US20200247578A1

US20200247578A1 - Tear open package assembly and method

Info

Publication number: US20200247578A1
Application number: US16/778,294
Authority: US
Inventors: Peter Towle
Original assignee: CCL Label Inc
Current assignee: CCL Label Inc
Priority date: 2019-02-01
Filing date: 2020-01-31
Publication date: 2020-08-06
Also published as: CA3070692A1

Abstract

A tear open container as shown and described herein. The tear open container may include a plurality of panels including a rear, left, front, right, top, bottom and include a dieline including perforations to allow a user to separate the container into a top portion and a bottom portion. The remaining bottom portion may be configured to store and display articles, such as binders, on a shelf. The top portion may be discarded. A tab and pull flap may be defined by the dieline and allow the user to easily remove the top portion from the bottom portion. The user may depress the tab to grasp the pull flap and perforate the remaining portions along the dieline.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/799,956, entitled “TEAR OPEN PACKAGE ASSEMBLY AND METHOD” filed on Feb. 1, 2019, which is incorporated by reference in its entirety.

FIELD OF INVENTION

The present disclosure generally relates to a container apparatus for transporting and storing items, in particular wherein the container apparatus is configured to store and transport and be easily opened while maintaining structural integrity. More particularly, the present disclosure relates to containers fabricated from paper, paperboard, corrugated paperboard and/or any appropriate material with a dieline configured for secure transport, storage, and display, with ease of access to the product contained therein.

BACKGROUND

Corrugated paperboard is typically used in many different applications. For example, corrugated paperboard is used to form containers, boxes, cartons, or dividers for holding, storing, stacking or shipping various articles.
Typically, corrugated containers have a bottom and four side walls, and are formed from a blank scored with fold lines or cut lines. Optionally, the container may include a top made from a separate blank for covering the opening of the container. The blanks are most often formed by automated machines in a continuous in-line process involving cutting, scoring, and molding continuous sheets of cardboard or paperboard. The paperboard may then be folded along the score lines or cut lines to form a container. The blanks may be folded into a container by an automated machine or by a consumer. Containers fabricated in whole or in part from paper, paperboard, cardboard, and corrugated paperboard are employed for the shipping and storage of a variety of articles. Many shipping container designs that utilize cardboard materials require an arrangement that can securely transport the articles within the container while reducing the risk of damaging the articles therein, while also allowing the products transported therein to be displayed after a portion of the container has been removed.
However, the containers of the prior art each have a problem in utilization that makes it difficult to tear open or to open without damage to remaining base of the container. For example, a container with a tear away pattern configured to remove a portion of the container while maintaining a base display portion may be damaged, resulting in an unappealing display or shelf presence. Further, known tear open containers may be difficult to disassemble and re-use without damaging the container.
Accordingly, it is an object of the present disclosure to provide a cost-efficient container that is easy to assemble and disassemble, and which has multiple features that allow for the product to be sufficiently protected during shipment, and improves the ease of removing a portion to display the product from a base portion which minimizes damages to the container. It is also an object to the present disclosure to provide a container that provides quick and easy access to its contents while it may be maintained in a display or shelf arrangement while generally protecting the contents thereof.
These and other desirable characteristics of the disclosure will become apparent in light of the present specification, including claims, and figures.

SUMMARY

Provided is a tear open container that may include a plurality of panels including a rear, left, front, right, top, bottom and include a dieline including perforations to allow a user to separate the container into a top portion and a bottom portion. The remaining bottom portion may be configured to store and display articles, such as binders, on a shelf. The top portion may be discarded. A tab and pull flap may be defined by the dieline and allow the user to easily remove the top portion from the bottom portion. The user may depress the tab to grasp the pull flap and perforate the remaining portions along the dieline.
In an embodiment, provided is a tear open container assembly comprising a blank formed from a generally continuous planar stock material that forms a plurality of panels including a first panel, a second panel, a third panel, a fourth panel, and an end panel configured to be assembled into a container. A dieline including perforations may be defined along the plurality of panels to allow a user to manually separate the container into a top portion and a bottom portion, wherein the dieline at least partially defines a tab and pull flap such that when the top portion is separated from the bottom portion, the bottom portion is configured to support and display at least one article therein. The tab may be configured to be depressed relative to the pull flap. The pull flap may be configured to be grasped and pulled to perforate the remaining portions of the dieline. The tab may be part of the bottom portion and the pull flap may be part, of the top portion. The dieline may extend continuously along each of the panels and may be configured to form a window between a first side edge and a second side edge along the front or third panel when the top portion is separated from the bottom portion. The dieline may be configured to separate each panel into the top portion and the bottom portion. The shape of the dieline may include a generally straight portion along the first panel, an angled portion along the second panel, a U-shaped portion along the third panel, and an angled portion along the fourth panel. The dieline may be aligned along each of the plurality of panels to form a continuous dieline that may be a series of cuts and ties configured to allow a user to manually tear along the dieline to remove the top portion from the bottom portion. The first panel, the second panel, the third panel, and the fourth panel may each include a top flap and a bottom flap. The tab and pull flap may be positioned along a bottom flap of the third or front panel. The end flap may extend from the fourth panel and may be configured to be attached to the first panel in an assembled configuration. The dieline may include a shark perf style perforation along the first panel, and a different style of perforation along the remaining plurality of panels, wherein the shark perf style perforation includes a series of diagonal cuts and ties that are configured to allow the top portion to pivot or hinge along the dieline once the pull flap has been perforated along the third panel, opposite from the first panel in an assembled configuration. The generally continuous planar stock material may include paperboard or corrugated cardboard stock, wherein the generally continuous planar stock material may be edge crush test (ECT) B-flute corrugated board.
In another embodiment, provided is a method of assembling a tear open container comprises providing a blank formed from a generally continuous planar stock material that forms a plurality of panels including a first panel, a second panel, a third panel, a fourth panel, and an end panel, wherein the plurality of panels are aligned along fold lines, and wherein the first panel, second panel, third panel, and forth panel each include a bottom flap and an opposite top flap, with each of the bottom flaps and top flaps aligned along fold lines. A dieline may be formed along each of the plurality of panels and include a continuous series of cuts and ties configured to allow a user to manually tear along the dieline to separate a top portion from a bottom portion. The at least one tab and a pull flap may be formed along the dieline. The plurality of panels and plurality of flaps may be folded along the fold lines to configure the blank into a tear open container. The dieline may be formed to include a generally straight portion along the first panel, and a generally U-shaped portion along the third panel opposite from the first panel when the blank is folded into the tear open container. The generally straight portion of the dieline along the first panel may include a shark perf style perforation, wherein the shark perf style perforation includes a series of diagonal cuts and ties that are configured to allow the top portion to pivot or hinge along the dieline.
In another embodiment, provided is a method of separating a tear open container. The steps comprise of pushing inwardly against opposite sides of a container formed by a blank of a generally continuous planar stock material that includes a plurality of panels assembled into the container. The container includes a continuous dieline defined along the plurality of panels, with the dieline at least partially defined by a tab and pull flap. The tab is pushed inwardly along its perimeter perforations. The pull flap is pulled along a front panel or along a bottom flap to separate a top portion of the container from a bottom portion. The top portion may be hinged along a back line of perforation that extends across a back panel. The dieline, along the opposite sides of the container, may be generally diagonal lines of perforation relative to a back line of perforation along a back panel.

BRIEF DESCRIPTION OF THE DRAWINGS

Operation of the disclosure may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:

FIG. 1 is an image of a plurality of products on a shelf with prior art versions of containers;

FIG. 2 is a top view of an embodiment of a un-assembled tear open container according to the present disclosure;

FIG. 3 is a perspective view of an embodiment of an assembled tear open container of FIG. 2;

FIG. 4A is an un-assembled view of a left side of the tear open container in accordance with the present disclosure;

FIG. 4B is an un-assembled view of a right side of the tear open container in accordance with the present disclosure;

FIG. 4C is an image of an opening diagram associated with the left and right sides of the tear open container in accordance with the present disclosure;

FIG. 5A is an un-assembled view of a top, front, and bottom side portions of the tear open container in accordance with the present disclosure;

FIG. 5B is an image of an opening diagram associated with the top, front, and bottom side portions of the tear open container in accordance with the present disclosure;

FIG. 6A is an un-assembled view of a top, back, and bottom side portions of the tear open container in accordance with the present disclosure;

FIG. 6B is an image of an opening diagram associated with the top, back, and bottom side portions of the tear open container in accordance with the present disclosure;

FIG. 7 illustrates perspective views of the assembled tear open containers of various sizes in accordance with the present disclosure;

FIG. 8 is a top view of an embodiment of an un-assembled tear open container according to the present disclosure;

FIG. 9 is a top view of an embodiment of an un-assembled tear open container according to the present disclosure;

FIG. 10 is a top view of an embodiment of an un-assembled tear open container according to the present disclosure;

FIG. 11 is a top view of an embodiment of an un-assembled tear open container according to the present disclosure;

FIG. 12 is a top view of an embodiment of an un-assembled tear open container according to the present disclosure;

FIG. 13A is an image of a bottom side of an embodiment of an assembled tear open container according to the present disclosure;

FIG. 13B is an image of a top side of an embodiment of an assembled tear open container according to the present disclosure;

FIG. 13C is an image of a top side of an embodiment of an assembled tear open container according to the present disclosure;

FIG. 14A is a schematic diagram of a left side of an embodiment of a tear open container according to the present disclosure;

FIG. 14B is a schematic diagram of a right side of an embodiment of a tear open container according to the present disclosure;

FIG. 14C is an enlarged portion of FIG. 14B;

FIG. 15A is a schematic diagram of an embodiment of a front side of a tear open container according to the present disclosure;

FIG. 15B is a schematic diagram of an embodiment of a front side of a tear open container according to the present disclosure;

FIG. 15C is a schematic diagram of an embodiment of a front side of a tear open container according to the present disclosure;

FIG. 16A is a schematic diagram of an embodiment of an end flap of a tear open container according to the present disclosure;

FIG. 16B is an enlarged portion of FIG. 16A;

FIG. 16C is an a schematic diagram of an embodiment of an end flap attached to a rear panel of a tear open container according to the present disclosure;

FIG. 17A is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17B is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17C is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17D is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17E is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17F is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17G is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17H is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 17I is a schematic diagram of an embodiment of an open pull tab of the tear open container;

FIG. 18A is a schematic diagram of an embodiment of a cutout geometry associated with a front side of a tear open container;

FIG. 18B is a schematic diagram of an embodiment of a cutout geometry associated with a front side of a tear open container;

FIG. 18C is a schematic diagram of an embodiment of a cutout geometry associated with a front side of a tear open container;

FIG. 18D is a schematic diagram of an embodiment of a cutout geometry associated with a front side of a tear open container; and

FIG. 19 is an image of an embodiment of an assembled tear open container with a top portion removed from a bottom portion according to the present disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the present teachings. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the present teachings. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the present teachings. In this disclosure, numerous specific details provide a thorough understanding of the subject disclosure. It should be understood that aspects of this disclosure may be practiced with other embodiments not necessarily including all aspects described herein, etc.
As used herein, the words “example” and “exemplary” mean an instance or illustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather than exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.
Further, unless context suggest otherwise, descriptions of shapes (e.g., circular, rectangular, triangular, etc.) refer to shapes meeting the definition of such shapes and general representation of such shapes. For instance, a triangular shape or generally triangular shape may include a shape that has three sides and three vertices or a shape that generally represents a triangle, such as a shape having three major sides that may or may not have straight edges, triangular like shapes with rounded vertices, etc.
While embodiments may refer to a particular example of the described tear open container for use in storing, transporting, and displaying articles, it is noted that disclosed embodiments may be applicable to various other uses. Described embodiments may be utilized for any application that requires storing, transporting, and displaying articles. Illustrated by FIG. 1 is an example of a prior art type of container used to display a plurality of articles on a shelf at a retail store. In particular, the articles are binders, and this type of tear open container is contemplated for transporting, storing, and displaying articles such as binders as displayed by FIG. 1. As illustrated, the plurality of binders may be stacked and arranged in a particular way to allow users to view and display such articles in a desirable and efficient manner. However, the embodiment of FIG. 1 utilizes a container that leaves a sloppy overall look, with portions having thumbholes partially attached that eventually become littered along the floor.
This disclosure includes a tear open container that provides an aesthetically pleasing and clean design that is easier to open than prior tear open type containers, is scalable with different article sizes, strong enough to stay structurally intact during palletized distribution, and with no thumbholes or residual material to detach and create a mess.
FIG. 2 illustrates an unassembled embodiment of a tear open container 20 according to the present disclosure. Here the container 20 may be formed from of a blank 10 that is cut from a generally continuous planar stock material such as, for example, corrugated cardboard material, paper, polymer, or plastic. However, the embodiments of the tear open container apparatus 20 may be made from any suitable material which can be cut and folded, but preferably made from paperboard or corrugated cardboard stock. The container 20 may be structured such that a cut and scored blank may be manufactured from the planar stock material, and the container may be constructed by folding the various panels, flaps, tabs, and walls in a prescribed manner. In one embodiment, the container may be made of ECT B-flute corrugated board. The resulting container may be self-maintaining and may be constructed without adhesives or other mechanical fasteners. The blanks may be cut such that corrugation flutes are arranged to run lengthwise or longitudinal relative to the blank material. The tear open container 20 may be assembled into six sides having a dieline 50 that allows the tear open container 20 to be separated to display articles therein while being structurally arranged on a retail shelf.
FIG. 2 illustrates the blank 10 of the container 20 in an unfolded state. FIG. 3 illustrates the blank 10 constructed into a folded or assembled state. The blank 10 may be cut completely through to form longitudinal slits, lateral slits, and tabs. The blank may be scored to form fold lines and foldable panels. The cuts and scores in the blank 10 may be configured to form the container 20 in its unfolded state. The tear open container 20 may include a first panel 22 (back panel), a second panel 24 (left panel), a third panel 26 (front panel) and a fourth panel 28 (right panel) that extend from one another. The first panel 22 may be attached to the second panel 24 along a first fold line 32. The second panel 24 may be attached to the third panel 26 along a second fold line 34. The third panel 26 may be attached to the fourth panel 28 along a third fold line 36. An end flap (glue flap) 30 may be attached to the fourth panel 28 along a fourth fold line 38. However, the end flap 30 may optionally be attached to the first panel 22 (not shown). In this embodiment, the first panel 22 has a common width as the third panel 26, and the second panel 24 has a common width as the fourth panel 28. Each panel may include a flap extending from an edge of the panel along another fold line. In one embodiment, a top flap 42 extends from a top edge of the panels and a bottom flap 44 extends from a bottom edge of each of the panels. Each of the flaps may be separately foldable along a fold line to allow the blank 10 to be assembled in a rectangular or cuboid configuration. Various embodiments of these configurations exist and are illustrated by FIGS. 8-12.
Notably, the end flap 30 may be attached to the first panel 22 with adhesive, tape, glue, or other fastener to properly assemble the container as illustrated in FIG. 3. The top flaps 42 and bottom flaps 44 may also be assembled with adhesive, tape, glue, or other fasteners. Once folded, opposing flaps may meet when folded and sealed. Additionally, in some embodiments, the flaps may include cutout portions 72, 74 (as illustrated by FIGS. 4A, 4B, 8-12 and illustrated schematically on FIGS. 18A-18D) that may aid in the opening of the tear open container. Notably, the flaps 44 from the first panel 22 and third panel 26 may be longer than the flaps from the second panel 24 and fourth panel 28 to allow edges of flaps 44 from the second panel 24 and fourth panel 28 to meet or align along the center of the container 20 when assembled.
A tear-away dieline 50 may extend through the panels to allow the tear open container to easily be opened to display the articles or contents therein. The dieline 50 may separate each panel into a top portion 60 configured to be removed or detached from a bottom portion 70 configured to support and display articles therein. In one embodiment, as illustrated by FIG. 2, the particular shape of the dieline 50 includes a generally straight portion 52 along the first panel 22, an angled portion 54 along the second panel 24, a U-shaped portion 56 along the third panel 26, and an angled portion 58 along the fourth panel 28. Each portion of the dieline 50 may be aligned to form a continuous dieline 50. The dieline 50 may be a series of cuts and ties configured to allow a user to manually tear along the dieline 50 to access within the container 20, but also allows for structural support of the container 20 before the top portion 60 is detached from the bottom portion 70. The shape of the dieline 50 allows for structural stability along the perimeter of the container 20 in addition to providing a window 104 (see FIG. 19) or opening to view the article along the third panel 26 or front of the container 20. Various embodiments of these configurations exist and are illustrated by FIGS. 8-12.
FIGS. 4A and 4B illustrate left side and right side panels 24, 28, respectively. Here the second panel 24 is shown as the left side with an angled portion 54 of the dieline 50 thereon. The fourth panel 28 is shown as the right side with another angled portion 58 of the dieline 50. The angled configuration of the dieline along the right and left sides of the container 20 allow for the user to manually push inwardly to easily break along the dieline 50 at the angled portions 54, 58 as illustrated by the diagram of FIG. 4C. The user can push inwardly along the top portion 60 relative to the dieline 50 to easily detach the top portion 60 relative the bottom portion 70. These figures also illustrate the cutout portions 72, 74 along the flaps 44 of the second panel 24 and fourth panel 28.
FIG. 5A illustrates an embodiment of the front side panel 26. Here the third panel (front panel) 26 is shown as the front side, with a U-shaped dieline 56 that extends from across the front side past the fold lines, along opposing sides of the third panel. This U-shaped dieline 56 may be configured to form at least one tab 100 and a pull flap 102 positioned along the flap 44 of the third panel 26 that allows the user to remove the top portion 60 from the bottom portion 70 and creates a window 104 to allow products positioned in the bottom portion 60 to be viewed. The tab 100 may include a finger sized perforation along the apex of the U-shaped dieline 56 to allow the user to depress along the dieline perforations. The pull flap 102 is formed to allow the user to grasp the pull flap 102 portion once the tab 100 has been depressed to easily remove the U-shaped portion of the top. In some embodiments, the tab 100 and pull flap 102 may be positioned along the front side of the container. See FIG. 2, which includes a plurality of tabs 100 along the dieline 50 on the front panel, right panel and left panel. In another embodiment, the tab 100 and pull flap 102 may be positioned along a bottom side of the container. See FIGS. 5A, 8, 9, 10, 11, 12, 13A. FIGS. 17A through 17I illustrate various dimensions and configurations of the tab 100 and pull flap 102 along the container.
It was determined that thumbholes are not needed to open the tear open container and may be removed from the design altogether. The described perforation geometry of the dieline 50 was optimized for a cleaner look on a retail shelf. In addition, the geometry of the tear open container may be designed for scalability which results in visual harmony between varying dimensions. The elimination of the thumbholes further results in a cleaner and improved looking container. Further, the flap structure has been designed to prevent tape from overlapping the perforated dielines when sealed.
With reference to FIGS. 4A, 4B, 4C, 5A, and 5B, the steps/opening geometry used in the tear open container are provided. Initially, after shipment of the container with the items therein, the left and right sides of the container may be broken by manually pushing in against the lines of perforation. Here, the left and right side perforation (angled portions 54, 58) may include cuts and ties with ½″ gap and ⅛″ tie. This perforation type provides strength during distribution, but is easily broken once forces are applied perpendicularly to it. See the diagram of FIG. 4C for the left/right side opening geometry of the container 20.
With reference to FIGS. 5A and 5B, the steps/opening geometry for the front panel is described. Here, the front of the container may be opened by pushing the tab 100 and pulling the pull flap 102 from the front or underside of the container. Various embodiments of the tab 100 and pull flap 102 are considered and are illustrated by FIGS. 17A-17I. Special opening geometry of the dieline may be along the front panel or along the bottom flap (as illustrated by FIG. 5B) to ensure that the front portion of the tear open container is easily and cleanly separated for retail display.
FIGS. 13A-13C illustrate images of the bottom side and top side of various sized containers. Here the top flaps 42 and bottom flaps 44 are illustrated to be folded inwardly to meet along the center of the container as it is assembled. The end user may tear off the top portion of the tear open container from the perforation on the back of the case. In FIGS. 13A and 13B, the front and rear panels have a width that is greater that the left and right panels. FIG. 9 illustrates an unassembled version of this configuration. In this embodiment, the top and bottom flaps and top side (FIG. 13A) and the bottom side (FIG. 13B) meet along the center and are longer than the top and bottom flaps of the left and right sides. Here the top and bottom flaps of the front and rear sides are approximately ½ the width of the left and right side top and bottom flaps and 2× the length of the left and right side top and bottom flaps. In FIG. 13C, the front and rear panels have a width that is greater than the left and right panel width. In this embodiment, the top and bottom flaps and front side and rear side are about 2× the width of the flaps of the left and right panels and each have a length that is approximately equal. Here the flaps of the right and left panels may not meet in the center. FIG. 10 illustrates an unassembled version of this configuration.
With reference to FIGS. 6A and 6B, the final step of opening the container is to tear off the top portion 60 along the back dieline perforation 52. This portion of the dieline 50 exists along the first panel 22. Once the sides and front perforation have been broken, the top portion 60 may be hinged open along the back line of the perforation line 52 that extends across the first panel 22. The end user may then remove the back line of the perforation 52 starting at either the left or right side of the back of the tear open container 20. The perforation on the back of the tear open container 20 may be optimized to be opened by being ripped horizontally. See the diagram of FIG. 6B.
FIG. 7 illustrates how various sizes may be utilized to compatibly display various products with different sized containers 20. Notably, the widths may be different, but the heights and depths may be arranged to be the same to compatibly display articles. At this point, the following sizes (in inches) of a tear open container as described have been validated as adequately strong for a set range of weight using distribution simulation.


Dimension	Minimum	Maximum

Inner Depth
10 + ½	11 + 9/16
Inner Width	4 + ⅝	15 + ⅝
Inner Height	11 + 11/16	11 + 13/16
Weight Range	No Min	12.95 lbs

Although the dimensions have been shown to work well, this design is scalable and can be applied to containers that may be larger or smaller than those that were validated. This design works well with dimensions of containers with a left to right width that is greater than or equal to the back to front depth. If a container is adequately deep, it can be wider than it is deep. As such, one dimension contemplated is the container having that is about 15+⅝″ wide by 11+ 9/16″ deep.
In one embodiment, as illustrated by FIG. 8, the particular shape of the dieline 50 includes a generally straight portion 52 along the first panel 22, a rounded curved portion 54 along the second panel 24, a U-shaped portion 56 along the third panel 26 that extends into the bottom flap, and a rounded curved portion 58 along the fourth panel 28. Each portion of the dieline 50 is aligned to form a continuous dieline 50 that may be a series of cuts and ties configured to allow a user to manually tear along the dieline 50 to access within the container 20. In this embodiment, the container removes most of the front face portion and leaves most of the side and rear panels. This shape allows for structural stability along the perimeter of the container 20 in addition to an opening or window 104 to view the article along the third panel 26 or front of the container 20.
In another embodiment, as illustrated by FIG. 11, the particular shape of the dieline 50 includes a generally straight portion 52 along the first panel 22, another straight portion 54 along the second panel 24, a U-shaped portion 56 along the third panel 26 that extends into the bottom flap 44, and another straight portion 56 along the fourth panel 28. Each portion of the dieline 50 is aligned to form a continuous dieline 50 that may be a series of cuts and ties configured to allow a user to manually tear along the dieline 50 to access within the container 20. In this embodiment, the container removes most of the side and rear panels. This shape allows for structural stability along the perimeter of the container 20 in addition to an opening or window 104 to view the articles in the bottom portion along the third panel 26 or front of the container 20.
In another embodiment, as illustrated by FIG. 12, the particular shape of the dieline 50 includes a generally angled portion 52 along the first panel 22, a straight portion 54 along the second panel 24, a U-shaped portion 56 along the third panel 26 that extends into the bottom flap 44, and a curved and straight portion 56 along the fourth panel 28. The curved and straight portion 56 along the fourth panel 28 is higher than the angled portion along the first panel 26 to cause the resulting bottom portion to appear to have asymmetrical heights of the side panels. Each portion of the dieline 50 is aligned to form a continuous dieline 50 that may be a series of cuts and ties configured to allow a user to manually tear along the dieline 50 to access within the container 20. In this embodiment, the container removes most of the side and rear panels. The shape allows for structural stability along the perimeter of the container 20 in addition to an opening or window 104 to view the article along the third panel 26 or front of the container 20.
FIGS. 14A, 14B, and 14C illustrate the schematic dimensions of an embodiment of the left and right panels. The left and right panels may be mirrors of each other or vary by about ⅛″. The location of the dieline 50 along the left and right panels may be angled along the surface between the rear panel and front panel.
FIGS. 15A, 15B, and 15C illustrate schematic dimension of embodiments of the front panel. The dieline 50 may form side edges 106, 108 along opposing sides of the pull flap 102. The left and right dielines may be mirror images of one another
FIGS. 16A and 16B illustrate a dimensional embodiment of the end or glue flap 30. The end flap or glue flap may be aligned vertically along the back, left or right panel to aid in the assembly of the tear open container. The glue flap 30 may include a single dieline 50 that extends horizontally along the surface and is aligned with the dieline along the panel of which it is attached.
It was found that certain perforation types are best suited for different sections of the container. The perforation type for each panel section is described in the sections below. That said, other perforation types (i.e., ¼″ ⅛″) could potentially be used successfully in this style of tear open container. Further, each step of opening the tear open container was thought out, and the perforation type and geometry was optimized for each step. The optimized design, in conjunction with the established opening steps, results in an easier to open container.
FIG. 16C illustrates use of a “shark perf” design of the dieline 50 along a rear panel. Here the dieline 50 includes a series of diagonal cuts and ties that may allow the top portion to pivot or hinge along the dieline 50 once the pull flap 102 has been perforated along the front panel. In this instance, the top portion may only be attached to the bottom portion along the rear panel dieline. This configuration would also allow for the rear panel dieline to be completely perforated but also allows for temporary hinge functionality. FIG. 16C illustrates one example of dimensions for this embodiment. Further, it should be noted that the glue flap 30 may overlap this portion of the dieline 50 and may also include a knock out (K/O) panel to ensure secure glue flap adherence to the rear panel.
FIGS. 17A through 17I illustrate various dimensions and configurations of the tab 100 and pull flap 102 along the container. These portions include unique geometry configured to allow a user to easily tear apart the top portion from the bottom portion. Illustrated are standard and narrow styles that allow the user to depress the tab 100 to break the line of perforation along the pull flap 102 and the tab 100. This may allow the user to grasp the pull flap 102 and pull upwardly to break the remaining lines of perforation along the dieline 50 of either side of the pull flap 102. In one embodiment, perforation lines exist between the tab 100 and the pull flap 102, wherein a tie portion along the perforation line exists at the intersection of the tab with the pull flap. See FIG. 17E. This tie portion may be about ⅛″ as measured both vertically and horizontally. Further, the tab 100 may include a cut line vertically along its side and a score line horizontally along the bottom. See FIG. 17E. The score line allows the tab to maintain attachment to the panel after the dieline between the tab and pull flap has been perforated. Notably, the dielines 50 along the right and left side panels may be perforated by applying a force directed inwardly relative to the container prior to the tab 100 being perforated to assist with the ease of separation. The tab 100 may be located along a center portion of the front panel or bottom flap of the front panel.
FIGS. 18A and 18B illustrate bottom right and bottom left flap cutout portions 72, 74. These cutout portions allow for easier use of the opening geometry. The cutout portions 72, 74 may be configured such that as blank 10 is assembled into the container 20, the cutout portions 72, 74 generally align with the tab 100 to allow a user to easily depress the tab 100 to perforate the dieline 50 between the tab and the pull flap. The cutouts may be located along leading edges of the corners of the bottom right and bottom left flaps. The cutouts may include 90 degree corners as illustrated by the figures.
FIG. 19 illustrates an embodiment of the tear open container 20 wherein the top portion 60 has been completely removed from the bottom portion 70, illustrating the position of the remaining window 104 between two side edges 106, 108.
Although the embodiments of the present disclosure have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present disclosure is not to be limited to just the embodiments disclosed, but that the disclosure described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.

Claims

I claim:

1. A tear open container assembly comprising:

a blank formed from a generally continuous planar stock material that forms a plurality of panels including a first panel, a second panel, a third panel, a fourth panel, and an end panel configured to be assembled into a container;

a dieline including perforations defined along the plurality of panels to allow a user to manually separate the container into a top portion and a bottom portion; and

wherein the dieline at least partially defines a tab and pull flap such that when the top portion is separated from the bottom portion, the bottom portion is configured to support and display at least one article therein.

2. The tear open container assembly of claim 1, where the tab is configured to be depressed relative to the pull flap.

3. The tear open container assembly of claim 2, wherein the pull flap is configured to be grasped and pulled and to perforate the remaining portions of the dieline.

4. The tear open container assembly of claim 1, wherein the tab is part of the bottom portion and the pull flap is part of the top portion.

5. The tear open container assembly of claim 1, wherein the dieline extends through each of the panels and is configured to form a window between a first side edge and a second side edge along the third panel when the top portion is separated from the bottom portion.

6. The tear open container assembly of claim 1, wherein the dieline is configured to separate each panel into the top portion and the bottom portion.

7. The tear open container assembly of claim 6, wherein the shape of the dieline includes a generally straight portion along the first panel, an angled portion along the second panel, a U-shaped portion along the third panel, and an angled portion along the fourth panel.

8. The tear open container assembly of claim 6 wherein the dieline is aligned along each of the plurality of panels to form a continuous dieline that may be a series of cuts and ties configured to allow a user to manually tear along the dieline to remove the top portion from the bottom portion.

9. The tear open container assembly of claim 8, wherein the first panel, the second panel, the third panel, and the fourth panel each include a top flap and a bottom flap.

10. The tear open container assembly of claim 8, wherein the tab and pull flap are positioned along a bottom flap of the third panel.

11. The tear open container assembly of claim 6, wherein the end flap extends from the fourth panel and is configured to be attached to the first panel in an assembled configuration.

12. The tear open container assembly of claim 1, wherein the dieline includes a shark perf style perforation along the first panel and a different style of perforation along the remaining plurality of panels, wherein the shark perf style perforation includes a series of diagonal cuts and ties that are configured to allow the top portion to pivot or hinge along the dieline once the pull flap has been perforated along the third panel, opposite from the first panel in an assembled configuration.

13. The tear open container assembly of claim 1, wherein the generally continuous planar stock material includes paperboard or corrugated cardboard stock.

14. The tear open container assembly of claim 13, wherein the generally continuous planar stock material is edge crush test (ECT) B-flute corrugated board.

15. A method of assembling a tear open container comprising:

providing a blank formed from a generally continuous planar stock material that forms a plurality of panels including a first panel, a second panel, a third panel, a fourth panel, and an end panel wherein the plurality of panels are aligned along fold lines and wherein the first panel, second panel, third panel, and forth panel each include a bottom flap and an opposite top flap, with each of the bottom flaps and top flaps aligned along fold lines;

forming a dieline along each of the plurality of panels to form a continuous series of cuts and ties configured to allow a user to manually tear along the dieline to separate a top portion from a bottom portion;

forming at least one tab and a pull flap along the dieline; and

folding the plurality of panels and plurality of flaps along the fold lines to configure the blank into a tear open container.

16. The method of claim 15 wherein the dieline is formed to include a generally straight portion along the first panel, and a generally U-shaped portion along the third panel opposite from the first panel when the blank is folded into the tear open container.

17. The method of claim 16 wherein the generally straight portion of the dieline along the first panel includes a shark perf style perforation, wherein the shark perf style perforation includes a series of diagonal cuts and ties that are configured to allow the top portion to pivot or hinge along the dieline.

18. A method of separating a tear open container comprising:

pushing inwardly against opposite sides of a container formed by a blank of a generally continuous planar stock material that includes a plurality of panels assembled into the container, and the container includes a continuous dieline defined along the plurality of panels, and the dieline at least partially defines a tab and pull flap;

pushing the tab; and

pulling the pull flap along a front panel or along a bottom flap to separate a top portion of the container from a bottom portion.

19. The method of claim 18 wherein the top portion is hinged open along a back line of perforation that extends across a back panel.

20. The method of claim 18 wherein the dieline along the opposite sides of the container is generally diagonal to lines of perforation relative to a back line of perforation along a back panel.