Carton blank, carton and method of forming the carton

• US 6,386,438 B1
• Filed: 06/28/2000
• Issued: 05/14/2002
• Est. Priority Date: 06/28/2000
• 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: Kastanek, Raymond S., Conatser, Robert L., Walsh, Joseph C.
• Primary Examiner(s): Young, Lee
• Assistant Examiner(s): Mai, Tri M.
• Application Number:
  US09/607,197
• Time in Patent Office: 685 Days
• Field of Search: 229/117.27, 229/217, 229/117.3, 229/231, 229/215, 229/219, 534/49, 493/96, 493/114, 493/907
• US Class Current: 229/117.27
• CPC Class Codes: B65D 5/6623 the lid being hinged about a line located in the top surface of the container

Abstract

A carton blank having an outer layer of a relatively rigid material, a first inner layer of a relatively rigid material superposed over a portion of the outer layer and a second inner layer of a relatively flexible layer of a fluid impervious material is provided with first and second weakened portions so that, after a carton has been formed from the carton blank, filled with a desired material and sealed, the first weakened portion may be broken to form a flip top lid which when moved in an arcuate path will gradually sever the second weakened portion to form an opening in the carton so that an amount of the desired material may be removed from the carton.

Claims

1. A carton blank comprising:

an outer layer comprising a first generally rectangular sheet of a relatively rigid material and having an outer surface and an inner surface;

said outer layer having a plurality of cut and fold lines formed therein for dividing said outer layer into a plurality of panels;

said outer layer having at least a first sidewall panel being integral with a second sidewall panel and a third sidewall panel and joined thereto by opposite fold lines;

a first top panel integral with said first sidewall panel and joined thereto by a fold line;

a second top panel integral with said second sidewall panel and joined thereto by a fold line;

a third top panel integral with said third sidewall panel and joined thereto by a fold line;

a first inner layer comprising a second generally rectangular sheet of a relatively rigid material having an outer surface and an inner surface;

said second generally rectangular sheet being opposite to portions of said first, second and third sidewall panels;

said second generally rectangular sheet having at least a first partial sidewall panel integral with a second partial sidewall panel and a third partial sidewall panel and secured thereto by opposite fold lines;

said first sidewall panel and said first partial sidewall panel having substantially the same width between said opposite fold lines thereof;

said second generally rectangular sheet having an upper edge portion and a lower edge portion;

at least a portion of said first partial sidewall panel adjacent to said lower edge being secured to at least a portion of said first sidewall panel;

said upper edge portion being located adjacent to but spaced from said fold lines between said first, second and third sidewall panels and said first, second and third top panels;

a second inner layer comprising a generally rectangular sheet of a relatively flexible fluid impervious material and having an outer surface and an inner surface;

at least portions of said outer surface of said second inner layer being secured to opposite portions of said inner surface of said outer layer;

at least other portions of said outer surface of said second inner layer being secured to at least portions of said inner surface of said first inner layer;

said second inner layer having a weakened portion located adjacent to but spaced from said upper edge of said first inner layer;

portions of said outer surface of said second inner layer surrounding said weakened portion being secured to opposite portions of said inner surface of said first inner layer; and

a continuous weakened portion in portions of said first, second and third sidewall panels for cooperating with said weakened portion in forming an opening in a carton formed from said outer layer and said first and second inner layers so that said weakened portions may be broken to form an opening in said carton and a flip top lid for opening or closing said opening.

2. A carton blank as in claim 1 wherein said continuous weakened portion comprises:

a first portion located in said first sidewall panel adjacent to but spaced from said at least a portion of said first sidewall panel and having end portions located in said opposite fold lines;

a second portion located in said second sidewall panel and extending at an acute angle between one of said end portions and said fold line between said second sidewall panel and said second top panel; and

a third portion located in said third sidewall panel and extending at an acute angle between the other of said end portions and said fold line between said third sidewall panel and said third top panel.

3. A carton blank as in claim 1 wherein:

said cut lines between said first and third top panels being spaced apart so that an open space is formed between said first and third top panels.

4. A carton blank as in claim 1 wherein:

said second top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said second top panel and said second sidewall panel;

an arcuate shaped score line in said second top panel extending between said opposite spaced apart fold lines;

said third top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said third top panel and said third sidewall panel; and

an arcuate shaped score line in said third top panel extending between said opposite spaced apart fold lines.

5. A carton blank as in claim 4 wherein:

said opposite spaced apart fold lines in said second and third top panels being located so that they are in a superposed position when said third top panel is superposed over said second top panel; and

said arcuate shaped score lines in said second and third top panels extend in opposite directions when said third top panel is superposed over said second top panel.

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

said carton blank having a fourth sidewall panel integral with one of said second and third sidewall panels and joined thereto by a fold line;

a glue tab panel integral with said fourth sidewall panel and joined thereto by a fold line;

a fourth top panel integral with said fourth sidewall panel and joined thereto by a fold line;

a first, second, third and fourth bottom panels respectively integral with said first, second, third and fourth sidewall panels and joined thereto by fold lines;

a fist strip of a relatively flexible material superposed over at least said first, second, third and fourth top panels and portions of said first, second, third and fourth sidewall panels adjacent to said fold lines between said top panels and said sidewall panels and secured to portions of said outer surface of said second inner layer; and

a second strip of a relatively flexible material superposed over at least said first, second, third and fourth bottom panels and portions of said first, second, third and fourth sidewall panels adjacent to said fold lines between said bottom panels and said sidewall panels and secured to other portions of said outer surface of said second inner layer.

7. A carton blank as in claim 6 wherein said continuous weakened portion comprises:

a first portion located in said first sidewall panel adjacent to but spaced from a portion of said lower edge and having end portions located in said opposite fold lines;

a second portion located in said second sidewall panel and extending at an acute angle between one of said end portions and said fold line between said second sidewall panel and said second top panel; and

a third portion located in said third sidewall panel and extending at an acute angle between the other of said end portions and said fold line between said third sidewall panel and said third top panel.

8. A carton blank as in claim 7 wherein:

said cut lines between said first and third top panels being spaced apart so that an open space is formed between said first and third top panels.

9. A carton blank as in claim 8 wherein:

said second top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said second top panel and said second sidewall panel;

an arcuate shaped score line in said second top panel extending between said opposite spaced apart fold lines;

said third top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said third top panel and said third sidewall panel;

an arcuate shaped score line in said third top panel extending between said opposite spaced apart fold lines;

said opposite spaced apart fold lines in said second and third top panels being located so that they are in a superposed position when said third top panel is superposed over said second top panel; and

said arcuate shaped score lines in said second and third top panels extend in opposite directions when said third top panel is superposed over said second top panel.

10. A carton blank as in claim 1 wherein:

said weakened portion having opposite end portions; and

the distance between said opposite end portions is less than the distance between one of said opposite spaced apart fold lines in said second top panel and the corresponding one of said opposite spaced apart fold lines in said third top panel.

11. A dispensing carton comprising:

a plurality of sidewall panels folded around parallel fold lines and held in folded relationship by a glue tab panel to form a central body portion;

said plurality of sidewall panels comprising at least one sidewall panel having integral second and third sidewall panels joined thereto by opposite fold lines;

an inner insert having at least a first partial sidewall panel, a second partial sidewall panel and a third partial sidewall panel superposed over portions of said first, second and third sidewall panels;

said insert having top and bottom edges;

said first partial sidewall panel being secured to facing portions of said first sidewall panel at a location adjacent to said bottom edge;

a continuous fluid impervious liner for said carton having a central body portion, a top portion and a bottom portion;

a plurality of bottom panels integral with said plurality of sidewall panels and joined thereto by fold lines;

a plurality of top panels integral with said plurality of sidewall panels and joined thereto by fold lines;

said bottom portion and said bottom panels being folded and secured together in a fluid tight relationship;

said top portion and said top panels being folded and secured together in a fluid tight relationship;

a first continuous weakened portion in portions of said first, second and third sidewall panels;

a second continuous weakened portion in said continuous fluid impervious liner in a portion thereof spaced from said top edge;

the portion of said fluid impervious liner surrounding said second weakened portion being secured to said insert; and

said first and second weakened portions when broken providing an opening and a flip top lid for said carton.

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

one of said plurality of top panels comprising a second top panel integral with said second sidewall panel;

said second top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said second top panel and said second sidewall panel;

an arcuate shaped score line in said second top panel extending between said opposite spaced apart fold lines;

another one of said plurality of top panels comprising a third top panel integral with said third sidewall panel;

said third top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said third top panel and said third sidewall panel; and

an arcuate shaped score line in said third top panel extending between said opposite spaced apart fold lines.

13. A dispensing carton as in claim 12 wherein:

said opposite spaced apart fold lines in said second and third top panels being in a superposed position; and

said arcuate shaped score lines in said second and third top panels extending in opposite directions.

14. A dispensing carton as in claim 11 wherein:

said top portion of said continuous fluid impervious liner being formed into a closed and folded configuration to form a fin joint having a central body portion and two opposite outwardly extending portions and wherein said central body portion has been folded over one of said two outwardly extending portions;

said top panels comprising two relatively long top panels and two relatively short top panels;

said fin joint having a central section and two opposite end sections;

one of said relatively long top panels superposed over said central section;

each of said two opposite end sections being folded and superposed over at least portions of opposite end portions of said one of said relatively long top panels;

each of said relatively short top panels being folded over and superposed over one of said folded over two opposite end sections; and

the other of said two relatively long top panels being folded over, superposed over and secured to said folded over two relatively short top panels and the portion of said one of said two relatively long top panels located between said folded over two relatively short top panels.

15. A dispensing carton as in claim 14 and further comprising:

one of said plurality of top panels comprising a second top panel integral with said second sidewall panel;

said second top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular said fold line between said second top panel and second sidewall panel;

an arcuate shaped score line in said second top panel extending between said opposite spaced apart fold lines;

another one of said plurality of top panels comprising a third top panel integral with said third sidewall panel;

said third top panel having opposite spaced apart fold lines extending in a direction substantially perpendicular to said fold line between said third top panel and said third sidewall panel; and

an arcuate shaped score line in said third top panel extending between said opposite spaced apart fold lines.

16. A dispensing carton as in claim 15 wherein:

said opposite spaced apart fold lines in said second and third top panels being in a superposed position; and

said arcuate shaped score lines in said second and third top panels extending in opposite directions.

17. A dispensing carton as in claim 16 wherein:

said two relatively short top panels being folded and superposed over at least portions of said one of said relatively long top panels so that at least portions of said folded over opposite end sections are sandwiched therebetween; and

said one of said relatively long top panels being dimensioned so that at least a portion of one of said folded over end sections is not sandwiched between one of said folded over said two relatively short top panels and said one of said two relatively long top panels.

18. A dispensing carton as in claim 17 and further comprising:

a flip top lid formed by separating said first and second continuous weakened portion;

said flip top lid being pivotally mounted on said two relatively long top panels by said superposed fold lines for movement between an opened and a closed position; and

apparatus associated with each of said two relatively long top panels for holding said flip top lid in said opened position.

19. A carton as in claim 18 wherein said apparatus comprises:

a tab portion in each of said two relatively long top panels formed by breaking said arcuately shaped score lines; and

at least portions of said tab portions being in a contacting relationship.

20. A method for forming a secured together top portion for a container comprising at least an outer layer comprising a plurality of sidewall panels and a glue panel folded around fold lines and secured together;

a plurality of bottom panels integral with said plurality of sidewall panels and joined thereto by fold lines;

a plurality of top panels integral with said plurality of sidewall panels and joined thereto by fold lines and wherein the plurality of top panel comprise two relatively long top panels and two relatively short top panels;

at least an inner layer comprising a flexible fluid impervious material having a central body portion, a bottom portion and a top portion wherein the central body portion is secured to at least portions of said plurality of sidewall panels and wherein the plurality of bottom panels and the bottom portion are folded and secured together to form an open ended carton ready to be filled with a desired material and wherein the fold lines between the plurality of top panels and the plurality of sidewall panels lie in a common plane and wherein the open ended carton has been filled with a desired material comprising;

folding and continuously sealing together portions of said top portion so as to have a central body portion and two opposite outwardly extending portions lying substantially in said common plane with said central body portion extending in a direction substantially parallel with said two relatively long top panels;

folding one of said two relatively long top panels to a location wherein it is superposed over said central section;

folding each of said two relatively short top panels so that one of said two opposite end sections is located between each of said two relatively short top panels and spaced apart portions of said one of said two relatively long top panels;

folding the other of said two relatively long top panels until it is superposed over said folded two relatively short top panels and the portion of said one of said two relatively long top panels located therebetween;

securing together facing portions of said other of said two relatively long top panels and said two relatively short top panels and said portion of said one of said two relatively long top panels;

wherein the plurality of sidewall panels comprise at least a first sidewall panel integral with a second and a third sidewall panel and connected thereto by fold lines;

a first continuous weakened portion formed in the first, second and third sidewall panels to form separable portions of the first, second and third sidewall panels;

an inner insert having at least first, second and third partial sidewalls joined by fold lines and superposed over portions of the first, second and third sidewall panels;

the inner insert having upper edge and a lower edge;

the first partial sidewall panel being secured to said first sidewall panel at a location adjacent to the bottom edge of the first partial sidewall panel;

the inner insert being enclosed within and secured to a portion of the inner layer of a flexible impervious sheet;

a second continuous weakened portion formed in a portion thereof parallel to and spaced from a portion of the top edge and additional weakened portions to form a pull tab;

applying a first force on said additional weakened portions to remove said pull tab;

breaking said first weakened portion so that said separable portions of said first, second and third sidewall panels can be moved;

moving said separable portions of said first, second and third sidewall panels in an arcuate path;

gradually severing said second weakened portion by said movement of said separable portions of said first, second and third sidewall panels to form an opening in said carton.

21. A method as in claim 20 and further comprising:

holding said separable portions of said first, second and third sidewall panels in an opened position so that an amount of the desirable material may be removed from said carton.