This disclosure generally relates to packages or cartons for holding and/or dispensing products.
One aspect of this disclosure is the provision of a carton having a tubular structure with an upper end defining a substantially closed first shape (e.g., a substantially rectangular shape/opening), and a lower end defining a substantially closed second shape (e.g., a shape/opening that is generally rectangular, with substantially rounded corners) that is substantially different from the first shape. The shape of the tubular structure transitions from the first shape to the second shape between the upper and lower ends of the tubular structure. One or more lines of disruption (e.g., fold, crease or score lines) may be located at the upper end of the tubular structure, and the lines of disruption may extend only partially along the tubular structure so that the shape of the tubular structure substantially smoothly transitions between the opposite upper and lower ends.
The carton may further include a top panel connected to the tubular structure and obstructing (e.g., closing) the opening at the upper end of the tubular structure. The top panel may have an outer periphery that substantially defines the first shape (e.g., the substantially rectangular shape). The carton may further include a bottom panel connected to the tubular structure and obstructing (e.g., closing) the opening at the lower end of the tubular structure. The bottom panel may have an outer periphery that substantially defines the second shape (e.g., the generally rectangular shape with substantially rounded corners).
The bottom panel may be formed from bottom end flaps that are respectively foldably connected to recessed edges proximate the lower end of the tubular structure. The top panel may be at least partially formed by an end flap that includes at least one fold line adapted for allowing the end flap to be formed into a spout. The carton may contain a bag containing product, and the carton may include a viewing window so that a user may see the product through the bag by way of the viewing window.
In accordance with one aspect of this disclosure, a blank for being erected into a carton includes: a plurality panels that are foldably connected to one another and are for being formed into a tubular structure, wherein the plurality of panels includes opposite first and second edges; a first end flap foldably connected to the first edge for obstructing (e.g., closing) an opening at an end of the tubular structure, wherein the first end flap has an outer periphery that defines a first shape (e.g., a substantially rectangular shape); and a second end flap foldably connected to the second edge (e.g., a recessed edge) for obstructing (e.g., closing) an opening at another end of the tubular structure, wherein the second end flap has an outer periphery that defines a second shape (e.g., a generally rectangular shape with substantially rounded corners) that is substantially different from the first shape. The blank may include one or more of the above-discussed features of the carton and/or other features.
In accordance with one aspect of this disclosure, a tubular structure may be formed from a blank, and the forming of the tubular structure may include forming an end of the tubular structure into a generally rectangular opening having substantially rounded corners. The generally rectangular opening having substantially rounded corners may be obstructed (e.g., closed) with a generally rectangular panel that is formed from the blank and has substantially rounded corners. The generally rectangular panel with substantially rounded corners may be formed from end flaps respectively folded about recessed edges of the blank. The forming of the tubular structure may also include forming and obstructing (e.g., closing) an end opening that is substantially rectangular.
Other aspects of this disclosure will become apparent from the following.
Having described some aspects of this disclosure in general terms, reference will now be made to the accompanying drawings, which may be schematic, are not necessarily drawn to scale, and wherein:
Referring now in greater detail to the drawings, in which like numerals refer to like parts throughout the several views, exemplary embodiments of this disclosure are described in the following. For example, a blank 10 is shown in
At the upper and lower ends 12, 14 of the blank 10, end flaps are attached to the main panels 20, 50 by fold lines that are transverse to the longitudinal fold lines 43, 93. More specifically, along the upper end 12 of the blank 10, an upper secondary end flap 22 is attached to an upper edge of the main panel 20 along a transverse fold line 21, an upper primary end flap 24 is attached to an upper edge of the main panel 20 along a transverse fold line 31, an upper secondary end flap 40 is attached to an upper edge of the main panel 20 along a transverse fold line 41, an upper secondary end flap 42 is attached to an upper edge of the main panel 50 along a transverse fold line 51, an upper primary end flap 44 is attached to an upper edge of the main panel 50 along a transverse fold line 61, an upper secondary end flap 46 is attached to an upper edge of the main panel 50 along a transverse fold line 71, and an attachment end flap 48 (e.g., adhesive end flap) is attached to an upper edge of the attachment panel 60 along a transverse fold line 81. One or more of the transverse fold lines 21, 31, 41, 51, 61, 71, 81 can be collinear with one another such that the transverse fold lines 21, 31, 41, 51, 61, 71, 81 may be characterized as being portions of a single transverse fold line 15 that extends all the way between opposite edges of the blank 10.
The upper primary end flap 24 includes several lines of disruption, namely transverse tear lines 30, 32, 34 and a series of cuts (e.g., slits) that form a tuck-in flap or tab 36. The lines of disruption in the upper primary end flap 24 form a tear strip 28 and another separable portion 26 of the upper primary end flap 24. The series of slits that form the tuck-in tab 36 are positioned between and connect inner ends of the tear lines 30, 32. As shown in
For at least one of (e.g., for each of) the upper main end flaps 24, 44, the end flap has an outer periphery that defines a substantially rectangular shape having corners that substantially define right angles, although differently shaped upper main end flaps are within the scope of this disclosure. More specifically and as shown in
The upper primary end flap 44 includes a tuck-in slot 38 sized to receive the tuck-in tab 36 after the carton 400 (
The upper primary end flaps 24, 44 are separated from the adjacent secondary upper flaps 22, 40, 42, 46 by way of cut outs or cuts, namely longitudinal slits 54. In contrast, the upper secondary end flaps 40, 42 are connected to one another by a longitudinal fold line 53, which is shown to be generally collinear with the longitudinal fold line 43. Similarly, the upper secondary end flaps 46, 48 are connected to one another by a longitudinal fold line 83, which is shown to be generally collinear with the longitudinal fold line 93. The longitudinal fold lines 53, 83 allow the end flaps 40, 42 and the end flaps 22, 46, 48 to respectively be flexed outwardly to form pouring spouts, or the like, (e.g., see the spout 300′ in
The main panels 20, 50 optionally include relatively short lines of disruption, namely score lines that may be referred to as longitudinal fold lines 23, 33, 63, 73. The longitudinal fold lines 23, 33, 63, 73 extend transverse to the transverse fold lines 21, 31, 41, 51, 61, 71, 81 for allowing or enhancing flexure of the main panels 20, 50 along the upper end 12 when the blank 10 is formed into carton 400 (
At the lower end 14 of the blank 10 as shown in
The recessed edges of the panels 20, 50, 60 that are respectively coextensive with the transverse fold lines 91, 101, 111, 121, 131, 141 are recessed relative to respective lowest edges of the main panels 20, 50 by virtue of respective cuts (e.g., curved slits 104 and longitudinally extending straight slits 105) that respectively extend downwardly from the recessed edges/respectively extend inwardly from the lowest edges of the main panels 20, 50. One or more of the transverse fold lines 91, 101, 111, 121, 131, 141 may be characterized as being portions of one or more larger fold lines. For example, ends of the transverse fold lines 101, 111 are contiguous and collinear. Similarly, ends of the transverse fold lines 131, 141 are contiguous and collinear. Also, the transverse fold lines 91, 101, 111, 121, 131, 141 may alternatively be located at lowest edges of the panels 20, 50 rather than being located at the recessed edges.
Reiterating from above and for example, for each of the upper main end flaps 24, 44, the end flap has an outer periphery that defines a substantially rectangular shape having corners that substantially define right angles. In contrast, for at least one of (e.g., for each of) the lower main end flaps 70, 78, the flap has an outer periphery that defines a shape that is substantially different from the substantially rectangular shape defined by the outer peripheries of the upper main end flaps 24, 44. More specifically, for at least one of (e.g., for each of) the lower main end flaps 70, 78, the flap has an outer periphery that defines a generally rectangular shape having beveled corners (e.g., substantially rounded corners). More specifically and in accordance with the first embodiment, the main end flaps 24, 44, 70, 78 are all about the same size, except, for example, that the corners of the lower main end flaps 70, 78 are substantially more rounded as compared to the corners of the upper main end flaps 24, 44. For example, whereas
The lower secondary end flaps 74, 76 are connected to one another by a longitudinal fold line 103, which is generally collinear with the longitudinal fold line 43. Similarly, the lower secondary end flaps 80, 82 are connected to one another by a longitudinal fold line 113, which is generally collinear with longitudinal fold line 93. Each of the pair of end flaps 40, 42, the pair of end flaps 46, 48, the pair of end flaps 74, 76, and the pair of end flaps 80, 82, may be referred to as a single end flap that optionally includes and is divided (e.g., bifurcated) by the respective longitudinal fold line 53, 83, 103, 113 or any other suitable line of disruption, such as a cut or slit.
An example of a method of erecting the carton 400 (
A generally rectangular bottom panel (e.g., composite bottom panel) with substantially rounded corners is formed from the lower end flaps 70, 74, 76, 78, 80, 82 for obstructing (e.g., closing) the opening at the lower end 14 of the carton 400 (
After the flattened tubular structure is formed from the blank 10 as discussed above, the tubular structure is “opened”/no longer collapsed so that at least one panel (e.g., the main panels 20, 50 together) extend around a longitudinal axis and open interior of the tubular structure. The bottom panel may be formed while the tubular structure is “opened”/no longer collapsed. The lower end 14 of the open tubular structure may be manually shaped, or the lower end 14 of the open tubular structure may be automatically shaped, such as through the use of an automated system including mandrel(s) and/or outer forming or supporting structures, or any other suitable shaping mechanism or process, so that the opening at the lower end 14 of the open tubular structure substantially defines the same (albeit slightly larger) generally rectangular shape having substantially rounded corners as the lower main end flaps 70, 78. Throughout this Detailed Description section of this disclosure, the generally rectangular shape having substantially rounded corners may more generally be referred to in geometrical terms as a substantially closed shape that is generally rectangular and has beveled corners.
While the lower end 14 of the open tubular structure defines the generally rectangular shape having substantially rounded corners, first the lower main end flap 78 is folded inwardly about ninety degrees along the transverse fold line 121/the respective recessed edge of the main panel 50 so that the lower main end flap 78 is pivoted into the interior of the open tubular structure, then the lower main end flap 70 is folded inwardly about ninety degrees along the transverse fold line 91/the respective recessed edge of the main panel 20 so that the lower main end flap 70 is pivoted into the interior of the open tubular structure, then the lower secondary end flaps 74, 76, 80, 82 are folded inwardly about ninety degrees along the respective transverse fold lines 101, 111, 131, 141/the respective recessed edges of the panels 20, 50, 60 so that the lower secondary end flaps 74, 76, 80, 82 are pivoted into the interior of the open tubular structure. The lower secondary end flaps 74, 76, 80, 82 are attached (using adhesive material or any other suitable fastening mechanism(s)) to the opposite ends of the lower main end flap 70 so that the fold lines 103, 113, 151 are substantially parallel to one another and the fold lines 103, 113 extend along the fold line 151, so that the otherwise open tubular structure has a closed lower end 14. As a result, the open (e.g., upwardly open) tubular structure has a closed lower end 14, and the lower ends of the main panels 20, 50 define the generally rectangular shape having substantially rounded corners. As a result, the carton 400 (
The lower secondary end flaps 74, 76, 80, 82 may be adhesively or otherwise attached to the opposite ends of the lower main end flap 70 manually or through the use of an automated system that may include mandrel(s) and/or outer forming or supporting structures, or any other suitable mechanisms or processes. The generally rectangular bottom panel with rounded corners may be formed in a different manner. For example, the lower end flaps 70, 74, 76, 7880, 82 can be folded and/or attached in another manner or order without departing from the scope of this disclosure.
Then, optionally and if desired, and perhaps theoretically depending upon the rigidity of the material from which the blank 10 is constructed, the tubular structure with the closed lower end 14 may be flattened (e.g., substantially flattened) by having the lower main end flap 78, which is within the interior of the tubular structure, in opposing face-to face relation or contact, or the like, with the main panel 50, and then folding along the fold lines 43, 93, 103, 113, 151. Thereafter at a desired time, the substantially flattened tubular structure with the closed lower end 14 may be formed into the open tubular structure with the closed lower end/upwardly open carton 400. Any suitable product (e.g., food stuffs) may be disposed within the interior of the carton 400 (
When the open tubular structure with the closed lower end 14/upwardly open carton 400 (
The substantially rectangular top panel 160 (e.g., composite top panel shown in
As shown in
Referring primarily to
A second embodiment of this disclosure is like the first embodiment, except for variations noted and variations that will be apparent to one of ordinary skill in the art. For example and referring to
As best understood with reference to
When the window 200′ and the bag B′ are both included in the carton 400′, the bag B′ will typically be constructed of a material (e.g., polymer film) that may be seen through. That is, when the window 200′ and the bag B′ are both included, the bag B is typically formed of a material that allows the product therein to be viewed therethrough (e.g. the bag B could be formed of a polymer film or other clear or opaque substances).
The bags B, B′ may be sealed and installed and/or formed in the cartons 400, 400′ in any suitable manner. As schematically shown in
In some examples of this disclosure, the bags B, B′, which are optional and may be omitted, are within the cartons 400, 400′ but are not adhered to or otherwise connected to the interior surface of the cartons 400, 400′ containing the bags B, B′. Alternatively, the bags B, B′ may be adhered to or otherwise connected to the interior surface of the cartons 400, 400′ containing the bags B, B′. For example and as shown in
In
For each of the cartons 400, 400′, any bag therein may include a spout or spout-like feature adjacent to the carton's spouts 300′ (
In
The bags B′, B″, B′″ may be formed of any material, such as food-grade polymer film, and the bags may be formed of a repulpable or other recycled material or materials to function at least generally as described herein. Generally, the upper ends of the bags B′, B″, B′″ are sealed closed after product (e.g., food) is inserted therein. The bags B′, B″, B′″ may be sealed liners that are formed inside the cartons 400, 400′ and/or the bags may be installed into the cartons after the bags are filled in lieu of being adhered to the blank prior to the blank being formed into a carton.
The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar or any other suitable materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.
In accordance with the above-described embodiments of the present disclosure, a line of disruption in the form of a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In accordance with the first embodiment, all of the fold lines 21, 31, 41, 51, 53, 61, 71, 81, 83, 101, 103, 111, 113, 131, 141 may be score/crease lines, and the fold lines 91, 93, 121, 151 may each be formed by an alternating series of slits and score/crease lines.
As an example, a line of disruption in the form of a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.
Directional references (e.g., top, upper, bottom, lower, longitudinal, transverse, side, or the like) have been used in this disclosure for ease of understanding and not for the purpose of limiting the scope of this disclosure.
It will be understood by those skilled in the art that while the present disclosure has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention as set forth in the claims.
This application claims the benefit of U.S. Provisional Application No. 61/255,240, which was filed on Oct. 27, 2009. The entire disclosure of U.S. Provisional Application No. 61/255,240, which was filed on Oct. 27, 2009, is incorporated herein by reference.
Number | Date | Country | |
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61255240 | Oct 2009 | US |