Patent Abstract:
An end load carton includes a closure system having a tab constituting part of a control region which is spaced from a free edge of an upper flap of the carton by a support region. The control region also includes a press zone adjacent the tab. After initially opening a top portion of the carton by releasing an adhesive connection between the upper flap and a lower flap, the tab can be positioned in a slot formed in the lower flap to reclose the carton. More specifically, the upper and lower flaps can be selectively interconnected through the closure system by pushing on the press zone to depress the upper and lower flaps in order to open up the slot and align the tab with the slot. To reopen the carton, the support region can be readily grasped and pulled to open carton without fear of tearing the upper flap.

Full Description:
FIELD OF THE INVENTION 
     The invention generally pertains to packaging products, particular food products, in cartons and, more specifically, to an end load carton incorporating a system enabling the carton to be readily and repeatedly opened and closed in a convenient and effective manner. 
     BACKGROUND OF THE INVENTION 
     In connection with shipping products, such as food products, from a manufacturer to a retail establishment, it is known to package the products in a carton, seal the carton, and ship the carton for delivery to a designated retail establishment. Although various materials could be used in making the cartons, the most common material employed is paperboard. In general, the paperboard is provided in the form of a blank which can be conveniently stored in a flat configuration but easily erected through a simple folding operation to establish an open-ended carton which can be filled and sealed, typically in an automated process. These cartons are not only lightweight and quite strong, but the paperboard is advantageously recyclable. 
     In some situations, the cartons are designed with a closure system which enables the carton to be opened and closed numerous times prior to depleting the products therein. For example, it is widely known to package cereal and other food products in end load cartons and to provide the cartons with closure systems operating between upper and lower flaps of top portions of the cartons. After this type of carton is initially unsealed, a tab projecting from the upper flap is designed to be slipped into a slot provided in the lower flap in order to re-close the carton for future access. However, it is not uncommon for a user to initially detach the upper and lower flaps by grasping the tab and pulling on the tab in attempting to overcome adhesive forces securing the upper and lower flaps. Unfortunately, this manner of opening the carton often leads to the tab being torn, thereby rendering the closure system unsatisfactory or even unsuitable for reclosure purposes. In fact, a common design actually provides for the tab extending from the remainder of the upper flap through obtuse angles, with the flap typically tearing at the vertexes of these angles. 
     A known prior art arrangement of this type is represented in  FIGS. 1-3  wherein  FIG. 1  shows an open ended carton  5  including a top portion  10  having an upper flap  15  adhered to a lower flap  20  such as in a sealed, shipping state. Upper flap  15  is formed with a central tab  25  which is provided for reclosure purposes and essentially established by forming a pair of generally V-shaped cutouts  30  and  31  at spaced locations along a free edge  35  of carton  10 . Most often, a carton formed in this fashion is initially sealed with adhesive extending below end regions  40  and  41  of upper flap  15 . As indicated above, it is quite common for a user to initially peel up tab  25 , grip the same, and pull up on tab  25  in an attempt to separate upper flap  15  from lower flap  20 . However, the adhesive can be quite strong, often leading to the area associated with tab  25  ripping from each vertex  45  associated with the cutouts  30  and  31  a substantially portion of upper flap  15  as represented by the tear lines  47  and  48  in  FIGS. 2 and 3 . When this occurs and tab  25  is later used to reclose open ended carton  5  through insertion into a slot  50  formed in lower flap  20 , end regions  40  and  41  are really not pressed against lower flap  20  as intended, as represented in  FIG. 3 . 
     In addition to the above, prior known closure systems of this type are not considered to be particularly advantageous for use with individuals of all ages and levels of ability. For instance, individuals suffering from arthritis of the hands can find it particularly difficult to manipulate the tab in combination with the slot in repeatedly opening and closing such a carton. In any case, in light of these and other drawbacks, it would be desirable to provide an open end carton with a closure system which is at least significantly less prone to tearing and can be readily utilized by individuals of varying ages and abilities. In addition, it would be desirable to provide a closure system for an open ended carton wherein the system feels, and potentially even sounds, more secure than prior known systems, thereby providing a tactical feedback which can convey a sense of confidence to the user regarding the effectiveness of the closure system. 
     SUMMARY OF THE INVENTION 
     The invention is directed to an end load carton having a closure system including a tab constituting part of a control region which is spaced from a free edge of an upper flap of the carton by a support region of the closure system. The control region also includes a press zone adjacent the tab. After initially opening the carton by releasing an adhesive connection between the upper and a lower flap of the carton, the tab is configured to be received in a slot formed in the lower flap to reclose the carton. More specifically, the upper and lower flaps can be selectively interconnected through the closure system by pushing on the press zone to depress the upper and lower flaps in order to open up the slot and align the tab with the slot. To reopen the carton, the support region can be readily grasped and pulled to open carton without fear of tearing the upper flap. 
     With the ability of a user to pull on support region and press on control region in operating the closure system, the overall closure system can be easily manipulated by individuals of varying ages and abilities including both children and the elderly having arthritic or other limitations. In any case, additional objects, features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an upper portion of a sealed end load carton including a closure system constructed in accordance with the prior art. 
         FIG. 2  is a perspective view of the prior art end load carton of  FIG. 1  in a partially open condition. 
         FIG. 3  is a perspective view of the prior art end load carton of  FIGS. 1 and 2 , with the carton shown in a reclosed condition. 
         FIG. 4  is a perspective view of an upper portion of a sealed, end load carton including a closure system constructed in accordance with the present invention. 
         FIG. 5  is a plan view of a paperboard blank from which the carton of  FIG. 4  is erected. 
         FIG. 6  is a perspective view, similar to that of  FIG. 4 , but showing the carton in a reclosed condition through the use of the closure system of the invention. 
         FIG. 7  illustrates an individual opening the closure system of either of  FIG. 4 or 6 . 
         FIG. 8  is a plan view, similar to that of  FIG. 5 , but showing a paperboard blank for a carton incorporating a modified version of the closure system. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     With initial reference to  FIG. 4 , an open ended carton constructed in accordance with the present invention is generally indicated at  55 . Carton  55  includes a top portion  58  including a closure system  62  between an upper flap  66  and a lower flap  69 . At this point, it should be noted that the use of terms, such as upper, lower, inner, outer, front, rear and the like, is for reference purposes only in describing exemplary forms of the invention as set forth herein and illustrated in the drawings. Therefore, these terms should not be considered limiting as to the overall invention. 
     In accordance with a preferred embodiment, carton  55  is formed from a blank  78  as shown in  FIG. 5 . Blank  78  can be made from various materials, particularly paperboard which is known for use in the food industry for forming various types of food cartons, such as cereal boxes. In any case, blank  78  is stamped from a single sheet to establish a first or front face panel  81  which is connected to a first side panel  84  along a fold line  85 . On another side of first face panel  81  is established a second side panel  89  which is connected with first face panel  81  through a fold line  90 . Second side panel  89  also has associated therewith a fold line  91  which connects second side panel  89  to a second or rear face panel  94 . On an opposing side of second face panel  94  is formed a connecting flap  97  which also has an associated fold line  98 . In the embodiment depicted, connecting flap  97  has tapered ends such as indicated at  100 . 
     First side panel  84  also has associated therewith an upper connecting flap  102  and a lower connecting flap  103 . Each of connecting flaps extend from first side panel  84  along a respective fold line  105 ,  106  and is provided thereon with adhesive as generally indicated at  107  for upper connecting flap  102 . In a similar manner, second side panel  89  is joined to an upper connecting flap  110  and a lower connecting flap  111  through respective fold lines  113  and  114 . In a similar manner to upper and lower connecting flaps  102  and  103 , upper and lower connecting flaps  110  and  111  are also provided with adhesive, such as indicated at  115 . 
     As illustrated in this figure, upper flap  66  has a free edge  120  which is contoured to include rounded ends  122  and  123 , as well as a central apex region  125  which is preferably radiused. Although the overall contour can vary in accordance with the invention, a generally smooth contour is desired such that no sharp points or tear initiation points exist. From free edge  120  in the area of central apex region  125 , upper flap  66  is formed with inwardly angled score lines  129  and  130 . Score lines  129  and  130  are linked through an arcuate base score line  133 . In addition, a cut line  137  extends entirely through upper flap  66  between inner terminal ends  139  and  140  of score lines  129  and  130 . With this construction, upper flap  66  is formed with a support region  141  extending from central apex region  125 , between angled score lines  129  and  130 , to cut line  137 . In addition, upper flap  66  defines a control region  144  between cut line  137  and arcuate base score line  133 . Due to the presence of cut line  137 , control region  144  has a free end (not separately labeled). Between terminal ends  139  and  140  of cut line  137  and along the free end of control region  144 , a tab  150  of closure system  62  is established. More specifically, control region  144  is constituted by tab  150  and an adjacent press zone (not separately labeled) as will be more detailed further below. 
     As also shown in this figure, upper flap  66  has end regions  151  and  152  on either side of both support region  141  and control region  144 . In addition, upper flap  66  is connected to first face panel  81  along a fold line  153 . In a manner generally similar to first face panel  81 , lower flap  69  of second face panel  94  is connected to second face panel  94  along a fold line  155  and includes end regions  156  and  157 . As illustrated, lower flap  69  is provided with outwardly spaced adhesive zones  158  and  159 , which are generally shown to be oval in shape, in end regions  156  and  157  respectively and can be established with the use of a wide range of adhesives, including glue, double-sided or pressure sensitive tape or the like. At this point, it should be noted that adhesive zones  158  and  159  are not limited to this particular shape, but are limited to certain areas and smaller in size compared to adhesive regions typically provided on cartons of this type. In addition, a preferred embodiment of the invention has cut lines about both adhesive zones  158  and  159 . That is, lower flap  69  is cut partially through its overall thickness, e.g., half way through the thickness of lower flap  69 , about both adhesive zones  158  and  159  for reasons which will be detailed below. Between adhesive zones  158  and  159 , lower flap  69  is provided with a cut line defined by a longitudinal segment  164  and pair of spaced upwardly and inwardly (based on the view shown) extending legs  165  and  166 . With this arrangement, the area between legs  165  and  166  is still attached to the remainder of lower flap  69  and, along longitudinal segment  164 , a slot  170  is established. 
     Carton  55  also has a bottom portion  172  which, in addition to connecting flaps  103  and  111 , includes an outer flap  174  connected to first face panel  81  along a fold line  175  and an inner flap  177  connected to second face panel  94  along a fold line  178 . As for inner flap  177 , this part of carton  55  is formed with a contoured region  180  that extends away from second face panel  94  from a fold line  178 , as well as an edge portion  181  which establishes an adhesive region. Contoured region  180  is provided with an arcuate central zone  186  which is convex in nature and establishes a corresponding concave curvature to part of edge portion  181 . For reasons which will be detailed more fully below, this curvature mimics a lower most edge  188  of outer flap  174  of first face panel  81 . 
     With this arrangement, carton  55  can be formed by folding blank  78  along fold lines  85 ,  89 ,  91  and  98  such that first face panel  81  and second face panel  94  are spaced by second side panel  89  and extend substantially parallel to each other. In a similar fashion, first side panel  84  will be arranged opposite to second side panel  89  and will extend over connecting flap  97  so as to be secured thereto by the adhesive provided on connecting flap  97 . Lower flaps  103  and  111  are folded inward relative to both first face panel  81  and second face panel  94  and then inner flap  177  of second face panel  94  is folded so as to extend over and be adhesively secured to lower flaps  103  and  111 . Thereafter, the outer flap  174  of first face panel  81  is folded upon the inner flap  177  of second face panel  94  and secured thereto based on the adhesive on edge portion  181  of inner flap  177  of second face panel  94 . Given the contoured nature of the adhesive provided on the inner flap  177 , a secure arrangement is provided along the length of edge portion  181 . At this point, carton  55  has an open top and can be readily filled with product, such as various types of food products, including cereal. Thereafter, upper connecting flaps  102  and  110  are folded inward, lower flap  69  is seated upon connecting flaps  102  and  110  and then upper flap  66  is adhesively attached at adhesive zones  158  and  159  to lower flap  69  to complete the packaging arrangement. 
     In accordance with the present invention, it is important that closure system  62  can be utilized to repeatedly open and close carton  55 . More specifically, upon initially opening carton  55 , the adhesive connections between upper flap  66  and lower flap  69  through space adhesive zones  158  and  159  are overcome and then closure system  62  is utilized. When initially opening carton  55 , the cuts made partially through lower flap  69  around adhesive zones  158  and  159  aid in preventing damage to upper flap  66  during this process. That is, when initially sealed, carton  55  takes the form illustrated in  FIG. 4 . Carton  4  but can be initially opened with a user grasping support region  141  and pulling up on upper flap  66 , such as indicated in  FIG. 7 . With the cuts provided about adhesive zones  158  and  159 , the fiber of upper flap  66  remains intact. Rather, layer portions of lower flap  69  at the adhesive zones  158  and  159  will tear and remain affixed to upper flap  66 , while tear propagation will be avoided. Given the minimal size and location of adhesive zones  158  and  159 , the required opening force will be reduced. 
     When it is desired to again close carton  55 , the press zone of control region  144  is pressed to deflect upper and lower flaps  66  and  69  until tab  150  becomes aligned with and received in slot  170 . Thereafter, releasing control region  144  will establish the reclosed condition shown in  FIG. 6  wherein tab  150  extends within slot  170  and below lower flap  69 . When it is desired to reopen carton  55 , support region  141  is then grasped as indicated in  FIG. 7  and pulled to remove tab  150  from within slot  170 . Notably, the use of the paperboard for blank  78 , the formation of tab  150  out of control region  144  and the cooperation of tab  150  with the structure establishing slot  170  provides a rigorous interconnection which actually results in a snapping sound upon release. The development of this sound is seen to be advantageous as it establishes an audible feedback signal to a user and increases the user&#39;s level of confidence of both the overall effectiveness and robustness of closure system  62 . 
     Based on the above, it should be readily apparent that the invention provides for an end load carton with an enhanced closure system. Given the construction of closure system  62  and the characteristics of adhesive zones  158  and  159 , support region  141  can readily be pulled to open carton  55  without fear of tearing upper flap  66 . The inclusion of the various score lines  129 ,  130  and  133  advantageously makes the support region  141  more pliable and able to flex when being manipulated. In addition, particularly with the ability of a user to pull on support region  141  and press on part of the control region  144  in operating closure system  62 , the overall closure system  62  can be easily manipulated by a user, even individuals of varying ages and abilities including both children and the elderly having arthritic or other limitations. Furthermore, the contour of the outer flap  174  is made to generally be a mirror image of central apex region  125 , thereby saving material when forming multiple cartons from a single blank. Of course, the central apex region can take various different forms, as well as corresponding changes in the outer flap. For instance,  FIG. 8  shows a modified version of the carton of the invention formed from a blank  78 ′ having a free edge  120 ′ which is more flattened, resulting in a reduced support region  141 ′, small adhesive zones  158 ′ and  159 ′, a moderately shaped outer flap  174 ′ for the first face panel  81  and a correspondingly configured inner flap  177 ′. Basically, it is desired to form the outer flap  174 ,  174 ′ with a generally convex curvature all the way across the free edge  120 ,  120 ′ so as to be void of any tear initiation points. Regardless, the tab associated with the closure system is still recessed from the free edge of the upper flap and a support region is connected thereto through score lines which provides for a pliable handle for use in opening the closure system in an efficient and effective manner. Certainly, additional variations are possible to even further enhance this feature. For instance, with reference to either  FIG. 4 or 8 , the control region can be debossed so as to extend below a plane of the upper flap while the score lines are embossed. With this arrangement, it is even easier to see where to push the control region for closure purposes and the support region even sits up off the lower flap a bit such that the support region is easier to grab when opening the closure system. In any case, although disclosed with the reference to preferred embodiments of the invention, is should be readily apparent that various changes and modifications can be made to the invention without departing from the spirit thereof. Instead, the invention is only intended to be limited by the scope of the following claims.

Technology Classification (CPC): 1