Patent Abstract:
Packaging boxes and packaging methods for providing the ability to quickly open tape-sealed packages while eliminating the necessity for cutting tools and potential cutting injuries associated with these cutting tools. Through the inclusion of at least one perforated access panel in at least one end portion of a corrugated packaging box, hand access is provided to an end of the tape allowing the length of tape to be completely removed without the use of any cutting tools. The at least one perforated access panel can include a punch-in section and a tear-away section wherein a tape end is positioned over at least a portion of the punch-in section. The punch-in section can be pushed inwards providing access to the tear-away section. Pulling on the tear-away section results in the tear-away section and correspondingly, the tape being torn from the packaging box.

Full Description:
FIELD OF THE INVENTION  
       [0001]     The invention relates to tape-closed packaging and more particularly to packaging having perforated cut-outs promoting tape removal during package opening.  
       BACKGROUND OF THE INVENTION  
       [0002]     Packages and boxes made of corrugated paperboard are well known and are frequently used in a wide variety of applications including, for example, the packaging of food products for shipment and storage. The use of corrugated paperboard in these applications is popular because the paperboard allows for large quantities of boxes to be made quickly and inexpensively. In addition, boxes made of corrugated paperboard may be recycled or used repeatedly such that disposal costs are reduced and/or eliminated.  
         [0003]     When loaded boxes arrive at their destination, the boxes are typically unloaded such that packaged goods can be accessed for use or sale. In order to maintain the packaged goods within the box, the boxes are typically closed using an adhesive or through application of tape. When opening boxes that have been closed with an adhesive or tape, a person often must utilize a cutting tool such as, for example, a knife, scissors, razor blade and the like. Use of these cutting tools can be inconvenient as there is a risk to potential damage to the packaged goods while at the same time increasing the potential for cutting injuries often associated with said cutting tools.  
       BRIEF SUMMARY OF THE INVENTION  
       [0004]     Corrugated packaging and the associated methods disclosed herein provide an ability to quickly open packages sealed with tape while eliminating the potential for cutting injuries typically associated with cutting tools. Through the inclusion of a perforated access panel in at least one end portion of a corrugated package, hand access is provided to an end of the tape allowing the length of tape to be completely removed without the use of any cutting tools.  
         [0005]     In one aspect, the present disclosure relates to a packaging box comprising corrugated paperboard for retaining product during shipment and storage. The packaging box includes at least one perforated access panel in an end wall of the packaging box. The at least one perforated access panel can comprise a punch-in section and a tear-away section wherein a tape end is positioned over at least a portion of the tear-away section. The punch-in section can be pushed inwards providing access to the tear-away section. Pulling on the tear-away section results in the tear-away section being torn from the packaging box wherein the tape end is simultaneously ripped from the packaging box allowing the length of tape to be removed from the packaging box.  
         [0006]     In another aspect, the present disclosure provides methods for quickly and safely opening a packaging box. Generally, the methods provide for accessing a tear-away section of a perforated access panel wherein removing the tear-away section simultaneously removes an end portion of a length of tape. Access to the tear-way section can be gained by pushing in a knock-out portion of the perforated access panel.  
         [0007]     In another aspect, the present disclosure provides for a packaging system for use during shipment and storage of goods. The packaging system can comprise a corrugated paperboard box for placement of the goods within and a length of tape for holding top flaps of the corrugated paperboard box in a closed configuration. The corrugated paperboard box can comprise at least one perforated access panel allowing for quick and safe removal of the length of tape when accessing the interior of the corrugated paperboard box.  
         [0008]     As used throughout the specification, the terms top and bottom generally refer to a shipping or storage orientation of a packaging box and to distinguish opposed sides of a packaging box. The terms top and bottom are not intended to limit a packaging box to a particular shipping and/or storage orientation. With some products contained within the packaging box, shipping and/or storage orientation will have no effect upon the product such the top and bottom surfaces are interchangeable as there may be no preferred shipping orientation.  
         [0009]     The various embodiments and aspects of the present disclosure are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:  
         [0011]      FIG. 1  is a perspective view of a prior art packaging box having a top portion of the packaging box closed with an adhesive.  
         [0012]      FIG. 2  is a perspective view of a prior art packaging box having a top portion of the packaging box closed with a length of tape.  
         [0013]      FIG. 3  is a perspective view of an embodiment of a packaging box having at least one perforated access panel for providing access to a tape end of a length of tape used to closed the packaging box.  
         [0014]      FIG. 4  is a top view of the packaging box of  FIG. 3  in an unassembled flat configuration.  
         [0015]      FIG. 4   b  is an enlarged view of a perforated access panel in the unassembled flat configuration of  FIG. 4 .  
         [0016]      FIG. 5  is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.  
         [0017]      FIG. 6  is an enlarged top view of the packaging box of  FIG. 5  taken at Detail  6  of  FIG. 5 .  
         [0018]      FIG. 7  is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.  
         [0019]      FIG. 8  is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.  
         [0020]      FIG. 9  is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0021]     As illustrated in  FIGS. 1 and 2 , a packaging box  100  of the prior art can comprise a top surface  102 , a bottom surface  104 , a pair of side surfaces  106   a ,  106   b  and a pair of end surfaces  108   a ,  108   b . Top surface  102  can comprise a pair of hinged major flaps  110   a ,  110   b  rotatably attached to the corresponding side surface  106   a ,  106   b  at a hinge member  112 . Additionally, top surface  102  can comprise a pair of hinged minor flaps  113   a ,  113   b  rotatably attached to the corresponding end surfaces  108   a ,  108   b  at a hinge member  115 . Hinge member  112  and hinge member  115  generally comprise a scored portion  114  or scored line distinguishing the hinged flaps from the corresponding side or end surface. Though not depicted in detail, bottom surface  104  can substantially resemble top surface  102  in construction and appearance. Packaging box  100  can comprise suitable materials of construction such as, for example, single or multi-wall construction utilizing cardboard, paperboard, corrugated paper, chipboard and combinations thereof.  
         [0022]     As illustrated in  FIG. 1 , packaging box  100  is formed into a closed configuration  116  by rotatably folding the hinged minor flaps  113   a ,  113   b  toward one another wherein the hinged major flaps  110   a ,  110   b  are folded over hinged minor flaps  113   a ,  113   b  and into proximity such that the hinged major flaps  110   a ,  110   b  meet along a sealing interface  118 . As illustrated in  FIG. 1 , hinged major flaps  110   a ,  110   b  can be retainably maintained at sealing interface  118  through the application of a suitable adhesive on a bottom side of hinged major flaps  110   a ,  110   b  to the hinged minor flaps  113   a ,  113   b  wherein the hinged minor flaps  113   a ,  113   b  provide further structural support.  
         [0023]     As illustrated in  FIG. 2 , hinged major flaps  10   a ,  10   b  can be similarly formed and retained into closed configuration  116  using a length of packing tap  120  long enough to cover the sealing interface  118  and at least partially wrap over and attach to the end surfaces  108   a ,  108   b . Packing tape  120  can comprise a suitable packing tape such as, for example, packing tape available from Minnesota Mining and Manufacturing of St. Paul, Minn.  
         [0024]     Packaging box  100 , as illustrated in  FIG. 1 , can require the use of specialized packaging equipment to properly apply the adhesive for closing hinged major flaps  110   a ,  110   b . The adhesive may require application at increased temperatures, which can provide a risk to personnel handling packaging box  100 . When packaging box  100  is to be opened, generally a tearing force must be applied to the hinged major flaps  110   a ,  110   b  so as to separate the hinged major flaps  110   a ,  110   b  from the hinged minor flaps  113   a ,  113   b , which can result in tearing of the hinged major flaps  110   a ,  110   b  such that full access is not provided to the packaging box  100 . The tearing action also generally requires the tearing force be applied by the individual opening packaging box  100  and in some instances may require increased strength and exertion by the individual. In addition, packaging box  100  can be opened through the use of cutting tools to remove the hinged major flaps  110   a ,  110   b  and the hinged minor flaps  113   a ,  113   b  from the packaging box  100 . By necessity, these cutting tools have sharp edges and/or points wherein use of these cutting tools necessarily increases the potential for injuries to a user such as, for example, cuts and/or piercings to the individual opening the packaging box  100 . In addition, damage can be unintentionally inflicted upon the goods and products contained within the packaging box  100  as the cutting tool is utilized to access the interior of the packaging box  100 .  
         [0025]     Packaging box  100 , as illustrated in  FIG. 2 , generally requires the use of cutting tools such as, for example, a knife, razor, scissors and the like, to cut the packing tape  120  along sealing interface  118 . As said cutting tools have sharp edges by necessity, use of said cutting tools can result in injuries such as, for example, cuts and piercings to individuals opening the packaging box  100 . In addition, damage to products contained within the packaging box  100  can be inflicted as the cutting tool is used to cut the packing tape  120 . Individuals opening packaging box  100  can attempt to open the packaging box by tearing at a tape end  122  of the packing tape  120  but this can be inefficient resulting in increased time for the individual to open the packaging box  100 .  
         [0026]     A representative packaging box  200  of the present invention is illustrated in  FIGS. 3 and 4 . Packaging box  200  generally resembles packaging box  100  in that packaging box  200  comprises top surface  202 , a bottom surface  204 , a pair of side surfaces  206   a ,  206   b  and a pair of end surfaces  208   a ,  208   b . Top surface  202  generally comprises a pair of hinged major flaps  210   a ,  210   b  rotatably attached to the corresponding side surface  206   a ,  206   b  at a hinge member  212  and a pair of hinged minor flaps  213   a ,  213   b  attached to the corresponding end surface  208   a ,  208   b  at hinge member  212 . Hinge member  212  generally comprises a scored portion  214  or scored line distinguishing the hinged flap from side surface. Bottom surface  204  can substantially resemble top surface  202  in construction and appearance. Packaging box  200  can comprise suitable materials of construction such as, for example, single or multi-wall construction utilizing cardboard, paperboard, corrugated paper, chipboard and combinations thereof. End surface  208   a  can comprise a perforated access panel  216  having a punch-in portion  218  and a tear-away portion  220  as illustrated in  FIG. 3  or, alternatively, both end surface  208   a  and end surface  208   b  can comprise at least one perforated access panel  216  as illustrated in  FIG. 4 .  
         [0027]     As illustrated in  FIG. 3 , packaging box  200  can be formed into a closed configuration  222  by rotatably folding the hinged minor flaps  213   a ,  213   b  toward one another wherein the hinged major flaps  210   a ,  210   b  are folded over the hinged minor flaps  213   a ,  213   b  and into proximity such that the hinged major flaps  210   a ,  210   b  meet along a sealing interface for example sealing interface  118  shown in  FIG. 1 . Hinged major flaps  210   a ,  210   b  can be retainably maintained at sealing interface  118  using a length of packing tap  120  long enough such that when the sealing interface  118  is fully covered, the tape end  122  wraps over and at least partially covers the tear-away portion  220  of the perforated access panel  216 . In one presently preferred embodiment, tape end  122  does not wrap over and/or cover the punch-in portion  218 .  
         [0028]     As illustrated in  FIG. 4 , packaging box  200  can be stored and/or transported in a flat configuration  224  or alternatively, a partially assembled configuration wherein perimeter tab  234  is pre-attached to the inside of side surface  206   b  using a suitable attachment method such as, for example, use of an adhesive and/or tape. As illustrated in  FIG. 4 , packaging box  200  can further comprise a pair of bottom minor flaps  228   a ,  228   b  and a pair of bottom major flaps  230   a ,  230   b . The various surfaces and flaps can be distinguished by scored lines  232 . Packaging box  200  can further comprise a perimeter attachment tab  234  for operatively joining end surface  208   a  with side surface  206   b.    
         [0029]     As illustrated in  FIGS. 3, 4  and  4   b , access panel  216  and more specifically, punch-in potion  218  and tear-away portion  220  are defined by a first perforated link  235  and a second perforated link  237  wherein each perforated link comprises a plurality of spaced apart perforations  236  extending fully through the thickness of flat configuration  224 . The perforations  236  can have a perforation length  238  from about 0.067 inches to about 1.0 inches. Perforation length  238  and perforation spacing  240  between perforations  236  can be specifically selected to provide the necessary retaining strength such that neither the first perforated link  235  or second perforated link  237  are pushed out or broken by products stored and transported by packaging box  200  while providing for easy separation along first perforated link  235  and second perforated link  237  to a person intentionally accessing the interior of packaging box  200 . Product characteristics that can effect the design of perforated access panel  216  can include, for example, product size, product layout, product shape, product weight and product quantity.  
         [0030]     In use, the flat configuration  224  is folded inwardly along the scored lines  232  such that side surfaces  206   a ,  206   b  are in a substantially parallel relation while end surfaces  208   a ,  208   b  are also arranged in a substantially parallel orientation. Perimeter attachment tab  234  is attached to an inner surface of side surface  206   b  using a suitable attachment mechanism such as, for example, an adhesive or tape. Bottom minor flaps  228   a ,  228   b  are folded inwardly wherein the bottom major flaps  230   a ,  230   b  are folded inwardly to capture the bottom minor flaps  228   a ,  228   b . The bottom major flaps  230   a ,  230   b  can be retained in an inwardly folded, retained relation to define bottom surface  204  using suitable attachment techniques such as, for example, the use of adhesives and/or tape as previously described with respect to packaging box  100 . Once the bottom surface  204  has been defined, products can be loaded into an interior portion of the packaging box  100 . Products can comprise bulk packaged goods such as, for example, refrigerated or frozen dough products or stacked goods such as, for example, trays of refrigerated or frozen dough products.  
         [0031]     Once packaging box  200  has been loaded with product, the hinged minor flaps  213   a ,  213   b  are rotatably folded toward one another such that hinged major flaps  210   a ,  210   b  can be folded over the hinged minor flaps  213   a ,  213   b  and approximated along sealing interface  118  as described previously with respect to packaging box  100 . A length of tape  120  is placed over the sealing interface  118  and wrapped onto the end surfaces  208   a ,  208   b  such that the tape end  122  resides at least partially over the tear-away portion  220  of the perforated access panel  216 . At this point, packaging box  200  is prepared for transportation and storage.  
         [0032]     At time of use, an individual accesses the product with packaging box  200  by breaking the second perforated link  237  through pushing the punch-in portion  218  of the perforated access panel  216  into the interior of packaging box  200 . By pushing in the punch-in portion  218 , the tear-away portion  220  becomes accessible for grabbing by the individual. The individual grabs the exposed tear-away portion  220  and rips the tear-away portion  220  away from the end surface  208   a  along the first perforated link  235 . As the tear-away portion  220  is removed, the tape end  122  remains attached to the tear-away portion  220  such that the length of tape  120  begins to be torn from the packaging box  200 . Through continued pulling of the tear-away portion  220 , the length of tape  120  is removed along the length of sealing interface  118  allowing both the hinged major flaps  210   a ,  210   b  and hinged minor flaps  213   a ,  213   b  to be folded back along the scored lines  232  connecting the hinged major flaps  210   a ,  210   b  with the side surfaces  206   a ,  206   b  and the hinged minor flaps  213   a ,  213   b  with the end surfaces  208   a ,  208   b  so as to expose the interior of packaging box  200  and allow access to the products.  
         [0033]     As illustrated in  FIGS. 5, 6 ,  7  and  8 , packaging box  200  can comprise a variety of alternative configurations for the perforated access panel based upon product characteristics such as, for example, product size, product layout, product shape, product weight and product quantity. With reference to  FIGS. 5 and 6 , packaging box  200  can comprise at least one perforated access panel  242  having a generally semi-circle shaped punch-in portion  244  and a generally rectangular tear-away portion  246 . In another alternative embodiment illustrated in  FIG. 7 , packaging box  200  can comprise a perforated access panel  248  having a generally rectangular punch-in portion  250  and a generally rectangular tear-away portion  252 . In another alternative embodiment illustrated in  FIG. 8 , packaging box  200  can comprise a perforated access panel  254  having a generally rectangular tear-away portion  256  and a punch-in portion  258  wherein punch-in portion  258  comprising a first punch-in portion  258   a  and a second punch-in portion  258   b . As illustrated in  FIG. 8 , tear-way portion  256  can be positioned in the end surfaces  208   a ,  208   b  such that scored line  232  is used to partially define the tear-away portion  256 .  
         [0034]     In another embodiment, packaging box  200  can comprise perforated access panels for providing access to one or both of the top surface  202  and bottom surface  204  as illustrated in  FIG. 9 . Packaging box  200  comprises a pair of top perforated access panels  258   a ,  258   b  and a pair of bottom perforated access panels  260   a ,  260   b . As depicted in  FIG. 9 , the top perforated access panels  258   a ,  258   b  and bottom perforated access panels  260   a ,  260   b  can have a similar configuration with a generally semi-circle shaped punch-in portion  262  and a generally semi-circle shaped tear-away portion  264 . In use, bottom surface  204  can be closed using tape  120 , as previously described with respect to top surface  202 , wherein tape end  122  resides at least partially over one or both of bottom perforated access panels  260   a ,  260   b . Packaging box  200  can be used advantageously with products wherein the shipping and/or storage orientation of the products such as, for example, right side up or upside down, is unimportant. In this manner, product can be accessed through the top surface  202  or bottom surface  204  depending upon which orientation is most convenient to the person opening packaging box  200 .  
         [0035]     It will thus be seen according to the invention a highly advantageous packaging box and methods for packaging. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.

Technology Classification (CPC): 1