US20110095075A1

US20110095075A1 - Carton With Differently Shaped Ends

Info

Publication number: US20110095075A1
Application number: US12/913,048
Authority: US
Inventors: Felicia Pinkstone
Original assignee: Graphic Packaging International LLC
Current assignee: Graphic Packaging International LLC
Priority date: 2009-10-27
Filing date: 2010-10-27
Publication date: 2011-04-28

Abstract

A blank is erected into a tubular structure having opposite end openings. One of the end openings is substantially rectangular. The other end opening is generally rectangular with substantially rounded corners. The erected blank includes an end panel that is substantially rectangular and obstructs the substantially rectangular end opening. The erected blank includes an end panel that is generally rectangular with rounded corners. The generally rectangular end panel with rounded corners obstructs the end opening that is generally rectangular with rounded corners.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 61/255,240, which was filed on Oct. 27, 2009.

INCORPORATION BY REFERENCE

The entire disclosure of U.S. Provisional Application No. 61/255,240, which was filed on Oct. 27, 2009, is incorporated herein by reference.

BACKGROUND

This disclosure generally relates to packages or cartons for holding and/or dispensing products.

SUMMARY

One aspect of this disclosure is the provision of a carton having a tubular structure with an upper end defining a substantially closed first shape (e.g., a substantially rectangular shape/opening), and a lower end defining a substantially closed second shape (e.g., a shape/opening that is generally rectangular, with substantially rounded corners) that is substantially different from the first shape. The shape of the tubular structure transitions from the first shape to the second shape between the upper and lower ends of the tubular structure. One or more lines of disruption (e.g., fold, crease or score lines) may be located at the upper end of the tubular structure, and the lines of disruption may extend only partially along the tubular structure so that the shape of the tubular structure substantially smoothly transitions between the opposite upper and lower ends.
The carton may further include a top panel connected to the tubular structure and obstructing (e.g., closing) the opening at the upper end of the tubular structure. The top panel may have an outer periphery that substantially defines the first shape (e.g., the substantially rectangular shape). The carton may further include a bottom panel connected to the tubular structure and obstructing (e.g., closing) the opening at the lower end of the tubular structure. The bottom panel may have an outer periphery that substantially defines the second shape (e.g., the generally rectangular shape with substantially rounded corners).
The bottom panel may be formed from bottom end flaps that are respectively foldably connected to recessed edges proximate the lower end of the tubular structure. The top panel may be at least partially formed by an end flap that includes at least one fold line adapted for allowing the end flap to be formed into a spout. The carton may contain a bag containing product, and the carton may include a viewing window so that a user may see the product through the bag by way of the viewing window.
In accordance with one aspect of this disclosure, a blank for being erected into a carton includes: a plurality panels that are foldably connected to one another and are for being formed into a tubular structure, wherein the plurality of panels includes opposite first and second edges; a first end flap foldably connected to the first edge for obstructing (e.g., closing) an opening at an end of the tubular structure, wherein the first end flap has an outer periphery that defines a first shape (e.g., a substantially rectangular shape); and a second end flap foldably connected to the second edge (e.g., a recessed edge) for obstructing (e.g., closing) an opening at another end of the tubular structure, wherein the second end flap has an outer periphery that defines a second shape (e.g., a generally rectangular shape with substantially rounded corners) that is substantially different from the first shape. The blank may include one or more of the above-discussed features of the carton and/or other features.
In accordance with one aspect of this disclosure, a tubular structure may be formed from a blank, and the forming of the tubular structure may include forming an end of the tubular structure into a generally rectangular opening having substantially rounded corners. The generally rectangular opening having substantially rounded corners may be obstructed (e.g., closed) with a generally rectangular panel that is formed from the blank and has substantially rounded corners. The generally rectangular panel with substantially rounded corners may be formed from end flaps respectively folded about recessed edges of the blank. The forming of the tubular structure may also include forming and obstructing (e.g., closing) an end opening that is substantially rectangular.
Other aspects of this disclosure will become apparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

Having described some aspects of this disclosure in general terms, reference will now be made to the accompanying drawings, which may be schematic, are not necessarily drawn to scale, and wherein:

FIG. 1 is a plan view of a flat blank that may be erected into a carton, in accordance with a first embodiment of this disclosure.

FIG. 2 is a front pictorial view of a closed carton erected from the blank of FIG. 1.

FIG. 3 is a rear pictorial view of the carton of FIG. 2 with its upper end open, and a bag within the carton being upwardly open and extending through the upper, open end of the carton, in accordance with the first embodiment.

FIG. 4 is a pictorial view of a closed carton in accordance with a second embodiment of this disclosure.

FIG. 5 is a pictorial view of the carton of FIG. 4 with its upper end open, and a spout formed at one end of the upper opening.

FIG. 6 is a pictorial view of the carton of FIGS. 4 and 5 with the spout formed at one end of the upper opening, a bag within the carton being upwardly open and extending through the upper, open end of the carton, and the bag being viewable by way of a viewing window (e.g., hole in the carton) in accordance with the second embodiment.

FIG. 7 is a plan view of the flat blank of FIG. 1 with a bag attached thereto, in accordance with a version of the first embodiment of this disclosure.

FIG. 8 illustrates a series of bags that include projecting spout sections and are connected end-to end, and that are for being separated from one another for use within the blanks and cartons, in accordance with various embodiments of this disclosure.

DETAILED DESCRIPTION

Referring now in greater detail to the drawings, in which like numerals refer to like parts throughout the several views, exemplary embodiments of this disclosure are described in the following. For example, a blank 10 is shown in FIG. 1 and described in the following, in accordance with a first embodiment of this disclosure. The blank 10 may be characterized as generally including an upper end 12 and a lower end 14. The blank 10 includes main panels 20, 50 connected to one another along a longitudinal fold line 43, and an attachment panel 60 (e.g., adhesive panel) connected to the main panel 50 along a longitudinal fold line 93.
At the upper and lower ends 12, 14 of the blank 10, end flaps are attached to the main panels 20, 50 by fold lines that are transverse to the longitudinal fold lines 43, 93. More specifically, along the upper end 12 of the blank 10, an upper secondary end flap 22 is attached to an upper edge of the main panel 20 along a transverse fold line 21, an upper primary end flap 24 is attached to an upper edge of the main panel 20 along a transverse fold line 31, an upper secondary end flap 40 is attached to an upper edge of the main panel 20 along a transverse fold line 41, an upper secondary end flap 42 is attached to an upper edge of the main panel 50 along a transverse fold line 51, an upper primary end flap 44 is attached to an upper edge of the main panel 50 along a transverse fold line 61, an upper secondary end flap 46 is attached to an upper edge of the main panel 50 along a transverse fold line 71, and an attachment end flap 48 (e.g., adhesive end flap) is attached to an upper edge of the attachment panel 60 along a transverse fold line 81. One or more of the transverse fold lines 21, 31, 41, 51, 61, 71, 81 can be collinear with one another such that the transverse fold lines 21, 31, 41, 51, 61, 71, 81 may be characterized as being portions of a single transverse fold line 15 that extends all the way between opposite edges of the blank 10.
The upper primary end flap 24 includes several lines of disruption, namely transverse tear lines 30, 32, 34 and a series of cuts (e.g., slits) that form a tuck-in flap or tab 36. The lines of disruption in the upper primary end flap 24 form a tear strip 28 and another separable portion 26 of the upper primary end flap 24. The series of slits that form the tuck-in tab 36 are positioned between and connect inner ends of the tear lines 30, 32. As shown in FIG. 1, the series of slits that form the tuck-in tab 36 include oblique slits that respectively extend upwardly from the inner ends of the tear lines 30, 32, and a transverse slit that connects the upper ends of the oblique slits. The tear strip 28 is connected to the inner portion of the upper primary end flap 24 along the tear lines 30, 32. The tear strip 28 is partially defined by, and extends along, the tuck-in tab 36 (e.g., the slits that define the tuck-in tab). The separable portion 26 is connected to the tear strip 28 by the tear line 34. As will be discussed in greater detail below, the tear strip 28 is removable from the remainder of the upper primary end flap 24 by separating the tear strip 28 along the tear lines 30, 32, 34. Optionally, the separable portion 26 can be removed together with tear strip 28, if desired.
For at least one of (e.g., for each of) the upper main end flaps 24, 44, the end flap has an outer periphery that defines a substantially rectangular shape having corners that substantially define right angles, although differently shaped upper main end flaps are within the scope of this disclosure. More specifically and as shown in FIG. 1, some of the corners of the substantially rectangular shapes defined by the outer peripheries of the upper main end flaps 24, 44 may be slightly rounded. Also as shown in FIG. 1, the opposite ends of the tear strip 28 may cause the outer periphery of the upper main end flap 24 not to be perfectly rectangular. Notwithstanding, whether the outer peripheries of the upper main end flaps 24, 44 are perfectly rectangular or a little less than perfectly rectangular, as shown in FIG. 1, the outer peripheries of the upper main end flaps 24, 44 may be referred to as being substantially rectangular.
The upper primary end flap 44 includes a tuck-in slot 38 sized to receive the tuck-in tab 36 after the carton 400 (FIGS. 2 and 3) is formed from the blank 10. As shown in FIG. 1, the tuck-in slot 38 may be formed by a series of slits that include a transverse slit and oblique slits that respectively extend upwardly from the opposite ends of the transverse slit.
The upper primary end flaps 24, 44 are separated from the adjacent secondary upper flaps 22, 40, 42, 46 by way of cut outs or cuts, namely longitudinal slits 54. In contrast, the upper secondary end flaps 40, 42 are connected to one another by a longitudinal fold line 53, which is shown to be generally collinear with the longitudinal fold line 43. Similarly, the upper secondary end flaps 46, 48 are connected to one another by a longitudinal fold line 83, which is shown to be generally collinear with the longitudinal fold line 93. The longitudinal fold lines 53, 83 allow the end flaps 40, 42 and the end flaps 22, 46, 48 to respectively be flexed outwardly to form pouring spouts, or the like, (e.g., see the spout 300′ in FIGS. 5 and 6). Alternatively, other arrangements of flaps may be used for closing the ends of the carton 400 (FIGS. 2 and 3). For example, the longitudinal fold lines 53, 83 may be replaced with cuts, such as slits.
The main panels 20, 50 optionally include relatively short lines of disruption, namely score lines that may be referred to as longitudinal fold lines 23, 33, 63, 73. The longitudinal fold lines 23, 33, 63, 73 extend transverse to the transverse fold lines 21, 31, 41, 51, 61, 71, 81 for allowing or enhancing flexure of the main panels 20, 50 along the upper end 12 when the blank 10 is formed into carton 400 (FIGS. 2 and 3). As shown in FIG. 1, the longitudinal fold lines 23, 33, 63, 73 are respectively collinear with the longitudinal slits 54. The longitudinal fold lines 23, 33, 63, 73 extend in the upper end 12 of the blank for facilitating formation of the upper end 12 into a substantially rectangular configuration when the blank 10 is formed into carton 400. The longitudinal fold lines 23, 33, 63, 73 extend only partially toward the lower end 14 so that, as best understood with reference to FIGS. 2 and 3, in the downward direction, the carton 400 transitions from the substantially rectangular configuration to a more rounded configuration (e.g., a substantially rounded side arrangement) at the lower end 14 of the carton 40.
At the lower end 14 of the blank 10 as shown in FIG. 1, a lower main end flap 70 is connected by a transverse fold line 91 to a recessed edge of the main panel 20, lower secondary end flap 74 is connected by a transverse fold line 101 to a recessed edge of the main panel 20, lower secondary end flap 76 is connected by a transverse fold line 111 to a recessed edge of the main panel 50, lower main end flap 78 is connected by a transverse fold line 121 to a recessed edge of the main panel 50, lower secondary end flap 80 is connected by a transverse fold line 131 to a recessed edge of the main panel 50, and lower secondary end flap 82 is connected by a transverse fold line 141 to the attachment panel 60.
The recessed edges of the panels 20, 50, 60 that are respectively coextensive with the transverse fold lines 91, 101, 111, 121, 131, 141 are recessed relative to respective lowest edges of the main panels 20, 50 by virtue of respective cuts (e.g., curved slits 104 and longitudinally extending straight slits 105) that respectively extend downwardly from the recessed edges/respectively extend inwardly from the lowest edges of the main panels 20, 50. One or more of the transverse fold lines 91, 101, 111, 121, 131, 141 may be characterized as being portions of one or more larger fold lines. For example, ends of the transverse fold lines 101, 111 are contiguous and collinear. Similarly, ends of the transverse fold lines 131, 141 are contiguous and collinear. Also, the transverse fold lines 91, 101, 111, 121, 131, 141 may alternatively be located at lowest edges of the panels 20, 50 rather than being located at the recessed edges.
Reiterating from above and for example, for each of the upper main end flaps 24, 44, the end flap has an outer periphery that defines a substantially rectangular shape having corners that substantially define right angles. In contrast, for at least one of (e.g., for each of) the lower main end flaps 70, 78, the flap has an outer periphery that defines a shape that is substantially different from the substantially rectangular shape defined by the outer peripheries of the upper main end flaps 24, 44. More specifically, for at least one of (e.g., for each of) the lower main end flaps 70, 78, the flap has an outer periphery that defines a generally rectangular shape having beveled corners (e.g., substantially rounded corners). More specifically and in accordance with the first embodiment, the main end flaps 24, 44, 70, 78 are all about the same size, except, for example, that the corners of the lower main end flaps 70, 78 are substantially more rounded as compared to the corners of the upper main end flaps 24, 44. For example, whereas FIG. 1 shows that some of the corners of the upper main end flaps 24, 44 may be slightly rounded, the corners of the lower main end flaps 70, 78 are substantially more rounded, such as by having radiuses of curvature that are at least two times as large, at least three times as large, at least four times as large, at least five times as large, or greater than five times as large as any radius of curvature of the corners of the upper main end flaps 24, 44. Other configurations and relationships are also within the scope of this disclosure.
The lower secondary end flaps 74, 76 are connected to one another by a longitudinal fold line 103, which is generally collinear with the longitudinal fold line 43. Similarly, the lower secondary end flaps 80, 82 are connected to one another by a longitudinal fold line 113, which is generally collinear with longitudinal fold line 93. Each of the pair of end flaps 40, 42, the pair of end flaps 46, 48, the pair of end flaps 74, 76, and the pair of end flaps 80, 82, may be referred to as a single end flap that optionally includes and is divided (e.g., bifurcated) by the respective longitudinal fold line 53, 83, 103, 113 or any other suitable line of disruption, such as a cut or slit.
An example of a method of erecting the carton 400 (FIGS. 2 and 3) is described in the following primarily with reference to FIG. 1, in accordance with the first embodiment of this disclosure. Either side of the blank 10 may define the exterior of the carton 44. The blank 10 may be folded along the longitudinal fold lines 43, 93. The attachment panel 60 may be attached to the free, longitudinal marginal edge of the main panel 20, such as by using adhesive material or any other suitable fastening mechanism(s). As a result, the blank 10 will be in the form of a flat tubular structure (e.g., collapsed tubular structure).
A generally rectangular bottom panel (e.g., composite bottom panel) with substantially rounded corners is formed from the lower end flaps 70, 74, 76, 78, 80, 82 for obstructing (e.g., closing) the opening at the lower end 14 of the carton 400 (FIGS. 2 and 3). The lower end flap 70 may optionally include, and be bifurcated by, a transverse fold line 151 so that the carton 400 may be collapsed/substantially flattened after the bottom panel is at least partially formed. The end flaps 74, 76, 80, 82, may be characterized as dust flaps and/or attachment flaps that may function in combination with the end flaps 70, 78 so that the bottom panel is a semi-automatic bottom panel. Other bottom panels are within the scope of this disclosure.
After the flattened tubular structure is formed from the blank 10 as discussed above, the tubular structure is “opened”/no longer collapsed so that at least one panel (e.g., the main panels 20, 50 together) extend around a longitudinal axis and open interior of the tubular structure. The bottom panel may be formed while the tubular structure is “opened”/no longer collapsed. The lower end 14 of the open tubular structure may be manually shaped, or the lower end 14 of the open tubular structure may be automatically shaped, such as through the use of an automated system including mandrel(s) and/or outer forming or supporting structures, or any other suitable shaping mechanism or process, so that the opening at the lower end 14 of the open tubular structure substantially defines the same (albeit slightly larger) generally rectangular shape having substantially rounded corners as the lower main end flaps 70, 78. Throughout this Detailed Description section of this disclosure, the generally rectangular shape having substantially rounded corners may more generally be referred to in geometrical terms as a substantially closed shape that is generally rectangular and has beveled corners.
While the lower end 14 of the open tubular structure defines the generally rectangular shape having substantially rounded corners, first the lower main end flap 78 is folded inwardly about ninety degrees along the transverse fold line 121/the respective recessed edge of the main panel 50 so that the lower main end flap 78 is pivoted into the interior of the open tubular structure, then the lower main end flap 70 is folded inwardly about ninety degrees along the transverse fold line 91/the respective recessed edge of the main panel 20 so that the lower main end flap 70 is pivoted into the interior of the open tubular structure, then the lower secondary end flaps 74, 76, 80, 82 are folded inwardly about ninety degrees along the respective transverse fold lines 101, 111, 131, 141/the respective recessed edges of the panels 20, 50, 60 so that the lower secondary end flaps 74, 76, 80, 82 are pivoted into the interior of the open tubular structure. The lower secondary end flaps 74, 76, 80, 82 are attached (using adhesive material or any other suitable fastening mechanism(s)) to the opposite ends of the lower main end flap 70 so that the fold lines 103, 113, 151 are substantially parallel to one another and the fold lines 103, 113 extend along the fold line 151, so that the otherwise open tubular structure has a closed lower end 14. As a result, the open (e.g., upwardly open) tubular structure has a closed lower end 14, and the lower ends of the main panels 20, 50 define the generally rectangular shape having substantially rounded corners. As a result, the carton 400 (FIGS. 2 and 3) may be characterized as having a distinctive appearance and/or the substantially rounded corners seek to enhance the ease with which the carton 400 may be manually grasped.
The lower secondary end flaps 74, 76, 80, 82 may be adhesively or otherwise attached to the opposite ends of the lower main end flap 70 manually or through the use of an automated system that may include mandrel(s) and/or outer forming or supporting structures, or any other suitable mechanisms or processes. The generally rectangular bottom panel with rounded corners may be formed in a different manner. For example, the lower end flaps 70, 74, 76, 78 80, 82 can be folded and/or attached in another manner or order without departing from the scope of this disclosure.
Then, optionally and if desired, and perhaps theoretically depending upon the rigidity of the material from which the blank 10 is constructed, the tubular structure with the closed lower end 14 may be flattened (e.g., substantially flattened) by having the lower main end flap 78, which is within the interior of the tubular structure, in opposing face-to face relation or contact, or the like, with the main panel 50, and then folding along the fold lines 43, 93, 103, 113, 151. Thereafter at a desired time, the substantially flattened tubular structure with the closed lower end 14 may be formed into the open tubular structure with the closed lower end/upwardly open carton 400. Any suitable product (e.g., food stuffs) may be disposed within the interior of the carton 400 (FIGS. 2 and 3), such as by passing the product through the open upper end 12 of the carton.
When the open tubular structure with the closed lower end 14/upwardly open carton 400 (FIGS. 2 and 3) is formed and thereafter, the relatively short longitudinal fold lines 23, 33, 63, 73 (FIGS. 1-3) in the upper end of the carton seek to cause (e.g., substantially cause) the upper end 12 of the carton (e.g., the upper opening of the carton) to substantially define the same substantially rectangular shape as the upper main end flaps 24, 44. A substantially rectangular top panel 160 (FIG. 2) of the carton 400 is for closing (the opening at) the upper end 12 of the carton and may help to maintain the substantially rectangular configuration of the upper end 12 of the carton 400. Throughout this Detailed Description section of this disclosure, the substantially rectangular shape may more generally be referred to in geometrical terms as a substantially closed shape that is substantially rectangular. When the carton 400 is fully erected and fully closed, the bottom panel and the top panel 160 are typically parallel (e.g., substantially parallel) with one another.
The substantially rectangular top panel 160 (e.g., composite top panel shown in FIG. 2) for closing the upper end 12 of the carton 400 is formed from the upper end flaps 22, 24, 40, 42, 44, 46, 46. The top panel 160 may be formed/the opening at the upper end 12 of the carton 400 may be obstructed (e.g., closed) by folding the upper secondary end flaps 22, 40, 42, 46, 46 inwardly about ninety degrees respectively along the transverse fold lines 21, 31, 41, 51, 61, 71, 81, then the upper main end flap 44 is folded inwardly about ninety degrees along the transverse fold line 61, and then the upper main end flap 24 is folded inwardly about ninety degrees along the transverse fold line 31. The separable portion 26 of the upper main end flap 24 is attached (using adhesive material or any other suitable fastening mechanism(s)) to the respective portion of the upper main end flap 44, to complete formation of the substantially rectangular top panel 160.
As shown in FIGS. 2 and 3, the upper end 12 of the carton 400 is substantially rectangular, whereas the lower end 14 of the carton 400 generally has rounded or arced sides along the fold lines 43, 93 proximate the lower end 14 of the carton (e.g., the lower end is generally rectangular with substantially rounded corners). Between the upper and lower ends 12, 14 of the carton, the tubular portion of the carton transitions (e.g., substantially smoothly transitions) between the contrasting shapes at the opposite ends 12, 14.
Referring primarily to FIGS. 2 and 3, the upper end 12 of the closed carton 400 may be opened by manually tearing away the optional tear strip 28. As shown in FIG. 3, the tear strip 28 has been removed along tear the lines 30, 32, 34 (FIG. 1). For example, FIG. 3 shows the carton 400 in an upwardly open configuration. Optionally, the carton 400 may be lined with or otherwise contain a bag B that is shown upwardly open in FIG. 3. After the upper end 12 of the 400 has been opened, it may be closed by the remaining portion of the substantially rectangular top panel 160 (FIG. 2)/the remaining portion upper main end flap 24 and the other upper end flaps 22, 40, 42, 44, 46, 46. The remaining portion of the substantially rectangular top panel 160 may be releasably secured by inserting the tuck-in tab 36 into the suck-in slot 38 (FIG. 1).
A second embodiment of this disclosure is like the first embodiment, except for variations noted and variations that will be apparent to one of ordinary skill in the art. For example and referring to FIGS. 4 and 5, the carton 400′ according to the second embodiment of this disclosure is like the carton 400 of the first embodiment, except that the upper main end flap 24′ of the carton 400′ of the second embodiment does not include the separable portion 26 (FIG. 1) or tear strip 28 (FIG. 1) of the first embodiment. Notwithstanding, the carton 400′ of the second embodiment typically, although optionally, includes a tuck-in tab 36′ adapted for being received in a tuck-in slot 38′.
FIG. 5 shows the carton 400′ with a spout 300′ formed at one side of the upper end 12′, although substantially similar spouts may be formed at either side of the upper end. The spout 300′ is formed by outward flexing (e.g., folding) the upper secondary end flaps 40′, 42′ along fold the fold line 53′, or outwardly flexing (e.g., folding) the upper secondary end flaps 22′, 46′, 48′ along the fold line 83′. In addition to providing a spout 300 in just one pair or group of end flaps 40′, 42′ or 22′, 46′, 48′, optionally, spouts can be formed in both sides of the upper end 12′ of carton 400′. The pairs of fold lines 43′, 53′ and 83′, 93′ being respectively aligned seeks to enhance formation of the spouts 300′.
FIG. 6 shows the carton 400′ containing a bag B′ that is upwardly open adjacent the spout 300′. The opened bag B′ and the spout 300′ cooperate to enable access to the bagged product in the carton 400′. The spout 300′ may function as a guiding mechanism that seeks to enhance control over the process of pouring the product out of the opening in the bag B′ while the bag is within the carton 400′.
As best understood with reference to FIG. 6, the cartons 400, 400′ may optionally include one or more windows 200′ that are typically in the form of holes through the main panel 20′ and/or the main panel 50′. The optional window 200′ typically allows for viewing of product or other materials inside the bags B, B′. Generally, the window 200′ can be formed of any substance that allows viewing access from the exterior to the interior of the carton 400′, and can enable visual assessment of the type of ingredients, the quality of ingredients, the level of product remaining in the carton, or any host of other reasons viewing access may be desired. The window 200′ has an irregular shape in FIG. 6; however, any other suitable shape (e.g., a rectangular shape) may be used. The window 200 can be formed in any shape, size, dimension, and/or at any suitable distance from the upper end 12′ or the lower end 14′ of the carton 400′. Whereas the inclusion of a bag B′ is optional, the bag B′ will typically be present when one or more windows 200′ are included in the carton 400′, unless, for example, the hole that defines the window 200′ is separably covered with a material (e.g., polymer film) that typically may be seen through.
When the window 200′ and the bag B′ are both included in the carton 400′, the bag B′ will typically be constructed of a material (e.g., polymer film) that may be seen through. That is, when the window 200′ and the bag B′ are both included, the bag B is typically formed of a material that allows the product therein to be viewed therethrough (e.g. the bag B could be formed of a polymer film or other clear or opaque substances).
The bags B, B′ may be sealed and installed and/or formed in the cartons 400, 400′ in any suitable manner. As schematically shown in FIG. 6, the upper end of the bag B includes seals 500′ formed by adhesive material or any other suitable form of sealing, such as through the application of heat, ultrasonic signals, or the like. The seals 500′ are schematically illustrated by parallel lines in FIG. 6. The seals 500′/sealing lines or the like may extend transversely where the bag' is opened, and longitudinally where the bag B′ is to remain closed. For example, adhesive material may be applied in specific/contrasting amounts and/or patterns in a manner that signals to a user that the bag B is supposed to be open in a specific (e.g., predetermined) area, as shown in FIG. 6. There may be a lesser amount or number of the seals 500′/sealing lines or the like where the bag B′ is intended to be opened.
In some examples of this disclosure, the bags B, B′, which are optional and may be omitted, are within the cartons 400, 400′ but are not adhered to or otherwise connected to the interior surface of the cartons 400, 400′ containing the bags B, B′. Alternatively, the bags B, B′ may be adhered to or otherwise connected to the interior surface of the cartons 400, 400′ containing the bags B, B′. For example and as shown in FIG. 7 in accordance with a version of the first embodiment, the bag B may be adhered to the blank 10 with patterns of adhesive material 502. Generally, the bag B, with its lower end sealed, may be adhered to the blank 10 on the main panel 50 (e.g., the side that does not include the crease (e.g., transverse fold line 151) at the bottom). Thus, as shown in FIG. 7, the bag B is adhered to blank 10 by the adhesive material 502 on the main panel 50. Alternatively or additionally, adhesive material 502 can be applied onto the main panel 20, so that the bag B becomes adhered to the main panel 20 when the carton 400 is erected.
In FIG. 7, the bag B is schematically shown as having closed bottom formed by a pinch seal 600 or any other suitable seal along the bottom of the bag B. A fin seal 700 or any other suitable seal may be used to form the tubular precursor of the bag B. The seals 600, 700 may be conventional and may be any suitable types of seals that may be adapted to accommodate for a wide variety of possible needs that may depend upon the size, type, thickness, orientation, etc. of the bag B. Similarly, the adhesive material 502 (e.g., glue) may be applied in different amounts, configurations, and locations than shown in FIG. 7.
For each of the cartons 400, 400′, any bag therein may include a spout or spout-like feature adjacent to the carton's spouts 300′ (FIG. 6). For example, each of the above-discussed bags B, B′ may be replaced with one of the bags B″ schematically shown in FIG. 8. In FIG. 8, a series of the bags B″ are schematically shown connected end-to end, and the bags B″ to be used within the cartons 400, 400′ may be cut from one another (e.g., slit or torn from one another, or the like) along a curved line 504″ so as to include projecting spout sections 506″. The projecting spout sections 506″ are for being opened to form a spout of the bag B″ for dispensing. The bags B″ would typically be arranged in the cartons 400, 400′ so that the projecting spout sections 506″ would be adjacent the spouts 300′ (FIG. 6). As shown in FIG. 8, the spout sections include seals 500″ formed by adhesive material or any other suitable form of sealing, such as through the application of heat, ultrasonic signals, or the like.
In FIG. 8, the seals 500″, sealing lines or the like are schematically illustrated by parallel lines. The seals 500″, sealing lines or the like in the projecting spout sections 506″ are schematically illustrated as extending transversely. The seals 500″ sealing lines or the like in other than the projecting spout sections 506″ are schematically illustrated as extending longitudinally. There may be a lesser amount or number of the seals 500″/sealing lines or the like in the projecting spout sections 506″, so that the projecting spout sections 506″ may be manually opened more easily that the other sealed sections. For example, the seals 500″ may be formed in predetermined specific/contrasting amounts and/or patterns in a manner that signals to a user that the bag B″ is supposed to be open in the projecting spout section 506″. There may be a lesser amount or number of the seals 500″/sealing lines or the like in the projecting spout section 506″.
The bags B′, B″, B′″ may be formed of any material, such as food-grade polymer film, and the bags may be formed of a repulpable or other recycled material or materials to function at least generally as described herein. Generally, the upper ends of the bags B′, B″, B′″ are sealed closed after product (e.g., food) is inserted therein. The bags B′, B″, B′″ may be sealed liners that are formed inside the cartons 400, 400′ and/or the bags may be installed into the cartons after the bags are filled in lieu of being adhered to the blank prior to the blank being formed into a carton.
The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar or any other suitable materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank. In accordance with the above-described embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blanks can also be laminated or coated with one or more sheet-like materials at selected panels or panel sections.
In accordance with the above-described embodiments of the present disclosure, a line of disruption in the form of a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In accordance with the first embodiment, all of the fold lines 21, 31, 41, 51, 53, 61, 71, 81, 83, 101, 103, 111, 113, 131, 141 may be score/crease lines, and the fold lines 91, 93, 121, 151 may each be formed by an alternating series of slits and score/crease lines.
As an example, a line of disruption in the form of a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.
Directional references (e.g., top, upper, bottom, lower, longitudinal, transverse, side, or the like) have been used in this disclosure for ease of understanding and not for the purpose of limiting the scope of this disclosure.
It will be understood by those skilled in the art that while the present disclosure has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention as set forth in the claims.

Claims

1. A carton comprising,

a tubular structure having

an upper end defining a substantially closed first shape, and

a lower end defining a substantially closed second shape that is substantially different from the first shape;

the tubular structure having a shape that transitions from the first shape to the second shape between the upper and lower ends of the tubular structure;

a top panel connected to the tubular structure and obstructing the upper end of the tubular structure, wherein the top panel has an outer periphery that substantially defines the first shape; and

a bottom panel connected to the tubular structure and obstructing the lower end of the tubular structure, wherein the bottom panel is spaced apart from and substantially parallel to the top panel, and the bottom panel has an outer periphery that substantially defines the second shape.

2. The carton according to claim 1, wherein the top panel includes an end flap, and the end flap includes a fold line adapted for allowing the end flap to be formed into a spout.

3. The carton according to claim 1, further comprising a viewing window within and positioned between the upper and lower ends of the tubular structure.

4. The carton according to claim 1, further comprising a bag positioned in the tubular structure, wherein the bag includes a spout.

5. The carton according to claim 1, wherein:

the lower end of the tubular structure includes a lower edge and a recessed edge;

as compared to the lower edge, the recessed edge is recessed into the plurality of panels; and

the bottom panel is foldably connected to the recessed edge.

6. The carton according to claim 1, wherein:

the first shape comprises a substantially rectangular shape having corners that substantially define right angles, and

the second shape comprises a generally rectangular shape having beveled corners.

7. The carton according to claim 6, wherein the beveled corners are substantially rounded corners:

8. The carton according to claim 1, wherein:

the tubular structure comprises at least one panel that extends around and defines a longitudinal axis of the carton;

the at least one panel includes a plurality of score lines that extend along the longitudinal axis, from proximate the upper end of the tubular structure toward the lower end of the tubular structure.

9. The carton according to claim 8, wherein the plurality of score lines do not extend to the lower end of the tubular structure.

10. The carton according to claim 1, wherein:

the at least one panel includes a plurality of fold lines that extend along the longitudinal axis, from proximate the upper end of the tubular structure toward the lower end of the tubular structure.

11. The carton according to claim 10, wherein the plurality of fold lines do not extend to the lower end of the tubular structure.

12. A blank for being erected into a carton, the blank comprising:

a plurality of panels that are foldably connected to one another and are for being formed into a tubular structure, wherein the plurality of panels includes opposite first and second edges;

a first end flap foldably connected to the first edge for obstructing an end of the tubular structure, wherein the first end flap has an outer periphery that defines a first shape; and

a second end flap foldably connected to the second edge for obstructing an end of the tubular structure, wherein the second end flap has an outer periphery that defines a second shape that is substantially different from the first shape.

13. The blank according to claim 12, wherein:

the plurality of panels further includes a third edge that is opposite from the first edge;

the third edge is proximate both the second edge and the second end flap; and

as compared to the third edge, the second edge is recessed into the plurality of panels.

14. The blank according to claim 12, wherein:

15. The blank according to claim 14, wherein the beveled corners are substantially rounded corners:

16. The blank according to claim 12, wherein:

the plurality of panels is formed into the tubular structure;

the ends of the tubular structure are opposite first and second ends that respectively include the first and second edges of the plurality of panels;

the first end of the tubular structure is adapted for substantially defining the first shape when the blank is erected into the carton; and

the second end of the tubular structure is adapted for substantially defining the second shape when the blank is erected into the carton.

17. The blank according to claim 16, wherein the plurality of panels includes a plurality of fold lines that extend from proximate the first end of the tubular structure toward the second end of the tubular structure.

18. The blank according to claim 17, wherein the plurality of fold lines do not extend to the second end of the tubular structure.

19. A method of forming a carton, comprising:

forming a tubular structure from a blank, comprising forming an end of the tubular structure into a generally rectangular shape having substantially rounded corners; and

obstructing the end with a panel having a generally rectangular shape with substantially rounded corners, comprising forming the panel from the blank.

20. The blank according to claim 19, wherein the forming of the panel from the blank comprises folding a plurality of end flaps respectively about a plurality of recessed edges of the tubular structure into an interior of the tubular structure, and fastening at least some of the end flaps to one another.