A self-erecting end-loading top-dispensing container which is convertible from a substantially flattened configuration for shipping the empty container into an erected box-like configuration for loading product into the container and for shipping loaded containers. By removing a tear-away portion of the top panel, the container is convertible into a tray having an open top for dispensing product. Connecting webs join the end closures of the container to the front and rear side walls, preserving the structural integrity of the container when the removable top is torn away.

TECHNICAL FIELD 
The present invention relates generally to disposable containers formed 
from a single sheet of paperboard or the like, and particularly relates to 
a container which is shipped in a flattened configuration, erected into a 
box-like configuration for loading product into the container and for 
shipping loaded containers, and is convertible into a tray having an open 
top for dispensing product. 
BACKGROUND ART 
Many attempts have been made in the packaging industry to provide customers 
with convenient containers which are easy and economical to ship prior to 
loading, and which when loaded with product allow convenient dispensing of 
product carried by the container. In the health services and medical 
professions, there is often a need to dispense medical goods in small 
stackable trays, each tray carrying the items needed for one patient. For 
example, small plastic trays carrying a syringe, a cleaning swab, and a 
drug may be stacked several trays high and shipped as a unit by the 
manufacturer of the medical goods. A zippered score allows a portion of 
the container to be removed to grasp the trays one at a time for use with 
an individual patient. 
Typically, dispensers for these products have end closures which are glued 
once the stack of product trays is loaded into the container. The use of 
end closures which are glued unfortunately requires that the empty 
containers be assembled and glued at the manufacturer's facilities after 
the containers are loaded, thereby requiring an investment in 
container-erecting equipment. 
Designs for containers which include end closures which are not glued but 
consist of tuck flaps at either end solve the problem of the need for 
container-erecting equipment, but these type containers cannot reliably 
include a tear-away portion on the container. Tearing away a removable 
portion of a tuck-flap type container in order to allow dispensing product 
results in an unstable container which simply falls apart and does not 
function to hold together the supply of product trays. 
SUMMARY OF THE INVENTION 
The present invention solves problems with prior art dispensing containers 
by providing an erectable, end-loading, top-dispensing container which is 
convertible from a substantially flattened configuration for shipping the 
empty containers into an erected box-like configuration for loading 
product into the container and for shipping loaded containers. The 
container is further convertible into a tray having an open top for 
dispensing product. 
Generally described, the present invention comprises a container fabricated 
from a single blank of paperboard or the like, comprising a top panel, a 
bottom panel supported in spaced-apart relation to the top panel, a front 
side wall and a rear side wall each connecting the top panel and the 
bottom panel, and a pair of collapsible end closures which assume a 
collapsed, flattened position when the container is in a flattened 
configuration and which assume an erected position when the container is 
erected. A tear score is provided in the container for removing a 
substantial portion of the top panel to create an open-topped tray for 
dispensing product, and connecting webs are provided for joining the end 
closures to the front side wall and the rear side wall for maintaining the 
structural integrity of the container when the tear-away portion of the 
top panel is removed. 
According to the preferred embodiment of the invention, one of the end 
closures comprises interlocking flaps defining an automatic end closure. 
The flaps automatically interlock to form an assembled end wall for the 
container when the container is erected. The other end closure preferably 
comprises a tuck panel which assumes a disassembled flattened 
configuration when the container is flattened, and which includes a tuck 
flap insertable in between a connecting web and the bottom panel to define 
an openable and closable product insertion end wall when the container is 
erected. 
Preferably, the connecting webs comprise container material extending 
between the tuck panel and each of the side walls. Each web includes a 
score line extending from the intersection of the tuck panel and the 
adjoining side wall to facilitate folding of the web when the tuck panel 
closure is closed. 
Also in the preferred embodiment, the tear score comprises a line tearing 
defined by a plurality of spaced-apart cuts in the container material. The 
cuts define a plurality of container material bridges between the portion 
of the top panel to be removed and the remainder of the container. The 
bridges are operative to twist without delamination when the container is 
folded along the score in the flattened configuration, and are further 
operative to permit controlled delamination along the score line when the 
removable portion of the top panel is torn away. Preferably, the 
spaced-apart cuts are generally Z-shaped and include a center cut line 
oriented angularly with respect to the line of tearing, and further 
include a pair of generally parallel cut lines extending in opposite 
directions from the end of the center cut line. 
Also in the preferred embodiment, a second tear score is included for 
removing a portion of one of the side walls together with the removed part 
of the top panel, so as to allow convenient access to product within the 
container. The removable portion is preferably V-shaped so as to create a 
relatively wide opening near the top of the container and a relatively 
narrow opening disposed toward the bottom of the container for inserting a 
finger to grasp the removable portion of the side panel. Also, in the 
preferred embodiment a web of container material is included between the 
automatic end closure and the front side wall to provide additional 
structural integrity when the portion of the top panel is removed. 
The invention has the further advantage that it can be constructed from a 
single sheet of paperboard or the like which can be folded and glued into 
a flat configuration for shipping and handling. When the container is to 
be loaded with product, it can be easily popped up into an erected 
configuration ready to receive product into the opened end closure. The 
tuck-flap end closure is then closed, and the filled container is ready to 
be shipped. 
Thus, it is an object of the present invention to provide a self-erecting 
end-loading, top-dispensing container. 
It is a further object of the present invention to provide a container 
which is convertible from a substantially flattened configuration for 
shipping the empty containers into an erected box-like configuration for 
loading product into the container and for shipping loading containers, 
and which is further convertible into a tray having an open top for 
dispensing product. 
It is a further object of the present invention to provide an end-loading, 
top-dispensing container wherein a portion of the top of the container is 
removed to allow dispensing product, and wherein the end closures of the 
container are joined to the side walls of the container for maintaining 
the structural integrity of container when the removable portion of the 
top panel is removed for dispensing product. 
It is a further object of the present invention to provide an erectable, 
top-dispensing container convertible from a flattened configuration into a 
box-like configuration having a top portion which is removable for 
dispensing product, wherein the removable top portion is defined by a tear 
score line which permits twisting of the container material without 
delamination when the container is folded in the flattened configuration 
but which permits controlled delamination along the tear score when the 
portion of the top panel is removed.

DETAILED DESCRIPTION 
Referring now in more detail to the drawings, in which like reference 
numerals represent like parts throughout the several views, FIG. 1 shows a 
paperboard blank 10 which is assembled to construct the container of the 
present invention. The blank 10 is cut and scored from paperboard or the 
like. 
The blank 10 includes a top panel 12, a bottom panel 14, a front or first 
side wall member or panel 15, and a rear or second side wall member or 
panel 16. The top or first panel member 12 is substantially rectangular, 
and is hingedly connected along a transverse score line 20 to the front 
side wall 15. The top panel is hingedly connected at another transverse 
score line 21 to the rear side wall 16. A glue flap 22 is hingedly 
connected at still another transverse score line 24 to permit securing the 
bottom panel 14 to the rear side wall 16. 
Referring to FIGS. 2 and 5, it is seen that the side walls 15, 16 hold the 
top and bottom panels in spaced-apart relation, and a rectangular tubular 
enclosure is formed when a cut edge 23 of the rear side wall 16 is adhered 
to the glue flap 22. 
Preferably, the transverse score line 21 connecting the top panel 12 and 
the rear side wall 16 is a jump cut score which allows removal of the top 
panel in a manner described below. 
As best seen in FIG. 5, the completed and erected container 25 has a closed 
end indicated generally at 26, which is closed by flap means forming a 
conventional "automatic end closure". In FIG. 1, the automatic end closure 
26 is seen to comprise an end flap 30 foldably connected to the bottom 
panel 14, an end flap 31 foldably connected to the front side wall 15, an 
end flap 32 foldably connected to the top panel 12, and an end flap 33 
foldably connected to the rear side wall 16, all of the end flaps 30-33 
being connected along a collinear longitudinal score line 34. 
Glue spots 35 are applied to the end flaps 31 and 33 on the outside of the 
blank 10, and adhere to the areas 36 shown in dotted relief in FIG. 1 on 
the end flaps 30, 32, for creating the automatic end closure. When the 
container 25 is erected, the end flaps 30 and 32 interlock in a 
conventional manner, as shown in FIG. 5, to provide rigidity to the 
automatic end closure. 
Referring again to FIG. 1, an end wall flap 40 is hingedly connected along 
a longitudinal line 41 to the top panel 12 for creating an openable and 
closable product insertion opening in the erected container. The end wall 
flap includes a conventional tuck flap 42 for inserting into the erected 
container. 
The end wall flap 40 is connected to the front side wall 15 and the rear 
side wall 16 via connecting webs or dust flaps 45, 46, respectively. The 
dust flap 46 is connected to the end wall flap 40 along a part of the 
transverse score line 21, while the dust flap 45 is connected to the end 
wall flap along an extension of the transverse score line 20. These 
connections are shown at 47 and 48, respectively. Accordingly, the front 
and rear side panels 15, 16 remain connected to the end wall flap 40 after 
the removable portion of the top panel 12 is torn away, thereby 
maintaining the structural integrity of the container. 
When the end wall flap 40 is closed, the dust flaps 45, 46 fold inwardly 
along connections 47, 48 and their connections to panels 15, 16 and are 
forced to bend in the center along fold lines 51, 52. The fold lines 51, 
52 extend outwardly from the intersection of the end wall flap 40 and the 
front and rear wide walls 15, 16, as best seen in FIG. 2. The product 
insertion opening of the container is closed by folding the end wall flap 
40 against the open end of the container and by inserting the tuck flap 42 
beneath the edges 53, 54 of the dust flaps 45, 46, which frictionally 
retain the tuck flap 42. 
A tear-away portion 60 is defined in the top panel 12 and front side wall 
15, as may be seen in FIG. 2. The tear-away portion 60 is partially 
defined in the blank of FIG. 1 by a score line or zipper score comprising 
a plurality of spaced-apart cuts. In the preferred embodiment, a zipper 
score line 61 is provided between the top panel 12 and the end wall flap 
40 to define one edge of the tear-away portion. A second zipper score 62 
is defined along a portion of the longitudinal score line 34 at the 
juncture between the top panel 12 and the end flap 32. Note in FIG. 1 that 
the zipper score 62 is provided only along a portion of the juncture 
between the top panel 12 and the end flap 32, leaving another portion 63 
of the longitudinal score line 34 fully connected and merely creased. 
Both of the zipper scores 61, 62 are defined by a plurality of spaced-apart 
cuts in the container material which define a plurality of container 
material bridges 64 (FIG. 6) between the tear-away portion 60 of the top 
panel and the remainder of the container. The blank 10 is preferably 
oriented with the grain of the paperboard running longitudinally, that is, 
along the line of tearing of scores 61 and 62, so that the bridges 64 are 
operative to twist without delamination when the container is folded along 
the zipper scores 61, 62 in the flattened configuration. The zipper scores 
are further operative to permit controlled delamination along the line 
defined by the scores when the tear-away portion of the top panel is 
removed. 
More particularly, the spaced-apart cuts of the zipper scores 61, 62 are 
generally Z-shaped, as shown in FIG. 6. Each of the Z-shaped cuts includes 
a center cut line 65 oriented angularly with respect to the line of 
tearing (shown as a dashed line) of the zipper score 61. A pair of 
generally parallel cut lines 66, 67 extend in opposite directions from the 
ends of the center cut line 65 generally along the direction of the zipper 
score line 61. Each one of the parallel cut lines 66, 67 overlaps an 
adjacent one of the parallel cut lines of the adjacent Z-shaped cut, as 
shown at 68, such that a line drawn normal to the end of one of the 
parallel cut lines intersects the adjacent one of the parallel cut lines 
of the adjacent Z-shaped cut. 
The particular Z-shaped cuts allow twisting of the container material 
bridges 64 between parallel cut lines of adjacent cuts when the container 
is folded. In particular, when the container is folded in the flattened 
configuration such as shown in FIGS. 3 and 4, the zipper score 62 is 
caused to fold 180 degrees. With the particular Z-shaped cuts disclosed 
herein, the container material does not delaminate when folded, but 
advantageously twists in the container material bridge 64 as the edge at 
the automatic end closure is folded inwardly to flatten the containers. 
After the container is erected, and the tear-away portion 60 is to be 
removed, the zipper scores 61, 62 permit controlled delamination along the 
line of the zipper scores. Thus, upon removal of the tear-away portion, if 
the paperboard tends to tear transversely from the end of one of the 
parallel cut lines 66, 67, the tear will meet an adjacent one of the 
parallel cut lines of the adjacent Z-shaped cut and be directed along the 
adjacent cut. Accordingly, the zipper scores 61, 62 remain strong enough 
to hold the carton together during shipment, and then tear away easily 
when the container is converted into a tray. Since the lines of the zipper 
scores 61, 62 are aligned with the grain of the paperboard, because of the 
construction of the zipper scores, the folding along the scores causes 
twisting of the paperboard fibers without tearing them. 
At the juncture between the top panel 12 and the end flap 32 of the 
automatic end closure, a conventional tear-away score 70 extends from the 
end of the zipper score 62 diagonally across the corner of the top panel 
12, creating a reinforcing connecting web 71. The connecting web 71 is 
left in place because in the automatic end closure, the end flaps 31 and 
32 are not glued together but are held in position by the interlocking of 
flaps 30 and 32. Thus, the connecting web 71 joins the interlocking 
automatic end closure to the front side wall 15, and maintains the 
structural integrity of the container when the top is torn away. 
At the end of the zipper score 62 opposite the connecting web 71, a short 
jump-cut score 72 runs diagonally across the corner of the top panel 12 so 
that the machining of the blank does not have to extend entirely into the 
corner. At this corner of the completed container, the end flaps 32 and 33 
are glued together. 
The transverse score line 21 defines another edge of the tear-away portion 
60. Because the tear-away portion is torn away along this score 21 after 
the zipper score lines 61, 62 have been torn, much better leverage is 
obtained in removing the tear-away portion and the score 21 does not need 
to tear away as easily as the zipper scores 61, 62. Accordingly, a fine 
jump-cut is preferable and gives adequate structural strength to the 
erected container. 
Still further defining the tear-away portion 60 is a panel 75 of the front 
side wall 15 which remains integrally connecated along the transverse 
score line 20 to the top panel 12. This panel 75 of the front panel 15, 
when removed, defines a substantially V-shaped opening which is relatively 
wide for accessing product in the container near the top panel, and a 
relatively narrow opening toward the bottom panel for inserting a finger 
to grasp the panel 75 for removal. 
In FIG. 1, the removed panel 75 of the front side wall 15 is defined by 
reverse-cut scorings 76, 77 placed in a V-shape in the front side wall 15. 
Those skilled in the art will understand that a reverse cut comprises a 
cut part way into the paperboard from opposite sides of the paperboard 
along parallel spaced-apart lines, whereby controlled delamination of the 
paperboard occurs when the panel is grasped and pulled outwardly. This 
type of tear-away scoring is used to provide strength prior to opening. 
At the end of the reverse cut tear-away scorings 76, 77, a pair of short, 
almost full cut tear-away scorings 78, 79 are provided to easily tear 
away. Intersecting full cuts 81, 82, and 83 at the narrow lower extreme of 
the panel 75 allow the surrounding paperboard to be pushed inwardly, 
permitting insertion of a finger to grasp the panel 75 for removal. 
It will now be appreciated that the tear-away portion 60 in the preferred 
embodiment extends between the zipper scores 61, 62 across the entire top 
panel 12, to both of the end closures of the erected container. 
Accordingly, there is provided convenient access to the product carried 
within the container and easy removal of the product from the open tray 
defined after removal of the tear-away portion 60, as illustrated in FIG. 
5. 
In order to assemble the container, the flaps of the automatic end closure 
are folded against the top, bottom and side walls in a conventional 
manner. The glue spots 35 are applied, and glue is applied to the glue 
flap 22. The bottom panel 14 is folded about transverse score line 19, and 
then the side wall 16 is folded about transverse score 21 to connect the 
bottom and side panels and to complete the automatic end closure. The 
container will then assume the flattened configuration shown in FIGS. 3 
and 4. Advantageously, the empty and flattened containers may be shipped 
to an intermediate user such as a product manufacturer for loading product 
in the container. 
When such a user desires to erect the container for loading product, 
pressure is simply applied inwardly to the folded scores, which will cause 
the end flaps 30-33 of the automatic end closure to slide past one another 
and lock themselves together in a well known manner. The erected 
configuration is illustrated in FIG. 2. Product can then be inserted into 
the container and the tuck flap 42 inserted between the edges 53, 54 of 
the dust flaps 45 and 46 to close the container. The filled containers may 
then be shipped carrying product without fear of premature separation 
along any of the perforated score lines. 
In order to remove product from the container for dispensing, especially 
for removing one of a stack of products carried in the container, the end 
user inserts a finger into the opening defined by the full cuts 81-83, 
grasps the panel 75 of the front side wall 15, and pulls outwardly. The 
panel 75 will delaminate along the reverse-scorings 76, 77 and the pair of 
almost-full cut scorings 78, 79. An upward continuing pull will separate 
the portion 60 across the conventional tear-away score 70, and along the 
zipper scores 61, 62. A transverse and upward pull along the transverse 
jump-cut score line 21 tears the tear-away portion away from the 
container, exposing the product carried in the container. The container 
then assumes an open tray as illustrated in FIG. 5. 
It will be seen that when the tear-away portion 60 has been removed, the 
structural integrity of the container is maintained by the connecting webs 
or dust flaps 45, 46, which maintain the end wall flap 46 connected to the 
front and rear side walls of the container and by the connecting web 71, 
which maintains the connection between the front side wall 15 and the 
automatic end closure 26. Thus, product can be kept in the open-top 
container tray and still be retained and protected by the walls of the 
container. 
While this invention has been described in detail with regard to a 
preferred embodiment thereof, it should be understood that variations and 
modifications can be made without departing from the spirit and scope of 
the invention as defined in the following claims.