US20110297561A1

US20110297561A1 - Easy-opening carton for shipping and storing cut paper

Info

Publication number: US20110297561A1
Application number: US13/212,778
Authority: US
Inventors: Timothy J. Justice
Original assignee: International Paper Co
Current assignee: International Paper Co
Priority date: 2006-10-13
Filing date: 2011-08-18
Publication date: 2011-12-08
Also published as: WO2012024510A1

Abstract

An easy to carry lightweight carton for shipping and storing cut paper and for providing rapid and easy access to the paper when the carton is opened. The carton has a base portion and a lid pivotally attached to the base portion. A front wall of the carton may be pivoted down when the lid is pivoted up to facilitate access to the contents of the carton for ease of unloading of paper from the carton. A carry handle is built into the base portion to facilitate carrying of the carton. The carry handle position causes the center of gravity of the carton to be closer to a user's body when carrying the carton. The carton may be re-closed after it is opened.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional U.S. patent application that claims the benefit of U.S. provisional application Ser. No. 61/374, 872, filed on Aug. 18, 2010; and claims priority of U.S. application Ser. no. 12/082,453, filed on Apr. 10, 2008; which in turn claims priority of U.S. application Ser. No 11/580,515, filed on Oct. 13, 2006, all of which are hereby incorporated hereinto by reference as if fully restated herein.

BACKGROUND OF THE INVENTION

This invention relates to packaging, and especially to a package for paper products. More particularly, the invention relates to a shipping and storage carton for cut sheets of paper, wherein the carton has a size and weight to promote easy handling and storage and has an easy-opening feature including a fold-down side to facilitate access to the paper. The carton may be reclosed after opening to keep unused paper fresh and neatly stacked, and has a built-in handle for ease and convenience in carrying the carton.
Cut-sized paper, such as conventional photocopy paper, typically is wrapped in reams each containing, for example, 500 sheets. It is common for a plurality of reams to be bundled together and packaged in a corrugated container for shipping, storage and handling. For example, it is common to package from five to ten reams of paper in a single container, with a lid secured over the container to keep the reams from falling out of the container during shipping and handling. Since a single ream of paper weighs about five pounds, packages containing from five to ten reams of paper are heavy and difficult to handle. Moreover, they are relatively large and require substantial storage space. Further, the reams of paper are closely surrounded by the container walls, and the lack of space between the reams of paper and the container walls makes it difficult to remove the reams of paper for use. Additionally, each ream must be individually opened to gain access to the paper, and the ream wrap disposed of.
Single wrapped reams of paper also are commonly sold, and although these packages are easy to handle and store, they do not protect the paper from physical damage. Further, most equipment used in the home or in small offices does not hold a full ream of paper. Consequently, after a ream is opened and the desired amount of paper removed, the remaining unused paper is unprotected.
Many home and small office users prefer to purchase several reams of paper at once, rather than to buy single reams more frequently, but prefer not to buy as many as ten reams at once. Packages have been developed that hold five reams of paper, but even these packages are heavy, and, as such, are more suitable for industrial and commercial purchasers, which typically will have material handling equipment such as power lifts and hand carts to handle such heavy items. Average home users who wish to purchase several reams of paper at once typically do not have access to such material handling equipment.
Unwrapped cut sheets of paper are sometimes packaged loose in cartons designed to closely fit the paper and protect it from damage. Unwrapped cut sheets of paper do not require removal and discarding of ream wrap, but conventional cartons of this type generally are also sized to hold from five to ten reams of paper and thus are relatively difficult to handle and store. Moreover, these cartons generally have either a removable lid or foldable flaps to close the top of the carton, and the lid is removed or the flaps opened to form an open top through which product is removed from the carton. With such packaging it is difficult to remove the contents without damaging the carton or inverting it to pour the contents out because of the lack of space to insert the hands of the user between the side walls of the carton and the paper stored therein.
Additionally, and particularly for the larger containers that are commonly used for shipping and storing cut sheets of paper, it is common for the stacks of paper to stand taller than the container base sidewalls, whereby the lid actually rests upon the top of the stacks rather than on the upper ends of the container sidewalls. Because it is common for several containers to be stacked on top of one another during shipping, reams of paper packed in the stacked containers typically compress as air that was trapped between the individual sheets within the reams during the wrapping process is “squeezed” out. As a result, it is not uncommon for the containers to be compressed as the stacks of reamed paper compress. That is, as the individual reams compress, it is not uncommon for the containers to become “less tall” by virtue of the fact that the container lid (which rests upon the top of the paper stacks) moves closer towards the container base. For this reason, paper suppliers prefer not to secure the lids directly to the carton bases using an adhesive because the shear strength of typical hot melt adhesives cannot withstand the shear strain resulting from movement of the lid relative to the container base. In such situations, the lids become disassociated from the container bases, thereby permitting the reams of paper to spill out of the container. Free lids also become entangled in automated material handling equipment, thereby causing machine shut downs and shipping inefficiencies. Thus, it has become common to utilize ancillary securing devices, such as straps and the like, rather than or in addition to adhesive, to hold such container lids onto their respective bases. However, such devices do not always prevent the lids from becoming disassociated from the bases. For example, as the containers are compressed (for the reasons described above), the straps are loosened and are free to slip either partially or entirely off of the container, allowing the lids to become disassociated from the bases, resulting in product spillage and/or damage. In addition to the free lids (which may become entangled in material handling equipment), the free straps may likewise become entangled in the material handling equipment, resulting in machine shut downs and shipping inefficiencies. Operator safety is also reduced, as the free straps and free lids clutter the workspace.
It is desirable therefore to provide a carton for shipping and storing sheets of paper, such as photocopy paper or the like, which not only is smaller and lighter in weight than conventional multi-ream containers and accordingly is easier to handle and store, but which also protects the paper against physical damage from the environment. It is also desirable to provide a carton that the lid is directly attached the carton bases but yet strong enough to withstand the shear strain resulting from movement of the lid relative to the carton's base.
It is also desirable to provide a carton that enables the sheets of paper to be easily and quickly unloaded from the carton, wherein the carton is adapted to remain sealed during shipping, handling and storing operations without the need to utilize ancillary securing devices such as straps and the like, and wherein the carton may be reclosed after opening.
In addition, it is desirable to provide an apparatus, such as a carry handle or the like, associated with the carton to facilitate handling thereof A combination of a smaller multi-ream container together with a carry handle, for example, is ideally suited for retail sales to home users.

SUMMARY OF THE INVENTION

The present invention comprises a carton for shipping and storing cut sheets of paper, wherein the carton holds fewer sheets of paper than conventional containers for this purpose, and is therefore lightweight and easy to handle and store. The carton is constructed for easy access to the paper for unloading it from the carton, and is particularly adapted to ship and store unwrapped sheets of paper, although it may be adapted for shipping and storing individually wrapped reams of paper.
The carton includes a base portion having at least one side wall that may be pivoted downwardly to open the carton and expose the contents for easy removal, and a lid portion engaged over the base portion to close the top of the carton and normally hold the pivoted side wall in closed position. When the lid is opened, that side wall may be pivoted downwardly to expose the paper at the top and one side to facilitate access to it.
The openable side wall enables the user to easily and quickly grasp and unload the paper stored in the carton, without the necessity of forcing the hands or fingers between the carton side walls and the contents, or turning the carton over and dumping out the contents. Moreover, the lid and openable side wall may be reclosed to protect the paper remaining in the carton.
In a preferred embodiment the carton of the invention has a built-in carry handle and is adapted to hold more than one ream of paper, but may contain less than the five or ten reams normally placed in a conventional package. For example, one embodiment of the carton of the invention is adapted to hold approximately three reams of paper, resulting in a lightweight package that is easy to handle. It is not intended, however, to limit the invention to a carton for holding three reams of paper. The carton can be adapted for any quantity of paper, but is generally limited to an amount that is easy to handle and store and that the built-in carry handle can reliably support. After the carton is opened, the user may simply grasp and unload as many sheets as desired, without the need to open individual reams, and the carton may be reclosed to protect the unused sheets.
In a preferred construction, the base portion comprises a bottom wall, opposite end walls, and front and back walls folded from a single unitary blank of corrugated paper. End flaps on the back wall are folded inwardly and secured to the end walls by adhesive or other suitable fastening means so that the back wall and end walls remain in an upright position. End flaps or tuck-in flaps on the front wall are folded inwardly but are not attached to the end walls. Instead, they tuck in between the end walls and paper held in the carton, whereby the front wall can be pivoted downwardly to open the front of the carton. After the desired quantity of paper is removed from the carton, the front wall can be pivoted back up to an upright position, with the tuck-in flaps tucked between the end walls and paper to re-close the carton.
The lid portion comprises a lid folded from a single unitary blank. The lid has a top wall, depending end flanges, and depending front and back flanges. The back flange has glue flaps on its opposite ends, turned inwardly to lie inside and parallel to the end walls. In the assembled carton, the lid back flange and associated first glue flaps are secured by adhesive or other suitable fastening means to the back and end walls, respectively, of the base portion. The lid front flange has a width to extend downwardly over an upper edge portion of the base portion front wall, to hold the front wall in its upright closed position when the lid is in its operative closed position. Second glue flaps on opposite ends of the front flange are turned inwardly to lay inside and parallel to the end flanges and are attached to the end flanges by adhesive or other suitable fastening means. The bottom edge of the lid front flange is secured to the base portion front wall by a spot of glue, adhesive or other suitable fastening means. Alternatively, with this construction, a tear strip may be used to securely hold the lid to the base portion.
A carry handle is attached to the base portion to facilitate carrying the carton, and comprises a flexible strap attached to a base plate that is secured to the inner surface of the front wall of the base portion. The flexible strap extends through aligned openings in the base portion and the lid top wall. Generally, in the previous design of the art, inventors have used inset plate to augment and reinforces the attachment of the carry handle to the carton. In one embodiment of the present invention, the carry handle is directly attached to the front wall of the base portion without using an intermediate insert plate. For example, such insert plates are described in U.S. application Ser. No. 11/580515 filed on Oct. 13, 2006 which is herein in its entirety incorporated by reference.
The carton of the invention may be opened to gain access to the paper stacked inside, and reclosed to protect the remaining paper. It does not require substantial adhesive attachment between the lid and the base, or separate securing means such as straps to keep the lid assembled to the base. Further, the carton preferably holds more than one ream of paper, preferably about three reams, and because of its reduced size and weight, and the provision of a carry handle, the carton is easy to carry and store.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing as well as other objects and advantages of the invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:

FIG. 1 is a top perspective view of a preferred carton constructed in accordance with the invention;

FIG. 2 is a plan view of a blank B1 from which the carton base is formed;

FIG. 3 is a plan view of a blank B2 from which the carton lid is formed;

FIG. 4 relates to FIG. 2, showing a top perspective view of the base portion of the carton and a carry handle, with the lid omitted and the front wall is partially pivoted toward an open position;

FIG. 5 relates to FIG. 3, showing a partially folded perspective view of the lid; and

FIG. 6 is a top perspective view of the carton of FIG. 1, showing the lid pivoted upwardly with the movable front wall pivoted to a partially open position to denote the carry handle of FIG. 4 being adhesively attached to an inner surface of a movable front wall, and wherein the carton contains unwrapped sheets of paper.

DETAILED DESCRIPTION OF THE INVENTION

A preferred carton in accordance with the invention is indicated generally at 10 in the drawings. The carton 10 comprises a rectangularly shaped base portion 11, a lid portion 12, and a carry handle 13. The base portion 11 has a bottom wall 14, opposite end walls 15 and 16, a back wall 17, a movable front wall 18, and an interior space 19 (not shown in this view). The lid 12 is telescopically received over the interior space (shown in FIG. 4) and has a top wall 20, depending end flanges 21 and 22, a depending back flange 23, and a depending front flange 24. Although is not critical to the utility of the present invention, glue spots 25 are joined to the bottom edge of the front flange 24 to secure the front of the lid 12 to the base portion front wall 18, and optionally, a tear strip (not shown) may extend between the front flange and glue strip to separate the front flange from the glue strip and enable the lid to be pivoted upwardly.
Details of construction of the base portion 11 can be best seen with reference to FIGS. 2 and 4. A blank B1 for making the base portion 11 is illustrated in FIG. 2, and comprises bottom wall panel 14, opposite end wall panels 15 and 16 foldably joined to opposite edge of the bottom wall panel, back wall panel 17 foldably joined to a back edge of the bottom wall panel, and movable front wall panel 18 foldably joined to a front edge of the bottom wall panel. Glue flaps 27 and 28 are foldably joined to opposite ends of the back wall panel 17, and tuck-in flaps 29 and 30 are foldably joined to opposite ends of the front wall panel 18. A shaped opening 43 is formed generally through the center of the front wall panel 18 to receive the carry handle 13 as described below.
Assembly of the base portion 11 is best seen in FIG. 2. The glue flaps 27 and 28 on opposite ends of the back wall 17 are folded inwardly and glued or otherwise suitably fastened to the inner surface of the respective end walls 15 and 16, but the tuck-in flaps 29 and 30 on opposite ends of the front wall 18 are merely folded inwardly to lie against the inner surface of the respective end walls 15 and 16. The respective tuck-in flaps 29 and 30 slide between the corresponding end walls 15 and 16 and paper held in the carton, when the front wall 18 is moved between its upright and lowered pivoted positions, respectively. The tuck-in flaps 29 and 30 may be suitably shaped, e.g., with a curvilinear free end edge 31 as shown, to facilitate entry of those into the space between the respective end walls 15 and 16 and paper as the front wall 18 is moved to its upright closed position. A finger access cut-out 32 may optionally be provided in the upper edge of the front wall 18 to facilitate moving it downwardly.
Details of construction of the lid portion 12 can be best seen with reference to FIG. 3-5. A blank B2 for making the lid 12 is illustrated in FIG. 3, and comprises top wall panel 20, end flange panels 21 and 22 foldably joined to opposite ends of the top wall panel 20, back flange panel 23 foldably joined along fold line L to a back edge of the top wall panel 20, and front flange panel 24 foldably joined along a front edge of the top wall panel 20. Glue spots 25 are disposed near the free edge of the front flange panel 24. First glue flaps 33 and 34 are foldably joined to opposite ends of the respective end flange panels 21 and 22, and second glue flaps 35 and 36 are foldably joined to opposite ends of the outer surface of the respective end walls 15 and 16 of the base portion. A shaped opening 37 is formed generally through the center of the front flange panel 24 to permit the carry handle 13 through thereof as described below. A finger access cut-out 45 may optionally be provided in the free edge of the to facilitate detaching the glue spots or other fastening means that hold the bottom edge of the lid front flange to the base portion front wall when opening the carton for the first time, if desired.
As best seen in FIG. 5, the first glue flaps 33 and 34 on opposite ends of the front flange panel 24 are secured by adhesive or other suitable fastening means against the inner surface of the respective end flanges 21 and 22, but the second glue flaps 35 and 36 are secured by adhesive or other suitable fastening means against outer surface of the respective end walls 15 and 16 of the base portion as depicted in FIG. 6. This permits the lid to be pivoted upwardly or downwardly about the fold line L and the lid 12 is directly attached to the base portion 11. As best seen in FIGS. 1 and 4, the carry handle 13 includes a flexible strap 40 attached to a rectangular base plate 41 that is adhesively attached to the inner surface of the front wall 18, with the strap projecting through a shaped opening 43 and through the shaped opening 37 in the lid front flange panel 24. It should be noted that the carry handle 13 is now parallel to the longer dimensions of the cut size paper contained in the carton. In addition, the location of the carry handle 13 provides ergonomics advantage since the center of gravity of the carton 10 is now closer to a user's body. Further, the carry handle and opening configuration comprising the handle, the lid front flange panel and front wall of the base portion is positioned such that the carry handle 13 is attached to the front wall 18 of the base portion, the front wall of the base portion being perpendicular to the plane of the surface of the paper and along the long edges of the stacked paper. In addition, the location of the carry handle 13 provides ergonomic advantage since the center of gravity of the carton is now closer to a user's body. Advantageously, the carry handle 13 in this configuration assists in retaining the lid portion in the closed position after the carton is opened for the first time by prying the glue spots or other adhesive means connecting the lid front flange to the base portion front wall or alternatively after a tear strip has been removed. The position of the carry handle 13 being pulled through the opening 37 in the lid front flange is especially useful for keeping the contents from spilling when carrying the carton after the carton has been opened for the first time.
As seen in FIG. 6, the carton is compact, enabling it to be easily stored under a desk or on a shelf Opening of the carton 10 is easily accomplished simply by using a user's index finger in cut out 45 to detach the lid portion from the base portion that is spot glued and pivoting the lid upwardly, after which the front wall 18 can be pivoted downwardly to gain access to the paper held in the carton. After the desired amount of paper has been removed, the moveable front wall 18 can be returned to its upright position, with the tuck-in flaps 29, 30 inserted between the base end walls and the paper held in the carton, and the lid 12 returned to its lowered position to close the package and hold the front wall in its closed position.
In summary, the present invention is directed to a carton for shipping and storing a quantity of cut sheets of paper and comprises a carton base portion having a bottom wall, opposed upstanding front and back walls and opposed upstanding end walls, each joined along a bottom edge to a respective edge of the bottom wall to define an interior space. A lid is pivotally attached to the base portion. The lid has a top wall with depending end flanges, a depending front flange having a pair of first glue flaps, and a depending back flange having a pair of second glue flaps. The first glue flaps is attached to the end flanges and the second glue flaps is attached to the base portion. The base portion front wall is unsecured to adjoining end walls and is pivotable about its bottom edge downwardly and away from the carton to an open position when the lid is moved upwardly away from the front wall, thereby exposing the cut paper at the top and one side to permit easy access to paper contained in the carton for rapid unloading of the paper from the carton. The base portion front wall has inwardly turned tuck-in flaps on opposite ends thereof which tuck into the carton in contiguous, parallel, overlapping relationship with adjacent end walls when the front wall is in closed position. A carry handle is attached to the base portion front wall to facilitate carrying of the package.
The inwardly turned first and second glue flaps are on opposite ends of the lid front flange and the lid back flange respectively. The first glue flaps on the lid front flange is attached to respective the lid end flanges, and the second glue flaps on the lid back flange is free of attachment to the lid end flanges. The glue flaps on the lid back flange are attached to the respective base portion end walls. A bottom edge of the lid back flange and a bottom edge of the first glue flaps on the lid back flange are attached to the base portion back wall and end walls, respectively. The tuck-in flaps on the base portion front wall are relatively narrow so that they may be moved into and out of the carton without unduly disturbing the contents of the carton. The lid top wall is foldably attached to the lid back flange along a fold line, and the lid pivots upwardly about the fold line. The tucked-in flaps have free end edges, and the free end edges are shaped to facilitate insertion thereof into the carton. A shaped opening is formed through center of the base portion front wall to receive the carry handle. The carry handle includes a flexible strap attached to a base plate at its opposite ends and the base plate is adhesively attached to the base portion front wall. A lid shaped opening is formed through center of the front flange to permit the carry handle inserted through thereof The carry handle position is parallel to a longer dimension of the cut size paper contained in the carton. The carry handle position causes the center of gravity of the carton to be closer to a user's body when carrying the carton. Glue spots are disposed near the free edge of the lid front flange to adhesively secure the lid to the base portion.
It should now be appreciated that the present invention provides a material-saving, quickly erected carton especially useful in retaining, transporting variety of products such as loose papers or envelops, by way of example. The carton is designed with a carry handle attached in the front of the carton which provides an ergonomic advantage since the center of gravity of the carton is now closer to the user's body. As described above, the structure of the back wall, the end panels, the moveable front panels, the depending front flange, and top portion panel enhance the rigidity, stackability, venting capability and manufacturing cost effectiveness of the carton. In the present invention, the lid is directly attached to the base portion and configured such that does not dissociate from the base portion under the shear strain resulting from the movement of the lid relative to the container base. The blanks used to form the carton lid and base portion each has a symmetrical design, which reduces erecting and closing labor. The lay flat design of the blank speeds the cutting and packaging process and facilitates easy shelving.
While the invention has been shown for holding unwrapped sheets of paper, it should be understood that it could be used for holding wrapped reams of paper, and although the preferred embodiment is designed for holding about three reams of paper, the carton could be sized for holding other quantities of paper so long as the size and weight do not exceed amounts (for example, about 20 pounds) that provide ease of handling and carrying by the carry handle.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A carton for shipping and storing a quantity of cut sheets of paper, comprising:

a carton base portion having a bottom wall, opposed upstanding front and back walls and opposed upstanding end walls, each joined along a bottom edge to a respective edge of the bottom wall to define an interior space;

a lid pivotally attached to the base portion, the lid having a top wall with depending end flanges, a depending front flange having a pair of first glue flaps, and a depending back flange having a pair of second glue flaps, the first glue flaps being attached to the end flanges and the second glue flaps being attached to the base portion;

the base portion front wall being unsecured to adjoining end walls and being pivotable about its bottom edge downwardly and away from the carton to an open position when the lid is moved upwardly away from the front wall, thereby exposing the cut paper at the top and one side to permit easy access to paper contained in the carton for rapid unloading of the paper from the carton;

the base portion front wall having inwardly turned tuck-in flaps on opposite ends thereof which tuck into the carton in contiguous, parallel, overlapping relationship with adjacent end walls when the front wall is in closed position; and

a carry handle attached to the base portion front wall to facilitate carrying of the package.

2. The carton of claim 1 wherein:

Inwardly turned first and second glue flaps are on opposite ends of the lid front flange and the lid back flange respectively, the first glue flaps on the lid front flange is attached to respective the lid end flanges, and the second glue flaps on the lid back flange is free of attachment to the lid end flanges.

3. The carton of claim 2 wherein:

the glue flaps on the lid back flange are attached to the respective base portion end walls.

4. The carton of claim 3 wherein:

a bottom edge of the lid back flange and a bottom edge of the first glue flaps on the lid back flange are attached to the base portion back wall and end walls, respectively.

5. The carton of claim 1 wherein:

the tuck-in flaps on the base portion front wall are relatively narrow so that they may be moved into and out of the carton without unduly disturbing the contents of the carton.

6. The carton of claim 1 wherein:

the lid top wall is foldably attached to the lid back flange along a fold line, and the lid pivots upwardly about the fold line.

7. The carton of claim 1 wherein:

the tucked-in flaps have free end edges, and the free end edges are shaped to facilitate insertion thereof into the carton.

8. The carton of claim 1 further comprising:

a shaped opening formed through center of the base portion front wall to receive the carry handle.

9. The carton of claim 1 wherein:

the carry handle includes a flexible strap attached to a base plate at its opposite ends and wherein the base plate is adhesively attached to the base portion front wall.

10. The carton of claim 1 further comprising:

a lid shaped opening formed through center of the front flange to permit the carry handle inserted through thereof

11. The carton of claim 1 wherein:

the carry handle position is parallel to a longer dimension of the cut size paper contained in the carton.

12. The carton of claim 1 wherein:

the carry handle position causes the center of gravity of the carton to be closer to a user's body when carrying the carton.

13. The carton of claim 1 wherein:

Glue spots are disposed near the free edge of the lid front flange to adhesively secure the lid to the base portion.

14. A carton for shipping and storing a quantity of cut sheets of paper comprising:

a carry handle attached to the base portion front wall and the carry handle position causes the center of gravity of the carton to be closer to a user's body when carrying the carton.

15. The carton of claim 14 wherein:

16. The carton of claim 14 wherein:

17. The carton of claim 14 wherein: