Abstract:
A carton is provided for holding and positioning articles for easy access. The carton may also be used for dispensing articles that contain products such as food and beverages. The carton includes various unique features, including an opening feature that provides easy access to the articles, and a tilt feature that positions the articles at the front end of the carton. Also provided is a carton blank, such as a paperboard blank, which is cut to a specific shape, and creased and scored, cut or perforated in specific areas. Methods for forming the blanks into cartons and for operating the opening and positioning features are also described.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   The present application claims priority to U.S. provisional patent application Ser. No. 60/543,382, filed Feb. 10, 2004, which application is incorporated by reference as if set forth herein in its entirety. 

   FIELD OF THE INVENTION 
   The present invention generally relates to cartons for holding articles and for positioning those articles for easy access. More specifically, the present invention relates to dispensing cartons having a tilting mechanism for positioning articles within the carton. 
   BACKGROUND OF THE INVENTION 
   Enclosed cartons with positioning features for displaying or dispensing articles have been used in the past. Many of these cartons require the user to detach a portion of the carton, manipulate the portion to fashion a positioning assembly, and place the assembly under the carton. Other types of cartons include positioning features that require adhesives to hold the positioning assembly in place or to adhere the positioning assembly to the carton, while still other cartons with attached positioning features require the user to insert the positioning assembly into preformed slots in the carton. In many instances, after the user engages the positioning assembly, the structural integrity of the carton is destroyed, and once the positioning feature is removed from the carton, the user generally cannot reclose the carton. Furthermore, many conventional carton positioning assemblies are structurally weak, and are easily flattened by excessive weight. 
   SUMMARY OF THE INVENTION 
   The present invention generally relates to a carton with a positioning assembly for holding and positioning articles for easy access, and a method of positioning such a carton. The present invention can be used, for example, in dispensing articles that contain products such as food and beverages. These articles can include beverage containers such as cans, bottles and PET containers, as well as other containers preferably being round in shape, such as those used in packaging foodstuffs or non-foodstuff items. In one aspect of the present invention, a carton is provided with a positioning assembly that can be positioned easily without the use of adhesives. In another aspect of the present invention, a carton is provided with a positioning assembly that can be reclosed after engagement of the positioning assembly. In a further aspect of the present invention, a carton is provided with a positioning assembly that does not require the user to detach a portion of the carton. 
   The invention also includes a carton blank, such as a paperboard blank, which is cut to a specific shape, then creased and scored, cut, or perforated in specific areas. The carton blank defines elongate panels between the creases or fold lines, and includes dust flaps at the respective ends of the panels. The carton blank is folded to form a sleeve, and when fully assembled, with the end flaps closed, the assembled carton has a front or forward end, a rearward end, and a top wall, a bottom wall, front and rear walls, and first and second side walls. 
   For purposes of illustration, the present invention is disclosed as a paperboard carton, sized and dimensioned to contain beverages in PET bottles, or cans of beverages. The carton illustrated in the drawing figures is sized to hold twelve articles in a 2×6 configuration, although the present invention is not limited to any specific size or dimension. For example, the present invention also would work satisfactorily if sized and shaped to hold articles in other configurations, such as 3×4, 2×4, 2×5, etc. The carton includes various unique features, including an opening feature that provides easy access to the articles, and a positioning assembly that positions the articles at the front end. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the carton containing PET bottles showing the opening flap removed and the tilt assembly in its operable position. 
       FIG. 2  is a side view of the carton of  FIG. 1 , containing PET bottles in a 2×6 arrangement. 
       FIG. 3  is an end view of the carton containing containers with the dispenser fully connected to the remainder of the carton. 
       FIG. 4  is a perspective view of the carton containing containers illustrating the opening of the dispenser. 
       FIG. 5  is a perspective view of the carton containing PET bottles showing the dispenser opened but attached to the remainder of the carton. 
       FIG. 6  is an end view of the carton containing PET bottles in a 2×6 arrangement with the dispenser removed. 
       FIG. 7  is an end bottom view of the rearward end of the carton showing the tilt assembly fully connected to the remainder of the carton. 
       FIG. 8  is a perspective top view of the rearward end of the carton showing the tilt assembly fully connected to the remainder of the carton. 
       FIGS. 9A to 9C  are side views of the carton illustrating the steps in properly positioning the tilt assembly in its operable position. 
       FIG. 9D  is a perspective view, on an enlarged scale, of the bottom rearward end of the carton, showing the tilt assembly in its operable position. 
       FIG. 10  is an end bottom view of the rearward end of the carton containing PET bottles in a 2×6 arrangement with the tilt assembly pulled downward. 
       FIG. 11  is a perspective view of the rearward end of the carton containing PET bottles in a 2×6 arrangement showing the tilt assembly in its operable position. 
       FIG. 12  is a plan view of a blank from which a carton according to this invention is formed. 
       FIG. 13  is an end view of the carton containing cans. 
       FIG. 14  is an end view of the carton of  FIG. 13  containing cans in a 2×6 arrangement with the dispenser removed. 
       FIG. 15  is a side view of the carton of  FIG. 13  containing cans in a 2×6 arrangement showing the dispenser removed and the tilt assembly in its operable position. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   For a more complete understanding of the present invention, reference should be made to the following detailed description and accompanying drawings, wherein like reference numerals designate corresponding parts throughout the figures. 
   To facilitate understanding and explanation of the carton of the present invention, the elements and numerals described herein will utilize the terms “upper,” “lower,” “top,” “bottom,” “front,” and “back” to distinguish portions of the halves of the carton and of the blank. These conventions are included merely for ease of explanation and understanding of the present description, however, and should not be limiting in any manner. For example, the descriptions of the panels as “upper,” “lower,” etc., also can be referred to as “first,” “second,” etc. 
   The tear lines can be continuous and can be comprised of any combination of perforations, tears, scores, creases, folds, cut scores, tear lines, or any combination of these or other inclusions formed in the container blank. 
     FIG. 1  is a perspective view of a carton C in accordance with one embodiment of the present invention with the opening flap removed. The positioning assembly in the illustrated embodiment of the invention comprises a tilt assembly T, which is shown in its operable position. Two tubular-shaped PET beverage bottles are positioned on a support surface SS beside the opening end or front end  5  of the carton in  FIG. 1 . The tilt assembly T is positioned at the rearward end  6  of carton C. 
     FIG. 2  is a side view of the carton of  FIG. 1 . In  FIG. 2 , the PET bottles B are contained in the carton in a 2×6 arrangement, with each bottle in the top row being positioned directly above a corresponding bottle in the bottom row. The first bottle B 1  in the upper row of PET bottles is visible at the opening end or front end  5 . 
     FIG. 3  is an end view of the carton C with the dispenser  7  fully connected to the remainder of carton C so that two rows of six PET bottles are contained within the fully enclosed carton. The dispenser  7  shown in  FIG. 3  includes opening flap  10  defined by a demarcation line  11 . This demarcation line can be a cut line, score line, or other weakened area, which allows a user to manually separate the dispenser  7  from the carton along the line  11 , and remove the dispenser  7  from the remainder of the carton C. The opening flap  10  optionally also may define a finger flap  12  along one of the carton walls. The finger flap  12  can be included to assist a user in initiating the opening of the carton by pushing inwardly on the finger flap  12  to break the carton along line  11 . Preferably, the finger flap  12  is located on the top wall  13  of the carton, although the present invention could be configured to allow one or more finger flaps located on other walls, such as one or both of the side walls  14  and  15  or the front wall  16 . 
     FIG. 4  shows a fully enclosed carton C that holds PET bottles, and illustrates the removal of dispenser  7 . The user pushes one or more fingers inwardly to open the carton C, initially along the portion of the line  11  that defines finger flap  12 . The user then pulls outwardly on flap  12  and on flap  10 , away from the remainder of the carton to begin separating the opening flap  10  from the remainder of carton C along the demarcation line  11 . Even if finger flap  12  is not incorporated, the opening process usually begins along the portion of the line  11  defined in the top wall  13  of the carton. As the opening flap  10  continues to be pulled, the flap  10  also separates along the line  11  defined in first side wall  14  and second side wall  15 . Continued pulling on the flap  10  will begin to separate flap  10  from the front wall  16 , as shown in  FIG. 5 . At this point the dispenser  7 , a unitary structure, can either remain attached to the carton as shown in  FIG. 5 , forming a basket, or optionally can be removed entirely from the carton by pulling along demarcation line portion  17 , which extends along opening end or front end  5  approximately from point  17 A to point  17 B. Portion  17  generally is spaced above the bottom panel of the carton a distance less than the diameter of one of the containers held in the carton, this distance being sufficient to prevent the containers from rolling out of the carton while the dispenser is open and to preserve the structural integrity of the carton. 
     FIG. 6  shows the carton C holding PET bottles B in a 2×6 arrangement with opening flap  10  removed from the carton. An access opening  8  is defined by the edges of the top wall  13 , side walls  14  and  15  and front wall  16  as outlined by demarcation line  11 . The containers or bottles held in the carton do not dispense automatically, but are positioned at the front end of the carton for ready individual removal by grasping the forward-most container in the carton at the access opening  8 . 
   Preferably, the articles in the carton are tubular, having round side walls, such as cans and bottles, so that the articles roll forwardly when the tilt assembly is engaged as discussed below. The carton of the present invention is ideally suited for holding beverage cans, PET bottles and food stuff containers such as rolls, biscuits, etc. Any other containers in other configurations holding non-food items, such as motor oil, can be held and automatically positioned in the present carton. 
   The carton can also include a tilt assembly T that can be engaged, that is, placed in its operable position, to elevate the rearward end  9  of the carton. When the tilt assembly T is engaged, the carton&#39;s rearward end  9  is elevated above the supporting surface SS, such as the counter, refrigerator shelf or cabinet or shelf supporting the carton. When the carton is manually placed in this elevated position, the tubular containers will roll forwardly from the rearward end  9  toward the opening end or front end  5  by gravity, so that the containers are positioned to allow the user to reach into the carton through the access opening  8 , and easily remove them. 
     FIG. 7  is an end view of the rearward end  9  of the carton C, viewed from behind and below the carton. The bottom wall  21  terminates along score line  22 , which preferably is a cut score line. The carton&#39;s rear wall  23  extends from cut line  22  upwardly to top edge  24 , where the rear wall  23  meets the top wall  13 . The tilt assembly T of carton C is defined by various preformed lines, including perforated lines, solid crease lines, cut crease lines and cut score lines. Those skilled in the art, however, will understand that, although the tilt assembly T of the present invention works well using the lines as described herein, other combinations of these lines could be substituted for the specific combinations described herein. 
   As shown in  FIG. 7 , perforated line  25  extends from point  32  across bottom wall or panel  21  to side wall  14 .  FIG. 8  shows line  25  continuing across the lower, rear corner of side wall  14  upwardly toward the carton edge  26  where side wall  14  meets rear wall  23 . Line  25  then extends across rear wall  23  to the opposite carton edge  27 , where rear wall  23  meets side wall  15 . The distance between line  25  and bottom wall  21  is less than the diameter of one of the containers held in the carton, though other heights are possible. A tab or finger flap  28  optionally can be defined in rear wall  23  by perforated line  25 , as shown in  FIG. 8 . The line  25  extends in identical fashion across the lower, rear corner of side wall  15  to bottom wall  21 , and then to point  33 , shown in  FIG. 7 . 
   Referring again to  FIG. 7 , score line  22  is formed along the carton edge that joins rear wall  23  and bottom wall  21 . Spaced along bottom wall  21  forwardly from score line  22  is cut fold line  30 , as shown in  FIG. 7 . A rectangular panel  80  is defined between lines  22  and  30 . Also shown in  FIG. 7  is solid fold line  31 , which extends spaced from and forwardly of line  30  along bottom wall  21  from point  32  to point  33 . Fold line  30  is equidistant between lines  22  and  31 . A panel  81  having angled end portions ( FIG. 7 ) is defined between lines  30  and  31 . The angled end portions of panel  81  are defined by the portions of perforated line  25 , which extend from point  32  to side wall  14 , and from point  33  to side wall  15 . A tilt flap  35 , which includes panels  80  and  81 , is defined between lines  25  and  31 . 
   In order to position the tilt assembly T, tilt flap  35  is pulled downwardly by pushing inwardly along tab or finger flap  28  and pulling outwardly, away from carton C, in order to begin tearing rear wall  23  along perforated line  25 . At this point, the user will lift the rear end of the carton so that it is elevated from the support surface SS, such as a counter or shelf, high enough to allow flap  35  to be moved beneath bottom wall  21 . This allows the tilt flap  35  to be tom across the lower, rear corners of side walls  14 ,  15 , and along perforated line  25  in bottom wall  21  down to points  32  and  33 , as shown in  FIG. 10 . The tilt assembly T then constitutes a unitary structure that is hingedly attached to the carton along line  31 , and that preserves the structural integrity of the carton. 
   The tilt assembly T as shown in the figures includes penetrations on tear lines in the side panels. However, the tilt assembly T need not include portions of either or both side panels, but such are shown in the figures for consistency and ease of illustration herein. 
     FIG. 9A  is a side view of carton C, showing flap  35  pulled so that line  25  is completely torn down to points  32  and  33 .  FIG. 9B  shows the next step in engaging, or properly positioning, flap  35  in its operable position. In  FIG. 9B , the portion of flap  35  comprised of end wall  23 , as defined by line  25 , is positioned to contact bottom wall  21 . In this position of flap  35 , panel  80  is spaced from, but adjacent, panel  81 .  FIG. 9C  illustrates the final step in positioning the tilt assembly T, with panel  81  being pushed toward panel  80 , until panels  80  and  81  contact one another. As shown in  FIG. 9D , this position of flap  35  creates edge  82  (corresponding to line  30 ) which extends from point  83  to point  84 . Angled edge  85  extends from point  83  to point  86  and angled edge  87  extends from point  84  to point  88 . Tab  28  may be inserted into a slit  89  in bottom panel  21 . Edges  82 ,  85  and  87  of tilt assembly T collectively provide support for carton C, when carton C thereafter is placed on the support surface SS. When tilt assembly T is placed in this operable position, the carton C is then gently allowed to rest back onto the support surface SS so that flap  35  is folded entirely beneath the carton, as shown in  FIG. 11 . In this manner, the tilt flap  35  becomes the rear support surface for the carton C, thereby raising the rearward end of carton C above the support surface SS. The containers having round or tubular side walls, therefore, tend to roll away from rear wall  23  and towards front wall  16  for positioning and easy removal, as described above. (For clarity of illustration, no containers are shown in  FIG. 9D .) 
   Whenever desired, the tilt assembly T can be reclosed by reversing the order of the steps shown in  FIGS. 9A to 9C , returning it to its original position. 
   The present invention also includes a carton blank  90  for making the carton C described above. The carton blank  90  shown in  FIG. 12  is comprised of carrier board, such as SUS paperboard well known in the art, although the carton blank is not limited to any specific composition. For example, the blank also could be constructed of cardboard or of synthetic sheet material, such as plastic. The carton blank  90  includes crease or fold line  50  and fold line  51  that define top panel or wall  13  therebetween. Front top end flap  52  is defined at one end of top panel  13  and rear top end flap  53  is defined at the opposite end of panel  13 . The flaps described herein also are known in the art as dust flaps. Fold line  54  is spaced from fold line  50  to define side panel  14  therebetween. At the front or forward end of side panel  14  is front side end flap  55 , connected to side panel  14  by first transverse fold line  100 , and at the opposite end or rear end of side panel  14  is rear side end flap  56 , connected to side panel  14  by second transverse fold line  101 . The carton blank defines a first free edge  60 , which is spaced from and generally parallel to fold line  54  as shown in  FIG. 12 , to define fastening flap  61 . Spaced from and parallel to fold line  51  is fold line  62 , to define side panel  15  between fold lines  51  and  62 . At the forward end of side flap  15  is front side end flap  63 , connected to side panel  15  by first transverse fold line  100 , and at the rearward end of side panel  15  is rear side end flap  64 , connected to side panel  15  by second transverse fold line  101 . The carton blank  90  also defines a second free edge  65  spaced from and generally parallel to fold line  62  as shown in  FIG. 12 . Bottom panel  68  is defined between fold line  62  and free edge  65 . Front bottom end flap  69  is defined along the front portion of bottom panel  68 , and rear bottom end flap  70  is defined at the rear portion of bottom panel  68 . The blank is provided with score/cut line  11 , perforated line  25  and fold line  31 , so positioned and configured that when the carton is fully enclosed, as described below, these lines will define the previously-described dispenser  7  and tilt assembly T. 
   As known to those skilled in the art, carton blanks can be folded along the crease or fold lines to form a carton sleeve with fastening flap  61  overlapping and adhered to bottom flap  68 . The carton blank  90  shown in  FIG. 12  is folded in this manner to form the carton C of the present invention. A securing means such as a glue adhesive or compound is applied to flap  61  so that flap  61  is secured to flap  68  after the carton is folded, in order to form a sleeve. Also as known to those skilled in the art, once the carton C is formed into a sleeve, containers, such as the PET bottles or beverage cans depicted in the drawing figures are placed into the sleeve in the proper orientation. As shown, when the carton is fully enclosed and correctly inverted with top panel  13  being oriented upwardly, the containers lie on their respective sides. 
   The carton is fully enclosed by folding the end flaps described above to close the end portions, for example, by gluing the associated end flaps together to fully enclose the carton. The front end flaps cooperate to form front wall  16 , and the rear end flaps cooperate to form rear wall  23 . 
     FIGS. 13-15  show the carton of the present invention as described above enclosing beverage cans instead of PET bottles.  FIG. 13  is an end view of the carton containing cans.  FIG. 13  shows retainer walls W, which prevent the articles in both the top and bottom rows of articles from unintentionally rolling out of the carton when the dispenser  7  is open.  FIG. 14  is an end view of the carton of  FIG. 13  containing cans in a 2×6 arrangement with the dispenser removed.  FIG. 15  is a side view of the carton of  FIG. 13  containing cans in a 2×6 arrangement showing the dispenser removed and the tilt assembly in its operable position. 
   The above specification represents the best mode known to the inventor of carrying out the invention. Since many modifications of the invention can be made without departing from the spirit and scope of the invention, the breadth and depth of the invention resides in the claims hereinafter appended.