Carton, carton blank and method for forming the carton

• US 5,794,811 A
• Filed: 10/29/1996
• Issued: 08/18/1998
• Est. Priority Date: 12/21/1992
• Status: Expired due to Term

• Current Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Original Assignee: Graphic Packaging Corporation (Graphic Packaging International Incorporated)
• Inventors: Walsh, Joseph C.
• Primary Examiner(s): Elkins, Gary E.
• Application Number:
  US08/741,342
• Time in Patent Office: 658 Days
• Field of Search: 220/416, 220/418, 220/460-463, 229/3.1, 229/198.2, 493/96, 493/97, 493/162, 493/183, 53/485, 53/491
• US Class Current: 229/117.27
• CPC Class Codes: B31B 2105/001 made from laminated webs, e.g. including laminating the webs
• CPC Class Codes: B65D 5/56 Linings or internal coatings , e.g. pre-formed trays provided with a blow- or thermoformed layer to protect the articles from mechanical damage B65D81/127
• CPC Class Codes: B65D 5/563 Laminated linings; Coatings

Abstract

A carton blank for forming a leakproof carton comprising an outer enclosure formed from a relatively rigid material an openable top a closed bottom and a central body and a leakproof inner liner having a central body portion secured to the central body of the outer enclosure, a closed bottom and an openable closed top so that after portions of the material in the carton have been removed the top portion and adjacent portions of the inner liner'"'"'s central body may be separated from the central body of the outer enclosure and folded downwardly to protect the remaining material in the carton. In one embodiment, after all the material has been removed from the carton, the leakproof inner liner may be completely removed from the outer enclosure.

Claims

1. A carton blank comprising:

a unitary sheet of a relatively rigid material having an inner surface and an outer surface;

said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge;

said unitary sheet of a relatively rigid material having a length extending from said top edge to said bottom edge and a width extending from said left side edge to said right side edge;

said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of a relatively rigid material into a back wall panel, a front wall panel, opposite side wall panels, a glue tab panel and top and bottom panels extending outwardly in opposite directions from said front wall, back wall and opposite sidewall panels;

said glue tab panel having a top edge and a bottom edge and a perforated line extending from said top edge toward said bottom edge;

said inner surface of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel having a central body portion, a top body portion and a bottom body portion;

said central body portion located between and spaced from said fold lines between said front wall panel, said back wall panel and said opposite sidewall panels and said top and bottom panels and extending into said glue tab panel;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface with said outer surface having a central body portion, a top body portion a bottom body portion, a left side edge, a right side edge and top and bottom edges;

said generally rectangular sheet of a relatively flexible fluid impervious material having a length and a width corresponding to said length of said width of said unitary sheet of a relatively rigid material;

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material being secured to said central body portion of said front wall panel, said back wall panel said opposite sidewall panels and said glue tab panel;

at least portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material being secured by an adhesive permitting separation thereof from adjacent portions of said central body portion of said front panel, said back panel, said opposite sidewall panels and portions of said glue tab panel without damage thereto by the application of sufficient force; and

at least portions of said top and bottom body portion of said generally rectangular sheet of a relatively flexible fluid impervious material overlying but not secured to said top and bottom body portion of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel and said inner surface of said top and bottom panels.

2. A carton blank as in claim 1 and further comprising:

a sheet of a relatively flexible material secured to said top and bottom body portions of said generally rectangular sheet of a relative flexible fluid impervious material.

3. A carton blank as in claim 2 and further comprising:

at least portions of said glue tab panel between said perforated line and one of said left or right side edges being secured to other portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material with a relatively permanent adhesive so that said at least portions of said glue tab panel move with said other portions of said central body portion of said rectangular sheet of a relatively flexible fluid impervious material as said at least portions of said generally rectangular sheet are being separated from said central body portion of said front panel, said back panel, said opposite sidewall panels and the adjacent portions of said glue tab panel.

4. A carton blank as in claim 3 and further comprising:

a fold line formed in said glue tab extending from said top edge thereof to said bottom edge thereof and having at least a portion thereof located between said perforated line and said one of said left or right side edges; and

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material having an edge portion that is spaced from and parallel to the other of said left or right edges so that when said glue tab panel is folded around said fold line, outer surface of said glue tab panel comprises a portion of said outer surface of said unitary sheet of a relatively rigid material and a portion of said generally rectangular sheet of a relatively flexible fluid impervious material.

5. A carton blank as in claim 4 and further comprising:

the portion of said unitary sheet of a relatively rigid material forming the facing surfaces of said folded over portion of said glue tab panel having a thickness of approximately one-half of the thickness of the other portions of said unitary sheet of a relatively rigid material.

6. A carton blank as in claim 1 and further comprising:

at least portion of said glue tab panel between said perforated line and one of said left or right side edges being secured to said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material with an adhesive so that said portion moves with said at least portion of said central body portion of said rectangular sheet of a relatively flexible fluid impervious material as said at least portions are being separated from said central body portion of said front wall panel, said back wall panel, said opposite sidewall panels and the adjacent portion of said glue tab panel.

7. A carton blank as in claim 6 and further comprising:

a fold line formed in said glue tab extending from said top edge thereof to said bottom edge thereof and having at least a portion thereof located between said perforated line and said one of said left or right side edges; and

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material having an edge portion that is spaced from and parallel to the other of said left or right edges so that when said glue tab panel is folded around said fold line, outer surface of said glue tab panel comprises a portion of said outer surface of said unitary sheet of a relatively rigid material and a portion of said generally rectangular sheet of a relatively flexible fluid impervious material.

8. A carton blank as in claim 7 and further comprising:

the portion of said unitary sheet of a relatively rigid material forming the facing surfaces of said folded over portion of said glue tab panel having a thickness of approximately one-half of the thickness of the other portions of said unitary sheet of a relatively rigid material.

9. A carton blank comprising:

a unitary sheet of a relatively rigid material having an inner surface and an outer surface;

said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge;

said unitary sheet of a relatively rigid material having a length extending from said top edge to said bottom edge and a width extending from said left side edge to said right side edge;

said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of a relatively rigid material into a back wall panel, a front wall panel, opposite side wall panels, a glue tab panel and top and bottom panels extending outwardly in opposite directions from said front wall, back wall and opposite sidewall panels;

said glue tab panel having a top edge and a bottom edge and a perforated line extending from said top edge toward said bottom edge;

said inner surface of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel having a central body portion, a top body portion and a bottom body portion;

said central body portion located between and spaced from said fold lines between said front wall panel, said back wall panel and said opposite sidewall panels and said top and bottom panels and extending into said glue tab panel;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface with said outer surface having a central body portion, a top body portion a bottom body portion, a left side edge, a right side edge and top and bottom edges;

said generally rectangular sheet of a relatively flexible fluid impervious material having a length and a width corresponding to said length of said width of said unitary sheet of a relatively rigid material;

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material being secured to said central body portion of said front wall panel, said back wall panel said opposite sidewall panels and said glue tab panel;

said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material being secured by an adhesive permitting separation thereof from adjacent portions of said central body portion of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel without damage thereto by the application of sufficient force; and

at least portions of said top and bottom body portion of said generally rectangular sheet of a relatively flexible fluid impervious material overlying but not secured to said top and bottom body portion of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel and said inner surface of said top and bottom panels.

10. A carton blank as in claim 9 and further comprising:

at least portion of said glue tab panel between said perforated line and one of said left or right side edges being secured to said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material with an adhesive so that said portion moves with said at least portion of said central body portion of said rectangular sheet of a relatively flexible fluid impervious material as said at least portions are being separated from said central body portion of said front wall panel, said back wall panel, said opposite sidewall panels and the adjacent portion of said glue tab panel.

11. A carton blank as in claim 10 and further comprising:

a fold line formed in said glue tab extending from said top edge thereof to said bottom edge thereof and having at least a portion thereof located between said perforated line and said one of said left or right side edges; and

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material having an edge portion that is spaced from and parallel to the other of said left or right edges so that when said glue tab panel is folded around said fold line, outer surface of said glue tab panel comprises a portion of said outer surface of said unitary sheet of a relatively rigid material and a portion of said generally rectangular sheet of a relatively flexible fluid impervious material.

12. A carton blank as in claim 11 and further comprising:

the portion of said unitary sheet of a relatively rigid material forming the facing surfaces of said folded over portion of said glue tab panel having a thickness of approximately one-half of the thickness of the other portions of said unitary sheet of a relatively rigid material.

13. A carton formed from a carton blank comprising a unitary sheet of a relatively rigid material having an inner surface and an outer surface;

said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge;

said unitary sheet of a relatively rigid material having a length extending from said top edge to said bottom edge and a width extending from said left side edge to said right side edge;

said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of a relatively rigid material into a back wall panel, a front wall panel, opposite side wall panels, a glue tab panel and top and bottom panels extending outwardly in opposite directions from said front wall, back wall and opposite sidewall panels;

said glue tab panel having a top edge and a bottom edge and a perforated line extending from said top edge toward said bottom edge;

said inner surface of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel having a central body portion, a top body portion and a bottom body portion;

said central body portion located between and spaced from said fold lines between said front wall panel, said back wall panel and said opposite sidewall panels and said top and bottom panels and extending into said glue tab panel;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface with said outer surface having a central body portion, a top body portion a bottom body portion, a left side edge, a right side edge and top and bottom edges;

said generally rectangular sheet of a relatively flexible fluid impervious material having a length and a width corresponding to said length of said width of said unitary sheet of a relatively rigid material;

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material being secured to said central body portion of said front wall panel, said back wall panel said opposite sidewall panels and said glue tab panel;

at least portion of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material being secured by an adhesive permitting separation thereof from adjacent portions of said central body portion of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel without damage thereto by the application of sufficient force; and

at least portions of said top and bottom body portion of said generally rectangular sheet of a relatively flexible fluid impervious material overlying but not secured to said top and bottom body portion of said front wall panel, said back wall panel, said opposite sidewall panels and said glue tab panel and said inner surface of said top and bottom panels, a sheet of a relatively flexible material secured to said top and bottom body portions of said generally rectangular sheet of a relative flexible fluid impervious material, at least portion of said glue tab panel between said perforated line and one of said left or right side edges being secured to said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material with an adhesive so that said portion moves with said at least portion of said central body portion of said rectangular sheet of a relatively flexible fluid impervious material as said at least portions are being separated from said central body portion of said front wall panel, said back wall panel, said opposite sidewall panels and the adjacent portion of said glue tab panel, a fold line formed in said glue tab extending from said top edge thereof to said bottom edge thereof and having at least a portion thereof located between said perforated line and said one of said left or right side edges, and said central body portion of said rectangular sheet of a relatively flexible fluid impervious material having an edge portion that is spaced from and parallel to the other of said left or right edges so that when said glue tab panel is folded around said fold line, outer surface of said glue tab panel comprises a portion of said outer surface of said unitary sheet of a relatively rigid material and a portion of said generally rectangular sheet of a relatively flexible fluid impervious material said portion of said unitary sheet of a relatively rigid material forming the facing surfaces of said folded over portion of said glue tab panel having a thickness of approximately one-half of the thickness of the other portions of said unitary sheet of a relatively rigid material comprising;

said unitary sheet of a relatively rigid material and said generally rectangular sheet of a relatively flexible fluid impervious material have been folded and sealed to form an open ended enclosure wherein a portion of said outer surface of said glue tab panel is secured to a portion of said inner surface of one of said front or back panels and portions of said generally rectangular sheet of a relatively flexible fluid impervious material adjacent to said right and left side edges thereof are continuously sealed together from said top edge to said bottom edge thereof;

said bottom body portion of said generally rectangular sheet of a relatively flexible fluid impervious material being folded and secured together and said bottom panel portions being folded and secured together to form a bottom closed end so that the carton can be filled with a desired material; and

said top body portion of said generally rectangular sheet of a relatively flexible fluid impervious material being folded and secured together and said top panel portions being folded and secured together to form a closed top end.

14. A method for forming an open ended enclosure from a carton blank comprising a unitary sheet of a relatively rigid material having an inner surface and an outer surface;

said unitary sheet of a relatively rigid material having a left side edge, a right side edge, a top edge and a bottom edge;

said unitary sheet of a relatively rigid material having a length extending from said top edge to said bottom edge and a width extending from said left side edge to said right side edge;

said unitary sheet of a relatively rigid material having a plurality of cut and fold lines for dividing said unitary sheet of a relatively rigid material into a back panel, a front panel, opposite side wall panels, a glue tab panel and top and bottom panels extending outwardly in opposite directions from said front, back and opposite sidewall panels;

said glue tab panel having a top edge and a bottom edge and a perforated line extending from said top edge and at least toward said bottom edge;

said inner surface of said front panel, said back panel, said opposite sidewall panels and said glue tab panel having a central body portion, a top body portion and a bottom body portion;

said central body portion located between and spaced from said fold lines between said front panel, said back panel and said opposite sidewall panels and extending into said glue tab panel;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface with said outer surface having a central body portion, a top body portion a bottom body portion, a left side edge, a right side edge and top and bottom edges;

said generally rectangular sheet of a relatively flexible fluid impervious material having a length and a width corresponding to said length of said width of said unitary sheet of a relatively rigid material;

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material being secured to said central body portion of said front panel, said back panel said opposite sidewall panels and said glue tab panel;

at least portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material being secured by an adhesive permitting separation thereof from adjacent portions of said central body portion of said front panel, said back panel, said opposite sidewall panels and said glue tab panel without damage thereto by the application of sufficient force;

said at least portions extending downwardly from said top body portion toward said bottom body portion thereof; and

at least portions of said top and bottom body portion of said generally rectangular sheet of a relatively flexible fluid impervious material overlying but not secured to said top and bottom body portions of said front panel, said back panel, said opposite sidewall panels and said glue tab panel and said inner surface of said top and bottom panels;

a sheet of a relatively flexible material secured to said top and bottom body portions of said generally rectangular sheet of a relative flexible fluid impervious material;

at least portion of said glue tab panel between said perforated line and one of said left or right side edges being secured to other portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material with a relatively permanent adhesive so that at least said portions of said glue tab panel move with said portions of said central body portion of said rectangular sheet of a relatively flexible fluid impervious material as said at least portions are being separated from said central body portion of said front panel, said back panel, said opposite sidewall panels and said adjacent portions of said glue tab panel;

a fold line formed in said glue tab panel extending from said top edge thereof to said bottom edge thereof and having at least a portion thereof located between said perforated line and said one of said left or right side edges; and

said central body portion of said rectangular sheet of a relatively flexible fluid impervious material having an edge portion that is spaced from and parallel to the other of said left or right edges so that a portion of the inner surface of said unitary sheet of a relatively rigid material is exposed comprising;

folding said glue tab panel and one of said opposite sidewall panels and the portion of said generally rectangular sheet of a relatively flexible fluid impervious material secured thereto around a fold line between said one of said opposite sidewall panels and one of said front or back wall panels and forming extended fold lines in said top and bottom body portions of said generally rectangular sheet of a relatively flexible fluid impervious material;

folding said at least portions of said glue tab panel located between said perforated line and said one of said left or right side edges and said other portions of the generally sheet of a relatively flexible fluid impervious material secured thereto around said fold line in said glue tab panel and extending the fold line into portions of said top and bottom body portions of said generally rectangular sheet of a relatively flexible fluid impervious material to form a continuous strip of said generally rectangular sheet of a relatively flexible fluid impervious material facing in the same direction as the outer surface of the remaining portion of the outer surface of said glue tab panel;

folding the other of said front or back panels and the portion of the generally rectangular sheet of a relatively flexible fluid impervious material secured thereto around a fold line between said other of said front or back wall panels and the other of said opposite sidewall panels and forming extended fold lines in said top and bottom body portions of said generally rectangular sheet of a relatively flexible fluid impervious material; and

sealing together facing portions of said outer surface of said glue tab panel and said exposed inner surface of said other of said front or back panels and facing portions of said continuous strip of a relatively flexible fluid impervious material and portions of said generally rectangular sheet of a relatively flexible fluid impervious material secured to the other of said front or back panels and the extensions thereof into said top and bottom body portions of said generally rectangular sheet of a relatively flexible fluid impervious material to form an open ended enclosure having a continuous inner surface formed from said generally rectangular sheet of a relatively flexible fluid impervious material.

15. A method as in claim 14 and further comprising:

forming a carton from said open ended enclosure comprising;

sealing together portions of said bottom body portion of said generally rectangular sheet of a relatively flexible material and said bottom panels to formed a carton having an open top and a closed bottom;

filling said carton with a desired material; and

sealing together portions of said top body portion of said generally rectangular sheet of a relatively flexible fluid impervious material and said top panels to form a closed top.

16. A method as in claim 15 and further comprising:

opening said top panel portion and said portions of said top body portion of said generally rectangular sheet of a relatively flexible fluid impervious material;

removing some of said material from said carton;

folding said top body portion and portions said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material to reclose said opening; and

severing said at least portions of said glue tab panel along said perforated line so that said portion of said glue tab panel may be folded with said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material.

17. A method as in claim 16 and further comprising:

separating said generally rectangular sheet of a relatively flexible fluid impervious material completely from said unitary sheet of a relatively rigid material.