Patent Publication Number: US-2010122998-A1

Title: Carton With Curved Panels And Opening Tab

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/199,682, which was filed on Nov. 19, 2008. 
    
    
     INCORPORATION BY REFERENCE 
     U.S. Provisional Application No. 61/199,682, which was filed on Nov. 19, 2008, is hereby incorporated by reference for all purposes as if presented herein in its entirety. 
     BACKGROUND OF THE DISCLOSURE 
     Cartons are useful for holding and transporting articles. In order to facilitate dispensing of articles from a carton, it is beneficial to form a dispenser with a portion of the carton. 
     SUMMARY OF THE DISCLOSURE 
     The present disclosure generally relates to blanks, packages, or cartons for holding and/or dispensing product. 
     In one aspect, the present invention includes a blank with a first panel connected along a first fold line to a second panel, the second panel is connected along a second fold line to a third panel, the third panel is connected along a first line of disruption to a fourth panel, and the fourth panel is connected along a third fold line to an adhesive panel. The first panel includes a peripheral edge with at least one end projection. The blank includes end flaps connected along a first end and along a second end. The blank also includes a dispensing panel in the third panel defined by tear lines and a dispensing panel projection that extends across the first line of disruption into the fourth panel. 
     The end flaps of the blank can include a first end flap at the first end connected along a first transverse fold line to the first panel, a second end flap at the second end connected along a second transverse fold line to the first panel, a third end flap at the first end connected along a first curved fold line to the second panel, a fourth end flap at the second end connected along a second curved fold line to the second panel, a fifth end flap at the first end connected along a second line of disruption to the third panel, a sixth end flap at the second end connected along a third line of disruption to the third panel, a seventh end flap at the first end connected along a third curved fold line to the fourth panel, and an eighth end flap at the second end connected along a fourth curved fold line to the fourth panel. The tear lines can include a first tear line that extends along the second line of disruption and a second tear line that extends along the third line of disruption. The tear lines can also include a third tear line that extends from the second line of disruption in the third panel in a first direction toward the dispensing panel projection and a fourth tear line that extends from the third line of disruption in the third panel in a second direction toward the dispensing panel projection. The third panel can also include two remainder portions, with a first remainder portion defined between the third tear line, the first line of disruption, and the second line of disruption and a second remainder portion defined between the fourth tear line, the first line of disruption, and the third line of disruption. The blank can also include an opening formed in the second panel. The opening can be covered by a substantially transparent material. 
     In another aspect, the invention includes a method of dispensing that includes providing a carton. The carton includes a first panel connected along a first fold line to a second panel, the second panel is connected along a second fold line to a third panel, the third panel is connected along a first line of disruption to a fourth panel, and the fourth panel is connected along a third fold line to an adhesive panel. A peripheral edge of the first panel includes at least one end projection. The carton also includes end flaps connected along a first end and along a second end. The carton further includes a dispensing panel in the third panel defined by tear lines and a dispensing panel projection that extends across the first line of disruption into the fourth panel. The method also includes folding the first panel, the second panel, the third panel, the fourth panel, and the adhesive panel along the first fold line, the second fold line, the first line of disruption, and the third fold line, respectively. The method further includes folding the end flaps to close the first end and the second end, and, separating the dispensing panel along the tear lines to create a dispensing opening in the third panel. 
     Further, the step of separating the dispensing panel can include lifting the dispensing panel projection in a direction away from the dispensing opening. Further still, the carton can include a viewing opening in the second panel. The viewing opening can be covered by a substantially transparent material that allows viewing of the interior of the carton. 
     In yet another aspect, the invention includes a carton that includes a first panel connected along a first fold line to a second panel, the second panel is connected along a second fold line to a third panel, the third panel is connected along a first line of disruption to a fourth panel, the fourth panel is connected along a third fold line to an adhesive panel, a first end panel formed by end flaps is connected along a first end, and a second end panel is connected along a second end. The first panel of the carton has a peripheral edge that includes at least one end projection. The carton also includes a dispensing panel in the third panel defined by tear lines and a dispensing panel projection that extends across the first line of disruption into the fourth panel. The adhesive panel is connected to an underside of the first panel. 
     The third panel of the carton can be connected to the first end panel along a second line of disruption and the third panel can be connected to the second end panel along a third line of disruption. The tear lines can also include a first tear line that extends along the second line of disruption and a second tear line that extends along the third line of disruption. Further, the tear lines can include a third tear line that extends from the second line of disruption in the third panel in a first direction toward the dispensing panel projection and a fourth tear line that extends from the third line of disruption in the third panel in a second direction toward the dispensing panel projection. Further still, the third panel can also include two remainder portions with a first remainder portion defined between the third tear line, the first line of disruption, and the second line of disruption and a second remainder portion defined between the fourth tear line, the first line of disruption, and the third line of disruption. Even further, the carton can include a viewing opening in the second panel covered by a substantially transparent material that allows viewing of the interior of the carton. The at least one end projection and the dispensing panel projection can be configured to form stands to support the carton in an upright configuration. The first end and the second end can be formed by end flaps connected to the first panel, the second panel, the third panel, and the fourth panel. The end flaps can be connected along curved fold lines to the second panel and the fourth panel. The end flaps can form a first handle at the first end and a second handle at the second end. 
     Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments upon reading the following detailed description of the exemplary 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 illustrate more clearly the embodiments of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a carton blank. 
         FIGS. 2 and 3  show the blank of  FIG. 1  folded in a preform or shipping configuration prior to being erected into a carton. 
         FIG. 4  shows a carton formed from the blank of  FIG. 1  in a closed configuration. 
         FIG. 5  shows the carton of  FIG. 4  supported on a front edge of the bottom panel and on tabs or projections along a front edge of the top panel. 
         FIG. 6  shows the carton of  FIG. 4  in a display configuration with a lid opened. 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     This disclosure generally relates to cartons suitable for storing and dispensing contents or articles, methods of erecting such cartons from a carton blank, and methods of dispensing from the formed carton. For purposes of illustration and not limitation, the detailed description below describes several embodiments of the invention within the context of a carton with an opener for dispensing contents or articles from the carton. Further, references herein to “end,” “side,” “front,” “rear,” “bottom,” and “top” refer to orientations or positions of elements when the carton is erected and/or disposed in an upright orientation. The terms “upper,” “lower,” “vertical,” “horizontal,” and “oblique,” and any variations thereof, generally refer to the location and/or orientation of an element or line with respect to a drawing figure in which it appears. Reference characters shared among the various embodiments disclosed herein indicate similar parts. 
       FIG. 1  illustrates an outside facing surface  3  of a carton blank  5  from which a carton  200  ( FIGS. 4-8 ) can be erected. The blank  5  includes a first side panel  10 , a second side panel  20 , a third side panel  30 , a fourth side panel  40 , and an adhesive panel  50 . Panel  10  is foldably connected along fold line  11  to panel  20 , panel  20  is foldably connected along fold line  21  to panel  30 , panel  30  is foldably connected along line of disruption  31  to panel  40 , and panel  40  is foldably connected along fold line  41  to adhesive panel  50 . End flap  12  is connected along a fold line  13  to a first end  4  of panel  10 . End flap  12  is defined between arcuate lines  9  and  19 , fold line  13 , and edge  91 . End flap  14  is foldably connected along a fold line  15  to a second end  6  of panel  10 . End flap  14  is defined between arcuate lines  49  and  59 , fold line  15 , and edge  93 . End flap  22  is connected along a fold line  23  to the first end  4  of panel  20 . End flap  24  is foldably connected along a fold line  25  to the second end  6  of panel  20 . Fold lines  23  and  25  are arcuate fold lines that form concave side edges of panel  20 . End flap  32  is connected along line of disruption  33  to the first end  4  of panel  30 . End flap  32  is defined between arcuate lines  29  and  39 , segment line  27  and tear line  73  that comprise line of disruption  33 , and edge  92 . End flap  34  is foldably connected along a line of disruption  35  to the second end  6  of panel  30 . End flap  34  is defined between arcuate lines  69  and  79 , segment line  37  and tear line  75  that comprise line of disruption  35 , and edge  94 . End flap  42  is connected along a fold line  43  to the first end  4  of panel  40 . End flap  44  is foldably connected along a fold line  45  to the second end  6  of panel  40 . Fold lines  43  and  45  are arcuate fold lines that form concave side edges of panel  40 . Fold lines  13 ,  15 ,  33 ,  35  are generally transverse to fold lines  11 ,  21 ,  31 ,  41 . One or more of fold lines  13 ,  23 ,  33 ,  43  could be replaced by a single fold line, such as indicated at  63 , and one or more of fold lines. One or more of fold lines  15 ,  25 ,  35 ,  45  could be replaced by a single fold line, such as indicated at  65 . End flaps  12 ,  14 ,  22 ,  24 ,  32 ,  34 ,  42 ,  44  generally extend in a direction away from respective fold lines  13 ,  15 ,  23 ,  25 ,  33 ,  35 ,  43 ,  45  toward periphery  8  of the blank. Further, in lieu of “panels,” the surfaces of carton  200  formed from the blank  5  can be referred to as “sides.” 
     Panel  10 , at periphery  8 , has a free front edge  16  with a curved, undulating shape forming a plurality of convex lobes or projections  17 . Although three projections  17  are shown in  FIG. 1 , greater or fewer numbers of projections are also possible. Additionally, a variety of different undulating and/or projecting shapes may be used. For example, a single projection may extend along a majority of the length of the bottom panel, and the front edge  16  may be straight, rather than undulating, at the projection. End flap  14  has a first concave free edge  49  that extends between a first end of the front edge  16  and a free edge  93  of end flap  14 . End flap  14  also has a second concave free edge  59  that extends between an intersection point of the fold lines  11 ,  25  and free edge  93 . End flap  12  has a first concave free edge  9  that extends between a second end of the front edge  16  and a free edge  91  of end flap  12 . End flap  12  further includes a second concave free edge  19  that extends between an intersection point of the fold lines  11 ,  23  and free edge  91 . 
     End flap  34  has a first concave free edge  69  that extends between an intersection point of fold lines  21 ,  25  and free edge  94  of end flap  34 . End flap  34  also has a second concave free edge  79  that extends between an intersection point of the fold lines  31 ,  45  and free edge  94 . End flap  32  has a first concave free edge  29  that extends between an intersection point of the fold lines  21 ,  23  and free edge  92  of end flap  32 . End flap  32  further includes a second concave free edge  39  that extends between an intersection point of the fold lines  31 ,  43  and free edge  92 . 
     A projection  78  extends slightly from panel  30  across fold line  31  into panel  40 , and is configured to form a stand or similar formation to help support carton  200  in an upright configuration, such as when carton  200  is disposed on a surface, such as a shelf. A central cutout or opening  80  is also provided in panel  20 . While opening  80  could be covered by a flap (not shown), generally, opening  80  is defined by a perimeter  82  surrounding a void  84 . The opening  80  is shown in  FIG. 1  as a bottle-shaped cutout or opening, though other shapes are within the scope of the invention. The opening  84  may optionally be covered or backed with a film, such as polyfilm or cellofilm. Generally, the opening  84  provides for viewing contents in the interior of the carton to allow, for example, evaluation of product remaining in the enclosed carton without separating the dispensing panel. 
     A dispensing feature  70  is formed in panel  30  and extends across fold line  31  and into panel  40  as shown in  FIG. 1 . Specifically, the dispensing feature  70  is defined by a cut line  71  that forms a projection  77  and a pattern of tear lines, including tear lines  72 ,  73 ,  74 ,  75 . Tear lines  73  and  75  extend along and generally collinear with respective lines of disruption  33  and  35 . Tear line  73  extends from the intersection of fold line  21  with line of disruption  33  to segment line  27  and then intersects with tear line  72 , which extends in a generally oblique direction to, or proximate to, cut line  71 . Tear line  75  extends from the intersection of fold line  21  with line of disruption  35  to segment line  37  and then intersects with tear line  74 , which extends in a generally oblique direction to, or proximate to, cut line  71 . Generally, tear lines  72 ,  73 ,  74 ,  75  and cut  71  effectively are connected in a generally continuous manner, to define, along with fold line  21 , a dispensing panel  95 . 
       FIGS. 2 and 3  show plan views of the blank  5  folded into a preform  100  in a substantially flat shipping configuration prior to erecting the carton  200 . In the shipping configuration, panel  40  acts as a front panel and adhesive panel  50  acts as a bottom closure panel, and panels  40  and  50  are folded along the fold line  31  approximately 180 degrees with respect to panel  30 , with the outer faces of the front panel  40  and the bottom closure panel  50  facing outwardly. Panel  10  here acts as a bottom panel and is folded along the fold line  11  approximately 180 degrees with respect to the panel  20  so as to overlap the inner face of the panel  20 , a portion of the inner face of the panel  30  (which acts as a top panel in this configuration) and the outer face of the adhesive panel  50 . The bottom panel  10  may be adhesively or otherwise attached to adhesive panel  50 , thereby forming a substantially flat carton preform. 
       FIGS. 4 and 5  show a carton  200  erected to a closed configuration from blank  5  or from preform  100  shown in  FIGS. 2 and 3 . The steps in the described process(es) are not limited to the sequence in which they are described, and may be performed in a number of different sequences. Prior to closing at least one of the panels or end flaps of the carton, such that an opening remains in the structure formed by the blank  5  ( FIG. 1 ) to allow access to the interior of the structure) the interior of the folded blank  5  or the preform  100  may be loaded with desired contents, product(s), or articles. 
     The blank  5  may be folded open from the configuration of  FIGS. 2 and 3  by folding the blank  5  along fold lines  11 ,  21 ,  41  and fold line  31  such that the bottom and top panels  10 ,  30  extend substantially parallel to each other, and the rear and front panels  20 ,  40  extend substantially parallel to each other between the bottom and top panels  10 ,  30 , with the rear and front panels  20 ,  40  extending substantially perpendicularly to the bottom and top panels  40 ,  20 . Specifically, panels  30 ,  50  may be folded along the fold lines  31 ,  41 , respectively, so as to extend rearward from panel  40 . Panel  20  may be folded along the fold line  21  to extend substantially parallel to panel  40  and panel  10  may be folded along fold line  11  to be substantially perpendicularly to the panel  30 . The adhesive panel  50  may be folded along fold line  41  to extend substantially parallel to panel  10 . Adhesive panel  50  may be attached to the inner or outer side of panel  10  by adhesive or other suitable attachment means. 
     During a folding sequence, the end flaps are folded toward the interior, with either the top end flaps or the base end flaps folded inward first. At end  4 , end flap  22  and end flap  42  may be folded inwardly along the arcuate fold lines  23 ,  43 , respectively, so as to extend substantially perpendicularly to the rear and front panels  20 ,  40 . End flap  32  may be folded downwardly along the tear line segment  73  and the fold line  27  to at least partially overlap end flap  22  and end flap  42 , and to extend substantially perpendicularly to the bottom and top panels  10 ,  30 . End flap  12  may be folded upwardly along the fold line  18  to at least partially overlap end flap  22 , end flap  42  and end flap  32 . It is noted that the configuration of end flap  12  and end flap  32  may be reversed such that end flap  32  at least partially overlaps end  12 . End flap  12  and end flap  32  may be adhesively or otherwise attached to each other, thereby forming a second side panel  230  including the end flap  22 , end flap  42 , end flap  32 , and end flap  12 . End flap  22  and the end flap  42  may not be adhesively attached to end flap  12  and end flap  32 , such that end flap  12  and end flap  32  are laterally spaced from end flap  22  and end flap  42 , thereby forming a second rear handle opening  232  and a second front handle opening  234  in the second side panel  230 . At end  6 , end flap  24  and end flap  44  may be folded inwardly along the arcuate fold lines  25 ,  45 , respectively, so as to extend substantially perpendicularly to the rear and front panels  20 ,  40 . End flap  34  may be folded downwardly along the tear line segment  75  and the fold line  37  to at least partially overlap the end flap  24  and the end flap  44 , and to extend substantially perpendicularly to the bottom and top panels  10 ,  30 . End flap  14  may be folded upwardly along the fold line  15  to at least partially overlap end flap  24 , end flap  144  and end flap  34 . It is noted that the configuration of the end flap  14  and end flap  34  may be reversed such that end flap  34  at least partially overlaps end flap  14 . End flap  14  and end flap  34  may be adhesively or otherwise attached to each other, thereby forming a first side panel  220  including end flap  24 , end flap  44 , end flap  34 , and end flap  14 . End flap  24  and end flap  44  may not be adhesively attached to the end flap  14  and the end flap  34 , such that end flap  14  and the end flap  34  are laterally spaced from end flap  24  and end flap  44 , thereby forming a first rear handle opening  222  and a first front handle opening  224  in the first side panel  220 . 
     Still referencing  FIGS. 4 and 5 , the carton  200  formed by the exemplary process provided above is generally parallelepipedal and includes, in an erected configuration of carton  200 , panel  10  that forms bottom panel  260 , panel  20  that forms rear panel  250 , panel  30  that forms top panel  210 , panel  40  that forms front panel  240 , end flaps  14 ,  24 ,  34 ,  44  that form first side panel  220 , and end flaps  12 ,  22 ,  32 ,  42  that form second side panel  230 . As shown in  FIG. 4  and  FIG. 6 , the at least partially detachable panel section  95  forms a lid  270  that is at least partially detachable from the top panel  30  for dispensing the articles B. The lid  270  is configured such that the tab  78  in the panel section  95  protrudes forward beyond the front panel  40  to facilitate easy gripping by a person&#39;s hand for opening the lid  270  ( FIG. 6 ). 
     As shown in  FIG. 4 , the lobes  17  (e.g., projections) on the front edge  16  of panel  10  extend forward beyond the front panel  40  by approximately the same distance that the tab  78  extends past the front panel  40 . Thus, when the carton is placed on support surface S, as shown in  FIG. 5 , with the front panel  40  facing downward toward support surface S, projections  17  and tab  78  form support members upon which the carton  200  can be disposed to stand. In addition to forming a stand, tab  78  forms an opening feature for opening the carton  200 . The support members may be shaped differently, or one or more of them may be omitted. 
     Referring to  FIG. 4 , the arcuate fold lines  43 ,  45  form concave corners at the junctions of the side panels  220 ,  230  and the front panel  40 . The first rear handle opening  222  and the first front handle opening  224  are formed in the first side panel  220  behind end flap  14  and end flap  34 . As shown in  FIG. 5 , the arcuate fold lines  23 ,  25  form concave corners at the junctions of the side panels  220 ,  230  and the rear panel  20 . The second rear handle opening  232  and the second front handle opening  234  are formed in the second side panel  230  behind end flap  12  and end flap  32 . The concave corners facilitate gripping by a person&#39;s hand of the flaps  24 ,  44  and the flaps  22 ,  42  of the side panel  220  and the side panel  230 , respectively, such as for the purpose of carrying or otherwise moving the carton  200 . The corners may be shaped differently (e.g., the corners may be straight, conventional corners). The handle openings  222 ,  224 ,  232 ,  234  may be sized and configured to receive a persons fingers and/or thumbs therein to provide access to the flaps  24 ,  44 ,  22 ,  42 , respectively. 
     As shown in  FIG. 5 , the opening  80  in panel  20  provides a window that renders the product, such as bars B shown in  FIG. 6 , visible from the exterior of the carton  200  when the carton is closed. The opening  80  may or may not be backed by a window film, such as polyfilm or cellofilm. 
     As shown in  FIG. 6 , when the carton  200  is resting on the support surface S with panel  10  facing downward, the lid  270  may be opened for dispensing product, such as bars B. The lid  270  may be opened by gripping tab  78 , pulling tab  78  upwardly to detach at least partially the panel section  95  from the remaining top panel sections  36 ,  38  along the tear lines  72 ,  74 , detaching along tear lines  73 , 75 , and folding the lid  270  upwardly along the fold line  21  to expose a dispenser opening  280 . The lid  270  may be reclosed or partially reclosed by folding the lid  270  downwardly along the fold line  21  to cover the dispenser opening  280 . Articles, such as for example, bars B as shown in  FIG. 6  may be placed inside the carton  200  prior to forming one or both of the side panels  220 ,  230 . 
     The blank and carton formed can be of any dimensions, which dimensions can be modified to receive, transport, and/or dispense different contents. For exemplary purposes only, the following dimensioning is provided for a blank that forms a carton. In the example embodiment, the blank can be approximately 6 to 12 inches in width (as measured from end flap  12  to end flap  14 ) and approximately 6 to 12 inches in length (as measured from projection  17  to panel  50 ), with the exemplary carton having a width of 8 3/16 inches and a length of 9.87 inches. The exemplary blank has a length of panel  10  of 3.18-inches, a length of panel  20  of 1 and ⅝ inches, a length of panel  30  of 2.94-inches, a length of panel  40  of 1 and ⅝ inches, and a length of panel  50  of ½-inch. The exemplary blank has a width of end flaps  14  and  34  of 1 and 15/32 inches, a width of panels  10  and  30  of 5¼ inches, a width of end flaps  12  and  32  of 1 and 15/32 inches, a width measured between flaps  22  and  24  across panel  20  of 7 and ⅜ inches, and a width measured between flaps  42  and  44  across panel  40  of 7 and ⅜ inches. A carton formed from this exemplary blank has an approximate size of 2.940 by 1 and ⅝ by 5¼ inches, has an approximate area of 68.03 inches, and has an approximate rule length of 94.597 inches. These dimensions are offered for exemplary purposes only and should not limit in any manner the scope of the invention or the claims. 
     In some instances in the foregoing, attaching parts together is described with reference to specific features and methods. However, the attaching may be carried out in any suitable manner, such as, but not limited to, through the use of adhesive material. 
     The term “line of disruption” is used in the specification. A line of disruption may be any suitable line, such as a fold line and/or tear line and/or cut line (e.g., a slit). The term “fold line” is used throughout the description. It is noted that, unless stated otherwise, the term “fold line” can include any at least somewhat line-like arranged, 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, conventional fold lines include: a crease, such as formed by folding; a score line, such as formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; 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. The term “tear line” is also used throughout the specification. A tear line can be any at least somewhat line-like arranged, although not necessarily straight, form of weakening that facilitates tearing therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, conventional tear lines include a slit that extends partially into the material along the desired line of weakness, a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or any combination of these features. 
     Each of the above-described concave-shaped features may be shaped differently. For example, they may have different curved shapes, or straight shapes, or any other suitable shapes. 
     The foregoing disclosure provides illustrative embodiments of the invention and is not intended to be limiting. As understood by those of skill in the art, the overall invention encompasses other embodiments not specifically enumerated herein. For example, although the carton is shown in the form of a generally parallelepipedal box, it can alternatively be shaped differently, and likewise the various detachable sections, panel sections, panels, flaps, projections, support members, tabs and lobes described herein can be shaped and arranged differently.