CARTON, CARTON BLANK AND METHOD FOR FORMING THE CARTON

Abstract: A leakproof carton formed from a foldable carton blank (2) which has a first sheet of relatively flexible material (50) secured along its lower edge portion (56) to the top of the sidewall panel portions (14, 16, 18, 20) and the glue tab panel portion (22), a second sheet of relatively flexible material (60) secured along its upper edge portion (66) to the bottom of the sidewall panel portions (14, 16, 18, 20) and the glue tab panel portion (22). Either a continuous coating of a plastic material or a film of a relatively flexible plastic material may be secured to the inner surfaces of the first and second sheets and the portion of the sidewall panel and glue panel portions therebetween.

Description: CARTON. CARTON BLANK AND METHOD FOR FORMING THE CARTON This application is a continuation-in-part of United States Patent Application Serial No. 994,132 filed December 21, 1992 for Carton, Carton Blank And Method For Forming The Carton of Joseph Christopher Walsh. FIELD OF THE INVENTION This invention is directed generally to cartons and methods for forming the cartons from carton blanks and more particularly to a leakproof carton and a method for forming it from a carton blank. BACKGROUND OF THE INVENTION There are many supposedly leakproof cartons on the market today. These are formed using a variety of methods. Some of the cartons are designed to hold granular materials while others are designed to hold liquid materials. While some of these leakproof cartons have been successful, there is always a need for improvement. BRIEF DESCRIPTION OF THE INVENTION This invention provides a leakproof carton formed from a carton blank on which is secure two relatively small sheets of a relatively flexible material with one portion of each sheet secured to portions of the carton blank to form a leakproof seal and other portions of each sheet forming a leakproof bottom closure and a leakproof top closure. In a preferred embodiment of the invention, the carton blank comprises a unitary sheet of relatively rigid material having an inner surface, an outer surface a left side edge, a right side edge, a top edge and a bottom edge, with the left and right side edges being perpendicular to the top and bottom edges. The unitary sheet of relatively rigid material has a plurality of cut and fold lines for dividing the unitary sheet of relatively rigid material into a plurality of sidewall panel portions, a glue tab panel portion, and top and bottom panel portions extending outwardly from said sidewall panel portions. A first sheet of relatively flexible material is superposed over the inner surface of the top panel portions and portions of said sidewall panel portions adjacent to the fold lines between them and the top panel portions and a portion of the inner surface of the glue tab panel portion. Securing means extending continuously between said right side edge and said left side edge, are -provided for sealing and securing a portion of the first sheet of relatively flexible material to the inner surface of the portions of said sidewall panel portions adjacent to the fold lines between them and the top panel portions and to the portion of the glue tab panel portion. A second sheet of relatively flexible material is superposed over the inner surface of the bottom panel portions, and other portions of the sidewall panel portions adjacent to the fold lines between them and the bottom panel portion and another portion of the inner surface of the glue tab panel portion. Securing means, extending continuously between said right side edge and said left side edge, are provided for sealing and securing a portion of the second sheet of relatively flexible material to the inner surface of the other portions of the sidewall panel portions adjacent to the fold lines between them and to the another portion of the glue tab panel portion. The first sheet of a relatively flexible material has an upper edge, a central body portion and a lower edge and the first securing means secure portions of the central body portion adjacent to the lower edge to the portions of the sidewall panel portions and the portion of the glue tab panel portion. The second sheet of a relatively flexible material has an upper edge, a central body portion and a lower edge and the second securing means secure portions of the central body portion adjacent to the upper edge to the other portions of the sidewall portions and the another portion of the glue tab panel portion. The first and second sheets of relatively flexible material and at least the exposed portions of the inner surface are fluid impervious . The first and second sheets of relatively flexible material have surfaces formed from a plastic material. In one embodiment of the invention, the plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portions and the glue tab panel portion extends outwardly form one of the left side and right side panel portions. A carton is formed from the above described carton blank by folding the sidewall panel portions and the glue tab panel portion around the fold lines therebetween securing the glue tab panel portion to one of the . sidewall panel portions sealing together the facing surface of the second sheet of relatively flexible material folding the bottom panel portions into superposed relationship and securing them together filling the carton with a desired material sealing facing together the surfaces of the first sheet of relatively flexible material and folding the top panel portions into superposed relationship and securing them together to form a leakproof carton. In one embodiment of the invention, the plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion, and the glue tab panel portion is secured to one of said front and back panel portions. The method further comprises securing the portions of said first and second sheets of relatively flexible material extending downwardly and upwardly from said glue tab panel portion to portions of the first and second sheets of relatively flexible material extending downwardly and upwardly from said one of said front and back panel portions. In another preferred embodiment of the invention, the carton blank is the same as that described above except for the location of the first and second sheets of a relatively flexible material. The first sheet of a relatively flexible material has an upper edge, a central body portion and a lower edge; and the first securing means secure portions of the central body portion adjacent to the upper edge to the portions of the sidewall panel portions and the portion of the glue tab panel portion. The second sheet of a relatively flexible material has an upper edge, a central body portion and a lower edge and the second securing means secure portions of the central body portion adjacent to the lower edge to the other portions of the sidewall panel portions and the other portion of the glue tab panel portion. The method of forming a carton from the another preferred carton blank comprises folding the remaining portion of the central body portion of the first sheet of relatively flexible material over the first securing means until the remaining portion is in superposed relationship over the first securing means, the top panel portions and the portion of the glue tab portion folding the remaining portion of the second sheet of relatively flexible material over the second securing means portion thereof until the remaining portion is in superposed relationship over the second securing means, the bottom panel portions and the another portion of the glue tab panel portion folding the sidewall panel portions and the glue tab panel portion around the fold . lines therebetween securing the glue tab panel portion to one of the sidewall panel portions sealing together the lowermost portion of the facing surfaces of the second sheet of relatively flexible material folding said bottom panel portions into superposed relationship and securing them together filling the carton with a desired material sealing together the uppermost portions of the facing surface of the first sheet of relatively flexible material and folding the top panel portions into superposed relationship and securing them together to form a leakproof carton. In another preferred embodiment of the invention, the carton blank is the same as that described above except for the location of the first and second sheets of a relatively flexible material. The first sheet of a relatively flexible material has an upper edge, a central body portion and a lower edge; and the first securing means secure portions of the central body portion adjacent to the upper edge to the portions of the sidewall panel portions and the portion of the glue tab panel portion. The second sheet of a relatively flexible material has an upper edge, a central body portion and a lower edge and the second securing means secure portions of the central body portion adjacent to the lower edge to the other portions of the sidewall panel portions and the other portion of the glue tab panel portion and glue tab panel portion is secured to one of said front and back panel portions. The method further comprises securing the portions of the first and second sheets of relatively flexible material extending downwardly and upwardly from the glue tab portion to portions of the first and second sheets of a relatively flexible material extending downwardly and upwardly from the one of the front and back panel portions. In another preferred embodiment of the invention, the carton blank comprises a unitary sheet of a relatively rigid material, such as paperboard, having an inner surface and an outer surface and a left side edge, a right side edge, a top edge and a bottom edge with the left and right side edges being perpendicular to the top and bottom edges. The unitary sheet of relatively rigid material has a plurality of cut and fold lines for dividing the unitary sheet of relatively rigid material into a plurality of sidewall panel portions, a glue tab panel portion, and top and bottom panel portions extending outwardly from the sidewall panel portions. A first strip, such as paper, of a relatively flexible material having an inner surface and an outer surface is superposed over the inner surface of the top panel portions and portions of the sidewall panel portions adjacent to but spaced from the fold lines between them and the top panel portions and a portion of the inner surface of said glue tab panel portion. A second strip, such as paper, of a relatively flexible material having an inner surface and an outer surface is superposed over the inner surface of the bottom panel portions, and other portions of the sidewall panel portions adjacent to the fold lines between them and the bottom panel portions and another portion of the inner surface of said glue tab panel portion. A continuous coating of a plastic material, such as polyethylene, covers the inner surfaces of the first and second strips of relatively flexible material and the remaining portions of the inner surfaces of the plurality of sidewall panel portions and the glue tab panel portion and holds the first and second strips of a relatively flexible material in the desired relationship with the unitary sheet of a relatively rigid material. The first strip of a relatively flexible material has an upper edge, a central body portion and a lower edge. If desired, first securing means are used to secure portions of the central body portion adjacent to the lower edge to the portions of the sidewall panel portions adjacent to but spaced from the fold lines between them and the top panel portions the portion of the glue tab panel portion. The second strip of a relatively flexible material has an upper edge, a central body portion and a lower edge. If desired, second securing means are used to secure portions of the central body portion adjacent to the upper edge to the portions of the sidewall portions adjacent to but spaced from the fold lines between them and the bottom panel portions and the another portion of said glue tab panel portion. In another preferred embodiment of the invention, the carton blank comprises a unitary sheet of a relatively rigid material, such as paperboard, having an inner surface and an outer surface and a left side edge, a right side edge, a top edge and a bottom edge with left and right side edges being perpendicular to the top and bottom edges. The unitary sheet of relatively rigid material has a plurality of cut and fold lines for dividing the unitary sheet of a relatively rigid material into a plurality of sidewall panel portions, a glue tab panel portion and top and bottom panel portions extending outwardly from the sidewall panel portions. A sheet of relatively flexible plastic material, such as polypropylene, is superposed over the inner surface of the unitary sheet of relatively rigid material . First securing means extend between the right side edge and the left side edge of the sheet of a relatively rigid material and secure a first portion of the sheet of a relatively flexible plastic material to the portions of the inner surfaces of the sidewall panel portions located between but spaced from the fold lines between them and the top and bottom panel portions and a first portion of the glue tab panel portion. A first sheet of a relatively flexible material, such as paper, is secured to a second portion of the sheet of relatively flexible plastic material and superposed over the top panel portions and the portions of the inner surfaces of the sidewall panel portions between the first portion of the sheet of relatively flexible material and the fold lines between them and said top panel portions and a second portion of said glue tab panel portion. A second sheet of a relatively flexible material, such as paper, is secured to a third portion of the sheet of a relatively flexible plastic material and superposed over the bottom panel portions and the portions of the inner surfaces of the sidewall panel portions between the first portion of the sheet of relatively flexible plastic material and the fold lines between them and the bottom panel portion and a third portion of the glue tab panel portion. In another preferred embodiment of the invention, the carton blank comprises a unitary sheet of a relatively rigid material, such as paperboard, having an inner surface and an outer surface and a left side edge, a right side edge, a top edge and a bottom edge. The unitary sheet of a relatively rigid material has a plurality of cut and fold lines for dividing the unitary sheet of a relatively rigid material into at least a plurality of sidewall panel portions, a glue tab panel portion and end panel portions. A unitary sheet of a relatively flexible material is superposed over and secured to the outer surfaces of the at least a plurality of the sidewall panel portions, the end panel portions and only a portion of the glue tab panel portion so that the remaining portion of the outer surface of said glue tab panel portion is exposed. The unitary sheet of a relatively rigid material and the unitary sheet of a relatively flexible material are non-compatible to the use of a water based adhesive. The relatively flexible material can be a plastic material or other material used to form the outer surfaces of the carton. A carton is formed from the carton blank described above by folding the sidewall panel portions around the fold lines securing the end panel portions together; filling said carton; and adhesively securing the exposed outer surface of the glue tab panel portion to a portion of the inner surface of one of the sidewall panel portions using a water based adhesive. In a preferred embodiment of the invention, the apparatus for forming a laminate of materials for use in forming carton blanks comprises a pair of laminating rolls having facing portions spaced a predetermined distance apart to form a nip therebetween. First feeding means are provided for feeding a continuous web of a relatively rigid material, such as paperboard, into the nip. Second feeding means are provided for feeding a plurality of continuous strips of a relatively flexible material, such as paper, in spaced apart superposed relationship over portions of the continuous web of relatively rigid material into the nip. Means are provided for applying a liquid plastic material, such as polyethylene, over exposed surfaces of the plurality of continuous strips of a relatively flexible material and the web of relatively rigid material as they enter the nip and also to form a pool of the liquid plastic material in the nip to ensure an even coating. Third feeding means are provided for feeding a continuous film of a relatively flexible plastic material into the nip so that one of the oppositely facing surfaces is in contact with the liquid plastic material to secure the continuous film of a relatively flexible plastic material to the exposed surfaces of the spaced apart continuous strips of relative flexible material and the exposed surface of the continuous web of relatively rigid material . In another preferred embodiment of the invention, the method for forming a laminate of materials for use in forming carton blanks using at least a pair of rotating laminating rolls comprises feeding a continuous web of a relatively rigid material into the nip between the rotating laminating rolls feeding a plurality of continuous strips of a relatively flexible material into the nip in spaced apart superposed relationship over portions of the continuous web of relatively rigid material and applying a liquid plastic material over the exposed surfaces of the plurality of continuous strips of a relatively flexible material and the continuous web of a relatively rigid material as they enter the nip, as described above, to provide a continuous surface of the plastic material and to hold the plurality of continuous strips of a relatively flexible material in superposed relationship to the portions of the desired continuous web of a relatively rigid material. In another preferred embodiment, the method further comprises feeding a continuous film of a relatively flexible plastic material having oppositely facing surfaces into the nip so that the one of the oppositely facing surfaces moves into contact with the liquid plastic material to secure the continuous film of a relatively flexible material to portions of the continuous web of a relatively rigid material and to the continuous strips of a relatively flexible material. In this embodiment, the method further comprises removing the continuous strips of relatively flexible material and the portions of the film of a relatively flexible material secured thereto from the laminate. BRIEF DESCRIPTION OF THE DRAWINGS Illustrative and presently preferred embodiments of the invention are shown in the accompanying drawings in which: Fig. 1 is a top plan view of the inside portion of a carton blank of a preferred embodiment of the invention; Fig. 2 is a perspective view of the carton blank of Fig. 1 slightly enlarged and folded so that desired materials may be placed therein; Fig. 3 is a perspective view of one closure for a sheet of relatively flexible material; Fig. 4 is a perspective view of another closure for the sheet of relatively flexible material; Fig. 5 is a top plan view of a carton blank of another preferred embodiment of the invention; Fig. 6 is a top plan view of the carton blank of Fig. 5 after initial operations have been performed thereon; Fig. 7 is a schematic illustration of a laminating process; Fig. 8 is a top plan view of a portion of a . preferred laminate being formed; Fig. 9 is a cross-sectional view taken on the line 9-9 of Fig. 8; Fig. 10 is a top plan view of a carton blank formed from the laminate of Fig. 8 as it moves through the formation of the cut and fold lines; Fig. 11 is a cross-sectional view taken on the line 11-11 of Fig. 10; Fig. 12 is a top plan view of a portion of another preferred laminate being formed; Fig. 13 is a cross-sectional view taken on the line 13-13 of Fig. 12; Fig. 14 is a top plan view of a carton blank formed from the laminate of Fig. 12 as it moves through the formation of the cut and fold lines; Fig. 15 is a cross-sectional view taken on the line 15-15 of Fig. 14; Fig. 16 is a perspective view of another carton of this invention; Fig. 17 is an end elevational view of Fig. 16; Fig. 18 is a top plan view of a portion of another preferred laminate being formed with the carton blanks to be formed therefrom illustrated in dashed lines; Fig. 19 is a cross-sectional view taken on the line 19-19 of Fig. 18; Fig. 20 is a top plan view of one of the carton blanks illustrated in Fig. 18; and Fig. 21 is a cross-sectional view taken on the line 21-21 of Fig. 20. DETAILED DESCRIPTION OF THE INVENTION In Fig. 1, there is illustrated the inner surface of a carton blank 2 of one preferred embodiment of the invention. The carton blank 2 has a left side edge 4, a right side edge 6, a top edge 8 and a bottom edge 10 with the left side and right side edges 4 and 6 being perpendicular to the top and bottom edges 8 and 10. A plurality of fold lines 12 divide the carton blank 2 into a back panel portion 14,- a right side panel portion 16, a front panel portion 18, a left side panel portion 20 and a glue tab panel portion 22. A plurality of fold lines 24 and a plurality of cut lines 26 divide carton blank 2 into a top back panel portion 28, top right side panel portion 30, top front panel portion 32, and top left side panel portion 34. A plurality of fold lines 36 and cut lines 38 divide the carton blank 2 into bottom back panel portion 40, bottom right side panel portion 42, bottom front panel portion 44 and bottom left side panel portion 46. It is understood that the carton blank illustrated in Figs. 1, 5 and 6 is for illustration purposes only and that this invention can be used with carton blanks of a variety of configurations. A first sheet 50 of a relatively flexible material having an upper edge 52 and a lower edge 54 overlies the top back 28, top right side 30, top front 32 and top left side 34 panel portions and portions of the back 14, right side 16, front 18, left side 20 and glue tab 22 panel portions. The portion 56 of the first sheet 50 of a relatively flexible material between the fold lines 24 and the lower edge 54 is secured to the underlying portions of the back 14, right side 16, front 18, left side 20 and glue tab 22 panel portions so as to form a continuous seal extending from the left side edge 4 to the right side edge 6. A second sheet 60 of a relatively flexible material having an upper edge 62 and a lower edge 64 overlies the bottom back 40, bottom right side 42, bottom front 44 and bottom left side 46 panel portions and portions of the back 14, right side 16, front 18, left side 20 and glue tab 22 panel portions. The portion 66 of the second sheet of a relatively flexible material between the fold lines 36 and the upper edge 62 is secured to the underlying portions of the back 14, right side 16, front 18, left side 20 and glue tab 22 panel portions so as to form a continuous seal extending from the left side edge 4 to the right side edge 6. The first 50 and second 60 sheets of a relatively flexible material are preferably formed from a paper material coated with a plastic material such as polyethylene such as that marketed by Eastman Kodak under the trade designation 808 P having a thickness between about 0.75 and 1.0 mils or other types of material having similar characteristics. The portions 56 and 66 are secured using adhesive or welding or other conventional sealing practices. The carton blank preferably comprises a unitary sheet of a composite laminate of layers of materials. The inside layer 9 preferably comprises a paperboard material such as 0.021 inch DKL (recycled) or other similar materials such as natural Kraft board. The outside layer comprises 0.75 mil polypropylene or other similar materials such as low density polyethylene which may be back printed to provide a desired appearance. Other thicknesses of the paperboard and plastic materials may be used. The method of forming the unitary sheet for forming the carton blank 2 is described in U.S. Patent No. 4,254,173 to Peer, Jr., which is hereby incorporated herein by reference thereto. If the carton is to be used for holding liquids the inside surface is coated with a suitable material such a polyethylene or other materials having similar characteristics. Also, a portion of the glue tab panel portion 22 is skived and hemmed in a conventional manner with polyethylene layer being folded over the exposed edge of the paperboard material . In Fig. 2, there is illustrated the outer surface 68 of a partially formed carton 70 from the carton blank 2 and has an open top end 72 so that it is ready for filling, the carton 70 is formed by folding the glue tab panel portion 22 around a fold line 12, then the left side panel portion 20 is folded around a fold line 12, the front panel portion is folded around a fold line 12, and then the right side panel portion 16 is folded around a fold line 12 until the glue tab panel portion 22 overlies a portion of the back panel portion 14. The glue tab panel portion 22 is then secured to the portion of the back panel portion 14 using any conventional sealing practice. At the same time, the portions 74 of the first 50 and second 60 sheets of relatively flexible material are secured to the portions 76 of the top back panel portion 28 and the bottom back panel portion 40. The second sheet 60 of relatively flexible material is then secured together in a conventional manner as described below. The bottom back panel portion 40 is folded around a fold line 36, the bottom left side 46 and bottom right side 42 panel portions are folded around fold lines 36 so that they are in superposed relationship to portions of the bottom panel portion 40 and the bottom front panel portion 44 is fold around a fold line 36 to a superposed relationship. The bottom panel portions 40, 42, 46 and 44 are then secured together using any conventional sealing practice. After the carton 70 has been filled, the carton is closed and sealed using conventional practices such as those illustrated in Figs. 3 and 4. In Fig. 3, the portions 78 and 80 are secured together, then folded over the line 82. The end flaps 84 and 86 are then folded over to form a leakproof carton. The top panel portions 28, 30 and 32 and 34 are then folded and secured together in the same manner as that described above in relation to the bottom panel portions 40, 42 44 and 46. In Fig. 4, a gable joint is used to seal the exposed portions of the first sheet 50 of the relatively flexible material. The portion of the first sheet 50 of a relatively flexible material above the left side panel portion is folded inwardly and secured together to form two end portions 88 and 90. The other end is formed in the same manner. The central portions 92 are secured together and they included the innermost portions of the end portions 88 and 90 to form a leakproof carton. In Figs. 5 and 6, there is illustrated another preferred embodiment of the invention. Since the carton 2 remains the same, it will be identified with the same reference numerals and the description remains the same. A first sheet 94 of a relatively flexible material having an upper edge 96 and a lower edge 98 overlies portions of the back panel portion 14, right side panel portion 16, front panel portion 18, left side panel portion 20 and glue tab panel portion 22. A section 100 of the first sheet 94 of a relatively flexible material is secure to these panel portions by any conventional practice to form a continuous seal extending between the right side edge 4 to the left side edge 6. A second sheet 102 of a relatively flexible material having an upper edge 104 and a lower edge 106 overlies other portions of the back panel portion 14, right side panel portion 16, front panel portion 18, left side panel portion 20 and glue tab panel portion 22. A section 108 of the first sheet 94 of a relatively flexible material is secured to these panel portions by any conventional practice to form a continuous seal extending between the right side edge 4 to the left side edge 6. The first step in forming a carton from the carton blank 2 of Fig. 5 is illustrated in Fig. 6. The lower edge 98 of the first sheet 94 of a relatively flexible material is moved toward the top edge 8 until it is contiguous to the top edge 8 and portions of the first sheet 94 of a relatively flexible material overlie the section 100 and the top back panel portion 28, the top right side panel portion 30, the top front panel portion 32 and the top left side panel portion 34 and is creased along the line 110 to hold it in place. The upper edge 104 of the second sheet 102 of a relatively flexible material is moved toward the bottom edge 10 until it is contiguous to the bottom edge 10 an portions of the second sheet 102 of a relatively flexible material overlie the section 108 and the bottom back panel portion 40, the bottom right side panel portion 42, the bottom front panel portion 44 and the bottom left side panel portion 46 and is creased along the line 112 to hold it in place. A carton 70 is formed, filled and sealed as described above in relation to Figs. 1-4. In Fig. 7, there is illustrated conventional laminating apparatus 120 used for forming the laminated products of this invention. The laminating apparatus comprises a pair of rotating rolls 122 and 124 having a nip portion 126. A continuous web 128 of a relatively rigid material, such as a paperboard described in United States Patent No. 4,254,173 dated March 31, 1981 and issued to Peer, Jr. which is incorporated herein by reference thereto is fed into the nip portion 126. At the same time, a plurality of continuous strips 130 of a relatively flexible material, such as a kraft paper, in spaced apart relationship are fed into the nip portion 126 to be in spaced apart superposed relationship on the continuous web 128. A liquid plastic material 132, such as polyethylene or other materials having similar characteristics, is sprayed into the nip portion 126 by a nozzle 134. A continuous film 136 of a relatively flexible plastic material, such as polypropylene or other materials having similar characteristics, having oppositely facing surfaces 138 and 140 is fed into the nip portion 126 so that the surface 138 moves into contact with the liquid plastic material 132. As the laminate passes through the nip portion 126, the surface 138 is secured to the continuous strips 130 of a relatively flexible material and the coated portion of the continuous web 128 of a relatively rigid material. The middle continuous strip 130 has a width twice the width of the end continuous strips 130 so that when forming the carton blanks, described below, the middle continuous strip will be cut in half. The laminate of Figs. 8 and 9 can be passed through further laminating apparatus to apply a conventional outer surface covering on the outer surface 142 of the continuous web 128 such as the reversed printed plastic film in the Peer, Jr. patent. After the formation of the laminate described above, the laminate is cut in half along the middle strip 130. Then, the end continuous strips 130 and the portions of the continuous film 136 of a relatively flexible plastic material are folded back upon themselves, as illustrated in Figs. 10 and 11 and passed through a conventional apparatus for forming cut lines and fold lines to produce a carton blank illustrated in Figs. 10 and 11. The carton blank 150 has a left side edge 152, a right side edge 154, a top edge 156 and a bottom edge 158 with the left side and right side edges 152 and 154 being perpendicular to the top and bottom edges 156 and 158. A plurality of fold lines 160 divide the carton blank 150 into a back panel portion 162, a left side panel portion 164, a front panel portion 166, a right side panel porion 168 and a glue tab panel portion 170. A plurality of fold lines 172 and a plurality of cut lines 174 divide the carton blank 150 into a top back panel portion 176, top left side panel portion 178, top front panel portion 180, and top right side panel portion 182.- A plurality of fold lines 184 and cut lines 186 divide the carton blank 150 into bottom back panel portion 188, bottom left side panel porion 190, bottom front panel portion 192 and bottom right side panel portion 194. It is understood that the carton blank illustrated in Figs. 10 and 11 is for illustration purposed only and that this invention can be used with carton blanks of a variety of configurations. The upper continuous strip 130 of Fig. 8 is folded over the fold line 196 and the half of the middle continuous strip 130 has been folded over the fold line 198. After the continuous strips 130 together with the portions of the film 136 secured thereto have been folded over, the laminate is passed through a conventional machine to form the cut and fold lines described above. Prior to forming a carton from the carton blank 150, the upper continuous strips 130 is folded back to overlie the top panel portions 176, 178, 180 and 182 and the portions 200, 202, 204 and 206 of the sidewall panel portions 162, 164, 166 and 168 and the portion 208 of the glue panel portion 170 and the lower continuous strip 130 is folded back to overlie the bottom panel portions 188, 190, 192 and 194 and the portions 210, 212, 214 and 216 of the sidewall panel portions 162, 164, 166 and 168 and the portion 218 of the glue panel portion 170. A carton is then formed and filled as described above in relation to_ Figs. 3 and 4. The inner surface of the carton will be the film 136 of the relatively flexible plastic material to form a leakproof carton. The laminate illustrated in Figs. 12 and 13 is formed using the apparatus of Fig. 7 but does not include the continuous film 136 of a relatively flexible plastic material. A continuous web 128 of a relatively rigid material, such as paperboard of the type in the Peer, Jr. patent, is fed into the nip 126 along with the plurality of continuous strips 130 of a relatively flexible material, such as paper, and a liquid plastic material, such as polyethylene, is fed into the nip 126 and as these materials pass through the nip 126 a continuous coating 230 of plastic is formed over the exposed surfaces of the continuous web 128 and the continuous strips 130. After the laminate of Figs. 12 and 13 is formed a surface coating or film may be applied to the outer surface 142 of the continuous web 128 as described above. Also, the laminate is cut in half along the middle continuous strip 130 and the continuous strips 130 are folded back as illustrated in Figs. 14 and 15 so that the cut and fold lines may be made. The continuous strips 130 are folded back, as described above, so that the cartons when formed as in Figs. 3 and 4 will have a continuous inner surface of a plastic coating 230. In some instances, it may be desirable to use a bead of adhesive to secure an edge portion of each continuous strip 130 to a portion of the continuous web 128. This can be done when the continuous strips 130 are superposed over portions of the continuous web 128 prior to entering the nip 126. In Figs. 16 and 17, there is illustrated a carton 240 having a plurality of sidewall panels 242, 244 and 246 and sealed together end panels 248. As illustrated in Figs. 16 and 17, the closure panel 250 and the glue tab panel 252 are in an opened condition so that packages 254 of cigarettes may be inserted therein. At the manufacture's plant for making cigarettes, after the packages 254 have been inserted, the closure panel 250 is temporarily sealed to the glue tab panel 252 and loaded into large boxes for shipment to distributing centers. During shipment the seal between the closure panel and the glue tab panel 252 breaks. This is done because at the distributing centers, it is necessary to apply the state and/or local tax stamps. After the tax stamps have been applied, the closure panel 250 is then permanently sealed to the glue tab panel 252. Since there are so many distributing centers, it is common for them to use conventional apparatus to apply a water base adhesive to secure the closure panel 250 to the glue tab panel 252. When a carton is formed from a composite material such as in the Peer, Jr. patent, glue tab panel 252 has a plastic surface facing the paperboard surface of the closure panel 250. Therefore, a water based adhesive will not be compatible to these surfaces so that a permanent seal cannot be made. Other surface materials may also result in non-compatible surfaces. In Figs. 18 and 19, there is illustrated a laminate from which a carton blank can be formed to have a desired reverse printed plastic film as an outer surface and still have compatible paperboard to paperboard surfaces on the closure panel 250 and the glue tab panel 252. The laminate of Figs. 18 and 19 is formed using the apparatus in Fig. 7. A continuous web 128 of a relatively rigid material, such as paperboard is fed into the nip 126,and two continuous strips 130 of a relatively flexible material, such as paper, are superposed over portions of the continuous web 128 so that the liquid plastic material 132 contacts only the exposed surfaces of the continuous web 128 and the continuous strips 130. A reverse printed plastic film, such as that illustrated in Fig. 7 as 136, is fed into the nip 126 from the other side so that it can be coated by the liquid plastic material 132. After this, the laminate is passed through apparatus, such as a vacuum roll, where the continuous strips 130 with the portion of the plastic film 136 adhered thereto are pulled away from the laminate to leave a portion 256 of the continuous web 250 exposed. The lower continuous strip 130 has a width that is one- half the width of the upper continuous strip 130. When the carton blank 258 of Figs. 20 and 21 is folded around the fold lines, the portion 256 will face the portion 260 of the continuous web 260 so that a water based adhesive may be used to form a permanent seal between these compatible surfaces. The carton blanks 258 are ' illustrated in Fig. 18 only to show that the glue tab panel portion 252 extend in the machine direction. The thickness of the various materials such as the continuous web 128, the plastic adhesive or coating 132 or 230, the continuous strip 130 and the plastic film have been exaggerated for illustration purposes. The continuous web 128, the plastic adhesive or coating 132 or 230 and the plastic film would be similar to the corresponding materials in the Peer, Jr. patent. The continuous strips 130 may comprise a kraft paper having a thickness of between about 0.75 and 1.0 mils or other types of materials having similar characteristics. While illustrative and presently preferred embodiments of the invention have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.

Claims: IN THE CLAIMS : 1. A carton blank comprising: a unitary sheet of a relatively rigid material having an inner surface and an outer surface; said unitary sheet of a material having a left side edge, a right side edge, a top edge and a bottom edge; said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of relatively rigid material into a plurality of sidewall panel portions, a glue tab panel portion, and top and bottom panel portions extending outwardly from said sidewall panel portions; a first sheet of a relatively flexible material having an inner surface and an outer surface superposed over said inner surface of said top panel portions and portions of said sidewall panel portions adjacent to but spaced from said fold lines between them and said top panel portions and a portion of said inner surface of said glue tab panel portion; a second sheet of a relatively flexible material having an inner surface and an outer surface superposed over said inner surface of said bottom panel portions, and other portions of said sidewall panel portions adjacent to but spaced from said fold lines between them and said bottom panel portion and another portion of said inner surface of said glue tab panel portion; and a continuous coating of a plastic material covering said inner surfaces of said first and second sheets of relatively flexible material and the remaining portions of said inner surfaces of said plurality of sidewall panel portions and said glue tab panel portion. 2. A carton blank as in claim 1 wherein: said coated first and second sheets of relatively flexible material and said remaining portions of said inner surfaces of said plurality of sidewall panel portion and said glue tab panel portion are fluid impervious. 3. A carton blank as in claim 1 wherein: said plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion; and said glue tab panel portion extends outwardly from one of said left side and right side panel portions. 4. A carton blank as in claim 3 wherein: said relatively rigid material is paperboard; and said relatively flexible material is paper. 5. A carton blank comprising: a unitary sheet of a relatively rigid material having an inner surface and an outer surface; said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge; said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of relatively rigid material into a plurality of sidewall panel portions, a glue tab panel portion and top and bottom panel portions extending outwardly from said sidewall panel portions; a sheet of a relatively flexible plastic material superposed over said inner surface of said unitary sheet of relatively rigid material; first securing means extending between said right side edge and said left side edge for securing a first portion of said sheet of a relatively flexible plastic material to the portions of said inner surfaces of said sidewall panel portions located between but spaced from said fold lines between them and said top and bottom panel portions and a first portion of said glue tab panel portion; a first sheet of a relatively flexible material secured to a second portion of said sheet of relatively flexible plastic material and superposed over said top panel portions and the portions of said inner surfaces of said sidewall panel portions between said first portion of said sheet of relatively flexible material and said fold lines between them and said top panel portions and a second portion of said glue tab panel portion; and a second sheet of a relatively flexible material secured to a third portion of said sheet of a relatively flexible plastic material and superposed over said bottom panel portions and the portions of said inner surfaces of said sidewall panel portions between said first portion of said sheet of relatively flexible plastic material and said fold lines between them and said bottom panel portion and a third portion of said glue tab panel portion. 6. A carton blank as in claim 5 wherein: said sheet of a relatively flexible plastic material is fluid impervious. 7. A carton blank as in claim 5 wherein: said first and second sheets of a relatively flexible material are not secured to said sheet of relatively rigid material. 8. A carton blank as in claim 7 wherein: said first and second sheets of a relatively flexible material comprising paper; and said sheet of a relatively rigid material comprising paperboard. 9. A carton blank as in claim 5 wherein: said plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion; and said glue tab portion extends outwardly from one of said left side and right side panel portions. 10. A carton blank comprising: a unitary sheet of a relatively rigid material having an inner surface and an outer surface; said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge; said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of a relatively rigid material into at least a plurality of sidewall panels, a closure panel, a glue tab panel and end panels; and a unitary sheet of a relatively flexible material superposed over and secured to said outer surfaces of said at least a plurality of said sidewall panels, said closure panel, said end panels and only a portion of said glue tab panel so that the remaining portion of said outer surface of said glue tab panel portion is exposed. 11. A carton blank as in claim 10 wherein: said unitary sheet of a relatively rigid material comprising paperboard; and said unitary sheet of a relatively flexible material comprising a, plastic material. 12. A carton blank as in claim 10 wherein: said unitary sheet of a relatively rigid material and said unitary sheet of a relatively flexible material are non-compatible to a water based adhesive. 13. A filled carton formed from the carton blank of claim 10 comprising: folding said sidewall panel portions around said fold lines; securing said end panel portions together; filling said carton; and adhesively securing said exposed outer surface of said glue tab panel portion to a portion of said inner surface of said closure panel . 14. A filled carton as in claim 13 wherein: said adhesive is a water based adhesive. 15. A method of forming a filled carton from said carton blank of claim 1 comprising: folding said sidewall panel portions and said glue tab panel portion around said fold lines therebetween; securing said glue tab panel portion to one of said sidewall panel portions; sealing together the lowermost portion of the facing surfaces of said second sheet of relatively flexible material; folding said bottom panel portions into superposed relationship and securing them together; . filling said carton with a desired material; sealing together the uppermost portions of the facing surfaces of said first sheet of relatively flexible material; and folding said top panel portions into superposed relationship and securing them together to form a leakproof carton. 16. A method as in claim 15 wherein: said plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion; and securing said glue tab panel portion to one of said front and back panel portions . 17. A method of forming a carton from said carton blank of claim 5 comprising: folding said sidewall panel portions and said glue tab panel portion around said fold lines therebetween; securing said glue tab panel portion to one of said sidewall panel portions; sealing together the lowermost portion of the facing surfaces of said second sheet of relatively flexible material; folding said bottom panel portions into superposed relationship and securing them together; . filling said carton with a desired material; sealing together the uppermost portions of the facing surface of said first sheet of relatively flexible material; and folding said top panel portions into superposed relationship and securing them together to form a leakproof carton. 18. A method as in claim 17 wherein: said plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion; and said glue tab panel portion is secured to one of said front and back panel portions. 19. Apparatus for forming a laminate of materials for use in forming carton blanks comprising: a pair of rolls having facing portions spaced a predetermined distance apart to form a nip therebetween; first feeding means for feeding a continuous web of a relatively rigid material into said nip; second feeding means for feeding a plurality of continuous strips of a relatively flexible material in spaced apart superposed relationship over portions of said continuous web of relatively rigid material into said nip; and coating means for applying a plastic coating material over exposed surfaces of said plurality of continuous strips of a relatively flexible material and said web of relatively rigid material as they pass through said nip. 20. Apparatus as in claim 19 wherein: said continuous strips of a relatively flexible material comprising paper; and said web of relatively rigid material comprising paperboard. 21. Apparatus as in claim 19 and further comprising: third feeding means for feeding a continuous film of a relatively flexible plastic material into said nip so that one of said oppositely facing surfaces is in contact with said coating of said plastic material to secure said continuous film of a relatively flexible plastic material to said exposed surfaces of said spaced apart continuous strips of relative flexible material and said exposed surface of said continuous web of relatively rigid material. 22. Apparatus as in claim 21 wherein: said continuous strips of a relatively flexible material comprising paper; said continuous web of a relatively rigid material comprising paperboard. 23. A method for forming a laminate of materials for use in forming carton blanks using at least a pair of rotating laminating rolls comprising: feeding a continuous web of a relatively rigid material into the nip between said rotating laminating rolls; feeding a plurality of continuous strips of a relati vely flexible material into said nip in spaced apart superposed relationship over portions of said continuous web of relatively rigid material; and applying a liquid plastic material over the exposed surfaces of said plurality of continuous strips of a relatively flexible material and said continuous web of a relatively rigid material in said nip to provide a continuous surface of said plastic material and to hold said plurality of continuous strips of a relatively flexible material in superposed relationship to said portions of said continuous web of a relatively rigid material. 24. A method as in claim 23 and further comprising: using paper as said continuous strips of a relatively flexible material; and using paperboard as said continuous web of a relatively rigid material. 25. A method as in claim 23 and further comprising: feeding a continuous film of a relatively flexible plastic material having oppositely facing surfaces into said nip so that the one of said oppositely facing surfaces moves into contact with said liquid plastic material to secure said continuous film of a relatively flexible material to portions of said continuous web of a relatively rigid material and to said continuous strips of a relatively flexible material. 26. A method as in claim 25 and further comprising: removing said continuous strips of said a relatively flexible material and said portions of said film of a relatively flexible material secured thereto from the laminate . 27. A carton blank comprising: a first layer comprising a unitary sheet of a relatively rigid material having an inner surface and an outer surface; said unitary sheet having at least a left side edge, a right side edge, a top edge and a bottom edge; said unitary sheet having a plurality of cut and fold lines for dividing said unitary sheet into at least a plurality of sidewall panel portions, a glue tab panel portion and top and bottom panel portions extending from said sidewall panel portions; a second layer comprising a fluid impervious material having portions secured to portions of said inner surface; and at least one sheet of a relatively flexible material located between portions of said first and second layers and being secured to said portion of said second layer and not secured to said portion of said first layer. 28. A carton blank comprising: a unitary sheet of a relatively rigid material having an inner surface and an outer surface; said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge, said left and right side edges being perpendicular to said top and bottom edges; said unitary sheet of relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of relatively rigid material into a plurality of sidewall panel portions, a glue tab panel portion and top and bottom panel portions extending outwardly from each of said sidewall panel portions; a first sheet of relatively flexible material superposed only over portions of said inner surface of said sidewall panel portions and a portion of said inner surface of said glue tab panel portion; first securing means extending continuously between said right side edge and said left side edge for sealing and securing a portion of said first sheet of relatively flexible material to portions of said inner surface of said sidewall panel portions adjacent to said fold lines between said sidewall panel portions and said top panel portions and to said portion of said glue tab panel portion and leaving a remaining portion unsecured; a second sheet of relatively flexible material superposed only over other portions of said inner surface of said sidewall panel portions and another portion of said inner surface of said glue tab panel portion; and second securing means extending continuously between said right side edge and said left side edge for sealing and securing a portion of said second sheet of relatively flexible material to said inner surface of said sidewall panel portions adjacent to said fold lines between said sidewall panel portions and said bottom panel portions and to said another portion of said glue tab panel portion and leaving a remaining portion unsecured. 29. A carton blank as in claim 28 wherein: said first and second sheets of relatively flexible material and at least the surfaces of said inner surface between said first and second securing means are fluid impervious . 30. A carton blank as in claim 28 wherein: said first sheet of a relatively flexible material having an upper edge, a central body portion and a lower edge; said first securing means securing portions of said central body portion adjacent to said upper edge to said portions of said sidewall panel portions and said portion of said glue tab panel portion; said second sheet of a relatively flexible material having an upper edge, a central body portion and a lower edge; and said second securing means securing portions of said central body portion adjacent to said lower edge to said other portions of said sidewall panel portions and said another portion of said glue tab panel portions. 31. A carton blank as in claim 28 wherein: said plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion; and said glue tab portion extends outwardly from one of said left side and right side panel portions. 32. A method of forming a carton from a carton blank having the structures defined in claim 28 comprising: folding the remaining portion of said first sheet of relatively flexible material over said first securing means until said remaining portion is in superposed relationship over said first securing means, said top panel portions and said portion of said glue tab portion; folding the remaining portion of said second sheet of relatively flexible material over said second securing means until said remaining portion is in superposed relationship over said second securing means, said bottom panel portions and said another portion of said glue tab panel portion; folding said sidewall panel portions and said glue tab panel portion around said fold lines therebetween so that said remaining portions of said first and second sheets of relatively flexible material have inner surfaces; securing said glue tab panel portion to one of said sidewall panel portions; sealing together portions of said inner surfaces of said second sheet of relatively flexible material; folding said bottom panel portions into superposed relationship and securing said bottom panel portions together; filling said carton with a desired material; sealing together portions of said inner surfaces of said first sheet of relatively flexible material; and folding said top panel portions into superposed relationship and securing said top panel portions together to form a leakproof carton. 33. A method as in claim 32 wherein: said plurality of sidewall panel portions comprise a back panel portion, a right side panel portion, a front panel portion and a left side panel portion; and securing said glue tab panel portion to one of said front and back panel portions.

Inventors: CONATSER ROBERT L, WALSH JOSEPH CHRISTOPHER, CONATSER, ROBERT, L., WALSH, JOSEPH, CHRISTOPHER
Applicants: GRAPHIC PACKAGING CORP, GRAPHIC PACKAGING CORPORATION
Application year: 1993
Main classification: B65D5
IPC codes: B31B7, B65D5