Patent Publication Number: US-8534538-B2

Title: Carton with product holding compartments

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/270,923, filed Jul. 15, 2009. 
     INCORPORATION BY REFERENCE 
     U.S. Provisional Patent Application No. 61/270,923, which was filed on Jul. 15, 2009, is hereby incorporated by reference for all purposes as if presented herein in its entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to cartons for holding products, and more particularly, to a carton having multiple compartments. 
     SUMMARY OF THE DISCLOSURE 
     In general, one aspect of the disclosure is directed to a carton for containing at least one product. The carton comprises a back panel, a front panel, a bottom panel, and a top flap. A first compartment is foldably connected to the back panel, and a second compartment is foldably connected to the front panel. The top flap is operable to overlap the first and second compartments of the carton. 
     In another aspect, the disclosure is generally directed to a blank for forming a carton for containing at least one product. The blank comprises a back panel, a front panel, a bottom panel, and a top flap. A first compartment flap is foldably connected to the back panel, and a second compartment flap is foldably connected to the front panel. The top flap is for overlapping a first compartment formed from the first compartment flap and a second compartment formed from the second compartment flap when the blank is formed into the carton. 
     In another aspect, the disclosure is generally directed to a method for forming a carton for containing at least one product. The method comprises obtaining a blank comprising a back panel, a front panel, a bottom panel, a top flap, a first compartment flap foldably connected to the back panel, and a second compartment flap foldably connected to the front panel. The method further comprises forming a first compartment by folding the first compartment flap with respect to the back panel, forming a second compartment by folding the second compartment flap with respect to the front panel, and at least partially closing the carton by folding the top flap to at least partially overlap the first and second compartments. 
     Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims. 
     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 a plan view of an exterior of a carton blank for forming a carton according to one embodiment of the disclosure. 
         FIG. 2  is a perspective view of a partially-erected carton according to one embodiment of the disclosure. 
         FIG. 3  is a perspective view of a carton in an open configuration according to one embodiment of the disclosure. 
         FIGS. 4-6  are perspective views of folding the carton of  FIG. 3  into a closed configuration according to one embodiment of the disclosure. 
         FIG. 7  is a plan view of an exterior of a carton blank for forming a carton according to a second embodiment of the disclosure. 
         FIG. 8  is a perspective view of a carton in an open configuration according to the second embodiment of the disclosure. 
         FIG. 9  is a perspective view of the carton of  FIG. 8  in a closed configuration. 
         FIG. 10  is a plan view of an exterior of a carton blank for forming a carton according to a third embodiment of the disclosure. 
         FIG. 11  is a plan view of an exterior of a carton blank for forming a carton according to a fourth embodiment of the disclosure. 
         FIG. 12  is a perspective view of a carton in an open configuration according to the fourth embodiment of the disclosure. 
         FIGS. 13 and 14  are perspective views of the carton of  FIG. 12  in a closed configuration. 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     The present disclosure generally relates to a carton or package that is used to hold various products, such as any suitable consumer product that is suitable for holding in a carton or package for quick access and use. Such products can include women&#39;s incontinence products, make-up, diaper wipes, or any other suitable product. Also, food products can be held in the carton such as snacks for infants, toddlers, children, or adults, or any other suitable food product. Further, pet treats such as dog or cat treats, or any other suitable product, can be held in the carton. 
       FIG. 1  is a plan view of the exterior side  1  of a blank, generally indicated at  3 , used to form a carton  5  ( FIGS. 3 and 6 ) according to a first exemplary embodiment of the disclosure. In the illustrated embodiment, the carton  5  has a front compartment  7  and a rear compartment  9 . Each of the compartments  7 ,  9  are capable of holding a product in an isolated compartment that is separated from the product in the other compartment. The front compartment  7  and the rear compartment  9  are positioned in generally side-by-side inverted relationship in a closed configuration of the carton  5  ( FIG. 6 ). The front compartment  7  and rear compartment  9  can be otherwise shaped, arranged, and/or positioned without departing from the disclosure. According to an exemplary embodiment of the disclosure, the carton  5  can be formed from a unitary, one-piece blank  3 , as shown in  FIG. 1 . 
     The blank  3  includes a longitudinal axis L 1  that extends generally in the direction of the length of the blank and a lateral axis L 2  that extends generally in the direction of the width of the blank. The blank  3  has a back panel  15 , a top flap  17  foldably connected to the back panel at a longitudinal fold line  19 , and a bottom panel  21  foldably connected to the back panel  15  at a longitudinal fold line  23 . A front panel  27  is foldably connected to the bottom panel  21  at a longitudinal fold line  29 . 
     In the embodiment of  FIG. 1 , a first (back) compartment flap  31  is foldably connected to the back panel  15  at a lateral fold line  33 . The first compartment flap  31  comprises a first side panel  35 , a compartment panel  37  foldably connected to the side panel  35  at a lateral fold line  39 . The compartment panel  37  includes oblique edges  41  that divide the compartment panel into first and second retaining portions  37   a ,  37   b . A second side panel  45  is foldably connected to the second portion  37   b  of the compartment panel  37  at a lateral fold line  47 . The compartment flap  31  has a first compartment bottom panel  49  foldably connected to the compartment panel  37  at the longitudinal fold line  23  that extends across the length of the blank  3 . A first bottom end flap  51  is foldably connected to the bottom panel  49  at a longitudinal fold line  53 . A first compartment side end flap  55 ,  57  is respectively foldably connected to one of the first and second side panels  35 ,  45  at the longitudinal fold line  23 . 
     In the illustrated embodiment, a second (front) compartment flap  61  is foldably connected to the front panel  27  at a lateral fold line  63 . The second compartment flap  61  is generally similar to the first compartment flap  31 . The second compartment flap  61  comprises a first side panel  65 , a compartment panel  67  foldably connected to the first side panel  65  at a fold line  69 , and a second side panel  71  foldably connected to the compartment panel  67  at a lateral fold line  73 . In one embodiment, the compartment panel  67  of the second compartment flap  61  has a generally U-shaped edge  75  that forms two upper retaining portions  67   a , and a lower retaining portion  67   b  extending between the upper retaining portions. The second compartment flap  61  has a second compartment bottom panel  77  foldably connected to the compartment panel  67  at a longitudinal fold line  79 . Second compartment side end flaps  81 ,  83  are respectively foldably connected to the first and second side panels  65 ,  71  at the longitudinal fold line  79 . A second bottom end flap  85  is foldably connected to the bottom panel  77  at a longitudinal fold line  87 . 
     In the illustrated embodiment an adhesive flap  91  extends between the first and second compartment flaps  31 ,  61  and is foldably connected to the second side panels  45 ,  71  at respective lateral fold lines  93 ,  95 . 
     In one embodiment, the top flap includes four independent moveable portions  17   a - 17   d  that allow the top flap to fold over the top of the compartments  7 ,  9  and conform to the shape of products held in the compartments. The top flap  17  includes respective longitudinal fold lines  99 ,  101 ,  103  that separate the respective moveable portions  17   a - 17   d . The longitudinal fold line  103  has two portions that extend from respective ends of a curved cut line  107 . The cut line  107  forms an edge of a protrusion  108  in the moveable portion  17   d  of the top flap  17 . The front panel  27  includes a curved cut  110  forming two moveable retention flaps  109 ,  111  in the front panel. 
     The blank  3  could have other features and aspects that are not shown by the drawings, or the features and aspects of the drawings that are illustrated could be modified without departing from the scope of the disclosure. 
     An acceptable method for forming the carton  5  from the blank  3  will be described in the following, in accordance with one exemplary embodiment of the disclosure. In accordance with one exemplary embodiment, the blank  3  can be erected into the carton  5  by folding the first compartment flap  31  along fold lines  33 ,  39 ,  47 , and  93  and folding the second compartment flap  61  along fold lines  63 ,  69 ,  73 , and  95  to form the open ended first and second compartments  7 ,  9 . The adhesive flap  91  is folded to be in face-to-face contact with the back panel  15 , bottom panel  21 , and front panel  27  and can be secured thereto by suitable adhesive (e.g., glue). The open-ended compartments  7 ,  9  shown in  FIG. 2  can be closed at respective bottom ends of the compartments. The back compartment  9  is closed by folding the bottom panel  49  and side end flaps  55 ,  57  about fold line  23  to at least partially overlap the bottom panel and side end flaps. The bottom end flap  51  is folded to be in face-to-face contact with the back panel  15 . The bottom end flap  51  can be secured to the back panel  15  by adhesive. In the illustrated embodiment, the bottom end of the front compartment  7  is closed in a similar manner. That is, the bottom panel  77 , side end flaps  81 ,  83 , and bottom end flap  85  close the bottom end of the front compartment  7 . 
     Once the front and back compartments  7 ,  9  are closed with the back panel  15 , the bottom panel  21 , and the front panel  27  generally in the same plane ( FIG. 3 ), the carton  5  is in an open configuration  150  and can be loaded with one or more products in each compartment. After the products have been loaded into the carton, the front compartment  7  is folded about fold line  29  to be generally inverted and adjacent to the back compartment  9  ( FIG. 4 ). That is, in one embodiment, the bottom panel  77  of the front compartment  7  is adjacent the top edge of the back compartment  9 . In one embodiment, the compartment panel  67  of the front compartment  7  is placed into face-to-face contact with the compartment panel  31  of the back compartment  9  ( FIGS. 4 and 5 ). As shown in  FIGS. 5 and 6 , the top flap  17  can be downwardly folded in the direction of arrow A 1 , to close the top of the back compartment  9  and to overlay the bottom panel  77  of the front compartment  7 . The protrusion  108  can be received in an opening at the cut  110  that is formed by inwardly folding the flaps  109 ,  111  to lock the downwardly folded top flap  17  in the closed position ( FIG. 6 ). The carton  5  is shown in a closed configuration  152  in  FIG. 6 . 
     The carton  5  can be opened by withdrawing the protrusion  108  from the cut  110  and upwardly folding the top flap  17  in the direction of arrow A 2  ( FIG. 6 ). Upon opening the top flap  17 , the rear compartment  9  can be accessed. The front compartment  7  can be accessed by further unfolding the carton along fold line  23  to the open configuration  150  shown in  FIG. 3 . The carton  5  can be formed by other alternative forming steps, and the carton can be opened to access products within either the front compartment  7  or rear compartment  9  by other alternative opening steps without departing from the disclosure. 
       FIG. 7  illustrates a blank  203  for forming a carton  205  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 like or identical reference numbers. The blank  203  can include a back panel  215 , a top flap  217  and a bottom panel  221  respectively foldably connected to the back panel  215 , and a front panel  227  foldably connected to the bottom panel  221 . The front flap  227  can include a curved cut  210  for receiving a protrusion  208  in the top flap  217 . A first compartment flap  231  includes a first side panel  235  foldably connected to the back panel  215  and a first compartment panel  237  foldably connected to the first side panel  235 , a second side panel  245 , and a first compartment bottom panel  249 . A second compartment flap  261  includes a first side panel  265  foldably connected to the front panel  227  and a second compartment panel  267  foldably connected to the first side panel  265 , a second side panel  271 , and a second compartment bottom panel  277 . An adhesive flap  291  can extend between the first and second compartment flaps  231 ,  261  and can be foldably connected to the second side panels  245 ,  271  at respective lateral fold lines. The blank  203  can be smaller in size than the blank  3  of the first embodiment and the compartment panels  237 ,  267  are identical to each other. Both of the compartment panels  237 ,  267  have U-shaped edges  275 . 
     The blank  203  of  FIG. 7  can be formed into the carton  205  in a generally similar manner as described above for the first embodiment. Alternatively, the blank  203  can be formed into the carton  205  by other steps and the blank  203  of the second embodiment could have other features. 
       FIG. 10  illustrates a blank  303  for forming a carton (not shown) of a third embodiment of the disclosure having similar features as the first and second embodiments. Accordingly, similar or identical features of the embodiments are provided with like or identical reference numbers. The blank  303  can include a back panel  315 , a top flap  317  and a bottom panel  321  respectively foldably connected to the back panel  315 , and a front panel  327  foldably connected to the bottom panel  321 . The front flap  327  can include a curved cut  310  for receiving a protrusion  308  in the top flap  317 . A first compartment flap  331  can be foldably connected to the back panel  315  and can include a first compartment panel  337  with a U-shaped edge  375 . A second compartment flap  361  can be foldably connected to the front panel  327  and can include a second compartment panel  367  with a U-shaped edge  375 . The blank  303  of  FIG. 10  can be formed into the carton in a generally similar manner as described above for the first embodiment. Alternatively, the blank  303  can be formed into the carton by other steps and the blank  303  of the third embodiment could have other features. 
       FIG. 11  illustrates a blank  403  for forming a carton  405  ( FIGS. 12-14 ) of a fourth embodiment of the disclosure having similar features as the first, second, and third embodiments. Accordingly, similar or identical features of the embodiments are provided with like or identical reference numbers. Generally the blank  403  can include a back panel  415 , a top flap  417  and a bottom panel  421  respectively foldably connected to the back panel  415 , and a front panel  427  foldably connected to the bottom panel  421 . The front flap  427  can include a curved cut  410  for receiving a protrusion  408  in the top flap  417 . A first compartment flap  431  includes a first side panel  435  foldably connected to the back panel  415  and a first compartment panel  437  foldably connected to the first side panel  435 , a second side panel  445 , and a first compartment bottom panel  449 . A second compartment flap  461  includes a first side panel  465  foldably connected to the front panel  427  and a second compartment panel  467  foldably connected to the first side panel  465 , a second side panel  471 , and a second compartment bottom panel  477 . An adhesive flap  491  can extend between the first and second compartment flaps  431 ,  461  and can be foldably connected to the second side panels  445 ,  471  at respective lateral fold lines. 
     The carton  405  differs from the carton  5  in that the carton of the fourth embodiment is an oblique rectangular prism having a top flap  417  and bottom panel  421  that are oblique relative to the front and back panels  415 ,  427 . In the first embodiment, carton  5  is a rectangular prism with the top  17  and bottom  21  being perpendicular to the front and back panels  15 ,  17 . In the embodiment of  FIGS. 11-14 , the fold line  423  of the blank  403  includes oblique portions  423   a ,  423   b  connecting the respective side end flaps  455 ,  457  to the respective side panels  435 ,  445 , and the fold line  479  includes oblique portions  479   a ,  479   b  connecting the respective side end flaps  481 ,  483  to the respective side panels  465 ,  471 . The side panels  435 ,  445  can include respective oblique top edges  432 ,  442  that are generally aligned with the respective oblique portions  479   a ,  479   b  of the fold line  479  in the closed configuration of the carton  5  ( FIG. 13 ). Similarly, the side panels  465 ,  471  can include respective oblique top edges  462 ,  472  that are generally aligned with the respective oblique portions  423   a ,  423   b  of the fold line  423  in the closed configuration of the carton  5  ( FIG. 13 ). 
     The blank  403  of  FIG. 11  can be formed into the carton  405  in a generally similar manner as described above for the first embodiment and as shown in  FIGS. 12-14 . Alternatively, the blank  403  can be formed into the carton  405  by other steps and the blank  403  of the third embodiment could have other features. For example, one or both of the compartment panels  437 ,  467  can have oblique edges similar to the oblique edges  41  of the compartment panel  37  in the first embodiment instead of the U-shaped edges  475  shown in  FIG. 11 . 
     In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank 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. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
     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. 
     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 disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed 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 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 exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and 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. 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.