Abstract:
A method for controlling the delamination of a package at the exposed edges of the package is disclosed. A carton is formed with a panel comprising at least one exposed edge, at least one partial depth cut proximate to the exposed edge, and a removable section positioned between the exposed edge and the partial depth cut. The separation of the removable section from the carton leaves an exposed edge with a reduced thickness, inhibiting delamination of the panel from the rest of the carton.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates to the field of packaging, and more particularly, to controlled delamination at the cut edges of a package. 
       BACKGROUND OF THE INVENTION 
       [0002]    A folding carton is typically formed by folding the various panels of a blank in a predetermined order and direction. The layout of the blank is manufactured using a die cutter with knife edges perpendicular to the face of the blank. As a result, the die cut edges of the blank have 90-degree or similar angles. Generally, assembly of the folding carton will have at least one flap which contains an exposed die cut edge. The paperboard material commonly utilized for folding carton ranges from 0.014 inches to 0.024 inches thick. This thickness of paperboard provides sufficient strength for the folding carton to maintain its shape and securely hold its contents. As a result, the exposed die cut edges have at least the thickness of the paperboard. This thickness allows an individual to use a fingernail to pick at the die cut edge on the flap and potentially pull the folded flap away from the rest of the carton, thereby providing access to the contents of the carton. 
         [0003]    Certain folding cartons, including for example those utilized for distribution of pharmaceutical drugs, contain contents that can be harmful or even lethal if accessed and misused. Thus, it is desirable to reduce the ability of children or mentally impaired adults from tampering with the exposed die cut edges of a carton. As described above, the exposed die cut edges can allow such individuals to access the contents of a folding carton by delaminating the top surface of the folding carton or separating panels adhesively coupled at the exposed die cut edge. In the case of a child-resistant package with a specific unlocking feature, ripping at the die cut edge of a glued panel can circumvent the child-resistant features altogether. Further, opening a folding carton in this manner can result in damage to the contents, particularly if the contents fall out of the package. 
         [0004]    To provide greater tamper resistance, manufacturers have considered methods for improving a folding carton in order to restrict tampering with the exposed cut edges. Such methods tend to add expense to the material and production costs. Techniques utilizing plastic laminations are common, but increase cost due to the lamination material and the time and machinery necessary to perform the lamination. Synthetic, tear-resistant paper and plastic sheets have also been used, but are expensive compared to traditional paperboard and are difficult to recycle. A plastic thermoform clam-shell packaging may be used, but such packages utilize plastic and can involve a difficult opening mechanism. Further, business that are concerned about their carbon footprint tend to avoid the use of both lamination and synthetic materials due to environmental effects and consumer complaints regarding the use of plastics. 
         [0005]    Another approach would be to use a die cutting tool that results in a bevel or recess at the cut edges. This approach is disadvantageous because the cut edge would expose the inner fibers of the paper and, at a minimum, would remove the smooth printable surface of the paper. 
         [0006]    Thus, there is a clear need to control the delamination at the cut edges of a folding carton without resorting to the use of plastic. There is a further need for a folding carton that is environmentally friendly and which requires minimal modifications to the layout of the blank, thereby reducing cost and increasing speed to market. 
       SUMMARY OF THE INVENTION 
       [0007]    The present disclosure provides an apparatus and method for controlling the delamination at the cut edges of a carton. A carton is formed comprising at least one exposed edge, at least one partial depth cut, and a removable section positioned between the exposed edge and the partial depth cut. The separation of the removable section from the carton results in two distinct edges, each with a reduced thickness. The reduced thickness inhibits further delamination. 
         [0008]    Other objects, features, and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure and the combination of parts, will become more apparent upon consideration of the following detailed description with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    A further understanding of the invention can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated embodiment is merely exemplary of systems and methods for carrying out the invention, both the organization and method of operation of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention. 
           [0010]    The detailed description makes reference to the accompanying figures wherein: 
           [0011]      FIG. 1  is a top plan view of the carton in accordance with the preferred embodiment of the invention in an unfolded position; 
           [0012]      FIG. 2  is a top plan view of the carton of  FIG. 1  with the locking ramp, top right panel, and left panel folded; 
           [0013]      FIG. 3  is a top plan view of the carton of  FIG. 1  with the inside panel further folded over the top panel; 
           [0014]      FIG. 4  is a top plan view of the carton of  FIG. 1  with the bottom right panel folded, and the top panel further folded over the bottom panel and bottom right panel; and 
           [0015]      FIG. 5A  is a side view of a carton with a delaminated material affixed; 
           [0016]      FIG. 5B  is a side view of the carton of  FIG. 5A  with the delaminated material removed. 
           [0017]      FIG. 6A  is a partial top perspective view of a carton with removable sections affixed; and 
           [0018]      FIG. 6B  is a partial top perspective of the carton of  FIG. 6A  with the removable sections removed. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0019]    A detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, methods, processes, systems, and operating structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention. 
         [0020]    None of the terms used herein, including “carton,” “panel,” “flap,” “edge,” and “section” are meant to limit the application of the invention. References to angles, including references to 90 degrees and 180 degrees, are approximate and intended to convey the concepts disclosed herein. The terms are used to illustrate the preferred embodiment and are not intended to limit the scope of the invention. Similarly, the use of these terms is not meant to limit the scope or application of the invention, as the invention is versatile and can be utilized in many applications, as will be apparent in light of the disclosure set forth herein. 
         [0021]    Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word as appropriate: any of the items in the list, all of the items in the list, and any combination of the items in the list. The following presents a detailed description of the preferred embodiment of the present invention with reference to the figures. 
         [0022]    Referring initially to  FIG. 1 , blank  100  preferably comprises paperboard and may optionally be coated in part or in whole with a polymer coating and/or lamination to make it more tear resistant. In other non-limiting embodiments, blank  100  can be made from durable paper, composite material, or other similar materials. Blank  100  is comprised of several panels which are folded along predetermined fold lines or pre-break lines in order to form a sleeve. The fold lines are scored and the pre-break lines are formed by a creasing operation, both of which are provided to make it easier to fold the various panels during assembly of the sleeve. During the manufacturing process of a sleeve, the several panels are folded at desired folding angles (e.g., 90 degrees or 180 degrees) and several panels may be glued to fixably couple the panels together. 
         [0023]    As shown, blank  100  comprises inside panel  102 , top panel  104 , bottom panel  106 , and top printing panel  108 . Inside panel  102  includes locking ramp  124  and top right panel  118 . Top right panel  118  is folded in relation to inside panel  102  about pre-break line  116 , and locking ramp  124  is folded in relation to inside panel  102  about pre-break line  122 . Inside panel  102  comprises a substantially rectangular cutout  126  to form edge  128 . Inside panel  102  and top right panel  118  together comprise a substantially circular or oval cutout  114  centered on pre-break line  116 . Further, top right panel  118  comprises a hook  120 . 
         [0024]    Also shown in  FIG. 1 , inside panel  102  is folded in relation to top panel  104  about fold line  130  and pre-break line  134  to form inside folding panel  132  between inside panel  102  and top panel  104 . Top panel  104  includes a substantially semi-spherical cut-out  136 . Top panel  104  is folded in relation to bottom panel  106  about fold line  140  and pre-break line  144  to form left folding panel  142 . Flap  138  is attached to left folding panel  142  and is folded in relation to left folding panel  142 . Top rear panel  154  is folded along pre-break line  152  to form a back wall for the sleeve. Top rear flap  158  is folded along pre-break line  156  to form a flap that will be sealed to top printing panel  108 . Top rear flap  158  comprises partial depth cut  160  along its outside edge. Bottom panel  106  and bottom right panel  150  together comprise a substantially circular or oval shaped cutout  146  centered on pre-break line  148 . 
         [0025]    Top printing panel  108  is folded in relation to bottom panel  106  about fold line  164  and pre-break line  168  to form right folding panel  166  between top printing panel  108  and bottom panel  106 . Right folding panel  166  includes flap  162  that is folded in relation to right folding panel  166 . Bottom rear panel  174  is folded along pre-break line  172 . Top printing panel  108  comprises partial depth cut  170  along its outside edge opposite pre-break line  168 . 
         [0026]    Referring to  FIGS. 2, 3, and 4 , the process of assembling a sleeve comprises folding the various panels of blank  100  in a predetermined order. While the process of assembling and affixing the sleeve in position is provided in detail, one of ordinary skill in the art will readily recognize that similar construction may be employed in like devices to accomplish the desired construction without departing from the spirit of the present invention. First, as shown in  FIG. 2 , locking ramp  124  is folded 180 degrees along pre-break line  122  and top right panel  118  is folded 180 degrees along pre-break line  116 . Left panel  110  is folded 90 degrees in relation to inside panel  102  along pre-break line  112 . 
         [0027]    Next, as shown in  FIG. 3 , inside panel  102  is folded 90 degrees in relation to inside folding panel  132  along fold line  130 . Inside folding panel  132  is folded along pre-break line  134  to position inside panel  102  within the perimeter of top panel  104 . Further, bottom right panel  150  is folded 180 degrees along fold line  148 . 
         [0028]    As shown in  FIG. 4 , top panel  104  is folded 90 degrees in relation to left folding panel  142  along fold line  140  and resides within the perimeter of bottom panel  106  when left folding panel  142  is folded 90 degrees along pre-break line  144 . Further, left panel  110  is adhesively coupled to left folding panel  142  by gluing the exterior surface of left panel  110  to the inside surface of left folding panel  142 . In the preferred embodiment, locking ramp  124  is held in place by abutting top panel  104 , but in other embodiments may be adhesively coupled to top panel  104 . Next, top printing panel  108  is folded 90 degrees in relation to right folding panel  166  along fold line  164  and resides within the perimeter of top panel  104  when right folding panel  166  is folded 90 degrees along pre-break line  168 . Right folding panel  166  is adhesively coupled to inside folding panel  132  by gluing the inside surface of right folding panel  166  to the exterior surface of inside folding panel  132 . Top printing panel  108  is adhesively coupled to top panel  104  by gluing the inside surface of top printing panel  108  to the exterior surface of top panel  104 . 
         [0029]    Next, flap  162  is folded 90 degrees in relation to right folding panel  166 , and flap  138  is folded 90 degrees in relation to left folding panel  142 . Bottom rear panel  174  is folded 90 degrees in relation to top printing panel  108  along pre-break line  172 . Bottom rear panel  174  is adhesively coupled to flap  138  and flap  162  by gluing the exterior surface of flap  138  and flap  162  to the interior surface of bottom rear panel  174 . 
         [0030]    Top rear panel  154  is folded 90 degrees in relation to bottom panel  106  along pre-break line  152  (not shown) and top rear flap  158  is folded along pre-break line  156 . Top rear panel  154  is adhesively coupled to bottom rear panel  174  by gluing the exterior surfaces of flaps  138  and  162  to the interior surface of top rear panel  154 . Top rear flap  158  is adhesively coupled to top printing panel  108  by gluing the interior surface of top rear flap  158  to the exterior surface of top printing panel  108  to form a back wall for the sleeve. 
         [0031]      FIGS. 5A, 5B, 6A, and 6B  depict how delamination is controlled at the cut edges of a sleeve. As shown in  FIGS. 5A and 5B , sleeve  200  comprises upper panel  204  coupled to lower panel  202  using adhesive  212 . Upper panel  204  includes partial depth cut  206 , die cut edge  208 , and removable section  210 . In the preferred embodiment, lower panel  202  and upper panel  204  are composed of a paperboard material with a thickness ranging from 0.014 inches to 0.024 inches. It should be apparent to one of ordinary skill in the art to use a thickness and/or other materials that provide sufficient strength to allow the sleeve to maintain its shape and securely contain its intended contents. As shown in  FIG. 5A , die cut edge  208  extends through the thickness of upper panel  204 , and partial depth cut  206  extends only partially through the thickness of upper panel  204 . 
         [0032]    Turning next to  FIG. 5B , removable section  210  is shown removed from upper panel  204  between die cut edge  208  and partial depth cut  206 . The removal of removable section  210  may occur when an individual picks at die cut edge  208  with a fingernail or other object. Successfully gripping upper panel  204  at die cut edge  208  will allow the individual to remove removable section  210 , but as shown in  FIG. 5B , will not allow the individual to decouple upper panel  204  from lower panel  202 . After removable section  210  has been removed, the thickness of die cut edge  208  is reduced. Specifically, the removal of removable section  210  produces two distinct edges, each with a reduced profile. The reduced profile of each edge is more difficult to grip with a fingernail or other object, and thus the individual will have more difficulty attempting to decouple upper panel  204  from lower panel  202 . 
         [0033]      FIGS. 6A and 6B  depict sleeve  300  formed from a blank as described herein. Top rear flap  304  is adhesively coupled to top printing panel  302 . Top printing panel  302  is adhesively coupled to a top panel (not shown). Top printing panel  302  and top rear flap  304  include a die cut edge  308  and a partial depth cut  306 . Removable sections  310  and  312  are positioned between die cut edge  308  and partial depth cut  306  for top rear flap  304  and top printing panel  302 , respectively. As shown in  FIG. 6B , removable sections  310  and  312  have been removed. The removal may occur as a result of an individual picking at the edge of removable sections  310  and  312  with a fingernail or other object. After removal of removable sections  310  and  312 , the thickness of die cut edge  308  is reduced. Specifically, the removal of removable section  310  produces two distinct edges, each with a reduced profile. Similarly, the removal of removable section  312  produces two distinct edges, each with a reduced profile. The reduced profile of these edges is more difficult to grip with a fingernail or other object, and thus the individual will have more difficulty attempting to decouple the panels from top printing panel  302  by picking at the edges. 
         [0034]    While the present invention has been described with reference to the preferred embodiment, which has been set forth in considerable detail for the purposes of making a complete disclosure of the invention, the preferred embodiment is merely exemplary and is not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. It should be understood that while a carton is used to disclose the preferred embodiment, the principles disclosed herein are applicable to other forms of products and packaging. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics.