WO1999046171A1

WO1999046171A1 - Two compartment carton for granular materials

Info

Publication number: WO1999046171A1
Application number: PCT/US1999/005312
Authority: WO
Inventors: Paulus Antonius Augustinus HÖFTE
Original assignee: The Procter & Gamble Company
Priority date: 1998-03-13
Filing date: 1999-03-11
Publication date: 1999-09-16
Also published as: EP0941935A1

Abstract

The invention relates to a side fill carton used for example for granular materials comprising an extra panel (15) between the top (11) and the bottom (13) panels and thus forming a second compartment (8) in which a three dimensional object (7), such as a tool kit for example, can be placed while being isolated from the main compartment (9).

Description

TWO COMPARTMENT CARTON FOR GRANULAR MATERIALS

Technical field

The invention relates to carton board containers for granular materials and

more particularly to such cartons which are side-fill cartons.

Background of the invention

Various types of containers are formed from carton board. Typical containers

made from carton board, also simply called cartons, have a substantially

parallelepipedal shape with six sides and twelve edges, namely the top, bottom,

back, front, left and right sides, the edges being defined by the two sides of

which they are the intersection, for example the edge between the top and the

back sides. For definition purposes, it will be considered in the following that

when the carton is upright the top and bottom sides are in the horizontal plane,

the four other sides being vertical. We will consider that if the front side of the

upright carton is facing an observer, the left side is on to the left of the observer

and the right side on to the right of the observer, the back side being invisible

for the observer. 2

Cartons are usually folded and glued from a die cut. A die cut, or blank, is a

flat structure which has not been folded or glued. At least three main steps

appear in the folding-gluing-filling process. In a first main step, the die cut is

folded and glued to form a sleeve. A sleeve is substantially a four sided

structure structured like a six sided carton of which two opposite sides are not

folded or glued. In the sleeve structure, four of the twelve edges of the carton

have been folded, these four edges being in a parallel direction to each other. It

should be noted that usually the remaining eight edges all have their direction

in a plane perpendicular to the direction of the four folded ones. The sleeve

structure has the advantage that it can be flattened. As a consequence, sleeves

can be stored or shipped easily. In a second main step, the carton is erected

from the sleeve, which means that one of the two opposite sides which were

not folded and glued during the sleeve step is now folded, four more edges

being consequently formed. At this stage, the carton cannot be flattened

anymore. However, it can be filled through the last non folded side. In the last

step, the last non folded side is folded and glued, so forming the four last

edges. In summary, when preparing a carton, the structure goes through

successive stages, namely the die cut, followed by the sleeve, which

subsequently is formed into an erected carton, before the closed carton stage.

Each of these stages is separated by one main folding-gluing step.

There are two alternative ways of forming the sleeve from the die cut, because

a choice can be made of the two opposite sides which will be left unfolded and 3

unglued. In a first way, these two side may be the top and bottom sides. In a

second way the right and left sides or the back and front sides will be left open.

In theory, it is considered equivalent to choose back/front or left/right because

these sides are differentiated only as a convention. However, the top/bottom

sides are normally perpendicular to gravity when the carton is in its upright

position.

In the first way of forming the sleeve, the sleeve will be formed of the front,

left, back and right sides, or of any circular permutation of these, while the top

and bottom sides will be left opened. In this case, the carton is usually erected

by folding the bottom, and then by folding the top after filling. This way avoids

having to turn the carton around after the filling process when the filling is

made by means of gravity, because the carton is already upright when filled.

In the second way of forming the sleeve, the sleeve will be formed, for

example, of the front, top, back and bottom sides, or of any circular

permutation of these, while the left and right sides will be left opened. In this

case, the carton is erected by folding indifferently the left or the right side, the

left for example, the erected carton being filled through the right side, which

should consequently be at the top of the carton during filling. Finally, the

carton will be closed. After closing, the carton may have to be turned around in

upright position, with the top side on the top. 4

As explained above, the eight edges which are not being folded to form the

sleeve have their direction in a plane perpendicular to the direction of the four

edges folded to form the sleeve. This means that in the die cut form, the four

sleeve folded edges are in one direction and the eight others in the substantially

perpendicular direction. By definition, the direction of the eight edges is called

the main folding direction or axial direction because most of the folding is

made along this direction. The other direction is the transverse direction.

Normally, the four edges of the transverse direction should be the sleeve

forming edges. As an example, in the first way for folding a sleeve, the

front/left, left/back, back/right and right/front edges would be along the

transverse direction, while in the second way of folding a sleeve, the front/top,

top/back, back/bottom and bottom/front edges would be along the transverse

direction.

A die cut is preferably made from a single piece. A die cut normally has a

specific grain direction. This means that the material forming the die cut is not

isotropic but has a preferred direction along which the die cut can be folded

more easily. This direction is the grain direction. For easy folding, it is

preferred that the main folding direction be in the grain direction.

For stiffness reasons, it is important that the grain direction is not horizontal,

and preferably vertical, when the carton in its upright position. This means that

the direction of gravity should be the grain direction for the front, back, left and 5

right sides of the carton when the carton is upright, or that the edges front/left,

left/back, back/right and right/front should follow the grain direction.

Consequently, the edges front/left, left/back, back/right and right/front should

not be in the transverse direction on the die cut. This leads to choosing the

second way of folding for stiffness reasons. Cartons folded in such a manner

are usually called side fill cartons. It should be noted that this denomination is

due to the folding method, and is not directly linked to the grain direction.

Examples of side fill cartons are disclosed in the pending applications JP-

09066927 published on the 11th of March 1997, or JP-09278029-A published

on the 38th of October 1997, or in applicant pending applications EP-

97202128.1 filed on the 10th of July 1997 or EP-98200031.7 filed on the 8th of

January 1998.

Side fill cartons disclosed in JP-09066927, EP-97202128.1 or EP-98200031.7

also include an extra panel together with a back flap associated with an edge to

the extra panel as well as the usual top panel. Such a structure with an extra

panel allows to form a lid with the top panel, which can be re-closed, while

having a robust top side with a double panel and improving sift proofhess, for

example for granular materials.

The invention relates to a carton, the carton comprising top and bottom sides

opposing each other, left and right sides opposing each other, and front and

back sides opposing each other, whereby: 6

a) the front side comprises a first front flap;

b) the top side comprises a top panel associated with an edge to the first front

flap;

c) the back side comprises a back panel associated with an edge to the top

panel;

d) the bottom side comprises a bottom panel associated with an edge to the

back panel;

e) the front side comprises a second front flap associated with an edge to the to

the bottom panel;

f) the carton comprises an extra panel situated between the top and bottom

panels, the extra panel being associated with an edge to the second front flap;

g) the back side comprises a back flap associated with an edge to the extra

panel;

h) the left side comprises a first left flap associated with an edge to the first

front flap, a second left flap associated with an edge to the back panel, a third

left flap associated with an edge to the bottom panel and a fourth left flap

associated with an edge to the second front flap;

i) the right side comprises a first right flap associated with an edge to the first

front flap, a second right flap associated with an edge to the back panel, a third

right flap associated with an edge to the bottom panel and a fourth right flap

associated with an edge to the second front flap.

Such a carton is known from EP-97202128.1. 7

Among the advantage of such cartons is that they are side fill cartons having an

extra panel, thus being relatively sift proof and having a robust structure.

While having these and other advantages, side fill cartons having such an inner

top panel have disadvantages. For example, such cartons do not allow placing

three dimensional objects such as a tool kit in a separated compartment, thus

requiring users to dig into the content to gain access to such an object, or to

erect this object from a two-dimensional structure, as in JP-09278029-A. In

addition, when such cartons are filled, a handle may be required for facilitating

transportation by the user.

Accordingly, it is an object of the present invention to produce a robust carton

which is more satisfactory for the user.

Summary of the invention

In accordance with the invention, this object is accomplished in a carton of the

above kind characterised in that

j) the back panel comprises a folding line along a direction parallel to the

plane of the top panel and situated between the extra and the top panels;

k) the second left and right flaps comprise a line of weakness situated between

the extra and the top panels. 8

A carton formed in accordance with the invention has a number of advantages.

Since the carton has a folding line in the back panel and since the second left

and right flaps comprise a line of weakness, a second compartment is formed,

the second compartment having as a top the top panel and as a bottom the extra

panel, while the main compartment has its top formed from the extra panel and

its bottom formed from the bottom panel. The access to the second

compartment is provided by lifting together the top part of the carton composed

of the top panel, the first front flap, the first and optional fifth left and right

flaps as well as the part of the secondOleft and right flaps beyond the line of

weakness and on the side of the top panel and the part of the back panel beyond

the folding line and on the side of the top panel, the folding line thus acting as

an hinge during the lifting of the top part of the carton. Indeed, once the top

part of the carton is lifted in this manner, direct access is gained to the content

of the second compartment. Access to the main compartment is for example

obtained by tearing off part of the extra panel or the complete extra panel

which forms both the floor of the second compartment and the roof of the other

one. Additionally, the second compartment can be provided with openings

allowing for example the insertion of fingers, thus forming a handle.

Brief description of the drawings

The invention will now be described by way of example and with reference to

the accompanying drawings in which: Figure 1 is a top plan view of a preferred embodiment of a die cut for forming a

carton according to the present invention.

Figure 2 is a top plan view of a partial sleeve made from the die-cut of Figure

1.

Figure 3 is a top plan view of a partial sleeve made from the partial sleeve of

Figure 2.

Figure 4 is a top plan view of a sleeve made from the partial sleeve of Figure 3.

Figure 5 is a top plan view of a preferred embodiment of elements of a die cut

with a first piece of liner for forming a carton according to the present

invention.

Figure 6 is a top plan view of a second piece of liner and of a partial sleeve

made from the die-cut with a first piece of liner of Figure 5.

Figure 7 is a top plan view of a partial sleeve made from the partial sleeve of

Figure 6.

Figure 8 is a top plan view of a sleeve made from the partial sleeve of Figure 7. 10

Figure 9 is a top plan view of a preferred embodiment of a first piece of a die

cut for forming a carton according to the present invention.

Figure 10 is a top plan view of a partial sleeve made from the first piece of the

die-cut of Figure 9.

Figure 11 is a top plan view of a second piece of a die cut for forming a carton

according to the present invention.

Figure 12 is a top plan view of a partial sleeve made from the assembly of first

and the second pieces of the die-cut according to Figures 10 and 11.

Figure 13 is a top plan view of a sleeve made from the partial sleeve of Figure

12.

Figure 14 is a top plan view of a preferred embodiment of a first piece of a die

cut for forming a carton according to the present invention with a liner.

Figure 15 is a top plan view of a partial sleeve made from the first piece of the

die-cut of Figure 14. 11

Figure 16 is a top plan view of a partial sleeve made from the assembly of first

and the second pieces of the die-cut according to Figures 15 and 11.

Figure 17 is a top plan view of a sleeve made from the partial sleeve of Figure

16.

Figures 18 to 21 describe an example of the erecting step of a carton according

to the present invention with a sequence starting from the complete sleeve of

either of Figures 4, 8, 13 or 17.

Figure 22 is a cross-sectional view of an embodiment of a carton according to

the invention along a plane parallel to the left side showing the wall

construction of the carton.

Figure 23 is a cross-sectional view of the embodiment of a carton according to

the invention made from the die-cut of Figure 1 along a plane parallel to the

left side showing the wall construction of the carton.

Figure 24 is a cross-sectional view of the embodiment of a carton according to

the invention made from the die-cut of Figures 9 and 11 along a plane parallel

to the left side showing the wall construction of the carton. 12

Figure 25 is a cross-sectional view of the embodiment of a carton according to

the invention made from the die-cut of Figures 5 and 6 along a plane parallel to

the left side showing the wall construction of the carton.

Figure 26 is a cross-sectional view of a further embodiment of a carton

according to the invention along a plane parallel to the left side showing the

wall construction of the carton.

Figure 27 is a cross-sectional view of an embodiment of a carton according to

the invention along a plane parallel to the front side showing the wall

construction of the carton.

Figure 28 is a cross-sectional view of a further embodiment of a carton

according to the invention along a plane parallel to the left side showing the

wall construction of the carton after opening.

Figure 29 is a perspective view of an embodiment of a carton according to the

invention after opening.

Figure 30 is a perspective view of a further embodiment of a carton according

to the invention after opening.

Description of the preferred embodiments 13

The carton of the present invention is preferably made of cardboard or

corrugated board, but other materials could also be used. Such cartons are

usually used for housing granular materials. The cartons normally have a

parallelepipedal shape with six sides. The sides can be defined as a top, bottom,

left, right, back and front sides. The top side is on the top of the carton when

the carton is in its upright position, the bottom side being opposite to the top

side. For the purpose of the description, the front and back sides are opposing

sides and the left and right side are opposite sides as well. Each of these sides

can be made of several layers of material. Each of the sides is usually of a

substantially rectangular shape, each side being limited at its borders by four

edges. The structure of the carton is due to links which can exist between

different layers of different sides through the edges. For example, if the front

side is made of a single layer, this layer may be linked to the left side through

the edge between the two sides, the link and the edge being provided by a

folded line or/and by glue. The layers which compose the sides of the carton

may be of different sorts. If such a layer is covering a complete side, it is called

a panel, and is said as corresponding to the side it covers. When a layer covers

a side only partially, it is called a flap, and it is said that it corresponds to the

side it covers. However, a flap may be extended up to the panel size, in which

case it is a long flap. Long flaps are particularly used for contributing to the

rigidity of the structure. Flaps and panels can also comprise cut outs allowing

use of a minimum amount of materials. Panels or flaps can be said as 14

associated to another layer, which means that they have a side in common with

this layer through a folded line, score line, line of weakness or by means of

gluing, in doing so describing an edge of the carton. Each side may comprise

one or more panels, one or more flaps, or a combination of these. In the present

application, the panels may have in their denomination the name of the side of

which they cover the surface, for example the bottom panel corresponds to the

bottom side. In the present application the flaps may have in their

denomination the name of the side with which they correspond once the carton

is folded, followed of the name of the flap or panel with which they are

associated. For example, the first left flap associated with an edge to the first

front flap is forming part of the left side in the folded carton and is physically

attached the front flap. It should be noted that the side denomination, namely

left, right, top, bottom, back and front, are conventional denominations which

are introduced for ease of explanation, and should not be limiting. Adhesive

can be used for gluing flaps or panels to each other. For example, cold ,water

or solvent based glue can be used, applied with rollers or glue guns, but also

hot melt glue, whether applied with glue guns or other glue applicators.

The carton structure of the present invention is such that the main compartment

can be easily made sift proof, or even air tight if a special glue pattern is

applied, so as to prevent air from passing through the structure, particularly if it

comprises sixth left and right flaps associated to the extra panel with an edge

along a folding line. The main compartment should preferably be sift proof 15

both through the sides and through the edges. By sift proof, what is meant is

that the content of the main compartment should not escape the carton in an

undesired manner, for example in the form of dust or particles.

In order to be sift proof through the sides, and if the side comprises a panel, it

has to be ensured that the panel does not accidentally burst. This is particularly

important on the sides which usually are more exposed to external intervention

which can lead to bursting. For this reason, the sides could comprise several

comprises several layers, for example by using a die cut made of a flute

between two liners, or simply by using a supplementary liner. If the side is

composed of flaps, it is important that the flaps co-operate with each other as

expected to obtain a sift proof structure. Usually, it is obtained by gluing the

flaps to each other.

The structure should equally be sift proof along the edges. This is usually not

difficult, except in the presence of a lid arrangement. Indeed, in the case of a

normal carton, all edges could be made sift proof by applying a sufficient

amount of glue. However, normal cartons should have a lid which can be lifted

and re-closed without difficulty. This means that the lid should not be glued

only with a limited amount of glue. This usually has the consequence that the

carton is not completely sift proof around the lid area, or that spillage occurs at

opening of the carton. 16

In the present invention, leakage can be prevented by using the extra panel, the

sixth left and right flaps and the back flap to seal with glue the main

compartment of the carton in the area of the extra panel. As a consequence, the

content of the main compartment will be kept away from the area of the second

compartment by the extra panel arrangement, so that the second compartment

can be lightly glued to be lifted easily.

The carton may also comprise a snap lock mechanism in the lid area, of any

kind known of the man skilled in the art, for example composed of a snap flap

and of a snap tab. Preferred here are audible snap lock mechanisms. The

second compartment may also be lifted at opening by means of a de-laminated

area (not indicated on the drawings) combined with perforations or with extra

glue spots. The carton may also comprise a tear strip for facilitating opening of

the lid.

The carton of the present invention should allow use of a minimised amount of

material for various reasons. Firstly, such a carton would not necessarily

require a liner for extra stiffness if the grain direction is oriented adequately.

Secondly, it is possible to use short flaps versions because skewing due to drag

back is limited, so that the flaps are co-operating with each other as expected

and do not need to be made larger to ensure that the carton is sift proof. Indeed,

skewing is not critical for this type of carton because the optional sixth left and

right flaps could make the carton sift-proof. Furthermore short flaps can be 17

used because the link between the top panel and, for example, the left or right

sides, is not critical, because the main compartment can be made sift proof

even if the top panel is not tightly pressed onto the extremity of the flaps, were

glue cannot be applied, so the main compartment can be made sift proof if

sixth left and right flaps are providing the sealing. Additionally, the content of

the main compartment can be increased at fixed cardboard quality because

there is limited skewing, so that the structure is more robust and maintains

better. This contributes to an additional object of the present invention for

producing a carton with a reinforced structure and to yet another object of the

invention which is to produce an ecological carton using a minimised quantity

of materials.

Indeed, the extra panel is preferably part of a second part of the die cut for

forming the carton, whereby it is a separated part of the die-cut. In such a case,

the second element of the die cut may be comprising the extra panel as well as

the back and third front flaps. The advantage of having such a separated second

part for the die cut is that it can be made from a different material, including

paper, plastic materials or films for forming a membrane, aluminium foil

carton board, metallized film or a combination of these.

Furthermore, the second part of the die-cut preferably comprise sixth left and

right flaps associated with the extra panel with an edge for example along a

folding line. With such a structure, the second part of the die-cut allows to 18

obtain a sift proof carton. Such a second part can have various shapes,

examples of which are illustrated in EP-98200031J.

In a general manner, the carton of the invention may comprise features and

variations of the existing cartons, such as for example the cartons disclosed in

EP 0 588 789 Bl or in WO 92/20583.

Usually, die cuts used for cartons are preferably made of one piece only. This

often leads to difficulties for integrating the entire structure while ensuring that

the final carton is sift proof and the carton easy to open. In the present

invention, such difficulties can be solved while fulfilling another object of the

present invention which is to produce a carton using a minimum amount of

material. This can be achieved in the present invention as the extra panel

together with the back and the optional third front flaps, as well as, optionally,

the sixth left and right flaps, are normally a separated part of the die cut, so that

it can be made from a different material. It should be mentioned that a die cut

usually has a grain direction. The folding or cutting directions may be chosen

so as to take account of the grain direction, considering that the cardboard is

more foldable along the grain direction. Care should be taken while designing

the die cuts that the grain direction is suitable, so that it ensures robustness and

easy folding of the carton. For example, in the die cut of Figure 1 , the grain

direction should be horizontal because it would allow easier folding of the left 19

and right flaps and because the front and back side will participate more

efficiently to supporting the structure if the grain direction of the panels of

which they are composed is aligned with gravity. The die cut may be made of

various materials including plain-board, corrugated board with or without

moisture barrier or corrugated plastic.

Extra parts may be added, such as extra flaps. For example, snap lock means

known of the man skilled in the art can be integrated to the die cut.

Figure 1 presents a die cut for a carton according to the invention. This die cut

is a one piece die cut comprising in its central part the following: the back flap

16, the extra panel 15, the second front flap 14, the bottom panel 13, the back

panel 12 with its folding line 1, the top panel 11, the first front flap 10, and the

two optional flaps being a snap flap 301 and a flap tab 302 which form a snap

lock 3 when the carton is re-closed. These are all following each other along a

first direction 100, separated from each other by folding lines along a second

direction perpendicular to the first direction 100. It should be noted that the

back panel 12 in this example has a length along the first direction of the die-

cut which substantially corresponds to the added lengths of the first 10 and

second 14 front flaps. The added lengths of the first 10 and second 14 front

flaps are slightly larger than the full length of the back panel 12 because it is

preferred that the first front flap 10 covers at least partially the second front

flap 14, thus facilitating re-closing of the carton. Indeed, in this embodiment, 20

the folding line 1 of the back panel 12 is at the level or in the plane of the extra

panel 15 when the carton is formed. In other words, when the carton is formed,

the folding line 1 forming a hinge between the main 9 and the second 8

compartments is beside the edge between the extra panel 15 and the back flap

16 and follows this edge. However, this is optional, and this folding line 1 of

the back panel 12 could also be at another level, this level being somewhere

between the top 11 and the extra 15 panels when the carton is formed. On both

sides of the central part, the die cut further comprises the left and right flaps,

including the first 20, 30 second 22, 32 third 23, 33 and fourth 24, 34 left and

right flaps, which are respectively linked by means folding lines along the first

direction to the first front panel 10, the back panel 12, the bottom panel 13 and

the second front flap 14. Furthermore, this die-cut comprises sixth left 25 and

right 35 flaps linked to the extra panel 15 along the first direction 100 by

means of folding lines, thus allowing to obtain a sift proof structure for the

main compartment 9. It should also be noted that this die cut comprises a line

of weakness 2 on the second left 22 and right 32 flaps which is aligned to the

folding line 1 of the back panel 12, the line of weakness 2 thereby being at the

level or in the plane of the extra panel 15. Such line of weakness 2 usually

consists in a linear or curvilinear portion which has a voluntarily weakened

structure, so that the material forming the carton will collapse preferably along

this linear portion once a force is applied to this purpose. The intensity of the

force needed depends on the material used and on the way the line of weakness

is manufactured. Indeed, a line of weakness can be provided thanks to 21

perforations, but it can also consist in a partial cut. In the die cut of Figure 1 , it

should be noted that the extra panel 15 has the same dimension along the first

direction 100 than the top 11 or the bottom 13 panels. This has as a

consequence that when the carton is folded from the die cut, the extra panel 15

is in a plane parallel to the plane of the top panel 11 or of the bottom panel 13,

as the back flap 16 is part of the back side. However, this is not a limitation,

and the extra panel 15 may have a dimension larger than the dimension of the

top 11 or bottom 13 panels along the first direction 100 so that when the carton

is mounted, the extra panel 15 is inclined at an angle. It should also be noted

that the die cut comprises fifth left 21 and right 31 flaps associated with an

edge to the top panel 11. These fifth left 21 and right 31 flaps are not necessary

to the structure but can be used for reinforcing it, or for making the second

compartment 8 sift proof.

The die-cut of Figure 1 is provided with glue 120 on the inner side of the back

panel 12 in the part beside the folding line 1 for the hinge on the side of the top

panel 11, in order to fold back and glue the back flap 16 as illustrated on Figure

2. In this example, the back flap 16 is glued between the folding line 1 of the

back panel 12 and the folding line between the back panel 12 and the top panel

11 because it is preferred to rigidity this portion. Indeed, in this manner the

back flap 12 will tend to maintain the second compartment 8 opened because it

will tend to stay aligned with the extra panel 15. This is particularly suited to

this die-cut because it is provided with snap-lock 3 features, so that the carton 22

can be maintained in the closed position even if the back flap 16 tends to open

it. However, the back flap 16 could also be glued when folded back, thus not

creating a constraint tending to open the carton, which would be most suitable

for cartons which are not provided with a snap lock 3 feature. However, this

would require folding back the back flap 16 prior to gluing as shown in EP-

97202128.1, more particularly on Figures 1 and 6-b of EP-97202128.1.

The die-cut as illustrated on the partial sleeve of Figure 2 can be further folded

so as to shape the snap lock 3 as illustrated on Figure 3, whereby the snap flap

301 and the snap tab 302 are folded back together.

Once this is done, the flaps forming the snap lock 3 can be glued onto the

outside of the second front flap 14 as illustrated on Figure 4, thus allowing to

obtain a closed sleeve.

Forming of such a sleeve is normally made by the carton supplier. Once folded

and glued, the sleeve can be shipped and delivered easily because it can be

flattened. The erection takes place afterwards, usually directly on a production

line.

Another embodiment for forming a sleeve is illustrated in figures 5 to 8. In this

particular embodiment, the die cut is further provided with a two parts liner 51 ,

52 which allows to further reinforce the structure of the carton. This particular 23

liner is made of two parts 51, 52, but a one part liner 5 could also be used. It is

also possible to reinforce only the second compartment 8 or only the main

compartment 9. Such reinforcement is particularly useful for cartons which

have a bigger size, or which need to be stacked in large numbers. This mostly

depends on the material used and on the size of the carton, the aim being to

avoid deformation of the structure. Indeed, in a preferred embodiment, the

carton according to the invention comprises an inner liner 5. In the example of

Figure 5, the liner 51 provided is covering the second front flap 14 as well as

the bottom panel 14 and a part of the back panel 12 comprised between the

folding line 1 of the back panel 12 and the bottom panel 14. Therefore, this

particular part 51 of liner covers the main compartment 9. Another part of liner

52 is added in Figure 6, covering the rest of the back panel 12, the top panel 11

and the first front flap 10 to reinforce the second compartment 8. It should be

noted that this part 52 of the liner could be extended on the snap flap 301 (and

or the snap tab 302) and on the extra panel 15, to be folded together with the

snap flap 301 and the folding line 1, in order to obtain a further reinforced

structure 53 as illustrated in Figure 26. A sleeve can thereafter be formed as

illustrated in Figure 8.

A further embodiment of a die-cut for forming a carton according to the

invention is presented on Figures 9 to 13. In this particular embodiment, the die

cut is formed from two separated pieces, one illustrated in Figure 9, the other

200 in Figure 11. A particular snap lock mechanism is illustrated here, whereby 24

the second part 200 of the die-cut comprises an optional third front flap 17 as

well as the extra panel 15, the back flap 16 and the optional sixth left 25 and

right 35 flaps. Indeed, this third front flap 17 can be provided with one or more

lines of weakness 304 which correspond to one or more lines of weakness 303

onto the second front flap 14, as illustrated on Figure 10, whereby these

corresponding lines of weakness 303, 304 can be glued the one onto the other

as illustrated on Figure 12. Indeed, such a mechanism is such that at opening

the lines of weakness will break when the second front flap 14 will be

separated from the third front flap 17, so that part of the second front flap 14

will remain on the third front flap 17 and part of the third front flap 17 will

remain on the second front flap 14, in such a manner that upon re-closure, the

former lines of weakness will interconnect to produce a snap lock. The sleeve

corresponding to this embodiment is illustrated in Figure 13.

A further embodiment of a die-cut for forming a carton according to the

invention is illustrated on Figure 14. This particular die-cut is in two parts and

is combined with a one piece liner 5, the first part of the die cut being as on

Figure 9, the second part being the part 200 of Figure 11. This embodiment

also comprises a snap lock mechanism as described in Figures 9 to 13. Folding

and gluing occurs as described in the sequence of Figures 15 and 16 to obtain

the sleeve of Figure 17. 25

Once a sleeve is obtained, the carton may be erected. An example of erection of

a carton according to the invention is illustrated in Figures 18 to 21. In a first

step the sleeve is unfolded to form a three dimensional structure, the optional

fifth 31, third 33 and optional sixth 35 right flaps being folded as indicated by

the arrows on Figure 18, folding being provided on packing line by means of

standard folding rails or tucker wheels. Thereafter, the carton takes a

rectangular cross section, which is better maintained rectangular if a sixth right

flap 35 is used, in order to reduce skewing. It should be noted that in this

example, the folding of the right side is described, but the left side could be

folded in an equivalent manner. Once folded, as in Figure 19, glue is applied

for example in a single operation as described on Figure 19, whereby glue is

applied on the second right flap 32 and on the first 30 and fourth 34 right flaps,

before folding of the second right flap 32 as described in Figure 20 and of the

first 30 and fourth 34 right flaps as in Figure 21. Thereafter, the right side of

the carton is formed, so that the left side is the only side remaining opened.

Once this is made, the carton may be turned around, the right side above, so as

to be filled. However, this is not necessary because on most carton folding

lines the folding can take place either from the above or under, so that the

carton does not require being turned around during folding and filling. It

should be noted that in the case of use of a carton according to the invention,

the main 9 and the second 8 compartments can be filled, the main compartment

9 being preferably filled with granular materials such as detergent powder,

while the second compartment 8 may be filled with a three dimensional object 26

such as a tool kit or preferably a scooping device 7, for example. By a three

dimensional object, it is meant that it is an object which has a total width, a

total length and a total height which all are substantially larger than the

thickness of the material from which the die-cut of the carton is made. The

dimension of this object may determine at which level the extra panel 15 is

placed in the carton. Once filling is achieved, the left side is folded, the folding

of the left side normally comprising the same steps as the folding of the right

side. This leads to a filled and closed carton structure, such as the structure

presented in Figures 29 or 30. It should be noted that this process allows use of

standard machines, so that an other object of the invention is to produce a

carton which is easy to process. Additionally, it is an object of the present

invention to produce a carton at lower costs.

Figure 22 illustrates a cross section of a carton according to the invention in a

plane parallel to the left or right sides and between these, the carton being made

for example from the die-cut of figure 1 without the snap lock flaps. These are

illustrated in Figure 23. In these Figures as well as in the Figure 28, the spring

effect of the back flap 16 to tend to maintain the second compartment 8 in an

opened position is illustrated. In Figure 23, a carton made from the die cut of

Figure 9 which comprises two parts is illustrated. The following Figure, Figure

25, illustrates a carton made from a one piece die-cut with a two parts liner 51,

52, as illustrated on Figures 5 to 8. In Figure 26, the structure is further

reinforced by extensions 53 of the liner. 27

Figure 27 illustrates a cross section in a plane parallel to and between the front

and back sides, whereby the extra panel 15 is provided with the optional sixth

left 25 and right 35 flaps providing an improved sift-proof main compartment

9. It should also be noted that the first left 20 and right 30 flaps are folded over

the optional fifth 21, 31 and second left 22 and right 32 flaps, and are also

extending over the fourth left 24 and right 34 flaps in the same manner as the

first front flap 10 may extend onto the second front flap 14 to facilitate re-

closure of the carton. Furthermore, it should be noted that in another preferred

embodiment, the optional fifth 21, 31 and second 22, 32 left and right flap can

press onto the extra panel 15 to retain it closed after re-closing the carton. In

the case illustrated, the optional fifth left 21 and right 31 flaps can participate

to making the second compartments 8 sift proof.

Once the carton is formed, the user can easily access the content of the main

compartment by opening or removing the extra panel 15 or part of it, from the

position illustrated in Figure 29 or 30 for example. Removal may be facilitated

by various ways known in the art, using perforated lines, partial cuts, tear strip

or tear tape, or by using easy release or easy peel glues around the edges for

example. Preferably such weakness lines are slightly curved to avoid damage

throughout the production and distribution chain. The extra panel may be only

partially removable, in such a manner that part of the extra panel remains to

avoid spillage of the content if, for example, the carton is inclined once opened. 28

The removable part may be used to display instructions or as a promotional

voucher or other items of the sort. In a preferred embodiment, the extra panel

or part of it is hinged as illustrated in Figure 28, so that it can be retained by the

snap lock flap once the carton is opened, thus allowing full access to the main

compartment. Upon re-closure, such a hinged part may be kept pressed down

by the optional fifth and/or the part of the third left and right flaps comprised

between the line of weakness and the top panel or by an indentation which may

also serve as a means for opening, or by an extending flap of an inner liner for

example. Such an indentation could be provided by a curvilinear line of

weakness placed on the extra panel in the form of a semicircle 40 having its

diameter corresponding to the edge between the extra panel and the second

front flap, for example, so that a user may push it in to pull part of the extra

panel away, while using it to maintain the same part upon re-closure. It should

be noted that a hinged part of the extra panel could be defined by partial and

reversed cuts, thus forming a shoulder or supporting edge to avoid that the

extra panel is pushed in the main compartment too far, i.e. beyond its original

position. In a preferred embodiment, the optional third front flap is glued at

least partly to the first front flap so as to open the main compartment when

opening the carton for the first time. It should also be noted that the snap lock

feature is optional and may be replaced by a pre-cut de-lamination zone.

Opening may also be provided by the optional third front flap, whereby this

optional third front flap 17 is linked with a folding line to the extra panel, and 29

has a part which is removable and defined by one or more lines of weakness, as

illustrated on Figure 29. This may be combined with a snap lock flap as

described in Figure 29 similar to the snap lock described in the die-cut of

Figures 9 to 13.

In a prefened embodiment of the invention, the die cut of the carton is

provided with a transparent window, for example on the left, right or front side

of the carton, whereby the user can evaluate the quantity of content remaining

in the main compartment. Evaluation could be facilitated by providing

graduation lines. Openings or cut outs in the second compartment could also

provide windows allowing to visualise the content of this second compartment.

In a preferred embodiment, the carton is provided with openings 6 comprised

in the front, back and top sides for forming a handle. Such openings 6 may be

provided through the die-cut and the liner if such a liner is provided for

reinforcing the second compartment. Such openings also allow the user to

visualise an object placed in the second compartment if there is such an object.

This is particularly suited for packing granules such as detergent powders,

whereby such powders may be kept in a sift-proof manner in the main

compartment, while a tool kit such as a scooping device is provided in the

second compartment, thus reducing the messiness which would be induced by

the extraction of such a three dimensional 7 object directly from the content of

the main compartment. Such an object may simply be glued within the second 30

compartment, for example with a single glue spot, to prevent movement of the

object, or locked with locking tongues formed for example by cut outs of the

openings providing a handle. Furthermore, placing such an object in the second

compartment is a tamper proof location, as a user would have to open the

carton to take the object.

Claims

31WHAT IS CLAIMED IS:

1. A carton, the carton comprising top and bottom sides opposing each other,

left and right sides opposing each other, and front and back sides opposing

each other, whereby:

a) the front side comprises a first front flap (10);

b) the top side comprises a top panel (11) associated with an edge to the first

front flap (10);

c) the back side comprises a back panel (12) associated with an edge to the top

panel (11);

d) the bottom side comprises a bottom panel (13) associated with an edge to

the back panel (12);

e) the front side comprises a second front flap (14) associated with an edge to

the to the bottom panel (13);

f) the carton comprises an extra panel (15) situated between the top (11) and

bottom (13) panels, the extra panel (15) being associated with an edge to the

second front flap (14);

g) the back side comprises a back flap (16) associated with an edge to the extra

panel (15);

h) the left side comprises a first left flap (20) associated with an edge to the

first front flap (10), a second left flap (22) associated with an edge to the back

panel (12), a third left flap (23) associated with an edge to the bottom panel

(13) and a fourth left flap (24) associated with an edge to the second front flap

(14); 32

i) the right side comprises a first right flap (30) associated with an edge to the

first front flap (10), a second right flap (32) associated with an edge to the back

panel (12), a third right flap (33) associated with an edge to the bottom panel

(13) and a fourth right flap (34) associated with an edge to the second front flap

(14); characterised in that

j) the back panel (12) comprises a folding line (1) along a direction parallel to

the plane of the top panel (11) and situated between the extra (15) and the top

(11) panels;

k) the second left (22) and right (32) flaps comprise a line of weakness (2)

situated between the extra (15) and the top (11) panels.

2. The carton according to any of the above claims, whereby the folding line

(1) is in the plane of the extra panel (15).

3. The carton according to any of the above claims, whereby the extra panel

(15) is in a plane parallel to the top panel (11).

4. The carton according to the above claims, whereby the left side further

comprises a fifth left flap (21) associated with an edge to the top panel (11),

the right side further comprising a fifth right flap (31) associated with an

edge to the top panel (11). 33

5. The carton according to any of the above claims, whereby the line of

weakness (2) is in the plane of the extra panel (15).

6. The carton according to any of the above claims, whereby the first left flap

(20) covers at least part of the second (22) and fourth (24) left flaps, the

first right (30) flap covering at least part of the second (32) and fourth (34)

right flap.

7. The carton according to any of the above claims, whereby the carton further

comprises a snap lock (3) mechanism.

8. The carton according to any of the above claims, whereby the extra panel

comprises means for opening (4), preferably partial cuts, reversed cuts,

perforations, tear tapes or a combination of these.

9. The carton according to any of the above claims, whereby the carton further

comprises a third front flap (17) associated with an edge to the extra panel

(15), whereby a separated piece of die cut is formed from the extra panel

(15), the third front flap (17) and the back flap (16).

10. The carton according to any of the above claims, whereby the left side

comprises a sixth left flap (25) associated to the extra panel (15) with an 34

edge and the right side comprises a sixth right flap (35) associated to the

extra panel (15) with an edge.

11. The carton according to any of the above claims, whereby the carton

further comprises an inner liner (5).

12. The carton according to any of the above claims, whereby the front and

back side as well as the top side comprise openings (6) for forming a

handle.

13. The carton according to any of the above claims, whereby a three

dimensional object (7) is contained in the volume between the top and the

extra panels.