BACKGROUND OF THE INVENTION
1. Technical Field
This invention generally relates to paperboard containers. More particularly, the invention relates to a paperboard container that can be moved from an expanded position to a collapsed position. Specifically, the invention relates to a paperboard container having a plurality of score lines thereon that permit the container to be collapsed upon application of manual force in specifically indicated locations.
2. Background Information
It is common to provide consumable liquids such as milk and juice in paperboard containers. During the manufacture of the containers, a combination of soft and hard woods are pulped, strained, and pressed into sheets of paperboard. A suitable type of waterproofing material, such as a polyethylene film, is applied to one or both sides of the paperboard. The paperboard is die cut into blanks that are shipped to the dairy or juice manufacturer for filling. At the factory, the blanks are assembled into cartons and are filled with milk or juice. Typically, most of these paperboard containers are thrown away after consumption of the liquids there. Many consumers are unaware of the fact that this type of container is recyclable. Even for those consumers who are aware of the recyclability of these products, disposal of the same is problematic because of the large quantity of empty space the containers occupy in recycling bins. Unlike plastic bottles, which can be somewhat crushed by hand, paperboard milk and juice containers are quite strong and rigid structures that do not crush easily.
There is therefore a need in the art for a collapsible paperboard container that can quickly and easily be collapsed to a reduced size.
SUMMARY OF THE INVENTION
The device of the present invention comprises a collapsible paperboard container and a blank for constructing the same. The container has a bottom wall with a peripheral wall extending upwardly therefrom. A plurality of score lines are provided in the peripheral wall which facilitate movement of this wall from an expanded position to a collapsed position in response to a manual force being applied thereto to cause a first portion of the wall to move toward a second portion thereof. Visual indicators are provided on the container to identify to the consumer where and how to apply manual force to the peripheral wall.
The blank is an improved blank for forming a gable-top paperboard container. The blank is a substantially rectangular sheet of paperboard having a longitudinal axis and a horizontal axis with opposing first and second edges disposed substantially parallel to the horizontal axis and first and second ends disposed substantially parallel to the longitudinal axis, Three longitudinally oriented, spaced apart fold lines are stamped into the sheet and extend between the first and second edges thereby dividing the sheet into four longitudinal panels disposed in a side-by-side horizontal arrangement. Four horizontally oriented fold lines extend between the first and second ends with a first fold line disposed proximate the first end and a second fold line disposed proximate the second end. A third of the horizontal fold line is disposed spaced approximately one quarter of the distance between the first and second ends and adjacent the first fold line; and the fourth horizontal fold line is disposed approximately one quarter of the distance between the first and second ends and adjacent the second fold line. The improved blank further includes a plurality of score lines stamped into the sheet at locations other than on the fold lines. The score lines are provided as lines of weakness to effect collapse of a container produced using the blank upon application of manual force. The blank further includes a plurality of visual indicators one of a front and back surfaces of the blank. These visual indicators are suggestive of areas where manual force should be applied in order to effect collapse of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a perspective view of a paperboard container in accordance with the present invention and shown in the expanded position;
FIG. 2 is a front elevational view of the container of FIG. 1 showing some of the visual indicators thereon;
FIG. 3 is a side elevational view of the container showing other of the visual indicators and showing some of the score lines about which the container is collapsible;
FIG. 4 is a perspective view of the container shown laying on its back to show yet other of the visual indicators thereon;
FIG. 5 is a bottom view of the container of FIG. 1 showing one of the visual indicators thereon together with the instructions as to how to fold the carton imprinted thereon;
FIG. 6 is a plan view of a blank of a Prior Art paperboard container showing an interior surface and the fold lines formed therein that are used for folding the blank to construct the container;
FIG. 7
a is a plan view of a blank in accordance with the present invention, showing an interior surface thereof and the fold lines formed therein that are used for folding the blank to construct the container, as well as the score lines that are used for collapsing the container once the contents of the container have been removed therefrom;
FIG. 7
b is a plan view of a blank of FIG. 7a, showing an exterior surface thereof and the visual indicators that are provided for suggesting where and how to apply manual force to the container constructed therefrom in order to collapse the same;
FIG. 8 is a side perspective view of the container showing a person holding the carton and applying fingertip pressure to a first group of the visual indicators to begin the collapse of the container of the bottom and side portions of the containers about the score lines;
FIG. 9 is a side perspective view of the container showing the bottom thereof being folded onto the front of the container by applying of fingertip pressure to a second group of visual indicators;
FIG. 10 is a side perspective view of the container showing application of fingertip pressure to the front of the carton to collapse the front thereof onto the back thereof; and
FIG. 11 is a side perspective view of the container showing the container in a fully collapsed position.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-5 show a collapsible paperboard container in accordance with the present invention and generally indicated at 10. Container 10 is designed to retain any suitable substance therein and that substance may include consumable liquids such as milk or juice. Container 10 has the general appearance of what is known in the industry as a gable-topped carton because of the distinctive pattern of the upper end of the container. FIG. 6 shows a blank used in the Prior Art for forming a gable-topped carton. FIG. 7 shows a blank used to form the gable-topped container 10 in accordance with the present invention. FIGS. 8-11 illustrate how container 10 is collapsed after all the contents retained therein have been removed.
Container 10 of the present invention includes a bottom wall 12 (FIG. 4), and a peripheral wall that is integral with the bottom wall 12 and extends upwardly away therefrom. The peripheral wall is comprised of a front panel 14, a pair of opposed side panels 16,18 and a back panel 20. Bottom wall 12 and front, back and side panels 14-20 surround and define an interior chamber 22. Chamber 22 is accessible through an opening in the top end of the peripheral wall. An uppermost portion of each of front panel 14, side panels 16, 18 and back panel 20 is folded inwardly toward a central region to and these uppermost portions are heat sealed together in such a manner as to form the distinctive shape of a gable-topped carton. In the exemplary embodiment, access is provided into interior chamber 22 via an opening 24 defined in front panel 14. A plastic pour spout 26 is secured to front panel 14 and surrounds opening 24. Spout 26 enables a consumer to more easily pour the contents out of container 10. Although not shown in the drawings, a removable seal is engaged in spout 26 immediately after introducing the substance into chamber 22. This ensure that none of the contents of container 10 are accidentally spilled during transport. A removable cap (not shown) is also provided for threadable engagement with spout 26. The seal is removed by the consumer after purchase and the cap is used to retain the contents within the container after that time.
In accordance with the present invention, container 10 is designed to be collapsible from an expanded position (FIGS. 1-5) to a collapsed position (FIG. 11) by the application of manual force, specifically by the application of fingertip applied pressure. In the expanded position the container 10 is able to hold a quantity of a substance in its interior chamber 22. When the contents of container 10 have been poured out of spout 26, container 10 may be collapsed so that it is of a reduced volume and therefore occupies substantially less space for either disposal in the garbage or placement in a household recycling container. The internal volume of container 10 is diminished by approximately 75% by moving container 10 from the expanded position (FIG. 1) to the collapsed position (FIG. 11).
In the expanded position, shown in FIGS. 1-5, container 10 is of a height H1 from the sealed tip 28 down to bottom wall 12. Container 10 is further of a width W1 measured between side panel 16 and side panel 18, and is of a depth D1 measured between front panel 14 and back panel 20. Front panel 14, side panels 16, 18 and back panel 20 all have a first section 14a, 16a, 18a and 20a that is of a second height H2 (FIG. 2) that is less than H1. A second section of each panel 14b, 18b and 20b is folded so as to angle inwardly toward each other and to form a top end of container 10. It will be understood that a second section of side panel 16 angles inwardly toward second section 18b of side panel 18 but is not illustrated in the attached drawings.
FIG. 6 shows the Prior Art blank that is identified by the reference character A. Blank A is die cut from a roll of paperboard that has been coated on both its interior and exterior surfaces with one or more layers of a waterproof plastic such as polyethylene. During manufacture, the paperboard has also had graphic material printed on one side thereof. A die cuts a plurality of blanks A from the roll and, at the same time, stamps a pattern of fold lines B into each blank A, effectively dividing the blank into four panels E1-E4. In FIG. 6, the fold lines B are represented by a plurality of dots. An opening F for a spout is cut into one of the panels, such as E3. The plastic spout (not shown) is inserted and secured in a manner known in the art. The blanks are fed through a sealing machine that folds them laterally along one or two of the fold lines B and creates an overlap between the free end C and the flap D. The overlapped area is heated and squeezed together. The polyethylene in this region melts and bonds the free end C and flap D together, creating a waterproof seam. The blanks are then flattened and shipped to the product manufacturer, such as a dairy or juice production plant. At this location, the flattened blanks A are placed into machinery that opens the blank A, folds a bottom portion F1-F4 of the panels E1-E4 inwardly toward each other and heat seals the same together. Tabs H2 and H4 are also overlapped with portions of the panels E1-E4 during this process and this heat sealed region becomes the bottom wall for the carton. The assembled cartons are then moved to a filling machine that places a pre-measured quantity of milk or juice into the interior. The filled cartons are moved into a sealing machine that folds an upper portion G1-G4 of the panels E1-E4 toward each other and overlapping tabs H1 and H3 in such a way as to form the gable-top shape shown in FIG. 1. The sealing machine heats and compresses the appropriate regions of the gable-top to seal the carton.
FIGS. 7
a and 7b show a blank 60 in accordance with the present invention. Blank 60 is used to manufacture a gable-top container 10 that is collapsible after the contents it carries have been removed. Blank 60 is of generally of the same overall appearance as the blank A of the Prior Art in that it is generally rectangular in shape and has a plurality of fold lines 62 formed therein. Blank 60 has a longitudinal axis “Y” and a horizontal axis “X”. Blank 60 further has first and second edges 61, 63 and first and second ends 65, 67. Fold lines 62 are located in substantially the same locations on blank 60 as fold lines B are located on blank A. Fold lines 62 are, once again, represented in this figure by a plurality of dots to indicate that they are substantially identically located and of like nature to the previously known fold lines B made in prior art blank A. Blank 60 is also defined, by fold lines 62, into four, generally rectangular panels. These panels will ultimately form the front panel, back panel and side panels of container 10 and are therefore identified in FIG. 7 as panels 14, 16, 18, and 20, respectively. Panel 14 defines opening 24 therein that spout 26 will be secured into the same manner as opening F and the associated spout would be provided on blank A. A plurality of tabs 71 and the flap 73 are provided on blank 60 to assist in effectively bonding and sealing container 10 during manufacture as was described with reference to Prior Art blank A.
However, in accordance with the present invention, blank 60 differs from the Prior Art blank A in that it also includes a plurality of score lines 64 that are stamped into the blank during manufacture. To differentiate between fold lines 62 and score lines 64, the latter are represented in FIG. 7 by a plurality of dashes. Score lines 64 are stamped into the blank 60 at specific locations that will enable container 10 to be collapsed when empty. Score lines 64 may be stamped into the interior surface 60a of blank 60 or into the exterior surface 62b thereof, or into both of the interior and exterior surfaces 60a, 60b as is needed for correct folding of the container 10 as will be hereinafter described. Each score line 64 is a shallow depression that preferably is semi-circular in cross-sectional shape and acts as a zone on the panels 14-20 that permits folding of the panel thereabout. It should be noted that none of score lines 64 fall in the same locations as fold lines 62 and, consequently, none of score lines 64 are used for folding the blank 60 into the gable-top shape during construction of the container 10.
Referring to FIGS. 1, 2, 7a and 7b, a first score line 64a is provided on section 14a of front panel 14. Container 10 has a longitudinal axis “Y” (FIG. 2) and first score line 64a is disposed at right angles to said longitudinal axis “Y” and therefore substantially parallel to bottom wall 12 of container 10 when container 10 is in a fully expanded position. First score line 64a is positioned approximately one quarter of the way up section 14a from bottom wall 12 and toward a sealed tip 28 of container 10. Each end of first score line 64a preferably is spaced slightly inwardly away from fold lines 62a, 62b that ultimately form the folded edges 68, 70 of front panel 14.
Still referring to FIGS. 1, 7a and 7b, a second score line 64b is provided on each of side panels 16 and 18. The following description is directed to side panel 18, but it will be understood that it applies equally to side panel 16. Second score line 64b comprises a substantially upside-down Y-shaped member having a first arm 72, a second arm first arm 72 and a third arm 76. Referring to FIG. 7, first arm 72 extends generally along a centerline of side panel 18 substantially parallel to the longitudinal axis “Y” of container. First arm originates proximate fold line 62c, extends through fold line 62d and terminates at a point 80. Point 80 is disposed approximately one quarter of the length of the portion 18a of side panel 18 as measured between a fold line 62e and fold line 62d. Fold line 62e is that region of the panel that will constitute a bottom side edge 82 (FIG. 1) of container 10. Second arm 74 extends inwardly from the intersection point of fold lines 62b, 62e, that will become front bottom corner 84 of container 10, and toward point 80. Second arm 74 preferably is disposed at an angle of 45 degrees relative to fold line 62e. Third arm 76 extends inwardly from the intersection of fold lines 62e and 62f, that will become back bottom corner 86 of container 10, and toward point 80. Third arm 74 preferably is disposed at an angle of 45 degrees relative to fold line 62e. Thus, first, second and third arms 72, 74, 76 of score line 64b intersect at point 80.
A third score line 64c is provided on each of side panels 16, 18. Third score-line 64c extends outwardly from intersection point 80 of first, second and third arms 72, 74, 76 of second score line 64b and toward first score line 64a. Third score line 64 is disposed substantially parallel to bottom wall 12 when container 10 is in the expanded position. Furthermore, third score line 64c is substantially co-linear with first score line 64a. An end of third score line 64c is disposed slightly inwardly from the respective one of fold lines 62a and 62b. Thus, third score line 64c is spaced slightly inwardly away from the associated front edges 68, 70 of container. The lack of a score line intersecting front edges 68, 70 helps container 10 maintain its integrity when full. If the score lines 64 did intersect the fold lines in locations like front edges 68, 70, the regions of intersection might become weakened and lead to the container leaking.
A plurality of fourth score lines 64d, 64e, 64f and 64g are provided on each of side panels 16, 18 proximate the outermost end thereof remote from bottom wall 12. Each of the fourth score lines 64d-64g is substantially V-shaped and comprises a first leg 84 and a second leg 86 that intersect at an apex 88. The apex 88 of each of the fourth score lines intersects fold line 62d. Each fourth score line originates proximate a first region of the first arm 72 of first score line 64b that is intermediate bottom wall 12 and fold line 62d and terminates proximate a second region of first arm 72 that is intermediate fold line 62d and fold line 62c. The first region of first arm 72 is positioned about one quarter of the length of panel 18a inwardly from fold line 62d. Fourth score lines 64e and 64f are shallower V-shapes than are fourth score lines 64d and 64g. Each leg 84 is disposed at a different angle relative to first arm 72 of second score line 64b and first legs 84 radiate outwardly away from second score line 64b in such a manner that first arm 72 and first legs 84 form a generally Y-shaped pattern. None of fourth score lines 64d-g intersect first arm 72 but it will be understood that they could, in fact, do so.
In addition to the score lines 64a-64g, blank 60 of the present invention further differs from the Prior Art blank A in that a plurality of visual indicators 66 are provided on the exterior surface 60b thereof. Visual indicators 66 are provided for two reasons. Firstly, they attract the consumer's attention and, when investigated by reading the bottom wall, teach the consumer that the container 10 may be recycled. Secondly, they teach that the container is collapsible for the purposes of either recycling or disposal. Thirdly, they provide specific instruction on how to collapse the container 10.
Visual indicators 66 are provided to suggest to the consumer that they may apply pressure to container 10 to move it from an expanded position to a collapse position. Visual indicators 66 identify regions on the container 10 where a consumer should apply fingertip pressure in order to collapse the container 10 when empty. Application of fingertip pressure in these particularly indicated regions will cause one of the panels in the peripheral wall to move toward one of the other panels, thereby altering the dimensions of the container. It should be noted that movement of the container 10 from an expanded position to a collapsed position is effected without breaking any of the seals that were formed during production of the container. So, for example, the seam formed by overlapping and heat sealing a portion of back panel 20 with side panel 18 is unaffected by the collapse. There is therefor no need for the consumer to “break down” the emptied container 10 by opening any of those heat sealed seams before collapsing the container.
Visual indicators 66 can be of any nature that is readily understandable by the consumer. So, as illustrated in FIGS. 1-5 for example, a first group of visual indicators 66a includes a graphic of the number “1”, a second group 66b includes a graphic of the number “2” and a third group 66c includes a graphic of the number “3”. These characters indicate in what order pressure should be applied to container 10. The visual indicators 66 are made further understandable by provision of a fourth visual indicator 66d that is imprinted on a portion of one or more of the regions of the panels 14-20 that will form the bottom wall 12 of container 10. The visual indicator 66d on these portions is a printed detailed instruction panel that visually and textually shows the consumer how to hold container 10 and how to collapse the same once empty by applying pressure in certain locations.
Container 10 is expanded to receive and retain a substance therein, such as juice or milk, in substantially the same manner as gable-topped cartons manufactured from the prior art blank A. However, container 10 is, unlike the prior art cartons, able to be collapsed when empty so as to occupy a smaller volume of space for disposal or recycling purposes. Container 10 is collapsed, once chamber 22 is emptied of its contents, in the manner illustrated in FIGS. 8 through 11. Firstly, if container 10 is as shown in FIGS. 1-5, the cap (not shown) that is used to seal spout 26 is removed and disposed or recycled separately. The container 10 is then placed on a flat and preferably rigid surface so that back panel 20 abuts this surface. The consumer then places a thumb 90 on each of the visual indicators 66a on front panel 14 and an index finger 92 on each of the visual indicators 66a on side panels 16, 18. The consumer applies downward and inward pressure on panels 14, 16 and 18, respectfully, by way of their thumbs 90 and index fingers 92. This pressure causes front panel 14 to fold about first score line 64a and move inwardly toward the interior of back panel 20. Additionally, the pressure causes the lower regions of side panels 16, 18 to begin to fold inwardly along second score lines 64b and toward each other. At this point, side panels 16, 18 are no longer orthogonal to bottom wall 12 as was the case when container 10 was fully expanded. Furthermore, the bottom front edge 94 of front panel 14 moves upwardly toward top front edge 96 of front panel 14 so that the distance between these two locations is reduced, This may be seen in FIG. 9. The consumer then applies pressure to the bottom wall in the region of the second visual indicator 66b by pushing downwardly on indicator 66b. This causes front panel 14 to fold about first score line 64a so that a first portion of the exterior surface of front panel 14 abuts a second portion of the exterior surface of front panel 14 (FIG. 10). The consumer then applies finger pressure to container 10 in the region of the third visual indicator 66c and pushes downwardly on the upper portion of front panel proximate edge 96. This pressure causes side panels 16, 18 to fold about score lines 64d-g from the position shown in FIG. 10 to the position shown in FIG. 11.
As is clearly evident from FIGS. 3 and 11, the depth of container 10 changes dramatically from D1 in an expanded position, to D2 in a collapsed position. D2 is substantially smaller than D1. The width W1 of the container remains substantially unchanged as does the height H1 thereof. Consequently, the overall volume, which is calculated as height×depth×width, is greatly reduced when container 10 is collapsed. It is estimated that the volume of the collapsed container is reduced by approximately 75% from that of the expanded container. The lower profile and substantially flattened container is more readily disposed of in either of a garbage container or a recycling container.
It will be understood that while container 10 is shown to have an opening 24 and spout 26 in front panel 14, container 10 may, alternatively, be provided without the opening 24, the spout 26 and the associated seal and cap, and may, instead, be opened by pulling outwardly on the side edges 14a, 20a (FIG. 1) of front and back panels 14, 20 to break the seal between the two and permit the upper portion of side panel 18 to be pulled outwardly into a position where it forms a spout for dispensing the liquid from chamber 22.
It should be noted that the score lines 64 are provided in locations that permit container 10 to be collapsed only in a single direction, i.e., the front panel 14 being pushed downwardly onto the interior surface of the back panel 20, with the side panels 16, 18 being folded thereinbetween. While it would be possible to provide score lines that would permit collapse in a variety of different directions, the quantity and placement of the visual indicators 66 that would be have to be provided to show the consumer how to effect these collapses, would be excessively complicated. This would likely cause the average consumer to be temporarily overwhelmed and therefore less likely to try and collapse the container.
It will further be understood that while the container 10 is shown as collapsing so that the front panel folds onto the back panel with the side panels being captured thereinbetween, container 10 may be collapsed in any one direction without departing from the spirit of the present invention.
It will still further be understood that while a gable-top container is illustrated as embodying the present invention, other shaped paperboard containers could be provided with appropriate score lines and visual indicators to aid in collapsing those containers to reduce their overall volume for recycling or disposal. So, for example, a container such as a juice box that is substantially rectangular in shape, could be provided with appropriate score lines and visual indicators that would enable it to be collapsed to reduce its overall volume.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
Patent Grant
8814034
