CARTON FOR PRODUCT AND LITERATURE INSERT

BACKGROUND OF THE INVENTION
Field of the Invention

The present invention relates generally to a carton and to a method for enclosing a product and a literature insert in a carton, and more particularly to carton and to a method for automatic filling of the carton with a product.

Description of the Related Art

Cartons, boxes or other containers which are formed from shaped blanks that have been folded to form the carton may be referred to as folded cartons. Folded cartons in which products are supplied to the public typically have, on their outer surfaces, printed information—which may include product usage instructions, warnings, indications, directions for use and other types of information. The outside of the carton provides a limited surface area on which to provide the printed information. The limited area on the outer surface of the carton can be inadequate in those situations where detailed instructions, federal, state, or locally required information, or in the case of pharmaceuticals, patient directions for use, drug facts or other important information, must be provided. In these situations additional literature is often added to the inside of the carton as a literature insert by the manufacturer, for example, on their packaging line.

The typical carton and literature insertion process is as follows: Cartons are glued and folded by the folding carton manufacturer with the carton end flaps left unglued. The cartons are flattened. The cartons are shipped to the manufacturer of the product to be packaged, erected from the flattened state by the product manufacturer, filled with the product and then the literature is placed into the package just before the carton end flaps are glued and closed. Arrangement of the literature inside the carton is important to the manufacturer who is filling the carton with product. The literature must be placed inside the carton in a position that allows for easy removal of the product and the literature. The current process of filling a carton with both literature and product is a complex packaging operation. During insertion of the literature and product into the carton the literature insert and the product collide and interfere with each other causing unplanned packaging line stoppages.

There are various methods for increasing copy space on or in a carton for information or instructions. One alternative is to include a loosely folded sheet of literature inside of the carton. This method can provide adequate information space. However, the literature is likely to be disposed of after opening of the package. Pharmaceutical packages in particular require that the important information on the pharmaceutical product be available to the patients when they take their medication.

In addition, the normally supplied literature inside the carton must be inserted into the package either by hand or by automated equipment in the carton filling production or in the packaging line during the manufacture of the product. The literature insertion step by the product manufacturer is a known cause of unplanned packaging line downtime, which increases waste and results in a loss of revenue. The literature insertion equipment is costly to install and maintain, and is often a limiting factor in productivity on a filling or packaging line.

Another known method for increasing copy space on or in a carton is to attach folded literature to the outside of the carton. This makes the literature susceptible to damage, accidental removal during handling and transport, and detracts from the aesthetics of the outside surface of the carton.

Still another method is to provide a carton that has a fifth and/or a sixth panel which wraps around the typical exterior of the carton and provides additional information space. The disadvantages of a fifth/sixth panel carton include: higher material costs, limited space compared to folded literature, additional complexity for senior citizens, and such cartons can be difficult to open for people with limited use of their hands such as the elderly or those with arthritis.

Another method is that the manufacturer of the product attaches the literature to the inside of a carton on the filling and/or packaging lines. This is problematic since any literature attached to the inside of the carton prior to the carton being filled with product must be folded down to very small dimensions and is typically bulky and protrudes into the inside of the carton, causing interference with the product insertion and making automated high-speed product insertion difficult or impossible.

Products are often packaged in cartons for sale. FIG. 1 shows an example of a product 10 that is provided in a carton 12. The carton 12 may contain information about the product and in general the carton has a greater surface area for such information than is available on the product itself. The carton may be a more convenient shape for shipping than the product. In the illustration, the product 10 is a bottle, such as a bottle of medication, although many other types of products may be provided. The product bottle 10 is of an overall cylindrical configuration with a neck 14 and lid 16. The carton 12 is generally rectangular and has a top opening with a cover flap 18 having a tuck tab 20 at its free end and two side flaps 22 and 24 on either side of the cover flap 18. The product 10 must be placed into the carton 12 prior to sale of the product. Automatic carton filling machines are used for inserting the product 10 into the carton 12.

Many products are provided with literature. The literature may include instructions, precautions, dose information, drug interaction information, or other information, depending on the product. The literature may be provided inside the carton 12. FIG. 2 shows a cross-sectional view of a carton 12 in which literature 26 in the form of a folded sheet or sheets of paper has been placed inside the carton 12 and the product 10 is being inserted, such as by an automated filling machine. In the illustration, the bottom of the product bottle 10 has struck the top edge of the folded literature 26 at 28, interfering with the automated filling process. The interference between the literature 26 and the product 10 may jam the automated filling machine, halt the automatic filling process, or damage the literature and/or the carton, for example.

A possible way to reduce interference between the literature 26 and the product 10 during automated filing is to provide a ramp in the carton 12. In FIG. 3, an embodiment of the carton 12 has a ramp 30 that folds from the top edge of the carton 12 into the interior of the carton 12. The literature 26 may be placed against a front wall 32 of the carton 12, such as by being secured with releasable adhesive, and the ramp 30 may be folded over the top of the literature 26. As the product 10 is inserted into the carton 12, the bottom edge of the product 10 slides along the ramp 30 so as to pass over the edge of the literature. The product 10 may be inserted into the carton 12 by the automated filling machine.

In FIG. 4, the literature 26 to be included with the product is large, for example, to include a lot of information about the product. The literature 26 has been folded to fit on one side of the carton 12. In particular, the folded literature 26 can be no wider than the side of the carton 12 to which it is to be attached. To get the large or thick sheet or sheets of literature 26 to the size of the side of the carton requires that the literature be folded many times, resulting in the folded literature having a considerably greater thickness than a folded smaller literature sheet. The unassembled carton or blank 34 is shown in FIG. 4 with the folded literature 26. In FIG. 5, the folded literature 26 has been placed on or attached to a side 36 of the unassembled carton 34. The folded literature 26 is no wider than the side 36 to which it is attached. In FIG. 6, the carton 12 has been assembled by folding and gluing the blank to provide the assembled carton. The literature 26 extends a considerable distance into the carton 12 from the side where it is attached. Not only does the thick folded literature present a considerable obstacle for automated filling machines but it also occupies a substantial part of the interior of the carton 12, reducing the room for the product or possibly requiring a wider or deeper carton to hold both the thick folded literature and the product.

SUMMARY

The present method and apparatus provides a carton and method to facilitate filling a carton with a product and with a literature insert for the product. The carton is configured to guide the product past the literature insert during filling of the carton. An advantage is provided when a product is to be inserted into a carton containing a large and/or thick literature insert in the carton with the product, although the method and apparatus are not limited to providing only a large and/or thick literature insert. Advantages may be provided by the present method and apparatus for providing other items in the carton as well or instead.

The present method and apparatus provides a carton with an attached literature insert that simplifies the step of enclosing the literature insert from the product manufacturer or packager. The present method and apparatus provides a carton with an attached literature insert inside that allows the product manufacturer or packager to achieve high-speed, automated filling of products into the carton without the attached literature insert interfering with insertion of the product during the carton filling, closure and gluing process.

The present method includes a method of forming a folding carton that protects the literature insert attached by the carton manufacturer and prevents the literature insert from interfering with the high speed automatic insertion of product into the folding carton.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a product and a carton for holding the product as known;

FIG. 2 is an enlarged, fragmentary cut-away view of a carton being filled with a product where the carton contains a literature insert to be included in the carton with the product as known;

FIG. 3 is a perspective cut-away view of a product being filled into a carton having a literature insert in the carton;

FIG. 4 is a perspective view of an unassembled carton and a folded literature insert to be included in the carton;

FIG. 5 is a perspective view of the unassembled carton of FIG. 4 showing the folded literature insert attached to a side panel of the carton;

FIG. 6 is a perspective view from the top of an assembled carton showing the folded literature insert attached to the inside of the carton;

FIG. 7 is a perspective view of an unassembled carton according to the present method and apparatus and showing a folded literature insert extending over two side panels of the carton;

FIG. 8 is a pattern for a carton blank according to the present method and apparatus;

FIG. 8a is an enlarged fragmentary view of the ramp of the carton blank of FIG. 8;

FIG. 8b is an enlarged fragmentary view of the literature insert of FIG. 8;

FIG. 9 is a perspective view of the unassembled carton blank of FIG. 8 and showing the literature insert to be included in the carton;

FIG. 10 is a perspective view of the unassembled carton blank of FIG. 9 showing the literature insert in place on two side panels of the carton;

FIG. 11 is a perspective view of the assembled carton formed from the blank of FIG. 10 from the top shown and showing the literature insert in the carton;

FIG. 12 is a perspective view of the carton of FIG. 11 and showing a product in the carton with the literature insert;

FIG. 13 is a bottom perspective view of a carton according to the present method and apparatus enclosing the literature insert and showing the bottom panels open for loading the product;

FIG. 14 is a bottom perspective view of the carton of FIG. 13 showing the product being inserted into the carton from the bottom;

FIG. 15 is a top perspective view of a carton according to the present method and apparatus showing the literature insert within the carton;

FIG. 16 is a manufacturing layout for a blank of an example of the present carton;

FIG. 17 is a top perspective view of a second embodiment of the present carton showing bottom flaps being moved into place and a literature insert within the carton;

FIG. 18 is a top perspective view of the second embodiment showing the bottom flaps partially closed;

FIG. 19 is a top perspective view of the second embodiment showing the bottom flaps in a closed and locked position;

FIG. 20 is a pattern or blank for forming the second embodiment of the carton;

FIG. 21 is a plan view of a literature insert for attachment in the second embodiment of the carton;

FIG. 22 is a top perspective view of a third embodiment of the present carton shown in an assembled state with a literature insert;

FIG. 23 is a top perspective view of the third embodiment showing the literature insert in the carton;

FIG. 24 is a top plan view of the third embodiment showing the literature insert mounted within the carton;

FIG. 25 is a pattern or blank for forming the third embodiment of the carton; and

FIG. 26 is a plan view of the literature insert for attachment within the third embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning to FIG. 7, an unassembled carton or blank 40 is shown as cut from sheet stock. The unassembled carton or blank 40 is scored, creased or otherwise formed to provide fold lines 42 where the blank 40 will be folded or bent to form an assembled carton. A literature insert 44 in the form of a sheet of paper that has been folded multiple times to obtain a rectangular shape is positioned on the blank 40. The literature insert 44 may be referred to as a brochure, a term of art referring to a folded flyer, whereas a flyer is a term of art that refers to a non-folded piece. The literature insert 44 has been folded to a size that spans two adjoining side panels of the carton 40. By comparison, the folded literature insert of FIGS. 4-6 has been folded to fit onto one side panel of the carton. The size of the unfolded sheet or flyer from which the brochure is formed is determined to some extent by the amount of information to be printed on the literature insert 44. When more printed information is to be provided on the literature insert 44, this requires a larger sheet of paper as the flyer, resulting in a thicker brochure once folded. The literature insert 44 that has been folded to fit onto two adjoining side panels may be more than twice as large as a folded literature insert that must be folded to fit onto a single side panel while providing the same folded thickness. Similarly, the literature insert 44 that has been folded to fit onto two adjoining side panels may be of a reduced folded thickness compared to a literature insert that is folded to fit onto one side panel.

FIG. 8 shows the blank 40 with an example of size and placement measurements for mounting the literature insert 44 on adjoining side panels. The blank 40 has a first side panel 46 with end flaps 48 and 50 at its opposite ends joined to the first side panel 46 by fold lines 52 and 54, respectively. The first side panel is of a rectangular shape. The top end flap 48 has a first taper at a left edge 56 (relative to the figure) and a second taper at a greater angle at the right edge 58. The bottom end flap 50 has the steeper second taper at the left edge 60 and has the first taper at the right edge 62, the opposite arrangement of tapers as for the top end flap 48.

The first side panel 46 is connected to a second side panel 64 by a fold line 66. The second side panel 64 has an edge 68 at a top end and an end cover 70 at the bottom end. The bottom end cover 70 is connected to the second side panel 64 by a fold line 72. The end cover 70 has a tuck tab 74 connected to the opposite end of the end cover 70 by a fold line 76.

The second side panel 64 is connected to a third side panel 78 by a fold line 80. The third side panel 78 has a top end flap 82 at one end connected by a fold line 84 and a bottom ramp 86 connected at the other end by a fold line 88. The top end flap 82 has the second steeper taper at the left edge 90 (with respect to the figure) and the first taper at the right edge 92. The bottom ramp 86 will be described in greater detail with respect to FIG. 8a.

The third side panel 78 is connected to a fourth side panel 94 by a fold line 96. The fourth side panel 94 includes a top end cover 98 connected to the fourth side panel 94 by a fold line 100. The top end cover 98 includes a tuck tab 102 connected by a fold line 104 at its opposite end from the fold line 100. The fourth side panel 94 has an edge 106 at its bottom.

The fourth side panel 94 is connected to an assembly flap 108 by a fold line 110. The assembly flap 108 may be provided with glue or other adhesive or other fastener to secure the assembly flap 108 to the first side panel 46 when the carton is assembled. For example, the assembly flap 108 may be glued to an inside surface of the first side panel 46. The assembly flap 108 may extend from either the fourth side panel 94 or from the first side panel 46.

A literature insert 112 is shown in place on the blank 40 where it may be positioned when the carton is assembled. The literature insert 112 may be a sheet of paper or other material that has been folded to form a brochure or other folded article. The literature insert 112 may include multiple sheets of paper or other material, which may be assembled to form a booklet or other folded material. Significantly, the literature insert 112 is of a size when folded to extend over portions of two adjoining side panels. In the illustration, the literature insert 112 extends over portions of the second side panel 64 and the third side panel 78, including extending across the fold line 80 that connects the second side panel 64 to the third side panel 78. The literature insert 112 is on the second and third adjoining side panels 64 and 78.

In an example, the literature insert 112 has a size when folded of 2 inches (50.8 mm) by 2.625 inches (58.74 mm). The literature insert 112 is positioned with a centerline 114 of the literature insert 112 positioned on and aligned with the fold line 80 between the two adjoining side panels 64 and 78 over which the literature insert 112 extends. The literature insert 112 is spaced by 0.143 inch (3.63 mm) from the fold line 96 at the opposite edge of the second side panel 64 from the fold line 80 and by the same distance from the fold line 96 at the opposite side of the side panel 78 from the fold line 80. In the example, the literature insert 112 is spaced by 0.250 inch (6.35 mm) from the fold lines 88 that connects the ramp 86 to the third side panel 78. Other positions for the literature insert 112 may also be provided. Other sizes of literature inserts may be provided. The literature insert 112 may be attached in place to the blank 40 while the blank 40 is in its flat, unfolded, unassembled condition. Alternately, the literature insert 112 may be attached when the carton has been partially or fully assembled. A bar code 116 and alignment mark 118 may be provided on the literature insert 112 for machine reading, for example, to ensure a correct alignment of a correct literature insert 112 in the correct carton.

FIG. 8a shows the bottom ramp 86 in detail. The bottom ramp 86 is connected by the fold line 88 to the third side panel 78. A first ramp portion 120 extends from the fold line 88 to a fold line 122. The fold line 122 includes an opening 124 at a middle of the fold line 122. The first ramp portion 120 includes a left edge 126 (relative to the drawing) aligned with the fold line 80 that connects the second side panel 64 to the third side panel 78. Said another way, the left edge 126 is aligned with the fold line 80 which is between the adjoining side panels 64 and 78 on which the literature insert 112 is positioned. Said yet another way, the left edge 126 is aligned with the centerline 114 of the literature insert 112. The illustrated left edge 126 is straight, although other shapes may be provided as desired. The illustrated left edge 126 forms a line with the fold line 80, but may be offset from the fold line 80 in some embodiments. A right edge 128 is formed at a taper, which may be the same or similar to the steeper second taper at edges 58, 60, and 90 (see FIG. 8).

The bottom ramp 86 includes a second ramp portion 130 that connects to the fold line 122 and extends to a fold line 132. The second ramp portion 130 has a left edge with a first left edge portion 134 in alignment with the left edge 126 of the first ramp portion 120 and a second left edge portion 136 that is set back from the left edge 126, for example at a curved edge 138. The first left edge portion 134 aligns with and is generally parallel to the left edge 126 of the first ramp portion 120 when the bottom ramp 86 is folded along the fold line 122. The second ramp portion 130 includes a right edge 140 that extends in a direction perpendicular to the fold line 88 from the end of the tapered right edge 128.

The second ramp portion 130 is connected to a step portion 142 by the fold line 132. The step portion 142 extends to a fold line 144 and has a length from the fold line 132 to the fold line 144 that may be proportionate to a thickness of the literature insert 122. The step portion 142 has a left edge 146 that is aligned with the left edge portion 136, and has a right edge aligned with the right edge 140. The fold lines 132 and 144 may be incompletely scored. For example, the scoring of the fold lines 132 and 144 may extend only part of the way across the bottom ramp 86. In the illustration, the scoring of the fold lines 132 and 144 ends a distance from the left edge 136.

The step portion 142 is attached to a landing portion 148 of the bottom ramp 86. The landing portion 148 has a left edge 150 aligned with the left edges 136 and 146 and a right edge 152 aligned with the right edge 140.

When folded at the fold lines, the bottom ramp 86 provides a cover for the lower edge of the literature insert 112 and a ramp over which the product may slide during automated filing of the carton. The step portion 142 covers the edge of the literature insert 112 and the landing portion 148 is disposed against the surface of the literature insert 112, between the literature 112 and the product.

The opening 124 provides a grasping location when the bottom ramp 86 has been folded and is closed to form an end flap over the end of the carton. The closed end flap formed by the folded bottom ramp 86 may be grasped by the opening 124 for opening the closed flap.

In FIG. 8b, the literature insert 112 has the centerline 114 for alignment with the fold line between the two side panels on which the literature insert will be positioned. The centerline 114 is shown at the center in this embodiment but need not be at the center in other embodiments. The center line 114 may be scored, embossed, creased or otherwise shaped to more easily fold along the centerline 114. In the illustrated embodiment, the literature insert 112 is attached to the third side panel 78 by adhesive. As shown, two spots of adhesive 154 are applied between the side panel 78 and the literature insert 112. The adhesive 154 is of a type that permits the literature insert 112 to be removed by a user while holding the literature insert 112 in place during filling of the carton. For example, rubber cement may be used as an adhesive 154.

FIG. 9 shows the blank 40 that is configured to be folded into a carton enclosing both literature and a product. The literature insert 112 to be provided in the carton is formed of one or more sheets of paper or other material that has been folded and is shown standing on edge. The literature insert 112 of the illustrated example is of the same size sheet of paper as that literature insert of FIG. 4 but has been folded one fewer times. As a result, the literature insert 112 is approximately half the thickness, or less, as compared to the literature insert of FIG. 4. The literature insert 112 has been folded to a size that is larger than one side panel of the carton. Further folding of the literature insert 112 to fit onto only one side of the carton would at least double the thickness of the literature insert 112. For the literature insert 112 of the thickness shown and for the carton blank 40 of the size shown, such further folding would cause the literature insert 112 to occupy a considerable portion of the interior of the carton, possibly leaving insufficient room inside the carton for a product or at least making insertion of the product into the carton problematic for automated filling machines. When provided in the assembled carton, the literature insert 112 is folded less often so that it is of a bigger size that will extend onto two adjacent side panels of the carton. A blank 40 for a small size carton may be provided while permitting a large literature insert 112 to be used. It is not necessary to increase the size of the carton when a larger literature insert 112 is desired.

FIG. 10 shows the literature insert 112 positioned on the blank 40 so as to extend onto two of the side panels 64 and 78. The literature insert is positioned where it will located after the carton has been assembled from the blank 40. The literature insert 112 may be attached to one of the side panels by adhesive so that it remains in the desired position during assembly and filling of the carton. For example, the literature insert 112 may be affixed using two spots of adhesive 154 as shown in FIG. 8b. Other arrangements of adhesive, such as a strip of adhesive, multiple strips of adhesive, adhesive connecting the literature insert 112 onto two of the side panels, or other arrangements are within the scope of this invention.

FIG. 11 shows the assembled carton 156 in an assembled state with the literature insert 112 within the carton. The bottom end cover 70 is closed and the top end cover 98 is open in this view. The figure shows represents the view seen by a customer who has opened the carton 156 and removed the product, for example.

The literature insert 112 is bent generally at a right angle and lies against the two side panels 64 and 78 of the carton 156 that it was placed on when positioned on the blank 40. The bottom ramp 86 has been folded so that the landing portion 148 lies against the surface of the literature insert 112 so that the literature insert is between the side panel 78 and the landing portion 148. The landing portion 148 extends into the interior of the carton 156 and presses onto the surface of the literature insert 112 that lies against the side panel 78. The edge of the landing portion 148 presses onto the portion of the literature insert 112 that lies against the side panel 64 to keep the literature insert 112 folded at a right angle and pressed against the side panel 64.

The second ramp portion 130 of the bottom ramp 86 extends generally parallel to the closed bottom 70 of the assembled carton 156. The opening 124 forms a notch at the edge of the second ramp portion 130. The notch 124 provides relief for the fold line 122 such that the fold line 122 folds cleanly and remains flat against the surface of the literature insert 112. The relief of fold line 122 can be facilitated by a variety of methods including but not limited to cut scores, perforations, or combinations. In particular, the first and second ramp portions 120 and 130 are folded to a closed position parallel to the bottom end cover 70 when closed and are unfolded to a position parallel to the side panel 78 when unfolded.

Because the bottom ramp 86 presses on both the surface of the literature insert 112 that is on the side panel 78 and the edge 150 of the bottom ramp 86 presses on the portion of the literature insert 112 that lies on the side panel 64, the literature insert 112 is kept folded against the side panels. The interior space of the carton 156 is clear of the literature insert to ensure that there is room for the product in the carton 156.

In FIG. 12, the carton 156 has been filed with the product 10. The product 10 fits into the carton 156 alongside the literature insert 112. A larger carton 156 is not required, even when the larger literature insert 112 is included. FIG. 12 shows the view as seen by a customer after opening top end flap 86 of the carton 156. Both the product 10 and the literature insert 112 are visible and accessible to the customer.

Turning to FIG. 13, the assembled carton 156 is configured for filling with the product 10 from the bottom. The literature insert 112 is in position within the assembled carton 156. The bottom end cover 70 is open and the end flap 50 is open. The bottom ramp 86 has been folded at the fold line 122 so that the first and second ramp portions 120 and 130 overlie one another. The step portion 142 extends over the bottom edge of the literature insert 112 and the landing portion 148 is positioned on the literature insert 112. The left edge 126 and 134 of the bottom ramp at the first and second ramp portions 120 and 130 presses on the bottom end cover 70 to hold it in an open position. The edge 150 of the landing portion 148 presses the literature insert 112 at the fold 114 to hold the center of the literature insert 112 against the inside corner of the carton 156. The step portion 142 of the bottom ramp 86 keeps the edge of the literature insert 112 out of the way and prevents the product from being blocked by the literature insert 112 as the product 10 is inserted. The edge 150 keeps the edge of the literature insert 112 which lies against the side panel 64 and which is not covered by the step portion 142 out of the way of the product 10 as it is being inserted. The literature insert 112 is kept tucked into the corner of the carton 156, the middle of the literature insert 112 being pressed into the corner and against the second side panel 64. The literature insert remains out of the way for bottom filling.

In this view, the top end cover 98 is shown in the open position although the top end cover 98 may be fastened in the closed position when the carton is being filled from the bottom. The top end cover 98 may either be left open or may be closed during bottom filling, as desired.

In FIG. 14, a product 10 in a bottle with a cap is being inserted into the open bottom of the carton 156, as indicated by the arrow 158. The bottom ramp 86 permits the product to be inserted into the carton using automated filling machines with little or no chance that the literature insert 112 will cause jamming or interference with the filling process. Large literature inserts 112 may be provided in the carton 156 without jamming and without requiring a larger size carton. As the product 10 is inserted, the product may contact the bottom ramp 86 at any of the second ramp portion 130, the step portion 142, and the landing portion 148. The contact between the product 10 and the bottom ramp 86 may further press the bottom ramp 86 against the literature insert 112 and thus further press the literature insert 112 out of the way of the product 10 as it is being inserted.

Turning to FIG. 15, the literature insert 112 is visible and accessible to the user from the top of the assembled carton 156 when the top end flap 98 is open and after the product 10 is removed. The literature insert 112 may easily be removed from the carton 156. The bottom ramp 86 does not cover or hide the literature insert 112 and does not interfere with access to or removal of the literature insert 112 by the user. The landing portion 148 of the bottom ramp 86 holds the literature insert 112 in a position tucked into the corner of the carton 156 even when the product 10 has been removed.

As is well understood, the end flaps 48 and 82 are closed first before closing the top end cover 98. When opening the carton 156, the top end cover 98 is opened and then the end flaps 48 and 82 are opened to access the carton interior. The same goes for closing or opening the bottom end flap 70 and the side flap 60 and bottom ramp 86.

In FIG. 16 is shown a layout 160 of a blank for an example of the present carton. Proportions and dimensions of the blank 160 are shown. In the example, the layout 160 provides a carton that is 33 mm (1.3 inches) on a side and 80 mm (3.125 inches) tall. Cuts, creases, perforations, scorings, and the like are indicated. The layout 160 is shown from the printed side of the blank which will become the outside of the carton 156. Other shapes, sizes and arrangements are possible within the scope of this invention. For example, the blank 160 of FIG. 16 is flipped as a mirror image compared to the blank as shown in FIG. 8. Both the blank of FIG. 8 and the mirror image blank of FIG. 16 may be assembled to form similar cartons having mirror image the features. Either arrangement are within the scope of this invention.

FIG. 17 shows a second embodiment of a carton 200 that includes four side panels 202, 204, 206 and 208. A top flap 210 and side flaps 212 and 214 close the top of the carton 200. The bottom of the carton is closed by bottom flaps 216, 218, 220 and 222. The bottom flaps 216-222 are in the open position in this view. An extension 224 includes a first leg 226 and a second leg 228 within the interior of the carton 200 and an end tab 230 fastened to the interior surface of the carton 200. The extension 224 defines a partition space within the carton 200 within which may be placed a product so that the product is held at a first corner 232 or that maintains the product in a position within the carton 200. For example, the extension 224 may maintain the product in the space between the extension 224 and a literature inert 234, or may help to secure a product that has an irregular shape.

The literature insert 234 is fastened within the carton 200 at a second corner 236 that is opposite the first corner 232. The literature insert 234 is folded at a crease line 238 and secured with the crease line 238 at the second corner 236 of the carton 200. The literature insert 234 may be maintained in the second corner 236 by one or more of the bottom flaps as the carton 200 is being filled. In the illustration, the carton 200 is somewhat flattened as a result of the bottom flaps being incompletely closed. The bottom flaps 216-222 are corner tuck flaps that engage one another to close the bottom of the carton 200.

The carton 200 is shipped and stored in its flattened condition prior to inserting the product into the carton. In the flattened condition, the corners 232 and 236 are in close proximity with one another as a result of the flattening. The bottom flaps 222 and 216 flex upward to press the literature insert 234 into place on the adjoining side panels, particularly at the bottom portion of the literature insert 234. The first and second legs 226 and 228 of the extension 224 press against the literature insert in the flattened condition, and in particular against the top portion of the literature insert. The literature insert 234 may be affixed in the carton 200 and is maintained in the desired position by the bottom flaps and the extension 224 when the carton is flattened. As the carton is erected by unflattening, the bottom flaps maintain the crease in the literature insert and facilitate it being moved into position against the adjoining side panels.

In FIG. 18, the carton 200 is on the way to assuming its final shape as the bottom flaps 216-222 are being moved toward the closed position. The literature insert 234 is held in the second corner 236. The extension 224 that forms the partition space within the carton 200 includes a base portion 240 that connects to and extends from the side panel 204. The base portion 240 is positioned against the inside of the side panel 206. The base 240 provides the assembly flap to which glue or other fastener is applied to affix the base 240 to the side panel 206 during carton assembly. At the end of the base portion 240 opposite the side panel 204 is the first leg 226. The first leg 226 connects to the second leg 228, which connects to the end tab 230, which is attached to the side panel 204. The extension 224 has a width of less than the side panels 202-208. In certain embodiments, the extension 224 is a relatively narrow strip that is spaced from both the top and the bottom of the carton 200.

FIG. 19 shows the carton 200 in its final shape with the bottom flaps 216-222 closed and in tucked engagement with one another. The literature insert 234 is held in the second corner 236 by adhesive in certain embodiments, and the extension 224 defines a partition space at the first corner 232. The bottom flaps 216, 218, 220 and 222 engage one another at the closed bottom of the carton 200. The top flap 210 is open so that the user may retrieve the literature insert 234 or may return the product to the carton 200.

The pattern or blank for the carton 200 is shown in FIG. 20. The side panels 206, 208, 202 and 204 are connected to one another in series. The base portion 240 extends from the side panel 204. The base portion 240 includes an assembly flap 258 that is glued or otherwise fastened to the inside surface of the side panel 206 during carton assembly. The base portion 240 has a cut out notch 256 above which is an extension 260. The extension 260 is connected by a fold line 262 to the first leg 226. The first leg 226 is connected by a fold line 264 to the second leg 228. The second leg 228 is connected by a fold line 266 to end tab 230. The lower edge of the first leg 226, a portion of the second leg 228 and a portion of the base 240 at the extension 260 has a lower edge 268. The lower edge 268 may provide clearance for the bottom flaps to fold upward into the carton when in a flattened condition. The second leg 228 has a downwardly extending tab 242 with a rounded corner that extends below the lower edge 268. The bottom flap 218 also has an extending tab 244. The extending tab 244 engages the downwardly extending tab 242 when the bottom flap 218 is folded into the interior of the carton 200, for example as shown in FIGS. 17 and 18. The engagement between the tabs 242 and 244 is seen in FIG. 17. When the carton 200 is in the assembled and flattened condition, the bottom flaps extend into the interior of the carton with the tabs 242 and 244 engaged. The bottom flaps remain open due to the tab engagement to permit a product to be introduced into the bottom of the carton 200 as the carton 200 is reshaped from the flattened state to an erected shape.

The base portion 240 has the lower edge 268 that extends along a portion of the base 240, along the first leg 226 and into the second leg 228 to provide clearance for the upwardly folded bottom flaps when the carton 200 is flattened. The lower edge 268 permits the first and second legs 226 and 228 to extend into contact with the literature insert 234 while the carton is in the flattened condition.

The bottom flaps 218 and 222 each have a diagonal fold line 246 and 248, respectively. The fold lines 246 and 248 may be provided with a crease or otherwise formed to permit folding at the lines 246 and 248. The bottom flaps 218 and 222 are folded at the fold lines 246 and 248 in FIG. 17 and are flattened and unfolded in the assembled view of FIG. 19. The fold lines 246 and 248 are affixed to the corners of the bottom flaps 216 and 220 so that the bottom of the carton 200 may be opened as shown in FIG. 17. The bottom flaps 216 and 220 have diagonal edges 250 and 252 to facilitate carton erection and locking the bottom flaps 222 and 244 in position.

The literature insert 234 is placed within the carton 200 at the location marked on the pattern of FIG. 20. The literature insert 234 extends from the side 208 panel to the side panel 202 with a crease line in the literature insert overlying the fold line between the side panels 208 and 202. In the illustration, the literature insert 234 has been folded to a size of 88.9 mm by 38.1 mm (3.5 inches by 1.5 inches) and is provided with a crease approximately half way along its length. As shown, a bar code or other machine readable indicia may be provided on the literature insert 234. The machine readable bar code or other machine readable indicia enables an assembly machine to match the correct literature insert 234 with the correct carton 200.

In FIG. 21, the literature insert 234 is shown in its folded state. The literature insert may be opened by a user to a large sheet or may be a multiple page booklet. The crease 238 is formed approximately at the center of the literature insert 234, although other crease locations are possible. The literature insert 234 is provided with two glue spots 254, both on the same side of the crease, by which the literature insert 234 is affixed to an inside surface of the carton 200.

Turning to FIG. 22, a third embodiment of a carton 300. The carton 300 has side panels 302, 304, 306 and 308 as well as a top flap 310 and two side flaps 312 and 314. Inside the carton 300 is attached literature insert 316. Also in the carton 300 is a partition 318 that separates the interior space of the carton 300 into a first partition space including the literature insert 316 and a second partition space. The partition 318 extends from a tab end 320 that extends from the side panel 302 and lies against the side panel 304.

With reference to FIG. 23, the carton 300 has the literature insert 316 positioned in a corner and against the side panels 302 and 308. The literature insert 316 is provided with a crease 322 that enables it to fold at the carton corner. The partition 318 extends within the interior of the carton and includes a first leg 324 and a second leg 326. The first leg 324 includes an opening 328. The partition 318 is spaced from the top of the carton and from the bottom of the carton 300.

In the view of FIG. 24, the literature insert 316 is folded at the crease 322 and provided inside the carton 300 against the side panels 302 and 308. The partition 318 extends into the carton interior to partition the interior space into a space containing the literature insert and a space into which a product may be inserted, for example. The partition 318 includes the first leg 324 and the second leg 326.

In FIG. 25, the pattern or blank for the carton 300 includes the top flap 310 extending from the side panel 304 and a bottom flap 332 extending from the side panel 308. Bottom side flaps 334 and 336 are provided for closing the bottom of the carton 300. The partition 318 includes the tab end 320, the first leg 324, the second leg 326, and a base 338. The base 338 extends between the side panel 304 and the second leg 326. The base 338 also provides the assembly flap for assembling the carton 300 by attaching the assembly flap to the inside of the first side panel 306. For example, the base or assembly flap 338 is glued to the inside of the side panel 306 to form the carton. The tab end 320 is attached for example by glue to the side panel 304. The tab end 320 has a tab 342 that extends into the opening 328. The first and second legs 324 and 326 keep the literature insert 316 from interfering with the product insertion, since the product will be inserted into the space defined by the side panels 304 and 306 and the legs 324 and 326.

A location for the literature insert 316 is marked on the pattern. The literature insert 316 is provided on the side panels 302 and 308. In the example, the literature insert 316 is a sheet folded to a size of 33.34 mm by 53.97 mm (1.3125 inch by 2.1250 inch). The literature insert 316 may be positioned 18.26 mm from a top of the carton and 11.1 mm from a fold between the side panels 306 and 308. The literature insert 316 may be marked with an indicia such as a bar code for matching the correct literature insert 316 to the correct carton 300.

FIG. 26 shows the literature insert 316 with the crease 322 approximately at the center of the literature insert. A single glue spot 340 may be provided for affixing the literature insert 316 in place.

The present carton provides advantages for affixing a literature insert or other object inside of a carton. When a provider of a product wishes to provide a larger size of the literature insert in a carton, the present method and apparatus permits the larger insert to be provided without increasing the size of the carton. It is foreseen that other objects instead of a literature insert may be provided in the carton and that the present carton may be used to position and hold such other objects as well. The present method and apparatus may be provided for automated filling or for manual filling of the carton.

The present apparatus and method addresses the need to affix a folded literature insert inside small cartons. The product may be provided in a small size carton without the need to increase the carton size, without the need to change scoring within the carton, and without impacting the opening force of the carton.

The folded literature insert is folded and glued at its midpoint to create a piece of scored literature insert that has half the thickness it would have if folded to fit onto one carton side panel. The literature insert is glued as normal, but leaves one-end free to bridge the score of the carton, resting on an opposite panel. The ramp or one of the interior embodiments noted in carton 200 or carton 300 guides the score in the literature insert into the score of the carton during set up.

The adhesive for attaching the literature insert purposes prevents fiber tearing. The carton has cut-out sections, perforations, partial cuts, or scores on ramps, partitions or end panels. The continuous blank has end flaps that provide partitions or end panels and that are adhesively glued to one another to provide one or more rectangular side, front or back panels or on top of adjacent bottom minor flaps, thus creating interior spaces to hold products and allow the automatic set up and locking of the carton bottom flaps as the carton is erected from a flattened state to a rectangular shape. The carton provides the folded literature insert attached using a non-fiber tearing adhesive and allows for tertiary visual and automated verifications that ensure the presence of the literature insert through packaging line operations.

Thus, there has been shown an apparatus and method for providing a literature insert in a carton so that the literature insert lies against two adjacent side panels of the carton. The carton includes a ramp extending from the lower end of the carton to hold the literature insert out of the way or one of the interior projections in the embodiments noted in carton 200 or carton 300 that holds the literature insert out of the way during insertion of the product into the carton. The ramp or one of the interior projection embodiments noted in carton 200 or carton 300 includes a portion or edge that presses the literature insert into the corner of the carton to maintain the literature insert in position against both carton side panels.

Aspects of the method and apparatus as set forth below.

In a first aspect, a blank configured for forming a carton when assembled, the carton being configured for enclosing a product and a literature insert, the blank comprising: a plurality of side panels connected to form sides of the carton when assembled, the plurality of side panels including two adjoining side panels connected to one another by a fold line, the two adjoining side panels having a literature mounting portion on both of the two adjoining side panels, the literature mounting portion extending over the fold line connecting the two adjoining side panels, the literature mounting portion being configured for receiving the literature insert in a position with the literature insert on both of the two adjoining side panels and with a fold of the literature insert aligned with and on the fold line connecting the two adjoining side panels; and a holding portion configured for holding the literature insert at the literature mounting portion when assembled.

In a second aspect, the blank according to the first aspect, wherein the holding portion includes a ramp extending from the one of the two adjoining side panels, the ramp being configured to provide a first portion extending from an end of the assembled carton and a second portion connected to the first portion, the second portion being configured to extend into an interior of the carton and to overlie an edge of the literature insert.

In a third aspect, the blank according to the second aspect, wherein the ramp includes an edge of the ramp configured for extending along the fold of the literature insert when the literature insert is mounted with the fold of the literature insert aligned with and on the fold line connecting the two adjoining side panels.

In a fourth aspect, a blank according to the first aspect, wherein the carton includes opposite side panels opposite respective ones of the two adjoining side panels; wherein the holding portion extends into an interior of the carton from the opposite side panels and toward the two adjoining side panels when assembled.

In a fifth aspect, a blank according to the fourth aspect, wherein the holding portion extends toward the literature mounting portion on the two adjoining side panels.

In a sixth aspect, a blank according to the fourth aspect, wherein the two adjoining side panels having the literature mounting portion are second and third side panels connected in series in the blank; wherein the opposite side panels are first and fourth side panels connected in series in the blank.

In a seventh aspect, a blank according to the sixth aspect, further comprising: an assembly flap extending from a side of the fourth side panel and configured for attachment to the first side panel; wherein the holding portion includes a first leg extending from the assembly flap and a second leg extending from the first leg; an end tab connected to the second leg, the end tab being configured for attachment to the first side panel when assembled.

In an eighth aspect, a blank according to the seventh aspect, wherein the assembly flap includes a cutout notch.

In a ninth aspect, a blank according to the seventh aspect, further comprising: a plurality of bottom flaps extending from the plurality of side panels; wherein the second leg includes a downwardly extending tab configured to selectively engage one of the plurality of bottom flaps.

In a tenth aspect, a blank according to the ninth aspect, wherein the one of the plurality of the bottom flaps includes an extending tab that is configured to selectively engage the downwardly extending tab of the second leg.

In an eleventh aspect, a blank according to the ninth aspect, wherein the plurality of bottom flaps are configured for folding into an interior of the carton in a flattened condition; and wherein the first leg and a portion of the second leg have a lower edge configured to clear the folded bottom flaps in the flattened condition.

In a twelfth aspect, a blank according to the seventh aspect, wherein the second leg includes an opening.

In a thirteenth aspect, a blank according to the twelfth aspect, wherein the end tab includes a tap extending into the opening in the second leg.

In a fourteenth aspect, a method for forming a carton, comprising: forming a blank having a plurality of side panels connected in series, two adjoining ones of the plurality of side panels defining a literature insert mounting location, the blank including a holding portion configured for holding a literature insert at the literature insert mounting location when assembled; affixing a literature insert at the literature insert mounting location, the literature insert being disposed on both of the two adjoining side panels; and holding the literature insert at the literature insert mounting location with the holding portion, the holding portion holding the literature insert out of the way during insertion of a product into the carton.

In a fifteenth aspect, a method according to the fourteenth aspect, wherein the holding includes abutting an edge of a ramp of the holding portion against a fold of the literature insert that is aligned and on a fold adjoining the two adjoining side panels.

In a sixteenth aspect, a method according to the fourteenth aspect, wherein the holding includes: extending a first leg from an assembly flap at a side edge of one of the side panels into an interior of the carton; extending a second leg from the first leg to another of the side panels; and affixing an end tap that is connected to the second leg onto the another of the side panels.

In a seventeenth aspect, a method according to the sixteenth aspect, further comprising: folding bottom flaps of the carton into an interior of the carton in a flattened state; and engaging a tab on one of the bottom flaps with a tab on the second leg.

In an eighteenth aspect, a continuous blank configured for forming a carton adapted for enclosing a product and a literature insert, comprising: a plurality of side panels connected to form sides of a carton when the carton is assembled, each of the plurality of side panels having a first end at a first end of the carton, the plurality of side panels including first and second adjoining side panels, the first and second adjoining side panels being configured for receiving the literature insert inside the carton in a position against both of the first and second adjoining side panels; an end cover extending from the first end of the first adjoining side panel, the end cover being configured for fastening in a closed position closing the first end of the carton; a ramp extending from the first end of the second adjoining side panel, the ramp including: a first ramp portion connected to the second adjoining side panel, a second ramp portion connected to the first ramp portion, and a landing portion connected to the second ramp portion, the ramp being selectively configured in a product loading position of the assembled carton with the first and second ramp portions overlying one another and extending from the first end of the carton, the landing portion disposed on a first portion of the literature insert in the product loading position, the first portion of the literature insert being positioned against the second adjoining side panel, the landing portion including an edge pressing against a second portion of the literature insert in the product loading position, the second portion of the literature insert being against the first adjoining side panel; the ramp being selectively configured in a closed position of the assembled carton with the first and second ramp portions overlying one another and the landing portion disposed on the first portion of the literature insert and the edge pressing against the second portion of the literature insert.

In a nineteenth aspect, the continuous blank according to the eighteenth aspect, further comprising: an adhesive on at least one of the first and second adjoining side panels, the adhesive being configured for attaching the literature insert to the at least one of the first and second adjoining side panels, the adhesive being of a type that releases the literature insert from adhesion to the respective side panel without fiber tearing of the literature insert.

In a twentieth aspect, the continuous blank according to the eighteenth aspect, further comprising: end flaps being configured to be adhesively glued to one another to provide automatic locking of the carton bottom flaps as the carton is erected from a flattened state to a rectangular shape.

Although other modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.

CARTON FOR PRODUCT AND LITERATURE INSERT

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CROSS-REFERENCE TO RELATED APPLICATION

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