RECLOSABLE CARTON

Abstract

A reclosable carton (11) is provided which may contain objects nearly the size of the carton that can be readily dispensed and where the carton can be conveniently re-closed by a user. A specific pattern of tear lines on the top (17) and front (19) panels allows easy opening and re-closing and allows for a reduction in packaging material usage to save production costs. The reclosable carton design reduces the risk of tearing other areas of the carton and maintains its integrity when it is opened by a user.

Description

The invention relates to a carton and specifically to one that is easily opened and re-closed by a consumer.

Reclosable cartons with front and top panels where each panel has 2 fixed sections and a single openable section that spans a fold line are known. U.S. Pat. No. 4,738,365 issued on Apr. 19, 1988 to Prater; U.S. Pat. No. 5,076,439 issued on Dec. 31, 1991 to Kuchenbecker; U.S. Pat. No. 5,085,323 issued on Feb. 4, 1992 to Kuchenbecker et al.; EP Patent No. 697340 issued on Oct. 28, 1998 to Inger; and GB Patent No. 1451138 to Carling O'Keefe Limited all describe examples of such cartons. Other related prior art disclosures include Brazil Patent No. MU 8400469-0 U issued to Filho and published on Oct. 25, 2005; and Brazil Patent No. PI 0205132-0 A issued to Bohlen et al. and published on Nov. 25, 2002.

Surprisingly, it was discovered that a reclosable carton could be designed with a top panel having four separated fixed sections and a front panel with two fixed sections. These fixed sections are arranged in a specific relationship that allows easy opening and re-closing and maximizes access to the contents of the carton such as e.g. a soap bar or other items that are approximately as large as the container. Moreover it was unexpectedly discovered that end flap overlap could be minimized to speed carton blank production and conserve materials without the danger of end flap damage when the carton was opened, thus maintaining carton integrity.

According to one aspect of the present invention there is provided a reclosable carton that is formed by folding a cut or stamped blank that includes a front panel and a top panel connected at a fold line where the front and top panels also have two spaced apart tear lines. The spaced apart tear lines define a reclosable portion extending across the fold line separating the front and top panels. The front reclosable panel has a finger tab connected at a fold line. The blank also includes a back panel connected both to a top panel at a fold line and to a bottom panel at a fold line. A glue panel is also connected to the bottom panel at a fold line, and further includes a locking slit flap connected to the glue panel at a fold line. Each of the front, top, back and bottom panels have opposite end flaps connected at fold lines to each of the front, top, back and bottom panels and each end flap has two spaced apart lateral edges and an axial edge. During assembly of the reclosable carton, the glue panel is attached to a front fixed section with adhesive, and the reclosable portion, finger tab and locking slit flap are kept free of adhesive.

In further detail, and with each of the ensuing features being preferred, each of the tear lines has a first end and a second end, and each of the tear lines intersect the fold line between the top and front panels at a point at least 3 mm from each of the adjacent top panel end flap lateral edges at the first end. Each of the tear lines intersect the fold line between the top panel end flap and the top panel at a distance of at least 3 mm from the nearest end flap lateral edge. Each of the tear lines extend partially along each of the top panel end flap fold lines, wherein each of the tear lines is spaced at least 3 mm from each of the lateral edges of the adjacent top panel end flaps. Furthermore, each of the tear lines intersects the fold line between the top and front panels at a point at least 3 mm from the adjacent top panel end flap lateral edge. Each of the tear lines also intersects the finger tab fold line and each of the spaced apart second ends of the tear lines is positioned at the outermost edge of the finger tab.

In addition the glue panel defines a locking slit, and the front reclosable section has a tuck flap connected to the finger tab at a fold line. The tuck flap is positioned to engage the locking slit when the finger tab is flexed in order to close the reclosable section of the carton after its initial opening along the tear lines.

Preferred embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, wherein like figures represent like features, in which:

FIG. 1 is a top planar view of a preferred embodiment of a sleeve blank shown in FIGS. 2-5 in assembled form;

FIG. 1A is a detailed portion of FIG. 1;

FIG. 2 is a perspective view of the assembled carton from the blank shown in FIG. 1;

FIG. 3A is a front elevational view of the assembled carton;

FIG. 3B is a rear elevational view of the assembled carton;

FIG. 3C is a side elevational view of the assembled carton.;

FIG. 4A is a perspective view of the assembled carton illustrating the first step in opening the carton when the tab is pulled from the front panel;

FIG. 4B is a perspective view of the assembled carton illustrating the second step in opening the carton when the openable portion 26 is separated from the front panel;

FIG. 4C is a perspective view of the assembled carton illustrating the third step in opening the carton when the openable portion is partially separated from the top panel;

FIG. 4D is a perspective view of the assembled carton illustrating a fourth step in opening the carton when the openable portion is completely separated from the top panel;

FIG. 5A is a perspective view of the assembled carton illustrating the first step in closing the carton when the when tab 50 is flexed upward while pulling openable portions 22 and 26 towards their original closed positions;

FIG. 5B is a perspective view of the assembled carton illustrating the second step in closing the carton when the reclosable portion 22 has been restored to its original closed position;

FIG. 5C is a perspective view of the assembled carton illustrating the third step in closing the carton when tab 50 is flexed further upward to align tuck flap 42 with locking slit 44; and

FIG. 5D is a perspective view of the assembled carton illustrating a fourth step in closing the carton when tuck flap 42 has been inserted in locking slit 44.

Referring to FIGS. 1-3, a carton blank 10 is stamped or cut from paperboard, coated paperboard that is coated with a natural or synthetic waterproof or water resistant material such as polyethylene or other synthetic or natural polymers, wax, other suitable materials or blends thereof. The blank may also be composed of other foldable or hingeable plastic or other suitable materials. If paperboard or coated paperboard is used, the basis weight is preferably between 200 and 450 grams per square meter (“gsm”) and more preferably between 250 and 350 gsm. If coated paperboard is used as described above, the coating weight is preferably between 10 and 50 gsm and more preferably between 12 and 25 gsm.

The carton blank is folded to form a reclosable carton 11. The blank 10 includes a front panel 19 and top panel 17 connected at fold line 28 having two spaced apart tear lines 58, 121, 122 and 126. Front panel 19 contains two fixed sections 25 and reclosable section 26. Top panel 17 contains two fixed sections 23, two fixed sections 27 and reclosable section 22. The tear lines define reclosable portions 22 and 26 extending across fold line 28. The front reclosable panel 26 has finger tab 50 connected at fold line 49. The back panel 18 is connected to the top panel 17 at fold line 24. The back panel is also connected to bottom panel 14 at fold line 20 and glue panel 12 is connected to bottom panel 14 at fold line 16. Glue panel 12 has a locking slit flap 45 connected at fold line 46. The front, top, back and bottom panels have opposite end flaps 38, 36, 34, 30 respectively connected at fold lines 37, 35, 33, 32 to each of the front, top, back and bottom panels respectively.

Each end flap has two spaced apart lateral edges and a single axial edge. More specifically, end flap 38 has lateral edges 100 and 104 and axial edge 102, end flap 36 has lateral edges 106 and 110 and axial edge 108, end flap 34 has lateral edges 112 and 116 and axial edge 114, and end flap 30 has lateral edges 118 and 130 and axial edge 120. Upon assembly of the carton from the blank, the glue panel 12 is attached to front fixed sections 25 with a suitable adhesive or optionally other equivalent attachment means such as interlocking tabs etc. The reclosable portions 22, 26, finger tab 50 and locking slit flap 45 are kept free of adhesive during folding and assembly of the carton to allow easy opening.

Each of the tear lines 58, 121, 122 and 126 has a first end 134 adjacent to tear line 122 and a second end 132 adjacent to tear line 126, wherein each of said tear lines intersects the fold line 24 at a point at least 3 mm from each of top panel end flap lateral edges 110 at the first end 134, and wherein each of said tear lines intersects fold lines 35 at a distance of at least 3 mm from axial edge 110. Each of said tear lines 58 extends partially along each of the fold lines 35. Each of said tear lines is also spaced at least 3 mm from each of the lateral edges 106 of top panel end flaps 36, and each of said tear lines intersects the fold line 28 between the top and front panels at a point at least 3 mm from top panel end flap lateral edge 106. In addition, each of said tear lines intersects the fold line 49 and each of the spaced apart second ends 132 of the tear lines is positioned at edge 200.

The glue panel 12 defines a locking slit 44, and the front reclosable section 26 has a tuck flap 42 connected to the finger tab 50 at a fold line 49, wherein the tuck flap is positioned to engage the locking slit 44 when the finger tab 50 is flexed when the carton is re-closed. In one preferred embodiment, the top panel end flap axial edge 108 and bottom panel axial edge 120 do not overlap in the assembled carton. Preferably the top panel end flap axial edge 108 and bottom panel axial edge 120 overlap by no more than 1 mm in the assembled carton as illustrated in FIGS. 3A and 3B.

In a preferred embodiment, the top panel 17 of the carton further includes (a) a pair of opposite fixed triangular segments 23 having legs 51, 51′ of respective lengths d5, d5′ extending along fold line 28 and adjacent legs 52, 52′ of respective lengths d3, d3′ extending along fold line 35; (b) a pair of opposite fixed triangular segments 27 each having leg 54, 54′ of respective lengths d1, d1′ extending along fold line 24 and adjacent legs 56, 56′ of respective lengths d3, d3′ extending along fold line 35; wherein fold line 28 has a length of d6, fold line 35 has a length of d4 and fold line 24 has a length of d2; and wherein:

(d1+d1′)/d2=A where A is in the range of 0.18 to 0.30;

(d3+d3′)/d4=B where B is in the range of 0.35 to 0.55; and

(d5+d5′)/d6=C where C is in the range of 0.15 to 0.26.

Preferably the tear line ends 132, 134 and points where the lines cross fold line 28 are disposed symmetrically between the end flaps, and opposed pair of triangle legs 51, 51′ are equal to each other. Similarly opposed pairs of triangle legs 52, 52′; 54, 54′ and 56, 56′ are also equal to each other as illustrated in FIGS. 1-3 so as to preferably create a symmetrical opened package. However the present invention also envisages an asymmetrical arrangement where one or more pairs of opposed triangle legs are not equal (i.e. 51 is not equal to 51′ etc.) provided the minimum 3 mm distance of a tear line from the nearest adjacent end flap lateral edge is maintained.

As illustrated in FIGS. 4A to D, the carton is opened by a user grasping finger tab 50 at its edge 200 and pulling to separate the tab from fixed sections 25 along the portion of tear lines 126 adjacent to edge 200 (FIG. 4A). Next reclosable section 26 is separated from fixed sections 25 along the remaining portion of tear lines 126 as the tab is pulled further upwards (FIG. 4B). Next reclosable section 22 is separated from fixed sections 23 along tear lines 121 and partially separated from top panel end flap 36 along a portion of tear line 58 as the tab is pulled further (FIG. 4C). Finally reclosable section 22 is fully separated from top panel end flap 36 along the remaining portion of tear line 58 and also separated from fixed sections 27 as the carton is completely opened (FIG. 4D).

As illustrated in FIGS. 5 A to D, the carton is closed as the user grasps tab 50, flexing it upward along fold line 49 thereby causing tuck flap 42 to move downward and away from the plane of section 26 while simultaneously pulling sections 22 and 26 back to their original closed position (FIGS. 5 A to C). Finally, the user inserts tuck flap 42 (not shown) into locking slit 44 thereby completing the closure of the carton (FIG. 5D).

While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of the invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.

Claims

1. A reclosable carton 11 comprising:

(a) a blank 10 including a front panel 19 and top panel 17 connected at a fold line 28 having two spaced apart tear lines 58, 121, 122, 126 defining a reclosable portion 22, 26 extending across said fold line 28, the front reclosable panel 26 having a finger tab 50 connected to the front reclosable panel 26 at a fold line 49, a back panel 18 connected to the top panel 17 at a fold line 24, said back panel connected to a bottom panel 14 at a fold line 20 and a glue panel 12 connected to bottom panel 14 at a fold line 16, the glue panel 12 having a locking slit flap 45 connected to the glue panel 12 at a fold line 46, wherein each of the front, top, back and bottom panels have opposite end flaps 38, 36, 34, 30 connected at fold lines 37, 35, 33, 32 to each of the front, top, back and bottom panels respectively, wherein each end flap has two spaced apart lateral edges 100, 104, 106, 110, 112, 116, 118, 130 and an axial edge 102, 108, 114, 120;

wherein the glue panel 12 is attached to front fixed section 25 with adhesive, wherein the reclosable portion 22, 26, finger tab 50 and locking slit flap 45 are kept free of adhesive during assembly of the carton;

(b) each of the tear lines has a first end 134 and a second end 132, wherein each of said tear lines intersect the fold line 24 at a point at least 3 mm from each of the adjacent top panel end flap lateral edges 110 at the first end 134, wherein each of said tear lines intersects fold lines 35 at a distance of at least 3 mm from each of lateral edges 110, wherein each of said tear lines extends partially along each of the fold lines 35 along leg 58, wherein each of said tear lines is spaced at least 3 mm from each of the lateral edges 106, wherein each of said tear lines intersects the fold line 28 between the top and front panels at a point at least 3 mm from each of top panel end flap lateral edges 106, wherein each of said tear lines intersects the fold line 49 and wherein each of the spaced apart second ends 132 of the tear lines is positioned at an edge 200; and

(c) said glue panel 12 defining a locking slit 44, said front reclosable section 26 having a tuck flap 42 connected to the finger tab 50 at a fold line 49 wherein the tuck flap is positioned to engage the locking slit 44 when the finger tab 50 is flexed in order to close the reclosable section of the carton after its initial opening along the tear lines.

2. The reclosable carton of claim 1 wherein the top panel end flap axial edge 108 and bottom panel axial edge 120 overlap by no more than 1 mm after assembly of the blank 10 into the carton.

3. The reclosable carton of claim 1 wherein top panel 17 further comprises:

(a) a pair of opposite fixed triangular segments 23 having legs 51, 51′ of respective lengths d5 and d5′ extending along fold line 28 and adjacent legs 52, 52′ of respective lengths d3 and d3′ extending along fold line 35;

(b) a pair of opposite fixed triangular segments 27 having legs 54 and 54′ of respective lengths d1 and d1′ extending along fold line 24 and adjacent legs 56 and 56′ of respective lengths d3 and d3′ extending along fold line 35;

(c) wherein fold line 28 has a length of d6, fold line 35 has a length of d4 and fold line 24 has a length of d2; and,

(c) wherein (d1+d1′)/d2=A where A is in the range of 0.18 to 0.30; (d3+d3′)/d4=B where B is in the range of 0.35 to 0.55; and (d5+d5′)/d6=C where C is in the range of 0.15 to 0.26.