US20060255105A1 - Carton having space saving feature - Google Patents

Abstract

A carton includes a space-saving feature which allows it to be split into two sections. When a portion of the carton contents have been used, an upper section of the carton can be separated, leaving the lower section in which to store the remaining contents. The upper section can also be slid down or telescoped over the lower section as the carton contents are consumed.

Description

BACKGROUND
• Conventional paperboard cartons are known. Such cartons often include a bag or other vessel held within the interior of the paperboard carton, which is used to store foodstuffs or other dispensable products. Conventional paperboard cartons, however, occupy a volume that is determined by the amount of product held within the carton upon initial sale. When a portion of the product held within the carton is consumed, the carton continues to occupy a relatively large storage space, which may be limited, to store a reduced amount of product.
SUMMARY
• According to a first embodiment, a carton comprises a first side panel, a front panel adjacent to the first side panel, a second side panel adjacent to the first side panel, a back panel adjacent to the first and second side panels, a top panel, a bottom panel, and a tear strip extending around a perimeter of the carton.
• According to the first embodiment, the height of the carton can be reduced by removing the tear strip, thereby separating the carton into upper and lower sections. The carton can be reduced in size when, for example, a portion of the contents of the carton have been consumed or otherwise dispensed. The remainder of the contents, which are accommodated within the lower section of the carton, are thereby stored in a carton which occupies less space than the original carton. The reduced size of the carton also allows a consumer to visually evaluate the reduced amount of product remaining in the carton, which may serve as cue to purchase more product.
• The upper section of the carton may be discarded, or, slid down over the lower section as carton contents are consumed.
• Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description of a preferred embodiment, taken in conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
• FIG. 1 is a plan view of a first, interior side of a blank used to form a carton according to a first embodiment.
• FIG. 2 is a plan view of a second, exterior side of the blank.
• FIG. 3 is a plan view of an erection step of the carton.
• FIG. 4 is a perspective view of an erection step of the carton.
• FIG. 5 is a perspective view of the erected carton.
• FIG. 6 is a perspective view illustrating use of the space saving feature of the carton.
• FIG. 7 is a perspective view illustrating use of the space saving feature of the carton.
• FIG. 8 is a perspective view illustrating use of the space saving feature of the carton.
• FIG. 9 is a perspective view illustrating use of an alternative space saving feature of the carton.
DETAILED DESCRIPTION
• The present embodiments are addressed to cartons having a space saving feature which allows a carton to be reduced in size after a portion of the contents of the carton have been consumed or otherwise dispensed.
• FIG. 1 is a plan view of a first,interior side5 of a blank8 used to form a carton150 (illustrated inFIG. 5) according to a first embodiment. Thefirst side5 will be disposed in the interior of theerected carton150.
• The blank8 comprises afirst side panel10 foldably connected to afront panel30 at a firsttransverse fold line31, asecond side panel50 foldably connected to thefront panel30 at a secondtransverse fold line51, and aback panel70 foldably connected to thesecond side panel50 at a thirdtransverse fold line71.
• The blank8 includes a section that is foldable into a “z” configuration, generally referred to as a “z-fold20 section,” that extends across the entire length of the blank8.
• The z-fold20 section includes afolding panel21 defined by afold line22 at a first edge, and atear strip24 at a second edge. Thetear strip24 is defined by atop tear line26 and abottom tear line28 extending parallel to one another across the length of the blank8, and may include atab portion25 at one or both ends of thestrip24. Thetear strip24 illustrated inFIG. 1 has a zipper or knife cut configuration, although other tear strip configurations may be used. Thez-fold20 section divides thefirst side panel10 into upper and lower firstside panel sections12,14, thefront panel30 into upper and lowerfront panel sections32,34, thesecond side panel50 into upper and lower secondside panel sections52,54, and theback panel70 into upper and lowerback panel sections72,74. A firstadhesive panel82 may be foldably connected to the upperback panel section72 at afold line84, and a secondadhesive panel86 may be foldably connected to the lowerback panel section74 at afold line88.
• The height of theupper panel sections12,32,52,72 plus the height of thetear strip24 may be H₁, and thelower panel sections14,34,54,74 have a height H₂. The height H₂illustrated inFIG. 1 is slightly larger than the Hi. The relative heights H₁, H₂can be varied, however, to achieve varying space-saving characteristics in thecarton150. In selected embodiments, H₁is within +/−30% of H₂.
• Thefirst side panel10 is foldably connected to a firstside top flap16 and a firstside bottom flap18. Thefront panel30 is foldably connected to afront top flap36 and afront bottom flap38. Thesecond side panel50 is foldably connected to a secondside top flap56 and a secondside bottom flap58. Theback panel70 is foldably connected to aback top flap76 and aback bottom flap78. Theflaps16,36,56,76 extend along a top marginal portion of the blank8, and theflaps18,38,58,78 extend along a bottom marginal portion of the blank8. When thecarton150 is erected, theflaps16,36,56,76 close a top opening of thecarton150, and theflaps18,38,58,78 close a bottom opening of thecarton150.
• Thefront top flap36 can include aclosure tab40 that is sized to be received in aclosure slit80 formed in the backtop flap76. Theclosure tab40 andclosure slit80 provide for recloseable sealing of thecarton150 after the top of thecarton150 is opened.
• One or morecut lines92,94 can be included to aid in sliding an upper section of thecarton150 over a lower section, as discussed below with reference toFIG. 9. One ormore apertures96,98,100 can be included in the blank8 to prevent binding during erection.
• The process of erecting thecarton150 will be discussed with reference toFIGS. 1-4. Referring toFIG. 2, which shows a second,exterior side6 of the blank8, adhesive102 is applied to the exterior side of thez-fold20 section. The adhesive102 can be formed from, for example, liquid glue, glue strips, or other materials. Referring toFIG. 3, which shows theinterior side5, thez-fold20 section is folded about thefold line22 and about the bottom tear line28 (shown inFIG. 1) so that thebottom panel sections14,34,54,74 are raised “upwardly,” or toward theupper panel sections12,32,52,72, in the direction of the arrow A. Folding thez-fold20 section causes thebottom panel sections14,34,54,74 to be adhered to thez-fold20 section by the adhesive102 (shown inFIG. 2).
• Referring toFIG. 4, the exterior sides of theadhesive panels82,86 (shown inFIG. 1) are provided with an adhesive and adhered to the interior sides of the upper and lower firstside panel sections12,14, respectively. The blank8 is then “opened” or “set up” to have the tubular shape shown inFIG. 4.
• FIG. 5 is a front perspective view of theerected carton150. Referring also toFIG. 4, thecarton150 is fully erected when thetop flaps16,36,56,76 are adhered in a conventional manner to form atop panel110, and thebottom flaps18,38,58,78 are adhered in a conventional manner to form abottom panel120. Thetear strip24 extends around the entire perimeter of thecarton150. A bag (not shown) or other vessel filled with product may be inserted in the carton in a conventional manner before closing theflaps16,36,56,76,18,38,58,78.
• FIGS. 6-8 illustrate use of the space-saving feature of thecarton150. Referring toFIG. 6, after the top of thecarton150 has been opened, and a portion of the contents within the carton have been consumed, thetear strip24 is grasped at thetear tab25 and pulled around the perimeter of thecarton150. Referring toFIG. 7, with thetear strip24 removed, thecarton150 may now be separated into two sections. Referring toFIG. 8, thecarton150 is separated into anupper section160 and alower section170. In the embodiment shown inFIG. 8, thetear strip24 divides thecarton150 roughly in half.
• Therefore, when about half of the carton contents have been consumed or otherwise dispensed from thecarton150, theupper section160 can be removed. In general, the height of theupper section160 may be at least a third of the height H of the carton150 (shown inFIG. 5).
• Theupper section160 can be discarded, and thelower section170 houses the remainder of the carton's contents. InFIG. 8, the contents are shown as held within abag130. Thebag130 can be folded over and clipped, or otherwise sealed, to close off the contents of the cartonlower section170.
• FIG. 9 illustrates an alternative space-saving feature of thecarton150 in which theupper section160 of thecarton150 is not discarded after removing thetear strip24.
• Instead, thetear strip24 can be removed at any time, and theupper section160 is slid down over thelower section170 in the direction of arrow B as the carton contents are consumed. Advantageously, when theupper section160 is retained, the engageable flaps36,76 can be used to close the top of thecarton150. Also, theupper section160 of thecarton150 may be repeatedly slid, or “telescoped,” over thelower section170 so that the variable height of the carton H₃closely tracks the height of product remaining in thecarton150. In many common consumer products, including cereals, there is considerable settling of carton contents during shipping. Therefore, the space-saving feature shown inFIG. 9 can be utilized immediately upon purchase, because of the typically large unoccupied volume at the top of the carton upon purchase.
• According to the above-described embodiments, the space required to store a newly purchased or partially consumed product is reduced substantially by either removing or “telescoping” the top section of the carton. Referring toFIG. 5, the indicated height H₁(also shown inFIG. 1) is at least about one third of an initial, unmodified, height H of thecarton150. In other embodiments, the height H₁can be about half the height H of thecarton150. The relative heights H₁, H can be varied, for example, to achieve varying space-saving characteristics in thecarton150.
• According to the above-described embodiments, the height of a carton can be reduced by separating the carton into upper and lower sections. The cartons can be reduced in size, for example, as the contents of the carton are consumed or otherwise dispensed. The remainder of the contents are thereby stored in a carton section which occupies less space than the original carton. The reduced size of the carton also allows a consumer to more easily determine the reduced amount of product remaining in the carton, which may serve as cue to purchase more product.
• Referring toFIG. 8, thetear strip24, or the exterior remainder of the z-fold20 revealed when thetear strip24 is removed, may, for example, include a coupon or a reminder to purchase additional product.
• In the exemplary embodiments discussed above, the blank may be formed from clay coated newsprint (CCN). In general, the blank may be constructed of paperboard, having a caliper of at least about14, for example, so that it is heavier and more rigid than ordinary paper. The blank, and thus the carton, 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 first and second sides of 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 blank may then be coated with a varnish to protect information printed on the blank. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
• 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 invention, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.
• A tear line can be any substantially linear, although not necessarily straight, form of weakening that facilitates tearing therealong. Specifically, but not for the purpose of narrowing the scope of the present invention, tear lines include: a cut that extends partially into the 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, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of cuts that extend completely through the material, with adjacent cuts being spaced apart slightly so that small somewhat bridge-like pieces of the material (e.g., ‘nicks’) are defined between adjacent cuts. The nicks are broken during tearing along the tear line. Such a tear line that includes nicks can also be referred to as a cut line, since the nicks typically are a relatively small in relation to the cuts. The term “line” as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines.
• 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. In contrast, where nicks are present in a cut line (e.g., tear line), typically the nicks will not be overly large or overly numerous in a manner that might cause a reasonable user to incorrectly consider the subject cut line to be a fold line.
• The above embodiments are described as having one or panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place.
• The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected preferred embodiments of the invention, but it is to be understood that the invention 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.

Claims (24)

1. A carton blank for forming a carton, comprising:

a first side panel;

a front panel;

a second side panel;

a back panel;

at least one top flap extending across a first marginal potion of the blank;

at least one bottom flap extending across a second marginal portion of the blank; and

a tear strip extending along at least substantially an entire length of the blank, through the first side panel, the front panel, the second side panel, and the back panel.

2. The blank ofclaim 1, wherein:

the tear strip divides the front panel into a lower front panel section and an upper front panel section; and

in a carton formed from the carton blank, a height of the upper front panel section plus a height of the tear strip is at least about one third of a height of the carton.

3. The blank ofclaim 1, wherein:

the tear strip divides the front panel into a lower front panel section and an upper front panel section; and

a height of the upper front panel section plus a height of the tear strip is within about +/−30% of a height of the lower front panel section.

4. The blank ofclaim 3, wherein a length of the front panel is approximately equal to a length of the back panel.

5. The blank ofclaim 1, further comprising a z-fold section extending along a length of the blank and adjacent to the tear strip.

6. The blank ofclaim 5, wherein the front panel, the first side panel, the back panel, and the second side panel are substantially rectangular.

7. A carton erected from the blank ofclaim 3.

8. The carton ofclaim 7, wherein the tear strip extends around substantially an entire perimeter of the carton.

9. A method of erecting a carton, comprising:

providing a blank according toclaim 5;

folding the blank at the z-fold section;

folding the blank about transverse fold lines so that the front panel and the back panel are substantially parallel;

closing the at least one top flap to form a top panel; and

closing the at least one bottom flap to form a bottom panel.

10. The blank ofclaim 1, wherein the blank is constructed of paperboard.

11. A carton, comprising:

a first side panel;

a front panel adjacent to the first side panel;

a second side panel adjacent to the first side panel;

a back panel adjacent to the first and second side panels;

a top panel;

a bottom panel; and

a tear strip extending around a perimeter of the carton.

12. The carton ofclaim 11, wherein:

the tear strip divides the front panel into a lower front panel section and an upper front panel section; and

a height of the upper front panel section plus a height of the tear strip is at least about one third of a height of the carton.

13. The carton ofclaim 12, further comprising a z-fold section extending around a perimeter of the carton adjacent to the tear strip.

14. The carton ofclaim 11, further comprising a z-fold section extending around a perimeter of the carton adjacent to the tear strip.

15. A method of conserving space occupied by a carton, comprising:

providing a carton according toclaim 11; and

separating the carton into an upper section and a lower section by removing the tear strip.

16. The method ofclaim 15, further comprising sliding the upper section downwardly over the lower section after separating the carton into upper and lower sections.

17. A carton, comprising:

a first side panel;

a front panel adjacent to the first side panel;

a second side panel adjacent to the first side panel;

a back panel adjacent to the first and second side panels;

a top panel;

a bottom panel; and

means for separating the carton into an upper section and a lower section, wherein

a height of the upper section is at least about one third of a height of the carton.

18. The carton ofclaim 17, wherein a length of the front panel is approximately equal to a length of the back panel.

19. The carton ofclaim 18, further comprising a z-fold section extending around a perimeter of the carton adjacent to the tear strip.

20. A method of conserving space occupied by a carton, comprising:

providing a carton according toclaim 17; and

separating the carton into an upper section and a lower section using the means for separating.

21. The method ofclaim 20, further comprising consuming a portion of a product held within the carton before separating the carton into the upper and lower sections.

22. The method ofclaim 20, further comprising sliding the upper section over the lower section after separating the carton into upper and lower sections.

23. A carton, comprising:

a first side panel;

a front panel adjacent to the first side panel;

a second side panel adjacent to the first side panel;

a back panel adjacent to the first and second side panels;

a top panel;

a bottom panel;

a tear strip extending around a perimeter of the carton, the tear strip dividing the front panel into a lower front panel section and an upper front panel section; and

a z-fold section extending around a perimeter of the carton adjacent to the tear strip, wherein

a height of the upper front panel section plus a height of the tear strip is at least about one third of a height of the carton, and

the front panel, the first side panel, the back panel, and the second side panel are substantially rectangular.

24. A carton blank for forming a carton, comprising:

a first side panel;

a front panel;

a second side panel;

a back panel, wherein a length of the front panel is approximately equal to a length of the back panel;

a plurality of top flaps extending across a first marginal potion of the blank;

a plurality of bottom flaps extending across a second marginal portion of the blank; and

a tear strip extending along at least substantially an entire length of the blank, through the first side panel, the front panel, the second side panel, and the back panel, wherein the tear strip divides the front panel into a lower front panel section and an upper front panel section; and

a z-fold section extending along a length of the blank and adjacent to the tear strip, wherein

in a carton formed from the carton blank, a height of the upper front panel section plus a height of the tear strip is at least about one third of a height of the carton, and

the front panel, the first side panel, the back panel, and the second side panel are substantially rectangular.

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