Patent Publication Number: US-8985336-B1

Title: Display carton and method of assembling

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/758,458, filed Jan. 30, 2013, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     A display carton can be used for packaging multiple units of a product, such as consumable cleaning containers, together and for visually displaying the product, such as in a retail setting. Display cartons typically have an open top and at least one partially open side to allow for the product to be seen by consumers. Such cartons, while holding multiple units of product, are typically stacked on top of each other, and therefore need to be designed to withstand the weight of the product in the cartons. The carton also needs to be designed for providing information about the product in the carton to the customers. Display cartons are generally made of cardboard, such as corrugated cardboard material, and can be assembled by cutting and folding a blank, and gluing or otherwise adhering portions of the blank together to form the carton. 
     BRIEF SUMMARY 
     According to one embodiment of the invention, a display carton includes a bottom wall, a first side wall extending upwardly from the bottom wall, a second side wall extending upwardly from the bottom wall, a front wall extending upwardly from the bottom wall between the first and second side walls and formed by multiple panels defining a rolled upper edge, and a rear wall formed by a first folded portion of the first side wall and a second folded portion of the second side wall, wherein the first folded portion at least partially overlaps the second folded portion and the first and second folded portions are adhered together at the overlap. 
     According to another embodiment of the invention, a method for assembling a display carton having a bottom wall, a first side wall extending upwardly from the bottom wall, a second side wall extending upwardly from the bottom wall, and a rear wall extending between the first and second side walls is provided. The method includes folding a first panel to form a first rear panel section and a first side panel section, wherein the first side panel section defines the first side wall, folding a second panel to form a second rear panel section and a second side panel section, wherein the second side panel section defines the second side wall, adhering the first rear panel section to the second rear panel section to form the rear wall, and folding a third panel to form an inner panel section and an outer panel section which define a front wall with a rolled upper edge, wherein the front wall extends upwardly from the bottom wall between the first and second side walls. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front perspective view of a display carton according to one embodiment of the invention. 
         FIG. 2  is a rear bottom perspective view of the display carton from  FIG. 1 . 
         FIG. 3  is a top plan view of a carton blank which can be used to make the display carton of  FIGS. 1-2 . 
         FIG. 4-7  show one method of assembling the carton blank of  FIG. 3  into the display carton shown in  FIG. 1-2 . 
     
    
    
     DETAILED DESCRIPTION 
     The invention generally relates to a display carton for packaging multiple units of a product, such as, but not limited to, consumable cleaning containers holding a cleaning chemistry.  FIG. 1  is a front perspective view of an assembled display carton  11  according to one embodiment of the invention. The display carton  11  includes opposing first and second side walls  40 ,  50 , a rear wall  74  extending between the side walls  40 ,  50 , a front wall  18  opposing the rear wall  74  and extending between the side walls  40 ,  50 , and a bottom wall  72  joining the side walls  40 ,  50 , rear wall, and front wall  18 . 
     The front wall  18  can extend upwardly from the bottom wall  72  between the first and second side walls  40 ,  50 . The height of the front wall  18  can be less than the height of the side walls  40 ,  50  in order to provide a front opening  82  in the display carton  11  for sliding the product in and out of the display carton  11 , and to provide information about the product in the display carton  11  to a user by allowing text and/or graphics on the product to be visible through the front opening  82 . The front opening  82  spans the entire width of the front wall  18 . 
     The rear wall  74  can be formed by first and second rear panel sections  42 ,  52 , and further includes an upper edge which includes a medial portion having a cutout  76 . The cutout  76  is formed by a first L-shaped edge  44  formed in the first rear panel section  42  and a second L-shaped edge  54  formed in the second rear panel section  52 . The cutout  76  can form an opening to provide the information about the product in the display carton  11  to the user. For example, when the display carton  11  is vertically stacked with other cartons, the user can easily discern the carton contents and the number of products in the display carton  11  through the cutout  76 . Multiple cutouts  76  can be provided in the upper edge of the rear wall  74 . Alternatively, one or more cutouts  76  can be formed through the rear wall  74  for providing information to the user. Similar cutouts  76  can be provided in the upper edge of and/or through the first side wall  40  and/or the second side wall  50 , in addition to or instead of the rear wall  74 . 
       FIG. 2  is a rear bottom perspective view of the display carton  11  from  FIG. 1 . In the present embodiment, the bottom wall  72  is formed by multiple, stacked, partially overlapping flaps  20 ,  22 ,  24 ,  26 ,  28 . The bottom wall  72  further includes one or more slots  60  which receive corresponding tabs  62  to assemble the front wall  18  ( FIG. 1 ). 
     An overlap  56  is formed by overlapping portions of the rear panel sections  42 ,  52  and the flaps  20 ,  26 . The overlap  56  extends downwardly along the rear wall  74 , and at least partially along the bottom wall  72 . The location of the overlap  56  can be configured to be offset from a center line  80  of the rear wall  74 , and the position of overlap  56  can be biased toward either the first side wall  40 , as illustrated in  FIG. 1 , or the second side wall  50  (not shown). In another embodiment, the overlap  56  can be centered along the center line  80  of the rear wall  74 , without biasing to either side wall  40 ,  50 . 
       FIG. 3  is a top plan view of one example of a carton blank  10  which can be used to make the display carton  11  of  FIGS. 1-2 . The carton blank  10  can be formed by die-cutting a sheet material and forming folding lines in predetermined locations and directions for easy folding of the panels of the carton blank  10  relative to one another. The folding lines can be “lines of weakness” in the blank  10 , such as scored or crimped lines, formed in the blank  10 . Other blank forming procedures can also be used to produce the blank  10 , including, but not limited to hand-cutting and laser-cutting. The sheet material for the carton blank  10  can include corrugated cardboard, corrugated plastic or other materials with sufficient rigidity that can also be folded. 
     Conceptually, a Cartesian coordinate system can be applied to the blank  10 , with an X-axis extending along the height of the blank  10 , a Y-axis extending along the length of the blank  10 , and a Z-axis (not shown) extending in a direction normal to the page. The X-axis and other axes parallel thereto define an “X-direction” of the blank  10 , the Y-axis and other axes parallel thereto define a “Y-direction” of the blank  10 . 
     The carton blank  10  includes a first end panel  12 , a second end panel  14 , and a third intermediate panel  16  between the first and second end panels  12 ,  14 . The third intermediate panel  16  can be hinged to the first and second end panels  12 ,  14  at folding lines  30 ,  32 , respectively. The folding lines  30 ,  32  run in the X-direction. 
     The first end panel  12  can be generally rectangular in shape, and can include the first side wall  40  and the first rear panel section  42 . A folding line  34  running in the X-direction is formed in the first end panel  12  to define the first side wall  40  and first rear panel section  42 , respectively. The height of the first panel  12  can be configured to be substantially same as the height of the units of product (not shown) that are to be received in the assembled display carton  11 . 
     The second end panel  14  can be formed as a substantial mirror image of the first end panel  12 , and can also be generally rectangular in shape, and can include the second side wall  50  and the second rear panel section  52 . A folding line  36  running in the X-direction is formed in the second end panel  14  to define the second side wall  50  and second rear panel section  52 , respectively. The height of the second end panel  14  can be configured to be substantially same as the height of the units of product (not shown) that are to be received in the assembled display carton  11 . 
     The third or intermediate panel  16  includes the front wall  18 , which can be of lesser height than the side walls  40 ,  50 , and can include an outer front panel  27  hinged to an inner front panel  29  at a double folding line  39  running in the Y-direction. The outer front panel  27  forms the outer front surface of the wall  27  when the blank  10  is assembled, and is further connected to the first and second end panels  12 ,  14  by the X-direction folding lines  30 ,  32 . The inner front panel  29  extends adjacent to the first and second side walls  40 ,  50 , but is separated from the first and second side walls  40 ,  50  by slits  64 ,  66 , respectively. 
     Multiple flaps extend from the lower sides of the panels  12 ,  14 ,  16 , and are defined by a common folding line  38  running in the Y-direction, including a first end flap  20  which extends from the first rear panel section  42 , a first intermediate flap  22  which extends from the first side wall  40 , a second end flap  26  which extends from the second rear panel section  52 , a second intermediate flap  24  which extends from the second side wall  50 , and a central flap  28  which extends from the inner front panel  27 . 
     The first flaps  20 ,  22  are separated from each other by a gap  84 , and the X-direction folding line  34  of the first panel  12  can terminate at the gap  84  between the two adjacent first flaps  20 ,  22 . The second flaps  24 ,  26  are likewise separated from each other by a similar gap  86 , and the X-direction folding line  36  of the second panel  14  can terminate at the gap  86  between the two adjacent second flaps  24 ,  26 . The central flap  28  is likewise separated from the intermediate flaps  22 ,  24  by gaps  88 ,  90 , respectively. 
     The central flap  28  includes one or more slots  60  formed adjacent the folding line  38 . The inner front panel  29  includes one or more corresponding tabs  62  on the free edge of the inner front panel  29 , opposite the double folding line  39 , which can be received in the slots  60 . The intermediate flaps  22 ,  24  can include notched edges  92 ,  94  to accommodate the insertion of the tabs  62  into the slots  60 , as described in more detail below. 
     The first rear panel section  42  and end flap  20  have a common first outer edge  96 . Likewise, the second rear panel section  52  and end flap  26  have a common second outer edge  98 . The L-shaped edges  44 ,  54  formed in the rear panel sections  42 ,  52 , can be joined to the outer edges  96 ,  98 , respectively. 
     The second rear panel section  52  and end flap  26  can be longer in the Y-direction than the first rear panel section  42  and end flap  20  to form an overlapping section  53  along the second outer edge  98  that is configured to extend over a corresponding overlapped section  43  along the first outer edge  96 . The overlapped and overlapping sections  43 ,  53  form the overlap  56  shown in  FIG. 2 . 
     The shape of the outer perimeter of the blank  10  can be formed by die-cutting or another suitable blank forming procedure, including forming the L-shaped edges  44 ,  54  in the first and second end panels  12 ,  14 , the tabs  62 , the gaps  84 ,  86 ,  88 ,  90 , and the notched edges  92 ,  94  in the intermediate flaps  22 ,  24 . The slots  60  and slits  64 ,  66  can also be formed during the same blank forming procedure. The folding lines  30 ,  32 ,  34 ,  36 , and  38  can be formed by scoring or crimping the blank  10 . 
     The carton blank  10  in  FIG. 3  can be assembled to form the display carton  11 , as illustrated in  FIGS. 1 and 2 . One method of assembling the carton blank  10  is shown in  FIGS. 3-7 . The sequence of steps discussed is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be grouped and executed at different times or divided into multiple steps, without detracting from the invention. 
     As shown in  FIG. 4 , the rear panel sections  42 ,  52  are folded about the folding lines  34 ,  36 , respectively, toward the intermediate panel  16 . The side walls  40 ,  50  are also folded about the folding lines  30 ,  32 , respectively, toward the intermediate panel  16  until the overlapping section  53  of the second rear panel section  52  overlaps the overlapped section  43  of the first rear panel section  42 , as shown in  FIG. 5 . 
     Referring to  FIG. 5 , during or after the folding step, an adhesive may be applied to at least one of the sections  43 ,  53  to adhere the sections  43 ,  53  together to form rear wall  74  with the overlap  56  shown in  FIGS. 1-2 . The adhesive can be glue or other another bonding material for chemically bonding the sections  43 ,  53 . In addition to adhesion, a physical fastener, such as staples, can be applied to the sections  43 ,  53  to further secure the sections  43 ,  53  together. 
     Referring to  FIG. 6 , the bottom flaps  20 ,  22 ,  24 ,  26 , and  28  can be folded inwardly along the folding line  38 , to form the bottom wall  72 . The bottom flaps  20 ,  22 ,  24 ,  26 , and  28  can be folded in many different orders and configurations to form the bottom wall  72 . For example, as illustrated in  FIG. 6 , the intermediate flaps  22 ,  24  can be folded inwardly first, followed by folding central flap  28  over a portion of the underside of the intermediate flaps  22 ,  24 . Then, the end flaps  20 ,  26 , which are already adhered together to form the overlap  56 , can be folded inwardly as one over a portion of the intermediate flaps  22 ,  24 . In the illustrated embodiment, the central flap  28  and the end flaps  20 ,  26  meet at a common line when folded, and do not overlap each other, as shown in  FIG. 2 . During or after folding, an adhesive can be applied to at least a portion of the flaps  20 ,  22 ,  24 ,  26 , and  28  such that all folded flaps  20 ,  22 ,  24 ,  26 , and  28  are firmly adhered together form the bottom wall  72 . 
     Referring to  FIG. 7 , the inner front panel  29  can be folded inwardly about the double folding line  39 , toward the bottom wall  72 , such that the inner front panel  29  lies against the outer front panel  27  to form the front wall  18 . The tabs  62  on the inner front panel  29  are inserted into the slots  60  formed on the central flap  28  of the bottom wall  72  to secure the inner front panel  29  in place, as shown in  FIGS. 1-2 . The notched edges  92 ,  94  on intermediate flaps  24  and  26 , respectively, provide adequate clearance around the slots  60  to accommodate insertion of the tabs  62  into the slots  60 . When assembled as shown in  FIGS. 1-2 , the outer and inner front panels  27 ,  29  form the front wall  18  with a rolled upper edge  100  at the double folding line  39 ; thus, the display carton  11  can be referred to as a roll front carton. The rolled upper edge  100  provides a smooth surface and conceals the internal flutes of the corrugated material, unlike a standard cut edge which exposes the internal flutes. 
     During assembly, folding of the carton blank  10  about the folding lines  30 ,  32 ,  34 ,  36 , and  38  can be performed by an automatic folding machine. Since the first set of folds about folding lines  30 ,  32 ,  34 ,  36  run in the same X-direction, all of the folds can easily be made by an automatic folding machine, eliminating the need for manual folding. Similarly, since the second set of folds about folding line  38  all run in the Y-direction, all of the folds can easily be made by an automatic folding machine. The only manual folding that may be required during the assembly of the carton blank  10  may be the folding of the front wall  18  about the double folding line  39 . 
     While discussed separately herein, it is understood that the blank forming and carton assembling processes can happen sequentially in one facility, such as by using sequential machines for cutting, scoring, folding, and gluing to form the assembled display carton  11 . A single machine can further perform more than one step. A step of printing, labeling or otherwise providing information on the carton  11 , and/or coating the carton  11  with a water- or grease-resistant coating can also be part of the blank forming and carton assembling process. 
     The apparatus and methods disclosed herein provide an improved display carton  11 . One advantage that may be realized in the practice of some embodiments of the described display carton  11  is that, during the assembly process, the display carton  11  requires only one manual folding step, and other folding steps can be done by an automatic folding machine, which can save assembly time. Another advantage that may be realized in the practice of some embodiments of the described display carton  11  is that the outer perimeter of the carton blank  10  is substantially rectangular, which maximizes the use of the blank material and can lower the materials cost. Yet another advantage is that the rolled upper edge  100  provides a smooth surface that conceals the internal flutes of the corrugated material and thus provides a more aesthetically pleasing appearance. The smooth rolled upper edge  100  also reduces the likelihood of consumers receiving paper cuts or scrapes while accessing product within the carton  11 . Moreover, the front opening  82  extends across the entire front wall  18 , which enhances visibility and eases removal of products contained therein compared to cartons having a less than full width front opening. 
     While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.