Patent Publication Number: US-6910600-B2

Title: In-line windowed facial tissue carton

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This application is related to Provisional Application No. 60/442,218 filed with the United States Patent and Trademark Office on Jan. 24, 2003. 

   FIELD AND BACKGROUND OF THE INVENTION 
   The invention relates generally to a tissue container, and more particularly, to a tissue container having a face and tab configuration that increases visible edge continuity and decreases edge alignment and flap requirements, and including a windowing material that is applied as part of an inline web printing process. 
   Increasingly, producers of consumer use product containers are making maximum use of the container surface area through the use of full face graphics, specialized graphics, including three dimensional, lenticular, holographic, laminated films, foils and other printed, photographic and digital effects. The increased use of such graphics creates a desire for the minimization of visible boundaries at the meeting point of edges to maximize the visual effect of the printed graphics. 
   Also, in the manufacturing of containers, or any other die cut process, the savings of material in the overall blank in order to accomplish the same construction is a continuing design goal. The savings in material corresponds to a direct savings in manufacturing costs, and more efficient production. It is highly desirable to have a container construction scheme that decreases the amount of container material required to construct a container having the same functionality. 
   Moreover, the process of applying windowing material to a tissue container, for example, generally requires a several staged process by which the container blank is printed separately from the windowing application process. A need exists to incorporate the application of the windowing material to the container as part of the printing process when printing in an inline web format. The combination of these steps in a single process reduces time and labor involved in the creation of the tissue container. 
   BRIEF SUMMARY OF THE INVENTION 
   Disclosed herein is a facial tissue container. The container comprises a top face comprising a plurality of top face portions, the top face portions for creating a facial tissue container opening; a bottom face disposed opposite the top face and comprising a plurality of bottom face portions; and a plurality of side faces in top-fold continuity with the top face and in bottom-fold continuity with the bottom face, the plurality of side faces creating a continuous decorative surface that extends in side-fold continuity across the side faces except at a facial tissue container side interface formed between two of the plurality of side faces. 
   Also disclosed is a tissue container comprising: a first section having a first section decorative portion, a top flap portion disposed at a first end of the first section decorative portion and a bottom flap portion disposed at a second end of the first section decorative portion; a second section connected to the first section, the second section having a second section decorative portion, a top flap portion disposed at a first end of the second section decorative portion and a bottom flap portion disposed at a second end of the second section decorative portion; a third section connected to the second section, the third section having a third section decorative portion, a top flap portion disposed at a first end of the third section decorative portion and a bottom flap portion disposed at a second end of the third section decorative portion; a fourth section connected to third section, the fourth section having a fourth section decorative portion and a top flap portion disposed at a first end of the fourth section decorative portion and a bottom flap portion disposed at a second end of the fourth section decorative portion; and a tab portion connected to a third end of the fourth section decorative portion, the tab portion for securing in overlapping fashion the fourth section decorative portion to the first section decorative portion; wherein top flap portions form a tissue container top face and define an opening in the top face, the bottom flap portions form a tissue container bottom face, and the first, second, third and fourth section decorative portions form a continuous decorative surface. 
   Also disclosed herein is a blank for construction of a facial tissue container. 
   Other aspects, embodiments, alternatives, objects and advantages will become apparent upon a reading of the detailed description that follows. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The drawings illustrate the best mode presently contemplated for carrying out the invention. 
     In the drawings: 
       FIG. 1  is a perspective view of a blank of a tissue container in accordance with one embodiment of the present invention; 
       FIG. 2  is a top plan view of the blank of  FIG. 1 ; 
       FIG. 3  is a perspective view of a tissue container formed from the blank of  FIG. 1 ; 
       FIG. 4  is a top plan view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention; 
       FIG. 5  is a side elevational view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention; 
       FIG. 6  is a front elevational view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention; 
       FIG. 7  is a bottom view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention; 
       FIG. 8  is a perspective view of a blank of a tissue container in accordance with one embodiment of the present invention; 
       FIG. 9  is a top plan view of the blank of  FIG. 8 ; 
       FIG. 10  is a perspective view of a tissue container formed from the blank of  FIG. 8 ; and 
       FIG. 11  is a top plan view of the tissue container of  FIG. 10  in accordance with one aspect of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1 and 2  are a perspective and top plan views, respectively, of a blank, generally indicated by the numeral  10  for a tissue container in accordance with one embodiment of the present invention. The blank  10  comprises a first section  12  having a first section decorative portion  14 , a top flap portion  16  disposed at a first end  18  of the first section decorative portion and a bottom flap portion  20  disposed at a second end  22  of the first section decorative portion. Blank  10  further comprises a second section  24  connected to first section  12 , the second section having a second section decorative portion  26 , a top flap portion  28  disposed at a first end  30  of the second section decorative portion and a bottom flap portion  32  disposed at a second end  34  of the second section decorative portion. The blank  10  still further includes a third section  36  connected to second section  24 , the third section having a third section decorative portion  38 , a top flap portion  40  disposed at a first end  42  of the third section decorative portion and a bottom flap portion  44  disposed at a second end  46  of the third section decorative portion. The blank  10  still further includes a fourth section  48  connected to third section  36 , the fourth section having a fourth section decorative portion  50  and a top flap portion  52  disposed at a first end  54  of the fourth section decorative portion and a bottom flap portion  56  disposed at a second end  58  of the fourth section decorative portion. Finally, blank  10  includes a tab portion  60  connected to a third end  62  of the fourth section decorative portion  50 . Tab portion  60  is utilized to secure, in overlapping fashion, the fourth section decorative portion  50  to the first section decorative portion  14  in constructing a facial tissue container that can be made from blank  10 . In one embodiment, first section and third section top flap portions  16  and  40  are truncated triangular in shape. Further, in one embodiment, second section top flap portion  28  and the fourth section top flap portion  52  are rectangular and further include a slot  41 . 
   Significantly, the first, second, third and fourth section decorative portions form a continuous decorative surface  64 , as indicated by line  66 . Continuous surface  64  is referred to as a continuous decorative surface in that it can receive vector or graphic art in, for example, printed form, to maximize a visual effect to a consumer. Advantageously, by spanning across several container portions, the continuous decorative surface eliminates printing problems that typically occur or result at discontinuous boundaries. As a result, blank  10  having continuous decorative surface is well-suited for use in an in-line printing environment. 
     FIGS. 3 and 4  show a perspective view and a top plan view, respectively, of tissue container  68  that can be formed from blank  10  of FIG.  1 . More specifically, shown are first section decorative portion  14  and second section decorative portion  26 , second section top flap portion  28 , fourth section top flap portion  52 , first section top flap portion  16 , and third section top flap portion  40 . Significantly, the top flap or face portions form a tissue container top or top face  70 . In the completed container  68 , portions  14  and  26  are folded so as to be in side fold continuity across edge  71 , and by this it is meant that there is a continuity of material (which used to create or form the continuous decorative surface described previously). The top flap portions define a tissue container opening  75  which can be spanned by a windowing material  73 , which can comprise a flexible thin plastic film. The plastic film can be attached to either the inside or outside surfaces of the container top. The plastic film can contain a dispensing opening formed therein. The dispensing opening can be a single slit or it can take on various cross or x-shaped configurations. Advantageously, the plastic film is applied to the container in-line as part of the printing operation. 
   The tissue container further comprises removable perforated portions  77  that cover at least a portion of the tissue container opening. The decorative portions can also be referred to as side faces. Significantly, the exterior of the container, and in particular the continuous decorative surface, is particularly well-suited for receiving commercially suitable decoration, such as image, print, indicia, graphics, fresnel lens, lenticular lens, color, an embossed area, a debossed area, and coating(s). 
     FIG. 5  is a side elevational view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention. Shown are first section decorative portion  14 , second section decorative portion  26  and third section decorative portion  38 , as well as first section top flap portion  16  and third section top flap portion  40 . The manner in which completed container  68  is folded is an important aspect of the present invention. By folding the container  68  such that flap portion  16  folds into first section decorative portion  14 , and similarly, decorative portion  40  folds into third section decorative portion  38 , continual unbroken surfaces  90  and  92  are created. The result is that any printed material on this surface will be more visually distinct, and not choppy nor broken, so as to enhance the visual experience of the user. Continual surfaces  90  and  92  are in side fold continuity about second section top flap portion  28  and fourth section top flap portion  52  ( FIGS. 3-4 ) to create container top  70 . 
     FIG. 6  is a front elevational view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention and illustrating one of the continuous faces. The side fold continuity of  FIG. 5  presents itself in side  14  in that the entire face is visible, without any glued or otherwise secured joints or edges. In addition, the side are folded to form part of top  70 , again without any discontinuity along edge  94 , again illustrating top fold continuity. 
     FIG. 7  is a bottom view of the tissue container of  FIG. 3  in accordance with one aspect of the present invention. Second and fourth section bottom flap or face portions  32  and  56  are folded around first and third section bottom flap portion  20  and  44  to create tissue container bottom or bottom face  96 . A seam  98  formed by the folding and joining of bottom flap portions  32  and  56  is visible, however, this is not detrimental to the overall aesthetic appearance of the container to a user since the seam is formed in the container bottom  96 , which is typically not seen in a point of purchase display. As such, the bottom  96  can be said to be in bottom fold continuity because there are not discontinuous along a perimeter  47  defined by edges  47   a-d.    
     FIGS. 8 and 9  are perspective and top plan views, respectively, of a blank, generally indicated by the numeral  110  for construction of a tissue container in accordance with another embodiment of the present invention. The blank  110  comprises a first section  112  having a first section decorative portion  114 , a top flap portion  116  disposed at a first end  118  of the first section decorative portion and a bottom flap portion  120  disposed at a second end  122  of the first section decorative portion. Blank  110  further comprises a second section  124  connected to first section  112 , the second section having a second section decorative portion  126 , a top flap portion  128  disposed at a first end  130  of the second section decorative portion and a bottom flap portion  132  disposed at a second end  134  of the second section decorative portion. The blank  110  still further includes a third section  136  connected to second section  124 , the third section having a third section decorative portion  138 , a top flap portion  140  disposed at a first end  142  of the third section decorative portion and a bottom flap portion  144  disposed at a second end  146  of the third section decorative portion. The blank  110  still further includes a fourth section  148  connected to third section  136 , the fourth section having a fourth section decorative portion  150  and a top flap portion  152  disposed at a first end  154  of the fourth section decorative portion and a bottom flap portion  156  disposed at a second end  158  of the fourth section decorative portion. Finally, blank  110  includes a tab portion  160  connected to a third end  162  of the fourth section decorative portion  150 . Tab portion  160  is utilized to secure, in overlapping fashion, the fourth section decorative portion  150  to the first section decorative portion  114  in constructing a facial tissue container that can be made from blank  110 . In one embodiment, first section and third section top flap portions  116  and  140  have a notched truncated triangular shape. Further, in one embodiment, second section top flap portion  128  and fourth section top flap portion  152  are generally rectangular in shape and further include a plurality of notches  153  so as to be “double notched”. 
   Here, the first, second, third and fourth section decorative portions form a continuous decorative surface  164 , as indicated by line  166 . As before, continuous surface  164  is referred to as a continuous decorative surface, and by spanning across several container portions, the continuous decorative surface again eliminates various printing problems that typically occur or result at discontinuous boundaries. Blank  110  is also well-suited for use in an in-line printing environment. 
   FIG.  10  and  FIG. 11  are perspective and top plan views, respectively, of a tissue container  168  formed from the blank of  FIGS. 8 and 9 . More specifically, shown are second section decorative portion  126 , third section decorative portion  138 , second section top flap portion  128 , fourth section top flap portion  152 , first section top flap portion  116 , and third section top flap portion  140 . Decorative portion  126  and top flap portion  128  illustrative top fold continuity. Significantly, the top flap portions form a tissue container top  170 . In the completed container  168 , the decorative portions are folded so that they are in side fold continuity. Also shown are tissues  180 , a plurality of which can be inserted in a known interleaved fashion, for example using a u-clip  182  of tissues. The perforated portions can be removed to create, for example, an oval or substantially rectangular tissue-dispensing opening. The tissue container is defined by a polyhedral body. As shown, the body is generally rectangular in shape or profile, however, it is to be understood that other shapes or profiles are contemplated and within the scope of the present invention. 
   The embodiments shown are exemplary in their depiction of the size (including section, portion, notch, slot and opening sizes) and relative proportions. 
   Advantageously, the tissue container can be built with fewer construction materials because there are fewer flaps. 
   The present invention has been described in terms of preferred embodiments. Equivalents, alternatives, and modifications, aside from those expressly stated herein, are possible and should be understood to be within the scope of the appending claims.