Abstract:
A device for breaking a series of perforations or cuts to open a carton or otherwise separate materials connected by a frangible severance line includes a pair of fold lines that converge away from the severance line, a collapsible line perpendicular to severance line and between the pair of fold lines, and third fold line perpendicular to and intersecting the collapsible line. A tear in the severance line is initiated by applying pressure in vicinity of the intersection of the collapsible line and the third fold line, which causes the device to apply tension to the frangible line, which is further weakened by having an elongated perforation that it centered on the axis of tension, and neighboring perforations that are angled toward the axis of tension. The angle of each perforation with respect to the axis of tension preferably varies depending on its location relative to the axis of tension.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims priority to U.S. Provisional Application No. 60/637,826, filed Dec. 20, 2004, the entirety of which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates generally to cartons for packaging multiple articles such as beverage cans or bottles, and more particularly, to a carton with an article dispenser that is opened using a pressure sensitive opening device.  
       BACKGROUND OF THE INVENTION  
       [0003]     Cartons for encasing and dispensing multiple articles such as soft drink cans or bottles are useful for enabling consumers to transport, store, and access the articles for consumption. The consumer typically prefers the flexibility of easily accessing the articles without reducing the ability of the carton to enclose the remaining articles. To that end, some cartons have dispensers which allow one or more articles to be removed through an opening as the carton continues to encase the remaining articles. The consumer tears out a portion of the carton to form an opening from which articles may be dispensed.  
         [0004]     Beverage cartons with an article dispenser formed by a removable section are known in the art. Typically, the removable section is defined by a tear line. To open the carton, a finger flap is pressed such that a portion of the removable section is separated from the carton. Then, the removable section is gripped and pulled outwardly, which causes the tear line to break all the way down to the bottom wall. In so doing, the removable section is allowed to swing down together with a part of the bottom end flap, which creates an access opening through which the cans in the carton are exposed. The opening is so dimensioned that at least part of the periphery of the opening serves as a can stopper that prevents the cans from undesirably rolling out of the carton through the opening.  
         [0005]     However, the typical finger flap has been found not to be user-friendly because it is not easy to separate it from the carton wall. This is because the entire side carton wall may yield to the pressing force applied to the finger flap and, as a result, sufficient shearing stress is not induced along the tear line. Moreover, consumers such as children may not be able to apply sufficient force to initiate a tear to open the carton to retrieve an article. Furthermore, even when the finger flap successfully initiates separation of the removable section from the carton wall, the consumer must insert one or more fingers in the narrow space between that portion of the removable section and the remaining carton wall. Thus, the known means for tearing the carton to form the opening can be somewhat difficult, particularly if the consumer is unable to visibly distinguish the finger flap from the remainder of the frangible line so as to find the appropriate point at which to initiate the tear. The addition of a precut aperture such as an insertion flap compromises the structural integrity of the carton and increases its susceptibility to infiltration of light, moisture, and dust.  
         [0006]     What is needed, therefore, is a carton that includes article dispenser that is conveniently opened. Such a carton should have a user-friendly means for initiating the removal of the removable portion, and for grasping and removing the removable portion, as well as a reliable article stopper.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention solves the problems identified above by advantageously reducing the effort required to open a carton dispenser to access the articles contained therein. More specifically, the various embodiments of the invention provide an improved means for opening a carton dispenser. The means for opening the carton dispenser is pressure sensitive, and thus, a user simply applies pressure to break the connection between the dispenser and the remainder of the carton. The configuration of the means for opening the carton dispenser reduces the amount of pressure that is required to open the dispenser without significantly degrading the integrity of the carton before and after the dispenser has been opened.  
         [0008]     Generally, the invention is described in the context of a carton having a top wall, a pair of opposed side walls hingedly connected to the top wall, a bottom wall hingedly connected to the side walls, and an end wall hingedly connected to end edges of each of the side, top, and bottom walls.  
         [0009]     The carton includes an article dispenser with a fully or partially removable portion that is formed from one or more of the carton walls. The periphery of the removable portion is defined at least in part by a frangible line or a series of cooperating frangible lines.  
         [0010]     The means for opening the carton dispenser includes an opening device for breaking the frangible line. The opening device is bounded by at least a portion of the frangible line and by a pair of convergent fold lines. Each of the convergent fold lines originates at or near the frangible line and converges toward the other and away from the frangible line. In other words, the convergent fold lines converge toward one another, but do not necessarily meet or intersect one another. The divergent ends of the convergent fold lines approach abut, meet, or intersect the frangible line.  
         [0011]     A collapsible severance line is disposed between the convergent fold lines, preferably effectively bisecting the triangle formed by the convergent fold lines and the frangible line. One advantage of the severance line is that it reduces the amount of pressure required to break the frangible line by encouraging the carton to collapse inward in response to the application of pressure, thereby buckling the top wall of the carton so as to exert force upon the frangible line.  
         [0012]     A transverse fold line extends between the convergent fold lines, and in one embodiment is generally perpendicular to and intersects the collapsible severance line. This fold line directs externally applied pressure away from the frangible line, thereby pulling the frangible line apart.  
         [0013]     In certain embodiments, the opening device also includes an elliptical score line disposed between the convergent fold lines. The elliptical score line preferably has a major axis that coincides with or parallels at least part of the transverse fold line. The elliptical score line provides a target by which the user can identify the appropriate point to apply pressure to open the dispenser, and further encourages inward collapse so as to break of the frangible line.  
         [0014]     The frangible line is advantageously configured to respond to the pressure applied to open the dispenser. To that end, in some embodiments at least a portion of the frangible line is substantially weakened, such as by means of an extended cut line that may be adjacent and perpendicular to said collapsible severance line. Here, this cut line is the weakest portion of the frangible line and is configured to separate first, thereby initiating the separation of the remainder of the frangible line, which is relatively stronger. In other embodiments, the remainder of the shared portion of the frangible line that defines the opening device comprises multiple interrupted cut lines in series with one another and with the cut line. Each of the cut lines is angled toward the collapsible severance line, creating a saw-tooth or zigzag tear when the frangible line is broken. The angled cut lines may be continued along the entirety of the frangible line, or some other combination series of cuts, half cuts, scores, or perforations may be used to complete the periphery of the article dispenser.  
         [0015]     The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]      FIG. 1  is a blank for forming an exemplary carton having an article dispenser.  
         [0017]      FIG. 2  is a partial plan view of an opening device according to an exemplary embodiment of the invention.  
         [0018]      FIG. 3  is a perspective view of a carton formed from the blank of  FIG. 1 , the carton including the opening device of  FIGS. 1 and 2 .  
         [0019]      FIG. 4  is a partial perspective view illustrating the application of finger pressure to activate the exemplary opening device.  
         [0020]      FIG. 5  is a partial perspective view illustrating a user using the exemplary opening device to access the edge of a removable portion.  
         [0021]      FIG. 6  is a partial side elevation illustrating the carton of  FIG. 3  in an opened condition with the removable portion partially removed.  
         [0022]      FIG. 7  is a perspective view illustrating the carton of  FIG. 3  in an opened condition with the removable portion completely removed.  
     
    
     DETAILED DESCRIPTION  
       [0023]     As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples to illustrate aspects of the invention that may be embodied in various and alternative forms. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as an illustration, specimen, model, or pattern. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known materials or methods have not been described in detail to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but as a basis for the claims and for teaching one skilled in the art to variously employ the present invention.  
         [0024]     Referring now to the drawings in which like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton opening device according to the teachings of the present invention. In the embodiments detailed herein, the term carton refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for enclosing, carrying, and dispensing articles such as beverage cans. However, it is contemplated that the teachings of the invention can be applied to any container, the opening of which requires the breaking a frangible connection.  
         [0025]     The features and aspects of the invention are described with reference to an exemplary carton  300  formed from a foldable sheet material such as paperboard, corrugated board, plastic, laminates, any combination thereof, or the like. To encourage an understanding of the various aspects of the invention, the construction of an exemplary carton will now be described in some detail. The foldable sheet material is typically provided as a unitary blank  100 , the inside surface of which is shown in  FIG. 1 . The blank  100  includes a bottom panel  102  hingedly connected along longitudinal fold line  103  to a first side panel  104 , which is hingedly connected along fold line  106  to a top panel  108 , which is hingedly connected along fold line  110  to a second side panel  112 , which is hingedly connected along fold line  114  to an edge flap  116 . Each of the panels is hingedly connected, respectively, to end flaps  118   a,    120   a,    136   a  or end wall panels  122   a,    124   a,  which are defined in part by respective transverse fold lines  126   a,    130   a,    138   a,    128   a,    132   a  disposed along one edge of the blank  100 . At the opposite edge of the blank  100 , the panels may also include hinged connections to similar end flaps  118   b,    120   b,    136   b  or end wall panels  122   b,    124   b  defined in part by transverse fold lines  126   b,    130   b,    138   b,    128   b,    132   b.  More specifically, first side panel  104  is hingedly connected to end wall panels  122   a,    122   b  along respective fold lines  128   a,    128   b.  Top panel  108  is hingedly connected to end flaps  120   a,    120   b  along respective fold lines  130   a,    130   b.  Second side panel  112  is hingedly connected to end wall panels  124   a,    124   b  along respective fold lines  132   a,    132   b.  Bottom panel  102  is hingedly connected to end flaps  118   a,    118   b  along respective fold lines  126   a,    126   b.  Edge flap  116  is hingedly connected to end flaps  136   a,    136   b  along respective fold lines  138   a,    138   b.    
         [0026]     The blank  100  includes a frangible line  140 , which when the carton is erected, defines a removable portion T. The removable portion T can have any shape, size, or orientation that is suitable for dispensing articles, and thus, the illustrated version is provided as a non-limiting example. To define the exemplary removable portion T, the frangible line  140  curves somewhat as it extends from the distal edge of end wall panel  122   a  across fold line  128   a  and onto side panel  104 . The frangible line  140  traverses a portion of side panel  104 , extending longitudinally from fold line  128   a  toward end wall panel  122   b,  transversely toward bottom panel  102 , longitudinally again toward end wall panel  122   b,  and transversely toward top panel  108 . The frangible line  140  crosses fold line  106  to traverse top panel  108 , then crosses fold line  110  onto side panel  112 . The frangible line  140  extends across a portion of side panel  112  and across the length of end wall panel  124   a  so as to approximate a mirror image of its path across side panel  104  and end wall panel  122   a.  Thus, the exemplary removable portion T is symmetrical, although symmetry is not requisite for implementation of the systems or methods of the invention. It is contemplated that the frangible line  140  includes, but is not limited to, a line of perforations, a line of short slits, a line of half cuts, a single half cut, any combination of slits, score lines, and half cuts, or the equivalent, as will be understood by those skilled in the art.  
         [0027]     The section of frangible line  140  that traverses the top panel  108  will now be referred to as frangible section  142 .  FIG. 2  provides an enlarged view of the carton  300  from the perspective of the top panel  108 , including the opening device  200 . A subsection  144  of frangible section  142  is adjacent to and defines one edge of the opening device  200  of the present invention. The opening device  200  is further defined by a first fold line  202  and a second fold line  204 . The fold lines  202 ,  204  converge toward one another. The direction of convergence  206  of the fold lines  202 ,  204  is substantially perpendicular to the subsection  144 . In the embodiment shown, means for weakening such as a slit, cut, half-cut, or series of slits, cuts or half-cuts form a severance line  208  that is in alignment with the direction of convergence  206 . The extent of the severance line  208 , as defined by the depth, width, and length of the cuts or slits comprising the severance line  208 , is sufficient to compensate for or overcome the stiffness of the carton material when pressure is applied to the opening device  200 , so as to encourage the opening device  200  to collapse inward toward the interior of the carton. An additional fold line  212  extends transversely between the fold lines  202 ,  204 , thereby directing the applied pressure away from the frangible subsection  144 , which is itself placed in tension. The configuration of the opening device  200  concentrates and focuses the force generated by a user pressing the opening device  200 , preferably at or in the vicinity of the intersection of the severance line  208  and the fold line  212 . The axis of tension  210  created by this pressure preferably coincides generally with the direction of convergence  206 . As the pressure exerted on the opening device  200  increases, the tension applied to subsection  144  also increases. When the tension exceeds the tear strength of the frangible subsection  144 , the subsection  144  separates so as to initiate separation of the remainder of frangible line  140 . Elliptical score line  213  indicates the preferred pressure point for tearing subsection  144  and further promoting an inward collapse. It is contemplated that each of the fold lines in this embodiment includes, but is not limited to, a line of perforations, a score line, a line of short slits, a line of half cuts, a single half cut, any combination of slits, score lines, and half cuts, or the equivalent, as will be understood by those skilled in the art.  
         [0028]     As is also illustrated in  FIG. 2 , the subsection  144  includes multiple angled perforations  214  that include any means for controllably weakening the carton, including slits, cuts, or half-cuts. The perforations  214  are interrupted by ties or nicks  216  that maintain the integrity of the subsection  144  until it is desirable to initiate tearing thereof. It is known to relate the depth and length of the perforations  214  and the width of the ties  216  that interrupt the perforations  214  to create a frangible line with sufficient tear strength to withstand the forces generated by carrying, stacking, or otherwise handling the carton  300  prior to opening the carton  300 , and to prevent the frangible line from excessively reducing the burst strength of the carton wall. Thus, such determinations are design choices dependent at least in part upon the size of the package, configuration, and weight of the contents. The angle of each perforation  214  is preferably determined by referencing the axis of tension  210 , so that at least some of the perforations  214  comprising the top panel section  142  of the frangible line  140  are angled toward the axis of tension  210 . The perforation  214   a  at the center of the subsection  144  is preferably elongated to comprise the weakest segment of subsection  144 , thereby encouraging the tear to initiate at the center of top panel  108  and to radiate toward either side panel  104 ,  112 . This result can be intensified if the centermost perforation  214   a  is also centered on and perpendicular to the axis of tension  210 . The angle of each perforation  214  with respect to the axis of tension  210  preferably varies depending on its location with respect to the axis of tension  210 . For example, the angle of perforations  214  may decrease in inverse proportion to their distance from the axis of tension  210  such that the angle of perforation  214   d  is less than that of the adjacent perforation  214   c  that is less than the angle of center perforation  214   a.  It is also preferred that the length of each perforation  214  varies depending on its location with respect to the axis of tension  210 . For example, the length of perforations  214  may decrease in inverse proportion to their distance from the axis of tension  210  such that the length of perforation  214   d  is less than that of the adjacent perforation  214   c  that is less than the length of center perforation  214   a.    
         [0029]     To erect the carton  300  shown in  FIG. 3 , the bottom panel  102  of the blank  100  is glued or is otherwise secured to the edge flap  116  to form the composite bottom wall  102 / 116  of carton  300 , which is at this point open-ended and tubular. End flaps  136   a,    136   b  are secured to respective end flaps  118   a,    118   b  to form composite end flaps  118   a/   136   a  and  118   b/   136   b.  The first side panel  104  becomes the first side wall  304  of the erected carton  300 . Similarly, the top panel  108  becomes the top wall  308 , and second side panel  112  forms the second side wall  312  of the erected carton  300 .  
         [0030]     After articles are grouped and loaded through either or both of the open ends of the carton  300 , the end flaps and end wall panels are folded and secured together to form opposing end closure structures of carton  300 . End wall panel  124   a  is secured to the inside surface of end wall panel  122   a.  Additionally, end flaps  120   a,    118   a/   136   a  may optionally support the integrity of the carton  300  by being secured to end wall panel  122   a  and/or to end wall panel  124   a.  The end flaps  120   b,    118   b/   136   b,  and end wall panels  122   b  and  124   b,  cooperate similarly to form the opposing end closure structure. As readily apparent from  FIG. 3  (showing the carton  300  in a closed condition), the end closure structures form respective end walls  302   a  and  302   b.    
         [0031]     The exemplary carton  300  illustrated in the drawings is adapted to hold a group of similarly dimensioned, cylindrical articles C (best shown in  FIG. 6 ), in one or more vertically arranged rows. The articles in each row are disposed on their sides in a side-by-side parallel fashion. Referring again to  FIG. 3 , side walls  304  and  312  are disposed alongside the ends of the articles of the group, while each end wall  302   a  and  302   b  of the carton is disposed adjacent to the side walls of the respective endmost articles. The carton  300  further comprises a suitable known handle H to allow the user to carry the carton.  
         [0032]     A method for opening the exemplary article dispenser will now be described with reference to  FIGS. 4 through 7 . A user applies downward force  400  ( FIG. 4 ) to activate the exemplary opening device  200 . The force is applied between the convergent fold lines  202 ,  204  and the frangible subsection  144 , and preferably is concentrated within the bounds of elliptical score  213 . The applied force  400  is preferably continuous and increases in magnitude until subsection  144  begins to tear. The user can apply the force  400  by pressing with one or more fingers, or by using any implement to initiate separation of subsection  144 . As shown in  FIG. 5 , once subsection  144  is at least partially torn or otherwise separated, the user inserts an implement or one or more fingers between the opening device  200  and the removable portion T so as to grasp the removable portion T. The user can then break the remainder of frangible line  140  to at least partially remove removable portion T, as can be seen in  FIG. 6 . If desired, the removable portion T is completely removed ( FIG. 7 ). In certain embodiments, severance line is intended to or subject to tear in response to the downward force F and preferably after subsection  144  tears, thereby creating a larger space between the opening device  200  and the removable portion T.  
         [0033]     The present invention has been illustrated in relation to a particular embodiment which is intended in all respects to be illustrative rather than restrictive. Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope of the invention. For example, as used herein, directional references such as “top”, “base”, “bottom”, “end”, “side”, “inner”, “outer”, “upper”, “middle”, “lower”, “front” and “rear” do not limit the respective walls of the carton to such orientation, but merely serve to distinguish these walls from one another. Any reference to hinged connection should not be construed as necessarily referring to a junction including a single hinge only; indeed, it is envisaged that hinged connection can be formed from one or more potentially disparate means for hingedly connecting materials.  
         [0034]     Moreover, the principles of the opening device can be applied to any container that is opened by means of a frangible severance line, or to any device or method for tearing a frangible connection between disparate materials or adjacent sections of the same material. Thus, the configuration, manufacture, and dimensions of cartons and articles described herein merely provide a point of reference for an understanding of an example of a suitable application for implementing the systems and methods of the invention. Accordingly, the scope of the present invention is described by the claims appended hereto and supported by the foregoing.