Abstract:
A dispensing carton includes a dispenser section having a deformation pattern provided therein. The deformation pattern facilitates removal of the dispenser section during opening of the carton.

Description:
RELATED APPLICATION 
       [0001]    This application is a continuation application of co-pending U.S. patent application Ser. No. 12/605,733, filed Oct. 26, 2009, which is a continuation of U.S. patent application Ser. No. 11/490,820, filed Jul. 21, 2006 (now issued as U.S. Pat. No. 7,673,789), which claims the benefit of U.S. Provisional Application No. 60/701,685, filed Jul. 22, 2005, the entire contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    Fully enclosed dispensing cartons having dispensing openings at a top portion of the carton are known. A conventional dispensing carton is typically formed from a unitary paperboard blank having a pattern of tear lines that define a dispensing section of the carton. When the dispensing section is torn away from the carton, containers held within the carton can be removed. Such dispensing sections, however, are difficult to remove because of the stiffness of the paperboard material, which may cause difficulty in gripping the dispensing flap for tearing at the tear lines. The cartons also tend to tear at locations other than along the tear lines defining the dispensing section. 
       SUMMARY 
       [0003]    According to a first embodiment, a carton comprises a first side panel, a top panel, a second side panel, a bottom panel, an exiting end panel, an end panel, and a dispenser section defined at least in part by a dispenser pattern extending at least through the top panel. The dispenser pattern includes a deformation pattern that facilitates gripping of the dispenser section and tearing of the carton along the dispenser pattern during opening of the dispenser. 
         [0004]    Other aspects, features, and details of embodiments of the present invention can be more completely understood by reference to the following detailed description of preferred embodiments, taken in conjunction with the drawings figures and from the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention. 
           [0006]      FIG. 1  is a plan view of a blank used to form a carton having a dispenser according to a first embodiment of the invention. 
           [0007]      FIG. 2  is a perspective view of the carton blank in a partially erected state. 
           [0008]      FIG. 3  is an end view of the carton blank in a partially erected state. 
           [0009]      FIG. 4  is a perspective view of the carton according to the first embodiment of the invention. 
           [0010]      FIG. 5  is an end view of the exiting end of the carton. 
           [0011]      FIG. 6  is a partial left side view of the carton. 
           [0012]      FIG. 7  is a partial right side view of the carton. 
           [0013]      FIG. 8  is a top plan view of the carton. 
           [0014]      FIGS. 9-12  illustrate the carton dispenser being opened. 
           [0015]      FIG. 13  is a perspective view of the carton with the dispenser opened. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The present invention generally relates to dispensers for cartons having a deformation pattern that allow the dispenser to be easily and reliably opened. The present invention can be used, for example, in cartons that contain articles or other products such as, for example, food and beverages. The articles can also include beverage containers such as, for example, cans, bottles, PET containers, or other containers such as those used in packaging foodstuffs. For the purposes of illustration and not for the purpose of limiting the scope of the present invention, the following detailed description describes generally cylindrical beverage containers as disposed within the carton embodiments. In this specification, the relative terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected cartons. For purposes of the description presented herein, the term “line of disruption” can be used to generally refer to cuts, creases, cut-space lines, cut-creases, tear lines, scores, cut-scores, cuts interspersed with nicks, and combinations of these features. A “breachable” line of disruption is a line of disruption that is intended to be breached during ordinary use of the carton. An example of a breachable line of disruption is a tear line. 
         [0017]      FIG. 1  is a plan view of a first, underside or interior side  5  of a blank  8  used to form a carton  150  (illustrated in  FIG. 4 ) according to a first embodiment of the invention. The first side  5  of the blank  8  will be disposed in the interior of the erected carton  150 . The blank  8  comprises a first side panel  10  foldably connected to a top panel  30  at a first transverse fold line  32 , a second side panel  70  foldably connected to the top panel  30  at a second transverse fold line  72 , and a bottom panel  90  foldably connected to the second side panel  70  at a third transverse fold line  92 . An adhesive flap  40  can be foldably connected to the first side panel  10  at a fourth transverse fold line  42 . The blank  8  may include a slotted handle  120  in the top panel  30 , or at one or more other locations in the blank. 
         [0018]    The first side panel  10  is foldably connected to a first side flap  12  and a first side exiting end flap  14 . The top panel  30  is foldably connected to a top flap  32  and a top exiting end flap  34 . The second side panel  70  is foldably connected to a second side flap  72  and a second side exiting end flap  74 . The bottom panel  90  is foldably connected to a bottom flap  92  and a bottom exiting end flap  94 . When the carton  150  is erected, the end flaps  12 ,  32 ,  72 ,  92  close one end of the carton  150 , and the exiting end flaps  14 ,  34 ,  74 ,  94  close an exiting end of the carton  150 . The end flaps  12 ,  32 ,  72 ,  92  extend along a first marginal area of the blank  8 , and may be foldably connected at a first longitudinal fold line  60  that extends along the length of the blank  8 . The exiting end flaps  14 ,  34 ,  74 ,  94  extend along a second marginal area of the blank  8 , and may be foldably connected at a second longitudinal fold line  62  that extends along the length of the blank  8 . The longitudinal fold lines  60 ,  62  may be, for example, straight or substantially straight fold lines, or may be offset at one or more locations to account for, for example, blank thickness. 
         [0019]    According to one aspect of the invention, the carton blank  8  includes a dispenser pattern  100  that defines a dispenser  110  in the erected carton  150  (illustrated in  FIG. 4 ). The dispenser pattern  100  includes a tear line pattern  102  and a deformation pattern  80 . 
         [0020]    The tear line pattern  102  extends across the panels  10 ,  30 ,  70  and the exiting end flaps  14 ,  74 ,  94 . The perimeter of the tear line pattern  102  is defined by first and second side tear lines  22 ,  24  and a top tear line  26 . The first side tear line  22  includes an oblique section  23  that extends obliquely from a side edge of the first side exiting end flap  14 . The first side tear line  22  then turns to extend transversely across the longitudinal fold line  62  and into the first side panel  10 . The first side tear line  22  divides the first side exiting end flap  14  into a first tear away section  16  and a first retainer section  18 . The second side tear line  24  includes an oblique section  25  that extends obliquely from a side edge of the second side exiting end flap  74 . The second side tear line  24  then turns to extend transversely across the longitudinal fold line  62  and into the second side panel  70 . The second side tear line  24  divides the second side exiting end flap  74  into a second tear away section  76  and a second retainer section  78 . The top tear line  26  extends between the first and second side tear lines  22 ,  24  and may designed to be torn continuously with the first and second side tear lines  22 ,  24 . The top tear line  26  extends across the first and second side panels  10 ,  70  and across the top panel  30 . A center portion of the top tear line  26  includes a generally v-shaped access portion. The tear lines  22 ,  24 ,  26  can form a generally continuous breachable line of disruption such as a tear line, or, one or more interruptions can be included in and between the tear lines. The tear line pattern  102  also comprises spaced oblique tear lines  96 ,  98  in the bottom exiting end flap  94 . The tear line pattern  102  defines a removable dispenser section  50  in the erected carton  150 . 
         [0021]    According to one aspect of the invention, the deformation pattern  80  is a pattern of lines of disruption in the blank  8  that allows the dispenser section  50  to deform during opening of the carton  150 . Deformation of the dispenser section  50  allows a user to more easily grasp the dispenser section  50 , and also facilitates reliable tearing along the tear line pattern  102  during opening of the dispenser  110 . The deformation pattern  80  includes first and second v-shaped edge deformation lines  52 ,  53  first and second curved, access deformation lines  54 ,  56 , and first and second oblique top deformation lines  58 . 
         [0022]    A first v-shaped, edge deformation line  52 ,  53  extends along each end of the top tear line  26 . The first v-shaped edge deformation line  52 ,  53  extends obliquely through the first side panel  10 , from the juncture of the tear lines  22 ,  26 , to the transverse fold line  32 . At the transverse fold line  32 , the first edge deformation line  52 ,  53  extends obliquely through the top panel  30  towards the first access deformation line  54 . Similarly, the second v-shaped edge deformation line  52 ,  53  extends obliquely through the second side panel  70 , from the juncture of the tear lines  24 ,  26 , to the transverse fold line  72 . At the fold line  72 , the second v-shaped edge deformation line  52 ,  53  extends obliquely through the top panel  30  towards the first access deformation line  54 . 
         [0023]    The first and second access deformation lines  54 ,  56  are disposed in the dispenser section  50  with their concave faces opposing the generally v-shaped central portion of the top tear line  26 . The first access deformation line  54  may extend across substantially all of the width of the top panel  30 , and may extend adjacent to the top tear line  26  at each end of the deformation line  54 . The first curved access deformation line  54  may be, for example, arcuate in shape, with the concave portion of the arc opposing the concave section of the top tear line  26 . The second curved access deformation line  56  may extend across at least about one third of the width of the top panel  30 , and may extend adjacent to the top tear line  26  at each end of the deformation line  56 . The second access deformation line  56  may be, for example, arcuate in shape, with the concave portion of the arc opposing the concave section of the top tear line  26 . The access deformation lines  54 ,  56  are illustrated as generally arcuate, although other shapes are possible. For example, the access lines  54 ,  56  may have a v-shape. 
         [0024]    First and second oblique top deformation lines  58  extend from at or adjacent to respective corners of the dispenser section  50 , and converge toward one another as they approach the first access deformation line  54 . The first and second oblique top deformation lines  58  can intersect with or extend to points adjacent to the first curved deformation line  54 . 
         [0025]    The top panel  30  can have a width W 1  that generally corresponds to a height of a container C to be held within the carton  150 . The first and second retainer sections  18 ,  78  can each have a height H 1  selected to retain a container or containers C within the carton  150 , as discussed in further detail below. The side panels  10 ,  70  have a height H 2  that generally corresponds to the height of the carton  150 . Erection of the carton  150  is discussed below with reference to  FIGS. 2-4 . 
         [0026]      FIG. 2  is a perspective view of an erection step of the carton  150 . The carton  150  is erected by gluing the adhesive flap  40  (shown in  FIG. 1 ) to the bottom panel  90  so that the first side panel  10 , the top panel  30 , the second side panel  70 , and the bottom panel  90  may be opened into a generally tubular form or sleeve, as shown in  FIG. 2 . The back end of the tubular sleeve is closed by folding the end flaps  32 ,  92  across the open back end of the tubular form, folding the side end flap  12  over the flaps  32 ,  92  and adhering the flaps together, and then folding the side end flap  72  over the flaps  12 ,  32 ,  92  and adhering the flap  72  thereto. Similarly, referring to  FIG. 3 , the exiting end of the tubular sleeve is closed by folding the exiting end flaps  34 ,  94  across the open exiting end of the tubular form, folding the side exiting end flap  14  over the flaps  34 ,  94  and adhering the flaps together, and then folding the side exiting end flap  74  over the flaps  14 ,  34 ,  94  and adhering the flap  74  thereto.  FIG. 3  illustrates the exiting end flaps  14 ,  34 ,  74 ,  94  being closed over containers C loaded inside the tubular sleeve. The containers C may be loaded into the sleeve in a conventional manner before one or both ends of the tubular form are closed. In the exemplary embodiment, the carton  150  encloses twelve 12-ounce beverage containers C. The containers C are arranged in the carton  150  in a 2×6×1 configuration. 
         [0027]      FIG. 4  is a perspective view of the carton  150  constructed from the blank illustrated in  FIG. 1 . The carton  150  is parallelepipedal in shape. In the erected carton  150 , the end flaps  12 ,  32 ,  72 ,  92  form a first end panel  130  and the exiting end flaps  14 ,  34 ,  74 ,  94  form an exiting end panel  140 . The dispenser  110  extends across the side panels  10 ,  70 , the top panel  30 , and the exiting end panel  140 , and comprises the removable dispenser section  50 . In  FIG. 4 , the 2×6×1 arrangement of containers C is indicated by hidden lines. 
         [0028]      FIG. 5  is an end view of the carton  150 . As shown in  FIG. 5 , the first and second side tear lines  22 ,  24  of the dispenser  110  can be separated by a width W 2  at the tops of the retainer sections  16 ,  76 , and may converge to a width W 3  at or adjacent to the bottom of the exiting end panel  140 . The width W 2  may be selected to optimize the ease of removal of containers C from the carton  150  once the dispenser  110  is opened. The retainer sections  16 ,  76  may extend to uppermost points having a height H 1  that is shorter than a height  11   2  of the carton  150 . The height H 1  may be selected, for example, to retain an uppermost row or layer of containers C within the carton once the dispenser  110  is opened, as is discussed in further detail below. 
         [0029]      FIGS. 6 and 7  are side views of the carton  150 , and illustrate the depth D 1  to which the first and second side tear lines  22 ,  24  extend into the first and second side panels  10 ,  70 , respectively.  FIG. 8  is a top view of the carton  150 . As shown in  FIG. 8 , the first and second oblique top deformation lines  58  extend from respective upper corners of the dispenser section  50  and may connect to or extend adjacent to the first, curved access deformation line  54  of the deformation pattern  80 . 
         [0030]      FIG. 9  is a perspective view of the dispenser  110  being opened. Opening may be begun by pressing downwardly on the top panel  30  between the top tear line  26  of the tear line pattern  102  and the first curved deformation line  54  of the deformation pattern  80  so that the top panel  30  tears along the top tear line  26 . At this stage, gripping of the dispenser section  50  and tearing along the top tear line  26  is facilitated by deformation of the top panel  30  at the first and second curved access deformation lines  54 ,  56  of the deformation pattern  80 . The upper edges of the carton  150  may also begin to flex inwardly at the first and second v-shaped edge deformation lines  52 . The first and second curved access deformation lines  54 ,  56  allow the dispenser section  50  to flex inwardly to facilitate access to the dispenser section  50  during tearing. 
         [0031]    Referring to  FIGS. 10 and 11 , the tear line pattern  102  is further torn long the first and second side tear lines  22 ,  24  (see also  FIGS. 6 and 7 ), which extend down the first and second side panels  10 ,  70 , respectively. Referring also to  FIG. 1 , a center portion of the bottom exiting end panel  94  disposed between the tear lines  96 ,  98  may be adhered to the tear away sections  16 ,  76 , and is removed during opening of the dispenser  110 . During opening of the dispenser  110 , gripping of the dispenser section  50  and tearing along the tear line pattern  102  is facilitated by further deformation of the top panel  30  at the deformation lines  54 ,  56 ,  58 , and inward deformation of the upper edges of the carton  150  at the v-shaped deformation lines  52 ,  53 . 
         [0032]      FIG. 12  is a perspective view of the carton  150  with the dispenser  110  opened, leaving a dispenser opening  105 . With the dispenser section  50  removed, the container C in the top or uppermost row or layer adjacent to the dispenser opening can be easily accessed and removed from the carton  150 . Also, the dispenser opening  105  may extend downward in the exiting end panel  140  such that containers C in the lower row are also accessible by hand. 
         [0033]      FIG. 13  is an end view of the carton  150  illustrating the exiting end panel  140  after opening the dispenser  100 . As shown in  FIG. 13 , the containers C may be generally cylindrical in shape and may have a height H C  and a diameter D C . The height H 1  of the retainer sections  18 ,  78  may be selected to retain the container in the uppermost row of containers. For example, the height H 1  can be in the range of about 110-200% of the container diameter D C . In other embodiments, the height H 1  can be in the range of about 130-180% of the container diameter D C . The upper width W 2  may be between about 30-90% of the height H C  of the containers C or the carton width W 1  (shown in the  FIG. 1 ). In other embodiments, the width W 2  is between about 40-70% of the height H C  or the carton width W 1 . The lower width W 3  may be between about 10-70% of the height H C  of the containers C or the carton width W 1 . In other embodiments, the width W 3  is between about 30-50% of the height H C  or the carton width W 1 . In general, the widths W 2  and W 3  between the retainer sections  18 ,  78  are selected to be large enough so that a user can insert a finger into the dispenser opening  105  and pull a container C upwardly and out through the dispenser opening  105 . 
       EXAMPLE 1  
       [0034]    A carton as illustrated in  FIGS. 4-13  accommodated twelve 12-ounce cans. The cans were arranged in a 2×6×1 arrangement, as shown in  FIG. 4 . The curved access deformation lines  54 ,  56  were generally circular arcs comprised of cut-crease lines, with the cuts extending through the blank (i.e., 100% cuts). The deformation lines  52 ,  53 ,  58  were crease lines. 
         [0035]    For purposes of illustration, the present invention is generally disclosed in the context of paperboard cartons or packages sized and dimensioned to contain generally cylindrical beverage containers in a two-row configuration with multiple columns of beverage containers included in each row. Other types of containers, however, can be accommodated within a carton according to the present invention. The dimensions of the blank may also be altered, for example, to accommodate various container forms. 
         [0036]    The blank  8  can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blank can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blank may then be coated with a varnish to protect any information printed on the blank. The blank may also be coated with, for example, a moisture barrier row, on either or both sides of the blank. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling a dispenser to function as described above. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
         [0037]    In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. 
         [0038]    A tear line can be any substantially linear, although not necessarily straight, breachable line of disruption that facilitates tearing therealong. Specifically, but not for the purpose of narrowing the scope of the present invention, tear lines include: a cut that extends partially into the material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type of tear line is a series of cuts that extend completely through the material, with adjacent cuts being spaced apart slightly so that small somewhat bridge-like pieces of the material (e.g., ‘nicks’) are defined between adjacent cuts. The nicks are broken during tearing along the tear line. Such a tear line that includes nicks can also be referred to as a cut line, since the nicks typically are a relatively small in relation to the cuts. 
         [0039]    The term “line” as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines. 
         [0040]    The above embodiments may be described as having one or panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place. 
         [0041]    In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections. 
         [0042]    The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected embodiments of the invention, but it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art.