Note: Descriptions are shown in the official language in which they were submitted.
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Attorney Docket #: IPK-041357-US
TAMPER-RESISTANT AND LEAK-RESISTANT CONTAINER
Field of the Invention
The present invention relates generally to paperboard containers or cartons
that are
capable of shipping articles, such as flowable or pourable substance and more
particularly, to
a container that is tamper proof, easily carried by hand, and having the
capability permitting
the substance to be poured therefrom.
BACKGROUND OF THE INVENTION
Conventional foldable cartons are well known and are used in a variety of
applications. For example, the packaging industry utilizes a vast number of
cartons in
which numerous products are packaged for subsequent shipment. These foldable
cartons
or container have been equipped with variety of carry handles to accommodate
grasping
by the fingers of user. Such cartons or containers are used to store a wide
variety of
flowable substance. One problem with these cartons or containers is that the
pourable
substance can spill out through the carry handles. One solution in the past
has been to
refrain from packing flowable substance to the top of the cartons. This can
waste
significant capacity in the container.
Accordingly, there is need to for a container that is tamper-resistant, leak-
resistant,
and is easily carried on by hands of a user.
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SUMMARY OF THE INVENTION
The present invention is directed to a paperboard container having generally
finger
access or handhold openings forming carry handles in the end walls and is
defined by two
adjacent tapered punch-out panels aligned end-to-end and hinged at their outer
ends to a
respective end wall. When two adjacent tapered punch-out panels punched out
they fold
oppositely to one another and inwardly into the container in laterally spaced
relation to
one another on opposite sides of the respective openings. A tear-out panel in
one end
wall adjoins the associated hand hold openings and when removed forms a
dispensing or
pourable opening immediately below the associated hand hold openings.
The container further has top end wall flaps, with a first flap panel hinged
to the
top edge of a respective associated end wall and folded inwardly to form a
partial top
closure, and a second flap panel hinged to the first panel and folded at a
downwardly
inclined angle back beneath the first panel so that its free edge lies between
the finger
access opening and the dispensing opening. This angled panel extends the full
width of
the container and defines a shield between the contents of the container and
the respective
associated finger access openings. A tab on the free edge of the second panel
is engaged
in a slot at the bottom of the respective finger access openings to hold the
shield in
position. The inwardly folded punch out panels that form the finger access
openings are
engaged snugly between the first and second flap panels, effecting partial
seals
at opposite side edges of the finger access openings, and with the second flap
panels
prevent leakage of the container contents through the finger access openings.
A further
tear-out panel is located in the free edge of the second panel, and when
removed forms an
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enlargement of the dispensing opening in the container end wall. In addition,
the blank
that forms the container is cut so that small lateral tabs are formed at the
base of the
bottom-forming flaps, and these tabs tighten up the corners of the folded
container to
prevent leakage of the contents through these areas.
Accordingly, one aspect of the present invention is directed to a container
for
shipping and dispensing flowable substance. The container comprises a
plurality of side
walls and bottom wall flaps that are foldably joined to bottom edges of the
side walls and
are folded inwardly therefrom into overlapping relationship with one another
to form a
bottom wall closure. Top wall flaps are foldably joined to upper edges of the
side walls
and are folded inwardly therefrom into overlapping relationship with one
another to form
a top wall closure. Cut lines are formed in an opposed pair of the side walls
at respective
upper edges thereof, defining first punch-out panels that are pushed inwardly
to form
handhold openings in the opposed pair of side walls. The top wall flaps
adjacent the
handhold openings are forming a ceiling for the respective handhold openings.
A partition
panel is extending angularly downwardly from the top wall flaps to a bottom
edge of each
the handhold opening to isolate flowable contents of the container from the
handhold
openings. Each of the partition panels is folded from the top wall flaps at
locations spaced
from adjacent the side walls and each having a free edge engaged in the
respective
handhold opening at a bottom edge thereof to retain the partition panels in
position.
Additional cut lines are in one of the side walls of the opposed pair of side
walls,
adjoining the handhold opening below the free edge of the partition panel,
defining a
second punch-out panel that is pushed inwardly to form a dispensing opening.
The
dispensing opening is isolated from the handhold opening by the partition
panel. The first
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punch-out panels each comprise first and second tapered panels connected
together along
a frangible line at their inner ends and foldably are connected at their outer
ends to the
respective side wall. The first and second panels are extending between the
respective
adjacent partition panel and the respective adjacent top wall flaps to form
side walls at
opposite sides of each of the handhold opening. The first pouch-out panels is
also serving
to hold the partition panel downwardly against a bottom edge of the handhold
openings.
A frangible tear line is formed in the free edge of the partition panel
adjacent the
dispensing opening, defining a tear-out panel in the free edge of the
partition panel that
can be removed to enlarge the dispensing opening.
The juncture of the two adjoining side walls and associated bottom flaps form
a
bottom comer, and a small laterally projecting tab is formed on a side edge of
at least one
of two adjacent bottom wall flaps at the juncture of the bottom wall flaps and
associated
side walls. The tab is squeezed into the bottom corner to tighten the corner
and fill any
small space that may otherwise be present at the corner, thereby preventing
leakage of
flowable substance through the bottom corners of the container.
Another aspect of the present invention is directed to a blank for making a
container for flowable substance comprises a plurality of side wall panels
that are
foldably joined together along adjacent side edges. A plurality of top wall
flaps are
foldably joined to top edges of the side wall panels. A plurality of bottom
wall flaps are
foldably joined to bottom edges of the side wall panels. Adjacent side edges
of the bottom
wall flaps is separated from one another by a slotted relief cut extending
from an outer
free edge of the bottom wall flaps to adjacent but spaced from the juncture of
the bottom
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wall flaps with the side wall panels, defining a small laterally projecting
tab on a side
edge of at least one of the bottom wall flaps at the juncture.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following
description of the preferred embodiments when read in conjunction with the
accompanying drawings in which:
Figure 1 is a top perspective view of a container having an integrally first
handhold
opening formed therein and a dispensing opening immediately below the first
handhold
opening in accordance to a preferred embodiment of the present invention;
Figure 2 is similar top perspectives view of the container in Fig. 1 showing
an
integrally formed therein a second handhold opening opposite to the first
handhold opening;
Figure 3 is a top perspective view of the container in Fig. I illustrating the
top portion
of the container in a partially folded position;
Figure 4 is the same as container in Fig. 3 illustrating partially closed view
of the top
portion of the container by a top wall closure;
Figure 5A is an enlarged view of a portion of the container in Fig. 1 showing
the first
handhold opening in an open position and the dispensing opening in a closed
position;
Figure 5B is an expanded cross-sectional view of the Fig. 5A taken along line
5B-5B.
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Figure 5C is the same as Fig. 5A, illustrating the dispensing opening in an
open
position;
Figure 6 is a perspective view of a bottom portion of the container shown in
Figs. 1-4;
Figure 7 is a plan view of a cut and scored paperboard blank for forming the
container
in Figs. 1-4 in accordance to a preferred embodiment of the present invention;
and
Figures 7A, 7B, and 7C are close-up views of a portion of the blank shown in
Fig. 7.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms,
there
is shown in the drawings and will herein be described in detail preferred
embodiments of
the invention with the understanding that the present disclosure is to be
considered as an
exemplification of the principles of the invention and is not intended to
limit the broad
aspect of the invention to the embodiments illustrated.
Figure 1 is a top perspective view of a container 10 having an integrally
formed
therein a first handhold opening 12a and a dispensing opening 14 immediately
below the
first handhold opening 12 in accordance to a preferred embodiment of the
present
invention. The container 10 includes a second handhold opening 12b formed
therein
opposite to the first handhold opening 12a. The container 10 comprises
opposing top and
bottom walls 16a, 16b, opposite end walls 18a, 18b, and opposite side walls
20a, 20b.
The opposing top and bottom walls 16a, 16b are spaced apart from one another
by the
opposite end walls 18a, 18b and the opposite side walls 20a, 20b. The opposing
top and
bottom walls 16a, 16b are foldably joined to longitudinal opposite edges of
the side walls
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20a, 20b, and the end walls 18a, 18b are foldably joined to transverse
opposite edges of
the side walls 20a, 20b. The top wall panel 16a defines by two flap panels
16a', 16a" and
the bottom wall 16b defines by two outer flap panels 16b', 16b" and two inner
flap panels
62a', 62a" as best shown in Fig. 7. The opposing top and bottom walls 16a,
16b; the
opposite end walls 18a, 18b; and the opposite side walls 20a, 20b are all
cooperating with
one another to form the container 10. While this specific embodiment has two
side walls
20a, 20b and two end walls 18a, 18b, the container 10 of the present invention
may have
any number of side walls or end walls so long as the container's functions
described
herein are not compromised.
The first and second handhold openings 12a, 12b are formed in the respective
end
walls 18a, 18b. The handhold openings 12a, 12b are defined by two adjacent
tapered
punch-out panels 22a, 22b that are detachably connected together along a
frangible line
23 at the their inner ends and foldably connected at their outer ends 24 to
the respective
end walls 18a, 18b. When two adjacent tapered punch-out panels 22a, 22b are
pushed
inwardly, they fold oppositely to one another and inwardly into the container
10 in
laterally spaced relation to one another on opposite sides of the respective
handhold
openings 12a, 12b. The tapered punch-out panels 22a, 22b form side walls at
opposite
sides of the each handhold openings 12a, 12b. A first tear-out panel 25 in the
end wall
18a adjoins the associated handhold opening 12a and when removed forms a
dispensing
or pourable opening 14 immediately below the associated handhold opening 12a.
Figure 2 is similar to Fig. 1, showing an integrally formed therein the second
handhold opening 12b opposite to the first handhold opening 12a. The tapered
punch-out
panels 22a, 22b are arranged in a manner such that a user can gain access
thereto the
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handhold openings 12a, 12b without gaining access to the interior of the
container 10
wherein the flowable or pourable substance are stored therein. It should also
be noted that
the handhold openings 12a, 12b are formed in a manner that affords a user to
grab the
container 10 by the handhold openings 12a, 12b without compromising the
interior of the
container 10. Accordingly, the handhold openings 12a, 12b are tamper-resistant
that are
formed in the end walls 18a, 18b as shown in Figs 1 and 2. The container 10
may contain
any number of handhold openings; however, in the preferred embodiment of the
present
invention, the container 10 includes two handhold openings 12a, 12b.
Figures 3 and 4 are similar to Fig. 1, illustrating the top portion of the
container 10
in a partially folded position. Each of the end walls 18a, 18b includes a
respective pair of
first and second flap panels 26a', 26b' and 28a, 28b. Each of the respective
first flap
panels 26a', 26b' is hinged to the top edge of a respective associated end
wall 18a, 18b
and folded inwardly to form a respective partial top closure 26a, 26b as best
shown in
Fig. 4. Each of the respective second flap panels 28a, 28b, also defined as
partition
panels, is hinged to the respective first flap panels 26a', 26b' and folded at
a downwardly
inclined angle back beneath the respective first flap panel 26a', 26b' so that
its free edge
32 lies between the respective handhold openings 12a, 12b and the respective
dispensing
opening 26 as best depicted in Figs 5A-5C. Each of the angled second flap
panels 28a,
28b extends the full width of the container 10 and defines a partition or
shield between
the contents of the container 10 and the respective associated handhold
openings 12a,
12b.
A tab 34 on the free edge 32 of the each second flap panels 28a, 28b is
engaged in
a slot 36 at the bottom of the respective handhold openings 12a, 12b to hold
the partition
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or shield panels 28a, 28b in position. The inwardly folded punch out panels
22a, 22b that
form the handhold openings 12a, 12b are engaged snugly between the respective
pair of
first and second flap panels 26a', 26b' and 28a, 28b, effecting partial seals
at opposite
side edges of the handhold openings 12a, 12b, and with the angled second flap
panels
28a, 28b, prevent leakage of the container 10 contents through the handhold
openings
12a, 12b. A frangible tear line 38 is formed in the free edge of the second
flap panels
28a, 28b. The frangible tear line 38 defines a second tear out panel 40
adjacent the
handhold openings 12a, 12b and can be removed to enlarge the handhold openings
12a,
12b as best depicted in Fig. 5C.
Referring again to Figs. 5A-5C, each of the tapered punch-out panels 22a, 22b
includes a score line 42 formed therein to facilitates the panels 22a, 22b to
engage snugly
between the first and second flap panels 26a', 26b' and 28a, 28b and to
prevent the
respective second flap panels 28a, 28b to be pushed upwardly by the content of
the
container 10 during dispensing of the pourable substance. In addition, it
should be noted
that when in folded position, the respective second flap panels 28a, 28b forms
a ceiling
for the respective handhold openings 12a, 12b. As one of ordinary skilled in
art would
appreciates that a second dispensing opening may be located in the container
10, and thus
may be partially integrated in the second handhold opening 12b similar to that
described
hereinabove with respect to handhold opening 12a. However, in the preferred
embodiment of the present invention, as depicted in Figs. 1 and 2, there is
only one
dispensing opening 14 formed on the end wall 18a. In use, the first tear-out
panel 25 is
pushed inwardly to open the dispensing opening 14 one may lift and tip the
container 10
using, in part, the handhold opening 12a in a manner that pours the shipped
article from
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the container 10 through the dispensing opening 14. Accordingly, use of the
frangible
tear line affords the user of the container 10 the ability to convert the
container of the
present invention from a tamper-resistant shipping container to a container
capable of
pouring the contents and/or articles from within.
Figure 6 is a perspective view of a bottom portion of the container 10 shown
in
Fig. 1. The bottom wall 16b and/or top wall 16a may contain at least one leak-
resistant
feature 44 at the outer edges thereof. The embodiment in Figure 7 shows one
leak-
resistant feature 44 that is located at an outer edge of the bottom wall 16b
and is
protruding outwardly therefrom. The leak-resistant feature 44 may be of any
feature that
is able to reduce leaking of the contents and/or articles from within the
container 10, but
preferably is a webbed tab 46 that is attached to the bottom wall 16b. In
addition, Fig. 7
shows respective first and second leak-resistant features 48, 50, wherein the
first leak-
resistant feature 48 is located at the corner formed by the edges of sidewalls
18b, 20b and
bottom wall 16b and the second leak-resistant feature 50 is located at the
corner formed
by the edges of sidewalls 18b, 20a and bottom wall 16b and protruding
outwardly
therefrom. Each leak-resistant feature 48, 50 may be any feature that is able
to reduce
leaking of the contents and/or articles from within the container, but
preferably are
webbed tabs 52, 54 that are attached to the bottom wall 16b.
When fully erected, each webbed tab 48, 52, 54 is compressed so tightly and in
a
manner to seal any free edge of the container 10 so as to sterically hinder
the contents of
the container from leaking therefrom these edges. In these embodiments, the
leak-
resistant features may be located anywhere, but preferably are located at the
corners of the
container 10 where the edges of the side walls and the edges of the bottom
wall meet with
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one another. While not shown, the same leak-resistant features may be located
similarly
where the edges of the side walls and the edges of the top wall meet, more
preferably the
corner where the edge of the top wall 16a meets the edges of the side walls
18a, 20b
and/or where the edge of the top wall 16a meets the edges of the side walls
18b, 20a. The
leak-resistant features are more prevalent on the bottom of the container 10
because the
articles have a greater probability to leak at the corners of the bottom of
the container 10.
The container maintains it erected shipping and pouring positions by attaching
the
walls in any way, preferably gluing the walls together and/or taping the walls
together.
Also, the walls may contain fastening tabs that are commonly used for hand-
erecting,
rather than machine erecting. In the exemplified embodiment, the side walls
20a, 20b and
end walls 18a, 18b are attached to one another by a glue flap 56 as shown in
Fig. 3. The
container 10 of the present invention may be made from any one or more blanks
that are
capable of being folded and erected to form the container 10. Accordingly, the
present
invention also relates to such blanks capable of being erected into the
container 10 of the
present invention.
Figure 7 shows one such blank, more specifically, is a plan view of a cut and
scored paperboard blank 60 for forming the container 10 in Fig. 1 in
accordance to a
preferred embodiment of the present invention.
The blank 60 is divided into three sections 64, 66, and 68 by two
substantially
parallel longitudinal fold lines 70, 72. Section 64 is further divided by cut
lines 74, 76,
and 78 into four panels, two top wall panels 16a', 16a" and two panels 26a',
26b'. In the
folded position, the two top wall panels form the top wall 16a and the a pair
two panels
wherein each of which further is divided into respective pair of first and
second flap
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panels 26a', 26b' and 28a, 28b by fold lines 82, 84 as depicted in Fig. 3.
Section 66 is
divided by fold lines 86, 88, 90 into two end walls panels 18a', 18b' and two
side walls
panels 20a' and 20b'. Section 68 is divided into two outer bottom wall panels
16b', 16b"
and two inner bottom wall panels 62a', 62a". In the folded position, the outer
bottom wall
panels 16b', 16b" form the bottom wall 16b by folding onto one another into an
overlapping relationship and the inner wall panels 62a', 62a" fold onto one
another into
an overlapping relationship. The bottom wall flaps 16b' foldably joined to
bottom edges
of said side wall panels 20a', 20b' wherein adjacent side edges of the bottom
wall flaps is
separated from one another by a slotted relief cut 92 extending from an outer
free edge of
the bottom wall flaps 16b' to adjacent but spaced from the juncture of the
bottom wall
flaps 16b' with the side wall panels 20a', 20b', defining a small laterally
projecting tab 46
on a side edge of at least one of the bottom wall flaps 16b' the juncture 44
as best
depicted in Fig. 6.
The top wall flaps 16a' are foldably joined to the side wall panels 20a', 20b'
and
the first and second flap panels 26a', 26b' and 28a', 28b' are subdivided by a
transverse
fold lines 82, 84 into a top wall partial closure panel 26a', 26b' and a
partition panel 28a',
28b'. The top wall closure panel 26a' is adjacent the associated end wall
panel 18a', and
the partition panel 28a', 28b' is on the free edge of the top wall partial
closure panels
26a', 26b' and adapted to extend angularly downwardly toward the associated
end wall
panels 18a', 18b' and into engagement with a bottom edge of the handhold
openings
12a', 12b' in a container 10 erected from the blank 60 to isolate the handhold
openings
12a', 12b' from the dispensing openings 14.
Figures 7A, 7B, and 7C depict the enlarged views of a portion of the blank 60
in
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Fig. 7. In Fig. 7A and 7B, the handhold openings 12a, 12b are defined by two
adjacent
tapered punch-out panels 22a, 22b that are detachably connected together along
a
frangible line 23 at the their inner ends and foldably are connected at their
outer ends 24
to the respective end walls 18a, 18b. When two adjacent tapered punch-out
panels 22a,
22b are pushed inwardly, they fold oppositely to one another and inwardly into
the
container 10 in laterally spaced relation to one another on opposite sides of
the respective
handhold openings 12a, 12b. The first tear-out panel 25 in the end wall 18a
adjoins the
associated handhold opening 12a and when removed forms the dispensing or
pourable
opening 14 immediately below the associated handhold opening 12a as discussed
in detail
hereinabove. As shown in Fig. 7C, the tab 34 on the free edge 32 of the each
second flap
panels 28a, 28b is engaged in the slot 36 at the bottom of the respective
handhold
openings 12a, 12b to hold the second flap panels 28a, 28b, also defined as
partition or
shield panels, in position.
Manual set-up of the container 10 is easily accomplished. First, the blank 60
is
folded along the fold lines 86, 88, and 90 and then the glue flap 56' is
preferably glued to
the longitudinal side of the end wall panel 18b'. Next, the inner wall panels
62a' are
folded inwardly with respect to fold line 72 and the bottom wall panels 16b'
are folded
with respect to fold line 72 and glued onto one another in an overlapping
relationship to
form the bottom wall 16b as shown in Figs. 1-3. Then, the second flap panels
28a', 28b'
are folded with respect to the transverse fold lines 82, 84 toward the
interior of the
container 10 and folded at a downwardly inclined angle back beneath the
respective
first flap panel 26a', 26b' so that the tab 34 lies between the respective
handhold
openings 12a, 12b and the respective dispensing opening 14. Each of the angled
second
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flap panels 28a, 28b extends the full width of the container 10 and defines a
partition or
shield between the contents of the container 10 and the respective associated
handhold
openings 12a, 12b. When the angled second flap panels 28a, 28b extends the
full width of
the container 10, the first flap panels 26a', 26b' form partial top closures
26a, 26b.
Finally, after flowable substance placed in the interior of the container, the
pair of flap
panels 16a'fold onto one another in an overlapping relationship with respect
to the fold
line 70 and glued thereon to enclose the container 10. When the container 10
is in the
closed position, the pair of flap panels 16b' which form the top wall 16b,
rest on the
partial top closures 26a, 26b.
In sum, the present invention is directed to a container for shipping and
dispensing
flowable substance. The container as described hereinabove comprising a
plurality of side
walls and bottom wall flaps are foldably joined to bottom edges of the side
walls and are
folded inwardly therefrom into overlapping relationship with one another to
form a
bottom wall closure. Top wall flaps are foldably joined to upper edges of the
side walls
and are folded inwardly therefrom into overlapping relationship with one
another to form
a top wall closure. Cut lines are formed in an opposed pair of the side walls
at respective
upper edges thereof, defining first punch-out panels that are pushed inwardly
to form
handhold openings in the opposed pair of side walls. The top wall flaps
adjacent the
handhold openings are forming a ceiling for the respective handhold openings.
A partition
panel is extending angularly downwardly from the top wall flaps to a bottom
edge of each
the handhold opening to isolate flowable contents of the container from the
handhold
openings. The partition panels each being folded from the top wall flaps at
locations
spaced from adjacent the side walls and each having a free edge engaged in the
respective
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handhold opening at a bottom edge thereof to retain the partition panels in
position.
Additional cut lines are in one of the side walls of the opposed pair of side
walls,
adjoining the handhold opening below the free edge of the partition panel,
defining a
second punch-out panel that is pushed inwardly to form a dispensing opening.
The
dispensing opening is isolated from the handhold opening by the partition
panel. The first
punch-out panels each comprise first and second tapered panels connected
together along
a frangible line at their inner ends and foldably are connected at their outer
ends to the
respective side wall. The first and second panels are extending between the
respective
adjacent partition panel and the respective adjacent top wall flaps to form
side walls at
opposite sides of each of the handhold opening. The first pouch-out panels is
also serving
to hold the partition panel downwardly against a bottom edge of the handhold
openings.
A frangible tear line is formed in the free edge of the partition panel
adjacent the
dispensing opening, defining a tear-out panel in the free edge of the
partition panel that
can be removed to enlarge the dispensing opening.
The juncture of the two adjoining side walls and associated bottom flaps form
a
bottom corner, and a small laterally projecting tab is formed on a side edge
of at least one
of two adjacent bottom wall flaps at the juncture of the bottom wall flaps and
associated
side walls. The tab is squeezed into the bottom corner to tighten the corner
and fill any
small space that may otherwise be present at the corner, thereby preventing
leakage of
flowable substance through the bottom corners of the container.
A blank for making a container 10 for flowable substance comprises a plurality
of
side wall panels that are foldably joined together along adjacent side edges.
A plurality of
top wall flaps are foldably joined to top edges of the side wall panels. A
plurality of
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bottom wall flaps are foldably joined to bottom edges of the side wall panels.
Adjacent
side edges of the bottom wall flaps is separated from one another by a slotted
relief cut
extending from an outer free edge of the bottom wall flaps to adjacent but
spaced from
the juncture of the bottom wall flaps with the side wall panels, defining a
small laterally
projecting tab on a side edge of at least one of the bottom wall flaps at the
juncture.
Alternatively, the slotted relief cut maybe replaced by a cut line extending
from free edge
of the bottom wall flaps to the fold line 72.
Numerous modifications and variations on the present invention are possible in
light of the above teachings. It is, therefore, to be understood that within
the scope of the
accompanying claims, the invention may be practiced otherwise than as
specifically
described herein.
It should be understood that fold lines and score line as used herein may be
used
interchangeably so long as the function of the line is not destroyed.
While the invention has been described with reference to a preferred
embodiment,
it will be understood by those skilled in the art that various changes may be
made and
equivalents may be substituted without departing from the scope of the
invention. In
addition, many modifications may be made to adapt a particular situation or
material to
the teachings of the invention without departing from its scope. Therefore, it
is intended
that the invention not be limited to the particular embodiment disclosed, but
that the
invention will include all embodiments falling within the scope of the
appended claims.
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