Patent Grant
8950657
The present disclosure generally relates to cartons for holding and dispensing contents such as powders, granular materials, and other flowable materials. More specifically, the present disclosure relates to cartons having a handle in at least a bottom corner of the carton.
In general, one aspect of the disclosure is directed to a carton for containing and dispensing flowable materials. The carton comprises a plurality of panels that extends at least partially around an interior of the carton. The plurality of panels can comprise a front panel, a back panel, a first side panel, and a second side panel. At least one bottom flap is respectively foldably connected to a respective panel of the plurality of panels. The at least one bottom flap can at least partially form a closed bottom end of the carton. A handle can extend in at least the bottom end proximate the back panel.
In another aspect, the disclosure is generally directed to a blank for forming a carton. The blank can comprise a plurality of panels comprising a front panel, a back panel, a first side panel, and a second side panel. At least one bottom flap can be respectively foldably connected to a respective panel of the plurality of panels. The at least one bottom flap can be for at least partially forming a closed bottom end of the carton formed from the blank. The blank fan further include handle features in at least the at least one bottom flap for forming a handle extending in at least the bottom end proximate the back panel in the carton formed from the blank.
In another aspect, the disclosure is generally directed to a method of forming a carton. The method can comprise obtaining a blank comprising a plurality of panels comprising a front panel, a back panel, a first side panel, and a second side panel, at least one bottom flap respectively foldably connected to a respective panel of the plurality of panels, and handle features in at least the at least one bottom flap. The method can also include forming an interior of the carton at least partially defined by the plurality of panels. The forming the interior of the carton can comprise forming an open-ended sleeve. The method can further include positioning the at least one bottom flap to at least partially close a bottom end of the open-ended sleeve. The positioning the at least one bottom flap can comprise positioning the handle features to form a handle adjacent the back panel.
Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.
According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
The present disclosure generally relates to cartons with features for containing and facilitating dispensing articles such as flowable materials, liquids, powders, etc. The articles can include, but are not limited to, particulates, granular materials, powders, and the like, or any combination thereof. Examples of such materials include, but are not limited to, rice, beans, sugar, flour and other flowable solid products, such as cat litter, sand, soaps, and detergents. In this specification, the terms “lower,” “bottom,” “upper” and “top” indicate orientations determined in relation to fully erected and upright cartons.
The carton blank 3 has a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiment, the blank 3 comprises a front panel 10 foldably connected to a first side panel 20 at a first lateral fold line 21. A back panel 30 is foldably connected to the first side panel 20 at a second lateral fold line 31. A second side panel 40 is foldably connected to the back panel 30 at a third lateral fold line 41. In the illustrated embodiment, the blank 3 includes an attachment panel 50 foldably connected to the second side panel 40 at a fourth lateral fold line 52. Alternatively, the attachment panel 50 could be connected to the front panel 10 or omitted without departing from the disclosure.
The front panel 10 is foldably connected to a front top flap 12 and a front bottom flap 14. The first side panel 20 is foldably connected to a first side top flap 22 and a first side bottom flap 24. The back panel 30 is foldably connected to a back top flap 32 and a back bottom flap 34. The second side panel 40 is foldably connected to a second side top flap 42 and a second side bottom flap 44. The attachment panel 50 is foldably connected to an attachment top flap 54 and an attachment bottom flap 56. When the carton 5 is erected, the front and back top flaps 12, 32, side top flaps 22, 42, and attachment top flap 54 close a first (e.g., top) end 51 of the carton, and the front and back bottom flaps 14, 34, side bottom flaps 24, 44, and attachment bottom flap 56 and close a second (e.g., bottom) end 53 of the carton (
The front and back top flaps 12, 32, side top flaps 22, 42, and attachment top flap 54 extend along a first marginal area of the blank 3, and are foldably connected at a first longitudinal fold line 62 that extends along the length of the blank. The front and back bottom flaps 14, 34, side bottom flaps 24, 44, and attachment bottom flap 56 extend along a second marginal area of the blank 3, and are foldably connected at a second longitudinal fold line 64 that also extends along the length of the blank, though the longitudinal fold line 64 can be interrupted by cut lines as described below. The longitudinal fold lines 62, 64 may be, for example, substantially straight, or offset at one or more locations to account for blank thickness or for other factors.
As shown in
In the illustrated embodiment, the dispenser panel 87 is further defined by a first dispenser fold line 103 extending in the front top flap 12, a second dispenser fold line 105 extending in the first side top flap 22, and a third dispenser fold line 107 extending in the second side top flap 42. The dispenser fold lines 103, 105, 107 are disposed so that the dispenser fold lines are aligned and overlapped when the top end 51 is closed (
As shown in
The dispenser 7 may be otherwise sized, shaped, and/or located in the carton 5 without departing from the scope of this disclosure. For example, the dispenser panel 87 might extend in only one of the first and second side panels 20, 40, only partially across the front panel 10 in the longitudinal direction L1, or a combination thereof. Further, the dispenser 7 may be omitted from the carton 5 without departing from the scope of the disclosure.
As shown in
The top handle 11 can be otherwise shaped and located in the carton 5 without departing from the scope of this disclosure. For example, the top handle openings 131, 133 and the handle strip 140 can extend laterally or obliquely in the side top flaps 22, 42. Further, the handle panel 138 can be secured to either of the side top flaps 22, 42, and it can be secured to the innermost surface or the outermost surface of the top end 51. Alternatively, the handle panel 138 can be disposed between the overlapping side top flaps 22, 42. In another example, the top handle 11 could be formed by two or more spaced-apart openings formed in the top end 51. Further, the top handle 11 can be omitted without departing from the scope of the present disclosure.
In the illustrated embodiment, a corner handle 111 is formed at an angled corner 109 of the carton 5. The angled corner 109 includes and is formed by an oblique or lower portion 160 of the back panel 30 and triangle portions 162, 164 of the respective first and second side panels 20, 40. The lower portion 160 is defined by at least a longitudinal crease or other line of weakening 161 and the longitudinal fold line 64. The triangle portion 162 is foldably connected to the lower portion 160 by the lateral fold line 31 and is defined by at least an oblique fold line 163 extending in the first side panel 20. The triangle portion 164 is foldably connected to the lower portion 160 by the lateral fold line 41 and is defined by at least an oblique fold line 165 extending in the second side panel 40. The triangle portions 162, 164 are separated from the respective side bottom flaps 24, 44 along respective cuts 167, 169, which can interrupt the longitudinal fold line 64. The cuts 167, 169 could be other forms or lines of weakening (e.g., tear lines) without departing from the disclosure. As shown in
The features of the corner handle 111 include corner handle openings 172, 174 formed in the respective handle portions 176, 178 in the respective side bottom flaps 24, 44. In the assembled carton 5, as shown in
In accordance with the exemplary embodiment, the carton blank 3 can be erected into the carton 5 by folding the carton blank 3 along fold lines 21, 31, 41, 52. The attachment panel 50 can be adhered to the interior surface of the front panel 10, and the adhesive flaps 54, 56 can be glued to the interior surfaces of the respective front flaps 12, 14, to form an open-ended sleeve. The bottom end 53 of the sleeve can be closed by respectively overlapping and adhering the front and back bottom flaps 14, 34 and side bottom flaps 24, 44. Particularly, the back bottom flap 34 is folded along the longitudinal fold line 64, and the lower portion 160 of the back panel 30 is folded along the longitudinal crease 161 while the triangular portions 162, 164 of the respective side panels 20, 40 are folded along respective fold lines 163, 165 into face-to-face contact with the respective side panels 20, 40. The front bottom flap 14 is folded inwardly along the longitudinal fold line 64, and the side bottom flaps 24, 44 are folded along the longitudinal fold line 64 to overlap the front and back bottom flaps 14, 34 so that the corner handle openings 172, 174 are generally aligned to form the corner handle 111. Accordingly, the bottom flaps 14, 24, 34, 44, 56 form the bottom end 53, the wedge-shaped handle recess 173 is formed at the angled corner 109, and the handle portions 176, 178 of the respective side bottom flaps 24, 44 extend along the bottom of the wedge-shaped handle recess 173. The overlapped handle portions 176, 178 provide a sturdy, tear-resistant handle 111. In the illustrated embodiment, the first side bottom flap 24 is external to the second side bottom flap 44; however, the second side bottom flap 44 can be configured to be external to the first side bottom flap 24 without departing from the scope of the present disclosure. In an alternative embodiment, only one of the side bottom flaps 24, 44 extends along the bottom of the wedge-shaped handle recess 173, and either handle portion 176, 178 is omitted.
The top end 51 can be closed and the top handle 11 can be formed by adhering the handle panel 138 to the interior surface of the second side top flap 42 so that the handle strip 140 extends through the handle opening 133 (
The assembled carton 5 is shown in
The top handle 11 can be used to grasp the carton 5 for carrying by grasping the handle strip 140 and pulling it upwardly through the handle openings 133, 131. As it is pulled upwardly, the handle strip 140 can unfold and expand so that a user can easily grasp the top handle. It is understood that the top handle 11 can be omitted, the carton 5 can include more than one handle configured similarly to the top handle 11, or that the top handle 11 can be otherwise shaped, arranged, and/or located without departing from the disclosure.
As shown in
The dispenser panel 87 extends laterally across the side top flaps 22, 42 to provide a convenient opener cavity at the dispenser opening 171 for access to the contents of the carton 5. A user can tip the carton 5 to pour contents through the dispenser opening 171, as desired. According to one embodiment, the carton 5 can be placed in a pouring position to pour out the contents of carton through the dispenser 7 as shown in
In one embodiment, the user can grasp the carton 5 anywhere with the second hand to further support the carton during pouring. For example, the user could grasp the carton at the front panel or the top handle 11. Alternatively, the user can keep the second hand free by resting the carton 5 on a pivot corner 209 formed by the portion of the longitudinal fold line 64 connecting the front bottom flap 14 to the front panel 10. The user pulls the angled corner 109 upwardly at the corner handle 111, pivoting the carton about the pivot corner 209 to lower the dispensing corner 9 until a portion of the flowable material contained in the carton 5 pours out of the carton through the opening 171 at the dispenser 7. The user continues to pivot the carton about the pivot corner 209 until the desired amount of the flowable material is dispensed. The carton 5 can be alternatively pivoted for pouring without departing from the present disclosure. Further, the contents of the carton can be alternatively dispensed from the carton, such as by scooping through the opening 171.
Accordingly, the angled corner 109 provides access to the corner handle 111 and allows the corner handle to be outside the panels forming the interior of the carton without increasing the footprint of the carton. Stated another way, the angled corner 109 is configured so that the corner handle openings 172, 174 do not penetrate to the interior of the carton, while the corner handle 111 does not extend beyond the edges of the top end 51 of the carton. Alternatively, the corner handle 111 can be configured to protrude past the back panel 30 or the side panels 20, 40. Accordingly, the interior of the carton 5 remains intact below the dispenser 7 to prevent leaking of the contents of the carton, and the carton retains sift resistancy. Further, extended panels and flaps requiring additional material are not required, and the angled corner 109 allows the corner handle 111 to be formed without requiring that additional pieces be attached during manufacturing, assembly, or use.
In an alternative embodiment, the angled corner 109 and the corner handle 111 can be otherwise configured or disposed at any corner of the carton 5.
In one embodiment, a liner, a bag, a reinforcing tape, a reinforcing insert, or a combination thereof can be adhered to, or otherwise disposed within, the interior of the carton 5. Alternatively, the liner, bag, tape, or other insert can be disposed externally with respect to the carton. The liner, bag, tape, or other insert can be used to avoid tearing of the carton 5 and delamination of the panels and flaps of the carton, or to seal the interior of the carton top prevent leaking of the contents. Alternatively, no liner, bag, tape, or other insert is used, and the carton 5 is filled with flowable material or other items directly.
The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar 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 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.
As an example, 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.
The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.
The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments that are within the scope of the claims. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 61/456,114, filed Nov. 1, 2010. The disclosure of U.S. Provisional Patent Application No. 61/456,114, which was filed on Nov. 1, 2010, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
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