Patent Publication Number: US-9850023-B2

Title: Carton with dispensing feature

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/744,941 filed Oct. 5, 2012. 
     INCORPORATION BY REFERENCE 
     The disclosure of U.S. Provisional Patent Application No. 61/744,941, which was filed on Oct. 5, 2012, is hereby incorporated by reference for all purposes as if presented herein in their entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to cartons for holding beverage containers or other types of articles. More specifically, the present disclosure relates to cartons having at least one dispensing feature. 
     SUMMARY OF THE DISCLOSURE 
     In general, one aspect of the disclosure is directed to a carton for holding a plurality of articles. The carton comprises a plurality of panels that extends at least partially around an interior of the carton. The plurality of panels comprises at least one top panel, at least one side panel foldably connected to the at least one top panel, and a bottom panel foldably connected to the at least one side panel. The carton further comprises a support foldably connected to the top panel for supporting at least one article of the plurality of articles and a dispenser for allowing removal of the plurality of articles from the carton. The dispenser comprises a dispenser panel that is at least partially defined by a tear line in the at least one side panel and the at least one top panel. The dispenser panel is for being at least partially removed for at least further opening a dispenser opening. 
     In another aspect, the disclosure is generally directed to a blank for forming a carton. The blank comprises a plurality of panels comprising at least one top panel, at least one side panel foldably connected to the at least one top panel, and a bottom panel foldably connected to the at least one side panel. The blank further comprises a support foldably connected to the top panel for supporting at least one article of the plurality of articles and dispenser features for forming a dispenser for allowing removal of the plurality of articles from the carton. The dispenser features comprise a dispenser panel that is at least partially defined by a tear line in the at least one side panel and the at least one top panel. The dispenser panel is for being at least partially removed for at least further opening a dispenser opening in the carton formed from the blank. 
     In another aspect, the disclosure is generally directed to a method of forming a carton. The method comprises obtaining a blank comprising a plurality of panels. The plurality of panels comprises at least one top panel, at least one side panel foldably connected to the at least one top panel, and a bottom panel foldably connected to the at least one side panel. The blank further comprises a support foldably connected to the top panel and dispenser features for forming a dispenser for allowing removal of the plurality of articles from the carton. The dispenser features comprise a dispenser panel that is at least partially defined by a tear line in the at least one side panel and the at least one top panel. The method further comprises positioning the plurality of panels to form an interior of the carton and loading a plurality of articles in the interior of the carton. The loading the articles comprises positioning at least one article of the plurality of articles for contact with the support. 
     Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. 
     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 disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is plan view of an exterior surface of a blank for forming a carton of the first embodiment. 
         FIG. 2  is a view of an interior surface of the blank of  FIG. 1 . 
         FIGS. 3-6  are various views showing the blank of  FIG. 1  being formed into the carton. 
         FIG. 7  is an end perspective view of the carton formed from the blank of  FIG. 1  in an open configuration. 
         FIG. 8  is an end perspective view of the carton of  FIG. 7  loaded with articles. 
         FIG. 9  is an enlarged view of a portion of the carton of  FIG. 7 . 
         FIG. 10  is a perspective view of the carton formed from the blank of  FIG. 1  in a closed configuration. 
         FIG. 11  is a view similar to  FIG. 10  showing a partially opened dispenser of the carton. 
         FIG. 12  is a view similar to  FIG. 11  with the dispenser completely opened. 
         FIG. 13  is a view similar to  FIG. 12 , with an article being dispensed. 
         FIG. 14  is a view of a first corner support proximate a loaded article of the carton formed from the blank of  FIG. 1 . 
         FIG. 15  is a view similar to  FIG. 14 , showing a centerline of the loaded article being maintained through the first corner support. 
         FIG. 16  is a plan view of an exterior surface of a blank for forming a carton of a second embodiment. 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     The present disclosure generally relates to cartons that contain articles such as containers, bottles, cans, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof. 
     Cartons according to the present disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes beverage containers (e.g., glass beverage bottles) as disposed within the carton embodiments. In this specification, the terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected and upright cartons. 
       FIG. 1  is a plan view of the exterior side  1  of a blank, generally indicated at  3 , used to form a carton  5  ( FIG. 10 ) according to one exemplary embodiment of the disclosure. The carton  5  can be used to house a plurality of articles such as containers C ( FIG. 8 ). In the illustrated embodiment, the carton  5  is sized to house twelve containers C in a 2×6 arrangement, but it is understood that the carton  5  may be sized and shaped to hold containers of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 3×4, 1×6, 3×6, 2×6×2, 3×3×2, 4×5, 3×5, 2×9, 2×6, 3×4, etc.). In one embodiment, the carton  5  has a dispenser  7  for accessing the containers C in the carton. As will be discussed below in more detail, the dispenser  7  can be positioned to an open position ( FIGS. 11-13 ) for accessing the containers C. The carton has a support  9  in an interior space  10  of the carton for supporting containers C prior to removal from the interior space through the dispenser  7 . 
     In one embodiment, the carton blank  3  has a longitudinal axis L 1  and a lateral axis L 2 . In the illustrated embodiment, the blank  3  comprises a first top panel  11  foldably connected to a first side panel  13  at a first lateral fold line  15 . A bottom panel  17  is foldably connected to the first side panel  13  at a second lateral fold line  19 . A second side panel  21  is foldably connected to the bottom panel  17  at a third lateral fold line  23 . A second top panel  25  is foldably connected to the second side panel  21  at a fourth lateral fold line  27 . In the illustrated embodiment, the blank  3  includes a support flap  29  foldably connected to the second top panel  25  at a fourth lateral fold line  31 . In alternative embodiments, the blank  3  can have alternative panel and/or flap arrangements. 
     The first top panel  11  is foldably connected to a first top end flap  35  and a second top end flap  37 . The first side panel  13  is foldably connected to a first side end flap  39  and a second side end flap  41 . The bottom panel  17  is foldably connected to a first bottom end flap  43  and a second bottom end flap  45 . The second side panel  21  is foldably connected to a first side end flap  47  and a second side end flap  49 . When the carton  5  is erected, the top end flap  35 , bottom end flap  43 , and side end flaps  39 ,  47  close a first end  55  of the carton, and the top end flap  37 , bottom end flap  45 , and side end flaps  41 ,  49  close a second end  57  of the carton. In accordance with an alternative embodiment of the present disclosure, different flap arrangements can be used for at least partially closing the ends  55 ,  57  of the carton  5 . 
     The top end flap  35 , bottom end flap  43 , and side end flaps  39 ,  47  extend along a first marginal area of the blank  3 , and are foldably connected at a first longitudinal fold line  61  that extends along the length of the blank. The top end flap  37 , bottom end flap  45 , and side end flaps  41 ,  49  extend along a second marginal area of the blank  3 , and are foldably connected at a second longitudinal fold line  63  that also extends along the length of the blank. The longitudinal fold lines  61 ,  63  may be, for example, substantially straight, or offset at one or more locations to account for blank thickness, varying width of the blank panels, or for other factors. 
     In the illustrated embodiment, the carton blank  3  includes features to form the carton  5  having tapered ends  55 ,  57 . That is, the blank  3  includes diamond corner panels  67 ,  69  that connect respective side end flaps  47 ,  49 ,  39 ,  41  to a respective one of the second side panel  21  and the first side panel  13 . The diamond corner panels  67 ,  69  are configured to allow the ends  55 ,  57  of the carton  5  to taper inwardly to the top of the carton. Each of the top panels  11 ,  25  can be shorter than the bottom panel  17  in the lateral direction L 2 , and the top of the carton formed from the partially overlapped top panels  11 ,  25  can be narrower between the ends  55 ,  57  than the bottom panel  17 . The tapered upper portions of the side panels  13 ,  21  and the ends  55 ,  57  are for accommodating containers C that have a wide bottom portion B and a narrow top portion T (FIG.  8 ). Alternatively, the ends  55 ,  57  and the sides  13 ,  21  can taper inwardly from the bottom to the top of the carton. The containers C having a wide bottom B and narrow top T can be tightly held in the carton with the narrow tops of the containers located adjacent to the ends  55 ,  57  being located in close proximity to the portions of the fold lines  61 ,  63  connecting the top end flaps  35 ,  37  to the top panel  11 . Also, the containers C located adjacent the first and second side panels  13 ,  21  can have the narrow tops of the containers located in close proximity to the fold lines  15 ,  27  to further enhance the tightness of the packing of the containers in the carton  5 . In alternative embodiments, the carton  5  could be otherwise shaped, arranged, and/or configured. 
     In one embodiment, the dispenser  7  comprises a first dispenser panel  101  that is at least partially defined by a first tear line  103  and comprises a portion of the second side panel  21  and the second top panel  25 , and a second dispenser panel  105  that is at least partially defined by a second tear line  107  and comprises a portion of the first top panel  11 . In the illustrated embodiment, the dispenser  7  comprises a third dispenser panel  111  that is at least partially defined by a third tear line  113  and comprises a portion of the second side panel  21  and the second top panel  25 , and a fourth dispenser panel  115  that is at least partially defined by a fourth tear line  117  and comprises a portion of the first top panel  11 . When the blank  3  is formed into the carton  5 , the second dispenser panel  105  overlaps the portion of the first dispenser panel  101  that is in the second top panel  25  and the fourth dispenser panel  117  overlaps the portion of the third dispenser panel  111  in the second top panel  25 . The blank  3  further comprises an adhesive region  151  extending between fold lines  61 ,  63  for adhering the first top panel  11  and the second top panel  25  for forming the dispenser  7  from the first, second, third, and fourth dispenser panels  101 ,  105 ,  111 ,  115 . The dispenser  7  could be otherwise shaped, arranged, configured such that one or more of the dispenser panels  101 ,  105 ,  111 ,  115  could have access features for accessing the dispenser panels and/or retaining features for retaining containers C in the carton  5 . Further, the dispenser  7  could comprises less than or more than four dispenser panels without departing from the disclosure. 
     In one embodiment, the first tear line  103  includes a first portion  103   a , a second portion  103   b , a third portion  103   c , a fourth portion  103   d , a fifth portion  103   e , and a sixth portion  103   f . The first portion  103   a  and second portion  103   b  each extend from the fourth lateral fold line  27  and are in the second top panel  25 . The fourth portion  103   d  and the fifth portion  103   e  each extend from the fourth lateral fold line  27  and are in the second side panel  21 . The third portion  103   c  extends between the first portion  103   a  and the second portion  103   b . In the illustrated embodiment, the second tear line  107  also includes a first portion  107   a , a second portion  107   b , and a third portion  107   c . The first portion  107   a  and the second portion  107   b  each extend from a free edge  11   a  of the first top panel  11 . The third portion  107   c  extends between the first portion  107   a  and the second portion  107   b . When the carton  5  is formed from the blank  3 , the respective portions  103   a ,  103   b , and  103   c  of the first tear line  103  are in registration with the respective portions  107   a ,  107   b , and  107   c  of the second tear line to form the dispenser  7 . Additionally, the third tear line  113  and the fourth tear line  117  can be formed similarly to the first tear line  103  and second tear line  107  and have similarly shaped portions. 
     In one exemplary embodiment shown in  FIGS. 2-10 , the carton  5  can be assembled from the blank  3  by initially folding the second side panel  21  and second top panel  25  along fold line  23  ( FIG. 3 ) and then folding the first top panel  11  along fold line  15  so that the first top panel overlaps the second top panel  25  and the support flap  29 . The first top panel  11  and second top panel can be secured in face-to-face contact by adhesive applied either to the interior surface of the first top panel  11  or the exterior surface of the second top panel  25 . As shown in  FIGS. 8-9 , the support flap  29  forms the support  9  that is free from attachment to the first side panel  13  or the overlapped top panels  11 ,  25 . In one embodiment, the support flap extends downwardly from the overlapped top panels  11 ,  25  at an angle with a free edge  121  of the flap being in contact with the first side panel  13 . Alternatively, a portion of the support flap  29  can be secured to the first side panel  13  without departing from the disclosure. 
     As shown in  FIGS. 5-8  the side panels  13 ,  21  can then be positioned relative to the top panels  11 ,  25  and the bottom panel  17  to form a generally open-ended tubular sleeve  127  at least partially forming the interior space  10 . The tubular sleeve  127  can be loaded with containers C ( FIG. 8 ) prior to closing the ends  55 ,  57  of the carton  5 , or one of the ends can be closed prior to loading the containers. Once the containers C are loaded, the ends  55 ,  57  of the sleeve  127  can be closed to form the closed carton  5 , as illustrated by  FIG. 10 , by at least partially overlapping the end flaps  35 ,  39 ,  43 ,  47  to close the first end  55 , and at least partially overlapping the end flaps  37 ,  41 ,  45 ,  49  to close the second end  57 . The carton  5  can be assembled and loaded by other positioning steps without departing from the disclosure. 
     As shown in  FIGS. 9, 14, and 15 , the support  9  comprises the support flap  29  that is positioned to support the tops T of the containers C when the carton  5  is laid on the first side panel  13 . For example and as shown in  FIGS. 10 and 12 , the carton  5  can be laid on the first side panel  13  when the carton is placed in a refrigerator or cooler so that the first side panel is in contact with a surface S (e.g., a shelf or support surface in a refrigerator) and the height of the carton is reduced. Reducing the height of the carton  5  by laying the carton on the first side panel  13  allows more efficient use of refrigerator space by allowing the carton to fit on a shelf (e.g. a bottom or middle shelf) having a smaller clearance height than if the carton  5  was placed in the refrigerator in the upright position (e.g., with the bottom panel  17  placed on a shelf or support surface). 
     As shown in  FIGS. 11-13 , the dispenser  7  can be opened by grasping a portion of the second dispenser panel  105  and tearing the second dispenser panel and the first dispenser panel  101  along respective tear lines  107 ,  103  to form a first dispenser opening  131 . Similarly, the dispenser  7  can be opened grasping a portion of the fourth dispenser panel  115  and tearing the fourth dispenser panel and the third dispenser panel  111  along respective tear lines  117 ,  113  to form a second dispenser opening  133 . As shown in  FIG. 13 , containers C can be removed from the first dispenser opening  131  or the second dispenser opening  133  by a consumer. The support panel  29  forms the support  9  adjacent the first side panel  13  that supports the tops T of the containers C when the carton  5  is laid in the dispensing configuration with the first side panel  13  on the support surface S. The configuration of the portions of the dispenser panels  101 ,  105 ,  111 ,  115  in the overlapped top panels  11 ,  25  provides a retention portion  141  of the overlapped top panels that prevents the containers from unintentionally being removed through either of the dispenser openings  131 ,  133 . The retention portion  141  is at least partially defined by the tear lines  103 ,  113  in the top panel  21 . Furthermore, the retention portion  141  contacts the tops T of containers adjacent the dispenser opening. Alternatively, the dispenser  7  can comprise only one of the dispenser openings  131 ,  103 , or the dispenser could be otherwise configured to have one or more openings of other shapes and sizes. Further, the dispenser  7  could alternatively include one or more dispenser panels in the first side panel  13  to allow the user to remove containers through dispenser opening(s) in the other side panel without departing from the disclosure. Also, the dispenser  7  could comprise one or more dispenser panels that comprise at least a portion of the bottom panel  17  without departing from the disclosure. Further, the dispenser  7  could be omitted without departing from the disclosure. 
     Alternatively, the dispenser  7  could comprise closure features wherein the dispenser openings  131 ,  133  can be closed such as by having one or more of the dispenser panels  101 ,  105 ,  111 ,  115  remaining foldably connected to one or more of the first top panel  11 , second top panel  25 , and the second side panel  21 . Also, the carton  5  could have one or more handle features in one or more of the top panels  11 ,  25 , the side panels  13 ,  21 , or the closed ends  55 ,  57 . 
     As shown in  FIG. 12 , the support flap  29  and the support  9  supports the tops T of the container C when the carton  5  is positioned with the first side panel  13  supported on a surface S. The support  9  supports the tops T of the containers in a manner that keeps the tops from contacting the side panel  13 . Therefore, according to one embodiment, the containers C can be accessed by separating the folded and glued end flaps  35 ,  39 ,  43 ,  47  at the first end  55  of the carton or by separating the folded and glued end flaps  37 ,  41 ,  45 ,  49  at the second end  57  of the carton. The carton  5  could contain articles other than beverage containers C (e.g., food products, medical products, etc.) without departing from the disclosure. The use of the support  9  and support flap  29  without the dispenser  7  of the first embodiment, allows the carton  5  to be placed in a refrigerator or display case with one or the other side panels  13 ,  21  being in contact with a support surface S so that the articles C are supported and the carton requires a reduced height or clearance space for storage. As shown in  FIG. 12 , the row of containers adjacent the side panel  13  are prevented from tilting or sloping downward toward the side panel  13  by the location of the support  9  that contacts the tops T of the containers C. The support  9  and/or support flap  29  can be otherwise shaped, arranged, and/or positioned without departing from the disclosure. 
       FIG. 16  shows a blank  201  of a second embodiment of the disclosure having similar features as the first embodiment. Accordingly, similar or identical features of the embodiments are provided with identical or similar reference numbers. The blank  201  a first dispenser panel  211  that is at least partially defined by a first tear line  213  and comprises a portion of the second side panel  21  and the second top panel  25 , and a second dispenser panel  215  that is at least partially defined by a second tear line  217  and comprises a portion of the first top panel  11 . The blank  201  further comprises an adhesive region  251  extending between fold lines  61 ,  63  for adhering the first top panel  11  and the second top panel  25  for forming a dispenser from the first and second dispenser panels. 
     In one embodiment, the first tear line  213  includes a first portion  213   a , a second portion  213   b , a third portion  213   c , a fourth portion  213   d , a fifth portion  213   e , and a sixth portion  213   f . The first portion  213   a  and the second portion  213   b  each extend from the fourth lateral fold line  27  and are in the second top panel  25 . The fourth portion  213   d  and the fifth portion  213   e  each extend from the fourth lateral fold line  27  and are in the second side panel  21 . The third portion  213   c  extends between the first portion  213   a  and the second portion  213   b . In the illustrated embodiment, the second tear line  217  also includes a first portion  217   a , a second portion  217   b , and a third portion  217   c . The first portion  217   a  and the second portion  217   b  each extend from a free edge  11   a  of the first top panel  11 . The third portion  217   c  extends between the first portion  217   a  and the second portion  217   b . When the blank  201  is formed into a carton, the respective portions  213   a ,  213   b , and  213   c  of the first tear line  213  are in registration with the respective portions  217   a ,  217   b , and  217   c  of the second tear line  217  to form the dispenser  7 . 
     The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks 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 blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections. 
     In accordance with the above-described embodiments of the present disclosure, 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 disclosure, 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. 
     As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits 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 tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. 
     The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place. 
     The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments that are within the scope of the claims. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure 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. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.