Note: Descriptions are shown in the official language in which they were submitted.
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REINFORCED CARTON WITH RECLOSABLE LID
FIELD OF THE INVENTION
[0001] The present invention related to reinforced cartons, and more
specifically to
a reinforced carton with a reclosable lid.
BACKGROUND
[0002] Cartons are typically shipped in bulk quantities. During shipping, the
cartons may be vertically stacked upon each other in order to maximize the
amount
of product shipped in a particular vessel. The amount of product shipped may
depend, however, on the load-bearing capacity of the stacked cartons. It is
therefore
desirable to produce cartons having high rigidity and/or strength in
compression for
shipping, and for other purposes such as the protection of the carton contents
in
general.
[0003] A conventional method for increasing the strength of a carton is to
produce
the carton from a blank of a different, stronger board material, or to produce
the
blank from the same carton material but of greater thickness or caliper. Such
methods typically increase the costs associated with manufacturing the carton,
with
the material costs of manufacture generally increasing according to the cost
of
increasing the strength and/or thickness of the entire blank. Some sections of
the
blank, however, may not be load-bearing, and the additional costs associated
with
increasing the strength of non-load bearing sections of the blank are wasted.
[0004] According to one aspect of the present invention there is provided a
carton
formed at least from an outer blank and an inner blank adhered to the outer
blank,
comprising a multi-ply front panel formed at least from the inner blank and
the
outer blank; a multi-ply first end panel formed at least from the inner blank
and the
outer blank; a multi-ply back panel formed at least from the inner blank and
the
outer blank; a multi-ply second end panel formed at least from the inner blank
and
the outer blank; a top panel; and a bottom panel, wherein a lid pattern is
formed at
least in the front panel, the first end panel and the second end panel, the
lid pattern
at least partially defining a latch and a pivotable lid, a base portion of the
latch is
formed in the outer blank and is adhered to the inner blank, and the lid
pattern
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defines at least part of a lower edge of the pivotable lid, and the latch is
defined at
least partially by a perimeter line of disruption in the outer blank.
[0005] Insert members may be introduced into certain carton structures to
increase
carton strength. Features of a certain complexity such as insert members,
however,
may require the carton blank to be prepared in a batch process, where features
or
articles are individually cut and/or glued to the carton blank. Batch
processing may
be slow, however, and may involve high costs.
SUMMARY
[0006] According to a first exemplary embodiment of the invention, a carton is
formed from an inner blank adhered to an outer blank. A lid pattern is formed
at
least in the outer blank and defines a pivotable lid in a top portion of the
carton.
When opened, the lid separates from the inner blank ply of the carton and can
be
pivoted between open and closed positions.
[0007] According to one aspect of the first embodiment, the inner blank forms
a
reinforcing sleeve lining on an inner surface of the outer blank that
increases the
strength of the carton. The inner blank can be configured to reinforce the
exterior
blank at any number of desired locations. Selected reinforcement of specific
areas
of the exterior blank can produce a high strength carton while using
relatively small
amounts of board.
[0008] According to another aspect of the first embodiment, a latch feature
can be
formed in the carton that allows the lid to be selectively opened and
reclosed. The
latch feature can incorporate portions of the inner and outer blank that
interact to
maintain the lid in a closed position.
[0009] According to yet another aspect of the invention, multi-ply carton
blanks
can be formed in a continuous process where outer and inner webs are
individually
and/or simultaneously provided with repeating patterns of disruption. The
outer and
inner webs are joined together in the continuous process to form carton blanks
that
have one or more multi-ply sections. The inner and outer carton blanks can be
formed from material webs that are capable of, for example, continuous and
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simultaneous processing on the same production line so that the multi-ply
blanks
are quickly and easily manufactured.
[0010] Other aspects, features, and details of the present invention can be
more
completely understood by reference to the following detailed description,
taken in
conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0011] FIG. 1 is a schematic illustration of a continuous process production
line
for producing multi-ply carton blanks.
[0012] FIG. 2A is a plan view of a multi-ply blank used to form a carton
having
a reclosable lid according to a first embodiment of the invention.
[0013] FIG. 2B is an isolated plan view of an inner blank ply of the multi-ply
blank of FIG. 2A.
[0014] FIG. 3 illustrates adhesive lines formed by the production line
illustrated
in FIG. 1.
[0015] FIG. 4 illustrates a pattern of lines of disruption formed in a first
material
web by the production line illustrated in FIG. 1.
[0016] FIG. 5 illustrates a pattern of lines of disruption formed in a second
material web by the production line illustrated in FIG. 1.
[0017] FIG. 6 illustrates a pattern of lines of disruption formed in the first
and
second material webs.
[0018] FIG. 7 illustrates the multi-ply carton according to the first
embodiment
of the invention.
[0019] FIGS. 8 and 9 illustrate opening of the reclosable lid of the first
carton
embodiment.
[0020] FIG. 10 illustrates reclosure of the reclosable lid.
DETAILED DESCRIPTION
[0021] Briefly described, an aspect of the present invention is directed to a
multi-
ply carton 190 (illustrated in FIG. 7) having enhanced strength and rigidity.
The
carton 190 is formed from a multi-ply blank 8 (illustrated in FIG. 2A)
comprising
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an exterior blank 5 reinforced with one or more interior reinforcing blanks
adhered
to the exterior blank. The multi-ply carton 190 may have a pivotable lid that
is
easy to access, open, and reclose. The lid may also interact with a
reinforcing
blank to prevent product from escaping the carton when the lid is closed. In
this
specification, the terms "bottom," "front," "back," "end" and "top" are used
to
indicate orientations determined in relation to fully erected cartons placed
in
upright configurations, and are not intended to limit the scope of the
invention.
[0022] The multi-ply blank 8 used to form a carton 190 may be formed, for
example, in a continuous process production line capable of forming multi-ply
blanks. FIG. 1 is a schematic illustration of such a continuous process
production
line. In FIG. 1, first and second webs of material A and B are unrolled
continuously and processed in the production line. The web A may be provided
with lines of disruption at a disrupting station D. The web B may be provided
with adhesive at station E before the webs A and B are laminated together at a
lamination station F. The combined webs A, B are subsequently passed through a
disrupting station G. The laminated webs A, B may then be separated into
individual multi-ply carton blanks 8 at the disrupting station G, and also
provided
with additional lines of disruption in the combined webs A, B. The combined
webs A, B are generally separated into the individual, multi-ply blanks 8 at
locations between repeating patterns of lines of disruption in the webs A, B.
Repeating patterns of disruption in the web B may differ, for example, from
patterns formed in the web A, if any, so that the individual plies of the
laminate
blanks 8 have different properties and/or capabilities.
100231 Referring to FIG. 2A, the multi-ply blank 8 used to form the carton 190
is formed from an outer blank 5 and an inner, reinforcing blank 6 adhered,
laminated or otherwise joined to the outer blank 5. The outer blank 5 can be
formed from, for example, a web of continuously moving web of material such as
the web B shown in FIG.1, and the inner blank 6 can be formed from a
continuously moving web of material such as the web A. The terms "outer" and
"inner" are used in this specification to indicate the location of the
respective
blank plies 5, 6 in cartons formed or erected from the finished multi-ply
blanks 8.
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In FIG. 2A, the entire outer or exterior print surface of the outer blank 5 is
visible,
and the inner blank 6 is joined to the opposite, interior or underside of the
outer
blank 5. The inner blank 6 is not visible in FIG. 2A and the lead line from
reference number 6 is therefore shown by dashed lines. Upper and lower edges 7
and 9, respectively, of the inner blank 6 are indicated in FIG. 2A by dashed
hidden lines. The inner blank ply 6 is illustrated separately (i.e., in
isolation) in
FIG. 2B.
[00241 The final multi-ply blank 8 is "multi-ply" in that the joined inner and
outer blank plies 6' and 5 comprising the multi-ply blank 8 include
substantial
overlapping portions. Also, a majority of the overlapping surfaces of the
inner and
outer blank plies 6, 5 may be adhered adjacent to one another. For example,
the
blanks 5 and 6 have slightly different perimeters or "footprints" and do not
overlap
at all points, but at least substantially all of the surface of the inner
blank 6 is
adjacent and/or adhered to the outer blank 5.
[00251 Referring again to FIG. 2A, the outer blank ply 5 comprises a back
panel
foldably connected to a first end panel 20 at a first transverse fold line 21,
a
front panel 30 foldably connected to the first end panel 20 at a second
transverse
fold line 31, and a second end panel 40 foldably connected to the front panel
30 at
a third transverse fold line 41. An adhesive panel 50 may be foldably
connected to
the second end panel 40 at a fourth transverse fold line 51. The blank 8 is
two-ply
where the inner blank 6 overlaps the sections of the outer blank 5 defined by
the
panels 10, 20, 30, 40, 50.
[00261 The back panel 10 is foldably connected to a back top flap 12 and a
back
bottom flap 14. The first end panel 20 is foldably connected to a first end
top flap
22 and a first end bottom flap 24. The front panel 30 is foldably connected to
a
front top flap 32 and a front bottom flap 34. The second end panel 40 is
foldably
connected to a second end top flap 42 and a second end bottom flap 44. The top
flaps 12, 22, 32, 42 extend along a first or top marginal area of the outer
blank 5,
and may be foldably connected along a first longitudinally extending fold line
62.
The bottom flaps 14, 24, 34, 44 extend along a second or bottom marginal area
of
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the outer blank S, and may be foldably connected along a second longitudinally
extending fold line 64.
[0027] The first and second longitudinal fold lines 62, 64 may be, for
example,
generally straight fold lines, or, the fold lines 62, 64 may be offset at one
or more
locations to account for, for example, blank thickness or other factors. When
the
carton 190 (FIG. 7) is erected, the top flaps 12, 22, 32, 42 close a top of
the carton
190, and the bottom flaps 14, 24, 34, 44 close a bottom of the carton 190. The
front top flap 32 can include a longitudinal fold line 35 defining a distal
section 36
in the front top flap 32. The front bottom flap 34 can include a longitudinal
fold
line 33 defining a distal section 38.
[0028] The upper and lower edges 7,.9 of the inner blank 6 are spaced a small
distance within the first and second longitudinal fold lines 62, 64,
respectively.
The clearances between the edges 7, 9 of the blank 6 and the respective fold
lines
62, 64 in the outer blank 5 allow the top and bottom flaps 12, 22, 32, 42, 14,
24,
34, 44 to be folded inwardly when erecting the carton 190.
[0029] According to one aspect of the invention, the outer blank 5 is provided
with a lid pattern 80 comprising lines of disruption that define a pivotable
lid 100
(illustrated in FIGS. 7-10) in the multi-ply carton 190. The lines of
disruption
forming the lid pattern 80 may be formed, for example, so that they do not
extend
into the inner blank ply 6, or extend into the inner ply a small degree.
[0030] The lid pattern 80 includes oblique breachable lines of disruption 102,
104 that extend across the end panels 20, 40, respectively, and define the
side
edges of a front wall 120 of the lid 100. The breachable lines of disruption
102,
104 may be, for example, tear lines formed from a series of cuts and/or
perforations. A pair of spaced parallel breachable lines of disruption 106,
108
extend through the panels 20, 30, 40 and define a tear strip 116 that defines
a
lower edge of the front wall 120. The breachable lines of disruption 102, 104
may
be, for example, tear lines formed from a cut-scores. Arcuate cuts 110, 112
may
be formed in the cut-score 108 to facilitate tearing of the tear strip 116.
Nicks may
be formed at one end of the tear strip 116 to define a tear tab 118 at an end
of the
tear strip 116.
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[0031] According to one aspect of the invention, a click-shut latch 130 is
formed
in the outer blank 5, and has an outer perimeter defined by a breachable
perimeter
line of disruption 140. The breachable perimeter line of disruption 140 may be
formed from, for example, a series of cuts and/or perforations. A base portion
134
of the click-shut latch 130 is foldably connected to a latch tab or flap 132
at a
longitudinal hinge or fold line 136. The pivotable lid 100 (FIG. 7) defined in
the
outer blank 5 may remain unadhered to the inner blank 6, except at the base
134 of
the click-shut latch 130. The pattern of adhesion of the inner blank 6 to the
outer
blank 5 is described in detail below with reference to FIGS. 2B and 3.
[0032] FIG. 2B is an isolated plan view of the side of the inner ply or blank
6
that is adhered to the outer blank S. In FIG. 2B, the inner ply 6 is shown
separate
and isolated from the outer blank 5 in order to more clearly illustrate the
lines of
disruption formed in the inner blank 6. The inner blank ply 6 comprises a back
panel 210 foldably connected to a first end panel 220 at the transverse fold
line 21,
a front panel 230 foldably connected to the first end panel 220 at the
transverse
fold line 31, a second end panel 240 foldably connected to the front panel 230
at
the transverse fold line 41, and an adhesive panel 250 foldably connected to
the
back panel 210 at a transverse fold line 51. The common reference numbers for
the transverse fold lines 21, 31, 41, 51 in the blanks 5, 6 are used to
indicate that
the fold lines in the inner and outer blank 5, 6 can be formed in a single
disrupting
operation (e.g., in the same nip defined by the male and female rollers G1, G2
of
the disrupting station G shown in FIG. 1). In accordance with the first
embodiment, this method of production ensures that the panels 210, 220, 230,
240,
250 of the inner blank 6 generally correspond to and align with the panels 10,
20,
30, 40, 50 respectively, in the outer blank 5.
[0033] FIG. 3 is an adhesive or glue target drawing illustrating the locations
of
longitudinally extending adhesive lines 160, 162, 164, 166, 168, 170, 172, 174
formed on the outer blank 5 in order to adhere the inner blank 6 to the outer
blank
5. One or more of the adhesive lines 160, 162, 164, 166, 168, 170, 172, 174
may
alternatively be applied to the inner blank 6 to adhere the blanks 5, 6
together.
The adhesive lines 160, 162, 164, 166, 168, 170, 172, 174 may be applied, for
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example, at the adhesive application station E shown in FIG. 1. As shown in
FIG. 3, the area of the outer blank 5 within the lid pattern 80 is free of
adhesive
except at the base 134 of the click-shut latch 130. This allows the lid 100
formed
from the lid pattern 80 to pivot away from the inner blank 6 when the latch
130 is
breached. The adhesive lines 160, 172 extend longitudinally alongside an upper
portion of the lid pattern 80 so that the inner blank 6 is adhered to the
outer blank
substantially to an upper edge of the carton 190 (shown in FIG. 9).
100341 An exemplary continuous processing method of forming multi-ply blanks
8 is discussed below with reference to FIGS. 1-6.
[00351 Referring to FIG. 1, the first and second webs of material A and B are
unrolled continuously from rolls. The outer blank 5 can be formed from the web
B and the inner blank 6 can be formed from the web A. Referring also to FIG.
4,
the first or inner web A can be provided with longitudinal cuts that define
the
upper and lower edges 7 and 9 of the inner blank 6. The longitudinal cuts can
be
provided if the roll of inner web material A has an initial width that is
greater than
the width of the final inner blank 6. The second or outer web B may then be
provided with the adhesive pattern illustrated in FIG. 3. In FIG. 1, the
adhesive
station E is schematically illustrated by a glue spray nozzle arrangement.
Other
apparatus for applying adhesive, such as print rollers, for example, can also
be
used to apply an adhesive pattern to the outer web B. After the application of
adhesive, the webs A and B are laminated together at lamination station F
(e.g., by
passing the webs through a nip defined between opposed rollers).
[00361 Referring to FIGS. 1, 5 and 6, the disrupting station G forms the
patterns
of disruption shown in FIGS. 5 and 6 in the combined web A, B. The disrupting
station G may, for example, form differing patterns of lines of disruption in
each
of the webs A, B. In the exemplary embodiment, the disrupting station G
repeats
the pattern shown in FIG. 5 end-to-end continuously in only the outer web B as
the web is advanced through the continuous process production line. The
pattern
shown in FIG. 6 is formed in both the outer web B and the inner web A.
[00371 As described above, the disrupting station G can comprise the first
male
roller G1 and the second female roller G2 with respective male and female die
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patterns for forming the patterns shown in FIGS. 5 and 6. With respect to the
pattern shown in FIG. 5, the portions of the disrupting die used to form the
outer
web B may also disrupt the inner web A to some small degree. However, the
pattern shown in FIG. 5 is not intended to be formed in the inner web A such
that
the functions associated with the pattern shown therein, particularly the lid
pattern
80, are imparted to the inner web A.
[0038] Both the inner web A and the outer web B are provided with the pattern
of lines of disruption shown in FIG. 6. The pattern shown in FIG. 6 is
repeated
end-to-end continuously in the combined webs A and B as the webs are advanced
through the production line. The perimeter cuts shown in FIG. 6 separate the
processed webs A, B into individual blanks 8. The resultant blanks 8 then exit
the
station G as shown in FIG. 1. Scrap material from the joined webs A, B can be
removed at this time.
[0039] The patterns illustrated in FIGS. 5 and 6 are illustrated as formed at
a
single disrupting station G (e.g., nip) comprising opposed male and female die
rollers. In an alternative embodiment, flat reciprocating dies can be used at
the
disrupting station G. In accordance with the first embodiment, the lines of
disruption shown in FIGS. 5 and 6 are formed "simultaneously" in the sense
that
they are formed at the same disrupting station G. In the exemplary embodiment,
the respective patterns are formed simultaneously in that a single pair of
rollers
G1, G2 forms the patterns. The patterns in FIGS. 5 and 6 may also be formed by
the same reciprocating die at the disrupting station G.
[0040] An exemplary method of constructing the carton 190 from the blank 8 is
discussed below.
[0041] Referring to FIGS. 2A, 2B and 3, the carton 190 may be erected by
folding the multi-ply blank 8 flat about the transverse fold lines 21, 41 and
adhering the exterior side of the adhesive panel 50 to the interior side of
the
second end panel 240 of the inner blank 6. The multi-ply blank 8 may then be
"opened" to have a generally rectangular tubular shape. To close the bottom of
the tubular carton form, the first and second end bottom flaps 24, 44 are
folded
inwardly, followed by the back bottom flap 14, then the front bottom flap 34.
The
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underside of the front bottom flap 34 is adhered to the exterior side of the
back
bottom flap 14. Portions of the first and second end bottom flaps 24, 44 may
also
be adhered to one or both of the bottom flaps 14, 34. To close the top of the
tubular carton form, the first and second end top flaps 22, 42 are folded
inwardly,
followed by the back top flap 12, then the front top flap 32. The underside of
the
front top flap 32 is adhered to the exterior side of the back top flap 12.
Portions of
the first and second end top flaps 22, 44 may also be adhered to the flaps 12,
32.
The flaps 12, 22, 32, 42, 14, 24, 34, 44 may be adhered by, for example, glue,
adhesives, or other means. Dispensable product, such as, for example, laundry
detergent, or other items, can be loaded into the carton at any time before
fully
enclosing the carton. Other articles and dispensable products may also be
accommodated within the carton.
[0042] FIG. 7 illustrates the erected carton 190 with the top and bottom ends
of
the tubular form closed. The erected carton 190 has a generally
parallelepipedal
form, with the outer blank 5 forming an outer ply of the carton, and the inner
blank
6 (not visible in FIG. 7) reinforcing the carton interior. Referring also to
FIG. 1,
the portion of the outer blank 5 defined by the lid pattern 80 in part defines
a
reclosable lid 100 in an upper portion of the carton 190. As shown in FIG. 7,
the
tear strip 116 extends partially around the perimeter of the carton 190.
[0043] FIGS. 8-10 illustrate opening and reclosing of the pivotable lid 100.
In
FIGS. 8-10, the surface of the inner blank 6 is shaded with stippling solely
to
distinguish the inner blank from the-outer blank 5, which is not shaded.
Referring
to FIG. 8, the pivotable lid 100 may be opened by grasping the tear tab 118
(shown in FIG. 1) and removing the tear strip 116 along the tear lines 106,
108.
The lid 100 may now be pivoted upward so that the outer blank 5 tears along
the
oblique lines of disruption 102 in the outer blank 5. If perforations are used
to
form the perimeter 140 of the latch 130, the user may also press in at the
base 134
and/or tab 132 to pre-break the perforation 140 before pivoting the lid 100
open.
The lid 100 can then be pivoted open about the fold or hinge line 62 as shown
in
FIG. 9. As shown in FIG. 9, the base 134 of the latch 130 is adhered to the
inner
blank 6 and separates from the remainder of the lid 100, which creates a latch
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aperture or opening 142 in the front wall 120 of the lid 100. The latch tab
132
remains attached to the base 134 and also separates from the lid 100. The
inner
blank 6 may remain intact and constitutes a reinforcing sleeve in the interior
of the
carton 190.
[0044] Referring to FIG. 10, the lid 100 may be reclosed by first bending the
latch tab 132 upwardly at the fold line 136 so that the latch tab 132 projects
outwardly from the inner blank 6 in a latching position. Alternatively,
opening of
the lid 100 may be sufficient to bend the latch -tab 132 to its latching
position. The
lid 100 is pivoted downwardly and selectively secured in a closed state by
engaging the latch tab 132 with the perimeter of the latch opening 142. It is
not
required that the latch tab 132 bend outwardly to secure the lid in its closed
position.
[0045] The pivotable lid 100 can be opened again by lifting upwardly on the
lid
100 to disengage the latch tab 132 from the latch opening 142. According to
the
above embodiment, the latch tab 132 can emit an audible noise, such as a
`click,'
when the tab 132 is engaged and/or disengaged with the latch opening 142.
[0046] According to the above embodiment, the carton 190 may be used as a
dispensing container for detergent and other particulate product. The carton
190
may be formed, for example, such that there are substantially no gaps between
the
laminated plies of the carton. The folding and gluing process may be greatly
simplified through the elimination of separate insert pieces and the related
equipment, resulting in faster production.
[0047] Also according to the above embodiment, an exterior carton blank can be
selectively reinforced at desired locations by one or more reinforcing blanks.
The
carton formed from the resulting multi-ply blank can accordingly have enhanced
strength and rigidity at selected sections of the carton. Selected
reinforcement of
specific areas of the exterior blank produces a high strength carton while
using
comparatively small amounts of board material.
[0048] In accordance with the exemplary embodiments, the cartons may be
constructed of paperboard, for example. The webs used to form the blanks may
be
thicker and heavier than ordinary paper. The blanks, and thus the cartons, can
also
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be constructed of other materials, such as cardboard, or any other material
having
properties suitable for enabling the carton to function at least generally as
described above. For example, one or both of the blanks may be formed from
coated solid unbleached sulfate (SUS) board.
[0049] One or more panels of the blanks discussed above can be coated with
varnish, clay, or other, similar materials, either alone or in combination.
The
coating may then be printed over with product, advertising, usage and other
information or images. The blanks may also be coated to protect any
information
printed on the blank. The blanks may be coated with, for example, a moisture
barrier layer, on either or both sides of the blanks.
[0050] In accordance with the exemplary embodiment of the present invention, a
fold or hinge line can be any substantially linear, although not necessarily
straight,
line of disruption in the blank that facilitates folding or hinged pivoting
therealong
during ordinary use and/or erection of a carton. More specifically, but not
for the
purpose of narrowing the scope of the present invention, fold lines include:
score
lines; crease lines; a cut or a series of cuts that extend partially into
and/or
completely through a blank along a desired line of weakness; and various
overlapping and sequential combinations of these features.
[0051] The above embodiments may be described as having one or panels
adhered together by glue. The term "glue" is intended to encompass all manner
of
adhesives commonly used to secure carton panels in place.
[0052] For purposes of the description presented herein, the term "line of
disruption" can be used to generally refer to a cut line, a score line, a tear
line, a
crease line, perforations, or a fold line formed in blank material (or a
combination
of at least one cut line, score line, tear line, crease line, and/or fold
line), or any
form of disruption in a blank, whether continuous or non-continuous. A
"breachable line of disruption" as disclosed in this specification refers to a
line of
disruption that is intended to be breached or otherwise torn during ordinary
use of
a carton. A tear line can be any breachable line of disruption as understood
in the
art that facilitates tearing therealong during ordinary use of the carton.
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[00531 In the present specification, the terms "panel" and "flap" may
generally
indicate portions of blanks wholly or partially demarcated by lines of
disruption.
A "panel" or "flap" need not be flat or otherwise planar. A "panel" or "flap"
can,
for example, comprise a plurality of interconnected and/or overlapping
generally
flat or planar blank sections.
[00541 The term "line" as used herein includes not only straight lines, but
also
other types of lines such as curved, curvilinear or angularly displaced lines.
[00551 It will be understood by those skilled in the art that while the
present
invention has been discussed above with reference to exemplary embodiments,
various additions, modifications and changes can be made thereto without
departing from the spirit and scope of the invention as set forth in the
following
claims.
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