Carton, carton blank and method for forming the carton

• US 5,918,799 A
• Filed: 07/01/1997
• Issued: 07/06/1999
• Est. Priority Date: 10/29/1996
• Status: Expired due to Term

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging Corporation
• Inventors: Walsh, Joseph C.
• Primary Examiner(s): Elkins, Gary E.
• Application Number:
  US08/886,683
• Time in Patent Office: 735 Days
• Field of Search: 229/117.3, 229/117.32, 229/117.33, 229/117.35, 229/164.2, 229/198.2, 493/96, 493/97, 493/162, 493/183, 53/485, 53/491
• US Class Current: 229/164.2
• 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 5/603 Flexible linings loosely glued to the wall of the container B65D5/0272 takes precedence

Abstract

A carton blank and a leakproof carton formed therefrom which carton has an outer enclosure formed from a relatively rigid material and having an openable top portion and a closed bottom portion and a leakproof inner liner having a central body portion secured to an opposed 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 sidewall 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, 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 to 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 by an adhesive holding said at least portions and said adjacent portions together but permitting separation thereof without damage thereto; and

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 top and bottom panels.

2. 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 sidewall 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;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface, 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 and 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 opposite portions 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 to said opposite portions of said front panel, said back panel, said opposite sidewall panels and portions of said glue tab panel by an adhesive holding said at least portions and said opposite portions together but permitting separation thereof without damage thereto; and

a portion of said carton blank comprising at least portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material adjacent to one of said left and right side edges overlying but not secured to at lest portions of said unitary sheet of a relatively rigid material adjacent to one of said left and right side edges.

3. A carton blank as in claim 2 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.

4. An open ended enclosure formed form 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 sidewall 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;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface, 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 and 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 opposite portions 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 to said opposite portions of said front wall panel, said back wall panel, said opposite sidewall panels and portions of said glue tab panel by an adhesive holding said at least portions and said opposite portions together but permitting separation thereof without damage thereto comprising;

a first portion comprising at least portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material adjacent to one of said left and right side edges overlying but not secured to at least portions of said unitary sheet of a relatively rigid material adjacent to one of said left and right side edges comprising;

a second portion of said carton blank comprising at least portions of said carton blank adjacent to the other of said left and right side edges being located between said non-secured portions of said first portion;

at least portions of said relatively flexible fluid impervious material of said first portion being secured to at least portions of said relatively flexible fluid impervious material of said second portion; and

at least portions of said relatively rigid material of said first portion being secured to at least portions of said relatively rigid material of said second portion.

5. A carton formed from the open ended enclosure of claim 4 comprising:

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 after said carton has been filled, and said top panel portions being folded and secured together to form a closed top end.

6. 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;

a generally rectangular sheet of a relatively flexible fluid impervious material having an inner surface and an outer surface, 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 opposite portions 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 to said opposite portions of said front panel, said back panel, said opposite sidewall panels and said glue tab panel by an adhesive holding said at least portions and said opposite portions together but permitting separation thereof without damage thereto, and having a first portion comprising at least portions of said central body portion of said generally rectangular sheet of a relatively flexible fluid impervious material adjacent to one of said left and right side edges overlying but not secured to at least portions of said unitary sheet of a relatively rigid material adjacent to one of said left and right side edges comprising;

folding said carton blank around at least some of said fold lines between said front and back panels, said opposite sidewall panels and said glue tab panel;

inserting a second portion of said carton blank comprising at least portions of said carton blank adjacent to the other of said left and right side edges between said non-secured portions of said first portion;

securing at least portions of said relatively flexible fluid impervious material of said first portion to at least portions of said relatively fluid impervious material of said second portion; and

securing at least portions of said relatively rigid material of said first portion to at least portions of said relatively rigid material of said second portion.

7. A method as in claim 6 and further comprising:

forming a carton from said open ended enclosure comprising;

folding and sealing together portions of said bottom body portion of said generally rectangular sheet of a relatively flexible fluid impervious material;

folding and securing together said bottom panel portions to form a carton having an open top end and a bottom closed end;

filling said carton with a desired material;

folding and securing together portions of said top body portion of said generally rectangular sheet of a relatively flexible fluid impervious material; and

folding and securing together portions of said top panel portions.