CA1150683A - Peelable on-package coupon and method for making same - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

A laminated container structure in which a peel-able coupon or the like forms an integral portion of the outer ply of the container wall and is defined by a perforated tear outline. In one embodiment, a release agent is coated on the back of the coupon area to prevent adherence of the coupon to the adhesive joining together the outer and inner plies of the container. In another embodiment, the inner ply is formed of cylinderboard adhesively fastened to the outer ply, the perforate coupon tear outline extending through the outer ply, adhesive and outer-most layer of the inner ply so that peeling of the coupon will not remove the inner layers of the inner ply and thus not destroy the integrity of the con-tainer.

Description

h683 The present invention relates to a l~minated or layered container structure and, more particularly, to a container or package having a readily detach-able coupon incorporated irl the outer ply or lamina thereof.
It is currently widespread practice in the mer-chandising of commodities which are packaged in closed containers, that a redeemable coupon, mailing pîece, ticket or the like be packaged in the con-tainer. This has the effect that the purchaser can-not redeem the coupon until the package is opened to provide access to the commodity and coupon contained therein. Alternatively, the coupon may be affixed to the exterior surface of the container adapted for easy detachment thereof by a purchaser or consumer.
However, this frequently entails the inadvertent loss of the coupon during storage, shipping or handling of the container, or may even be conducive to the theft of the coupon preceding the sale of the container. The coupon may also be printed on the exterior surface of the container or package, and may be cut out by the consumer after the container is opened. This, however, will destroy the integri-ty of the carton and prevent the merchandise con-tained therein from being stored for any appreciable length of time. Consequently, redemption of such a printed-on coupon is only practicable after the mer-chandise has been used and the container is in an emptied condition. ~oreover, removal of this type of coupon necessltates the employment of a sharp cutting object, such as a SCiSSQrS or knife.
More recently, containers or packages have been devèloped which incorporate easily detachable or peelable portions as integral elements of the outer ply of th~e container structure.

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Thus, Loderhose U.S. Reissue Patent 2~,962 dis-closes a phonograph record jacket having a detach-able or peelable picture-bearing section incorpor-ated in the outer ply of the jacket for separation thereof along a predetermined perforated tear out-line. In this construction the removal of the sec-tion, or pictorial portion, will leave a loose and readily tearable peripheral edge in one exterior sur-face of the jacket, thereby rendering ~he latter easily torn and unsightly when repeatedly handled for any significant period of time.
Krug U.S. Patent 2,420,045 relates to a coupon which is an element in the label of a container, adapted to be readily separated along perforated tear lines. However, in this instance~ the coupon is an appendage of the label, which is then folded over to provide a double-thickness portion suitable for peeling off by the ultimate purchaser or con-sumer of the container. This structure requires the utilization of extra lengths of label material, while concurrently permitting the coupon to be in-advertently or deliberately detached from the con-tainer prior to the sale of the latter.
Corrinet U.~. Patent 3,110,121 and Gorman et al. U.S. Patent 3,463,303 also describe containers providing for detachable elements as integral com-ponents of a label applied to a container wall structure. However, neither of these patents con-template the element being an integral portion en-tirely contained withln the outer ply of a laminate forming the wall structure of the con-tainer.
In order to obviate or ameliorate the short-comings and limitations encountered in the prior art containers incorporating removable surface portions, the present invention contemplates a laminated or ;

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~ 6~ 3 multiple-ply container structure comprising an inner ply of a semi-rigid material, such as paperboard, and an outer ply of a generally pliant material, such as glossy finished paper, adhesively joined thereto by means of a suitable laminant. Formed in the outer ply of the conta;;ner, as an integral com-ponent thereof, and through the intermediary of a tear outline consti~uted o~E perforations extending through said outer ply is a readily removable or peelable coupon, the peeling off of the coupon being adapted to be accomplished without adversely affect-ing the integrity of the container s-tructure or necessitating the use of special tools.
In one form of the invention, the interior sur-face of the outer ply, in effect, the surface in con-tact with the adhesive material bonding the outer ply to the inner ply of the laminated material is provided with a coating of a release agent or adhesive-repellent medium over an area which is co-extensive with the area defined by the coupon, in effect, within the region bounded by the perforate tear outline. The provision of this coating on the back portion of the outer ply forming -the coupon will facilitate the easy peeling off of the coupon by the purchaser of the package or container, and permit the coupon to be immediately redeemed at ~he location of purchase while the integrity of the con-tainer is concurrently fully maintained.
In another embodiment of the invention, wherein the inner wall of the laminated container is con-stituted of cylinderboard, namely of a multiple-ply or layered construction, the necessity for providing a release agent coating or adhesive-repellent medium between the surface of the coupon portion of the outer ply and the adhesive is obviated, since ~5~6133 peeling of~ of the coupon from the container will result in the concurrent removal therewith of the adhesive layer therebeneath and the outermost layer or top liner of the inner ply adhering to the adhe-sive material~ without advlerse effects on -the inte-grity of the package or container struc-ture.

The present invention provides a laminated container structure which will permit the in-corporation of a readily removable or peelable coupon as an integral component of the outer ply of the multi-plied container structure in which the removal of the coupon will not adversely affect the integrity of the container structure, and will allow for the coupon to be redeemed at the time of pur-chase oE the container.
~: Also, the present invention provides, as one embodiment, a laminated carton structure in which the portion of the outer ply constituting the coupon has the surface thereof facing an adhesive material coated with a release agent or adhesive-repellent medium to thereby permit the easy peeling off of the coupon without the necessity of employing any special-ized tools or sharp cutting implements.
An alternate embodiment of the present inven-tion is to provide a laminated container structure wherein the coupon which is incorporated in the out-er ply of the container as an integral portion there-of may be readily detached or peeled therefrom toget-her with the adhesive ma~erial and the outer layer of the inner ply without destroying or adversely ; affecting the integrity of the con-tainer, and in which the inner ply is formed o~ a multi-layered cylinderboard to thereby obviate the necessity of employing a release agent or adhesive-repellent coating beneath the coupon portion of the outer ply.

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Further, the invention provides an improved method for making a carton incorporating a peelable coupon in the outer surface thereof.
The present invention may be more readily under-stood by having reerence to the following detailed description of preferred embodiments of the inven-tive laminated con~ainer s~:ructure incorporating the peelable coupon, taken in conjunction with the accompanying drawings, in which:
Figure 1 ~hows a perspective view of a portion of a laminated container structure in conformance with the present invention;
Figure 2 is an elevational view o~ a portion of a container similar to that of Fig. 1 and illustrat-ing a somewhat modified coupon design;
Figure 3 is a sectional view, on an enlarged scale, taken along line 3-3 in Fig. 2;
Figure 4 is a partial elevational view of another embodiment of a laminated container struc-ture pursuant to the present invention;
Figure 5 is a sectional view, on an enlarged scale, taken along line 5-5 in Fig. 4, and illustrat-ing a cutting tool in its position when forming the perforated tear line;
Figure 6 is a view similar to that of Fig. S
showing the coupon formed in the outer ply of the contain~r structure in the process of being detach-ed; and Figure 7 schematically illustrates an installa-tion for producing laminated carton blanks.
Referring now in detail to the drawings, the embodiments illustrated in Figs. 1 to 3 are directed to a merchandise package or container structure 10 ~` which is basically constituted of a rectangularly-sided carton or bulk goods or products such as, for . ' ':
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U~8~3 example, cereal, cookies, condiments or other con-sumer oriented merchandise. The portions of con-tainer 10 shown in Fig. 1 includes the usual front and side panels 12 and 14. In ~he Fig. 2 embodi-ment, only a portion of the front panel 12 is shown.
As is well known in the art, the carton 10 may be constituted of a laminated or multi-ply construc-tion comprising an inner ply 16 formed of a relative-ly rigid paperboard or cardboard material and an outer ply 18 formed of a more pliant material, such as a glossy finished paper, adapted to have suitable indicia or art work imprinted thereon. The outer ply 18 is adhesively joined to the inner ply 16 through the interposition of a layer or coating of an adhesive material or glue 20.
A peelable or detachable coupon 22 or 23 may be incorporated in the outer ply 18, as an integral por-tion of the latter, on one of the panels 12 or 14 of the carton 10 by the provision of a tear outline comprised of slits or perforations 24 extending through at least the outer ply 18 to the adhesive layer ~0.
In order to facilitate the peeling away or tearing of of the coupon 22 or 23 from the contain-er 10 along the tear outline formed by the perfora-tions 24, a suitable release agent or adhesive-repellent medium 26 may be coated prior to lamina-tion of the materials on the rear surface of the coupon portion of the outer ply 18, in effect, the surface which is in contact with the adhesive material 20j to thereby prevent any adhesion between the back of ~he coupon 22 and the inner ply 16 of the container. Such release agent or adhesive-repellent medium may be constituted of any type, well-known to the art, which will not adhere to the .

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particular adhesive material 20 employed. The area of the surface of the outer ply 18 of the carton which is coated with the release agent 26 is sub-stantially coextensive with the surface area of the coupon 2~ confined within the tear olltline of the perforations 24.
In the embodiment of Fig. 2 the tear outline defining three sides of the coupon 23 consists of a series of short closely spaced slits 24 which serves to hold the respective coupon edges secure prior to peelin~ of the coupon. The fourth side of the tear outline includes at least one relatively longer slit 25 of a length sufficient to enable the coupon edge to be engaged and lifted such as by ones fingernail preparatory to peeling thereof.
In the embodiment of ~ig. 1 the coupon 22 is defined along one edge by a continuous slit 28 which ~ may at one end thereof include a curved protuberance - to serve as a gripping tab 30 for facilitating en-gagement of the coupon prior to peeling. The con-tinuous slit along one edge avoids the necessity of having to tear along twa edges simultaneously at the start of the peeling function and thereby minimi~es accidental tearing of the coupon itself.
In the event a wax laminating adhesive is employed J a partial severable bond will result in which case the tear outline may consist of con-tinuous slits along all edges of the coupon, since such partial bond will adequately secure the coupon prior to intentional peeling thereof.
Since the application of the release agent or adhesive-repellent medium 26 is restricted to the area of the rear surface of outer ply 18 which is substantially coextensive with the perforation tear outline 24, as shown in Fig. 3, subsequent to the .

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: , g peeling away of the coupon 22, the outer periphery of that area will have the perforated edges of outer ply 18 closely adhered to ~-he inner wall 16~ thereby preventing any inadvertent tearing and disfiguring of the remaining outer ply of the container 10.
Moreover, since the perforations 24, 25, 28 do not cut into the inner ply 16 to any appreciable extent, the strength and integrity of the carton 10 remains essentially unimpaired to allow for long-term stor-age and use by the consumer of the merchandise con-tained therein.
The laminated container structure or package 40 illustrated by the embodiment in Figures 4 through 6 of the drawing differs from that of the embodiments shown in Figures l to 3 in that no release agent or adhesive-repellent medium is interposed between the rear surface of outer paper ply 4~ forming the coupon and the adhesive material or glue 44 bonding the outer ply 42 to the inner paperboard ply 46.
In this embodiment, the inner ply 46 is gen-erally constituted of cylinder board, namely, laminated plies or layers of fibers produced in accordance with the cylinder process for making paperboard. This construction provides a plurality of layers 46a, 46b, 46c, 46d, 46e, and so forth, depending upon the desired board thickness of the inner ply 46. These layers or plies adhere intimate-ly to each other but are able to be separated from each other by the mere expedient of being pulled apart.
A d~tachable or peelable coupon 48 is formed in one of the panel surfaces 50 of the container 40 by providin~ a tear outline 52 constituted of contin-uous slits encompassing the coupon area. The slits may be formed by a suitable cutting tool 54, and are , .~

~ . ' ' - ~ , ~ ' cut to extend through the outer ply 42, the adhesive material 44 and the outermost ply or top liner 46a of the cylinderboard 46. Thus, when it is desired to peel the coupon 48 from the container 40, one needs only to insert a fingernail into one of the slits 52 and to pull the coupon 48 away from the con-tainer surface in the direction of arrow A, as shown in Fig. 6 of the drawing. This will cause the layers 46a and 46b of the inner ply 46 to separate, without disturbing the integrity of the closed con-tainer 40.
It should be noted that the use of printed ~
cylinder board alone, without a paper ply laminated thereto, will produce a similar result. In this case a portion of the top liner of~the board itself serves as a coupon which is peelable from the re~
mainder of the board.
Fig. 7 of the drawing illustrates schematically an arrangement or method for making laminated carton blanks erectable into the novel carton structure incorporating a peelable coupon or the like as here-tofore described. As shown, a continuous web 60 of pliant pac~aging material intended to serve as the outer ply of the resultant cartons, such as a glossy finish paper, is fed from a supply spool 62 and directed by suitably located rolls 64 to a series of three printing stations 66, 68 and 70 in succession.
Each printing station includes a receptacle 72 for containing a printing media in which is immersed a printing or etched cylinder 76 cooperating with an impression roll 74 for applying the print~media to the web. Also associated with each print station is a heated chamber or oven for drying the imprint made at the respective print station before the we~ pro-ceeds to the next station of the series.
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, , ~5~6~3 The print media applied to the web at the first print station 66 is an ink which may be applied over the entire top surface of the web, the imprint in-cluding suitable text or legend for that portion of the web ultimately becomming a peelable coupon on the resultant carton.
In applications where it is desired that print-ing be carried on the backside of the resultant cou-pon, this can be accomplished at printing station 68, the printing cylinder of which to apply an ink imprint on the backside of the web only in the area thereof constituting the coupon. At print station 70 the print media is a release agent which, as in the case of the preceding print station, is applied to the backside of the web in the area thereof con-stituting the coupon.
Although the disclosed example shows provision for one color printing, it should be understood that multi-color printing of the web 60 could be achieved by provision of an appropriate or desired number of additional printing stations according to the numbers of different colors desired. Also, if printing on the backside of the coupon portion of the web is not desired, the printing station 68 would be eliminated. After receiving a coating of the release agent on the backside of the coupon area, the web 60 proceeds to laminating rolls 92, 94 where it is joined to a continuous web 80 of a heavier more rigid packaging material, such as paper-board or the like which is supplied from a spool 82 thereof. The paperboard web 80 as it leaves the spool`82 is directed by guide rollers 84 to a laminant applicator comprised of a laminating cylinder 88 immersed in a laminan~ contained in receptacle 90 and operating in conjunction with an , .

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impression roll 86 to apply the laminant to the en-tire suface of the web which interfaces with the continuous web 60. The two webs thus become firmly bonded to one another over their entire interfacing surfaces except in the coupon area thereof which as aforementioned has a coating of a release agen-t applied thereto.
The cutter wheel 96 is provided not only with knives for severing entire carton blanks from the web but also with shorter knives 54 adapted for less board penetration and arranged to produce the tear outline defining ~he coupon area of the resultant cartons. As heretofore mentioned the tear outline consists of perforations or slits, which may be either continuous or discontinuous, through the outer ply but stopping short of any appreciable pene-tration of the inner board ply of the laminated material so as to thereby enable peeling off of the coupon without destroying or substantially effecting the integrity of the carton.
Although Fig. 7 shows a cutter of the rotary type, it should be understood that othcr types of cutters, such as a flat bed type, could be utilized to achieve the same results. Also, for reasons of disclosure simplification, Fig. 7 shows the printing operation occurring simul~aneously or in line with the laminating, cutting operation. This, however~
is not a necessary aspect of the disclosed method.
Since printing presses could generally run at a con-siderably higher speed than laminators or cutters, in many instances it could be more practical and preferred to pre-print the paper web 60 and rewind it for laminating and cutting at a subsequent in-dependent operation. In this manner, one printing installation can be utilized to meet the needs of more than one laminator-cutter installation.
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From the foregoing i-t will become readily apparent that the present invention provides a novel and improved means and method for incorporating re-deemable coupons or the like with packaged consumer products. It can be produced at substantially the same cost as the most conventional form printed on carton coupons but has the additional advan-tage over such conventional coupons of being immediately re-deemable at the time of purchase in that it may be easily detached or peeled off from the carton with-out adversely affecting or destroying the integrity of the carton, or requiring the use of specialized tools or cutting instruments.
While there has been shown and described what are considered to be preferred embodiments of the invention, it should be understood that variations in form and detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited -to the exact form and detail shown hereln and described, nor to anything other than the whole of the invention as hereinafter claimed.

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Claims (17)

The embodiment of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A carton formed from a blank of flexible packaging material comprised of plural coextensive layers of fibrous matter, the outer layer of said material being adapted to have indicia imprinted thereon and including a removable section completely enclosed by a tear outline, said tear outline follow-ing a generally rectangular configuration and consisting of a series of slits penetrating through said outer layer, said tear outline along at least the major portion of one side thereof consisting of a continuous slit to facilitate separation of said section from said carton, said section being peelable from said carton along said tear outline leaving the remaining layers of said material intact to provide integrity for the carton after said section is removed.

2. The container according to Claim 1 wherein said packaging material is cylinderboard and said outer layer is the top liner thereof.

3. A container according to Claim 1 wherein each side of said tear outline consists of a continuous slit.

4. A container formed from a blank of laminated packaging material comprised of an inner relatively rigid coextensive ply constituting a plurality of separable layers of fibrous matter and an outer ply of a more pliant material adapted to have indicia imprinted on the outer surface thereof, a laminating adhesive disposed between said plies for bonding said plies to one another, said packaging material having a removable section completely enclosed by a tear outline consisting of slits penetrating through said outer ply and at least the outer layer of said inner ply, said removable section consisting of a portion of said outer ply and the portion of the outer layer of said inner ply bonded thereto being peelable from said container along said tear outline while leaving the remaining layers of said inner ply intact to maintain the integrity of the container.

5. A container according to Claim 4 wherein the slits enclosing the removable section are continuous to facilitate the peeling of said section from said container.

6. A container according to Claim 5 wherein the inner ply of said packaging material is cylinderboard.

7. A folding carton formed entirely from prelaminated packaging material comprised of an inner ply of paper-board and an outer relatively pliant ply of paper adapted to have indicia imprinted on at least the outer surface thereof, a laminant adhesive disposed intermediate said ply for laminating same to each other, said outer ply having a removable section at a predetermined area thereof, and an adhesive release agent coated on the inner surface of the removable section to prevent adhesive bonding of said section with said inner ply, and said removable section enclosed by a tear outline comprised at least partly of adhesive-free discontinuous slits penetrating completely through said outer ply, said removable section being peelable therefrom said carton along said tear outline leaving said inner ply intact to maintain the integrity of said carton.

8. A carton according to Claim 7 wherein said tear out-line is generally rectangular in configuration with at least the major portion of one side thereof comprising a continuous slit to facilitate the separation of said removable section from said carton.

9. A carton according to Claim 8 wherein said outline at one end of said continuous slit includes a curved protuber-ance defining a tab to facilitate gripping of said removable section in preparation for the peeling thereof from said carton.

10. A carton according to Claim 7 wherein the adhesive release agent is a wax substance.

11. A method for making laminated carton blanks in-corporating in the outer ply thereof a peelable section com-prising the steps of, printing on the outer surface of a continuous web of flexible packaging material indicia appropriate to the end use of the resultant carton as a container, including the printing at predetermined areas of said surface indicia appropriate to the use of each said predetermined area as a separate printed medium having utility other than that said carton, applying to the inner surface of said predetermined areas a coating of an adhesive repellant substance by a printing cylinder at a print station in line with the print station where-of said indicia is printed on the outer surface of said flexible packaging material, adhesively laminating said web with a continuous web of less flexible packaging material with the outer surface of the former becoming the outer surface of the laminate, cutting said laminate into individual carton blanks each including at least one of said predetermined areas, and cutting completely through the outer ply of each blank in a tear outline enclosing a said predetermined area and to a depth less than the thickness of the said laminate to render each said predetermined area of said outer ply a peelable section thereof.

12. The method according to Claim 11 wherein the step of cutting said laminate into individual carton blanks and the step of cutting through the outer ply of each blank in a tear outline are performed concurrently.

13. The method according to Claim 11 including the step of printing the inner surface of said predetermined areas with indicia appropriate to the use thereof as a separate printed medium prior to the step of applying thereto a coating of an adhesive repellant substance.

14. The method according to claim 13 wherein the step of cutting said laminate into individual carton blanks and the step of cutting through the outer ply of each blank in a tear outline are per-formed concurrently.

15. The method according to claim 13 including the step of printing the inner surface of said pre-determined areas with indicia appropriate to the use thereof as a separate printed medium prior to the step of applying thereto a coating of an adhesive repellent substance.

16. A container formed from a blank of packaging material, comprised of plural coextensive layers of fibrous matter, the outer layer of said material being adapted to have indicia imprinted thereon and including a removable section completely enclosed by a tear outline consisting of slits penetrating through said outer layer, said section being peelable from said container along said tear outline leaving the remaining layers of said material intact to maintain the integrity of the container.

17. A method for making laminated carton blanks incorporating, in the outer ply thereof, a peelable section, said method comprising the steps of, providing a continuous web of flexible packaging material adapted to have indicia printed on one surface thereof, said web including predetermined areas of said surface, applying to the other surface of said predetermined areas a coating of an adhesive repellent substance, adhesively laminating said web with a continuous web of packaging material with the said one surface of the former becoming the outer surface of the laminate, cutting said laminate into individual carton blanks each including at least one of said predetermined areas, and cutting completely through the outer ply of each blank in a tear outline enclosing said predetermined area and to a depth less than the thickness of the said laminate to render each said predetermined area of said outer ply a peelable section thereof.