Abstract:
A carton for transporting and dispensing liquid-based materials including a sealed base, tapered side panels, and a gable top. The top portion of the carton includes a fold-over flap including a seal to close the carton. The seal is tamper-proof such that, upon reopening the carton, the seal is damaged and reveals evidence of tamper. The carton may be carried using a handle attachable to the top of the carton.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates to consumer packaging, and more specifically to a single-use carton for transporting beverages and other items. 
       BACKGROUND OF THE INVENTION 
       [0002]    While the present invention has wide industry applicability, it is particularly useful for transporting take-out beverages dispensed at retail food and drink establishments such as stores, restaurants, and breweries. 
         [0003]    Many breweries and brewpubs allow patrons to take home draft beer, and the typical means of doing so is with a growler. A growler is a glass or ceramic jug which may be sold or loaned to patrons by the brewery and filled with beer from a tap at the brewery. A drawback of a growler is that it often must be purchased for an additional fee or returned to the brewery. Growlers also generally have a screw-on cap or a hinged porcelain gasket cap, which may be opened and closed without limitation. Growlers do not include any means to close the growler in a semi-permanent or tamper proof manner. Thus, in jurisdictions having laws prohibiting an open carton of alcohol, it is not possible to show that the growler remained closed during transportation. 
         [0004]    What is desired therefore is an improved means for transporting beverages and other items. 
       SUMMARY OF THE INVENTION 
       [0005]    Accordingly, it is an object of the present invention to provide a carton for transporting beverages and other items with a tamper-proof seal. It is also an object of the present invention to provide a carton that is adapted for single use and is disposable and/or bio-degradable. 
         [0006]    These and other objects of the present invention are achieved by means of a carton including a sealed based, tapered sides, and a top portion with a tamper-proof seal. In a preferred embodiment, the seal includes an adhesive or tape disposed between two surfaces of the top portion. Once closed, the seal cannot readily be opened without damaging the top portion of the carton. In particular, opening the tamper-proof seal reveals evidence of tamper. In some embodiments, the carton is comprised of a cardboard material with a film or coating on at least one side, such as a polyethylene coating. 
         [0007]    Further provided is a carton including handle to transport the carton. The handle includes flaps that fold under the gables of the carton and an opening to receive the top portion or flap of the carton. In some embodiments, the opening of the handle includes a serrated edge or holes which cooperate with the top portion or flap of the carton to secure the handle. In some embodiments, the carton may be at least partially opened and the contents dispensed with the handle in place. 
         [0008]    In some embodiments, the top portion of the carton includes a plurality of embossed lines or detents which, upon assembly, cooperate with one another to prevent spillage out of the top of the carton. The carton may also include embossed lines or detents on the tapered sides which provide a fill line for the contents. 
         [0009]    Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  shows a carton according to an exemplary embodiment of the present invention in an assembled and sealed configuration. 
           [0011]      FIG. 2  shows a carton according to an exemplary embodiment of the present invention in an assembled and open configuration prior to use. 
           [0012]      FIGS. 3A  shows a carton according to an exemplary embodiment of the present invention in an unassembled configuration. 
           [0013]      FIG. 3B  shows another carton according to an exemplary embodiment of the present invention in an unassembled configuration. 
           [0014]      FIG. 3C  shows another carton according to an exemplary embodiment of the present invention in an unassembled configuration. 
           [0015]      FIG. 4A  shows a top portion of a carton according to an exemplary embodiment of the present invention including a sealing strip in an unassembled configuration. 
           [0016]      FIG. 4B  shows the sealing strip of the carton shown in  FIG. 4A  prior to use. 
           [0017]      FIG. 4C  shows a closed seal on the carton shown in  FIG. 4A . 
           [0018]      FIG. 4D  shows a reopened seal on the carton shown in  FIG. 4A . 
           [0019]      FIG. 5  shows a handle of the carton prior to assembly. 
           [0020]      FIGS. 6A-6D  show the handle of  FIG. 5  on the carton. 
           [0021]      FIG. 7  shows another handle of the carton prior to assembly. 
           [0022]      FIG. 8  shows the handle of  FIG. 7  on the carton in an opened position. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]      FIG. 1  shows a carton  10  according to an exemplary embodiment of the present invention in an assembled and sealed configuration. In the exemplary embodiment, the carton  10  is comprised of a biodegradable cardboard material. The cardboard material may have a polyethylene layer or coating on one or both sides. 
         [0024]    The carton  10  includes a top portion  20  including two gables  24  having exterior panels and interior panels. The top portion  20  also includes a fold-over flap  22  extending from an end of one of the gables  24 . In a preferred embodiment, the flap  22  includes a perforated separation line to permit a portion of the flap to be torn or unsealed (e.g., to create open a pouring spout on one side of the carton  10 ). The carton  10  further includes four upwardly tapered side panels  30 . 
         [0025]    As shown in  FIG. 2 , the top portion  20  of the carton  10  is open prior to use. A plurality of cartons  10  may be stored together in this configuration before use. The tapered design permits several cartons  10  to be stack one inside the other, such that a large number of empty cartons  10  may be stored in a small space (e.g., in a restaurant or bar). 
         [0026]    After filling the carton  10 , the gables  24  are folded inward and the flap  22  is sealed down against one of the gables  24 . The carton  10  may then be transported with the contents enclosed. To dispense the contents, one of the two sides of the flap ( 22   a  or  22   b  shown in  FIG. 3A ) may be unsealed and a gable end opened up to create a pouring spout. Alternatively, the entire flap  22  may be unsealed to open the entire top of the carton  10 . 
         [0027]    The carton  10  is suitable for containing food and cold beverages, as well as non-food applications, and includes a sealing strip mechanism under the flap  22  which provides tamper evidence upon opening. The carton  10  is designed for, though not limited to, single use transportation. For example, the carton  10  may be used to transport beverages, liquid-based foods (e.g., Chinese food, seafood, etc.), paints, and even solid foods and materials. In a preferred embodiment, the carton  10  is used for transporting beer or other alcoholic beverages. 
         [0028]    The carton further includes a base  40 . As shown in  FIG. 3A , the base  40  is formed by a plurality of panels which are folded together. The base  40  is sealed such that it is watertight and able to retain liquids in the carton  10 . 
         [0029]    In one exemplary embodiment, the watertight seal of the base  40  is formed by a hot melt sealing process. For example, the base panels of the carton  10  may be assembled and held over a stream of air that has been pre-heated to a pre-set temperature (e.g., 360 C). This melts the very fine film of polyethylene coating on the inside of the cardboard flaps. The carton  10  then travels over a water-cooled former (plough) which orients the flaps of the carton  10  and pushes them to an almost horizontal plane so that they are correctly aligned and folded one inside the other. The carton  10  then rests on a plate which is then raised to a set value by taking pressure off of pre-stressed springs. The plate has raised stake-points that correspond with the sealing points required to seal the base of the carton  10 . This process is only exemplary, and other means for forming a watertight seal on the base  40  may be employed. 
         [0030]    As shown in  FIG. 3B , the carton may also include a plurality of embossed lines or detents ( 30 ,  32 ,  34 ,  36 ) in the panels of the top portion  20 . The embossed lines or detents are also shown in  FIG. 2 . When the container is assembled, the lines or detents may abut one another and create an improved seal to prevent liquid from spilling out of the corners of the top portion  20 . 
         [0031]      FIG. 3C  shows another carton  12  according to an exemplary embodiment of the present invention prior to assembly. The carton  12  has an increased height as compared to the carton  10 . In the exemplary embodiment, the tapered side panels have a height of approximately 7 1/32 inches. In the assembled configuration, the width of the side panels is approximately 2.7 to 2.9 inches at the bottom and approximately 3.4 to 3.6 inches at the top. 
         [0032]    The increased height allows for an additional volume of liquids or solids in the carton  12 . When carton  12  is filled with beer, the increased height also advantageously provides additional volume to accommodate foam generated during the pouring process. As such, a standard volume of beer may be poured without overflowing from the carton  12  during the pouring process. The carton  12  further includes a fill line  37  (e.g., embossed line or detent), visible on the inside and/or outside of the carton  12 , to identify a particular volume, such as twelve fluid ounces, sixteen fluid ounces, or twenty-four fluid ounces. In the exemplary embodiment, the file line  37  is approximately 5 13/16 inches from the base. When the fill line is reached, the user may stop pouring and allow the beer to foam above the fill line  37 . 
         [0033]    The carton  12  also includes a plurality of embossed lines or detents ( 31 ,  33 ,  35 ) at the top portion. When the container is assembled, the lines or detents abut one another and create an improved seal to prevent liquid from spilling out of the corners of the top portion. 
         [0034]    As shown in  FIG. 3C , the carton may also include tabs  39  extending from the flap  23  on the top portion of the carton  12 . When the flap  23  is folded over or sealed against the top portion of the carton  12 , the tabs  39  extend downward and adjacent to the exterior of the gable. As described in more detail below, the tabs  39  cooperate with holes on an accessory handle to carry the carton  12 . 
         [0035]      FIG. 4A  shows a top portion of a carton  10  in an unassembled configuration in which the flap  22  comprises a sealing strip  24 . The sealing strip  24  includes double-sided adhesive or tape affixed to a surface, e.g., a gable panel, on the top portion  20  of the carton  10 . The sealing strip  24  further includes a liner or backing  26  removably disposed over the sealing strip  24 . After the carton  10  is filled, the backing  26  is removed from the strip  24  by the end user and the flap  22  is stuck down with the open adhesive to seal the carton  10 . 
         [0036]    The sealing strip  24  allows tamper evidence while the carton remains sealed, yet still allows pressure relief from carbonated beverages due to the fact that the seal is intentionally non-hermetic. In particular, the flap  22  may include small gaps which are not sealed. For example, the sealing strip  24  may have a length less than the length of the flap  22  (e.g., a 3 inch strip and a 4 inch flap) such that there are gaps in the seal at the corners of the flap. In other embodiments, the flap  22  may include unsealed gaps at other locations along the flap  22 . For example, the sealing strip  24  may be segmented and comprise several strips with gaps in between. 
         [0037]      FIGS. 4B and 4C  illustrate the process of closing the carton  10  after it is filled. The backing  26  is removed from the sealing strip  24 , and the flap  22  is folded over to create a seal. Once the seal is formed, it generally cannot be opened without at least partially damaging the top portion  20  of the carton  10  (see  FIG. 4D ). 
         [0038]    As shown in  FIG. 4D , opening the seal  22  may open the flap  22  of the top portion  20  and/or partially remove the sealing strip  24 . In some embodiments, the flap  22  includes a perforation to divide the flap  22  in two pieces,  22   a  and  22   b.  This allows half of the top portion  20  to be opened as a pouring spout. As shown, opening the sealed flap  22  creates irreversible evidence of tamper or destruction showing that the carton  10  has been opened and preventing resealing. This feature is particularly useful for jurisdictions having laws prohibiting an open carton of alcohol. Users can be assured that their carton  10  is sealed, and law enforcement personnel can inspect the carton  10  for tamper evidence to ensure that it has remained closed from the time of purchase. 
         [0039]      FIG. 5  illustrates a handle  40  for carrying the carton in an unassembled configuration. The handle  40  is made of a foldable material, such as cardboard. The handle includes two handle loops  41 . The handle  40  also includes two gable or retaining flaps  42  which fold underneath, and interlock with, the gables  24  at the top portion  20  of the container. The handle  40  further includes two assembly flaps  44  that fold through the opposite handle loop  51  and keep the two sides of the handle together.  FIGS. 6A-6D  show the handle installed on a carton  10 / 12 . 
         [0040]    In some embodiments, the handle  40  also includes an opening with serrated edges  46  through which the top portion of container extends (see  FIG. 6B ). The serrated edges  46  abut the upper end of the top portion  20  of the carton (e.g., below the flap  22 ) and assist the gable flaps  42  in securing the handle  40  to the carton. 
         [0041]    In some embodiments, the gable flaps  42  include a perforated centerline  48  to allow the container to be opened and unsealed with the handle  40  in place. The handle  40  cannot be reassembled after the perforated centerline  48  is broken, which provides another tamper-proof element to the container. 
         [0042]      FIG. 7  illustrates another hand  50  for the carton in an unassembled state. The handle  50  is made of a foldable material, such as cardboard. The handle includes two handle loops  51 . The handle  50  also includes two gable flaps  52  which fold underneath, and interlock with, the gables  24  at the top portion  20  of the container. The handle  50  further includes two assembly flaps  54  that fold through the opposite handle loop  51  and keep the two sides of the handle together. 
         [0043]    In the present embodiment, the handle  50  includes an opening  56  through which the top portion of container extends. Along the opening are two holes or cutouts  57 . The holes  57  receive the tabs  39  on the carton  12  to assist the gable flaps  52  in securing the handle  50  to the carton.  FIG. 8  shows a top inside view of the handle  50 , in a partially assembled or opened state, on a carton  10 / 12  to illustrate how the holes  57  interlock with the tabs  39 . 
         [0044]    In some embodiments, the gable flaps  52  further include a perforated centerline  58  to allow the container to be opened and unsealed with the handle in place. The handle cannot be reassembled after the perforated centerline  58  is broken, which provides another tamper-proof element to the container. 
         [0045]    Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many modifications and variations will be ascertainable to those of skill in the art.