Patent Publication Number: US-2010116874-A1

Title: Easy Opening Feature for a Taped Carton and Method Thereof

Description:
FIELD  
     The invention relates generally to an easy open feature for a taped carton. 
     BACKGROUND  
     Products are often packaged and shipped in a taped shipping carton or box in order to transport and deliver large quantities of products to a specific location. The cartons are often sized large enough to hold multiple products and/or packages. The shipping cartons are often made out of corrugated paperboard or other material that is shaped as a rectangle or square parallelepiped and has flaps that fold over on an upper surface and a lower surface to close the carton. As the flaps are folded, they are often secured by a strip of tape, or other similar adhering means, to keep the folded flaps together and sealed. The tape is often strongly bonded to the paperboard material of the carton and cannot easily be removed without tearing apart or cutting the carton, the tape, or both. 
     Once the sealed carton has reached its destination, the carton needs to be opened in order to gain access to the contents. One typical method to remove the tape can involve using a knife or other tool to slit the tape. However, with this method a user must take care not to cut too deeply so that the contents of the carton are not damaged by the knife. Another method is for the user to simply try to tear the tape and/or carton apart without any tools in order to gain access to the contents. This method can present a challenge if the user does not have enough force to tear off the tape or to tear apart the carton, and the carton and contents can become damaged or disfigured upon application of the necessary force. 
     As a result, there are various carton designs that try to improve upon the opening and/or sealing mechanisms of shipping cartons. 
     In U.S. Pat. No. 3,302,857, a container has an opening feature that consists of a weakened line of separation along top flap closures and a removable area along a side end wall. Tape can be placed over the weakened line of separation and down the side end wall over the removable area. To open the container, the removable area must be pressed inwardly, toward the interior of the container, to first free a portion of the edges of the removable area from the container side wall. The freed lower end of the removable area that is then exposed can be grasped and pulled outwardly to remove it from the interior of the container and then pulled upward. As the removable area is pulled upward, the container will continue to tear along the weakened portion of the top flap closures, which removes a portion of the top flap closures from the top flaps along with the tape that is adhered across the top of the weakened portions. To open the container, one must punch out the removable area from the side panel of the container, then pull up on the removable area to rip or separate the weakened portion of the top flap closures from the top part of the container. The top portion of the container and part of the side become torn in doing so. If the container were to be reclosed, the top flap closures would not close completely, having a gap therebetween. Additionally, there is a large amount of waste to dispose of after opening the container, i.e., the tape plus a portion of the paperboard container. 
     U.S. Pat. No. 6,471,120 describes a bag-in-box package or carton that can be closed or sealed without the use of tape simply by folding over and adhering the top panel to the carton. The top panel consists of a pair of major flaps and a pair of minor flaps, both visible from the top of the carton and both making up the top surface of the top panel. The carton is opened by pulling up on a tear strip grip that is attached to a tear strip which extends across the top panel of the carton and is ripped away upon pulling the grip upward across the top of the carton. The tear strip can consist of a weakened line, perforation, string, or other structure that aids in ripping and that divides the minor flaps into two segments to allow for the tear strip to pass therethrough. Upon opening the carton, the tear strip is pulled to tear or separate the minor flaps into two segments, while the minor flaps are still adhered to the carton, and to open the pair of major flaps. The carton only opens between the major flaps and not the minor flaps, which remain sealed or closed. Thus, access to the entire interior of the carton is limited. Furthermore, opening the carton requires effort to break apart a portion of the paperboard carton in order to open the top major flaps of the carton. 
     Therefore, a need remains for an easy to open feature that can enable removal of a tape strip without requiring the use of tools. 
     SUMMARY  
     An easy-open pull tab feature and method of opening is provided for a sealed and taped shipping carton. In a preferred embodiment, at least one partially perforated shape or removable pull tab is cut into the side of a shipping carton blank at the time of manufacture. The pull tab can be adjacent a hand-hold opening or can have its own access hole therein. Through the adjacent opening, the user can insert a finger behind the back of the tab and lift the tab upward in order to lift up and remove the partially perforated pull tab from the carton and as a result lift with it the tape that was applied to a top panel to seal the filled carton. The pull tab can then act as an anchor to pull and separate the tape from the carton along the remainder of the top panel in order to open the carton. 
     The partially perforated pull tab is positioned on an end panel of the shipping carton such that when the carton is taped to seal major flaps along the top panel together, the tape extends down the side end panel of the carton and covers a portion of the pull tab. No additional glues or adhesives are required to seal the flaps of the carton in order to close the carton. Furthermore, an end of the tape extends down along a side of the end panel of the carton and terminates at the tab, without leaving any loose end of tape exposed that may adhere to other surfaces such as other portions of the carton. Additionally, the user pulls up on an anchor, i.e., the tab, to initiate tape removal, rather than pulling on the tape strip itself which can tear or rip before removal of the entire strip can be effected. 
     As a result of the tab being provided adjacent to the opening, a lower edge of the tab is already accessible and free-standing from the rest of the carton, with only a portion of the tab connected to the carton along a perforated area or weakened region. This allows one to grasp the lower edge of the tab and to place one&#39;s fingers behind the tab in order to pull on the tab and lift it up and away from the perforated area of the carton without requiring excessive force and without requiring one to first push in the tab, since not all of the tab&#39;s edges are attached to the carton. The tab can be joined to the end wall by at least a portion of the weakened region yet have sufficient strength to permit the filled carton to be supported thereat by manual engagement of the tab at the opening without fracturing the weakened region. Thus, the tab can be removable by application of an outward manual force in excess of the outward manual force associated with supporting the filled carton by the tab so that the tape can be peeled off of the carton by fracturing the weakened region and then pulling the tab up and across the top of the carton. 
     Additionally, as the portion of the tab connected to the carton is released along its perforated area and lifted up, the tape strip placed over the top panel and part of the side end panel is also lifted up with the tab. As the tab is continually lifted upward, the tape strip from the top panel of the carton is also removed. Therefore, with the exception of the small piece of tab removed from the end panel of the carton, there is no significant ripping or tearing of the carton itself in order to remove the tape strip from the top panel of the carton. 
     After the tape strip is removed from the carton, the top panel and, in particular, a pair of flaps, i.e., major flaps, having adjacent edges can be pivotable between an open and closed position such that the carton can be completely opened to expose the entire interior area of the carton allowing complete accessibility to the contents packaged inside. If desired, the carton can be completely reclosed by folding the major flaps into a closed position without having any gaps between the flaps due to opening the carton. Furthermore, the remaining waste from opening the carton only consists of the tape strip and the small tab piece, rather than a large portion of the carton being ripped up with the tape strip. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         FIG. 1A  is a perspective view of an assembled carton that is sealed with tape across its top panel and down a portion of its end panel and tab; 
         FIG. 1B  is a detailed view of an end panel of the carton of  FIG. 1A ; 
         FIG. 2  is a perspective view of  FIG. 1A  showing the tab being lifted up and removed from the end panel; 
         FIG. 3  is another perspective view of  FIG. 1A  showing the tape being removed from the top panel of the carton using the tab to initiate the removal; and 
         FIG. 4  is a plan view of a blank used to make the carton shown in  FIG. 1A . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS  
     A carton having an easy-opening feature, such as a removable tab, that can be easily removed from the carton while also removing a tape strip along with it, and methods for opening the carton, are disclosed herein and illustrated in  FIGS. 1-4 . 
     In particular, as illustrated in  FIG. 1A , an assembled and sealed carton  10  is shown having a bottom panel  24 , a top panel  22 , a pair of side panels  26   a  and  26   b  that connect the top  22  and bottom  24  panels, and a pair of end panels  28   a  and  28   b  adjacent the side panels  26   a  and  26   b  and also connecting the top  22  and bottom  24  panels and further comprising at least one opening  12   a  therein having a partially perforated removable tab  14   a  adjacent the opening  12   a.  Alternatively, the tab provided on the end panel can have its own access opening or hole. A tape strip  16  can be applied to the top panel  22  of the carton  10  to seal and close the carton  10  while an end  17  of the tape strip  16  terminates at the tab  14   a.  Upon removing the partially perforated tab  14   a  from a perforated area  18  of the end panel  28   a,  the tape strip  16  is removed along with it. 
     The opening is located at one of the end panels  28   a  or  28   b.  The tab  14   a  is at least partially perforated and adjacent the opening  12   a.  Optionally, an opening  12  may be provided at each end panel  28   a  and  28   b,  and each opening  12  may also have a tab  14  adjacent the opening  12 , such that the tape strip  16  and tab  14  can be removed at either end. As can be seen in more detail in  FIG. 1B , the tab  14   a  has a weakened area  18 , such as a score line, a perforated portion, or the like, along one portion of the tab  14   a,  and a lower edge  20  that is not perforated or weakened. The lower edge  20  defines a portion of an upper edge of the opening  12   a,  and further provides for a grasping point or anchor upon removal of the tab  14   a,  as will be described herein. 
     The tab  14   a  can have any shape, and in one aspect, it can have a semi-circular shape where a curved edge portion is at least partially perforated, as shown in  FIG. 1B , and is attached to the end panel  28   a  via the curved edge portion, which in this aspect can comprise both a perforated portion  18  and a non-perforated portion  19 . The perforated portion  18  can make up the majority of the curved edge of the tab  14 , with a small, i.e., less than  10  percent, of the edge being a non-perforated portion  19 . The tab  14  is preferably partially perforated with a small section  19  adjacent the opening  12  being non-perforated. The non-perforated section  19  just adjacent the opening  12  gives the tab  14  extra durability and strength, such that the tab  14  cannot be accidentally removed or ripped away from the carton  10 , such as when carrying the carton  10  via its opening  12 . The straight edge  20  is not perforated and abuts a portion of the opening  12   a.    
     The carton  10  can be sealed with an adhesive strip, such as a tape strip  16 , that is placed over adjacent inner edges  38  and  40  of a pair of major flaps  30   a  and  30   b  on the top panel  22  of the carton  10  to keep the carton  10  closed and can extend down over the edges of the carton  10  between the top panel  22  and the end panels  28   a  and  28   b  and along a portion of the end panels  28   a  and  28   b.  At least one end  17  of the tape strip  16  can terminate at the tab  14   a,  at least partially covering the tab  14   a,  such that the end  17  of the tape strip  16  generally does not extend past the lower edge  20  of the tab  14   a  and into the opening  12   a.  The opposite end of the tape strip  16  can also extend down the other side of the end panel  28   b  and if an opening and tab is also present, then the opposite end of the tape strip  16  can likewise terminate at the opposite tab  14   b.  If the end  17  of the tape strip  16  is longer than the lower edge  20  of the tab  14   a,  then the tape strip  16  can be folded up and behind the tab  14   a  so that it wraps around the bottom or lower edge  20  of the tab  14   a  and seals to a back surface of the tab  14   a,  rather than extending into the opening  12   a.    
     The tab  14   a  further can have a width, w, that is at least as wide as a width, wT, of the tape strip  16  placed over the tab  14 , as shown in  FIG. 1B . The width, w, can also be wider than the tape strip width, wT. In one aspect, the tab  14   a  is semi-circular and has a width of about 2 inches and a radius of about 1 inch, with the width of the tape strip  16  not greater than about 2 inches. Preferably, the width, w, of the tab  14   a  will be wider than the width, wT, of the tape strip  16 . Where a second tab  14   b  is provided on the opposite end panel  28   b  the same features as discussed herein regarding the first tab  14   a  can likewise apply to the second tab  14   b.    
     Furthermore, the carton  10  can contain two openings  12   a  and  12   b,  as can be seen in  FIG. 4 , where a first opening  12   a  is on one of the end panels  28   a  and a second opening  12   b  is on the other end panel  28   b.  Accordingly, the carton  10  can also contain two tabs  14   a  and  14   b.  A first tab  14   a  is adjacent to the first opening  12   a,  and a second tab  14   b  is adjacent the second opening  12   b.  The second opening  12   b  is positioned generally opposite the first opening  12   a  when the carton is assembled. Where the carton  10  contains two openings  12   a  and  12   b,  the openings  12   a  and  12   b  can also be used as a handhold, such as for carrying or lifting the carton. The openings  12   a  and  12   b  can be used as such without disturbing the perforated area  18  of the tabs  14   a  and  14   b,  i.e., without also tearing or removing the tabs  14   a  and  14   b  from their respective end panel  28   a  or  28   b.  To offer additional strength to the tab  14  upon using its respective opening  12  as a handhold, the inner edges  19  of the tab  14  just adjacent the opening  12  can remain non-perforated to provide more durability upon transporting the carton  10 , with the remaining portion  18  of the tab  14  contained within the end panel  28   a  being perforated. The application of an outward manual force to remove the tab  14  is preferably in excess of the outward manual force associated with supporting a filled carton  10  at its tab  14  utilizing it as a handhold. Similarly, where only one opening  12  is provided, it may also be used as a handhold without a complimentary handhold or opening on the opposite end panel. 
     Turning again to  FIG. 4 , a blank  100  is illustrated that can be used to make the carton  10  as described herein. The manufacture of the blank  100  can be kept simple by providing one unitary piece that can have the openings  12   a  and  12   b  cut into the blank  100  as well as creating the perforated areas  18  of the tabs  14   a  and  14   b  all without the addition of extraneous materials to the blank  100 . If preferred, a small section  19  of the tab  14  just adjacent the opening  12  can remain non-perforated, as shown in  FIG. 4 . Additionally, the top panel  22  and the bottom panel  24  each contain a pair of major flaps and minor flaps which can be folded over upon each other to create a closure at the top  22  or bottom 24 panels. For instance, the bottom panel  24  has a pair of minor flaps  36   a  and  36   b  which can be folded at approximately a right angle to the adjacent end panel  28   a  or  28   b,  and can further have a pair of major flaps  34   a  and  34   b  that are then folded over the minor flaps  34   a  and  34   b  covering the minor flaps  34   a  and  34   b  to provide a closed surface for the bottom panel  24 . The major flaps  34   a  and  34   b  are also folded at approximately right angles to their adjacent side panels  26   a  or  26   b.  Once the major flaps  34   a  and  34   b  are folded to provide the closed bottom panel  24 , an adhesive or tape strip can be applied to adjacent edges  44  and  46  of the major flaps  34   a  and  34   b  and around the edge of the carton  10  to extend along a portion of the end panels  28   a  and  28   b  to keep the bottom panel  24  closed. 
     Similarly, the top panel  22  also has a pair of minor flaps  32   a  and  32   b  and a pair of major flaps  30   a  and  30   b  that can be folded at approximately right angles to adjacent end and side panels, respectively. The major flaps  30   a  and  30   b  are also folded over the folded minor flaps  32   a  and  32   b,  covering them, and are kept closed by the tape strip  16  applied at their adjacent edges  38  and  40 , respectively, the tape strip  16  further extending around the edge of the carton  10  to a portion of the end panels  28   a  and  28   b,  terminating at a tab  14   a  or  14   b  where one is present. The flaps, i.e., both the major  30   a  and  30   b  and minor  32   a  and  32   b  flaps, can be pivotable between an open and closed position. The major flaps  30   a  and  30   b  have a length that is generally the same as the length of the carton  10 , therefore, upon removing the tape strip  16  the entire interior length of the carton  10  can be accessed. Furthermore, the interior of the carton  10  can be used for storing packaged or unpackaged products therein which can be accessed upon opening of the carton  10 . 
     The blank further comprises multiple gaps  42  or slits that separate adjacent major and minor flaps. This gap  42  allows for the major and minor flaps to remain connected to their respective side or end panel yet be foldable, apart from the adjacent flap, to form the top or bottom panel. Additionally, an extension  48  of the end panel  28   a  can be provided to aid in keeping the carton  10  assembled. This extension  48  can extend beyond the edge of the blank  100  and can be folded under the opposite side panel  26   b  when the blank  100  is folded and assembled into a carton  10 . The extension  48  can also contain an adhesive to aid in keeping the carton  10  together. Optionally, the extension  48  can also be positioned on the opposite end of the blank  100  such that it is connected to a side panel  26   b  and folds under the opposite end panel  28   a  when assembled. 
     The assembled carton  10  can have any shape and size that is adequate for storing and transporting items therein. Typically, the carton  10  will have a rectangular shape. In one aspect, the carton  10  may have dimensions such as about 24 inches×about 12 inches, with a height between about 4½ inches to about 8½ inches. The opening  12  in the end panel  28  can be sized large enough for a person&#39;s fingers to be inserted therein for carrying purposes and to remove the tab  14 , yet small enough so that any products stored inside do not escape or pass through the opening  12 . Alternatively, the opening  12  and its associated tab  14 , if present, can be provided on a side panel  26  instead of an end panel  28 , as long as the adjacent edges  38  and  40  of the major flaps  30   a  and  30   b  would also be oriented along the same axis as the opening  12  such that removing the tape strip  16  upwards from the tab  14  also removes the tape  16  in a relatively straight line from the edges  38  and  40  of the major flaps  30   a  and  30   b.  The size of the tab  14 , as mentioned previously, should be about the same size as the tape  16  (i.e., the width of the tape) or larger. Therefore, the size of the tab  14  should correlate to standard widths of packing tape that are typically used for sealing shipping cartons. The material of construction of the carton  10  is any conventional material, such as corrugated board and the like. 
     In one aspect, the carton  10  can be used to package already packaged food products, such as packaged frozen pizzas, and the like. The approximate weight of an empty carton  10  can be about 1.5 pounds to about 2 pounds for a carton  10  large enough to package about 12 packaged pizzas. A packaged carton, such as one containing about 12 packaged pizzas, can have a weight of approximately 11 pounds to about 25 pounds when full. Therefore, when the openings  12  are used as handholds to carry and transport the filled carton  10 , the tabs  14  should be able to withstand such weights without prematurely tearing away from the carton  10 , as well as the tabs  14  being easily removable and tearable from the carton  10  upon desired removal from the carton  10 . Accordingly, in one aspect the tabs  14  can have a tab strength of approximately 2.5 pounds per square inch (psi), such that at least about 2.5 psi of force are required to fully remove or tear the tab  14  from the carton  10 . Likewise, in the same aspect, upon continued application of force to the tape  16 , a bond strength of the tape  16  would need to be overcome to remove the tape  16  from the carton  10 , such as a bond strength of at least about 3.5 psi. However, any variations of these bond strengths and/or tear strengths can be utilized as long as the criteria discussed herein is maintained. 
     A method of opening the sealed carton is described herein, and is illustrated in  FIGS. 2 and 3 . The carton  10  is sealed as described herein with an adhesive strip, such as the tape strip  16  shown in  FIG. 1A , which keeps the top panel  22  of the carton  10  closed. The tape strip  16  can extend down a portion of the end panel  28   a  to terminate at the tab  14   a,  at least partially covering the tab  14   a.  To open the carton  10  at its top panel  22  it is desired to remove the tape strip  16 . This can be done by inserting a finger behind the back of the tab  14   a  and applying a slight force to pull or lift the tab  14   a  upwards to release the tab  14   a  from the carton  10  along the weakened area  18  of the end panel  28   a , and along a non-perforated portion  19 , if used. Where a non-perforated portion  19  is also incorporated about a portion of the tab  14 , a slightly greater force may be required to initially remove the tab  14  from the carton  10  and to begin tearing it from the carton  10 , however, the amount of force required is still not as great as that needed to tear or remove a tab with no perforated area. The removed tab  14   a  is shown in  FIG. 2  after the lower edge  20  and/or the back of the tab  14  was grasped and pulled in the direction of arrow A. As the tab  14   a  is removed from the carton  10 , the end  17  of the tape strip  16  remains attached to the tab  14   a  and is likewise lifted from the end panel  28   a  of the carton  10  with the tab  14   a,  as the tab  14   a  is continually being lifted upwards. Upon continually applying a force to the tab  14   a  and the tape strip  16  in the direction of arrow B, as shown in  FIG. 3 , the tape strip  16  begins to peel off of the top panel  22  and continues to be removed from the edges  38  and  40  of the major flaps  30   a  and  30   b,  respectively. 
     Where the tape strip  16  is also adhered to the opposite end panel  28   b,  the tearing force can be continually applied in the direction of arrow B and then down the opposite end panel  28   b  until the tape strip  16  is also removed from the opposite end panel  28   b.  Once the tape strip  16  has been completely removed from the carton  10 , generally the only waste that is created is the remainder of the tape strip  16  and a small piece of the tab  14   a.    
     From the foregoing, it will be appreciated a sealed carton with an easy to open tab for removal of an adhesive strip is provided such that numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the easy open feature set forth in the claims. Therefore, the disclosure is not limited to the aspects and embodiments described hereinabove, or to any particular embodiments. Various modifications to the easy open feature can result in substantially the same carton and various other modifications to the method of opening the carton could be made.