The present disclosure relates to cartons, blanks for forming cartons, and methods associated with cartons and blanks for holding and carrying at least one article. In one embodiment, the present disclosure relates to a carton having a gable top with a sift-minimizing top closure configuration.
According to one aspect of the disclosure, a carton for holding at least one article, the carton comprises a plurality of panels, a plurality of panels, a first gusset, and a second gusset. The plurality of panels extends at least partially around an interior of the carton, the plurality of panels comprises a front panel, a first side panel, a second side panel, and a back panel. The plurality of end flaps is foldably connected to respective panels of the plurality of panels, the plurality of end flaps comprises a first end flap foldably connected to the front panel and a second end flap foldably connected to the back panel. The first gusset is foldably connected to a portion of the first side panel and the second gusset is foldably connected to a portion of the second side panel. At least the first end flap, the first gusset, and the second gusset cooperate to form a first closure of the carton, and the second end flap forms a second closure of the carton, the second closure at least partially overlaps the first closure.
According to another aspect of the disclosure, a blank for forming a carton for holding at least one article comprises a plurality of panels, a plurality of end flaps, a first gusset, and a second gusset. The plurality of panels is for extending at least partially around an interior of the carton formed from the blank, the plurality of panels comprises a front panel, a first side panel, a second side panel, and a back panel. The plurality of end flaps is foldably connected to respective panels of the plurality of panels, the plurality of end flaps comprises a first end flap foldably connected to the front panel and a second end flap foldably connected to the back panel. The first gusset is foldably connected to a portion of the first side panel and the second gusset is foldably connected to a portion of the second side panel. At least the first end flap, the first gusset, and the second gusset are for cooperating to form a first closure of the carton formed from the blank, and the second end flap is for forming a second closure of the carton formed from the blank, the second closure is for at least partially overlapping the first closure of the carton formed from the blank.
According to another aspect of the disclosure, a method of forming a carton for holding at least one article comprises obtaining a blank. The blank comprises a plurality of panels and a plurality of end flaps, the plurality of panels comprises a front panel, a first side panel, a second side panel, and a back panel, and the plurality of end flaps are foldably connected to respective panels of the plurality of panels. The plurality of end flaps comprises a first end flap foldably connected to the front panel and a second end flap foldably connected to the back panel. The blank further comprises a first gusset foldably connected to a portion of the first side panel and a second gusset foldably connected to a portion of the second side panel. The method further comprises folding the plurality of panels to at least partially extend around an interior of the carton. The method further comprises positioning the first end flap, the first gusset, and the second gusset to form a first closure of the carton. The method further comprises positioning the second end flap to form a second closure of the carton, the second closure at least partially overlaps the first closure.
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.
Cartons according to the present disclosure can accommodate articles of numerous different shapes. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes articles such as food products at least partially disposed within the carton embodiments.
In this specification, the terms “lower,” “bottom,” “upper”, “top”, “front”, and “back” indicate orientations determined in relation to fully erected cartons. Further, as described herein, cartons may be formed from blanks by overlapping multiple panels and/or end flaps. Such panels and/or end flaps may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure.
The blank 3, as shown, has a longitudinal axis L1 and a lateral axis L2. The blank 3 includes a back panel 25 foldably connected to a first side panel 27 at a lateral fold line 29. A front panel 31 is foldably connected to the first side panel 27 at a lateral fold line 33. A second side panel 37 is foldably connected to the front panel 31 at a lateral fold line 39. An adhesive flap 41 is foldably connected to the second side panel 37 at a lateral fold line 45.
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In the illustrated embodiment, the blank 3 includes a first gusset 79 comprising an upper portion 28 of the first side panel 27. The first gusset 79 includes a central or first gusset panel 81 foldably connected to a second gusset panel 83 and a third gusset panel 85 at respective fold lines 84, 86. As shown, the fold line 84 includes a first oblique portion 84a intersecting a second oblique portion 84b, and the fold line 86 includes a first oblique portion 86a intersecting a second oblique portion 86b. The first oblique portion 84a can intersect the second oblique portion 84b at an angle, for example, an obtuse angle, and the first oblique portion 86a can intersect the second oblique portion 86b at an angle, for example, an obtuse angle. The central gusset panel 81 is also foldably connected to a lower portion 30 of the first side panel 27 at a fold line 82 that intersects and interconnects the respective second oblique portions 84b, 86b of the respective fold lines 84, 86. The first gusset 79 could have other features and could be otherwise shaped, arranged, and/or configured, without departing from the scope of the disclosure.
As shown, a second gusset 88 comprises an upper portion 32 of the second side panel 37, and has similar features as the first gusset 79, as shown. In particular, the second gusset 88 includes a central or fourth gusset panel 91 foldably connected to fifth and sixth gusset panels 93, 95 at respective fold lines 94, 96 having respective first and second oblique portions 94a, 94b and 96a, 96b. The central gusset panel 91 is foldably connected to a lower portion 34 of the second side panel 37 at a curved fold line 92 that intersects and interconnects the respective second oblique portions 94b, 96b of the respective fold lines 94, 96. The central gusset panels 81, 91 are connected to a respective end flap 67, 71 at respective portions 64c, 64d of the longitudinal fold line 64. The gussets 79, 88 could be otherwise shaped, arranged, configured, and/or oriented without departing from the disclosure.
In this regard, the first and second gussets 79, 88 each include respective panels 81, 83, 85 and 91, 93, 95 that are configured for movement relative to one another to facilitate formation of the gable top 8 (
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The above-described formation of the carton 5 into the illustrated open-top configuration can be accomplished, for example, with a packaging system that can comprise different stations, modules, or components, such as a carton forming station, a wrapping station, a pick and place station, a closing or sealing station, or any other suitable station or components. The blank 3 can be formed into the carton 5 by other packaging systems without departing from the disclosure. As shown, the interior 6 of the carton 5 can be loaded with articles, such as flowable products P, as shown, by a suitable packaging or handling system (not shown) or, in other embodiments, can be manually loaded with articles.
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As shown, upon activation of the gussets 79, 88, respective top portions 43, 45 of the respective back panel 25 and front panel 31 are drawn to bend or curve toward one another such that the top portions 43, 45 are disposed in an oblique arrangement relative to respective bottom portions 47, 48 of the respective back panel 25 and front panel 31.
In this regard, the central gusset panels 81, 91 are positioned in an inwardly spaced arrangement with respect to the respective lower portions 30, 34 of the respective side panels 27, 37. Such positioning of the gussets 79, 88 can be accomplished, for example, by drawing or “pinching” the back panel 25 and the front panel 31 toward one another such that the gussets 79, 88 are activated as described above. In one embodiment, such activation of the gussets 79, 88 can occur directly, for example, by manual engagement of one or more portions of the gussets 79, 88 by a user, or, in another embodiment, through indirect activation by the approximation or pinching of the back panel 25 and the front panel 31 toward one another. In the exemplary embodiment shown, activation of the gussets 79, 88 results in at least partial folding of the second and third gusset panels 83, 85 relative to the central panel 81 at the respective fold lines 84, 86 and at least partial folding of the fifth and sixth gusset panels 93, 95 relative to the central panel 91 at respective fold lines 94, 96. Further, the second and third gusset panels 83, 85 are at least partially folded relative to the respective front and back panels 25, 31 at portions of respective fold lines 29, 33 and the fifth and sixth gusset panels 93, 95 are at least partially folded relative to the respective front and back panels 31, 25 at respective fold lines 39, 45. As shown, the central panels 81, 91 are also at least partially folded relative to the respective lower portions 30, 34 of the respective first and second side panels 27, 37 at respective fold lines 82, 92. The gusset panels 83, 95 overlap and are in at least partial face-to-face contact with the back panel 25 and the gusset panels 85, 93 overlap and are in at least partial face-to-face contact with the front panel 31.
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Accordingly, and as described herein, the carton 5 incorporates the first closure 7, the second closure 9 that at least partially overlaps the first closure 7, and the gussets 79, 88 such that the carton 5 provides a sift-proof or sift-minimizing configuration to inhibit, minimize, and/or prevent the passage of flowable products P (e.g., granular or powdered products) or associated particulate from within the interior 6 of the carton 5. Such configuration may be desirable, for example, in the case of smaller food products or other flowable products P, easily frangible food products P, and/or in instances in which carton 5 may be subject to movement or jostling. In one embodiment, such configuration can provide a substantially sealed, e.g., hermetically sealed, condition of the gable top 8 of the carton 5. Further still, the tapered configuration of the gable top 8 of the carton 5 (including the flat, planar configuration of the proximal portion 73 of end flap 65) provides a visually-distinctive carton configuration that can be readily identified among other cartons or packages.
The carton 5 could include various handle features for carrying the carton and could include various dispenser features for opening the carton. Further, the carton 5 could include other panel/flap closing configurations without departing from the disclosure. In one embodiment, the carton 5 can include a liner for maintaining food products P (
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 there along. 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 exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and 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. 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. 62/445,990, filed on Jan. 13, 2017. The disclosure of U.S. Provisional Patent Application No. 62/445,990, which was filed on Jan. 13, 2017, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
Number | Date | Country | |
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62445990 | Jan 2017 | US |