UNITARY BODY-LID CARTON BLANK

Abstract: A unitary carton blank (1) is constructed with the body (2) and lid (3) portions of the blank (1) removably connected to each other in a single manufacturing operation.

Description: UNITARY BODY-LID CARTON BLANK BACKGROUND OF THE INVENTION Carton blanks constructed of a series of connected foldable panels are available for consumer assembly of a carton. Prior art constructions are typically made with one blank for producing the body portion of the carton and a separate blank for producing the lid. Manufacture of separate blanks for the body and lid portions of the carton requires two separate manufacturing processes with the inherent labor costs. With the current separate body and lid components, custom width liner specifications are necessary for the manufacturing of the corrugated sheets, typically used to form the carton blanks. Also, with separate blanks for the body and lid portions of the carton, carton blanks received from the manufacturer are seldom the exact amount ordered of each blank. Specifications usually call for a specified quantity plus 5% and minus 0%. The mismatch of body and lid components resulting from a variance in ordered quantities is frequently encountered. The prior art does disclose a foldable blank for constructing a carton using an insertable divider or partition, formed as a detachable part of the blank. See, for example, U.S. patent 4,396,115. Nevertheless, the prior art fails to disclose or teach a unitary carton blank comprised of a body portion and a lid portion detachably connected to the body portion and further configured for printing, folding and packaging as a compact single unit. SUMMARY OF THE INVENTION In accordance with the present invention, the unitary carton blank is constructed with the body and lid portions of the blank removably connected to each other in a single manufacturing operation. The single blank structure allows the body and the lid to be die-cut, printed, glued and packaged as one unit, thus reducing manufacturing time and thereby increasing output production. The ability to produce more product in the same amount of time creates opportunities to decreased finished goods inventory. Due to the construction of the carton blank of the present invention, standardized raw liner specifications for the corrugated supplier are possible. The standard size minimizes the supplier's exposure to raw materials and maximizes the supplier's production capacity. Elimination of the separate lid reduces material handling and receiving, administration, and system requirements for maintaining inventory records for separate body and lid blanks. Further, mismatch of components respecting quantities of separate bodies and lids is eliminated. With the construction of the unitary carton blank of the present invention, the body portion of the blank can be folded into a collapsed carton blank with the lid overlying and fully contained within the parameters of the body portion of the blank. This provides a neat unit readily adapted for packaging in groups of stacked blanks. Also, in accordance with another feature of the present invention, the body and lid portions of the blank are configured whereby the lid is provided with double edge panels for reinforcing the single wall panels of the body of the erected carton. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a plan view of the carton blank of the present invention; Fig. 2 is a plan view of a double blank assembly in accordance with the invention, as shown in Fig. 1; Fig. 3 is a plan view, partially broken away to show overlapping panel sections, of the folded collapsed carton blank of Fig. 1; Fig. 4 is a plan view of a modified embodiment of the carton blank of the invention; and Fig. 5 is a plan view, partially broken away to show overlapping panel sections, of the folded collapsed carton blank of Fig. 4. DETAILED DESCRIPTION OF THE INVENTION The carton blank of the present invention is constructed of corrugated fiberboard. The blank 1 is shown in Fig. 1 as comprised of a plurality of panel sections foldably connected together. A first plurality of panel sections defines the body 2 of the carton blank and a second plurality of panel sections defines the lid 3 of the carton blank. The body includes a bottom panel section defined by two bottom panels 4 and 5, a pair of side panel sections defined by two side panels 6 and 7, and a pair of end panel sections defined by four end panels 8, 9, 10 and 11. The side panel 6 also includes a flap panel 6'. The lid, on the other hand, includes a top panel section, defined by the single top panel 12, a pair of side edge panel sections, defined by a left side edge panel 13 and a right side edge panel 14, and a pair of end edge panel sections, defined by the end edge panels 15, 16, 17 and 18. As shown in Fig. 2, the die cutting and scoring equipment used for producing the carton blank originally forms two carton blanks of identical shape and dimensions. This structure is cut horizontally along the line 19 to form two identical carton blanks, constructed as shown in Fig. 1. For purposes of description, each of the panels of the carton blank, as viewed in Figs. 1, 2 and 4, includes a top edge, a bottom edge, a left side edge and a right side edge. With reference to the embodiment of Fig. 1, the side panel 6 has the left edge of the end panel 8 foldably connected to its right side edge. Also, the bottom edge of the bottom panel 4 is foldably connected to the top edge of the side panel 6. The end panel 8 has the left side edge of the other side panel 7 foldably connected to its right side edge. The other side panel 7 has its top edge foldably connected to the bottom edge of the bottom panel 5 and the left side edge of a second end panel 9 foldably connected to its right side edge. The bottom panel 5 has a third end panel 10 foldably connected to its left side edge and a fourth end panel 11 foldably to its right side edge. The bottom edge of each of these end panels 10 and 11 are removably connected to the top edge of the end panels 8 and 9, respectively. This connection is by way of perforations and is broken by the consumer when assembling the carton, as is well known. The lid 3 is removably connected to the right side edge of the end panel 9. This connection is also by perforations so that the lid 3 can be removed from the body 2 to permit separate assembly of the body and the lid into their final carton configuration. In the embodiment shown in Fig. 1, the lid 3 has its side edge panel 13 connected to the right side edge of the end panel 9. This side edge panel 13 and the opposite edge panel 14 each include the conventional end tabs 13 ' , 14 ' which are folded toward each other and interlocked with the end edge panels 15, 16 and 17, 18 during assembly of the lid, as is customary. As further shown in Fig. 1, the lid and body have the same dimension as measured from a straight line drawn through the bottom edge of any of the side and end panels 6-9 to a straight line drawn through the top edge of any of the bottom and end panels 4, 5, 10 and 11. Also, for reasons explained below, the dimension of the lid as measured across the top panel 12 and two side edge panels 13 , 14 is slightly less than the width of either of the side panels 6 and 7, as measured from their left side edge to their right side edge. In a preferred embodiment of the invention, the blank has an overall height of 22 3/16 inches, with the panel 6 having a height of 10 inches and the panel 4 a height of 12 3/16. Also, the panels have the following width dimensions: Panel Width (in) 6 15 3/8 7 15 3/8 8 12 1/8 9 12 1/16 12 12 7/16 13 1 3/8 14 1 3/8 Fig. 3 shows the carton blank in a folded collapsed state. This is the state in which the blank is packaged in a stack with a number of other blanks and the state in which the customer receives the blank. As shown in Fig. 3, the panels 4 and 6 of the blank have been folded 180° along a first fold line extending along the left side edge of the end panel 8, to a position underneath the remaining panels of the body 2. The blank is also folded 180° along a second fold line extending along the right side edge of the other side panel 7 to bring the end panel 9 into overlapping relationship with the flap panel 6 ' . This overlapping relationship is along the right side edge of the end panel 9. By the use of suitable adhesive, the flap 6' is secured to the right side edge of the end panel 9. As shown in Fig. 3, the folded collapsed body of the panel defines a predetermined surface area by way of the panels 5, 7, 8 and 10. In accordance with the teachings of the present invention, the lid overlies the body and fits within this surface area. In Fig. 3, the upper left hand corner of the figure has been broken away to show the location of the lid 3 and its containment within the surface area of the body panels. This is accomplished by having the distance between the left side edge of the end panel 9 of the body 2 and the right side edge of the right side edge panel 14 of the lid slightly less than the distance between the first and second fold lines. The containment of the lid is further facilitated by having the dimension of a lid, as measured across the top panel 10 and the two side edge panels 13 and 14 slightly less than the width of the side panel 6. With the embodiment of the carton blank shown in Figs. 1-3, those skilled in the art will readily understand the assembly steps for the carton body and lid. The body, as assembled, will have a double bottom, comprised of the bottom panels 4 and 5, and double end walls 8, 10 and 9, 11. The assembled lid is adapted to be placed over the open end of the body with the top panel 12 over the open end and the side edge panels 13 and 14 engaging the side panels 6 and 7 of the body and the double end edge panels 15, 16 and 17, 18 of the lid engaging with the double end panels 8, 10, 9, 11 of the body. Figs. 4 and 5 show an alternative embodiment of the present invention. In these figures, the same reference numbers followed by the prime sign are used for designating the same panels as in the embodiment of Figs. 1-3. With the embodiment of Figs. 4 and 5, the lid and the body are dimensioned whereby the double walled end edge panels 15 ' , 16 ' and 17 ' , 18 ' , when placed over the open end of the assembled body will engage with the side panels 6 ' , 7 ' . This, in turn, will reinforce the top edges of these side panels which are of single thickness.

Claims: CLAIMS 1. A unitary carton blank comprising: a) an open ended body including a plurality of first panel sections foldably connected together for forming said body, said first panel sections including: i) a bottom panel section, ii) a pair of side panel sections, and iii) a pair of end panel sections; and b) a lid including a plurality of second panel sections foldably connected together for forming said lid and removably connected to one of said first panel sections and dimensioned for placement on the open end of said body, said second panel sections including: i) a top panel section for placement over the open end of said body, ii) a pair of side edge panel sections for engagement with the side panel sections of said body, and iii) a pair of end edge panel sections for engagement with the end panel sections of said body. 2. A unitary carton blank according to claim 1 wherein: a) the first panel sections further include a flap panel section foldably connected to one of said side and end panel sections for gluing to the other of said side and end panel sections to form a folded collapsed body of a predetermined surface area; and b) said lid overlies said body and fits within said surface area when said flap panel is glued to the other of said side and end panel sections. 3. A unitary carton blank according to claim 2 wherein: a) said bottom panel section includes at least one bottom panel; b) each of said pair of side panel section is defined by a single side panel; c) each of said pair of end panel sections includes two end panels; d) each of said panels includes a top edge, a bottom edge, a left side edge and a right side edge; e) one of said side panels includes a flap panel foldably connected to the left side edge thereof and has the left side edge of one of said end panels foldably connected to the right side edge thereof; f) said one end panel has the left side edge of the other of said side panels foldably connected to the right side edge thereof; g) said other of said side panels has its top edge foldably connected to the bottom edge of said bottom panel and the left side edge of a second end panel foldably connected to the right side edge thereof; h) said bottom panel has a third and fourth end panel foldably connected, respectively, to the left side edge and right side edge thereof; and i) said lid is removably connected to the right side edge of said second end panel. 4. A unitary carton blank according to claim 3 wherein: a) said lid is connected to the right side edge of said second end panel by a line of perforations. 5. A unitary carton blank according to claim 4 wherein: a) said carton blank is folded 180° along a first fold line extending along the left side edge of said one end panel and is folded 180° along a second fold line extending along the right side edge of the other side panel to bring said flap panel and said second end panel into overlying relationship along the right side edge of said second end panel; b) said flap panel is adhesively attached to said second end panel in said overlying relationship; c) each of said side panels together with said bottom panel has a first dimension as measured between the bottom edge of said other side panel and the top edge of said bottom panel; d) the lid has a second dimension as measured across said top panel section and said pair of end edge panel sections which is no greater than said first dimension; e) each of said side panels has a third dimension as measured between its left and right side edges thereof ; f) the lid has a fourth dimension as measured across said top panel section and said pair of side edge panel sections which is no greater than said third dimension; and g) said lid is removably connected to the right side edge of said second end panel along part of one of said side edge panel sections of said lid, and is disposed in overlying relationship with said one side panel with said end edge panel sections of said lid disposed no lower than a straight line drawn through the bottom edge of said one side panel and no higher than a straight line drawn through the top edge of said bottom panel. 6. A unitary carton blank according to claim 5 wherein: a) said second dimension is about equal to said first dimension; b) said fourth dimension is about equal to said third dimension. 7. A unitary carton blank according to claim 3 wherein: a) said carton blank is folded 180° along a first fold line extending along the left side edge of said one end panel and is folded 180° along a second fold line extending along the right side edge of the other of said side panels to bring said flap panel and said second end panel into overlying relationship along the right side edge of said second end panel; b) said flap panel is adhesively attached to said second end panel in said overlying relationship; c) the side edge panel sections of said lid include a left side edge panel and a right side edge panel, each having a left side edge and a right side edge; d) a part of said left side edge of the left side edge panel of said lid is connected to the right side edge of said second end panel of said body by a line of perforations; e) each of said side panels of said body together with said bottom panel has a first dimension as measured between the bottom edge of said other side panel and the top edge of said bottom panel; f) the lid has a second dimension as measured across said top panel section and said pair of end edge panel sections which is no greater than said first dimension; g) the distance between the left side edge of said second end panel of said body and the right side edge of said right side edge panel of the lid is no greater than the distance between said first and second fold lines. 8. A unitary carton blank according to claim 1 wherein: a) each of said pair of side panel sections of said body is defined by a single side panel; b) each of said pair of end panel sections of said body includes two end panels; c) each of said pair of side edge panel sections of said lid includes two side edge panels; and d) each of said pair of end edge panels sections of said lid is defined by a single end edge panel. 9. A unitary carton blank according to claim 8 wherein: a) said bottom panel section includes at least one bottom panel; b) each of said panels includes a top edge, a bottom edge, a left side edge and a right side edge; c) one of said side panels includes a flap foldably connected to the left side edge thereof and has the left side edge of one of said end panels foldably connected to the right side edge thereof; d) said one end panel has the left side edge of the other of said side panels foldably connected to the right side edge thereof; e) said other of said side panels has its top edge foldably connected to the bottom edge of said bottom panel and the left side edge of a second end panel foldably connected to the right side edge thereof; f) said bottom panel has a third and forth end panel foldably connected, respectively, to the left side edge and right side edge thereof, and g) said lid is removably connected to the right side edge of said second end panel by a line of perforations. 10. A unitary carton blank according to claim 9 wherein: a) said carton blank is folded 180° along a first fold line extending along the left side edge of said one end panel and is folded 180° along a second fold line extending along the right side edge of the other side panel to bring said flap panel and said second end panel into overlying relationship along the right side edge of said second end panel; b) said flap panel is adhesively attached to said second end panel in said overlying relationship; c) each of said side panels together with said bottom panel has a first dimension as measured between the bottom edge of said other side panel and the top edge of said bottom panel; d) the lid has a second dimension as measured across said top panel section and said pair of end edge panel sections which is no greater than said first dimension; e) said lid is removably connected to the right side edge of said second end panel along part of one of said side edge panel sections of said lid, and is disposed in overlying relationship with said one side panel with said end edge panel sections of said lid disposed no lower than a straight line drawn through the bottom edge of said one side panel and no higher than a straight line drawn through the top edge of said bottom panel.

Inventors: DVORAK JOHN, JUNGE SCOTT, DVORAK, JOHN, JUNGE, SCOTT
Applicants: ACCO BRANDS INC, ACCO BRANDS, INC.
Application year: 1998
Main classification: B65D5
IPC codes: B65D5