Abstract:
An easy to carry lightweight carton for shipping and storing cut paper and for providing rapid and easy access to the paper when the carton is opened. The carton has a base portion and a lid pivotally attached to the base portion. A front wall of the carton may be pivoted down when the lid is pivoted up to facilitate access to the contents of the carton for ease of unloading of paper from the carton. A carry handle is built into the lid to facilitate carrying of the carton. The carton may be re-closed after it is opened.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation-in-part of U.S. patent application Ser. No. 11/445,446, filed Jun. 1, 2006, which in turn claims the benefit of U.S. provisional patent application Ser. No. 60/772,468, filed on 10 Feb. 2006, U.S. provisional patent application Ser. No. 60/698,156, filed on 11 Jul. 2005, and U.S. provisional patent application Ser. No. 60/686,211, filed on 1 Jun. 2005, all of which are hereby incorporated hereinto by reference as if fully restated herein. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Technical Field of the Invention  
         [0003]     This invention relates to packaging, and especially to a package for paper products. More particularly, the invention relates to a shipping and storage carton for cut sheets of paper, wherein the carton has a size and weight to promote easy handling and storage and has an easy-opening feature including a fold-down side to facilitate access to the paper. The carton may be reclosed after opening to keep unused paper fresh and neatly stacked, and has a built-in handle for ease and convenience in carrying the carton.  
         [0004]     2. Brief Description of the Related Art  
         [0005]     Cut-sized paper, such as conventional photocopy paper, typically is wrapped in reams each containing, for example, 500 sheets. It is common for a plurality of reams to be bundled together and packaged in a corrugated container for shipping, storage and handling. For example, it is common to package from five to ten reams of paper in a single container, with a lid secured over the container to keep the reams from falling out of the container during shipping and handling. Since a single ream of paper weighs about five pounds, packages containing from five to ten reams of paper are heavy and difficult to handle. Moreover, they are relatively large and require substantial storage space. Further, the reams of paper are closely surrounded by the container walls, and the lack of space between the reams of paper and the container walls makes it difficult to remove the reams of paper for use. Additionally, each ream must be individually opened to gain access to the paper, and the ream wrap disposed of.  
         [0006]     Single wrapped reams of paper also are commonly sold, and although these packages are easy to handle and store, they do not protect the paper from physical damage. Further, most equipment used in the home or in small offices does not hold a full ream of paper. Consequently, after a ream is opened and the desired amount of paper removed, the remaining unused paper is unprotected.  
         [0007]     Many home and small office users prefer to purchase several reams of paper at once, rather than to buy single reams more frequently, but prefer not to buy as many as ten reams at once. Packages have been developed that hold five reams of paper, but even these packages are heavy, and, as such, are more suitable for industrial and commercial purchasers, which typically will have material handling equipment such as power lifts and hand carts to handle such heavy items. Average home users who wish to purchase several reams of paper at once typically do not have access to such material handling equipment.  
         [0008]     Unwrapped cut sheets of paper are sometimes packaged loose in cartons designed to closely fit the paper and protect it from damage. Unwrapped cut sheets of paper do not require removal and discarding of ream wrap, but conventional cartons of this type generally are also sized to hold from five to ten reams of paper and thus are relatively difficult to handle and store. Moreover, these cartons generally have either a removable lid or foldable flaps to close the top of the carton, and the lid is removed or the flaps opened to form an open top through which product is removed from the carton. With such packaging it is difficult to remove the contents without damaging the carton or inverting it to pour the contents out because of the lack of space to insert the hands of the user between the side walls of the carton and the paper stored therein.  
         [0009]     Additionally, and particularly for the larger containers that are commonly used for shipping and storing cut sheets of paper, it is common for the stacks of paper to stand taller than the container base sidewalls, whereby the lid actually rests upon the top of the stacks rather than on the upper ends of the container sidewalls. Because it is common for several containers to be stacked on top of one another during shipping, reams of paper packed in the stacked containers typically compress as air that was trapped between the individual sheets within the reams during the wrapping process is “squeezed” out. As a result, it is not uncommon for the containers to be compressed as the stacks of reamed paper compress. That is, as the individual reams compress, it is not uncommon for the containers to become “less tall” by virtue of the fact that the container lid (which rests upon the top of the paper stacks) moves closer towards the container base. For this reason, paper suppliers prefer not to secure the lids directly to the container bases using an adhesive because the shear strength of typical hot melt adhesives cannot withstand the shear strain resulting from movement of the lid relative to the container base. In such situations, the lids become disassociated from the container bases, thereby permitting the reams of paper to spill out of the container. Free lids also become entangled in automated material handling equipment, thereby causing machine shut downs and shipping inefficiencies. Thus, it has become common to utilize ancillary securing devices, such as straps and the like, rather than or in addition to adhesive, to hold such container lids onto their respective bases. However, such devices do not always prevent the lids from becoming disassociated from the bases. For example, as the containers are compressed (for the reasons described above), the straps are loosened and are free to slip either partially or entirely off of the container, allowing the lids to become disassociated from the bases, resulting in product spillage and/or damage. In addition to the free lids (which may become entangled in material handling equipment), the free straps may likewise become entangled in the material handling equipment, resulting in machine shut downs and shipping inefficiencies. Operator safety is also reduced, as the free straps and free lids clutter the workspace.  
         [0010]     It is desirable therefore to provide a carton for shipping and storing sheets of paper, such as photocopy paper or the like, which not only is smaller and lighter in weight than conventional multi-ream containers and accordingly is easier to handle and store, but which also protects the paper against physical damage from the environment.  
         [0011]     It is also desirable to provide a carton that enables the sheets of paper to be easily and quickly unloaded from the carton, wherein the carton is adapted to remain sealed during shipping, handling and storing operations without the need to utilize ancillary securing devices such as straps and the like, and wherein the carton may be reclosed after opening.  
         [0012]     In addition, it is desirable to provide an apparatus, such as a carry handle or the like, associated with the carton to facilitate handling thereof. A combination of a smaller multi-ream container together with a carry handle, for example, is ideally suited for retail sales to home users.  
       SUMMARY OF THE INVENTION  
       [0013]     The present invention comprises a carton for shipping and storing cut sheets of paper, wherein the carton holds fewer sheets of paper than conventional containers for this purpose, and is therefore lightweight and easy to handle and store. The carton is constructed for easy access to the paper for unloading it from the carton, and is particularly adapted to ship and store unwrapped sheets of paper, although it may be adapted for shipping and storing individually wrapped reams of paper.  
         [0014]     The carton includes a base portion having at least one side wall that may be pivoted downwardly to open the carton and expose the contents for easy removal, and a lid portion engaged over the base portion to close the top of the carton and normally hold the pivoted side wall in closed position. When the lid is opened, that side wall may be pivoted downwardly to expose the paper at the top and one side to facilitate access to it.  
         [0015]     The openable side wall enables the user to easily and quickly grasp and unload the paper stored in the carton, without the necessity of forcing the hands or fingers between the carton side walls and the contents, or turning the carton over and dumping out the contents. Moreover, the lid and openable side wall may be reclosed to protect the paper remaining in the carton.  
         [0016]     In a preferred embodiment the carton of the invention has a built-in carry handle and is adapted to hold more than one ream of paper, but less than the five or ten reams normally placed in a conventional package. For example, the carton of the invention is adapted to hold approximately three reams of paper, resulting in a lightweight package that is easy to handle. It is not intended, however, to limit the invention to a carton for holding three reams of paper. The carton can be adapted for any quantity of paper, but is generally limited to an amount that is easy to handle and store and that the built-in carry handle can reliably support, which generally does not substantially exceed three reams. After the carton is opened, the user may simply grasp and unload as many sheets as desired, without the need to open individual reams, and the carton may be reclosed to protect the unused sheets.  
         [0017]     In a preferred construction, the base portion comprises a bottom wall, opposite end walls, and front and back walls folded from a single unitary blank of corrugated paper. End flaps on the back wall are folded inwardly and secured to the end walls by adhesive or other suitable fastening means so that the back wall and end walls remain in an upright position. End flaps or tuck-in flaps on the front wall are folded inwardly but are not attached to the end walls. Instead, they tuck in between the end walls and paper held in the carton, whereby the front wall can be pivoted downwardly to open the front of the carton. After the desired quantity of paper is removed from the carton, the front wall can be pivoted back up to an upright position, with the tuck-in flaps tucked between the end walls and paper to re-close the carton.  
         [0018]     The lid portion comprises a lid folded from a single unitary blank, with an insert sheet and carry handle assembled to it. The lid has a top wall, depending end flanges, and depending front and back flanges. The back flange has end flaps on its opposite ends, turned inwardly to lie inside and parallel to the end flanges but unattached to the end flanges. In the assembled carton, the lid back flange and associated end flaps are secured by adhesive or other suitable fastening means to the back wall and end walls, respectively, of the base portion. The lid front flange has a width to extend downwardly over an upper edge portion of the base portion front wall, to hold the front wall in its upright closed position when the lid is in its operative closed position. End flaps on opposite ends of the front flange are turned inwardly to lay inside and parallel to the end flanges and are attached to the end flanges by adhesive or other suitable fastening means. A glue strip on the bottom edge of the lid front flange is secured by adhesive or other suitable fastening means to the base portion front wall, and a tear strip extends along the bottom edge of the front flange between the front flange and the glue strip. With this construction, when the tear strip is removed the lid may be pivoted upwardly to expose the paper held in the carton and uncover the front wall so that it may be pivoted downwardly to facilitate access to the paper.  
         [0019]     A carry handle is attached to the lid to facilitate carrying the carton, and comprises a flexible strap attached to a base plate that is secured beneath an insert panel placed in the lid between the lid top wall and the top sheets of paper. The flexible strap extends through aligned openings in the insert panel and lid top wall. The insert panel may comprise corrugated cardboard, or chipboard, or other suitable material.  
         [0020]     The carton of the invention may be opened to gain access to the paper stacked inside, and reclosed to protect the remaining paper. It does not require substantial adhesive attachment between the lid and the base, or separate securing means such as straps to keep the lid assembled to the base. Further, the carton preferably holds more than one ream of paper, preferably about three reams, and because of its reduced size and weight, and the provision of a carry handle, the carton is easy to carry and store. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]     A better understanding of the invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like reference numerals represent like parts, and wherein:  
         [0022]      FIG. 1  is a plan view of the blank from which the carton base is formed;  
         [0023]      FIG. 2  is a plan view of the blank from which the lid is formed;  
         [0024]      FIG. 3  is a plan view of the insert sheet used in assembling the carry handle to the lid;  
         [0025]      FIG. 4  is a perspective view of the lid in an inverted, upside-down position;  
         [0026]      FIG. 5  is an exploded top perspective view of the lid and carry handle assembly of the carton of the invention;  
         [0027]      FIG. 6  is a top perspective view of the base portion of the carton of the invention, with the lid omitted and the front wall partially pivoted toward an open position;  
         [0028]      FIG. 7  is a top perspective view of a preferred package constructed in accordance with the invention;  
         [0029]      FIG. 8  is a top perspective view of the package of  FIG. 7 , showing the tear strip removed and the lid pivoted upwardly, with the movable front wall pivoted to a partially open position, and wherein the carton contains unwrapped sheets of paper;  
         [0030]      FIG. 9  is a top perspective view of the package of  FIG. 8 , with the lid pivoted to a fully open position and the movable front wall pivoted fully downwardly; and,  
         [0031]      FIG. 10  is a top perspective view of the package of  FIG. 9 , with the lid and front wall returned to their closed positions. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0032]     A preferred carton in accordance with the invention is indicated generally at  10  in the drawings. The carton comprises a rectangularly shaped base portion  11 , a lid portion  12 , and a carry handle  13 . The base portion has a bottom wall  14 , opposite end walls  15  and  16 , a back wall  17 , a movable front wall  18 , and an open top  19 . The lid  12  is telescopically received over the open top and has a top wall  20 , depending end flanges  21  and  22 , a depending back flange  23 , and a depending front flange  24 . A glue strip  25  is joined to the bottom edge of the front flange to secure the front of the lid to the base portion front wall, and a tear strip  26  extends between the front flange and glue strip to separate the front flange from the glue strip and enable the lid to be pivoted upwardly.  
         [0033]     Details of construction of the base portion  11  can be seen best with reference to  FIGS. 1 and 6 . A blank B 1  for making the base portion  11  is illustrated in  FIG. 1 , and comprises bottom wall panel  14 , opposite end wall panels  15  and  16  foldably joined to opposite ends of the bottom wall panel, back wall panel  17  foldably joined to a back edge of the bottom wall panel, and movable front wall panel  18  foldably joined to a front edge of the bottom wall panel. Glue flaps  27  and  28  are foldably joined to opposite ends of the back wall panel, and tuck-in flaps  29  and  30  are foldably joined to opposite ends of the front wall panel.  
         [0034]     Assembly of the base portion  11  is seen best in  FIG. 6 . The glue flaps  27  and  28  on opposite ends of the back wall  17  are folded inwardly and glued or otherwise suitably fastened to the inner surface of the respective end walls  15  and  16 , but the tuck-in flaps  29  and  30  on opposite ends of the front wall  18  are merely folded inwardly to lie against the inner surface of the end walls. The tuck-in flaps slide along the end walls, between the end walls and paper held in the carton, when the front wall  18  is moved between its upright and lowered pivoted positions. The tuck-in flaps may be suitably shaped, e.g., with a curvilinear free end edge  31  as shown, to facilitate entry of them into the space between the end walls and paper as the front wall is moved to its upright closed position. A finger access cut-out  32  may be provided in the upper edge of the front wall  18  to facilitate moving it downwardly, if desired.  
         [0035]     Details of construction of the lid portion  12  can be seen best with reference to  FIGS. 2-5 . A blank B 2  for making the lid  12  is illustrated in  FIG. 2 , and comprises top wall panel  20 , end flange panels  21  and  22  foldably joined to opposite ends of the top wall panel, back flange panel  23  foldably joined along fold line L to a back edge of the top wall panel, and front flange panel  24  foldably joined along a front edge of the top wall panel. Glue strip panel  25  is joined to the free edge of the front flange panel by tear strip  26  extending between the front flange and glue strip to enable separation of the front flange from the glue strip. First glue flaps  33  and  34  are foldably joined to opposite ends of the front flange panel  24 , and second glue flaps  35  and  36  are foldably joined to opposite ends of the back flange panel  23 . A shaped opening  37  is formed generally through the center of the top wall panel to receive the carry handle  13  as described below.  
         [0036]     As seen best in  FIG. 4 , the first glue flaps  33  and  34  on opposite ends of the front flange panel  24  are secured by adhesive or other suitable fastening means against the inner surface of the respective end flanges  21  and  22 , but the second glue flaps  35  and  36  are merely folded inwardly parallel to the end flanges and are not attached thereto. A band of adhesive  38  is applied along a bottom edge of the back flange panel  23  and a bottom edge of the second glue flaps  35  and  36  to attach these parts to the back wall and end walls, respectively, of the base portion when the lid is assembled to the base. The glue strip  25  also is adhesively attached to the base front wall, and with the band of adhesive  38  comprises the only adhesive attachment of the lid to the base portion. This permits the lid to be pivoted upwardly about the fold line L when the tear strip is removed to separate the front flange of the lid from the glue strip (see  FIG. 8 ). That is, the end flanges  21  and  22 , being free of attachment to the second glue flaps  35  and  36 , are permitted to slide along the glue flaps and not resist upward movement of the lid as it is raised to its upward pivoted position.  
         [0037]     As seen best in  FIG. 5 , the carry handle  13  includes a flexible strap  40  attached to a rectangular base plate  41  that is adhesively attached to the bottom of an insert sheet  42  sized to fit in the lid beneath the top wall, with the strap projecting through a shaped opening  43  in the sheet  42  and through the shaped opening  37  in the lid top wall. The sheet  42  may be adhesively attached to the underside of the lid top wall, or merely fit into the lid between the top wall and the paper sheets without being attached to the top wall. Either way, this construction results in a very strong carry handle.  
         [0038]     As seen in  FIGS. 7-10 , the package is compact, enabling it to be easily stored under a desk or on a shelf Opening of the package is easily accomplished simply by removing the tear strip and pivoting the lid upwardly, after which the front wall can be pivoted downwardly to gain access to the paper held in the carton. After the desired amount of paper has been removed, the front wall can be returned to its upright position, with the tuck-in flaps inserted between the base end walls and the paper held in the carton, and the lid returned to its lowered position to close the package and hold the front wall in its closed position.  
         [0039]     While the invention has been shown for holding unwrapped sheets of paper, it should be understood that it could be used for holding wrapped reams of paper, and although the preferred embodiment is designed for holding about three reams of paper, the carton could be sized for holding other quantities of paper so long as the size and weight do not exceed amounts (for example, about 20 pounds) that provide ease of handling and carrying by the carry handle.  
         [0040]     While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims.