Packages, blank for making packages and associated methods

Abstract

Cartons are formed from two or more continuous webs that can individually or concurrently provided with cuts, scores, or other lines of disruption.

Description

RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No. 10/318,437, filed Dec. 13, 2002, the entire contents of which are hereby incorporated by reference.

This application claims the benefit of U.S. Provisional Application No. 60/688,505, filed Jun. 8, 2005, and U.S. Provisional Application No. 60/724,537, filed Oct. 7, 2005, the entire contents of both documents being hereby incorporated by reference.

BACKGROUND

Conventional cartons may include features such as closure devices, lids, and other convenient features. Features of a certain complexity, however, may require the carton blank to be prepared in a batch process, where features or articles can be individually cut and/or glued to the carton blank. Batch processing is slow when compared to continuous processes, and may involve higher costs.

SUMMARY

According to a first exemplary embodiment of the invention, a carton is formed from an inner blank joined to an outer blank. The carton includes one or more divider panels formed from the inner blank that divide the carton interior into vertical columns. A removable dispenser portion can be defined at a bottom portion of the carton. When the dispenser is opened, articles can be dispensed from the carton.

According to the first exemplary embodiment, articles can be accommodated in separate columns within the carton. If desired, different types of articles can be accommodated in the separate columns. The blank used to form the carton can be produced in a high-speed continuous process.

According to a second exemplary embodiment of the invention, a carton is formed from an inner blank joined to an outer blank. The carton includes inner and outer breach patterns in the inner and outer blanks, respectively. The breach patterns each extend around a periphery of the carton, and allow the carton to be divided into an upper and a lower section.

According to the second exemplary embodiment, when the carton is separated into upper and lower sections, both the upper and lower sections of the carton can be used to display articles. If desired, different types of articles can be accommodated in the separate sections. The inner blank may act as a reinforcing sleeve or insert and provides high compressive strength for the carton. One or more divider panels can be formed in the inner blank. The divider panels can be used to separate the interiors of the upper and/or lower carton sections into separate compartments. The blank used to form the carton can be produced in a high-speed continuous process.

According to a third exemplary embodiment of the invention, a carton is formed from an inner blank joined to an outer blank. One or more ends of the carton may be closed by folding end flaps formed from the outer blank over an open end of the carton, and interengaging portions of the inner blank adjacent to the end flaps with the end flaps.

According to the third exemplary embodiment, the ends of the carton can be provided with a relatively tight seal. The seal closes off the open end of the carton at the perimeter of the open end. The tight seal at the carton end allows relatively fine particulate matter to be accommodated within the carton. If the inner blank is fluid-resistant, fluids may be accommodated in the carton. The blank used to form the carton can be produced in a high-speed continuous process.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.

FIG. 1 is a schematic illustration of a continuous process production line.

FIG. 2A is a plan view of a blank used to form a carton according to a first embodiment of the invention.

FIG. 2B is a plan view of an exterior ply of the blank of FIG. 2A.

FIG. 2C is a plan view of an interior ply of the blank of FIG. 2A.

FIGS. 3A and 3B illustrate erection of the first carton embodiment.

FIG. 4 illustrates the first carton embodiment.

FIG. 5 illustrates the first carton embodiment with a dispenser of the carton opened.

FIG. 6A is a plan view of a blank used to form a carton according to a second embodiment of the invention.

FIG. 6B is a plan view of an interior ply of the blank of FIG. 6A.

FIG. 7 illustrates the second carton embodiment.

FIGS. 8A and 8B illustrate opening of the second carton embodiment.

FIG. 9 is a plan view of an alternative interior ply for the second carton embodiment.

FIG. 10 illustrates an opened second carton embodiment having the alternative interior ply shown in FIG. 9.

FIG. 11 is a plan view of a blank used to form a carton according to a third embodiment of the invention.

FIGS. 12A and 12B illustrate erection of the third carton embodiment.

FIG. 13 illustrates the third carton embodiment.

DETAILED DESCRIPTION

FIG. 1 is a schematic illustration of a continuous process production line suitable for producing blanks according to the embodiments disclosed in this specification. In FIG. 1, a web of material B is repeatedly provided with one or more lines of disruption at a first disrupting station E, and a web of material A is repeatedly provided with one or more lines of disruption at a second disrupting station F. The webs of material A, B may then be laminated together at a lamination station G, and passed through a third disrupting station H. The laminated webs may be separated into individual two-ply carton blanks C at the third disrupting station H, and also, if desired, provided with additional lines of disruption. The combined webs are generally separated into the individual blanks C at the points between the repeating patterns of lines of disruption.

In general, each of the cartons discussed herein can be formed from exterior (or outer) and interior (or inner) webs, which are indicated by reference signs A and B in FIG. 1, respectively. The terms “inner” and “outer” are used in this specification to indicate the location of the respective webs (and corresponding blank plys) in a product, such as a carton, formed or erected from the finished multi-ply blanks C. The outer and inner webs A and B may each be individually provided with one or more lines of disruption prior to laminating the webs together. Unless specifically stated otherwise, the plan views of final blanks of this specification illustrate blanks having significant portions with at least two plys (i.e., “multi-ply”) formed from individual webs A and B, such as the two-ply blank C shown in FIG. 1.

For purposes of the description presented herein, the term “line of disruption” can be used to generally refer to a cut line, a score line, a tear line, a crease line, perforations, a fold line, or other disruptions formed in a blank (or a combination of at least one cut line, score line, tear line, crease line, and/or fold line, or other disruptions). A “breachable” line of disruption as disclosed in the specification refers to a line of disruption that is intended to be breached or otherwise torn during ordinary use of a carton.

FIG. 2A is a plan view of a final multi-ply blank 8 used to form a carton 150 (illustrated in FIG. 4) according to a first embodiment of the invention. The blank 8 is formed from an outer blank 5 and an inner blank 6 adhered, laminated or otherwise joined to the outer blank 5. The outer blank 5 and the inner blank 6 are illustrated separately in FIGS. 2B and 2C, respectively. The outer surface or print surface of the outer blank 5 is visible in FIG. 2A, and the inner blank 6 is joined to the opposite, interior or underside of the outer blank 5. Therefore, only portions of the inner blank 6 are visible in FIG. 2A. The final blank 8 is “multi-ply” in that the inner and outer blank plys 5 and 6 comprising the blank 8 include substantial overlapping portions.

The terms “two-ply” and “multi-ply” do not indicate that all sections of the blank 8 are formed from two or more plys. For example, the blanks 5 and 6 have slightly different perimeters or “footprints” and do not overlap at all points. In general, the outer blank 5 may be formed from a continuous web such as the web A shown in FIG. 1, and the inner blank 6 may be formed from a separate, continuous web B. The separate webs A and B may undergo processing in the production line of FIG. 1, for example, including lamination together at station G, and separation into a final two-ply blank 8 at the third disrupting station H.

Referring to FIG. 2A, the blank 8 comprises a back panel 10 foldably connected to a first end panel 20 at a first transverse fold line 21, a front panel 30 foldably connected to the first end panel 20 at a second transverse fold line 31, and a second end panel 40 foldably connected to the front panel 30 at a third transverse fold line 41. An adhesive flap 50 can be foldably connected to the second end panel 40 at a fourth transverse fold line 51. The transverse fold lines 21, 31, 41 can be formed by, for example, cuts or scores extending through both the inner and outer blanks 6, 5.

The back panel 10 is foldably connected to a top back flap 12 and a bottom back flap 14. The first end panel 20 is foldably connected to first top end flap 22 and a first bottom end flap 24. The front panel 30 is foldably connected to a front top flap 32 and a front bottom flap 34. The second end panel 40 is foldably connected to a second top end flap 42 and a second bottom end flap 44. When the carton 150 (FIG. 4) is erected, the top end flaps 12, 22, 32, 42 close a top of the carton 150, and the bottom end flaps 14, 24, 34, 44 close a bottom of the carton 150. The top end flaps 12, 22, 32, 42 extend along a first or top marginal area of the blank 8, and may be foldably connected at the first longitudinal fold line 72 that extends along the length of the blank 8. The bottom end flaps 14, 24, 34, 44 extend along a second or bottom marginal area of the blank 8, and may be foldably connected at the second longitudinal fold line 74 that also extends along the length of the blank 8. The longitudinal fold lines 72, 74 may be straight fold lines, or may be offset at one or more locations to account for, for example, blank thickness or other factors. Handle apertures 82, 84 may be formed in the flaps 22, 42, respectively.

The blank 8 includes an outer dispenser pattern 100 that in part defines a dispenser in the carton 150 (illustrated in FIG. 4). The outer dispenser pattern 100 is formed in the outer blank 5 and generally does not extend into the inner blank 6. The lines of disruption forming the dispenser pattern 100 can be formed in the outer web A, for example, before lamination to the inner web B. The outer dispenser pattern 100 includes curved lines of disruption such as cuts or breachable perforations 106 that extend across the front panel 30 and define an upper edge of an outer or exterior dispenser panel 102 of the dispenser pattern 100. Oblique breachable lines of disruption 104 and the fold lines 31, 41 define side edges of the outer dispenser panel 102, and the fold line 74 defines a bottom edge of the panel 102. The fold lines 31, 41, 74 may be perforated or otherwise weakened where they border the dispenser panel 102 to facilitate removal of the panel 102. An access cutout 108 may be formed in the outer blank 5 at the top edge of the outer dispenser pattern 100. In FIG. 2A, a small portion of the inner blank 6 is visible through the outer access cutout 108.

FIG. 2B is a plan view of the outer ply or blank 5 of the blank 8. A continuous series of outer blanks 5 may be formed from the web A in the production line illustrated in FIG. 1. Repeating patterns of lines of disruption in the web A may be formed, for example, at the disrupting station F shown in FIG. 1. At the end of the production line, each outer blank 5 is joined to a corresponding inner blank 6 to form the blanks 8. Any combination of the lines of disruption formed in the web A may be formed at the disrupting station F. For example, the outer dispenser pattern 100 may be formed at station F. The outer blank 5 includes panels 13, 23, 33, 43 that form the outer plys of the two-ply panels 10, 20, 30, 40.

FIG. 2C is a plan view of the inner ply or blank 6 of the blank 8. A continuous series of inner blanks 6 may be formed from the web B in the production line illustrated in FIG. 1. Repeating patterns of lines of disruption formed in the web B may take place, for example, at the disrupting station E shown in FIG. 1.

The inner blank 6 includes panels 15, 25, 35, 45 that form the inner plys of the two-ply panels 10, 20, 30, 40. The back panel 15 includes a transverse fold line 19 that divides the panel 15 into panels 17 and 18. The panel 17 is a first divider panel that in part separates the interior of the carton 150 (FIG. 4) into two vertical columns. A second divider panel 36 is defined in the panel 35 by a cut 38 and a fold line 37. The second divider panel 36 is arranged to join with the first divider panel 17 in the carton 150.

The inner blank 6 includes an inner dispenser pattern 120 that in part defines a dispenser in the carton 150 (illustrated in FIG. 4). The inner dispenser pattern 120 is formed in the inner blank 6 and the lines of disruption forming the dispenser pattern 120 can be formed in the outer web B, for example, before lamination to the outer web A. The dispenser pattern 120 includes an upper perimeter line of disruption such as a cut or breachable perforation 126 that extends across the panel 35 and defines an upper edge of an inner dispenser panel 122. Breachable lines of disruption 124 define side edges of the inner dispenser panel 102, and the fold line at the bottom edge of the panel 122 may be perforated, for example, to facilitate removal of the inner dispenser panel 122.

The exterior side of the inner blank 6 can be joined to the interior side of the outer blank 5 across essentially the entire overlapping surface area of the blanks 5, 6, except at the panels 17, 36. The dispenser panels 102, 122 may be adhered together so that they may be removed from the carton in a single step. Any combination of the lines of disruption formed in the web B may be formed at the disrupting station E. For example, the inner dispenser pattern 120, the fold lines 19, 37 and the cut 39 may be formed at station E. Final processing of the webs, including separation of the combined webs A and B into blanks 8, occurs at station H. The transverse fold lines 21, 31, 41, 51 can be formed simultaneously in the inner and outer blanks 5, 6 at station H.

An exemplary method of erection of the carton 150 from the blank 8 will now be discussed with reference to FIGS. 2A-3B. The interior or underside of the adhesive flap 50 is adhered to the exterior of the panel 10 of the outer blank 5, and the first and second divider panels 17, 36 are adhered together. The blank 8 can now be opened up into a generally tubular form as shown in FIGS. 3A and 3B. FIG. 3A is a top perspective view and FIG. 3B is a front view of the generally tubular form. The divider panels 17, 36 fold away from the remainder of the inner blank 6, extend across an interior volume of the tubular form, and divide the tubular form into two vertical columns.

Referring to FIGS. 2A and 4, the bottom end of the tubular blank form is closed by folding the flaps 14, 34 inwardly, folding the flap 24 over the flaps 14, 34, and then folding the flap 44 over the flap 24. The bottom end flaps 14, 24, 34, 44 can be adhered together by adhesives such as, for example, glue. Similarly, the top flaps 12, 32 are folded inwardly, the top flap 42 is folded over the flaps 12, 32, and the top flap 22 is then folded over the flaps 12, 32, 42. The top end flaps 12, 22, 32, 42 can be adhered together by, for example, adhesive.

FIG. 4 illustrates the erected carton 150 with its top and bottom ends closed. Product, such as particulate matter, discrete articles, or other items, such as pouches, may be loaded into the carton 150 at any time before closing the top and bottom ends of the carton.

FIG. 5 illustrates the carton after opening at the outer and inner dispenser patterns 100, 120. Referring to FIGS. 4 and 5, the carton 150 can be opened by accessing the upper edge of the outer dispenser panel 102 at the cutout 108, and pulling the outer dispenser panel 102 so that the outer blank 5 tears along the lines of disruption 104, 106 in the outer blank 5. Referring to FIG. 2C, the inner dispenser panel 122 is adhered to the outer dispenser panel 102, and pulling the outer dispenser panel 102 causes the inner blank 6 to tear along the lines of disruption 124, 126. Removal of the inner and outer panels 102, 122 leaves a dispenser opening 140 in the front panel 30.

As shown in FIG. 5, and also in FIG. 3A, the joined panels 17, 36 separate the carton 150 into two vertically extending columns 141, 142. Articles can therefore be separated into two separate columns in the carton. Articles such as relatively flat pouches, for example, can be stacked in two separate columns and individually dispensed from the dispenser opening 140. If desired, a first type of article can be stored in the first column 141 and a second type of article can be stored in the second column 142. The two-ply blanks 8 used to form the carton 150 can be formed, for example, in a high-speed continuous process.

FIG. 6A is a plan view of a final multi-ply blank 208 used to form a carton 350 (illustrated in FIG. 7) according to a second embodiment of the invention. The blank 208 is formed from an outer blank 205 and an inner blank 206 adhered, laminated or otherwise joined to the outer blank 205. The outer surface or print surface of the outer blank 205 is visible in FIG. 6A, and the inner blank 206 is joined to the opposite, interior or underside of the outer blank 205. The inner blank 206 is not visible in FIG. 6A. Because the inner blank 206 is not visible in FIG. 6A, the lead line from reference number 206 is indicated by dashed lines.

The final blank 208 is “multi-ply” in that the inner and outer blank plys 205 and 206 comprising the blank 208 include substantial overlapping portions. The terms “two-ply” and “multi-ply” do not indicate that all sections of the blank 208 are formed from two or more plys. For example, the blanks 205 and 206 have slightly different perimeters or “footprints” and do not overlap at all points. In general, the outer blank 205 may be formed from a continuous web such as the web A shown in FIG. 1, and the inner blank 206 may be formed from a separate, continuous web B. The webs A and B may undergo processing in the production line, including lamination together at station G, and separation into final two-ply blanks 208 at the third disrupting station H.

Referring to FIG. 6A, the blank 208 comprises a first end panel 210 foldably connected to a first side panel 220 at a first transverse fold line 221, a second end panel 230 foldably connected to the first side panel 220 at a second transverse fold line 231, and a second side panel 240 foldably connected to the second end panel 230 at a third transverse fold line 241. An adhesive flap 250 can be foldably connected to the second side panel 240 at a fourth transverse fold line 251. The transverse fold lines 221, 231, 241 can be formed by, for example, cuts or scores extending through both the inner and outer blanks 206, 205.

The first end panel 210 is foldably connected to a top first end flap 212 and a bottom first end flap 214. The first side panel 220 is foldably connected to first top side flap 222 and a first bottom side flap 224. The second end panel 230 is foldably connected to a second end top flap 232 and a second end bottom flap 234. The second side panel 240 is foldably connected to a second top side flap 242 and a second bottom side flap 244. When the carton 350 (FIG. 7) is erected, the top end flaps 212, 222, 232, 242 close a top of the carton 350, and the bottom end flaps 214, 224, 234, 244 close a bottom of the carton 350. The top end flaps 212, 222, 232, 242 extend along a first or top marginal area of the blank 208, and may be foldably connected at the first longitudinal fold line 272 that extends along the length of the blank 208. The bottom end flaps 214, 224, 234, 244 extend along a second or bottom marginal area of the blank 208, and may be foldably connected at the second longitudinal fold line 274 that also extends along the length of the blank 208. The bottom end flaps 214, 224, 234, 244 can be of the interlocking type, with scores formed 226, 246 formed in the end flaps 224, 244 to facilitate manipulation of the bottom flaps and closing of the bottom of the carton. The longitudinal fold lines 272, 274 may be straight fold lines, or may be offset at one or more locations to account for, for example, blank thickness or other factors.

The blank 208 includes an outer breach pattern 300 that in part allows the carton 350 (illustrated in FIG. 7) to be divided into two separate sections. The outer breach pattern 300 is formed in the outer blank 205 and generally does not extend into the inner blank 206. The lines of disruption forming the outer breach pattern 300 can be formed in the outer web A, for example, before lamination to the inner web B. The outer breach pattern 300 includes longitudinal lines of disruption such as cuts or breachable perforations 302, 308, and oblique lines of disruption 304, 306. Spaced upper and lower lines of disruption 310, 312 define a tear strip 314 in the second end panel 230. The outer breach pattern 300 extends at least substantially along an entire length of the blank 208.

FIG. 6B is a plan view of the inner ply or blank 206 of the blank 208. A continuous series of inner blanks 206 may be formed from the web B in the production line illustrated in FIG. 1. Repeating patterns of lines of disruption formed in the web B may take place, for example, at the disrupting station E shown in FIG. 1.

The height of the inner blank 206 may be selected so that it is substantially equal to or slightly smaller than the distance between the fold lines 272, 274 in the outer blank 205. The inner blank 206 is adhered to the interior surface of the outer blank 205 generally between the fold lines 272, 274. The inner blank 206 includes panels 213, 223, 233, 243 that form the inner ply of the two-ply panels 210, 220, 230, 240.

The inner blank 206 includes an inner breach pattern 320 that in part allows the carton 350 (illustrated in FIG. 7) to be divided into two separate sections. The inner breach pattern 320 is formed in the inner blank 205 and generally does not extend into the outer blank 205. The lines of disruption forming the breach pattern 320 can be formed in the inner web B, for example, before lamination to the outer web A. The inner breach pattern 320 includes longitudinal lines of disruption such as cuts or breachable perforations 322, 328, and oblique lines of disruption 324, 326. Spaced upper and lower lines of disruption 330, 332 define a tear strip 334 in the panel 233. In the erected carton 350, the lines 322, 324, 326, 328 may be spaced a small distance below their corresponding lines 302, 304, 306, 308 in the outer blank 205. The tear strip 334 in the inner blank 206 may be adhered to the tear strip 314 in the outer blank 205 so that they may be removed in a single step.

The exterior side of the inner blank 206 can be joined to the interior side of the outer blank 205 across essentially any or all of the entire overlapping surface area of the blanks 205, 206, except in the vicinity of the breach patterns 300, 320. Any combination of the lines of disruption formed in the web B may be formed at the disrupting station E. For example, the inner breach pattern 320 may be formed at station E. Final processing of the webs, including separation of the combined webs A and B into blanks 208, occurs at station H.

The carton 350 can be erected by adhering the exterior of the adhesive flap 250 to the interior suface of the first end flap 210. The blank 208 can now be opened up into a generally tubular form. The bottom end flaps 214, 224, 234, 244 are interlocked to close the bottom of the tubular form. The top end flaps 212, 222, 232, 242 are adhered together to close the top end.

FIG. 7 illustrates the erected carton 350 with its top and bottom ends closed. Product, such as particulate matter, discrete articles, or other items or goods, may be packed into the carton 350 at any time before closing the top and/or bottom ends of the carton 350. The outer breach pattern 300 extends around the entire perimeter of the carton 350. The inner breach pattern 320, which is not visible in FIG. 7, also extends around the carton perimeter and is adjacent to the outer breach pattern 300. Each of the breachable lines of disruption 322, 324, 326, 328 in the inner blank 206 may be spaced a small distance below a corresponding line of disruption 302, 304, 306, 308, respectively, in the outer blank 205.

The carton 350 may be separated into two sections at the breach patterns 300, 320. Referring to FIG. 8A, the overlapping tear strips 314 and 334 (FIG. 6B) may be torn from the carton 350 to initiate opening. The tear strips 314, 334 may be adhered together so that they can be removed in a single step. Referring to FIG. 8B, a first or upper section 360 of the carton 350, located above the breach patterns 300, 320, can be pulled from a second or bottom section 370. FIG. 8B illustrates the portions of the inner blank 206 that line and reinforce the carton 350.

As shown in FIG. 8B, two separate sections 360, 370 are formed from the carton 350, and each carton section can be used, for example, to display articles or other product accommodated in the carton 350. After display, the upper section 360 can be used as a removable lid for the lower section 370. Product can therefore be displayed in one or both of the sections 360, 370 and then stored in the carton 350 by replacing the upper section 360 on the lower section 370. The carton 350 may have a relatively high strength in vertical axial compression due to the inner blank 206, which acts as an inner liner or sleeve for the carton.

FIG. 9 is a plan view of an alternative inner blank 206′ that can be used with the outer blank 205 illustrated in FIG. 6A. The inner blank 206′ is generally similar to the inner blank 206 shown in FIG. 6B, and may be adhered, laminated or otherwise joined to the outer blank 205 as discussed above. The inner blank 206′ also includes a divider panel 380 that can be used to divide the interior of a lower carton section into two compartments. The divider panel 380 may be defined by a longitudinal line of disruption 390 and three transverse lines of disruption, 382, 384, 388. The transverse lines 384, 382 may be fold lines, and the lines 390, 388 may be breachable lines such as cuts, perforations or tear lines. An adhesive flap 386 is defined between the fold lines 384, 382. The blanks 206′, 205 may be adhered together in areas of the blanks outside of the vicinity of the breach patterns 300, 320 and the panels 380, 386.

FIG. 10 illustrates a lower carton section 370′ resulting from forming a carton from the blanks 206′, 205 and separating the carton at the inner and outer breach patterns. The inner and outer blanks 206′, 205 can be formed into a carton in a manner similar to forming the carton 350. The lower carton section 370′ is similar to the lower section 370 (FIG. 8B). In the lower section 370′, however, the divider panel 380 is folded out from a remainder of the inner blank 206′ at the fold line 384 and extends across the interior of the lower section 370′. The adhesive flap 386 (FIG. 9) is adhered to the opposite side of the section 370′. The divider panel 380 divides the interior of the lower carton section 370′ into two separate compartments.

In FIG. 9, the divider panel 380 is illustrated at one end of the inner blank 206′. In general, a divider panel can be defined anywhere in the inner blank 206, including in the opposite end of the blank 206′, or above the breach pattern 320. A divider panel formed above the breach pattern 320 can be used to construct a divider in an upper carton section. Multiple divider panels can be defined in the inner blank 206′.

FIG. 11 is a plan view of a final multi-ply blank 408 used to form a carton 550 (illustrated in FIG. 13) according to a third embodiment of the invention. The blank 408 is formed from an outer blank 405 and an inner blank 406 adhered, laminated or otherwise joined to the outer blank 405. The outer surface or print surface of the outer blank 405 is visible in FIG. 11, and the inner blank 406 is joined to the opposite, interior or underside of the outer blank 405. A portion of the inner blank 406 is visible at the leftmost side of the blank 408 and at the bottom of the blank 408 in FIG. 11. In general, the outer blank 405 may be formed from a continuous web such as the web A shown in FIG. 1, and the inner blank 406 may be formed from a separate, continuous web B. The webs A and B may undergo processing in the production line illustrated in FIG. 1, including lamination together at station G, and separation into a final two-ply blank 408 at the third disrupting station H.

Referring to FIG. 11, the blank 408 comprises a first end panel 410 foldably connected to a first side panel 420 at a first transverse fold line 421, a second end panel 430 foldably connected to the first side panel 420 at a second transverse fold line 431, and a second side panel 440 foldably connected to the second end panel 430 at a third transverse fold line 441. An adhesive flap 450 can be foldably connected to the first end panel 410 at a fourth transverse fold line 451. The transverse fold lines 421, 431, 441, 451 can be formed by, for example, cuts or scores extending through both the inner and outer blanks 406, 405.

The first end panel 410 is foldably connected to a top first end flap 412 and a bottom first end flap 414. The first side panel 420 is foldably connected to first top side flap 422 and a first bottom side flap 424. The second end panel 430 is foldably connected to a second end top flap 432 and a second end bottom flap 434. The second side panel 440 is foldably connected to a second top side flap 442 and a second bottom side flap 444. The top end flaps 412, 422, 432, 442 extend along a first or top marginal area of the blank 408, and may be foldably connected at a first longitudinal fold line 462 that extends along the length of the blank 408. The bottom flaps 414, 424, 434, 444 extend along a second or bottom marginal area of the blank 408, and may be foldably connected at a second longitudinal fold line 464 that also extends along the length of the blank 408. The longitudinal fold lines 462, 464 can be formed by, for example, cuts or scores extending through both the inner and outer blanks 406, 405.

The inner ply or blank 406 of the blank 408 may be a relatively thin, pliable material. If the material of the blank 406 is sufficiently thin and/or pliable, the blank 406 can be formed as a continuous sheet substantially free of scores, folds, etc. For thicker and/or more rigid inner blank materials, scores, fold lines and/or other lines of disruption may be formed in the inner blank 406 in order to facilitate folding of the inner blank 406 when erecting the carton 550. For example, fold lines may be formed in the inner blank 406 that coincide with one or more of the fold lines 421, 431, 441, 451, 462, 464 in the outer blank 405. Additional fold lines may be formed in the inner blank 406 in the vicinity of one or more of the end flaps 412, 422, 432, 442, 414, 424, 434, 444, as discussed in further detail below.

An exemplary method of erection of the blank 408 into the carton 550 will now be discussed with reference to FIGS. 12A and 12B. According to one aspect of the present embodiment, one or both ends of the carton 550 can be provided with relatively tight seals. Referring also to FIG. 11, the carton 550 can be erected by adhering the exterior of the adhesive flap 550 and the end of the inner blank 406 adjacent to the adhesive flap 550 to the interior side of the second side panel 440. The blank 208 can now be opened up into a generally tubular form. The inner blank 406 can be provided with vertical fold lines, such as scores, for example, to facilitate bringing the blank 408 into a closed tubular form. Both ends of the tubular form can now be closed with a relatively tight seal. The bottom of the carton is illustrated as closed in FIG. 12A. The bottom end may be closed in a manner substantially identical to the top end. Closing of the top end is discussed below.

The inner blank 406 is adhered to the top end flap 422 and to the top end flap 442 in generally trapezoidal areas, as shown in FIG. 12A. The inner blank 406 is not adhered to the flap 422 at the corner sections of the flap 422 outside of folded portions 502, 504 of the inner blank 406. Similarly, the flap 442 is not adhered to the inner blank 406 in the corner sections of the flap 442 outside of folded portions 506, 508 of the inner blank 406. The inner blank 406 can be provided with lines of disruption, such as fold lines, at the locations 502, 504, 506, 508 to facilitate folding at these locations. The free upper edges of the inner blank 406 to the left and right in FIG. 12A are folded inwardly in the directions of the arrows so that the inner blank 406 assumes the configuration shown in FIG. 12A. The top end flaps 412, 432 are then folded over the inner blank 406 in the directions of the curved arrows, as shown in FIG. 12A. Alternatively, the inner surfaces of the end flaps 412, 432 can be adhered to the exterior of the inner blank 406, and the inner blank 406 can be folded inwardly simultaneously with folding of the flaps 412, 432. The triangular-shaped overlapped sections of the inner blank 406 may be adhered together.

Referring to FIG. 12B, the top end flap 442 is folded over the flaps 412, 432. If desired, the flap 442 and the portion of the inner blank 406 adhered thereto can be adhered to the upper surface of the end flaps 412, 432. The top end flap 422 is then folded over the flap 442. The flap 422 and, if desired, the portion of the inner blank 406 adhered to the flap 422 are adhered to the upper surface of the flap 442 to complete closure of the top end of the carton.

FIG. 13 illustrates the carton 550 with both ends closed. According to the method of erection discussed above, a relatively tight seal may be provided for one or both of the carton ends. Referring to FIG. 12A, the portion of the inner blank 406 beneath the flaps 412, 432 extends inwardly toward the center of the open carton end. Referring to FIG. 12B, the small open rectangular area in FIG. 12A is closed by the covering flap 442 and then by the flap 422, as shown in FIG. 13. The tight seal allows the carton 550 to be used to store, for example, fine particulate matter, such as powdered sugar and other particulate products. If the inner blank 406 is made from a leak-resistant material, such as foil, for example, the carton 550 can be used to store liquids.

In accordance with the exemplary embodiments, the cartons may be constructed of paperboard, for example. The paperboard webs used to form the blank may be thicker and heavier than ordinary paper. The blanks, and thus the cartons, 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. For example, the blanks may be formed from coated solid unbleached sulfate (SUS) board. The blanks can also be laminated to or coated with one or more web-like materials at selected panels or panel sections.

One or more panels of the blanks discussed above can be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product, advertising, and other information or images. The blanks may also be coated to protect any information printed on the blank. The blanks may be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.

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. 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.

The above embodiments may be 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 carton panels in place.

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 the present specification, a “panel” need not be flat or otherwise planar. A “panel” can, for example, comprise a plurality of interconnected generally flat or planar sections.

The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected 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

1. A carton formed at least from an inner blank and an outer blank, comprising:

a multi-ply front panel formed at least from the inner blank and the outer blank;

a first end panel;

a multi-ply back panel formed at least from the inner blank and the outer blank;

a second end panel;

first divider panel formed at least from the inner blank, the first divider panel extending from the front panel through an interior of the carton and at least partially separating the carton interior into two sections.

2. The carton of claim 1, wherein the first divider panel is folded away from the front panel.

3. The carton of claim 2, further comprising a second divider panel formed at least from the inner blank, the second divider panel extending from the back panel through an interior of the carton and at least partially separating the carton interior into the two sections.

4. The carton of claim 3, wherein the first and second divider panels are joined together in the carton interior.

5. The carton of claim 3, wherein the two sections are vertical columns.

6. The carton of claim 3, further comprising at least one dispenser panel defined in the front panel.

7. The carton of claim 6, wherein the at least one dispenser panel comprises a first dispenser panel defined in the outer blank and a second dispenser panel defined in the inner blank, the first and second dispenser panels being adhered together.

8. The carton of claim 1, further comprising a plurality of top end flaps at least partially closing a top end of the carton, and a plurality of bottom end flaps at least partially closing a bottom end of the carton.

9. A multi-ply carton blank formed at least from an inner blank and an outer blank, comprising:

a multi-ply front panel formed at least from the inner blank and the outer blank;

a first end panel;

a multi-ply back panel formed at least from the inner blank and the outer blank;

a second end panel;

a first divider panel formed at least from the inner blank, the first divider panel being defined by at least one line of disruption in the inner blank and the first divider panel being foldable away from the outer blank.

10. The multi-ply carton blank of claim 9, further comprising a second divider panel formed at least from the inner blank, the second divider panel being defined by at least one line of disruption in the inner blank and the second divider panel being foldable away from the outer blank.

11. The multi-ply carton blank of claim 10, further comprising at least one dispenser pattern formed in the multi-ply carton blank, the at least one dispenser pattern defining at least one dispenser panel.

12. The multi-ply carton blank of claim 9, further comprising a plurality of top end flaps disposed along a first marginal area of the multi-ply carton blank and a plurality of bottom end flaps disposed along a second marginal area of the multi-ply carton blank.

13. A carton formed at least from an inner blank and an outer blank, comprising:

a multi-ply first panel formed at least from the inner blank and the outer blank;

a multi-ply second panel formed at least from the inner blank and the outer blank;

a multi-ply third panel formed at least from the inner blank and the outer blank;

a multi-ply fourth panel formed at least from the inner blank and the outer blank, wherein the first, second, third and fourth panels define a generally tubular form;

at least one flap at least partially closing a top end of the carton;

at least one bottom flap at least partially closing a bottom end of the carton;

a first divider panel formed from the inner blank, the first divider panel extending from the first panel through an interior of the carton; and

a second divider panel formed from the inner blank, the second divider panel extending from the third panel through an interior of the carton, wherein

the first and second divider panels are adhered to one another in the carton interior, and wherein the first and second divider panels divide the carton interior into two vertical columns.

14. The carton of claim 13, further comprising at least one dispenser panel adjacent to the at least one bottom flap.

15. A carton formed at least from an inner blank and an outer blank, comprising:

a multi-ply first side panel formed at least from the inner blank and the outer blank;

a first end panel;

a multi-ply second side panel formed at least from the inner blank and the outer blank;

a second end panel;

a first breach pattern extending around a perimeter of the outer blank, through the first side panel, the first end panel, the second side panel, and the second end panel; and

a second breach pattern extending around a perimeter of the inner blank, through the first side panel, the first end panel, the second side panel, and the second end panel, wherein

the first breach pattern is adjacent to the second breach pattern, the first and second breach patterns allowing the carton to be divided into a first section and a second section.

16. The carton of claim 15, wherein the first breach pattern defines a tear strip.

17. The carton of claim 15, wherein the first breach pattern is vertically offset from the second breach pattern.

18. The carton of claim 15, further comprising a plurality of top end flaps at least partially closing a top end of the carton, and a plurality of bottom end flaps at least partially closing a bottom end of the carton.

19. The carton of claim 15, further comprising a divider panel formed from the inner blank, the divider panel being folded away from the first side panel and adhered to the second side panel.

20. A multi-ply carton blank formed at least from an inner blank and an outer blank, comprising:

a multi-ply first side panel formed at least from the inner blank and the outer blank;

a multi-ply first end panel formed at least from the inner blank and the outer blank;

a multi-ply second side panel formed at least from the inner blank and the outer blank;

a multi-ply second end panel formed at least from the inner blank and the outer blank;

a first breach pattern extending along a length of the outer blank, through the first side panel, the first end panel, the second side panel, and the second end panel; and

a second breach pattern extending along a length of the inner blank, wherein the first breach pattern is adjacent to the second breach pattern.

21. The multi-ply carton blank of claim 20, wherein the first breach pattern defines a tear strip.

22. The multi-ply carton blank of claim 20, wherein the first breach pattern is offset from the second breach pattern.

23. The multi-ply carton blank of claim 20, further comprising a plurality of top end flaps disposed along a first marginal area of the multi-ply carton blank and a plurality of bottom end flaps disposed along a second marginal area of the multi-ply carton blank.

24. A carton formed at least from an inner blank and an outer blank, comprising:

a multi-ply first panel formed at least from the inner blank and the outer blank, a first end flap extending from the first panel and at least partially closing a first end of the carton, a first portion of the inner blank being adjacent to and below the first end flap;

a multi-ply second panel formed at least from the inner blank and the outer blank, a second end flap extending from the second panel and at least partially closing the first end of the carton, a second portion of the inner blank being adjacent to and below the second end flap;

a multi-ply third panel formed at least from the inner blank and the outer blank, a third end flap extending from the third panel and at least partially closing the first end of the carton, a third portion of the inner blank being adjacent to and below the third end flap; and

a multi-ply fourth panel formed at least from the inner blank and the outer blank, a fourth end flap extending from the fourth panel and at least partially closing the first end of the carton, a fourth portion of the inner blank being adjacent to and below the fourth end flap;

wherein the first, second, third and fourth panels define a generally tubular form, and wherein

the fourth end flap and the fourth portion of the inner blank are above the first and third end flaps.

25. The carton of claim 24, wherein the second end flap and the second portion of the inner blank are above the fourth end flap.

26. The carton of claim 25, wherein the second portion of the inner blank is adhered to the second end flap.

27. The carton of claim 26, wherein the fourth portion of the inner blank is adhered to the fourth end flap.

28. The carton of claim 27, wherein the second portion of the inner blank is folded upon itself under the second end flap, and the fourth portion of the inner blank is folded upon itself under the fourth end flap.

29. The carton of claim 28, wherein the second end flap is adhered to the fourth end flap.

30. A method of closing an end of a carton formed at least from an inner blank and an outer blank, comprising:

providing a carton comprising: a multi-ply first panel formed at least from the inner blank and the outer blank, a first end flap extending from the first panel; a multi-ply second panel formed at least from the inner blank and the outer blank, a second end flap extending from the second panel, a second portion of the inner blank being adhered to the second end flap; a multi-ply third panel formed at least from the inner blank and the outer blank, a third end flap extending from the third panel; a multi-ply fourth panel formed at least from the inner blank and the outer blank, a fourth end flap extending from the fourth panel, a fourth portion of the inner blank being adhered to the fourth end flap, wherein the first, second, third and fourth panels define a generally tubular form;

folding a first portion of the inner blank over a first open end of the carton;

folding a third portion of the inner blank over the first end of the carton;

folding the first end flap over the first portion of the inner blank;

folding the third end flap over the third portion of the inner blank;

after folding the first and third end flaps, folding the second end flap over the first and third end flaps; and

folding the fourth end flap over the first end of the carton.

31. The method of claim 30, wherein folding the fourth end flap occurs after folding the second end flap.

32. A method of making a carton blank, comprising:

advancing a first continuous web through a production line;

advancing a second continuous web through the production line;

forming a series of first patterns of disruption in the first web at a first disrupting station;

forming a series of second patterns of disruption in the second web at a second disrupting station;

joining the first web to the second web; and

cutting the joined, continuous first and second webs into multi-ply carton blanks at locations transverse to a direction of advancement of the first and second webs, the cut locations being disposed between adjacent first patterns of disruption and between adjacent second patterns of disruption.

33. The method of claim 32, further comprising simultaneously forming at least one line of disruption through both the first and second webs at a location between where the first and second webs are cut into multi-ply carton blanks.

34. The method of claim 32, wherein the first web moves continuously through the first disrupting station while the second web moves continuously through the second disrupting station.

35. The method of claim 32, wherein forming the series of second patterns of disruption in the second web comprises forming at least one divider panel in the second web.

36. The method of claim 35, wherein forming the series of first patterns of disruption in the first web comprises forming at least one dispenser pattern in the first web.

37. The method of claim 32, wherein forming the series of first patterns of disruption in the first web comprises forming a breach pattern in the first web, the breach pattern extending along substantially the entire distance between consecutive locations where the first and second webs are cut into multi-ply carton blanks.

38. The method of claim 37, wherein forming the series of second patterns of disruption in the second web comprises forming at least one divider panel in the second web.