Patent Publication Number: US-7717322-B2

Title: Packages, blanks for making packages and associated methods

Description:
RELATED APPLICATIONS 
   This application is a continuation of Application No. PCT/US06/022560, filed Jun. 8, 2006, which designates the United States and claims the benefit of U.S. Provisional Application No. 60/688,505, filed Jun. 8, 2005 and U.S. Provisional Application No. 60/724,537, filed Oct. 7, 2005, the specifications and drawings of all of the aforesaid applications being hereby incorporated by reference. 
   This application is related to application Ser. No. 10/318,437, filed Dec. 13, 2002, the entire contents of which are hereby incorporated by reference. 

   BACKGROUND 
   Conventional cartons may include features such as closure devices, lids, and other convenient features. Features of a certain complexity, however, may require the carton blank to be prepared in a batch process, where features or articles can be individually cut and/or glued to the carton blank. Batch processing is slow when compared to continuous processes, and may involve higher costs. 
   SUMMARY 
   According to a first exemplary aspect of the invention, a carton is formed from an inner blank joined to an outer blank. The carton includes a rotatable dispenser panel that allows product to be selectively dispensed from the carton. 
   According to a second exemplary aspect of the invention, a carton is formed from an inner blank joined to an outer blank. The carton includes a display feature that allows an extension panel of the outer blank to be moved away from a remainder of the carton into a highly visible position. 
   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. 

   
     BRIEF DESCRIPTION OF THE 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 invention. 
       FIG. 1  is a schematic illustration of a continuous process production line. 
       FIG. 2  is a plan view of a blank used to form a carton according to a first embodiment of the invention. 
       FIG. 3  is a plan view of an exterior ply of the blank of  FIG. 2 . 
       FIG. 4  is a plan view of an interior ply of the blank of  FIG. 2 . 
       FIG. 5  illustrates the first carton embodiment. 
       FIGS. 6 and 7  illustrate operation of a dispenser feature of the carton. 
       FIG. 8  illustrates operation of a display feature of the carton. 
   

   DETAILED DESCRIPTION 
     FIG. 1  is a schematic illustration of a continuous process production line suitable for producing blanks according to the embodiments disclosed in this specification. In  FIG. 1 , a web of material B is repeatedly provided with one or more lines of disruption at a first disrupting station E, and a web of material A is repeatedly provided with one or more lines of disruption at a second disrupting station F. The webs of material A, B may then be laminated together at a lamination station G, and passed through a third disrupting station H. The laminated webs may be separated into individual two-ply carton blanks C at the third disrupting station H, and also, if desired, provided with additional lines of disruption. The combined webs are generally separated into the individual blanks C at the points between the repeating patterns of lines of disruption. 
   In general, each of the cartons discussed herein can be formed from exterior (or outer) and interior (or inner) webs, which are indicated by reference signs A and B in  FIG. 1 , respectively. The terms “inner” and “outer” are used in this specification to indicate the location of the respective webs (and corresponding blank plys) in a product, such as a carton, formed or erected from the finished multi-ply blanks C. The outer and inner webs A and B may each be individually provided with one or more lines of disruption prior to laminating the webs together. Unless specifically stated otherwise, the plan views of final blanks of this specification illustrate blanks having significant portions with at least two plys (i.e., “multi-ply”) formed from individual webs A and B, such as the two-ply blank C shown in  FIG. 1 . 
   For purposes of the description presented herein, the term “line of disruption” can be used to generally refer to a cut line, a score line, a tear line, a crease line, perforations, a fold line, or other disruptions formed in a blank (or a combination of at least one cut line, score line, tear line, crease line, and/or fold line, or other disruptions). A “breachable” line of disruption as disclosed in the specification refers to a line of disruption that is intended to be breached or otherwise torn during ordinary use of a carton. 
     FIG. 2  is a plan view of a final multi-ply blank  8  used to form a carton  190  (illustrated in  FIG. 5 ) according to a first embodiment of the invention. The blank  8  is formed from an outer blank  5  and an inner blank  6  adhered, laminated or otherwise joined to the outer blank  5 . The outer blank  5  and the inner blank  6  are illustrated separately in  FIGS. 3 and 4 , respectively. The outer surface or print surface of the outer blank  5  is visible in  FIG. 2 , and the inner blank  6  is joined to the opposite, interior or underside of the outer blank  5 . Therefore, the inner blank  6  is not visible in  FIG. 2 . The final blank  8  is “multi-ply” in that the inner and outer blank plys  5  and  6  comprising the blank  8  include substantial overlapping portions. 
   The terms “two-ply” and “multi-ply” do not indicate that all sections of the blank  8  are formed from two or more plys. For example, the blanks  5  and  6  may have slightly different perimeters or “footprints” and may not overlap at all points. In general, the outer blank  5  may be formed from a continuous web such as the web A shown in  FIG. 1 , and the inner blank  6  may be formed from a separate, continuous web B. The separate webs A and B may undergo processing in the production line of  FIG. 1 , for example, including lamination together at station G, and separation into a final two-ply blank  8  at the third disrupting station H. 
   Referring to  FIG. 2 , the blank  8  comprises a first side panel  10  foldably connected to a first end panel  20  at a first transverse fold line  21 , a second side panel  30  foldably connected to the first end panel  20  at a second transverse fold line  31 , and a second end panel  40  foldably connected to the second side panel  30  at a third transverse fold line  41 . An adhesive flap  50  can be foldably connected to the first side panel  10  at a fourth transverse fold line  51 . The transverse fold lines  21 ,  31 ,  41  can be formed by, for example, cuts or scores extending through both the inner and outer blanks  6 ,  5 . 
   The first side panel  10  is foldably connected to a first side top flap  17  of the outer blank  5  and a first side top flap  18  of the inner blank  6 , and a bottom first side flap  14 . The first end panel  20  is foldably connected to first end top flap  22  and a first end bottom flap  24 . The second side panel  30  is foldably connected to a second side top flap  37  or the first outer blank  5  and a second side top flap  38  of the inner blank  6 , and a second side bottom flap  34 . The second end panel  40  is foldably connected to a second end top flap  42  and a second end bottom flap  44 . The top end flaps extend along a first or top marginal area of the blank  8 , and may be foldably connected at the first longitudinal fold line  72  that extends along the length of the blank  8 . The bottom end flaps extend along a second or bottom marginal area of the blank  8 , and may be foldably connected at the second longitudinal fold line  74  that also extends along the length of the blank  8 . The longitudinal fold lines  72 ,  74  may be substantially straight fold lines, or may be offset at one or more locations to account for, for example, blank thickness or other factors. 
   The blank  8  includes an outer display pattern  100  that in part defines a display feature  185  in the carton  190  (illustrated in  FIG. 5 ). The outer display pattern  100  is formed in the outer blank  5  and generally does not extend into the inner blank  6 . The lines of disruption forming the outer display pattern  100  can be formed in the outer web A, for example, before lamination to the inner web B. The outer display pattern  100  includes spaced lines of disruption such as cuts  102 ,  104  that extend across the first side panel  10  and define upper and lower edges of the display feature  185 . A cut  106  extends through the panel  10  and may connect the lines  102 ,  104 . A fold line, such as a cut-space line  108  extends through the panel  10  adjacent to the fold line  51 . A pull tab  111  is defined by a perimeter cut  110 . Curved cuts  116 ,  118 ,  120  define an extension panel  126  in the pattern  100 . A fold line, such as a cut-space line  122 , foldably connects first and second pivot panels  127 ,  128 . A fold line, such as a cut-space line  124 , in part defines an adhesive panel  129  adjacent to the panel  128 . The outer display pattern  100  interacts with an inner display pattern  130  formed in the inner blank  6 , as discussed in detail below with reference to  FIG. 4 . 
   The blank  8  also includes an outer dispenser pattern  140  that in part defines a dispenser  180  in the carton  190  (illustrated in  FIG. 5 ). The outer dispenser pattern  140  is formed in the outer blank  5  and generally does not extend into the inner blank  6 . The lines of disruption forming the outer dispenser pattern  140  can be formed in the outer web A, for example, before lamination to the inner web B. The outer dispenser pattern  140  includes a perimeter line of disruption  144  that defines a rotatable dispenser panel  142 , and a cutout aperture  146  in the dispenser panel  142 . The perimeter line  144  can be a breachable line of disruption or a cut, for example. The cutout  146  could also be breachable line defining a knockout section, for example, that could be removed before use of the dispenser  180 . A clearance cutout  148  is formed along the fold line  72 . The outer dispenser pattern  140  also includes a removable cover panel  150  defined by a breachable perimeter line of disruption  152 . The outer dispenser pattern  140  interacts with an inner dispenser pattern  160  formed in the inner blank  6 , as discussed in detail below with reference to  FIG. 4 . 
     FIG. 3  is a plan view of the outer ply or blank  5  of the blank  8 . A continuous series of outer blanks  5  may be formed from the web A in the production line illustrated in  FIG. 1 . Repeating patterns of lines of disruption in the web A may be formed, for example, at the disrupting station F shown in  FIG. 1 . At the end of the production line, each outer blank  5  is joined to a corresponding inner blank  6  to form the blanks  8 . Any combination of the lines of disruption formed in the web A may be formed at the disrupting station F. For example, the outer display pattern  100  or outer dispenser pattern  140  may be formed at station F. The outer blank  5  includes panels  13 ,  23 ,  33 ,  43  that form the outer plys of the two-ply panels  10 ,  20 ,  30 ,  40 . 
     FIG. 4  is a plan view of the inner ply or blank  6  of the blank  8 . A continuous series of inner blanks  6  may be formed from the web B in the production line illustrated in  FIG. 1 . Repeating patterns of lines of disruption formed in the web B may take place, for example, at the disrupting station E shown in  FIG. 1 . 
   The inner blank  6  includes panels  15 ,  25 ,  35 ,  45  that form the inner plys of the two-ply panels  10 ,  20 ,  30 ,  40 . The inner blank  6  includes an inner display pattern  130  that in part defines the display feature  185  in the carton  190  (illustrated in  FIG. 5 ). The inner display pattern  130  is formed in the inner blank  6  and the lines of disruption forming the display pattern  130  can be formed in the inner web B, for example, before lamination to the outer web A. The inner display pattern  130  may include a breachable perimeter line or cut  134  defining a slider panel  132  in the panel  15 . An inner dispenser pattern  160  is also formed in the inner blank  6 . The inner dispenser pattern  160  comprises first and second dispenser apertures  162 ,  164 . The dispenser apertures  162 ,  164  could also be knockout sections defined by breachable perimeter lines. 
   Any of the cuts described above can be substituted with breachable lines of disruption, such as tear lines, for example. 
   The exterior side of the inner blank  6  can be joined to the interior side of the outer blank  5  across essentially the entire overlapping surface area of the blanks  5 ,  6 , except at the panels  126 ,  127 ,  128  in the outer blank  5 . The adhesive panel  129  is adhered to the slider panel  132 , and the base of the tab  111  also adhered to the slider panel  132 . The dispenser panel  142  and the cover panel  150  should not be adhered to the inner blank  6 . The end flaps  17 ,  18  are not adhered together, and the end flaps  37 ,  38  are not adhered together. The end flaps  27 ,  28  may be adhered together to form the end flap  22 , and the end flaps  47 ,  48  may be adhered together to form the end flap  42 . 
   Any combination of the lines of disruption formed in the web B may be formed at the disrupting station E. For example, the inner display pattern  130 , and the inner dispenser pattern  160  can be formed at station E. Final processing of the webs, including separation of the combined webs A and B into blanks  8 , occurs at station H. The transverse fold lines  21 ,  31 ,  41 ,  51  can be formed simultaneously in the inner and outer blanks  5 ,  6  at station H. 
   The carton may be erected by adhering the exterior of the adhesive flap  50  to the interior side of the panel  40 . The blank  8  can now be opened up into a generally tubular form. The bottom end of the tubular blank form may closed by folding the end flaps  24 ,  44  inwardly, folding the flap  14  over the flaps  24 ,  44 , and then folding the flap  34  over the flap  14 . The two-ply bottom end flaps  14 ,  24 ,  34 ,  44  can be adhered together by adhesives such as, for example, glue. 
   The two-ply top flaps  22 ,  42 , which can comprise, top flaps  27 ,  28  adhered together and top flaps  47 ,  48  adhered together, respectively, are folded inwardly. Next, the flap  38  is folded over the flaps  22 ,  42 . The flap  18  is then folded over the flap  38  and adhered thereto. The flap  17  is then folded over the flap  18  and adhered thereto at locations outside of the panel  142 . The flap  37  is then folded over the flap  17  and adhered to the flap  17  at locations outside of the panel  142 . 
     FIG. 5  illustrates the erected carton  190  with its top and bottom ends closed. Product, such as particulate matter, discrete articles, or other items, such as pouches, may be loaded into the carton  190  at any time before closing the top and bottom ends of the carton. 
     FIGS. 6 and 7  illustrate operation of the dispenser feature  180 . Referring to  FIG. 6 , the cover panel  150  may be removed at the perimeter line of disruption  152 , leaving a dispenser opening  156  in the panel  37 . The dispenser panel  142  may be rotated between the panels  37  and  18 . In  FIG. 6 , the panel  142  is in a closed position. In  FIG. 7 , the dispenser panel  142  is rotated to a dispensing position, where the aperture  146  is aligned with the opening  156 . Product can be dispensed from the carton  190  when the dispensing feature  180  is in the dispensing configuration of  FIG. 7 . 
     FIG. 8  illustrates operation of the display feature  185 . The display feature  185  is actuated by pulling on the pull tab  111 . The slider panel  132  is adhered to the pull tab  111 , and in turn causes the adhesive panel  129  to move the left in  FIG. 8 . The adhesive panel  129  is foldably connected to the second pivot panel  128 , and the second pivot panel  128  moves the left and pivots upwardly about the fold line  124 . The first pivot panel  127  is foldably connected to the second pivot panel  128  at the fold lines  122 , and moves to the left and pivots also about the fold line  108 . This movement causes the extension panel  126  to extend to a highly visible position away from the panel  10 . A side panel opening  138  is left as the slider panel  132  moves to the left. 
   In accordance with the exemplary embodiments, the cartons may be constructed of paperboard, for example. The paperboard webs used to form the blank may be thicker and heavier than ordinary paper. The blanks, and thus the cartons, can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. For example, the blanks may be formed from coated solid unbleached sulfate (SUS) board. The blanks can also be laminated to or coated with one or more web-like materials at selected panels or panel sections. 
   One or more panels of the blanks discussed above can be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product, advertising, and other information or images. The blanks may also be coated to protect any information printed on the blank. The blanks may be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. 
   In accordance with the exemplary embodiments, 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 invention, 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. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line. 
   The above embodiments may be described as having one or panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place. 
   The term “line” as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines. 
   In the present specification, a “panel” need not be flat or otherwise planar. A “panel” can, for example, comprise a plurality of interconnected generally flat or planar sections. 
   The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected embodiments of the invention, but it is to be understood that the invention 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.