Information
-
Patent Grant
-
6719143
-
Patent Number
6,719,143
-
Date Filed
Friday, February 8, 200222 years ago
-
Date Issued
Tuesday, April 13, 200420 years ago
-
Inventors
-
Original Assignees
-
Examiners
-
CPC
-
US Classifications
Field of Search
US
- 206 736
- 206 738
- 206 745
- 206 746
- 206 747
- 206 774
- 206 769
- 229 240
-
International Classifications
-
Abstract
A carton blank includes first and second spaced main panels and first and second side flaps abutting first and second side edges, respectively, of the first main panel. Third and fourth side flaps abut first and second side edges, respectively, of the second main panel and an intermediate panel is disposed between first ends of the first and second spaced main panels. A cover flap abuts a second end of the second main panel and a display flap includes first and second portions adjacent to one another wherein the first portion is joined to a second end of the first main panel by a score line and the second portion is joined to the second end of the first main panel by a perforated line collinear with the score line.
Description
TECHNICAL FIELD
The present invention relates to product cartons, and more particularly, to cartons that can be converted from a shippable form to a displayable form.
BACKGROUND ART
Finished products are typically packed into cartons and shipped to merchants for sale to the general public. The merchants thereafter unpack the finished products and stack them manually on display racks or store shelves in order for consumers to easily locate and pick out products. This process is time consuming and labor intensive. Certain carton designs have attempted to address this problem through the use of convertible designs that allow the merchant to display products in the cartons in which they were shipped.
Leftwich et al., U.S. Pat. No. 5,657,872, discloses a storage/display container. The container has two removable sides and a removable top cover that enable a merchant to convert the container from a shipping container to a display container. The sides and top cover are removed from the container by the merchant and the products within the container are exposed with the two remaining sides and lips along the front and rear edges of the container defining the boundaries of the container. The front lip of the container can further be removed by the merchant to allow consumers to slide products out of the container if further containers are stacked on top.
Rosenbaum, U.S. Pat. No. 6,158,579, also discloses a storage/display container. The container includes a foldable portion comprised of the top of the container and a portion of the front of the container. A merchant utilizes the foldable portion of the container to create a fold up header at the rear of the container that displays advertising for the products within. After the fold up header is created the front of the container consists of a skirt that defines the front edge of the container and contains the products within.
These container designs allow merchants to display products within the cartons that the products were shipped in and can be placed by the merchant on the floor, countertop or shelves for consumers to view. However, placement of the cartons on a shelving unit creates problems in both designs and neither design allows a merchant to effectively choose between a floor/counter display and a shelf display. Specifically, in the case of the Leftwich et al. patent the container is placed on a shelf with the open side facing out. As a result, when the consumer views the container there is little or no surface space on the side of the container nearest the consumer to identify the products within. This problem may be magnified in regard to flat products or in situations where the products are pushed into the back of the container where the consumer cannot easily view the products within to identify them.
The Rosenbaum container can also be somewhat problematic for consumers and merchants. The container cannot easily fit in the opening between closely spaced shelves because of the fold up header created when the merchant converts the container into the display form. Furthermore, where the shelf spacing is such that the carton will fit in such opening, the fold up header is disposed in back of the shelf where consumers are unable to see printed material on the header due to obstruction and/or a lack of light. Thus, the consumer encounters the same problem as with the Leftwich et al. container, whereby the consumer is left with little viewable container surface by which to identify the products within. Also, the skirt prevents consumers from easily reaching into the bottom of the container to retrieve flat products and interferes with the ability of the merchant to readily ascertain the number of products remaining in the carton.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a carton blank includes first and second spaced main panels and first and second side flaps abutting first and second side edges, respectively, of the first main panel. The carton blank further includes third and fourth side flaps abutting first and second side edges, respectively, of the second main panel and an intermediate panel disposed between first ends of the first and second spaced main panels. Also provided is a cover flap abutting a second end of the second main panel and a display flap having first and second portions adjacent to one another wherein the first portion is joined to a second end of the first main panel by a score line and the second portion is joined to the second end of the first main panel by a perforated line collinear with the score line.
A further aspect of the present invention comprehends a carton including top and bottom spaced main panels and first and second side flaps abutting first and second side edges, respectively, of the bottom main panel. The carton further includes third and fourth side flaps abutting first and second side edges, respectively, of the top main panel and secured to the first and second side flaps, respectively and an intermediate panel integral with first ends of the top and bottom spaced main panels. A display flap is also provided having first and second portions adjacent to one another wherein the first portion is joined to a second end of the bottom main panel by a score line and the second portion is joined to the second end of the bottom main panel by a perforated line collinear with the score line. A cover flap is joined to a second end of the top main panel and is secured to the display flap.
Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is an elevational view of one side of a carton blank according to the present invention;
FIG. 2
is an elevational view of the opposite side of the carton blank of
FIG. 1
;
FIGS. 3-6
are isometric views of a process of erecting the carton blank of
FIGS. 1 and 2
;
FIGS. 7-9
are isometric views steps undertaken to convert the carton of
FIG. 6
from a shipping form to a display form;
FIGS. 10 and 11
are isometric views of the carton of
FIGS. 7-9
showing removal of the second main panel and cover flap to complete the conversion process to a display form according to a first embodiment of the present invention; and
FIGS. 12 and 13
are isometric views of the carton of
FIGS. 7-9
showing folding of the second main panel and cover flap and tucking of such elements to complete the conversion process to a display form according to a second embodiment of the present invention
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to
FIG. 1
, a carton blank
20
includes a first side
21
and comprises sections of corrugated cardboard or other paperboard material connected by score lines and/or perforated lines. A first main panel
22
is attached at score lines
24
,
26
to first and second side flaps
28
,
30
respectively. The first main panel
22
is also attached to an intermediate panel
32
at a score line
34
. The first main panel
22
is further attached to a front or display flap
36
at a line
38
.
The front or display flap
36
includes a first section
40
attached at a perforated line
42
to a second section
44
. The first section
40
of the display flap
36
is further attached to the first main panel
22
at a score line
46
that forms a first part of the line
38
. The second section
44
of the display flap
36
is attached to the first main panel
22
at a scored and perforated line
48
. The scored and perforated line
48
forms a second part of the line
38
. The display flap
36
further includes a third section
50
disposed between the first and second sections
40
,
44
. The third section
50
is defined by cut lines
52
,
54
and
56
.
First and second tabs
60
,
62
are attached to opposing ends of the first side flap
28
. The first tab
60
is adjacent to the intermediate panel
32
and is connected to the first side flap
28
at a score line
64
. The second tab
62
is adjacent to the second section
44
of the display flap
36
and is attached to the first side flap
28
at a scored and perforated line
66
. Third and fourth tabs
68
,
70
are attached to opposing ends of the second side flap
30
at score lines
72
,
74
, respectively. The third tab
68
is disposed at a location adjacent the intermediate panel
32
whereas the fourth tab
70
is adjacent the first section
40
of the display flap
36
.
A second main panel
80
is attached to the intermediate panel
32
at a scored and perforated line
82
. Third and fourth side flaps
84
,
86
are attached to opposing sides of the second main panel
80
at scored and perforated lines
88
,
90
, respectively. A cover flap
92
is attached to the second main panel
80
at a score line
94
. Furthermore, as shown in
FIG. 2
, which illustrates a second side
95
of the blank
20
, the second main panel
80
is comprised of first and second folding panel sections
96
,
98
respectively. The first folding panel section
96
is attached to the second folding panel section
98
at a score line
100
that extends between the scored and perforated lines
88
and
90
Preferably, although not necessarily, the score line
100
forms 90 degree angles with respect to the scored and perforated lines
88
and
90
. Also preferably, the score line
100
is formed only in the second side
95
and not the first side
21
, although the score line
90
could be formed in both sides
21
and
95
, if desired.
Also, in other embodiments any or all of the scored and/or perforated lines could be replaced with other lines of weakness in the corrugated cardboard or other paperboard material used in the carton blank that enable the material to bend or tear as described below.
Industrial Applicability
The process of erecting the carton blank
20
to obtain an erected carton
110
is illustrated in
FIGS. 3-6
. Referring first to
FIG. 3
, the carton blank
10
is oriented by a user with the side
95
having the score line
100
separating the first and second folding panel sections
96
,
98
facing up. All of the following steps of erecting the carton
110
are preferably undertaken by equipment designed to accomplish such steps but can also be accomplished manually.
The first and second side flaps
28
,
30
are folded up along the score lines
24
,
26
, respectively, as shown in
FIGS. 3 and 4
. Before, during or after this folding step the tabs
60
,
62
,
68
,
70
are folded up/in relative to the first and second side flaps
28
,
30
along the score lines
64
,
72
,
74
and along the scored and perforated line
66
. Adhesive of any suitable type is applied to outwardly-directed faces
60
a
,
62
a
,
68
a
,
70
a
(see also
FIG. 1
) of the tabs
60
,
62
,
68
,
70
, respectively, at any suitable point in the process. Thereafter, the display flap
36
and the intermediate panel
32
are folded upwardly along the lines
38
and
34
, respectively, and adhesively attached to the outwardly-directed faces
60
a
,
62
a
,
68
a
,
70
a
of the tabs
60
,
62
,
68
,
70
(FIG.
5
).
If desired, the foregoing steps can be undertaken in any suitable sequence. For example, one or both of the tabs
60
,
62
may be folded upwardly relative to the first side flap
28
and the first side flap
28
may thereafter be folded upwardly relative to the first main panel
22
. One or both of the tabs
68
,
70
can then be folded upwardly relative to the second side flap
30
and the second side flap
30
may thereafter be folded upwardly relative to the first main panel
22
. Adhesive can then be applied to the outwardly-directed faces
60
a
,
62
a
,
68
a
,
70
a
of the tabs
60
,
62
,
68
,
70
and the display flap
36
and the intermediate panel
32
may be folded upwardly in sequence or simultaneously into contact with the outwardly-directed faces
60
a
,
62
a
,
68
a
,
70
a
of the tabs
60
,
62
,
68
,
70
.
Referring again to
FIGS. 3 and 4
, the third and fourth side flaps
84
,
86
are then folded up along the scored and perforated lines
88
,
90
, respectively, relative to the second main panel
80
. Before, during or after such folding, adhesive is applied to inner faces
84
a
,
86
a
of the third and fourth side flaps
84
,
86
. After placing product in the carton, and as seen in
FIG. 5
, the second main panel
80
is then folded down along the scored and perforated line
82
until the second main panel
80
contacts one or more of upper edges
112
,
114
of the first and second side flaps
28
,
30
and an upper edge
116
of the display flap
36
. The third and fourth side flaps
84
,
86
are then folded down into contact with and adhered to outer surfaces
28
a
,
30
a
(also see
FIG. 1
) of the first and second side flaps
28
,
30
. If desired, adhesive may be applied to the outer surfaces
28
a
,
30
a
in addition to or in place of the adhesive on the inner faces
84
a
,
86
a
of the third and fourth side flaps
84
,
86
. Alternatively or in addition, the third and fourth side flaps
84
,
86
may be held in place by adhesive tape or any other securing means (not shown). Finally, the cover flap
92
is folded down along the score line
94
and the cover flap
92
is attached to the display flap
36
, preferably by adhesive tape (not shown), so that the carton
110
assumes the erected shipping form shown in FIG.
6
.
The process of converting the erected carton
110
into a first display form is shown in
FIGS. 7-11
. Referring to
FIG. 7
, the adhesive tape seal is first broken or severed by a user and the cover flap
92
is folded up along the score line
94
. Referring to
FIG. 8
, the second main panel
80
is then pulled up and torn from the third and fourth side flaps
84
,
86
along the scored and perforated lines
88
and
90
, respectively. The third and fourth side flaps
84
,
86
remain secured to the first and second side flaps
28
,
30
after such tearing.
Then, referring to
FIG. 9
, the third section
50
is punched or knocked out (if it has not already been removed from the first and second sections
40
,
44
). The user inserts a finger into the hole left by removal of the third section
50
and grasps and removes the second section
44
of the display flap
36
from the first section
40
and the first main panel
22
by tearing at the perforated lines
42
and
48
. At this time, the second tab
62
is also separated and removed from the first side flap
28
by tearing the scored and perforated line
66
.
At this point, the user has the option of converting the carton
110
into one of two display forms. If the carton is to be placed in closely-spaced shelves, the user may elect to remove the second main panel
80
and the attached cover flap
92
from the intermediate panel
32
(and the remainder of the carton
110
) by tearing along the scored and perforated line
82
, as seen in
FIG. 10
to obtain the configuration shown in FIG.
11
. This configuration comprises a first or limited height display form. Once the carton
110
is placed on the merchant's shelf with the display flap
36
facing outwardly, purchasers can readily observe printed material provided on the first section
40
identifying and/or promoting the product in the carton
110
.
In the event that the carton
110
is to be placed at a location where vertical spacing is not a limiting factor, the user may elect to convert the carton from the configuration shown in
FIG. 9
to a second display form. Specifically, as seen in
FIG. 12
, the user folds the second main panel
80
along the score line
100
to place the second folding panel section
98
into face-to-face abutment with the first folding panel section
96
. At this point the user tucks the cover flap
92
into abutment with the tabs
60
,
68
. The side edges of the cover flap
92
and adjacent portions of the second folding panel section
98
remaining after tearing of the scored and perforated lines
88
and
90
may slightly engage inner surfaces
120
,
122
of the side flaps
28
,
30
to maintain the second folding panel section
96
in position against the first folding panel section
98
. Alternatively or in addition, the cover flap
92
may be tucked behind the product in the carton
110
and/or adhesive and/or adhesive tape may be used to maintain the second folding panel section
96
in upstanding position against the first folding panel section
98
as seen in FIG.
13
. Preferably, an outer surface
124
of the second folding panel section
96
includes printed matter thereon identifying and/or promoting the product in the carton
110
.
In either form, a purchaser or the merchant can easily observe how much product remains in the carton
110
, due to the removal of the second section
44
of the display flap
36
from the first section
40
down to the level of the first main panel
22
. This feature is particularly useful in the case of flat or small product. Further, the merchant need not unpack product from the carton
110
prior to display thereof. Promotional matter on the carton
110
is readily observed by the customer.
As an alternative to the embodiments described above, the cover flap
92
may be secured by any suitable fastening means to the display flap
36
and may further be configured substantially identically to the display flap
36
. In other words, the cover flap
92
may include three sections shaped substantially identically to the sections
40
,
44
and
50
and which are separated from one another by lines of substantially similar design and shape as the lines
42
,
52
,
54
and
56
when the cover flap
92
overlies the display flap
36
. In such an embodiment, the section of the cover flap
92
overlying the section
44
may be secured to the second main panel
80
at a scored and perforated line. During conversion, the sections
50
and
44
, and the sections of the cover flap
92
corresponding thereto may be removed, leaving the section
40
and the section of the cover flap
92
corresponding thereto in place. In this case, the remaining portion of the cover flap
92
may have printed matter thereon describing or referring to the product in the carton.
In still another embodiment, all or portions of one or more of the first through fourth side flaps
28
,
30
,
84
,
86
, the intermediate panel
32
and/or the tabs
60
,
68
and
70
may be removed during the conversion process. This may be accomplished by tearing at one or more additional perforated lines or other line(s) of weakness. This may allow a the user to remove an entire corner of the carton to enhance the visibility of the product in the carton.
Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.
Claims
- 1. A carton blank, comprising:first and second spaced main panels; first and second side flaps abutting first and second side edges, respectively, of the first main panel; third and fourth side flaps abutting first and second side edges, respectively, of the second main panel; an intermediate panel disposed between first ends of the first and second spaced main panels; a cover flap abutting a second end of the second main panel; and a display flap having first and second portions adjacent to one another wherein the first portion is joined to a second end of the first main panel by a score line and the second portion is joined to the second end of the first main panel by a perforated line collinear with the score line.
- 2. The carton blank of claim 1, wherein the second portion is joined to the first portion by a further perforated line.
- 3. The carton blank of claim 2, wherein a removable punch-out portion is disposed between the perforated lines.
- 4. The carton blank of claim 1, wherein each of the first and second side flaps includes an associated pair of opposing tabs defined by further score lines.
- 5. The carton blank of claim 4, wherein the further score line defining one of the opposing tabs adjacent the second portion is also perforated.
- 6. The carton blank of claim 1, wherein the second main panel includes an additional score line at an intermediate portion thereof.
- 7. The carton blank of claim 1, wherein the third and fourth side flaps are joined to the second main panel by combined score and perforated lines.
- 8. A carton, comprising:top and bottom spaced main panels; first and second side flaps abutting first and second side edges, respectively, of the bottom main panel; third and fourth side flaps abutting first and second side edges, respectively, of the top main panel and secured to the first and second side flaps, respectively; an intermediate panel integral with first ends of the top and bottom spaced main panels; a display flap having first and second portions adjacent to one another wherein the first portion is joined to a second end of the bottom main panel by a score line and the second portion is joined to the second end of the bottom main panel by a perforated line collinear with the score line; and a cover flap joined to a second end of the top main panel and secured to the display flap.
- 9. The carton of claim 8, wherein the second portion is joined to the first portion by a further perforated line.
- 10. The carton of claim 9, wherein a removable punch-out portion is disposed between the perforated lines.
- 11. The carton of claim 8, wherein each of the first and second side flaps includes an associated pair of opposing tabs defined by further score lines.
- 12. The carton of claim 11, wherein the further score line defining one of the opposing tabs adjacent the second portion is also perforated.
- 13. The carton of claim 8, wherein the second main panel includes an additional score line at an intermediate portion thereof.
- 14. The carton of claim 8, wherein the third and fourth side flaps are joined to the second main panel by scored and perforated lines.
US Referenced Citations (67)
Foreign Referenced Citations (1)
Number |
Date |
Country |
2 162 063 |
Nov 1972 |
FR |