48provided at spaced locations in back21. Each starter strip portion47,48includes a finger deflecting tab52and a gripping tab53defining a respective terminal end of tear strip45. As will be described more fully below in reference toFIGS.4-6, finger deflecting tab52is meant to be punched out to enable a select one of gripping tabs53to be grabbed by a user in order to enable tear strip45to be removed, with tear strip45included a first side tear strip portion56, a front side tear strip portion57and a second side tear strip portion58(FIG.6only). As best shown inFIG.2, back21is pre-formed with a perforated hinge line63, as well as a fold line64, each of which is spaced from tear strip45. In addition, carton5is provided with rear corner cutouts67and68extending between tear strip45and perforated hinge line63along portions of back21and sides18and19respectively. In a similar manner, front corner slits72and73extend down from tear strip45at the corners between front15and each of sides18and19. At this point, it should be noted that the use of terms, such as upper, lower, inner, outer, front, rear, side and the like, is for reference purposes only in describing exemplary forms of the invention as set forth herein and illustrated in the drawings. Therefore, these terms should not be considered limiting as to the overall invention.

In accordance with a preferred embodiment, carton5is formed from a blank76as shown inFIG.3. Blank76can be made from various materials, particularly cardboard which is widely known for use in the food industry for forming various types of food cartons. In any case, blank76is stamped from a single sheet to establish back21which is defined by a rear panel78. Rear panel78includes an upper connecting fold line82leading to lower flap27, as well as a lower connecting fold line84leading to interlocking main flap35of bottom22. As shown, main flap35includes spaced extensions87and88extending on either side of recessed portion38. Connected to rear panel78by a fold line89is a first side panel91defining side18. First side panel91includes an upper connecting fold line93leading to a first inner flap94. First inner flap94is shown to include tapered side sections95and96, an upper central concave recess99and a hole100located between concave recess99and upper connecting fold line93. First side panel91also has an associated lower connecting fold line104with in-folded side flap31. In the embodiment shown, side flap31includes a first, inwardly extending angled side edge107leading to a second, outwardly extending angled side edge109, which collectively establishes an interlocking tab111.

First side panel91is connected along a fold line117to a front panel120defined by, in part, front15. Front panel120has an associated upper connecting fold line123leading to upper flap26and a lower connecting fold line126leading to interlocking main flap34. Main flap34is shown to include inwardly angled, opposing side edges129and130which lead to tongue member37. Carton5also includes a second side panel135connected along a fold line136to front panel120. Second side panel135has an upper connecting fold line138joining side19with a second inner flap140which, in a manner similar to inner flap96is provided with tapered side sections141and142. Second side panel135is also connected to in-folded side flap32along a lower connecting fold line145. In-folded side flap32is basically a mirror image of side flap31and therefore includes a first angled side edge147leading to a second angled side edge148in defining an interlocking tab150. Finally, blank76includes a first fold line151between second side panel135and an upper attachment flap153, as well as a second fold line155between second side panel135and a lower attachment flap157. As shown, upper attachment flap153is located above tear strip45, while lower attachment flap157is located below tear strip45.

In assembling blank76ofFIG.3into carton5ofFIGS.1and2, the various panels are folded along lines89,117,136,151and155, with upper attachment flap153and lower attachment flap157being secured to rear panel78with adhesive (not shown). Thereafter, in-folded side flaps31and32are folded along lower connecting fold line104and lower connecting fold line145respectively, with tabs111and150being interlocked. Thereafter, main flaps34and35are folded along lower connecting fold line84and lower connecting fold line126respectively, with tongue member37being inserted within recessed portion38to arrive at the assembled bottom22shown inFIG.2. In closing off the remainder of carton5, lower inner flap94is folded along upper connecting fold line93, along with upper inner flap140being folded along upper connecting fold line138. Finally, lower flap27is folded along upper connecting fold line82and then upper flap26is folded along upper connecting fold line123and glued to main flap35in order to form top10of carton5as shown inFIG.1.

Reference will now be made toFIG.4-6in describing the manner in which carton5is opened. With initial reference toFIG.4, a user has selected to insert a thumb to establish a hole at finger deflecting tab52of starter strip portion48which enables tab53to be readily grasped. As shown inFIG.5, gripping tab53has been pulled such that tear strip45has extended completely across side18. This pulling of gripping tab53continues as tear strip45is removed across front15, side19and again to back21as represented inFIG.6. With the detachment of starter strip portion47, tear strip45is completely removed, thereby establishing a pivoting cover163for carton5, with cover163being pivotable about perforated hinge line63of a hinge body portion164connecting cover163to a main body portion165of carton5as illustrated by the arrow inFIG.7.

More specifically, cover163is formed from top10and upper sections (not separately labeled) of each of the front, rear, and opposing side panels120,78,91and135, while being connected to a lower section of rear panel78. At this point, it should be again noted that the terms like “front”, “rear” and “side” are only being used with reference to the embodiment depicted in the figures for use in explaining the invention. Therefore, by way of example, the carton could be rotated to make one side of the carton the “rear” for cover connecting purposes without departing from the invention. In any case, hinge body portion164defines a hinge axis along line63, while also including at least one additional fold line64established by forming blank76with a crease during the stamping process. In the embodiment shown, fold line64is aligned with tear strip45and spaced from hinge axis63. An additional fold line (not shown) could optionally be provide at a position further spaced from hinge axis63. As will be detailed further below, the fold line(s) accommodates vertical shifting of cover163.

Prior to detailing the pivoting of cover163, specific reference is made toFIG.8in describing additional aspects associated with the invention. Although carton5could be used for storing and accessing a wide range of product, the most preferred use for carton5is packaging dry pet food, particularly for dogs or cats. In one form, cartons5made in accordance with the invention can define 5-20 lb boxes for storing dry pet food which can be dispensed for feeding purposes over an extended period of time. In connection therewith, carton5may include a bag172containing the pet food, with the bag172being either rolled closed or otherwise sealed to retain odors, along with the closing of cover163, between feedings. In addition, for use in measuring and dispensing the pet food, a utensil176is provided. More specifically, utensil176includes a scoop portion177and a handle portion178shown to include a through hole179. For supporting utensil176between uses, cover163is advantageously designed with first inner flap94either frictionally fit or adhesively attached only along edges adjacent tapered side sections95and96. This mounting arrangement establishes a pocket (not separately labeled), between flap94and lower flap27, within which handle portion178can be slid. Given the presence of central concave recess99, scoop portion177is snugly received. In addition, with the presence of hole100, handle portion178is exposed to assist in maneuvering utensil176as needed.

Reference will now be made toFIGS.7,9and10in describing the manner in which cover163can be shifted between an opened position (FIG.7), to a partially closed position (FIG.9) and then to a fully closed position (FIG.10). As discussed above, cover163can pivot about hinge axis63which is preferably established by a line of perforations formed in rear panel78. In any case, it has been found that initially opening cover163by folding it back relative to front15establishes a readily flexible hinge axis. Closing of carton5is performed by initially pivoting cover163from the opened position ofFIG.7to the partially closed position ofFIG.9in which a front portion (not separately labeled) of cover163extends over and overlaps part of front panel120. Then, a rear portion of cover163is pushed down, causing hinge body strip164, constituting the only portion of carton5interconnecting cover163and main body portion165, to fold along the one or more fold lines63. This folding of the hinge-defining strip182enables cover163to shift downward so as to extend about and overlap each of sides18and19of carton5, as well as even part of back21. In addition, given the removal and size of starter strip portions47and48, hinge body strip182has a length less than the width of rear panel78so there is no interference with this folding operation. Due to the nature of the material of blank76, main body portion165can flex to some extent to accommodate this overlap. However, the inclusions of one or more of corner cut-outs67,68and/or corner slits72,73have been found to greatly enhance the ease in which cover163can be placed in the fully closed position, while also providing a more snug, retention fit to better seal carton5between uses. When the contents of carton5are depleted, enlarged opening41can be used to pull open interlocked bottom22, with tongue37being removed from recess38and interlocking tbs11and150being pulled apart to enable blank76to readily assume a double layered, flat broken down posture, with cover163attached, for recycling purposes.

Based on the above, it should be readily apparent that the invention provides for a carton that is convenient to initially open, while establishing an advantageous, friction fit cover closure arrangement. In any case, although disclosed with reference to preferred embodiments of the invention, is should be readily apparent that various changes and modifications can be made to the invention without departing from the spirit thereof. Instead, the invention is only intended to be limited by the scope of the following claims.