DISPLAY READY CARTON

Abstract

Disclosed is a display ready carton that can be converted from a shipping container to a display container without the use of tools in an efficient and reliable manner. The carton, and blanks for preparing the same, generally comprise a plurality of panels formed integrally from a sheet of material with one of the panels having a tear-out panel disposed thereon. To display the contents of the carton at retail, the tear-out panel is removed by tearing the carton along lines of weakness disposed substantially along one panel of the carton. The tear-out panel may be integrally connected to a flap for sealing the top or bottom portion of the carton and the flap may also be removed when removing the tear-out panel such that the carton contents are accessible from two faces.

Description

BACKGROUND

Products for sale at retail such as packaged food and consumer goods are commonly shipped and stored in cardboard cartons. The products are often subsequently removed from the carton and placed on a shelf for display and sale. This process requires the retailer to expend time and labor, increasing its costs. To eliminate the removal and shelving of individual products, display ready cartons have been proposed. For example, U.S. Publication No. 2005/0184139A1 to Gasior discloses a cubic container for shipping and displaying goods having a first tear seam along a lower portion of the front panel, which extends upward at an angle across side flaps attached to the front panel. A second tear seam is formed at a fold line between the top panel and back panel, which permits the top panel, a portion of the front panel, and portions of front side flaps to be removed for forming the display case. While such cartons allow for the shipping and display of goods in a single container, they are difficult to open because the tear seams extend across multiple panels and a large portion of the carton is removed leaving the contents unsupported.

Another display ready carton is disclosed in U.S. Pat. No. 5,167,324 to Miller. The carton, which is designed for the shipping tubes and can be converted without the use of tools, includes a tear strip along a mid-portion of the front and side walls, and a score along a mid-portion of the back wall. When the tear strip is removed, the score is readily broken, and the top portion is removed to display tubes contained within the carton. Like Gasior, Miller fails to provide stored goods with support along all sides of the carton once opened and requires the user to tear along multiple faces of the carton to create the opening. Accordingly, a need exists for an improved display ready case and blank for forming the same.

SUMMARY

The present invention discloses a carton for shipping and storing goods, particularly packaged consumer products such as disposable wearable absorbent articles, beauty care products, household items such as wipes and scrubbers for cleaning and family care products such as facial tissue, bath tissue and disposable towels. The carton of the present invention is readily converted to a display case and may be placed directly upon a retailer shelf to be shopped by the consumer. The carton includes a removable portion, generally disposed on the front panel, that allows the carton to be readily converted from a shipping container to a dispensing container. The removable portion, generally referred to herein as a tear-out panel, is defined by several lines of weakness, two of which are generally arranged perpendicular to one another to facilitate easy removal of a portion of the carton front panel to access the carton contents. While removal of the tear-out panel opens the case and provides access to the carton contents, the carton sidewalls and a portion of the front wall remain substantially intact to support and retain the contents.

Accordingly, in one embodiment, the present invention provides a substantially cubic carton having a bottom wall, a top wall, opposite first and second side walls and opposite front and back walls defining an interior portion for storing and displaying packaged consumer goods, the carton comprising: a plurality of integrally connected panels separated from one another by a fold line and defining a back panel, a front panel, and first and second side panels; a first closure flap integrally connected to the front panel; and a tear-out panel disposed in a continuous portion of the front panel and defined by first and second laterally extending lines of weakness and a longitudinally extending line of weakness extending across the front panel between the first and second laterally extending lines of weakness; wherein removal of the tear-out panel by a user removes a portion of the front panel and the first closure flap allowing access to an interior portion of the carton from at least a portion of the front and top walls of the carton.

In another embodiment, the present invention provides a carton for shipping and displaying a plurality of packaged consumer goods having a top and a front face, the carton comprising: a front panel; a right side panel integrally connected to the front panel and separated therefrom by a first laterally extending fold line; a left side panel integrally connected to the front panel and separated therefrom by a second laterally extending fold line; a top flap integrally connected to the front panel; and first and second laterally extending lines of weakness extending at least partially along the first and second laterally extending fold lines respectively, and a longitudinally extending line of weakness disposed on the front panel and extending continuously between the first and second laterally disposed lines of weakness, the laterally and longitudinally extending lines of weakness defining a tear-out panel therebetween; wherein removal of the tear-out panel by a user removes a portion of the front panel and the first flap allowing access to the packaged consumer goods from at least the front and top faces of the carton.

In yet another embodiment, the present invention provides a carton blank comprising: a front panel and an integrally connected major top flap; a right side panel and an integrally connected first minor top flap; a left side panel and an integrally connected second minor top flap; a tear-out panel disposed on the front panel and bounded by first and second laterally extending lines of weakness, and a longitudinally extending line of weakness; wherein first and second notches are formed between the major top flap and first and second minor flaps respectively, and wherein the first and second laterally extending lines of weakness extend from the first and second notches respectively to the longitudinally extending line of weakness.

DESCRIPTION OF THE FIGURES

FIG. 1 is a top plan view of a carton blank useful in constructing a display ready carton according to the present invention;

FIG. 2 is a perspective view of a display ready carton according to the present invention;

FIG. 3 is a perspective view of a display ready carton in an open configuration according to the present invention; and

FIG. 4 is a perspective view of a display ready carton in an open configuration according to the present invention.

DETAILED DESCRIPTION

A carton is disclosed, particularly a carton for storing and displaying packages of consumer goods at retail. The carton is generally formed from a blank comprising a plurality of panels integrally formed from a sheet of material. The plurality of panels define a top, bottom, longitudinally opposite first and second side walls, and laterally opposite front and back walls when the carton is erected from the blank. One or more flaps may be coupled to an edge of one or more of the panels, the flaps being foldable and fixable to form a top or bottom of the carton. To display the contents of the carton at retail a portion of the carton is removed prior to placing the carton on a shelf or display. The portion of the carton that is removed prior to display is generally referred to as a tear-out panel and is preferably integrally connected to a portion of the carton, preferably along a single panel of the carton, such as the front panel of the carton. While the tear-out panel may be integrally connected to the front panel, one skilled in the art will appreciate that cartons falling within the scope of the present invention may have a tear-out panel integrally connected to any one of the laterally extending panels, such as the front, back, or one of the two side panels.

In those instances where the carton comprises flaps in addition to the laterally extending panels, which form the front, back and side walls of the carton, the flaps may be folded to form the carton top and bottom walls. In certain embodiments, the carton top and bottom walls are formed by closure flaps integrally connected to each of the laterally extending panels. In a particularly preferred embodiment, a closure flap may extend continuously from a front panel having a tear-out panel disposed thereon. In such instances removal of the tear-out panel by a user removes a portion of the carton front wall as well as a portion of the top wall. In this manner, removal of the tear-out panel also removes the integrally connected closure flap and opens the carton on two faces to facilitate ready access to its contents.

In a particularly preferred embodiment, the closure flaps comprise a pair of substantially rectangular shaped flaps extending from side edges of the front and back panels. The free edges of the two substantially rectangular flaps may be disposed in substantially parallel, adjacent relation to one another and brought together to close and seal the top of the carton. The closure flaps may be maintained in their substantially closed position by a tape closure member affixedly connecting the two flaps. In certain embodiments it may be preferably not to affix the flaps to any other panel of the carton, such as by an adhesive, to facilitate removal of one of the flaps when the tear-out panel is removed, and the carton is opened for display and dispensing.

The tear-out panel is generally configured and joined to the sheet at a weakened line so as to be removable by a user without the use of tools. The lines of weakness may be arranged to facilitate easy removal of the tear-out panel and to form an opening in at least one of the laterally extending carton panels and more preferably along a laterally extending panel and the carton top or bottom face. In a particularly preferred embodiment, the opening is formed by removal of a portion of the front panel and a closure flap extending continuously therefrom.

In certain preferred embodiments the lines of weakness surrounding and defining the tear-out panel extend substantially longitudinally and laterally relative to the carton dimensions so as to promote ergonomic and efficient opening of the carton with minimal effort and without tearing of the panels. In a particularly preferred embodiment, the tear-out panel is defined at least partially by a pair of spaced apart laterally extending lines of weakness that are substantially parallel to one another. The laterally extending and spaced apart lines of weakness may be disposed on a portion of the front panel or along the fold line between the front panel and a pair of foldably connected side panels.

While the laterally extending and spaced apart lines of weakness may be disposed along the fold lines that separate the front panel from the opposed side panels, in other embodiments, they may be disposed along the front panel. In those instances where the weakened line joining the tear-out panel to the sheet is spaced from at least one fold at the perimeter of the front panel, a marginal part of the front panel remains in place when the tear-out panel has been removed. Regardless of whether the lines of weakness are disposed along a lateral fold line or on the front panels, it is generally preferred however, that the lines of weakness are arranged such that the side panels remain substantially intact when the tear-out panel is removed by a user and the carton is opened. In this manner it may be preferable that the side panels be substantially free from any lines of weakness.

In addition to the laterally extending and spaced apart lines of weakness, the carton further comprises a longitudinally extending line of weakness disposed on the front panel and defining a portion of the tear-out panel. The longitudinally disposed line of weakness generally extends across the front panel between the first and second laterally disposed lines of weakness and together the longitudinally and laterally extending fold lines define a portion of the tear-out panel perimeter. Preferably however, the longitudinally extending line of weakness extends only along the front panel and does not extend along either of the side panels. In this manner, when the tear-out panel is separated from the carton by a user tearing along the lines of weakness the side panels remain substantially intact and the carton is accessible via the front panel.

When the tear-out panel is removed the carton still provides support to the carton contents such that they can be stored and displayed in the now open carton. It is generally preferable that the carton contents are laterally supported along the full carton height by the back panel and first and second side panels. Lateral support is provided along the full carton width by the pair of opposed side panels. Further lateral support is provided to a portion of the carton contents, generally a portion that is less than the full height of the carton, by the portion of the front panel that remains intact after removal of the tear-out panel.

In this description, terms concerning relative directions and positions such as “lateral”, “longitudinal”, “left”, “right”, “up”, “down”, “top”, and “bottom”, etc., or “top”, “bottom”, “front”, “rear” and “side”, etc., whether used as nouns, adjectives or adverbs, refer to the orientation of the carton of the present invention or the relative position of panels as the carton is illustrated in the particular drawing figure under discussion. The carton of the invention can be placed in any orientation such as resting on its top, bottom, side, end, or the like, and the respective tear-out panels can likewise be located in any of the panels, provided that the carton meets the claims defining the invention when in at least one corresponding orientation. In short, terms of relative position and orientation are not intended to limit the invention to a particular orientation.

The term “connected” when used to describe the relationship between two or more structures, means that such structures are secured or attached either directly or indirectly through intervening structures and include movable connections such as pivoting connections as well as creases, perforation lines, score lines, and the like. The term “integral” or “integrally connected” when used to describe the relationship between two or more structures means that the structures are parts of a single piece of material but does not exclude a line of weakness such as perforations, scores, or other subdivisions.

Lines representing fold lines are shown in the drawings by broken and solid lines that represent lines along which the material can be weakened or caused preferentially to fold by any of various means. For example, corrugated or other material can be compressed along a thin line defining a fold, or can be cut part way through along the line, or cut all or part way through the line, or cut all or part way through at spaced intervals, forming preferential fold lines in the knocked-down flat (“KDF”) blank and/or in the erected carton.

With reference now to the figures, one embodiment of a blank 10 for forming a carton of the present invention is illustrated in FIG. 1. The blank 10 has lateral 11 and longitudinal 13 dimensions and includes a front panel 12, two side panels 14 and 16, and back panel 18. The panels are generally rectangular in shape and may be folded together to form a substantially cubic carton. The blank 10 is preferably fabricated from corrugated paperboard, and a preferred direction for the flutes of the corrugation is laterally 11, as blank 10 is viewed in FIG. 1.

Each of the first and second side panels 14 and 16 include a pair of flaps, 20, 21 and 22, 23 respectively, extending from panel end edges 24, 25, 26, 27. In the illustrated embodiment the flaps 20, 21, 22, 23 are minor flaps in that they do not completely close the carton when folded together, however, the invention is not so limited. In certain embodiments, such as illustrated in FIG. 1, the top pair of flaps 20, 22 may be shaped such that only two sides are parallel to one another while the shape of the bottom pair of flaps 21, 23 may be substantially rectangular. In certain instances, it may be preferable that the top of pair of flaps be shaped so as to increase the surface area of product that is exposed when the carton is opened by removing the tear-out panel.

With continued reference to FIG. 1, the blank 10 includes front and back panels 12 and 18. Each of the front and back panels 12 and 18 include a pair of flaps, 30, 31 and 32, 33 respectively, extending from end edges 34, 35, 36, 37. In the illustrated embodiment the flaps 30, 31 and 32, 33 are major flaps in that they substantially close the carton when folded together, however, the invention is not so limited. In certain instances, the top two flaps 30, 32 may be folded and joined in abutment and taped together to seal the carton, while the bottom two flaps 31, 33 may be folded and adhesively adhered to bottom minor flaps 21, 23 which they overlay when folded. In still other embodiments the top and bottom of the carton may be formed by folding together the top flaps 30, 32 and bottom flaps 31, 33 in abutment and taping the flaps together without the use of adhesive disposed between the major and minor flaps.

As further illustrated in FIG. 1, the blank 10 comprises a tear-out panel 50 disposed substantially along a portion of the front panel 12. The tear-out panel 50 is configured to be removable from the blank 10 by tearing a plurality of lines of weakness 52, 54, 56 disposed about a portion of its perimeter. Preferably the lines of weakness extend substantially longitudinally and laterally relative to the carton so as to promote ergonomics and efficient opening of the carton with minimal effort and without tearing of the panels. In a particularly preferred embodiment, such as the blank 10 illustrated in FIG. 1, the tear-out panel 50 is defined at least partially by a pair of spaced apart laterally extending lines of weakness 52, 54 that are substantially parallel to one another. The laterally extending and spaced apart lines of weakness 52, 54 are disposed along the fold lines separating the front panel 12 and a pair of foldably connected side panels 14, 16.

In a particularly preferred embodiment, such as illustrated in FIG. 1, the laterally extending lines of weakness 52, 54 extend along the fold lines 57, 59 separating the front panel 12 and side panels 14, 16 and terminate at first and second flap slots 60, 62 separating minor flaps 20, 22 from major flap 30. In the illustrated embodiment however, the laterally extending lines of weakness 52, 54 do not extend along the entirety of the fold lines 57, 59, but rather along only a portion thereof such that a portion of the front panel 12 remains intact when the tear-out panel 50 is removed.

While the laterally extending and spaced apart lines of weakness may be disposed along the fold lines that separate the front panel from the opposed side panels, in certain embodiments, they may be disposed along the front panel. It is generally preferred however, that the laterally extending and spaced apart lines of weakness are disposed such that the side panels remain substantially intact when the carton is opened by a user.

In addition to the laterally extending and spaced apart lines of weakness 52, 54 the carton blank 10 further comprises a longitudinally extending line of weakness 56 disposed on the front panel 12 and defining a bottom portion of the tear-out panel 50 perimeter. The longitudinally disposed line of weakness 56 generally extends across the front panel 12 between the first and second laterally disposed lines of weakness 52, 54 and together the longitudinally and laterally extending fold lines 52, 54, 56 define a portion of the tear-out panel 50 perimeter. In certain instances it may be preferable not to extend the longitudinal line of weakness 56 beyond the lateral lines of weakness 52, 54 and further that the longitudinal line of weakness 56 does not extend along either of the side panels 14, 16. In this manner, when the tear-out panel is separated from the carton by a user tearing along the lines of weakness the side panels remain substantially intact and the carton is accessible via the front panel.

In certain embodiments the blank may further comprise a cut-out handle formed in front panel along longitudinally extending line of weakness. A line of weakness may surround the cut-out handle such that a user completely removes carton material within the cut line to form the handle. A portion of carton material, however, may optionally remain to permit carton material within the handle to be folded from the front panel. In other instances, the portion of the carton material within the cut line surrounding the handle may be removed as part of fabricating the carton to make it quicker and easier for a user to grasp the handle and remove the tear-out panel.

With reference now to FIG. 2 a carton 100 according to one embodiment of the present invention is illustrated. In the illustrated embodiment the carton top wall 102, first side wall 104 and front wall 106 are visible and the carton 100 has an overall cubic shape. The front wall 106 is formed by a folded front panel 110 and has a tear-out panel 112 disposed thereon. The tear-out panel 112 is separable from the front panel 110 by tearing along lines of weakness 113, 114, 115 disposed about its perimeter. The front panel 110 further comprises a cut-out handle 120 formed in front panel 110 and positioned below the longitudinally extending line of weakness 114.

The lines of weakness 113, 114, 115 generally consist of a pair of laterally extending and spaced apart lines of weakness 113, 115 and a longitudinally extending line of weakness 114 that extends between the first and second laterally disposed lines of weakness 113, 115. In certain preferred embodiments, such as illustrated in FIG. 2, the longitudinally extending line of weakness 114 intersects the laterally extending and spaced apart lines of weakness 113, 115 at substantially 90 degrees. In this manner, the longitudinally extending line of weakness 114 is substantially parallel to the front panel top edge 124, and the laterally extending lines of weakness 113, 115 are substantially parallel to the front panel side edges 125, 126, which are formed along the fold line between the front panel and first and second side panels respectively.

The carton top wall 102 is formed by a pair of substantially rectangular closure flaps 121, 122 extending from top edges 123, 124 of the front and back panels. The edges of the closure flaps 121, 122 abut one another and may be joined together with tape to close and seal the top of the carton. When the tear-out panel 112 is removed from the carton 100 by tearing along lines of weakness 113, 114 closure flap 122 is also removed, allowing the contents of the carton to be accessed from two faces of the carton, as will be discussed in more detailed below in reference to FIGS. 3 and 4.

FIGS. 3 and 4 show alternative embodiments of the carton 100 in an open configuration with the tear-out panel and a first closure flap removed. The carton contents 150 are accessible via both the top face 102 and front face 106 of the carton 100. The second closure flap 121 remains intact, as does a portion of the front panel 110 and the entirety of the side panels (left side panel 104 shown in the figures). Further, with the tear-out panel removed first and second minor flaps 151, 152 are now visible and form a portion of the carton top 102 to store and retain the contents 150.

With continued reference to FIGS. 3 and 4, when the carton 100 is opened by removal of the tear-out panel and a first closure flap removed, the carton contents 150 remain surrounded by at least a portion of the carton panels or flaps that form each wall—top, bottom, front, back, left and right side wall—of the carton. For example, with reference to FIG. 3 the carton top face 102 consists of a major flap 121 and a pair of minor flaps 151, 152 that at least partially surround the carton contents 150. A portion of the contents, however, are accessible through the top face as a result of a major flap being removed along with the tear-out panel. A portion of the front panel 110 also remains to secure and store the contents 150, despite a portion of it being removed with the tear-out panel. Finally, the carton side panels (left side panel 104 shown in FIG. 3) retain their full height even after removal of the tear-out panel. This lends additional support to the carton contents and maintains the integrity of the carton.

Claims

1. A substantially cubic carton having a bottom wall, a top wall, opposite first and second side walls, and opposite front and back walls, the carton walls defining an interior portion for storing and displaying packaged consumer goods, the carton comprising: a back panel, a front panel, and first and second side panels, the panels integrally connected and separated from one another by a fold line;a first closure flap integrally connected to the front panel; anda tear-out panel disposed in a continuous portion of the front panel and defined by first and second laterally extending lines of weakness and a longitudinally extending line of weakness extending across the front panel between the first and second laterally extending lines of weakness;wherein removal of the tear-out panel by a user removes a portion of the front panel and the first closure flap allowing access to an interior portion of the carton from at least a portion of the front and top walls of the carton.

2. The carton of claim 1 wherein the first and second laterally extending lines of weakness are disposed substantially along the fold line between the front panel and first and second side panels respectively.

3. The carton of claim 1 wherein the first and second laterally extending lines of weakness are disposed on the front panel.

4. The carton of claim 1 wherein the first and second side panels are substantially free from lines of weakness.

5. The carton of claim 1 wherein the first and second laterally extending lines of weakness are disposed at substantially right angles to the longitudinally extending line of weakness.

6. The carton of claim 1 wherein the front panel has a length dimension and a width dimension and the first and second laterally extending lines of weakness have a length less than the panel length dimension and the longitudinally extending line of weakness has a length substantially equal to the panel width dimension.

7. The carton of claim 1 further comprising a second closure flap integrally connected to the back panel.

8. The carton of claim 7 wherein the first and second closure flaps are each major flaps having a first free edge and the free edges are brought into abutment with one another to form a closed carton top wall.

9. The carton of claim 8 wherein the major flap free edges are joined together with tape.

10. The carton of claim 7 wherein the second closure flap remains intact after the tear-out panel is removed by a user.

11. The carton of claim 7 further comprising third and fourth opposing closure flaps integrally formed with the first and second side panels respectively.

12. The carton of claim 1 further comprising a notch disposed at a height below the longitudinally disposed line of weakness.

13. A carton for shipping and displaying a plurality of packaged consumer goods having a top and a front face, the carton comprising: a front panel;a right side panel integrally connected to the front panel and separated therefrom by a first laterally extending fold line;a left side panel integrally connected to the front panel and separated therefrom by a second laterally extending fold line;a top flap integrally connected to the front panel; andfirst and second laterally extending lines of weakness extending at least partially along the first and second laterally extending fold lines respectively, and a longitudinally extending line of weakness disposed on the front panel and extending continuously between the first and second laterally disposed lines of weakness, the laterally and longitudinally extending lines of weakness defining a tear-out panel therebetween;wherein removal of the tear-out panel by a user removes a portion of the front panel and the first flap allowing access to the packaged consumer goods from at least the front and top faces of the carton.

14. The carton of claim 13 wherein the right and left side panels are substantially free from lines of weakness.

15. The carton of claim 13 wherein the first and second laterally extending lines of weakness are disposed at substantially right angles to the longitudinally extending line of weakness.

16. The carton of claim 13 wherein the front panel has a length dimension and a width dimension and the first and second laterally extending lines of weakness have a length less than the panel length dimension and the longitudinally extending line of weakness has a length substantially equal to the panel width dimension.

17. The carton of claim 13 wherein upon removal of the tear-out panel the carton consists of a partially open top panel, full height left and right side panels, and partially open front panel.

18. A carton blank comprising: a front panel and an integrally connected major top flap;a right side panel and an integrally connected first minor top flap;a left side panel and an integrally connected second minor top flap;a tear-out panel disposed on the front panel and bounded by first and second laterally extending lines of weakness, and a longitudinally extending line of weakness;wherein first and second notches are formed between the major top flap and first and second minor flaps respectively and wherein the first and second laterally extending lines of weakness extend from the first and second notches respectively to the longitudinally extending line of weakness.

19. The carton blank of claim 18 wherein the right and left side panels are substantially free from lines of weakness.

20. The carton blank of claim 18 wherein the first and second laterally extending lines of weakness are disposed at substantially right angles to the longitudinally extending line of weakness.