US20070284424A1

US20070284424A1 - Expandable carton

Info

Publication number: US20070284424A1
Application number: US11/760,305
Authority: US
Inventors: John M. Holley
Original assignee: Meadwestvaco Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2006-06-09
Filing date: 2007-06-08
Publication date: 2007-12-13

Abstract

A leak resistant expandable carton is end-loadable and expandable to retain ice or other matter above a compartment loaded with articles such as cans or bottles. The carton is expanded by separating its top wall with a tear strip and then by raising composite top end flaps, which are hingedly connected to the top wall and to the end walls of the carton. As the composite top end flaps are raised, the top wall sections are raised to be side extensions that are coplanar with and to extend above a pair of side walls. At the same time, the composite top end flaps unfold and are raised to be end extensions that are coplanar with and to extend above the pair of end walls. The side and end extensions are substantially continuously interconnected so that the expanded portion of the carton is relatively rigid and contiguous.

Description

RELATED APPLICATIONS

This application claims priority to U.S. Application No. 60/804,393, filed Jun. 9, 2006, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

This invention relates generally to cartons and, more specifically, to cartons that are expandable to a larger volume.

BACKGROUND OF THE INVENTION

Cartons that are expandable to increase their volume or capacity are known in the art, and are useful to allow a consumer to, for example, add ice to a carton that is full of beverage cans or bottles. These cartons are often also designed to retain liquid as the ice melts.
Some such cartons are made expandable by the addition of extension panels and gusset panels, which must be stowed until the carton is expanded, and thus often inhibit machine loading of articles into the cartons. Specifically, the extension panels and gusset panels obstruct an open end of the carton when the carton is arranged as a tubular structure for end loading, thereby preventing smooth mechanical loading. To overcome this obstruction, these expandable cartons must be hand loaded, which is much less efficient compared to the output of contemporary high speed packaging automated processes. Therefore, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies. What is needed is an expandable carton that easily can be mechanically loaded or that otherwise includes extension panels and gusset panels that do not obstruct loading of articles into the open ends of the carton when the carton is arranged as a tubular structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary blank for forming an expandable carton, according to an embodiment of the present invention.

FIGS. 2-5 are perspective and partial perspective views that illustrate steps for erecting the expandable carton from the blank of FIG. 1.

FIG. 6 is a perspective view of a fully erected expandable carton formed from the blank of FIG. 1.

FIG. 7 is an end elevational view of an end closure structure of the expandable carton of FIG. 6.

FIGS. 8-13 are perspective and partial perspective views that illustrate steps for opening the expandable carton of FIG. 6.

SUMMARY OF THE INVENTION

The present invention addresses the shortcomings of the prior art by providing an end loadable carton that is expandable to include a chimney that increases the volume of the carton so that ice or other matter can be placed in close proximity to the original contents of the carton. Advantageously, the loaded carton becomes a package that is easy to carry and to open, and the process of opening the package substantially automatically creates the chimney, thereby readying the package for unloading or for addition of ice. Ideally, the carton is formed from a unitary blank, further facilitating erecting the carton by automated process.
Generally described, the carton is erected into a tubular, sleeve-like configuration defined by a top wall, side walls, a bottom wall and end closures that define end walls at the open ends of the tubular structure. The top wall is divisible longitudinally into two sections. The end closures include a composite top end flap that is hingedly connected to the top wall and to a respective end wall. More specifically, the top end flap is hingedly connected along end edges of each of the top wall sections and is hingedly connected along the upper edges of a pair of side end flaps that are included in the respective end closure.
According to one aspect of certain exemplary embodiments of invention, the carton is expanded by operating a tear strip that extends between the top wall sections. The sections are liberated from one another, but remain hingedly connected to each composite top end flap, and thus to the end closures. The top end flap is pulled outwardly and upwardly away from the remainder of the end closure. The composite top end flap includes end extension panels and gusset panels which allow the separated sections of the top wall to then become substantially coplanar with respective side walls and the extension panels and gusset panels to become substantially coplanar with respective end walls. Thereby, a chimney of the carton is formed to increase the capacity of the carton.
In certain embodiments, the composite top end flap is stowed as an exposed layer of the end closure by being at least partially overlapped by a bottom end flap. A tear away tab may be provided in the overlapping portion of the bottom end flap as an easily accessible hand hold that is secured to the composite top end flap and that detaches from the remainder of the bottom end flap as the chimney is erected. However, it is contemplated that the composite top end flap may simply be tacked down or releasably glued in place.
Thus, one aspect of the invention is an expandable carton that includes a top wall, a bottom wall, a first side wall, and a second side wall that are hingedly connected to one another to form a tubular sleeve-like structure. Each open end of the tubular structure is enclosed by a first end wall and a second end wall. Articles such as cans or bottles loaded through the open ends of the tubular structure are enclosed in the resulting compartment that is subsequently enclosed by end walls.
Each end wall is a composite end closure made up of several elements, including the composite top end flap, a pair of side end flaps, and a bottom end flap, the composite top end flap being hingedly connected to the top wall and to each of the pair of side end flaps, the side end flaps being hingedly connected to the first side wall and to the second side wall, respectively.
The top wall is divisible to define and separate at least a first and a second section thereof, wherein after being separated, the first and second section can be raised to form extensions of the first and second side walls as the composite top end flap is raised away from the end wall and toward the top wall. During this same motion, the composite top end flap unfolds and separates in part to reveal its constituent parts as it is raised to form an extension of the end wall. In this fashion, the side extensions and the end extensions define the periphery of an expanded portion of the carton.
More specifically, the composite top end flap includes a pair of extension panels and a pair of gusset panels, each of the extension panels being connected to one of the side end flaps by one of the gusset panels. Each extension panel is hingedly connected to one of the top wall sections. The extension panels of each composite end flap are initially connected to one another along a severance line that extends from one end of the tear strip; the extension panels are separated along this severance line, which breaks as the composite end flap is raised. Together, the extension panels and gusset panels cooperate to form a web that encloses an end of the expanded portion.
According to another aspect of certain embodiments, the bottom end flap serves to detachably secure the composite end flap prior to expanding the carton. To that end, the bottom end flap overlaps the composite top end flap at least partially, with the overlapping portion including a tear away tab. The tear away tab is preferably the only portion of the bottom end flap that is glued or otherwise secured to the composite top end flap, and is defined at least in part by a severance line, the ends of which lie closer than its middle. The severance line that defines the tab is in registry with a distal edge of the composite top end flap so that a user can insert a finger to grasp the tear away tab, which also engages the composite top end flap to which the tab is directly secured. Once grasped, the tear away tab can be lifted to sever its connection to the bottom end flap and thereby to liberate the underlying distal end of the composite top end flap. The tear away tab may be secured to both gusset panels so as to hold the gusset panels together as the carton is expanded.
The separated top wall sections can be raised to be substantially coplanar with respective side walls, and the composite top end flap can be raised and arranged such that the extension panels and the gusset panels are substantially coplanar with the side end flaps. In effect, therefore, the original side walls and end walls are simply extended in height to achieve expansion of the carton. The side and end extensions are substantially continuously interconnected so that the expanded portion of the carton is relatively rigid and contiguous.
According to another aspect of the invention, the expandable carton is formed from a unitary blank, which greatly simplifies its construction. The blank includes major panels that become the top, bottom, and side walls, these major panels being connected in series along transverse edges in any sequence that yields the desired configuration. For example, the first panel in the series may be a first partial side panel that is hingedly connected along its side edge to a top panel, which is hingedly connected along its side edge to a second side panel, which is hingedly connected along its side edge to a bottom panel that is connected along its side edge to a second partial side panel. Together the first and second partial side panels form a composite side wall to which first and second partial side end flaps are connected to form a composite side end flap. Alternatively, an edge flap may allow interconnection of the bottom panel to the first side panel. Those skilled in the art will readily appreciate the ability to shift the sequence panel by panel to alter the design without escaping the scope of the invention.
The top panel includes a tear strip that extends between its end edges, and a severance line extends from each end of the tear strip to define abutting edges of a pair of extension panels that are hingedly connected along each end edge of the top panel. A gusset panel interconnects each of the extension panels and an adjacent full or partial side end flap. A notch or gap may remain between the two gusset panels to ensure that the upper edge of the expanded portion of the carton is level, or the gusset panels may abut one another as well.
Bottom end flaps are hingedly connected along the end edges of the bottom panel. Each bottom end flap is hingedly connected by a web panel to a side end flap and the lower part of the composite side end flap. In this fashion, leak resistant bottom corners are formed when the carton is erected. Toward the distal end of each bottom end flap, a severance line defines the tear away tab. In the embodiments described herein, the severance line is somewhat arcuate with its distal ends being closer to the distal end of the bottom end flap than its medial section.
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.

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 an expandable carton. In describing the expandable carton, the following terms, among others, will be used.
The term “fold line” is used herein to refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line is typically a scored line, an embossed line, or a debossed line.
The term “severance line” refers to all manner of lines that facilitate separating portions of the substrate from one another or that indicate optimal separation locations.
Severance lines and fold lines can each include elements that are formed in or through the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, combinations thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality
Referring to the exemplary embodiment illustrated in FIG. 1, an expandable carton 600 (shown in FIG. 6) is formed from a blank 100, which is preferably a single sheet of suitable substrate. 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, cardboard, plastic, or the like. The carton may include a water resilient coating on at least one surface. In the exemplary embodiment, the blank is designed for packaging beverage cans. It is envisaged that other articles and/or different arrangements of articles may be contained within the carton and that the blank may therefore be sized accordingly.
As used herein, 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, any combination thereof, and the like.
The blank 100 includes a series of primary panels which define the walls of a tubular structure T of the expandable carton 600 shown in FIG. 6. Specifically, the blank 100 includes first side panels 110, 118, a top panel 112, a second side panel 114, and a bottom panel 116. The primary panels are hingedly connected one to the next transversely along fold lines. First side panel 110 is hingedly connected to the top panel 112 along a fold line 120, the top panel 112 is hingedly connected to the second side panel 114 along a fold line 122, the second side panel 114 is hingedly connected to the bottom panel 116 along fold line 124, and the bottom panel 116 is hingedly connected to first side panel 118 along a fold line 126. In addition, a handle reinforcing flap 119 is hingedly connected to first side panel 118 along a fold line 128. In the exemplary embodiment, the first side panel 110 includes an optional handle H and the fold line 128 is interrupted by a handle aperture A. Those skilled in the art will recognize that the handle is most useful in applications where liquid retention is not needed, or a liner is provided to prevent leakage of liquid.
End flaps are hingedly connected to opposite ends of each primary panel along fold lines. The end flaps are configured and arranged to form end closure structures at respective open ends of the tubular structure T of the expandable carton 600 and thereby define the end walls of the expandable carton 600. The blank 100 is substantially symmetric such that the end flaps that are hingedly connected to opposite ends of each primary panel are substantially similar. Accordingly, the end closure structures of the carton 600 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 generally applicable to 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 useful for understanding the invention.
First side end flaps 130 a, 138 a are hingedly connected to first side panels 110, 118 along fold lines 140 a, 148 a, respectively, top end flap 132 a is hingedly connected to top panel 112 along a fold line 142 a, second side end flap 134 a is hingedly connected to second side panel 114 along a fold line 144 a, and bottom end flap 136 a is hingedly connected to bottom panel 116 along a fold line 146 a. The top end flap 132 a is divisible to define first and second extension panels 170 a, 172 a which are detachably connected to one another along a severance line 164 a.
The top and bottom end flaps are connected to adjacent side end flaps by a gusset panel. The top end flap 132 a is connected to the side end flaps 130 a, 134 a by gusset panels 174 a, 176 a, respectively. The bottom end flap 136 a is connected to the side end flaps 134 a, 138 a by web panels 171 a, 173 a, respectively. The exemplary extension panels 170 a, 172 a, web panels 171 a, 173 a, and gusset panels 174 a, 176 a are shown as individual panels, although in practice, a gusset panel may consist of several interconnected possibly foldable sections, and an extension panel can similarly include multiple sections.
The extension panels 170 a, 172 a are hingedly connected to the gusset panels 174 a, 176 a along fold lines 178 a, 180 a, respectively, and are partially separated from the gusset panels 174 a, 176 a along severance lines 182 a, 184 a, respectively. Each of the severance lines 182 a, 184 a extends between an end of a respective fold line 178 a, 180 a and a notch 166 a, which is a void between the distal edges E3, E4 of the gusset panels 174 a, 176 a and the distal edge E5 of the top end flap 132 a. The gusset panels 174 a, 176 a include distal edges E1, E2, respectively. The gusset panels 174 a, 176 a are further hingedly connected to the side end flaps 130 a, 134 a along fold lines 150 a, 152 a, respectively.
The side end flaps 134 a, 138 a are hingedly connected to the web panels 171 a, 173 a along a fold line 175 a, 177 a, respectively. The web panels 171 a, 173 a are further hingedly connected to the bottom end flaps 136 a, 138 a along fold lines 154 a, 156 a, respectively.
Glue receiving portions G of the gusset panels 174 a, 176 a are provided near the distal edges E3, E4 of the gusset panels for the application of glue or other adhesives, as will be described below. The bottom end flap 136 a includes a severance line 179 a that at least partially defines a tear away tab P. The tear away tab P of the bottom end flap 136 a will align with the glue receiving portions G of the gusset panels 174 a, 176 a, when the carton 600 is erected, as described in further detail below.
The top panel 112 includes a tear strip 190 which defines first and second top wall sections 192, 194 that are formed by separating the top panel 112 along the tear strip 190. The tear strip 190 aligns with and extends between inner ends of the severance lines 164 a, 164 b and between fold lines 142 a, 142 b. The opposing distal ends of the severance lines 164 a, 164 b extend to the notches 166 a, 166 b, respectively. The extension panels 170 a, 172 a are hingedly connected to respective portions 192, 194 of the top panel 112 along fold line 142 a.
Erecting the carton 600 from the blank 100 may be accomplished with the folding operations as described herein. The operations can be performed entirely or in part by automatic erecting machinery or manually. The method of performing the erecting process is not limited to the exemplary method described. Particularly, the order of the steps can be altered according to manufacturing requirements, steps may be added or omitted, and the means for securing components to one another may vary. The surfaces of sheet material may be secured together by suitable means for securing, including tape, staples, interlocking folds, slits, or notches, VELCRO®, glue or other adhesives, and the like.
In the exemplary embodiments, glue is applied to the inside surface of the handle reinforcing flap 119, and the handle reinforcing flap 119 is folded along fold line 128 such that the inside surface of the handle reinforcing flap 119 is secured to the inside surface of the first side panel 118. Thereby, the continuous edge of the aperture A is doubled over to define a handle cutout (not shown). The tubular structure T of the carton 600 is formed by securing the first side panels 110, 118 to one another to form a composite first side panel 110/118. Specifically, glue is applied to a portion of the outside surface of the first side panel 118, which is secured to a portion of the inside surface of first side panel 110 such that the handle cutout in the first side panel 118 substantially aligns with the handle H. In addition, the first side end flaps 130 a, 138 a are secured to one another to form a composite first side end flap 130 a/138 a.
As shown in FIG. 2, at this stage, the end flaps extend outwardly to be coplanar with a respective wall of the tubular structure T of the carton 600 to facilitate automatic loading. Accordingly, articles such as cans C (shown in FIG. 13) can be easily end loaded into the carton 600 because the extension panels and the gusset panels do not obstruct the opening of the tubular structure T.
Referring to FIGS. 3-7, the end closures of the carton 600 are formed by folding the end flaps as described herein. Generally speaking, the various elements of each end closure are arranged such that one folding step causes one or more other folds to occur simultaneously or subsequently. Each folding step may be performed automatically or manually. The first and second side end flaps 130 a/138 a, 134 a are folded inwardly with respect to the interior of the tubular structure T and along fold lines 140 a/148 a, 144 a to be substantially coplanar with one another.
This folding operation causes the web panels 171 a, 173 a to draw the bottom end flap 136 a at least partially upward and inward toward the interior of the tubular structure T. The outside surfaces of the web panels 171 a, 173 a are simultaneously folded toward the outside surface of side end flaps 134 a, 130 a/138 a along fold lines 175 a, 177 a, respectively. The bottom end flap 136 a is folded along fold line 146 a and the inside surfaces of the web panels 171 a, 173 a are folded toward the inside surfaces of the bottom end flap 136 a along fold line 154 a, 156 a, respectively. The web panels 171 a, 173 a are configured such that the bottom flap 136 a is automatically positioned at an acute angle relative to the plane defined by the side end flaps 134 a, 130 a/138 a, when the side end flaps 134 a, 130 a/138 a are folded inwardly so as to be coplanar.
The same folding operation forms the composite top end flap 432 a. As shown in FIG. 4, the top end flap 132 a is folded outwardly and away from the opening of the tubular portion of the carton 600 along the fold line 142 a and the inside surfaces of the gusset panels 174 a, 176 a are folded inwardly along fold lines 178 a, 180 a to be in a face contacting relationship with the inside surface of extension panels 170 a, 172 a, respectively. Thereby, the edges E1, E2 are brought together substantially to abut one another and align with the severance line 164 a. The edges E3, E4 substantially align with one another to create a substantially continuous edge, and the fold lines 150 a, 152 a substantially align with the fold line 142 a. In the exemplary embodiment, the length of each of the edges E1, E2 is greater than the length of the severance line 164 a such that inside surfaces of the glue receiving portions G of the gusset panels 174 a, 176 a extend beyond an edge E5 of the top flap 132 a (shown in FIG. 5).
As shown in FIGS. 4 and 5, a second folding operation is performed. The composite top end flap 432 a is folded toward the side end flaps 130 a/138 a, 134 a such that the outside surfaces of the gusset panels 174 a, 176 a are in a face contacting relationship with the outside surface of the side end flaps 130 a/138 a, 134 a. Adhesive is applied to the side end flaps 130 a/138 a, 134 a and the composite top end flap 432 a to secure the inside surface of at least a portion of the bottom end flap 136, including the tear away portion P. A typical automatic packaging machine then employs a static guide to complete the folding operation that positions the bottom end flap 136 a at vertical orientation overlapping the distal edge E5 of the top end flap 132 a. The bottom end flap 136 a is folded to be in a face contacting arrangement with the side end flaps 130 a/138 a, 134 a and the glue receiving portions G of the gusset panels 174 a, 176 a. Specifically, the tear away tab P of the bottom flap 136 a is secured to the glue receiving portions G of the gusset panels 174 a, 176 a to detachably secure a free end of the composite top end flap 432 a to the bottom end flap 136. Edges E4, E5 of the gusset panels 174 a, 176 may thereby align with, or be offset from, the severance line 179 a, as best shown in FIG. 7.
Thereby, the end closure structures of the carton 600 are formed, as shown in FIGS. 6 and 7, and the carton 600 is fully erected. The primary panels that define the tubular structure T and the end closure structures define the walls of the carton 600. The top panel 112 defines a top wall 612, the side panels 110/118, 114 define side walls 610, 614, the bottom panel 116 defines a bottom wall 616, and the end closure structures define end walls 618, 620, respectively.
Formation of the expanded portion or chimney of the carton 600 may be accomplished as follows to provide access to articles enclosed within and to increase the volume and capacity of the carton 600. Referring to FIGS. 6 and 8, the tear strip 190 is operated to separate the portions 192, 194 of the top wall 612. Referring to FIG. 9, a user can access the distal edge of the flap defined by the severance line 179 a to engage the tear away tab P and the underlying glue receiving portions G that are integral to the composite top end flap 432 a. Referring to FIGS. 9 and 10, the tear away tab P is detached from the bottom end flap 136 a as the composite top end flap 432 a is engaged, and pivoted outwardly from the plane of the end wall 618. It is contemplated that, in place of the tear strip 190, the sections 192, 194 can be directly connected to one another along an severance line (not shown) that can be manually broken or can be extensively weakened so that it is automatically broken by raising the composite top end flap 432 a.
Referring to FIGS. 11-13, as the composite top end flap 432 a is pivoted or folded along fold line 142 a toward the top wall 612, the extension panels 170 a, 172 a are separated along the severance line 164 a and fold outwardly and upwardly relative to the gusset panels 174 a, 176 a, respectively, until the gusset panels 174 a, 176 a and the extension panels 170 a, 172 a are substantially coplanar with one another and with the end wall 618. Thereby, the gusset panels 174 a, 176 a are in a sense unfolded along the fold lines 150 a, 152 a.
When the extension panels 170 a, 172 a are separated along the severance line 164 a, the sections 192, 194 that were integral to the top wall 612 can pivot outwardly from the plane defined by the top wall 612 of the carton 600. Specifically, the extension panels 170 a, 172 a act as gusset panels between the gusset panels 174 a, 176 a and the sections 192, 194 of the top wall 612 such that, as the gusset panels 174 a, 176 a are unfolded, the extension panels 170 a, 172 a facilitate upward and outward pivoting of the sections 192, 194 out of the plane of the top wall 612. Accordingly, when the gusset panels 174 a, 176 a are unfolded to be substantially coplanar with the end walls 618, 620 the sections 192, 194 of the top wall 612 are rotated to be substantially coplanar with the side walls 610, 614, respectively.
Thereby, the carton 600 is arranged to include an expanded portion, hereinafter referred to as a chimney, as shown in FIG. 13. Specifically, the top wall sections 192, 194 form extensions X1, X2 of the first and second side walls 610, 614 and the unfurled composite top end flaps 432 a, 432 b form extensions X3, X4 of respective end walls 618, 620. The side extensions X1, X2 and the end extensions X3, X4 define the periphery of the carton 600.
It should be understood that the chimney is at least partially formed from the end closure structures of the carton 600.
The present invention has been illustrated in relation to a particular embodiment which is intended in all respects to be illustrative rather than restrictive. Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope of the invention. For example, as used herein, directional references such as “top”, “base”, “bottom”, “end”, “side”, “inner”, “outer”, “upper”, “middle”, “lower”, “front” and “rear” do not limit the respective walls of the carton to such orientation, but merely serve to distinguish these walls from one another.
Any reference to hinged connection should not be construed as necessarily referring to a junction including a single hinge only; indeed, it is envisaged that hinged connection can be formed from one or more potentially disparate means for hingedly connecting materials.
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. An expandable carton, comprising:

a top wall, a bottom wall, a first side wall, and a second side wall hingedly connected to one another to form a tubular structure; and

a first end wall and a second end wall each enclosing an open end of said tubular structure, each comprising:

a composite top end flap and a pair of side end flaps, said composite top end flap being hingedly connected to said top wall, said side end flaps being hingedly connected to said first side wall and to said second side wall, respectively,

wherein:

said top wall is divisible to separate at least a first section of said top wall from a second section of said top wall;

said first and second sections, when separated, are movable to respective raised positions to form side extensions of said first and second side walls by raising said composite top end flaps toward said top wall to respective unfolded positions; and

each said composite top end flap, when in said unfolded position thereof, forms an end extension of a respective one of said end walls, said side extensions and said end extensions defining a periphery of an expanded portion of said carton.

2. The carton of claim 1, wherein each of said first end wall and said second end wall further comprises a bottom end flap, and said composite top end flap of said each end wall is detachably secured in place by said bottom end flap.

3. The carton of claim 1, wherein said composite top end flap of said each end wall comprises a pair of extension panels and a pair of gusset panels.

4. The carton of claim 3, wherein each of said pair of extension panels is hingedly connected to one of said pair of gusset panels.

5. The carton of claim 2, wherein said bottom end flap of said each end wall comprises a tear away tab that is secured to at least one of said pair of gusset panels of a respective composite top end flap to detachably secure said respective composite top end flap to said bottom end flap.

6. The carton of claim 3, wherein each of said pair of extension panels are detachably connected to the other along a severance line.

7. The carton of claim 6, wherein said severance line is capable of breaking as said composite top end flap is raised to said unfolded position thereof to detach each of said pair of extension panels from the other and to enable raising the said first and second sections.

8. The carton of claim 1, wherein said first and second sections of said top wall are defined with respect to one another by one of a tear strip and a severance line.

9. The carton of claim 5, wherein said bottom end flap at least partially overlaps said composite top end flap, and said tear away tab is defined at least in part by a severance line that is in registry with a distal edge of said composite top end flap.

10. The carton of claim 1, wherein said first and second sections, when in said raised positions, are substantially coplanar with said side walls respectively, and said each composite top end flap, when in said unfolded position thereof, is arranged such that said pair of extension panels and said pair of gusset panels are substantially coplanar with said side end flaps.

11. A blank for forming an expandable carton, comprising:

a top panel that is divisible to define a first section and a second section;

a first extension panel hingedly connected to said first section and a second extension panel hingedly connected to said second section;

a first side panel hingedly connected to said first section and a second side panel hingedly connected to said second section;

a first side end flap hingedly connected to said first side panel and a second side end flap hingedly connected to said second side panel;

a first gusset panel hingedly connected to said first extension panel; and

a second gusset panel hingedly connected to said second extension panel.

12. The blank of claim 11, further comprising:

a bottom panel hingedly connected to said second side panel;

a bottom end flap hingedly connected to said bottom panel; and

a tear away tab formed in said bottom end flap and defined by a severance line spaced apart from the distal edge of said bottom end flap.

13. The blank of claim 12, further comprising a pair of web panels interconnecting said bottom end flap with said second side end flap and with a third side end flap.

14. The blank of claim 11, wherein said first extension panel and said second extension panel are connected to one another along a severance line.

15. The blank of claim 11, further comprising a tear strip extending between said first section and said second section.

16. A package, comprising:

at least one article;

a carton enclosing said at least one article, said carton comprising a tubular structure with a top wall, a pair of side walls, and a bottom wall; and

an end wall for closing an end of said tubular structure, said end wall comprising a composite top end flap that is stowed as an exposed portion of said end wall;

wherein:

said top wall is divisible to form at least a first section and a second section;

said first and second sections, when divided, are capable of being raised to form side extensions of said first and second side walls; and

said composite top end flap is capable of being raised and configured to form an end extension of said end wall, said side extensions and said end extensions defining an expanded portion that extend above said at least one article.

17. The carton of claim 1, wherein said composite top end flap is hingedly connected to said side end flaps.

18. The blank of claim 11, said first gusset panel is hingedly connected to said first side end flap, and said second gusset panel is hingedly connected to said second side end flap.