Carton with top closure

• US 10,239,651 B2
• Filed: 01/09/2018
• Issued: 03/26/2019
• Est. Priority Date: 01/13/2017
• Status: Active Grant

• Current Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Original Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Inventors: Exner, Dana, Lenkeit, Gary
• Primary Examiner(s): Demeree, Christopher
• Application Number:
  US15/865,771
• Publication Number:
  US 20180201403A1
• Time in Patent Office: 441 Days
• Field of Search: 229126, 229149, 229137, 53456, 53467, 53491
• CPC Class Codes: B31B 2100/002 characterised by the shape of the blank from which they are formed
• CPC Class Codes: B31B 2110/35 rectangular, e.g. square
• CPC Class Codes: B31B 50/262 involving folding, leading, or trailing flaps of blanks
• CPC Class Codes: B65D 5/0227 with end closures formed by inward folding of flaps and securing them by heat-sealing, by applying adhesive to the flaps or by staples
• CPC Class Codes: B65D 5/061 Rectangular containers having a body with gusset-flaps folded inwardly beneath the closure flaps

Abstract

A carton for holding at least one article includes a plurality of panels that extends at least partially around an interior of the carton. The plurality of panels includes a front panel, a first side panel, a second side panel, and a back panel. A plurality of end flaps includes a first end flap foldably connected to the front panel and a second end flap foldably connected to the back panel. A first gusset is foldably connected to a portion of the first side panel and a second gusset is foldably connected to a portion of the second side panel. At least the first end flap, the first gusset, and the second gusset cooperate to form a first closure of the carton, and the second end flap forms a second closure of the carton. The second closure at least partially overlaps the first closure.

Claims

1. A carton for holding at least one article, the carton comprising:

a plurality of panels that extends at least partially around an interior of the carton, the plurality of panels comprises a front panel, a first side panel, a second side panel, and a back panel;

a plurality of end flaps foldably connected to respective panels of the plurality of panels, the plurality of end flaps comprises a first end flap foldably connected to the front panel, a second end flap foldably connected to the back panel, a third end flap foldably connected to the first side panel, and a fourth end flap foldably connected to the second side panel; and

a first gusset foldably connected to a portion of the first side panel and a second gusset foldably connected to a portion of the second side panel,

the first end flap, the third end flap, the fourth end flap, the first gusset, and the second gusset cooperate such that the third end flap and the fourth end flap overlap the first end flap to form a first closure of the carton, the first closure provides a first seal at the top of the front panel, the first side panel, the second side panel, and the back panel, and the second end flap forms a second closure of the carton, the second closure at least partially overlaps and at least partially envelops the first closure and provides a second seal at the top of the front panel, the first side panel, the second side panel, and the back panel.

2. The carton of claim 1, wherein the second end flap comprises a proximal portion foldably connected to a distal portion.

3. The carton of claim 2, wherein the proximal portion of the second end flap at least partially overlaps the first end flap, and the distal portion of the second end flap at least partially overlaps the front panel.

4. The carton of claim 2, wherein a portion of the first gusset is disposed inwardly toward the interior of the carton a first longitudinal distance, a portion of the second gusset is disposed inwardly toward the interior of the carton a second longitudinal distance, the first end flap has a length equal to a third longitudinal distance, and the front panel has a length equal to a fourth longitudinal distance, and the sum of the first longitudinal distance, the second longitudinal distance, and the third longitudinal distance is substantially equal to the fourth longitudinal distance.

5. The carton of claim 1, wherein an upper portion of the front panel is obliquely disposed relative to a lower portion of the front panel and an upper portion of the back panel is obliquely disposed relative to a lower portion of the back panel.

6. The carton of claim 5, wherein the second end flap comprises a proximal portion foldably connected to a distal portion, the distal portion of the second end flap is at least partially in face-to-face contact with the upper portion of the front panel.

7. The carton of claim 1, wherein the first gusset comprises a first gusset panel, a second gusset panel, and a third gusset panel.

8. The carton of claim 7, wherein the first gusset panel is foldably connected to each of the second gusset panel and the third gusset panel.

9. The carton of claim 8, wherein the first gusset panel is foldably connected to the second gusset panel by a first fold line having a first oblique portion intersecting a second oblique portion, and the first gusset panel is foldably connected to the third gusset panel by a second fold line having a first oblique portion and a second oblique portion.

10. The carton of claim 9, wherein the second oblique portion of the first fold line and the second oblique portion of the second fold line are interconnected by a curved fold line.

11. The carton of claim 10, wherein the second gusset comprises a fourth gusset panel, a fifth gusset panel, and a sixth gusset panel, the fourth gusset panel is foldably connected to the fifth gusset panel at a third fold line and the fourth gusset panel is foldably connected to the sixth gusset panel at a fourth fold line, each of the third fold line and the fourth fold line comprises a first oblique portion intersecting a second oblique portion, the second oblique portion of the third fold line and the second oblique portion of the fourth fold line are interconnected by a curved fold line.

12. The carton of claim 1, wherein each of the first end flap, the third end flap, and the fourth end flap is generally perpendicularly folded at the respective front panel, first side panel, and second side panel to at least partially form a flat gable top of the carton.

13. A blank for forming a carton for holding at least one article, the blank comprising:

a plurality of panels for extending at least partially around an interior of the carton formed from the blank, the plurality of panels comprises a front panel, a first side panel, a second side panel, and a back panel;

a plurality of end flaps foldably connected to respective panels of the plurality of panels, the plurality of end flaps comprises a first end flap foldably connected to the front panel, a second end flap foldably connected to the back panel, a third end flap foldably connected to the first side panel, and a fourth end flap foldably connected to the second side panel; and

a first gusset foldably connected to a portion of the first side panel and a second gusset foldably connected to a portion of the second side panel,

the first end flap, the third end flap, the fourth end flap, the first gusset, and the second gusset are for cooperating such that the third end flap and the fourth end flap overlap the first end flap to form a first closure of the carton formed from the blank, the first closure provides a first seal at the top of the front panel, the first side panel, the second side panel, and the back panel when the carton formed from the blank, and the second end flap is for forming a second closure of the carton formed from the blank, the second closure is for at least partially overlapping and at least partially enveloping the first closure of the carton formed from the blank and providing a second seal at the top of the front panel, the first side panel, the second side panel, and the back panel when the carton is formed from the blank.

14. The blank of claim 13, wherein the second end flap comprises a proximal portion foldably connected to a distal portion.

15. The blank of claim 14, wherein the proximal portion of the second end flap at least partially overlaps the first end flap when the carton is formed from the blank, and the distal portion of the second end flap at least partially overlaps the front panel when the carton is formed from the blank.

16. The blank of claim 14, wherein a portion of the first gusset is disposed inwardly toward the interior of the carton formed from the blank a first longitudinal distance, a portion of the second gusset is disposed inwardly toward the interior of the carton formed from the blank a second longitudinal distance, the first end flap has a length equal to a third longitudinal distance, and the front panel has a length equal to a fourth longitudinal distance, and the sum of the first longitudinal distance, the second longitudinal distance, and the third longitudinal distance is substantially equal to the fourth longitudinal distance.

17. The blank of claim 13, wherein an upper portion of the front panel is obliquely disposed relative to a lower portion of the front panel and an upper portion of the back panel is obliquely disposed relative to a lower portion of the back panel when the carton is formed from the blank.

18. The blank of claim 17, wherein the second end flap comprises a proximal portion foldably connected to a distal portion, the distal portion of the second end flap is at least partially in face-to-face contact with the upper portion of the front panel when the carton is formed from the blank.

19. The blank of claim 13, wherein the first gusset comprises a first gusset panel, a second gusset panel, and a third gusset panel.

20. The blank of claim 19, wherein the first gusset panel is foldably connected to each of the second gusset panel and the third gusset panel.

21. The blank of claim 20, wherein the first gusset panel is foldably connected to the second gusset panel by a first fold line having a first oblique portion intersecting a second oblique portion, and the first gusset panel is foldably connected to the third gusset panel by a second fold line having a first oblique portion and a second oblique portion.

22. The blank of claim 21, wherein the second oblique portion of the first fold line and the second oblique portion of the second fold line are interconnected by a curved fold line.

23. The blank of claim 22, wherein the second gusset comprises a fourth gusset panel, a fifth gusset panel, and a sixth gusset panel, the fourth gusset panel is foldably connected to the fifth gusset panel at a third fold line and the fourth gusset panel is foldably connected to the sixth gusset panel at a fourth fold line, each of the third fold line and the fourth fold line comprises a first oblique portion intersecting a second oblique portion, the second oblique portion of the third fold line and the second oblique portion of the fourth fold line are interconnected by a curved fold line.

24. The blank of claim 13, wherein each of the first end flap, the third end flap, and the fourth end flap is for being generally perpendicularly folded at the respective front panel, first side panel, and second side panel to at least partially form a flat gable top of the carton formed from the blank.

25. A method of forming a carton for holding at least one article, the method comprising:

obtaining a blank comprising a plurality of panels and a plurality of end flaps, the plurality of panels comprises a front panel, a first side panel, a second side panel, and a back panel, the plurality of end flaps are foldably connected to respective panels of the plurality of panels, the plurality of end flaps comprises a first end flap foldably connected to the front panel a second end flap foldably connected to the back panel, a third end flap foldably connected to the first side panel, and a fourth end flap foldably connected to the second side panel, the blank comprises a first gusset foldably connected to a portion of the first side panel and a second gusset foldably connected to a portion of the second side panel; and

folding the plurality of panels to at least partially extend around an interior of the carton;

positioning the first end flap, the third end flap, the fourth end flap, the first gusset, and the second gusset such that the third end flap and the fourth end flap overlap the first end flap to form a first closure of the carton, the first closure provides a first seal at the top of the front panel, the first side panel, the second side panel, and the back panel; and

positioning the second end flap to form a second closure of the carton, the second closure at least partially overlaps and at least partially envelops the first closure and provides a second seal at the top of the front panel, the first side panel, the second side panel, and the back panel.

26. The method of claim 25, wherein the second end flap comprises a proximal portion foldably connected to a distal portion.

27. The method of claim 26, wherein the proximal portion of the second end flap at least partially overlaps the first end flap, and the distal portion of the second end flap at least partially overlaps the front panel.

28. The method of claim 26, wherein a portion of the first gusset is disposed inwardly toward the interior of the carton a first longitudinal distance, a portion of the second gusset is disposed inwardly toward the interior of the carton a second longitudinal distance, the first end flap has a length equal to a third longitudinal distance, and the front panel has a length equal to a fourth longitudinal distance, and the sum of the first longitudinal distance, the second longitudinal distance, and the third longitudinal distance is substantially equal to the fourth longitudinal distance.

29. The method of claim 25, wherein an upper portion of the front panel is obliquely disposed relative to a lower portion of the front panel and an upper portion of the back panel is obliquely disposed relative to a lower portion of the back panel.

30. The method of claim 29, wherein the second end flap comprises a proximal portion foldably connected to a distal portion, the distal portion of the second end flap is at least partially in face-to-face contact with the upper portion of the front panel.

31. The method of claim 25, wherein the first gusset comprises a first gusset panel, a second gusset panel, and a third gusset panel.

32. The method of claim 31, wherein the first gusset panel is foldably connected to each of the second gusset panel and the third gusset panel.

33. The method of claim 32, wherein the first gusset panel is foldably connected to the second gusset panel by a first fold line having a first oblique portion intersecting a second oblique portion, and the first gusset panel is foldably connected to the third gusset panel by a second fold line having a first oblique portion and a second oblique portion.

34. The method of claim 33, wherein the second oblique portion of the first fold line and the second oblique portion of the second fold line are interconnected by a curved fold line.

35. The method of claim 34, wherein the second gusset comprises a fourth gusset panel, a fifth gusset panel, and a sixth gusset panel, the fourth gusset panel is foldably connected to the fifth gusset panel at a third fold line and the fourth gusset panel is foldably connected to the sixth gusset panel at a fourth fold line, each of the third fold line and the fourth fold line comprises a first oblique portion intersecting a second oblique portion, the second oblique portion of the third fold line and the second oblique portion of the fourth fold line are interconnected by a curved fold line.

36. The method of claim 25, further comprising generally perpendicularly folding each of the first end flap, the third end flap, and the fourth end flap at the respective front panel, first side panel, and second side panel to at least partially form a flat gable top of the carton.