US20060261140A1

US20060261140A1 - Carton with detachable portion

Info

Publication number: US20060261140A1
Application number: US11/419,443
Authority: US
Inventors: John Holley
Original assignee: Meadwestvaco Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC; SAP America Inc
Priority date: 2005-05-19
Filing date: 2006-05-19
Publication date: 2006-11-23
Also published as: WO2006125110A2; WO2006125110A3

Abstract

A carton (200) including a top wall (214), a bottom wall (218), opposing side walls (212, 216), and first and second end walls (220, 222). A detachable portion (210) of the carton (200) is defined by a severance line (180) to include at least a portion of the top wall (214) and a portion of the side walls (212, 216). The top wall portion (182) of the severance line (180) is spaced apart from the second end wall (222) by a certain distance D1 such that a portion of the top wall (214) remains to provide structural integrity to the carton (200) after the detachable portion (210) is detached. The distance (D1) is also determined such that articles (B) in the carton (200) are viewable and easily accessed. The minimum distance (D1) between a top wall portion (182) of the severance line (180) and the second end wall (222) is no greater than half of the distance between the first and second end walls (220, 222).

Description

RELATED APPLICATIONS

This application claims priority to U.S. Application No. 60/683,010, filed May 19, 2005, U.S. Application No. 60/722,854, filed Sep. 30, 2005, and U.S. Application No. 60/724,599, filed Oct. 6, 2005, the entirety of the aforementioned applications are incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

The invention relates to cartons, and more particularly, to a carton for enclosing multiple articles that includes a detachable portion for facilitating removal of the articles.

BACKGROUND OF THE INVENTION

Cartons for encasing multiple articles are useful for enabling consumers to obtain and transport a desired quantity of individual articles such as soft drinks or other beverages. When such a package of articles is obtained, a consumer frequently desires to remove one article from the carton at a time. It is known to provide a carton having a detachable portion for removing articles, which is provided when part of the carton is substantially detached or torn away from the carton to expose articles for removal.
A problem associated with such cartons is that a user can have difficulty in accessing articles through an opening provided by the detachable portion of the carton. Furthermore it can be difficult to see how many articles remain within the carton and such a carton is only suitable for dispensing the end most articles, which may not be desirable for use with cartons containing a variety of items.
It is also known to provide a carton for displaying articles where the entire top wall of the carton and significant portions of the side walls are removed for displaying the articles. A problem associated with such cartons is that the structural integrity of the carton is compromised because the whole of the top panel is left fully opened.
Therefore, a heretofore unaddressed exists to address the aforementioned deficiencies and inadequacies.

SUMMARY OF THE INVENTION

The various embodiments of the present invention overcome the shortcomings of the prior art by providing a carton with a detachable portion. The detachable portion can be detached to provide an access opening that facilitates visibility of and accessibility to articles within the carton without compromising the structural integrity of the carton.
The carton includes a tubular structure including a top wall, a bottom wall, and opposing side walls. First and second end walls are formed at the open ends of the tubular structure such that the end walls are connected to the top wall, the bottom wall, and the side walls. A detachable portion of the carton is defined by a severance line to include at least a portion of the top wall, at least a portion of the first end wall, and a portion of the side walls. The top wall portion of the severance line is offset from the second end wall by a certain distance such that a portion of the top wall of the carton remains to provide structural integrity after the detachable portion is removed. The offset distance is also determined such that articles in the carton are viewable and easily accessed. The minimum distance between a top wall portion of the severance line and the second end wall is no greater than half of the distance between the first and second end walls.
In certain embodiments, the top wall portion of the severance line is substantially closer to the second end wall than to the first end wall. The top wall portion of the severance line may be curved or otherwise contoured, in which case, the minimum distance between the top wall portion of the severance line and the second end wall is less than the distance between the first and second end walls.
In certain embodiments, the carton includes a tear initiation feature that is at least partially defined by the top wall portion of the severance line. The tear initiation feature can be located between the top wall portion of the severance line and either the first end wall or the second end wall. The tear inititation feature facilitates breaking the severance line to detach the detachable portion.
Other systems, methods, features, and advantages of the present invention will be or will become apparent to one with skill in the art upon examination of the following drawings and detailed description. All such additional systems, methods, features, and advantages are included within the scope of the present teaching and are protected by the accompanying claims.
The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary embodiment of a blank for forming a carton, according to the present invention.
FIGS. 2 and 3 are perspective views of a partially erected carton formed from the blank of FIG. 1, showing steps for forming the end closure structures of the carton.
FIG. 4 is a perspective view of a fully erected carton formed from the blank of FIG. 1.
FIG. 5 is a perspective view of the carton of FIG. 4 showing a tear initiation tab being displaced into the carton.
FIG. 6 is a perspective view of the carton of FIG. 4 showing the detachable portion being partially detached from the carton.
FIG. 7 is a perspective view of the carton of FIG. 8 showing the detachable portion being fully detached from the carton.
FIG. 8 is a perspective view of an alternative embodiment of a carton including a detachable portion, according to the present invention.
FIG. 9 is a perspective view of another alternative embodiment of a carton including a detachable portion, according to the present invention.
FIG. 10 is a plan view of an alternative embodiment of a blank for forming a carton, according to the present invention.
FIG. 11 is a perspective view of a carton formed from the blank of FIG. 10.
FIG. 12 is a perspective view of the carton of FIG. 11, showing a detachable portion being partially detached.
FIG. 13 is a perspective view of the carton of FIG. 11, showing the detachable portion being fully detached.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a carton including a detachable portion to facilitate the removal of articles from the carton. The carton is defined by a top wall, a bottom wall, side walls, and first and second end walls. The detachable portion is defined by a severance line that extends across at least the side walls, top wall, and first end wall of the carton. The top wall portion of the severance line is spaced apart from the second end wall by a minimum distance that is no greater than half the distance between the first end wall and the second end wall.
Referring to the exemplary embodiment illustrated in FIG. 1, a blank 100, which is preferably a single sheet of suitable substrate, is shown that can be folded and secured to form the carton 200 (shown in FIG. 4). It is to be understood that, as used herein the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, plastic, or the like. The terms “fold line” and “severance line” refer to all manner of printed lines indicating optimal fold or cut locations, frangible or otherwise weakened lines, perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, scored lines, slits, the path of a tear strip, any combination thereof, and the like.
Referring to FIG. 1, the blank 100 includes four primary panels which are hingedly connected one to the next along fold lines. The primary panels define the walls of a tubular structure portion of the carton 200 and include a first side wall panel 112, a top wall panel 114, a second side wall panel 116, and a bottom wall panel 118. The first side wall panel 112 is hingedly connected to the top wall panel 114 along fold line 122, the top wall panel 114 is hingedly connected to the second side wall panel 116 along fold line 124, and the second side wall panel 116 is hingedly connected to the bottom wall panel 118 along fold line 126. A glue flap 120 is hingedly connected to the bottom wall panel 118 along fold line 128.
End flaps are hingedly connected to opposite ends of each primary panel. The end flaps form end closure structures at respective open ends of the tubular structure portion of the carton 200. The blank 100 is substantially symmetric such that end flaps that are hingedly connected to opposite ends of each primary panel are substantially similar. Accordingly, the end closure structures of the carton 200 are substantially identical and like references have been used with a suffix “a” or “b” affixed to distinguish one end of the carton from the other. Thus, the description of an element or group of elements having a suffix “a” is suitable for a like-numbered element or group of elements having a suffix “b”. In certain instances, for clarity, only one of the like elements may be described unless a description of the other or both of the like elements is necessary for understanding the invention.
A side end flap 132 a is hingedly connected to the first side wall panel 112 along fold line 142 a. A top end flap 134 a is hingedly connected to the top wall panel 114 along fold line 144 a. A side end flap 136 a is hingedly connected to the second side wall panel 116 along fold line 146 a. A bottom end flap 138 a is hingedly connected to the bottom wall panel 118 along fold line 148 a.
The top end flap 134 a includes a handle aperture 150 a and a handle flap 152 a. The handle flap 152 a is hingedly connected to the top end flap 134 a along a fold line 154 a. Each of the side end flaps 132 a, 136 a include partial apertures or cutouts 156 a, 158 a, respectively, that align with the handle aperture 150 a when the end closure structure of the carton 200 is formed. The blank 100 further includes reinforcing flaps 160 a, 162 a that are hingedly connected to the upper edge of the side flaps 132 a, 136 a along fold lines 164 a, 166 a, respectively. The reinforcing flaps 160 a, 162 a are further defined by cut lines 168 a, 170 a and by apertures A. The reinforcing flaps 160 a, 162 are folded along the fold lines 164 a, 166 a to reinforce the handles of the carton 200.
The blank 100 further includes a continuous severance line 180 which defines a detachable portion 210 (shown in FIG. 6) when the blank 100 is erected to form the carton 200. The severance line 180 includes a top wall portion 182, side wall portions 184, 186, and end wall portions 188, 190. The top wall portion 182 of the severance line 180 extends across the top wall panel 114 between the fold lines 122, 124 and is substantially parallel to the fold line 144 b. Further, the top wall portion 182 of the severance line 180 is spaced apart from the fold line 144 b by a distance D1, as described in further detail below.
The side wall portions 184, 186 of the severance line 180 extend at least partially or across at least a portion of the side wall panels 112, 116 between the fold lines 122, 124 and the fold lines 142 a, 146 a, respectively, or otherwise connect the top wall portion 182 to the end wall portions 188, 190. The end wall portions 188, 190 of the severance line 180 extend across the side end flaps 132 a, 136 a between the fold lines 142 a, 146 a and the edge of the blank 100, respectively. When the blank 100 is erected to form the carton 200, the end wall portions 188, 190 of the severance line 180 align to form a substantially continuous severance line, as described in further detail below.
The blank 100 includes a tear initiation arrangement including a tear initiation tab 192. The tear initiation tab 192 is defined by a segment of the top wall portion 182 of the severance line 180, a fold line 194, and a pair of severance lines 196. The fold line 194 is spaced apart from the top wall portion 182 and the severance lines 196 extend from opposite ends of the fold line 194 to meet or intersect the top wall portion 182 of the severance line 180. In the exemplary embodiment, the tear initiation tab 192 is disposed between the top wall portion 182 of the severance line 180 and the fold line 144 a. However, in alternative embodiments, the tear initiation tab 192 may be disposed between the top wall portion 182 of the severance line 180 and the fold line 144 b.
A non-limiting method for forming the carton 200 from the blank 100 is now described. The bottom wall panel 118 is folded along the fold line 126 such that the inside surface of the bottom wall panel 118 is in flat face contact with the inside surface of the second side wall panel 116. Glue or other adhesive is applied to the glue flap 120 before folding the first side wall panel 112 along the fold line 122 such that the inside surface of the first side wall panel 112 is in flat face contact with the top wall panel 114 and the outside surface of the glue flap 120 is secured to the inside surface of the first side wall panel 112. Thereby, a collapsed tubular structure is formed. The collapsed tubular structure is erected into the open ended tubular structure shown in FIG. 2. Articles are loaded through one or both of the open ends of the tubular structure before folding the end flaps to form end closure structures.
The carton 200 is designed to package cylindrical articles that are typically arranged in columns and rows. It should be understood that the carton 200 can be designed to accommodate different numbers, shapes, sizes, or arrangements of articles as is not limited to the designs described herein. The carton may be used to package articles such as cans, bottles, pouches, brick-shaped containers, and the like.
Referring to FIGS. 2, 3, and 4, the side end flaps 132 a, 136 a are folded along fold lines 142 a, 146 a to be substantially coplanar such that the end wall portions 188, 190 of the severance line 180 substantially align. The top and bottom end flaps 134 a, 138 a are folded along fold lines 144 a, 148 a to overlap, and are secured to, the side end flaps 132 a, 136 a to form an end closure structure of the carton 200, as shown in FIG. 4. The top end flap 134 a overlaps the upper portion of the side end flaps 132 a, 136 a such that the handle aperture 150 a aligns with the cutouts 156 a, 158 a to define a reinforced handle.
In this embodiment, the top and bottom end flaps 134 a, 138 a are designed such that they do not overlap the end wall portions 188, 190 of the severance line 180 or otherwise do not obstruct the detachment of the detachable portion of the carton 200 along the end wall portions 188, 190 of the severance line 180. In alternative embodiments, where one or both of the top and bottom end flaps 134 a, 138 a overlap the end wall portions 188, 190 of the severance line 180, severance lines are included in the top and/or bottom end flaps 134 a, 138 a to facilitate detachment of the detachable portion of the carton. In this case, severance lines in the top and/or bottom end flaps 134 a, 138 a align with the end wall portions 188, 190 of the severance line 180 and additionally define the detachable portion of the carton.
When the blank 100 is folded and secured to form the carton 200, the primary panels and the end closure structures define the walls of the carton 200. The first side wall panel 112 defines a first side wall 212, the top wall panel 114 defines a top wall 214, the second side wall panel 116 defines a second side wall 216, and the bottom wall panel 118 defines a bottom wall 218. The end closure structures define first and second end walls 220, 222.
In this embodiment, the carton 200 encloses bottles B. The bottles B are arranged in rows and columns and the base of each is disposed on the inside surface of the bottom wall 218. In the embodiment shown in FIG. 6, the bottles B are are arranged in five rows and four columns. The columns of bottles B align or extend between the end walls 220, 222. The foremost row of articles B is closest to the first end wall 220 and the rearmost row of articles B is closest to the second end wall 222.
The detachable portion 210 of the carton 200 is defined by the severance line 180 to include portions of the top wall 214, the side walls 212, 216, and the first end wall 220. Referring to FIG. 4, the top wall portion 182 is spaced apart from the second end wall 222 by a distance D1 such that a portion of the top wall 214 remains after the detachable portion 210 of the carton 200 is detached. Similarly, the side wall portions 184, 186 of the severance line 180 are spaced apart from the second end wall 222 by a minimum distance D3 and the side wall portions 184, 186 of the severance line 180 are spaced apart from the bottom wall 118 by a minimum distance D4. In the exemplary embodiment, the distances D1, D3 are substantially the same and the distance D4 is no greater than half the height of the carton 200. Thereby, after the detachable portion 210 is detached, articles are accessible and portions of the top wall 214, the side walls 212, 216, and the first end wall 220 remain to preserve the structural integrity of the carton 200. It should be noted that the distance D4 is optionally greater than half the height of the carton 200.
A non-limiting method for detaching the detachable portion 210 from the carton 200 is now described. The tear initiation tab 192 is displaced into the carton 200 to allow a user to grasp the detachable portion 210 and detach it from the carton 200, as shown in FIG. 5. The tear initiation tab 192 is displaced into the carton 200 by applying a force on the tear initiation tab 192 that is sufficient to break the segment of the top wall portion 182 of the severance line 180 and the severance lines 196. The tear initiation tab 192 is positioned relative to the arrangement of articles in the carton 200 such that the tab 192 can be rotated along the fold line 194 into a space in the carton, for example, between two rows of articles. In other words, the tear initiation tab 192 is positioned so that the tops of the articles will not impede displacement of the tear initiation tab 192.
In the exemplary embodiment, the initiation tab 192 is positioned to be disposed between the two rows of bottles B which are closest to the second end wall 222. To position the tear initiation tab 192 between the rows of bottles B which are closest to the second end wall 222, the distance D1 may be approximately equal to the diameter of a bottle B. It should be noted that the tear initiation tab 192 may be positioned between other rows of bottles B so long as the distance D1 is no greater than half the distance between the end walls 220, 222. For example, the distance D1 may be approximately equal to two times the diameter of a bottle B for the embodiment shown in FIG. 6, which includes five rows of bottles B. In embodiments which include an alternative number of rows of articles, the distance D1 may be adjusted accordingly to position the tear initiation tab between two rows of bottles B. For example, for six rows of articles, the distance D1 may be one, two, or three times the diameter of an article.
The detachable portion 210 is at least partially detached along the severance line 180 to provide an access opening 230 in the carton 200. Referring to FIGS. 5 and 6, the detachable portion 210 is detached along the top wall portion 182 and the side wall portions 184, 186 of the severance line 180 and remains attached along the end wall portions 188, 190 of the severance line 180. Referring to FIG. 7, the detachable portion 210 is fully detached along the top, side, and end wall portions of the severance line 180. A portion of the top wall 214 remains with the carton 200 when the detachable portion 210 is removed to provide structural integrity for the carton 200. The remaining portion of the top wall 214 extends between the side walls 212, 216.
In this embodiment, when the detachable portion 210 is partially or fully detached, the lower portion of the first end wall 220 forms a stopper wall 720 that extends between the side walls 212, 216 to confine the bottles B within the opened carton 200. The upper edge of the stopper wall 720 is defined by the end wall portions 188, 190 of the severance line 180. The end wall portions 188, 190 are spaced apart from the bottom wall at a distance H that is substantially equal to half the height of the carton 200. When the access opening 230 is provided in the carton 200, the bottles B in the row adjacent the stopper wall 720 extend above the upper edge of the stopper wall so that they are visible and easily accessible. The bottles B in the other rows are also visible and accessible through the opening 230.
Modifications can be made to the foregoing embodiment without departing from the scope and spirit of the claimed invention. For example, in alternative embodiments, the carton 200 may not include a stopper wall 720. In such embodiments, the end wall portions 188, 190 of the severance line 180 extend along the fold line 148 a and the side wall portions 184, 186 of the severance line 180 extend from the top wall portion 182 to the lower corners of the side walls 212, 216 which are defined by the bottom wall 218 and the first end wall 220.
It should be noted that the shape and/or location of the severance line may be modified from that shown in the previous embodiment. Referring to FIG. 8, an alternative embodiment of a carton 800 is shown which is somewhat similar to the carton 200 with the exception of the shape or location of the severance line which defines the detachable portion of the carton 800. Specifically, the carton 800 includes a detachable portion 810 defined by a severance line 880. The severance line 880 includes a top wall portion 882, side wall portions 884, 886 and end wall portions 888, 890. In this embodiment, the top wall portion 882 is curved or arcuate. A point P1 on the top wall portion 882 of the severance line 880 is defined as that which is closest to the second end wall 882. The minimum distance D1 between the top wall portion 882 and a second end wall 822 is equal to the distance between the point P1 and the second end wall 822. Points P2 on the top wall portion 882 of the severance line 880 are defined as those which are furthest from the second end wall 882. In the exemplary embodiment, the points P2 are located where the top wall portion 882 of the severance line 880 meets or intersects edges E of the carton 800, which are defined by top wall 814 and a respective side wall 812, 816. The maximum distance D2 between the second end wall 822 and the top wall portion 882 of the severance line 880 is the distance between each point P2 and the second end wall 822 of the carton 800. In this embodiment, the distance D2 is greater than the distance D1. It should be noted that the points P2 may not be located on the edge E and that there may be a single point P2.
Referring to FIG. 9, an alternative embodiment of a carton 900 is shown which is somewhat similar to the carton 200 with the exception of the shape of the severance line which defines the detachable portion of the carton 900. The carton 900 includes a detachable portion 910 defined by a severance line 980. The severance line 980 includes a top wall portion 982, edge portions 983, 985, side wall portions 984, 986, and end wall portions 988, 990. In this embodiment, edges E are defined by top wall 914 and a respective side wall 912, 916. The edge portions 983, 985 extend along a segment of an edge E, respectively, between points P2 and P3. Points P2 on the top wall portion 982 of the severance line 980 are defined as those which are furthest from the second end wall 922. In this embodiment, the points P2 are located where the top wall portion 982 of the severance line 980 meets or intersects edges E. Points P3 on the side wall portions 984, 986 of the severance line 980 are defined as those which are closest to the second end wall 922. In this embodiment, the points P3 are located where each of the side wall portions 984, 986 of the severance line 980 meet or intersect an edge E. Accordingly, the edge portions 983, 985 of the severance line 980 extend between an end of the top wall portion 982 and an end of a respective side wall portion 984, 986.
The distance between the points P2 and the second end wall 922 is the maximum distance D2 between the second end wall 922 and the top wall portion 982 of the severance line 980. The distance between the points P3 and the second end wall 933 is a minimum distance D3 between the second end wall 922 and respective side wall portions 984, 986 of the severance line 980. In this embodiment, the distance D3 is greater than the distance D2.
Points P4 on the side wall portions 984, 986 of the severance line 980 are defined as those which are closest to the bottom wall 918. The distance between the points P4 and the bottom wall 918 is the minimum distance D4 between the side wall portions 984, 986 of the severance line 980 and the bottom wall 918. In the embodiment, the point P4 is located at a point where the side wall portions 984, 986 of the severance line 980 meet or intersect edges that are defined by the first end wall 920 and a respective side wall 912, 916.
In an alternative embodiment shown in FIGS. 10-13, a blank 1000 can be folded and secured to form a carton 1100. The blank 1000 includes five primary panels for forming the walls of a tubular structure portion of the carton 1100. The primary panels include a first bottom wall panel 1019, a first side wall panel 1012, a top wall panel 1014, second side wall panel 1016, and a second bottom wall panel 1018 which are foldably connected one to the next along fold lines 1022, 1024, 1026, and 1028.
End flaps are hingedly connected to opposite ends of each primary panel. The end flaps form end closure structures at respective open ends of the tubular structure portion of the carton 1100. The blank 1000 is substantially symmetric such that end flaps that are hingedly connected to opposite ends of each primary panel are substantially similar. Accordingly, the end closure structures of the carton 1100 are substantially identical and like references have been used with a suffix “a” or “b” affixed to distinguish one end of the carton 1100 from the other. Thus, the description of an element or group of elements having a suffix “a” is suitable for a like-numbered element or group of elements having a suffix “b”. In certain instances, for clarity, only one of the like elements may be described unless a description of the other or both of the like elements is necessary for understanding the invention. The end flaps of the blank 1000 include side end flaps 1032 a, 1036 a, top end flap 1034 a, and bottom end flaps 1038 a, 1039 a which are hingedly connected to respective primary panels along fold lines 1042 a, 1044 a, 1046 a, 1048 a, 1049 a.
The blank 1000 further includes a continuous severance line 1080 which defines a detachable portion 1110 when the blank 1000 is erected to form the carton 1100. The severance line 1080 includes a top wall portion 1082, side wall portions 1084, 1086, and end wall portions 1088, 1090. The top wall portion 1082 of the severance line 1080 extends across the top wall panel 1014 between the fold lines 1022, 1024 and is spaced apart from the fold line 1044 b.
The side wall portions 1084, 1086 of the severance line 1080 extend across the side wall panels 1012, 1016 between the fold lines 1022, 1024 and the fold lines 1042 a, 1046 a, respectively, or otherwise connect the top wall portion 1082 to the end wall portions 1088, 1090. The end wall portions 1088, 1090 of the severance line 1080 extend across the side end flaps 1032 a, 1036 a between the fold lines 1042 a, 1046 a and the edge of the blank 1000, respectively. When the blank 1000 is erected to form the carton 1100, the end wall portions 1088, 1090 of the severance line 1080 align to form a substantially continuous severance line, as described in further detail below.
A slot handle L, which is known in the art, is formed in top wall panel 1014 for carrying purposes. It should be clear to a person skilled in the art that any type of handle could be used and the handle could be located in any wall without departing from the scope of the invention including, for example, a strap handle.
A non-limiting method of forming the carton 1100 from the blank 1000 is now described. To form an erected carton 1100 from the blank 1000, the first bottom wall panel 1019 is folded along the fold line 1028 to be in flat face contact with the first side wall panel 1012. Glue or other adhesive is applied to the outermost edge of the first bottom wall panel 1019 and the second side wall panel 1016 is folded along the fold line 1024 to be in flat face contact with the top wall panel 1014. Thereby, the second bottom wall panel 1018 is secured to the first bottom wall panel 1019 to form a collapsed tubular structure. The collapsed tubular structure is then erected to form the open-ended tubular structure portion of the carton 1100 which defines a top wall 1114, side walls 1112, 1116, and a bottom wall 1118. After articles are loaded through one or both of the open ends of the carton 1100, the end flaps are folded and secured to form end closure structures, which define first and second end walls 1120, 1122, respectively, and thereby close the open ends of the tubular structure portion of the carton 1100.
In this embodiment, an end closure structure is formed by folding the top and bottom end flaps 1034 a, 1038 a/1039 a along the fold lines 1044 a, 1048 a/1049 a. Glue is applied to the outside faces of the top and bottom end flaps 1034 a, 1038 a/1039 a and the side end flaps 1032 a, 1036 a are folded along fold lines 1042 a, 1046 a to thereby secure the side end flaps 1032 a, 1036 a to the top and bottom end flaps 1034 a, 1038 a/1039 a. In this embodiment, the side end flaps 1032 a, 1036 a overlap and are secured to one another. It should be clear to someone skilled in art that there are many ways to construct the end walls 1120, 1122 of the carton 1100 including by securing only the side end flaps 1032 a, 1036 a together.
The carton 1100 encloses cans C that are arranged in a 6×2 array. Specifically, the cans C are arranged into two tiers and each tier includes six cans C. The cans C are disposed on their sides in a side by side parallel fashion such that the ends of the cans C abut the side walls 1112, 1116 of the carton 1100. It should be understood that other configurations of cans or other articles are possible without departing from the scope of the invention.
Referring to FIG. 11, the carton 1100 includes a detachable portion 1110 defined by the severance line 1080. A tear initiation tab 1092 is defined in the top wall 1114 by a segment of the top wall portion 1082 of the severance line 1080 and a severance line 1096. The tear initiation tab 1092 can be displaced such that the detachable portion 1110 can be grasped and pulled away to provide an access opening 1130.
The detachable portion 1110 is formed from a portion of the top wall 1114, a portion of the side panels 1112, 1116, and a portion of the first end wall 1120. In this embodiment, the detachable portion 1110 also comprises the slot handle L, although the slot handle L may be located in any wall.
Referring to FIG. 12, the detachable portion 1110 is partially detached from the carton 1100. The detachable portion 1110 is detached from the top wall 1114 and side walls 1112, 1116 and remains hingedly attached to the first end wall 1120 along the end wall portions 1088, 1090 of the severance line 1080. The detachable portion 1110 may be partially or fully detached, as shown in FIG. 13, to provide the access opening 1130 through which the cans C are accessible. The detachable portion 1110 is typically detached from the carton 1100 along end wall portions 1088, 1090 of the severance line 1080. If the detachable portion 1110 remains hingedly attached to the carton 1100 along the end wall portions 1088, 1090, the detachable portion 1100 can receive an article.
When the detachable portion 1110 is partially or completely detached, the lower portion of the first end wall 1120 forms a stopper wall 1320 that extends between the side walls 1112, 1116 to prevent the cans C from inadvertently exiting the carton 1100. In this embodiment, the upper edge of the stopper wall 1320 arches upwardly to maximize the retaining ability. The upper edge of the stopper wall 1320 is defined by the end wall portions 1088, 1090 of the severance line 1080 such that it is generally parallel to the cylindrical axis X-X of the endmost lower tier can C that is adjacent the stopper wall 1320. The height H of the stopper wall 1320 is defined as the maximum distance at which the end wall portions 1088, 1090 of the severance line 1080 are spaced apart from the bottom wall 1118. In this embodiment, the distance is less than the diameter of the cans C such that the contents of the carton 1100 are easily viewed through the opening 1130. In other words, all of the points along the upper edge of the stopper wall 1320 are less than the diameter from the bottom wall 1118. The stopper wall 1320 prevents the cans C from inadvertently exiting the carton 1100.
It is envisaged that the height of the stopper wall 1320 could be lesser or greater. For example, the height H of the stopper wall 1320 could be equal to that of the first end wall 1120. A taller stopper wall 1320 may be required, for example, to restrain articles contained in the upper tiers or uppermost rows of the carton 1100. Articles in the upper tiers may need to be restrained if greater than two tiers of articles are contained in the carton 1100. In this case, the severance line 1080 may extend along the edge defined by the top wall 1114 and the first end wall 1120. In this case, the detachable portion 1110 is formed from a portion of the top wall 1114 and a portion of the side panels 1112, 1116 such that the first end wall 1120 remains integral to the carton 1100. Alternatively, the height H of the stopper wall 1320 may be determined such that it is greater than the height of the number of tiers that need to be restrained minus the height of one tier.
It is also envisaged that, in certain embodiments, the stopper wall 1320 may be omitted if it is not needed to constrain articles in the carton 1100. In this case, the end wall portions 1088, 1099 of the severance line 1080 extend along an edge defined by the bottom wall 1118 and the first end wall 1120. The detachable portion 1110 is thereby formed from a portion of the top wall 1114, a portion of the side walls 1112, 1116, and the first end wall 1120.
In certain embodiments, the minimum distance D4 between the side wall portions 1084, 1086 of the severance line 1080 and the bottom wall 1118 is less than the diameter of a can C to provide accessibility to the bottom tier of cans C. For example, referring to FIG. 11, the minimum distance D4 between an arcuate segment of each of the side wall portions 1084, 1086 of the severance line 1080 is less than the diameter of the cans C such that the opposite ends of a lower tier can C are partially exposed. Specifically, the arcuate segments are disposed adjacent to the first end wall 1120 such that a user can easily grasp the endmost can C on the lower tier by its opposite ends.
In this embodiment, the arcuate segments allow access to only the endmost can C on the lower tier. After the endmost can C on the lower tier is removed, the cans C shift such that another can is forced against the stopper wall 1320 to become the endmost can C on the lower tier. Until all of the cans C in the upper tier are removed and at least one of the cans C in the bottom tier is removed, an endmost can C will be forced against the stopper wall 1320 for easy dispensing. In alternative embodiments, segments of the side wall portions 1084, 1086 of the severance line 1080 may be less than the diameter of cans C to expose any other lower tier cans C or multiple lower tier cans C.
The minimum distance D4 defines the minimum height of at least a portion of the side walls 1112, 1116 of the carton 1100 such that certain articles can be grasped without compromising the integrity of the stopper wall 1320. In certain embodiments, the distance D4 is less that the height H of the stopper wall 1320 such that the stopping ability of the stopper wall 1320 is optimized without inhibiting access to the cans C via the sidewalls 1112, 1116 of the carton 1100.
The side wall portions 1084, 1086 of the severance line 1080 facilitate accessing, as well as retaining, the upper tier of cans C. Specifically, referring to FIG. 11, a segment of each of the side wall portions 1084, 1086 is spaced apart from the top wall 1114 by a substantially constant distance D5. The distance D5 is determined such that a portion of the side walls 1112, 1116 are removed with the detachable portion 1110 to expose at least a portion of the ends of cans C in the upper tier. The distance D5 is also determined such that the ends of the upper tier of cans C are partially covered by the remaining portion of the side walls 1112, 1116 to retain the top tier of cans in the carton 1100. In addition, the minimum distance D3 between the side wall portions 1084, 1086 of the severance line 1080 and the second end wall 1122 is less than the diameter of a can C to provide accessibility to the rearmost can C in the upper tier without compromising the structural integrity of the carton 1100.
In any case, the detachable portion 1110 is formed from at least a portion of the top wall panel 1114 and a portion of the side panels 1112, 1116 such that the articles on the lower tier can be easily accessed without compromising the structural integrity of the carton 1110. The invention serves as a useful dispensing carton that can be placed upon a surface or within a compartment such as a refrigerator or pantry.
Modifications may be made in the foregoing without departing from the scope and spirit of the claimed invention. For example, the dispenser may be formed at either end of the carton according to the invention. It should be also appreciated that as used herein, directional references such as “top”, “bottom”, “end”, “side”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another.
It should be further appreciated that any reference to hinged or foldable connection should not be construed as necessarily referring to a single fold line only: indeed, it is envisaged that hinged connection can be formed from one or more of one of the following, a score line, a severance line or a fold line, without departing from the scope of invention.
The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.

Claims

1. A carton for enclosing a plurality of articles, comprising:

a tubular structure comprising a top wall hingedly connected to opposing side walls;

first and second end walls enclosing ends of said tubular structure, each end wall being hingedly connected to said top wall and said side walls; and

a detachable portion defined by a severance line extending across at least a portion of said top wall, at least a portion of said side walls, and a least a portion of said first end wall, the detachable portion being at least partially removable to form a dispenser for removing articles from said carton;

wherein the minimum distance between a top wall portion of said severance line and said second end wall is no greater than half of the distance between the first and second end walls.

2. The carton of claim 1, wherein the top wall portion of said severance line is substantially closer to said second end wall than to said first end wall.

3. The carton of claim 1, including a tear initiation arrangement that is hingedly connected to said top wall, and that is at least partially defined by said top wall portion of said severance line.

4. The carton of claim 3, wherein said tear initiation arrangement is located between said top wall portion of said severance line and said second end wall.

5. The carton of claim 1, wherein the minimum distance between at least one of the side wall portions of said severance line and the second end wall is no greater than half of the distance between the first and second end walls.

6. The carton of claim 5, wherein:

said tubular structure further comprises a bottom wall that is connected to said opposing side walls, said bottom wall opposing said top wall; and

the minimum distance between at least one of the side wall portions of said severance line and said bottom wall is no greater than half of the height of the carton.

7. The carton of claim 1, wherein said severance line extending at least partially across said end wall is severable to define the upper edge of a stopper wall, said stopper wall being for retaining articles in said carton upon removal of said detachable portion.

8. The carton of claim 6, wherein the maximum distance between said bottom wall and said upper edge of said stopper wall is greater than said minimum distance between said at least one of the side wall portions of said severance line and said bottom wall.

9. A carton for enclosing a plurality of articles, comprising:

a detachable portion defined by a severance line extending across at least a portion of said top wall, across at least a portion of said side walls, and generally along at least a portion of the hinged connection between said top wall and said first end wall, the detachable portion being at least partially removable to form a dispenser for removing articles from said carton;

wherein the minimum distance between a top wall portion of said severance line and said second end wall is no greater than half of the distance between the first and second end walls; and

wherein removal of said detachable portion along said hinged connection between said top wall and said first end wall defines the upper edge of a stopper wall that is for retaining articles in said carton.

10. The carton of claim 9, wherein:

said tubular structure further comprises a bottom wall that is connected to said opposing side walls, said bottom wall opposing said top wall;

the minimum distance between at least one of the side wall portions of said severance line and the second end wall is no greater than half of the distance between the first and second end walls; and

11. A package, comprising:

a plurality of substantially identical and substantially cylindrical articles arranged in an array having a plurality of rows;

a carton for enclosing said articles, said carton comprising:

a tubular structure comprising a top wall and an opposed bottom wall, each being hingedly connected to opposing side walls;

first and second end walls enclosing ends of said tubular structure, each end wall being hingedly connected to each of said top wall, bottom wall, and said side walls; and

a detachable portion defined by a severance line extending across at least a portion of said top wall, at least a portion of said side walls, and a least a portion of said first end wall, the detachable portion being at least partially removable to form a dispenser for selectively removing said articles from said carton;

12. The package of claim 11, wherein said minimum distance between said top wall portion of said severance line and said second end wall is at least half the diameter of one of said articles.

13. The package of claim 11, wherein removal of said detachable portion no more than partially exposes the rearmost row of articles disposed along said second end wall.

14. The package of claim 11, wherein said articles are disposed on bottoms thereof atop the bottom wall of said carton, with said rows being aligned with said first and second end walls.

15. The package of claim 11, wherein:

said articles are disposed on sides thereof in at least one tier extending along the bottom wall of said carton, with ends thereof being disposed said first and second end walls; and

the minimum distance between at least one of the side wall portions of said severance line and the bottom wall is no greater than half the diameter of one of said articles.