Abstract:
A carton for retaining, suspending, and dispensing rolls of wound web material and a method of manufacturing same are disclosed. The carton is a trunk to which a lid is hinged to allow the lid to be opened and closed and thereby allow access to the roll of wound web material. Retainers are provided at first and second ends to positively hold the roll within the carton for dispersal of the film. The retainers may also suspend the roll off of the bottom wall of the carton to avoid adhesion of the multiple layers of wound web of material, particularly materials employing pressure sensitive adhesives. A carton includes guide surfaces to facilitate automated assembly of the carton.

Description:
FIELD OF THE INVENTION 
     The invention generally relates to dispensers and, more particularly, relates to dispensers for use in conjunction with wound films such as plastic wrap, aluminum foil, wax paper, and the like. 
     BACKGROUND OF THE INVENTION 
     Cartons for the storage and dispersal of rolls of wound flexible film are well-known. Such cartons are typically manufactured from paperboard material and folded into a configuration conventionally referred to as a trunk-lid box wherein a base or box of the carton forms an enclosure for the roll with an open top, and the lid is folded relative to the trunk to form a natural hinge and thereby allow the lid to close the trunk. 
     A number of criteria need to be considered when manufacturing such a carton. One concern is the ease with which the material can be drawn from the roll. This criteria is a function of a number of variables including the type of material wound onto the roll, the manner in which the roll is positioned or placed within the carton, and the angle at which the material must be pulled from the carton. For example, if the material is of a high-tack quality, it may tend to adhere to itself thereby requiring a relatively high level of force to pull the material from the roll. Depending upon the degree of tack to the film, and the angle at which the material is pulled from the carton, the roll itself may tend to be pulled completely out of the carton, creating a source of frustration for the user. Moreover, once the roll is pulled from the carton, the risk of contamination of the film is increased. 
     Mechanisms have therefore been devised which perform a retention feature within the carton. In other words, the roll itself may be physically held within the carton such that upon a user pulling on the film, the roll is held against the force created by the user, while still enabling the roll to rotate and thereby dispense film. For example, U.S. Pat. No. 4,998,656, assigned to the present assignee, discloses a roll restraining dispensing carton wherein opposite ends of the carton include collars for retaining the roll within the carton. The collars include apertures which circumnavigate the ends of the roll to thereby physically hold the roll within the carton, and also provide a bearing surface around which the roll may rotate. 
     One further concern arises when the wound film is of a pressure sensitive adhesive variety. In such a situation, the weight of the roll resting upon itself may cause the individual layers of the film to adhere and thereby prevent, or severely hinder, dispersal of the film. It is therefore advantageous in such situations to mount the roll within the carton in a suspended manner such that the core of the roll is mounted for rotation, but wherein the film wound upon the roll is not resting upon itself. Such a suspension feature is also disclosed in the aforementioned U.S. Pat. No. 4,998,656. 
     While such a carton has proven to be successful, it would be advantageous to continue to improve such features. In addition, such cartons are typically manufactured and loaded with rolls of wound film in an automated process. It would therefore be advantageous to improve the ease of manufacturability of the carton as well. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, a film dispenser is provided which comprises a body, a lid hinged to the body, a roll of film, and first and second retainers. The body includes a base, first and second sides extending orthogonally from the base, and first and second ends extending from the base. The body defines an interior channel. The lid is hinged to the body and movable between closed and open positions. The lid prevents user access to the interior channel when in the closed position, whereas the interior channel is user accessible when the lid is in the open position. The roll of film is positioned within the interior channel and includes a core around which is wound a web of film. The web is narrower than the core and includes first and second ends. The first and second retainers are positioned proximate the first and second body ends, and each include a bearing plate substantially parallel to one of the first and second body ends, a spacer interconnecting the top edge of the bearing plate to a top edge of one of the first and second body ends, and a flap connecting a bottom edge of the bearing plate to the base of the body. The spacer and flap are substantially parallel to the body base and each end plate includes an aperture receiving one of the core ends. 
     In accordance with another aspect of the invention, a method of assembling a dispenser for rolls of wound web material is provided which comprises the steps of inserting a roll of wound web material into a tubular body having first and second opposed ends, and folding first and second end walls hinged to the tubular body toward the first and second opposed open ends, respectively. The roll includes a core around which web material is wound, wherein the web material is narrower than the core. The core includes first and second ends free of web material. The first and second ends of the core are captured in retaining apertures provided in the first and second end walls during the folding step. 
     In accordance with another feature of the invention, a dispenser for rolls of wound film is provided which comprises a trunk, a lid, and first and second retainers. The roll includes a core having first and second hollow ends, with film wound around the core. The film has a width less than the width of the core. The lid is hinged to the trunk and the first and second retainers are connected to the trunk and extend into an interior channel. First and second retainers penetrate into the hollow ends of the core to retain and suspend the core within the trunk. 
     These and other aspects and features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of a carton constructed in accordance with the teachings of the invention and depicted in an assembled, open configuration with a roll of wound material positioned therein; 
     FIG. 2 is an isometric view of the carton depicted in FIG. 1 but without a roll installed; 
     FIG. 3 is a sectional view of FIG. 1 taken along line  3 — 3  of FIG. 1; 
     FIG. 4 is a plan view of the carton of FIG. 1 depicted in an unassembled, unfolded state; 
     FIG. 5 is a side view of a roll being slid into the carton of FIG. 1 in accordance with the method of manufacturing of the present invention; 
     FIG. 6 is a side view of a roll entirely slid into a carton constructed in accordance with the teachings of the invention; 
     FIG. 7 is a side view of a carton constructed in accordance with the teachings of the invention and with end walls of the carton being folded upwardly to capture the roll; 
     FIG. 8 is a flow chart depicting steps for carton assembly in accordance with the teachings of the invention; 
     FIG. 9 is a plan view of a second embodiment of a carton constructed in accordance with the teachings of the invention and depicted in an unassembled, unfolded state; 
     FIG. 10 is a plan view of a third embodiment of a carton constructed in accordance with the teachings of the invention and depicted in an unfolded, unassembled state; 
     FIG. 11 is an isometric view of a fourth embodiment of a carton constructed in accordance with the teachings of the invention; 
     FIG. 12 is a plan view of the carton of FIG.  11  and depicted in an unassembled, unfolded state; 
     FIG. 13 is an isometric view of a fifth embodiment of a carton constructed in accordance with the teachings of the invention; and 
     FIG. 14 is a plan view of the carton depicted in FIG. 13 but depicted in a unassembled and unfolded state. 
    
    
     While the invention is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, and with specific reference to FIG. 1, a film dispenser constructed in accordance with the teachings of the invention is generally depicted by reference numeral  20 . As shown therein, film dispenser  20  includes a trunk  22  to which a lid  24  is naturally hinged at a fold  26 . The trunk  22  defines an interior channel  28  in which a roll  30  of wound web material  32  is positioned. In the preferred embodiment, the trunk  22  and lid  24  are manufactured from an integral piece of material such as paperboard, cardboard, corrugated board, microfluted board, or the like, and is folded and joined in a series of consecutive steps as will be described in further detail herein to form the film dispenser  20  for the roll  30 . 
     With reference now to FIG. 2, the carton  20  is depicted without a roll  30  therein, The trunk  22  includes a bottom wall  34 , a front side  36 , a border  37 , a back side wall  38  and first and second ends  40 ,  42 , respectively. The front side wall  36  and back side wall  38  extend orthogonally from the bottom wall and are parallel to one another. The first end  40  and second end  42  also extend orthogonally from the bottom wall and are parallel to one another. Accordingly, the trunk  22  forms a box-like structure having an open top  44  providing access to the interior channel  28 . 
     The lid  24  includes a top wall  46 , a front wall  48  extending orthogonally from the top wall  46 , and first and second opposed, parallel end walls  50 ,  52 , respectively. The top wall  46  includes a front edge  54  which meets a top edge  56  of the front wall  48  at a fold  58  (see FIG.  4 ). The top wall  46  further includes a back edge  60  which meets at a top edge  62  of the back side wall  38  of the trunk  22  at the fold  26 . The front wall  48  of the lid  24  further includes a bottom edge  64  which is scored or otherwise perforated at a juncture  66  with a removable tear strip  68 . 
     As shown in FIGS. 4-7, when the carton  20  is assembled, and prior to initial use, the tear strip  68  is intact and adhered to the front side wall  36  of the trunk  22 . Preferably, the tear strip  68  is adhered to the front side wall  36  with a plurality of discrete areas of adhesive (not shown). In so doing, the tear strip  68  is easily removed by a user by pulling upon an end tab  67  and along the score line  66 . The series of discrete areas  69  of adhesive adequately adhere the lid  24  to the trunk  22  prior to initial use, and yet enable a user to easily pull the tear strip  68  away from the carton to gain access to the roll  30 . It is preferable that the front side wall  36  include a top layer scored around the areas  69  of adhesive to further facilitate removal of the tear strip  68  when desired. While the drawings depict four areas  69 , it is to be understood that other numbers of areas  69  can be employed with similarly efficacy. The number and spacing of areas  69  can be tailored to provide various retention strengths as desired. 
     A cutter bar  70 , which may be serrated or otherwise formed with a sharpened edge, is disposed on an interior surface  71  of the front wall  48  of the lid  24  for severing strips of web material  32  from the roll  30 . In alternative embodiments, the cutter bar may be located elsewhere, such as on the bottom wall  34  of the trunk  22  proximate the front side  36 . 
     As shown in FIGS. 1 and 4, the end walls  40 ,  42 ,  50 , and  52  are formed from a series of flaps folded in a preferred sequence and adhered relative to one another. Starting with the end walls  40  and  42  of the trunk  22 , each wall  40 ,  42  includes a suspension flap  72 , a minor flap  74 , and a major flap  76 . The suspension flap  72  includes a bottom edge  78  which meets a side edge  80  of the bottom wall  34  at a fold  82 . The minor flap  74  includes a side edge  84  which meets a side edge  86  of the front side wall  36  at a fold  88 . The major flap  76  includes a side edge  90  which meets a side edge  92  of the back side wall  38  at a fold  94 . The end walls  50 ,  52  of the lid  24  similarly include a minor flap  91  and a major flap  93 . 
     Each suspension flap  72  includes a number of panels, as shown in FIG. 4, which when folded and adhered in a particular sequence not only form the end walls  40  and  42 , but also provide a mechanism by which the roll  30  is both retained within the trunk  22  and suspended for rotation therein. The suspension flap  72  includes an exterior wall  96  and interior wall  98 , a spacer  100  joining the exterior wall  96  to the interior wall  98 , a bottom strut  102  and a side strut  104 . The bottom and side struts  102  and  104 , respectively, extend from the interior wall  98  along folds  108  and  110 , respectively. The spacer  100  meets the exterior wall  96  at a fold  114  and meets the interior wall  98  at a fold  116 . 
     During assembly of the carton  20 , as shown in flow chart fashion in FIG. 8, a template  118  having the configuration depicted in FIG. 4 is cut from stock material. For example, the template  118  can be die-cut or stamped from stock paperboard material. This step is depicted as step  120  in the flow chart of FIG.  8 . The suspension flap  72  is then formed in a step  122  wherein the exterior wall  96  is first folded so as to be orthogonal relative to the bottom wall  34  of the trunk  22 . The spacer  100  is then folded relative to the exterior wall  96  so as to be parallel to the bottom wall  34 . The struts  102  and  104  are then folded relative to the interior wall  98  so as to be orthogonal thereto as well. The interior wall  98  is then folded relative to the spacer  100  so as to be orthogonal thereto and parallel to the exterior wall  96 . As shown in FIG. 8, the bottom strut  102  is then adhered to the bottom wall  38  in a step  124 , using a strip of adhesive  125 . 
     In a step  126 , the template  118  is folded at folds  26  so as to form a tube  127  (see FIG. 5) having a substantially rectangular cross-section with first and second open ends. The tear strip  68  is adhered to the front side wall  36  to maintain the tubular configuration. At the conclusion of step  126 , the tube  127  is typically knocked down by folding the tube into a flat configuration. Such folding facilitates storage and shipment. For example the tube  127  may be fabricated at a first facility and vendor and subsequently shipped to a second facility for loading with the roll  30 . 
     The tube  127  is typically loaded with the roll  30  in an automated process wherein the roll  30  is pushed into the tube  127  in a step  128 . More specifically, an arm driven by an actuator, such as a linear actuator, a chain and sprocket actuator, a hydraulic actuator, or the like, pushes against a first end  130  of the roll  30  causing the second end  132  of the roll  30  to slide along the bottom wall  34  of the trunk  22  as shown in FIG.  5 . For the purpose of illustration, the roll  30  is depicted at an exaggerated angle relative to the tube  127  during loading. In actual practice, the roll  30  may be substantially parallel to the tube  127 . In order to facilitate such a pushing motion, the bottom strut  102  may be provided with a guide surface  134 , as shown in FIG.  2 . In the first depicted embodiment, the guide surface  134  is provided in the form of a wedge-shaped recess  136  which serves to funnel the second end  132  of the roll  30  up and over the bottom strut  102 . More specifically, the wedge-shaped recess  136  includes first and second canted sides  138 ,  140  which meet at an apex  142 . By so positioning the recess  136 , the second end  132  initially meets the recess  136  at its widest point and slides along the canted sides  138  and  140 . This in turn pushes the second roll  132  up and over the bottom strut  102  in the direction of the apex  142  as shown by an arrow  143  in FIG.  6 . 
     Once the roll  30  is properly positioned within the trunk  22 , the first and second suspension flaps  72  are folded upwardly with respect to the bottom wall  34  in a step  144  in the direction of arrows  145 . Preferably, the first and second suspension flaps  72  are simultaneously folded upwardly as shown in FIG. 7, so as to lift the roll  30  off of the bottom wall  34 , while at the same time capturing the first and second ends  130 ,  132  of the roil  30  within a retainer  146  of each suspension flap  72 . In the first preferred embodiment, the retainer  146  is provided in the form of an aperture  148  (see FIG. 4) dimensioned to be slightly larger than the diameter of the roll  30 . In so doing, the interior wall  98  surrounds or circumnavigates the roll  30 . In this regard, it is important to note that the structure and dimensions of the suspension flaps  72  and roll  30  ensure that the roll  30  is adequately retained within the trunk  22 . More specifically, the spacer  100  and parallel exterior and interior walls  96 ,  98 , respectively, ensure that the suspension flap  72 , once assembled, provides a hollow interior space  150  into which the first and second ends  130 ,  132  penetrate, as shown in FIG.  1 . In addition, the roll  30  is sufficiently long to extend substantially from one exterior wall  96  to the other, preferably with the ends  130 ,  132  of the roll  30  not covered by film  32  each having a width substantially the same as the width of the space  150 . 
     In a preferred embodiment, depicted in FIGS. 2 and 3, the bottom strut  102  may have a width A of about ⅝ inches, and the strip of adhesive  125  may have a width B of ¼ inches, such that the ratio of A to B is at least 2.5. The first and second retainers may be spaced by a distance C of 11{fraction (15/16)} inches, and the wound web material  32  may have a width of 11½ inches, such that the ratio of C to D is at least 1.03. The spacer  100  may have a width E of ⅜ inches, and the roll  30  may have a width F of 12 inches, such that the ratio of E to F is at least 0.3. The foregoing is by way of example only, various other dimensions being employable with the teachings of the invention. The inventors have found that the above dimensions provide desirable utility in the form of, among other things, improved retention of the roll  30  within the carton  20 , enhanced ability of the roll  30  to rotate even in the event of the film  32  telescoping on the roll, and reduced likelihood of the adhesive  125  contacting the web material  32  or the wall  48  when in a deconstructed, flat position. 
     Once the suspension flaps  72  are folded upwardly so as to be orthogonal to the bottom wall  34 , they may optionally be adhered in place using the side strut  104 . More specifically, the side strut  104  may be adhered using adhesive against the back side wall  38 . This step is depicted as step  152  in FIG. 8, and would typically be performed only when the carton  20  is hand assembled. The end walls  40 ,  42  are completed by inwardly folding and adhering the minor flap  74  to the exterior wall  96 , and subsequently folding and adhering the major flap  76  to the minor flap  74 . The end walls  50 ,  52  of the lid  24  are similarly formed using the minor and major flaps  91 ,  92 , respectively. 
     In order to facilitate the lifting of the roll  30  off of the bottom wall  34  during the suspension step  144 , each of the suspension flaps may further be provided with a funnel mouth  154  as depicted in FIG.  4 . Each funnel mouth  154  is a continuation of the aperture  148  provided in the interior wall  98 . The aperture  148 , which is typically circular, thereby extends by way of the funnel mouth  154  toward the fold  114  proximate the spacer  100 . Accordingly when the first and second suspension flaps  72  are folded upwardly, sides  156  flanking the funnel mouth  154  engage the ends  130 ,  132  of the roll  30  and guide the roll  30  upwardly until penetrating the apertures  148 . Moreover, the existence of side struts  104  structurally fortify the interior wall  98  during the folding step. Due to the relatively thin expanses of cardboard in the interior wall  98  surrounding the apertures  148 , the wall  98  might tend to crumple during the folding step  144 . Using the side strut  104 , this likelihood is abated. In alternative embodiments more than one side strut  104  may be employed. 
     A second preferred embodiment of a carton constructed in accordance with the teachings of the invention is depicted in FIG.  9  and is referenced to by reference numeral  160 . The carton  160  is generally the same as the first embodiment depicted in FIGS. 1-7 and wherein like reference numerals apply, like reference numerals are used. One difference with regard to the second embodiment pertains to the shape of the guide surface  134 . In the second embodiment, the guide surface  134  is provided in the form a semi-circular recess  162 . It is important to understand that in both this embodiment and the first preferred embodiment, the bottom strut  102  is dimensioned so as to provide sufficient width so as to completely cover the adhesive  125  adhering the bottom strut  102  to the bottom wall  34  while at the same time providing a functional guide surface  134 . More specifically, as shown in FIG. 9, the width of the bottom strut  102  proximate the recess  162 , depicted as reference character G in FIG. 9, is sufficiently wide so as to cover the width B of the adhesive  125 , even after the bottom strut  102  is adhered to the bottom wall  34 , and the adhesive  125  is flattened and widened in the process. In so doing, the likelihood of the adhesive  125  engaging the roll  30  or web material  32  during assembly for usage is abated. 
     A third preferred embodiment of a carton constructed in accordance with the teachings of the invention is depicted in FIG.  10  and referenced to by reference numeral  166 . Again, where like reference numerals apply, like reference numerals are employed. In the depicted embodiment, the apertures  148  within the suspension flaps  72  are substantially lower than in the first and second embodiments. Accordingly, no funnel mouth  154  is employed, and the roll  30  is not initially suspended off of the bottom wall  34 . In addition, the front side wall  36  is of a lesser height to facilitate removal of the film or web material  32  from the roll  30 . 
     FIGS. 11 and 12 depict a fourth preferred embodiment of a carton  168  constructed in accordance with the teachings of the present invention. As with the other embodiments, where like reference numerals apply, like reference numerals are employed in the figures. As opposed to the first, second, and third embodiments, which provide retainers  146  which surround the roll  30 , the fourth embodiment employs retainers  146  which penetrate through the first and second ends  130  and  132 , respectively, of the roll  30 . As shown in FIG. 11, each retainer  46  is provided in the form of an inwardly extending arm  170 . Each arm  170  is substantially planar in configuration and includes a front edge  172 , a bottom edge  174 , and a top edge  176 . As shown in the plan view depicted in FIG. 12, each arm  170  is dual-plied in that a first ply  178  extends from the flap  76 , and a second ply  180  extends from the flap  74 . Accordingly, when the carton  168  is assembled, the first and second plies  178  and  180  are aligned together to provide a more rigid retainer  146  for support of the roll  30 . Alternatively, the plies  178 ,  180  may be adhered together. When the roll  30  is mounted within the carton  168 , the interior surface of the roll  30  rests upon the top edge  176  and rotates on the arms  170 . 
     FIGS. 13 and 14 depict a fifth preferred embodiment of a carton  182  constructed in accordance with the teachings of the invention. As with the other embodiments, where like reference numerals apply, like reference numerals are employed. As shown best in FIG. 13, the retainers  146  of the fifth embodiment are substantially wedge-shaped. Similar to the fourth embodiment, the wedge-shaped retainers  146  are designed to penetrate the first and second ends  130 ,  132  of the roll  30  for retention and suspension of the roll within the trunk  22 . Each of the wedge-shaped retainers  146  is formed by a foldable leg  184  extending from the flap  76 . Each foldable leg  184  includes a first extension  186  which meets a second extension  188  at a fold  190 . As shown best in FIG. 14, the foldable leg  184  tapers in width from a narrow dimension proximate the flap  74 , to a wide dimension at the free end of the second extension  188 . In addition, the second extension  188  includes a pair of opposed notches  192  which partially divide the second extension  188  and thereby form a locking tab  194 . The locking tab  194  cooperates with a slot  196  formed in the end walls  40 ,  42  to lock the retainers  146  in the operative position depicted in FIG.  13 . More specifically, once the  194  is inserted through the slot  196 , the tab  194  is folded parallel to the end walls  40 ,  42  and adhered thereto. When the roll  30  is loaded into the trunk  22 , the first and second ends  130 ,  132  are supported by the retainers  146  for suspension and rotation thereon. 
     From the foregoing, it will be appreciated that the present invention provides carton for retention, suspension, and dispersal of rolls of web material. It also provides a method for manufacturing such a carton in an automated process.