CARTON WITH PRODUCT HOLDING COMPARTMENTS CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No.
61/270,923, filed July 15, 2009.
INCORPORATION BY REFERENCE
[0002] U.S. Provisional Patent Application No. 61/270,923, which was filed on July
15, 2009, is hereby incorporated by reference for all purposes as if presented herein in its entirety.
BACKGROUND OF THE DISCLOSURE
[0003] The present disclosure generally relates to cartons for holding products, and more particularly, to a carton having multiple compartments.
SUMMARY OF THE DISCLOSURE
[0004] In general, one aspect of the disclosure is directed to a carton for containing at least one product. The carton comprises a back panel, a front panel, a bottom panel, and a top flap. A first compartment is foldably connected to the back panel, and a second compartment is foldably connected to the front panel. The top flap is operable to overlap the first and second compartments of the carton.
[0005] In another aspect, the disclosure is generally directed to a blank for forming a carton for containing at least one product. The blank comprises a back panel, a front panel, a bottom panel, and a top flap. A first compartment flap is foldably connected to the back panel, and a second compartment flap is foldably connected to the front panel. The top flap is for overlapping a first compartment formed from the first compartment flap and a second compartment formed from the second compartment flap when the blank is formed into the carton.
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[0006] In another aspect, the disclosure is generally directed to a method for forming a carton for containing at least one product. The method comprises obtaining a blank comprising a back panel, a front panel, a bottom panel, a top flap, a first compartment flap foldably connected to the back panel, and a second compartment flap foldably connected to the front panel. The method further comprises forming a first compartment by folding the first compartment flap with respect to the back panel, forming a second compartment by folding the second compartment flap with respect to the front panel, and at least partially closing the carton by folding the top flap to at least partially overlap the first and second compartments.
[0007] Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims.
[0008] The various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Fig. 1 is a plan view of an exterior of a carton blank for forming a carton according to one embodiment of the disclosure.
[0010] Fig. 2 is a perspective view of a partially-erected carton according to one embodiment of the disclosure.
[0011] Fig. 3 is a perspective view of a carton in an open configuration according to one embodiment of the disclosure.
[0012] Figs. 4-6 are perspective views of folding the carton of Fig. 3 into a closed configuration according to one embodiment of the disclosure.
[0013] Fig. 7 is a plan view of an exterior of a carton blank for forming a carton according to a second embodiment of the disclosure.
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[0014] Fig. 8 is a perspective view of a carton in an open configuration according to the second embodiment of the disclosure.
[0015] Fig. 9 is a perspective view of the carton of Fig. 8 in a closed configuration.
[0016) Fig. 10 is a plan view of an exterior of a carton blank for forming a carton according to a third embodiment of the disclosure.
[0017] Fig. 11 is a plan view of an exterior of a carton blank for forming a carton according to a fourth embodiment of the disclosure.
[0018] Fig. 12 is a perspective view of a carton in an open configuration according to the fourth embodiment of the disclosure.
[0019] Figs. 13 and 14 are perspective views of the carton of Fig. 12 in a closed configuration.
[0020] Corresponding parts are designated by corresponding reference numbers throughout the drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0021] The present disclosure generally relates to a carton or package that is used to hold various products, such as any suitable consumer product that is suitable for holding in a carton or package for quick access and use. Such products can include women's incontinence products, make-up, diaper wipes, or any other suitable product. Also, food products can be held in the carton such as snacks for infants, toddlers, children, or adults, or any other suitable food product. Further, pet treats such as dog or cat treats, or any other suitable product, can be held in the carton.
[0022] Fig. 1 is a plan view of the exterior side 1 of a blank, generally indicated at 3, used to form a carton 5 (Figs. 3 and 6) according to a first exemplary embodiment of the disclosure, hi the illustrated embodiment, the carton 5 has a front compartment 7 and a rear compartment 9. Each of the compartments 7, 9 are capable of holding a product in an isolated compartment that is separated from the product in the other
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compartment. The front compartment 7 and the rear compartment 9 are positioned in generally side-by-side inverted relationship in a closed configuration of the carton 5 (Fig. 6), The front compartment 7 and rear compartment 9 can be otherwise shaped, arranged, and/or positioned without departing from the disclosure. According to an exemplary embodiment of the disclosure, the carton 5 can be formed from a unitary, one-piece blank 3, as shown in Fig. 1.
[0023) The blank 3 includes a longitudinal axis Ll that extends generally in the direction of the length of the blank and a lateral axis L2 that extends generally in the direction of the width of the blank. The blank 3 has a back panel 15, a top flap 17 foldably connected to the back panel at a longitudinal fold line 19, and a bottom panel 21 foldably connected to the back panel 15 at a longitudinal fold line 23. A front panel 27 is foldably connected to the bottom panel 21 at a longitudinal fold line 29.
[0024] In the embodiment of Fig. 1, a first (back) compartment flap 31 is foldably connected to the back panel 15 at a lateral fold line 33. The first compartment flap 31 comprises a first side panel 35, a compartment panel 37 foldably connected to the side panel 35 at a lateral fold line 39. The compartment panel 37 includes oblique edges 41 that divide the compartment panel into first and second retaining portions 37a, 37b. A second side panel 45 is foldably connected to the second portion 37b of the compartment panel 37 at a lateral fold line 47. The compartment flap 31 has a first compartment bottom panel 49 foldably connected to the compartment panel 37 at the longitudinal fold line 23 that extends across the length of the blank 3. A first bottom end flap 51 is foldably connected to the bottom panel 49 at a longitudinal fold line 53. A first compartment side end flap 55, 57 is respectively foldably connected to one of the first and second side panels 35, 45 at the longitudinal fold line 23.
|0025] In the illustrated embodiment, a second (front) compartment flap 61 is foldably connected to the front panel 27 at a lateral fold line 63. The second compartment flap 61 is generally similar to the first compartment flap 31. The second compartment flap 61 comprises a first side panel 65, a compartment panel 67 foldably connected to the first side panel 65 at a fold line 69, and a second side panel 71
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foldably connected to the compartment panel 67 at a lateral fold line 73. In one embodiment, the compartment panel 67 of the second compartment flap 61 has a generally U-shaped edge 75 that forms two upper retaining portions 67a, and a lower retaining portion 67b extending between the upper retaining portions. The second compartment flap 61 has a second compartment bottom panel 77 foldably connected to the compartment panel 67 at a longitudinal fold line 79. Second compartment side end flaps 81, 83 are respectively foldably connected to the first and second side panels 65, 71 at the longitudinal fold line 79. A second bottom end flap 85 is foldably connected to the bottom panel 77 at a longitudinal fold line 87.
[0026] In the illustrated embodiment an adhesive flap 91 extends between the first and second compartment flaps 31, 61 and is foldably connected to the second side panels 45, 71 at respective lateral fold lines 93, 95.
[0027] In one embodiment, the top flap includes four independent moveable portions
17a-17d that allow the top flap to fold over the top of the compartments 7, 9 and conform to the shape of products held in the compartments. The top flap 17 includes respective longitudinal fold lines 99, 101, 103 that separate the respective moveable portions 17a-17d. The longitudinal fold line 103 has two portions that extend from respective ends of a curved cut line 107. The cut line 107 forms an edge of a protrusion 108 in the moveable portion 17d of the top flap 17. The front panel 27 includes a curved cut 110 forming two moveable retention flaps 109, 1 11 in the front panel.
[0028] The blank 3 could have other features and aspects that are not shown by the drawings, or the features and aspects of the drawings that are illustrated could be modified without departing from the scope of the disclosure.
[0029] An acceptable method for forming the carton 5 from the blank 3 will be described in the following, in accordance with one exemplary embodiment of the disclosure. In accordance with one exemplary embodiment, the blank 3 can be erected into the carton 5 by folding the first compartment flap 31 along fold lines 33, 39, 47, and 93 and folding the second compartment flap 61 along fold lines 63, 69, 73, and 95
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to form the open ended first and second compartments 7, 9. The adhesive flap 91 is folded to be in face-to-face contact with the back panel 15, bottom panel 21, and front panel 27 and can be secured thereto by suitable adhesive (e.g., glue). The open-ended compartments 7, 9 shown in Fig. 2 can be closed at respective bottom ends of the compartments. The back compartment 9 is closed by folding the bottom panel 49 and side end flaps 55, 57 about fold line 23 to at least partially overlap the bottom panel and side end flaps. The bottom end flap 51 is folded to be in face-to-face contact with the back panel 15. The bottom end flap 51 can be secured to the back panel 15 by adhesive. In the illustrated embodiment, the bottom end of the front compartment 7 is closed in a similar manner. That is, the bottom panel 77, side end flaps 81, 83, and bottom end flap 85 close the bottom end of the front compartment 7.
[0030] Once the front and back compartments 7, 9 are closed with the back panel 15, the bottom panel 21, and the front panel 27 generally in the same plane (Fig. 3), the carton 5 is in an open configuration 150 and can be loaded with one or more products in each compartment. After the products have been loaded into the carton, the front compartment 7 is folded about fold line 29 to be generally inverted and adjacent to the back compartment 9 (Fig. 4). That is, in one embodiment, the bottom panel 77 of the front compartment 7 is adjacent the top edge of the back compartment 9. In one embodiment, the compartment panel 67 of the front compartment 7 is placed into face-to-face contact with the compartment panel 31 of the back compartment 9 (Figs. 4 and 5). As shown in Figs. 5 and 6, the top flap 17 can be downwardly folded in the direction of arrow Al, to close the top of the back compartment 9 and to overlay the bottom panel 77 of the front compartment 7. The protrusion 108 can be received in an opening at the cut 1 10 that is formed by inwardly folding the flaps 109, 111 to lock the downwardly folded top flap 17 in the closed position (Fig. 6). The carton 5 is shown in a closed configuration 152 in Fig. 6.
[0031] The carton 5 can be opened by withdrawing the protrusion 108 from the cut
110 and upwardly folding the top flap 17 in the direction of arrow A2 (Fig. 6). Upon opening the top flap 17, the rear compartment 9 can be accessed. The front compartment 7 can be accessed by further unfolding the carton along fold line 23 to
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the open configuration 150 shown in Fig. 3. The carton 5 can be formed by other alternative forming steps, and the carton can be opened to access products within either the front compartment 7 or rear compartment 9 by other alternative opening steps without departing from the disclosure.
[0032] Fig. 7 illustrates a blank 203 for forming a carton 205 of a second embodiment of the disclosure having similar features as the first embodiment. Accordingly, similar or identical features of the embodiments are provided with like or identical reference numbers. The blank 203 can include a back panel 215, a top flap 217 and a bottom panel 221 respectively foldably connected to the back panel 215, and a front panel 227 foldably connected to the bottom panel 221. The front flap 227 can include a curved cut 210 for receiving a protrusion 208 in the top flap 217. A first compartment flap 231 includes a first side panel 235 foldably connected to the back panel 215 and a first compartment panel 237 foldably connected to the first side panel 235, a second side panel 245, and a first compartment bottom panel 249. A second compartment flap 261 includes a first side panel 265 foldably connected to the front panel 227 and a second compartment panel 267 foldably connected to the first side panel 265, a second side panel 271, and a second compartment bottom panel 277. An adhesive flap 291 can extend between the first and second compartment flaps 231, 261 and can be foldably connected to the second side panels 245, 271 at respective lateral fold lines. The blank 203 can be smaller in size than the blank 3 of the first embodiment and the compartment panels 237, 267 are identical to each other. Both of the compartment panels 237, 267 have U-shaped edges 275.
[0033] The blank 203 of Fig. 7 can be formed into the carton 205 in a generally similar manner as described above for the first embodiment. Alternatively, the blank 203 can be formed into the carton 205 by other steps and the blank 203 of the second embodiment could have other features.
[0034] Fig. 10 illustrates a blank 303 for forming a carton (not shown) of a third embodiment of the disclosure having similar features as the first and second embodiments. Accordingly, similar or identical features of the embodiments are
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provided with like or identical reference numbers. The blank 303 can include a back panel 315, a top flap 317 and a bottom panel 321 respectively foldably connected to the back panel 315, and a front panel 327 foldably connected to the bottom panel 321. The front flap 327 can include a curved cut 310 for receiving a protrusion 308 in the top flap 317. A first compartment flap 331 can be foldably connected to the back panel 315 and can include a first compartment panel 337 with a U-shaped edge 375. A second compartment flap 361 can be foldably connected to the front panel 327 and can include a second compartment panel 367 with a U-shaped edge 375. The blank 303 of Fig. 10 can be formed into the carton in a generally similar manner as described above for the first embodiment. Alternatively, the blank 303 can be formed into the carton by other steps and the blank 303 of the third embodiment could have other features.
[0035] Fig. 11 illustrates a blank 403 for forming a carton 405 (Figs. 12-14) of a fourth embodiment of the disclosure having similar features as the first, second, and third embodiments. Accordingly, similar or identical features of the embodiments are provided with like or identical reference numbers. Generally the blank 403 can include a back panel 415, a top flap 417 and a bottom panel 421 respectively foldably connected to the back panel 415, and a front panel 427 foldably connected to the bottom panel 421. The front flap 427 can include a curved cut 410 for receiving a protrusion 408 in the top flap 417. A first compartment flap 431 includes a first side panel 435 foldably connected to the back panel 415 and a first compartment panel 437 foldably connected to the first side panel 435, a second side panel 445, and a first compartment bottom panel 449. A second compartment flap 461 includes a first side panel 465 foldably connected to the front panel 427 and a second compartment panel 467 foldably connected to the first side panel 465, a second side panel 471, and a second compartment bottom panel 477. An adhesive flap 491 can extend between the first and second compartment flaps 431, 461 and can be foldably connected to the second side panels 445, 471 at respective lateral fold lines.
[0036] The carton 405 differs from the carton 5 in that the carton of the fourth embodiment is an oblique rectangular prism having a top flap 417 and bottom panel
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421 that are oblique relative to the front and back panels 415, 427. In the first embodiment, carton 5 is a rectangular prism with the top 17 and bottom 21 being perpendicular to the front and back panels 15, 17. In the embodiment of Figs. 11-14, the fold line 423 of the blank 403 includes oblique portions 423a, 423b connecting the respective side end flaps 455, 457 to the respective side panels 435, 445, and the fold line 479 includes oblique portions 479a, 479b connecting the respective side end flaps 481, 483 to the respective side panels 465, 471. The side panels 435, 445 can include respective oblique top edges 432, 442 that are generally aligned with the respective oblique portions 479a, 479b of the fold line 479 in the closed configuration of the carton 5 (Fig. 13). Similarly, the side panels 465, 471 can include respective oblique top edges 462, 472 that are generally aligned with the respective oblique portions 423a, 423b of the fold line 423 in the closed configuration of the carton 5 (Fig. 13).
[0037] The blank 403 of Fig. 11 can be formed into the carton 405 in a generally similar manner as described above for the first embodiment and as shown in Figs. 12- 14. Alternatively, the blank 403 can be formed into the carton 405 by other steps and the blank 403 of the third embodiment could have other features. For example, one or both of the compartment panels 437, 467 can have oblique edges similar to the oblique edges 41 of the compartment panel 37 in the first embodiment instead of the U-shaped edges 475 shown in Fig. 11.
[0038] In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
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[0039] As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.
[0040] In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.
[0041] The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term "glue" is intended to encompass all manner of adhesives commonly used to secure carton panels in place.
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The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.
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