Blank for forming a carton and a method of recycling hollow cores back into the carton

Abstract

A blank formed from cellulosic fibers is disclosed which is capable of being constructed into a carton. The carton is capable of housing a plurality of roll products, such as rolls of paper towels or rolls of toilet paper. Each of the roll products is wound onto a hollow core made from cellulosic fibers. The carton has a pair of dispensing openings through which the roll products can be individually removed. The carton also has a pair of openings through which an empty hollow core can be inserted back into the carton for the purpose of being recycled along with the empty carton. A method of recycling the empty hollow cores back into the carton is also disclosed.

Description

FIELD OF THE INVENTION

This invention relates to a blank capable of forming a carton having a pair of dispensing openings therein and a method of recycling hollow cores back into the carton. More particularly, this invention relates to a paperboard carton capable of housing a plurality of roll products, such as rolls of paper towels, rolls of toilet paper, rolls of dry wipes, etc. which are wound onto a hollow core formed from cellulose fibers, and recycling the hollow cores back into the carton.

BACKGROUND OF THE INVENTION

Today, many consumers desire to purchase products that utilize recycled materials and additionally can be recycled so as to benefit the environment. Paper products, especially paper towel and toilet paper are manufactured from cellulose fibers that have been recovered and recycled and this is considered a superior and much more sustainable approach to disposable paper product manufacturing. However, up until now, it has been difficult to recycle the materials used to package and dispense these disposable paper products. Most paper towels and toilet paper is wound onto a hollow, paper or cardboard core during manufacture for easy dispensing. These products are typically referred to as roll products and have a generally cylindrical shape and contain multiple sheets of paper towels or toilet paper. A plurality of these roll products is then typically wrapped in plastic in multiples of 4, 6, 8, 12, 24 rolls and then packed into corrugated fiberboard cartons for easy shipment to a retailer for ultimate sale to consumers.

It has been found that the plastic wrap or sheeting used to form the commonly used wrappers cannot be easily collected and recycled. Therefore, this plastic wrap is often discarded and eventually the plastic wrap is landfilled where it is slow to break down. Even in communities where consumers take the extra time to collect and recycle the plastic film, it is difficult for some recyclers to know the specific plastic from which the wrap was produced and therefore it may still be difficult to properly segregated and successfully recycled the plastic wrap. In addition, consumers who wish to recycle the plastic wrap and the empty paper cores must first separate the paper or cellulosic based hollow cores from the plastic wrap during the recycling process. For this reason, many consumers who desire green (recyclable/sustainable) products wish to purchase paper towels and toilet paper in paper-based (paperboard) packaging/cartons. Some existing paperboard cartons only contain a single dispensing opening that is accessed via a removable “tear off” panel through which the roll products can be removed. Existing paperboard cartons for use with other kinds of cylindrical shaped products only contain a single dispensing opening through which roll products could be removed. Since the cartons tend to have a rectangular cube shape, it is advantageous to construct the carton to have two dispensing openings formed therein to allow the consumer to vary the orientation of the carton as it is being stored on a shelf or in a closet while still being able to remove the roll products one at a time, as needed. One drawback with the existing paperboard cartons is that, up until now, there was no easy way to recycle the empty hollow cores and/or the removable panel covering the dispensing opening back into the carton once the sheets of paper towels or sheets of toilet paper were removed from the hollow cores. Many consumers were forced to discard the empty hollow cores and the removable cover panels in their garbage receptacles. By providing an easy to use recycling alternative, the consumer will now be able to dispose of the empty hollow cores and the removable cover panels and recycle them along with the original paperboard carton. No further segregation of materials is required.

Now a blank capable of forming a paperboard carton having a pair of dispensing openings formed therein has been invented which further includes a pair of openings through which hollow cores, which have had the cellulosic product removed there from and the removable panel(s), can be inserted back into the original carton and be recycled. In addition, a method of recycling the hollow cores and removable panels back into the carton is also disclosed.

SUMMARY OF THE INVENTION

Briefly, this invention relates to a blank for forming a carton having a pair of dispensing openings. The blank includes an adhesive tab and a back panel located adjacent to the adhesive tab. The back panel has a top and a bottom. The blank also has a first vertical fold line positioned between the adhesive tab and the back panel. The blank further has a top panel located adjacent to the back panel. The top panel has a top and a bottom. The blank also has a second vertical fold line positioned between the back panel and the top panel. The blank further has a front panel located adjacent to the top panel. The front panel has a top and a bottom. The blank also has a third vertical fold line positioned between the top panel and the front panel. The blank further has a bottom panel located adjacent to the front panel. The bottom panel has a top and a bottom. The blank also has a fourth vertical fold line positioned between the front panel and the bottom panel. The blank also has a back panel top flap located adjacent to the top of the back panel, a back panel bottom flap located adjacent to the bottom of the back panel, a top panel top flap located adjacent to the top of the top panel, a top panel bottom flap located adjacent to the bottom of the top panel, a front panel top flap located adjacent to the top of the front panel, a front panel bottom flap located adjacent to the bottom of the front panel, a bottom panel top flap located adjacent to the top of the bottom panel, and a bottom panel bottom flap located adjacent to the bottom of the bottom panel.

The blank further has a first horizontal fold line disposed between the back panel and the back panel top flap, between the top panel and the top panel top flap, between the front panel and the front panel top flap, and between the bottom panel and the bottom panel top flap. The blank further has a second horizontal fold line disposed between the back panel and the back panel bottom flap, between the top panel and the top panel bottom flap, between the front panel and the front panel bottom flap, and between the bottom panel and the bottom panel bottom flap. The blank still further includes a first tear panel formed in the front panel and having a pair of portions which extends partially into the top panel and the bottom panel, and when the first tear panel is removed a first opening is formed into the carton formed from the blank. The blank still further includes a pair of second tear panels, one of the pair of second tear panels formed in the top panel top flap and having a portion which partially extends into the top panel and the other of the pair of second tear panels formed in the bottom panel top flap and having a portion which partially extends into the bottom panel, and when the pair of second perforations is removed a second opening is formed into the carton formed from the blank.

This invention also relates to a carton formed from cellulose fibers and having a pair of dispensing openings formed therein. The carton is capable of housing a plurality of generally cylindrically shaped products formed from cellulose fibers. Each of the products is wound upon a hollow core formed from cellulose fibers and having a common diameter. The carton includes a top panel, a bottom panel aligned opposite to the top panel, a pair of end walls each being located between the top and bottom panels, and a front panel and a back panel each being located between the top panel and the bottom panel and adjacent to each of the pair of end walls. The carton also has a first tear panel formed in the front panel and having portions that extend into each of the top and bottom panels. The first tear panel defines a first opening when removed which provides access to at least one of the roll products housed within the carton. The carton further has a second tear panel formed in one of the pair of end walls and having portions that extend into each of the top and bottom panels. The second tear panel defines a second opening when removed which provides access to at least one of the roll products housed within the carton. The carton still further includes a pair of third tear panels formed in the top panel. The pair of third tear panels defines a pair of third openings when removed which allows the hollow cores to be inserted back into the carton through one of the third openings so that they can be recycled with the carton once one of the roll products has been removed from the carton.

Still further, this invention relates to a method of recycling hollow cores formed from cellulose fibers which are housed in a carton formed from cellulose fibers. Each of the hollow cores has a roll product formed from cellulose fibers wound upon it. The method includes the steps of inserting a plurality of the roll products into the carton and sealing the carton. The carton has a top panel, a bottom panel aligned opposite to the top panel, a pair of end walls each being located between the top panel and the bottom panel, a front panel and a back panel each being located between the top panel and the bottom panel and adjacent to each of the pair of end walls. The carton also has a first tear panel formed in the front panel and having portions that extend into each of the top and bottom panels. The first tear panel defines a first opening when removed which provides access to at least one of the roll products housed within the carton. The carton further has a second tear panel formed in one of the pair of end walls and having portions that extend into each of the top and bottom panels. The second tear panel defines a second opening when removed which provides access to at least one of the roll products housed within the carton. The carton still further has a pair of third tear panels formed in the top panel. The pair of third tear panels defines a pair of third openings when removed which allow the hollow cores to be inserted back into the carton through one of the pair of third tear panels once one of the roll products has been removed from the carton. The method also includes removing at least one of the third tear panels. The method further includes removing the roll product from the hollow core and then inserting the hollow core back into the carton through one of the pair of third openings.

The general object of this invention is to provide a blank capable of forming a carton having a pair of dispensing openings and a method of recycling hollow cores and tear panels back into the original carton. A more specific object of this invention is to provide a paperboard carton capable of housing a plurality of roll products, such as rolls of paper towels or rolls of toilet paper, which are wound onto a hollow core formed from cellulose fibers, and recycling the hollow cores back into the original carton.

Another object of this invention is to provide a carton having a first tear panel formed in the front panel and a second tear panel formed in one of the pair of end walls which allows roll products housed in the carton to be dispensed at two different locations.

Another object of this invention is to provide tear panel opening of a size and shape that will allow the consumer very easy access to the open core ends of the roll products for fast, sure dispensing without damage to the paper towel or bath tissue.

Another object of this invention is to provide a fifth tear panel that can be used to view the interior of the paperboard carton to easily determine the number of un-used paper rolls still remaining in the carton.

A further object of this invention is to provide a paperboard carton capable of housing a plurality of generally cylindrically shaped roll products each wound onto a hollow core formed from paper or cardboard, and providing an opening through which the hollow cores can be inserted back into the original carton so that both can be recycled together.

Still another object of this invention is to provide a method for recycling hollow cores formed from cellulose fibers which are housed in a carton formed from cellulose fibers.

Still further, an object of this invention is to provide a method for inserting an empty hollow core back into the original carton once the first roll product is removed from the carton.

Still further, an object of this invention is to provide a method for recycling the carton having at least one empty hollow core positioned therein.

Other objects and advantages of the present invention will become more apparent to those skilled in the art in view of the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a blank formed from cellulosic fibers into a paper, paperboard or cardboard blank that can be configured into a carton.

FIG. 2 is a top view of the blank shown in FIG. 1 after the four bottom flaps have been folded inward and the blank has been folded along the transverse central axis Y-Y.

FIG. 3 is a perspective view of a carton formed from the blank shown in FIG. 1.

FIG. 4 is a perspective view of a carton formed from the blank shown in FIG. 1 and having the first tear panel removed to reveal a couple of the roll products housed in the carton.

FIG. 5 is a top view of a portion of the top panel showing the semi-circular perforation line.

FIG. 6 is a top view of a portion of the front panel showing a perforation line having an alternative arrangement of cuts and land areas.

FIG. 7 is a partial cut away perspective view of an empty carton showing the second tear panel removed to form a second opening in the carton, and showing a pair of third tear panels formed in the top panel and a pair of fourth tear panels formed in the bottom panel with each of the third tear panels being coaxially aligned with one of the fourth tear panels.

FIG. 8 is a perspective view of a hollow core formed from cellulosic fibers.

FIG. 9 is a perspective view of the carton formed from the blank shown in FIG. 1 and having the pair of second tear panels removed to reveal a couple of the roll products housed in the carton.

FIG. 10 is a partial perspective of an alternative embodiment showing the second dispensing opening having an edge flush with the back panel of the carton and showing the portions of the pair of second tear panels that extends into the front and bottom panels form an offset arcuate configuration.

FIG. 11 is a partial perspective of still another alternative embodiment showing the second dispensing opening having a pair of detents positioned along the lower edge of the second dispensing opening and showing the portions of the pair of second tear panels that extends into the front and bottom panels form an angular configuration.

FIG. 12 is a partial perspective of still another embodiment showing the second dispensing opening having an edge flush with the back panel of the carton and having a pair of corner detents.

FIG. 13 is a flow diagram of a method of recycling empty hollow cores back into the carton.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-4, a blank 10 is shown in FIG. 1 along with a carton 12 which can be constructed from the blank 10, see FIGS. 3 and 4. The blank 10 can be formed from any cellulosic material. One or more different cellulosic fibers can be used to construct the cellulosic material. The cellulosic material can be paper, paperboard, cardboard or the like which is constructed from a plurality of cellulosic fibers. Desirably, the blank 10 is formed from paperboard. The material forming the blank 10 can be easily recycled or composted.

Referring to FIGS. 1 and 2, the blank 10 can be a generally rectangular or elongated member having a longitudinal central axis X-X and a transverse central axis Y-Y. The thickness of the blank 10, measured perpendicular to the X-X and Y-Y axes, can vary. The blank 10 can consist of one or more layers secured together. When two or more layers are present, each layer can have a similar or a different thickness. Desirably, when two or more layers are present, they are secured together such as by an adhesive. Alternatively, the two or more layers can be secured together by using heat, pressure, heat and pressure or by other mechanisms known to those skilled in the art. The one or more layers forming the blank 10 can be flat or planar layers or at least one of the layers can be corrugated or have some other configuration that adds thickness to the blank 10. The blank 10 is relatively thin. The blank 10 can have a thickness of less than about 0.2 inches. Desirably, the blank 10 has a thickness of less than about 0.1 inches. More desirably, the blank 10 has a thickness of less than about 0.05 inches. Even more desirably, the blank 10 has a thickness of less than about 0.03 inches.

Once the blank 10 is formed to a predetermined shape, it can be easily configured, folded, constructed or transformed into a carton 12. The blank 10 can contain one or more fold lines, score lines, crease lines, adhesive lines, etc. to facilitate folding and bending various portions and/or sealing or interlocking various portions together. The various portions of the blank 10 can be folded, bent over, doubled up, joined, taped, interlocked and/or be sealed or bonded together to form the carton 12, see FIGS. 3 and 4. Desirably, the blank 10 is configured such that it can be folded at several locations upon itself and be sealed or bonded at least one location to form the carton 12. Adhesive or glue is normally used to seal the carton 12.

Referring to FIGS. 3 and 4, the carton 12 formed from the blank 10 has a longitudinal central axis X-X, a transverse central axis Y-Y, and a vertical central axis Z-Z. The carton 12 can vary in size and shape. Desirably, the carton 12 is a rectangular cube having six sides with at least two of the sides having a rectangular face. Alternatively, the carton 12 can be a cube having six congruent square faces. Still another alternative is to form a carton having more than six faces, such as a hexagon shape, along with a top and a bottom. The overall size of the carton 12 can vary.

The carton 12 can be sized to house or retain a plurality of roll products 13. The roll products 13 are generally cylindrically shaped products formed from cellulosic fibers. The roll products 13 can be formed with eco-friendly features. For example, the roll products 13 can be made from recycled cellulose fibers. The roll products 13 can be made hypoallergenic. The roll products 13 can be made with no added dyes or fragrances and can even be whitened without using chlorine. Such roll products 13 include but are not limited to: rolls of paper towel, rolls of toilet paper, rolls of napkins, rolls of paper work-towels, rolls of dry wipes, rolls of wipers, etc. The size and shape of the roll products 13 can vary. Each of the roll products 13 is compressible by at least 10 percent measured perpendicular to its longitudinal central axis X₁-X₁, see FIG. 4. Each of the roll products 13 may also exhibit a relatively high coefficient of friction. Normally, the carton 12 can house from between 2 to 120 similar roll products 13. An even number or an odd number of roll products 13 can be housed or retained in the carton 12. Desirably, an even number of similar roll products 13 are housed in the carton 12. For rolls of paper towels or rolls of dry wipes, the carton 12 can be sized to house or retain 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, etc. rolls of paper towels. For rolls of toilet paper, the carton 12 can be sized to house or retain 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40 or more rolls of toilet tissue.

It should be understood that one could house different types of roll products 13 with the carton 12, if desired. Desirably, each carton 12 will retain a plurality of like kind of roll products 13.

Referring again to FIG. 1, the blank 10 will be described from left to right and from top to bottom. The blank 10 includes an adhesive tab 14. The size and shape of the adhesive tab 14 can vary. The adhesive tab 14 can include a continuous area of adhesive or glue or multiple intermittent areas of adhesive or glue that will bond to an adjoining portion of the blank 10 once the blank 10 is folded into the carton. The blank 10 also includes a back panel 16 located adjacent to the adhesive tab 14. The back panel 16 has a top 18 and a bottom 20. The top and bottom, 18 and 20 respectively, are measured relative to the transverse central axis Y-Y. The blank 10 also has a first vertical fold line 22 positioned between the adhesive tab 14 and the back panel 16. The first vertical fold line 22 extends parallel to the transverse central axis Y-Y. The first vertical fold line 22 can be a score, a crease, a groove, an indentation, a line of weakness, etc. that extends into a portion of the thickness of the blank 10. Those skilled in the art are well aware of how to form the first vertical fold line 22 in the blank 10.

The blank 10 further has a top panel 24 located adjacent to the back panel 16. The top panel 24 has a top 26 and a bottom 28. The blank 10 also has a second vertical fold line 30 positioned between the back panel 16 and the top panel 24. The second vertical fold line 30 extends parallel to the transverse central axis Y-Y. The second vertical fold line 30 can be a score, a crease, a groove, an indentation a line of weakness, etc. that extends into a portion of the thickness of the blank 10. Those skilled in the art are well aware of how to form the second vertical fold line 30 in the blank 10.

The blank 10 further has a front panel 32 located adjacent to the top panel 24. The front panel 32 has a top 34 and a bottom 36. The blank 10 also has a third vertical fold line 38 positioned between the top panel 24 and the front panel 32. The third vertical fold line 38 extends parallel to the transverse central axis Y-Y. The third vertical fold line 38 can be a score, a crease, a groove, an indentation, a line of weakness, etc. that extends into a portion of the thickness of the blank 10. Those skilled in the art are well aware of how to form the third vertical fold line 38 in the blank 10.

The blank 10 further has a bottom panel 40 located adjacent to the front panel 32. The bottom panel 40 has a top 42 and a bottom 44. The blank 10 also has a fourth vertical fold line 46 positioned between the front panel 32 and the bottom panel 40. The fourth vertical fold line 46 extends parallel to the transverse central axis Y-Y. The fourth vertical fold line 46 can be a score, a crease, a groove, an indentation, a line of weakness, etc. that extends into a portion of the thickness of the blank 10. Those skilled in the art are well aware of how to form the fourth vertical fold line 46 in the blank 10.

Still referring to FIG. 1, the blank 10 also has a back panel top flap 48 located adjacent to the top 18 of the back panel 16, a back panel bottom flap 50 located adjacent to the bottom 20 of the back panel 16, a top panel top flap 52 located adjacent to the top 26 of the top panel 24, a top panel bottom flap 54 located adjacent to the bottom 28 of the top panel 26, a front panel top flap 56 located adjacent to the top 34 of the front panel 32, a front panel bottom flap 58 located adjacent to the bottom 36 of the front panel 32, a bottom panel top flap 60 located adjacent to the top 42 of the bottom panel 40, and a bottom panel bottom flap 62 located adjacent to the bottom 44 of the bottom panel 40.

The back panel top flap 48 has a height h₁ and the front panel top flap 56 has a height h₃. The height h₁ of the back panel top flap 48 is approximately equal to the height h₃ of the front panel top flap 56. Desirably, the height h₁ of the back panel top flap 48 is equal to the height h₃ of the front panel top flap 56. The top panel top flap 52 has a height h₂ and the bottom panel top flap 60 has a height h₄. The height h₂ of the top panel top flap 52 is approximately equal to the height h₄ of the bottom panel top flap 60. Desirably, the height h₂ of the top panel top flap 52 is equal to the height h₄ of the bottom panel top flap 60. In addition, the height h₂ of the top panel top flap 52 as well as the height h₄ of the bottom panel top flap 60 are each greater than the height h₁ of each of the back panel top flap 48 and the height h₃ of the front panel top flap 56. The exact dimension of the heights h₁, h₂, h₃ and h₄ will vary depending upon the size of the carton 12.

Each of the back panel 16, the top panel 24, the front panel 32 and the bottom panel 40 has a width, w₁, w₂, w₃ and w₄ respectively. The width w₁ of the back panel 16 is approximately equal to the width w₃ of the front panel 32. Desirably, the width w₁ of the back panel 16 is equal to the width w₃ of the front panel 32. The width w₂ of the top panel 24 is approximately equal to the width w₄ of the bottom panel 40. Desirably, the width w₂ of the top panel 24 is equal to the width w₄ of the bottom panel 40. In addition, the width w₁ of the back panel 16 is greater than the width w₂ of the top panel 24, and the width w₃ of the front panel 32 is greater than the width w₄ of the bottom panel 40.

Still referring to FIG. 1, the back panel bottom flap 50 and the front panel bottom flap 58 are identical in size and configuration. The top panel bottom flap 54 and the bottom panel bottom flap 62 are identical in size and configuration. However, the back panel bottom flap 50 can be of a different size and configuration from the front panel bottom flap 54, if desired. In addition, each of the back panel bottom flap 50 and the front panel bottom flap 58 is larger in size than either of the top panel bottom flap 54 or the bottom panel bottom flap 62. Alternatively, the back panel bottom flap 50 and the front panel bottom flap 58 can be smaller or of equal size to the top panel bottom flap 54 or to the bottom panel bottom flap 62.

The blank 10 further has a first horizontal fold line 64 disposed between the back panel 16 and the back panel top flap 48, between the top panel 24 and the top panel top flap 52, between the front panel 32 and the front panel top flap 56, and between the bottom panel 40 and the bottom panel top flap 60. The blank 10 further has a second horizontal fold line 66 disposed between the back panel 16 and the back panel bottom flap 50, between the top panel 24 and the top panel bottom flap 54, between the front panel 32 and the front panel bottom flap 58, and between the bottom panel 40 and the bottom panel bottom flap 62. The first horizontal fold line 64 is aligned essentially parallel to the second horizontal fold line 66 and both the first and second horizontal fold line, 64 and 66 respectively, are aligned parallel to the longitudinal central axis X-X.

It should be understood that the blank 10 can be configured and constructed so as to form a hollow sleeve with an auto forming end or have two oppositely aligned manual or machine formable ends.

Still referring to FIG. 1, the back panel bottom flap 50 can optionally contain a first perforated line 51 formed along the second horizontal fold line 66 and a second perforated line 53 formed at an acute angle to the first perforated line 51. The second perforated line 53 intersects the second vertical fold line 30. The top panel bottom flap 54 can optionally contains a perforated line 55 formed along the second horizontal fold line 66. The top panel bottom flap 54 also has a spot of an adhesive or glue 57 secured thereto. The front panel bottom flap 58 can optionally contains a first perforated line 59 formed along the second horizontal fold line 66 and a second perforated line 61 formed at an acute angle to the first perforated line 59. The second perforated line 61 intersects the fourth vertical fold line 46. Lastly, the bottom panel bottom flap 62 can optionally contains a perforated line 63 formed along the second horizontal fold line 66. The bottom panel bottom flap 62 also has a spot of an adhesive or glue 65 secured thereto. When the perforation lines 51, 53, 55, 59, 61 and 63 are present, they cooperate with the second horizontal fold line 66 and enable the four bottom flaps 50, 54, 58 and 62 to be automatically formed into a wall of the carton 12.

Referring to FIGS. 1 and 2, the blank 10 shown in FIG. 1 can be folded along the Y-Y axis to form a flat folded carton 12, see FIG. 2. The flat folded carton 12 can be shipped from the manufacturer of the blank 10 to the customer who will fill the carton 12 with roll products 13. In the arrangement illustrated in FIG. 2, the adhesive tab 14 is already secured to the inside of the bottom panel 40 to form a flat hollow sleeve. The four bottom flaps 50, 54, 58 and 62 (not visible in FIG. 2) are folded into the flat hollow sleeve. As the hollow sleeve is manipulated into a four sided carton 12, the four bottom flaps 50, 54, 58 and 62 will move outward and interlock with one another to automatically form one end wall of the carton 12. This is referred to as a “self-forming end” or an “auto forming end”. This action saves time and leaves one open end into the carton 12. As the four bottom flaps 50, 54, 58 and 62 move outward to form an end wall, the adhesive spot 57 contacts the back panel bottom flap 50 and forms a secure attachment thereto. Simultaneously, the adhesive spot 65 contacts the front panel bottom flap 58 and forms a secure attachment thereto.

Returning to FIG. 1, the blank 10 further includes a first tear panel 68 formed in the front panel 32. The first tear panel 68 has a central portion 70 and a pair of end portions 72 and 74 which extends partially into the top panel 24 and the bottom panel 40, respectively. The size and shape of the first tear panel 68 can vary. Desirably, the first tear panel 68 can be of any geometrical shape. As depicted in FIG. 1, the first tear panel 68 has a rectangular central portion 70 sandwiched between the two end portions 72 and 74. The two end portions 72 and 74 are depicted as semi-circular in configuration although almost any geometrical configuration can be utilized. The rectangular central portion 70 is aligned along the longitudinal central axis X-X and the two end portions 72 and 74 are positioned at an end thereof.

It should be understood that one or more finger holes 75 can be optionally formed in the first tear panel 68. Each finger hole 75 can vary in size, shape and location. For example, in FIG. 1, two finger holes 75, 75 are depicted being formed in opposite ends of the first tear panel 68 approximate the vertical fold lines 38 and 46. Each finger hole 75 can be a closed outer portion of the carton 12 that is at least partially surrounded by perforations. As one pokes an index finger into the outer portion, the perforations break and a hole or opening is formed into the first tear panel 68. The index finger can then be used to tear or separate the first tear panel 68 from the carton 12.

Referring now to FIGS. 1, 5 and 6, the first tear panel 68 has a first perforation segment 76, a second perforation segment 78, a third perforation segment 80 and a fourth perforation segment 82. The four segments 76, 78, 80 and 82 combine to form a continuous line of perforations. Each of the perforation segments 76, 78, 80 and 82 can consist of a plurality of cuts 84 each separated by a land area 86. The length of the cuts 84 and the size of the land areas 86 can vary in dimension and thickness. Likewise, the cuts 84 and the land areas 86 can vary in geometrical shape. In FIG. 5, a portion of the top panel 24 is shown with the cuts 84 and the land areas 86 depicted as being arranged in a semi-circle. The cuts 84 have a length which range from about 3 to about 4 times the length of the land areas 86. However, the cuts 84 can have a smaller length, an equal length or a greater length than the land areas 86.

In FIG. 6, a portion of the front panel 32 is shown wherein the perforation segment 80 is formed by a pair of linear cuts 88 and 90. The cuts 88 and 90 can be aligned at an acute angle to one another. The cuts 88 and 90 can also contact one another or be spaced apart from one another. Each of the pair of cuts 88 and 90 is separated by a land area 92. As mentioned with regard to FIG. 5, the length, thickness and shape of the cuts 88 and 90 and the land areas 92 can vary.

Referring again to FIGS. 2 and 3, by tearing or breaking the perforation segments 76, 78, 80 and 82, the first tear panel 68 can be completely removed from the carton 12. When the first tear panel 68 is removed, a first dispensing opening 94 is formed in the carton 12 which is of sufficient size and shape to permit the roll products 13 housed in the carton 12 to be dispended one at a time. The lower or bottom row of the roll products 13 is dispensed through the first dispensing opening 94. The size and shape of the first dispensing opening 94 prevents the roll products 13 situated in the adjacent upper row from being dispensed. For example, if the carton 12 contains six roll products 13 arranged with a bottom row, a middle row and an upper row, with two roll products 13 in each row, only a roll product 13 situated in the bottom roll can be dispensed from the carton 12. When this roll product 13 is removed from the carton 12, the roll product 13 located immediately above it will move downward and occupy the empty space left by the roll product 13 that was removed. This means that there will be only roll product 13 left in the upper row.

Referring again to FIGS. 1-4 and 7, the blank 10 further includes a pair of second tear panels 96 and 98, see FIG. 1. The pair of second tear panels 96 and 98 is aligned parallel to the transverse central axis Y-Y of the blank 10. One of the pair of second tear panels 96 and 98 is formed in the top panel top flap 52 and has an end portion 100 which partially extends into the top panel 24. In FIGS. 1-4, the end portion 100 is shown having a semi-circular configuration although any geometrical shape can be used. The other of the pair of second tear panels 96 and 98 is formed in the bottom panel top flap 60 and has an end portion 102 which partially extends into the bottom panel 40. In FIG. 1, the end portion 102 is also shown having a semi-circular configuration although any geometrical shape can be used. The size and shape of the pair of second tear panel 96 and 98 can vary. Desirably, the pair of second tear panels 96 and 98 can be of any geometrical shape. The pair of second tear panels 96 and 98 is designed to mesh or mate with one another, see FIG. 4. When the pair of second tear panels 96 and 98 is removed from the carton 12, in a similar fashion as was described above with reference to the first tear panel 68, they form a single, second rectangular opening 104 into the carton 12, see FIG. 7. The pair of second tear panels 96 and 98 include one or more perforation segments as was described above with reference to the first tear panel 68. The cuts and land areas used to form the perforation segments can be similar or different from those shown in FIGS. 5 and 6. Desirably, the perforation segments around the pair of second tear panels 96 and 98 are identical to those used around the first tear panel 68.

As with the first tear panel 68, one or more finger holes 105 can be optionally formed in each of the pair of second tear panels 96 and 98. Each finger hole 105 can vary in size, shape and location. For example, in FIG. 1, a finger hole 105 is formed in each of the pair of second tear panels 96 and 98 approximate the horizontal fold line 64. Each finger hole 105 can be a closed outer portion of the carton 12 that is at least partially surrounded by perforations. As one pokes an index finger into the outer portion, the perforations break and a hole or opening is formed into the second pair of tear panels 96 and 98. The index finger can then be used to tear or separate the pair of second tear panels 96 and 98 from the carton 12.

Referring again to FIG. 1, one will notice that the top panel top flap 52 has a pair of spaced apart notches 97, 97 formed therein. The pair of notches 97, 97 is located adjacent to the second tear panel 96. The pair of notches 97, 97 allow adhesive positioned on the inside surface of the bottom panel top flap 60 to adhere to the outer surfaces of the back panel top flap 48 and the front panel top flap 56. This structure will then allow the four top flaps 48, 52, 56 and 60 to be secured together.

It should be understood that after the carton 12 is filled with a predetermined number of roll products 13, the four top flaps 48, 52, 56 and 60 are folded inward. First, the back panel top flap 48 and the front panel top flap 56 are simultaneously or sequentially folded inward. The top panel top flap 52 is then folded inward on top of the back panel top flap 48 and the front panel top flap 56. Two spots of adhesive can be applied to the inside surface of the bottom panel top flap 60 which will be aligned with the pair of notches 97, 97. Lastly, the bottom panel top flap 60 is folded over the top panel top flap 52. All four top flaps 48, 52, 56 and 60 are secured together, such as by an adhesive. Desirably, the adhesive is a hot melt adhesive. Alternatively, the adhesive can be a cold melt adhesive or any other type of adhesive known to those skilled in the art.

As depicted in FIGS. 1-4 and 7, when the first tear panel 68 and the combination of the pair of second tear panels 96 and 98 are removed, two identical sized and shaped first and second dispensing openings, 94 and 104 respectively, are formed into the carton 12. The first and second dispensing openings, 94 and 104 respectively, are sized and located so as to allow a single roll product 13 to be removed from the bottom row of the carton 12 at a given time. It should be understood that the carton 12 is designed to have only one of the first or second openings 94 or 104 being available at any time.

The first and second dispensing openings, 94 and 104 respectively, are aligned parallel to the longitudinal central axis X-X of the carton 12. The first opening 94 will be in a different panel from the second opening 104. Desirably, the first opening 94 will be located in a panel that is adjacent to or at 90 degrees the end wall containing the second opening 104 once the carton 12 is constructed. The first and second dispensing openings, 94 and 104 respectively, allow the carton 12 to be stored in two different orientations while still allowing the roll products 13 to be singularly dispended or removed from the carton 12. Typically, only one of the first and second dispensing openings, 94 and 104 respectively, will be opened at a given time. However, both of the first and second dispensing openings, 94 and 104 respectively, could be opened at the same time, if desired.

Referring again to FIG. 1, the blank 10 further includes a pair of third tear panels 106 and 108 formed in the top panel 24. Each of the pair of third tear panels 106 and 108 can be identical, similar or different in appearance. Each of the pair of third tear panels 106 and 108 can be formed to any desired geometrical configuration. In FIG. 1, each of the pair of third tear panels 106 and 108 is circular in configuration and of approximately equal size. Desirably, each of the pair of third tear panels 106 and 108 are of the same size and configuration. Each of the pair of third tear panels 106 and 108 contains a circumferential line of perforations 110. The circumferential line of perforations 110 can be a continuous line or a non-continuous line. The circumferential line of perforations 110 can consist of a single line or a combination of two or more lines. The circumferential line of perforations 110 can be linear or non-linear in appearance. Desirably, the circumferential line of perforations 110 is continuous and contains a plurality of arcuate cuts 112 which cooperate to form a circular configuration. The circumferential line of perforations 110 includes a plurality of cuts 112 each separated by a land area 114. The actual shape, length, thickness, etc. of the cuts 112 and the land areas 114 can vary as was explained above relative to the perforation segments 76, 78, 80 and 82. Those skilled in the art will be aware of various ways to construct a circumferential line of perforations which can be formed in the blank 10.

The circumferential line of perforations 110 extends essentially completely around each of the pair of third tear panels 106 and 108 to form a closed geometrical shape, e.g. a circle. The circumferential line of perforations 110 can later be completely punched out by the consumer so that all of the material circumscribed by the line of perforations 110 is removed. Alternatively, the circumferential line of perforations 110 does not have to be continuous and thus when the partially circumscribe area is punched out, a portion of the third tear panel 106 or 108 remains attached to the top panel 24. The portion of the third tear panel 106 or 108 that was broken at the circumferential line of perforations 110 can be folded back out of the way, either into or out of the carton 12.

Referring now to FIGS. 7 and 8, when at least one of the pair of third tear panels 106 and 108 is removed, a third opening 116, see FIG. 7, is formed into the carton 12. It should be understood that only one of the pair of third tear panels 106 and 108 needs to be removed in order to practice this invention. If desired, both of the pair of third tear panels 106 and 108 could be removed from the carton 12. When at least one of the third openings 116 is formed, it allows a person to insert an empty hollow core 118, see FIG. 8, back into the carton 12. Once the roll product 13, for example, a roll of paper towels or a roll of toilet paper, is used up, the empty hollow core 118 remains and must be recycled or discarded. The carton 12 provides an easy mechanism for allowing one or more of the empty hollow cores 118 to be inserted back into the paperboard carton 12. By doing so, one can later recycle the carton 12 as well as one or more of the empty hollow cores 118. Since the paperboard carton 12 and the hollow cores 118 are each formed from cellulosic fibers, they can be recycled in a similar fashion and at the same time.

In FIG. 8, the empty hollow core 118 is shown as an elongated cylindrical member having a round or circular cross-section. However, the empty hollow cores 118 can have any geometrical cross-sectional shape. Desirably, the cross-section of each of the empty hollow cores 118 is circular. As depicted, the empty hollow core 118 has an external or common diameter d, a thickness t and a length I. All three dimensions can vary.

For a typical roll of paper towel, the empty hollow core 118 can have an external or common diameter d that ranges from between about 1 to about 3 inches, desirably, from about 1.5 to about 2.5 inches, and more desirably, from between about 1.6 to about 2 inches. The empty hollow core 118 can have a thickness t that ranges from between about 0.01 to about 0.2 inches, desirably, from between about 0.02 to about 0.15 inches, and more desirably, from between about 0.05 to about 0.1 inches. The empty hollow core 118 can have a length l that ranges from between about 6 to 18 inches, desirably from between about 10 to 12 inches, and more desirably from between about 10.5 to about 11.5 inches.

For a typical roll of toilet paper, the empty hollow core 118 can have an external or common diameter d that ranges from between about 1 to about 3 inches, desirably, from about 1.5 to about 2.5 inches, and more desirably, from between about 1.6 to about 2 inches. The empty hollow core 118 can have a thickness t that ranges from between about 0.01 to about 0.2 inches, desirably, from between about 0.02 to about 0.15 inches, and more desirably, from between about 0.05 to about 0.1 inches. The empty hollow core 118 can have a length l that ranges from between about 3 to 6 inches, desirably from between about 3.5 to 5 inches, and more desirably from between about 3.75 to about 4.25 inches.

The external or common diameter d of each of the roll products 13 should be able to easily pass through either of the pair of third openings 116. Because of this, each of the pair of third openings 116 should have an accommodating configuration, i.e. circular, and have a diameter which is at least equal to the diameter d of the hollow cores 118 contained in the carton 12. Desirably, each of the third openings 116 should have a diameter which is greater than the diameter d of the empty hollow cores 118 which are designed to pass through it. More desirably, each of the third openings 116 is at least about 0.1 inches larger in diameter than the diameter d of the empty hollow cores 118 which are designed to pass through it. Even more desirably, each of the third openings 116 is at least about 0.2 inches larger in diameter than the diameter d of the empty hollow cores 118 which are designed to pass through it. It should be understood that the empty hollow cores 118 serve the function of allowing multiple sheets of the roll product 13 to be wound onto the empty hollow core 118 during manufacturing. During use of the roll product 13, the hollow core 118 can be positioned on a circular shaft or like structure to facilitate rotary motion so that one or more sheets of the roll product 13 can be easy removed. Once the roll product 13 is used up, the empty hollow core 118 is removed from the circular shaft or like structure and recycled or discarded while another full roll of product 13 is positioned on the circular shaft or like structure for future use. Normally, the shaft used to support a roll of paper towels 13 is horizontally or vertically mounted in a kitchen or some other room of a house. For toilet paper, the shaft is usually horizontally mounted in a bathroom.

Referring again to FIGS. 1 and 7, the pair of third tear panels 106 and 108 is formed in the top panel 24. Each of the pair of third tear panels 106 and 108 has a central axis X₂-X₂ which is located within about 3 inches of one of the first and second horizontal fold lines, 64 and 66 respectively. In addition, the central axis X₂-X₂ of each of the pair of third tear panels 106 and 108 is located within about 5 inches of one of the second and third vertical fold lines, 30 and 38 respectively. Furthermore, one of the pair of third tear panels 106 and 108 is located within about 2 inches of the end portion 72 of the first tear panel 68, see FIG. 1, and the other of the pair of third tear panels 106 and 108 is located within about 2 inches of the end portion of the second tear panels 96, see FIG. 1. In other words, the first 106 of the pair of third tear panels 106 and 108 is located adjacent to a first corner 120, see FIG. 7, and the second 108 of the pair of third tear panels 106 and 108 is located adjacent to a second corner 122, see FIG. 7. The corners 120 and 122 are located in the top panel 24 diagonally across from one another. This position is important because when the carton 12 is resting on one of its end panels and the first tear panel 68 is removed, the first roll product 13 can be removed from the carton 12. Once the first roll product 106 is removed, the remaining rolls of product 13 housed in the carton 12 will move downward and/or forward toward the first opening 94. This action will create a void area within the carton 12 located approximate the third tear panel 108 and will provide an empty space to accommodate the insertion of the empty hollow core 118. The third tear panel 108 is designed to be opened when the first dispensing openings 68 is torn open and the other third tear panel 108 is utilized when the second dispensing opening 96 & 98 is torn open.

It should be noted that the carton 12 can be tilted forward, if desired, so as to facilitate movement of the remaining roll products 13 within the carton 12 so that they move toward the first or second dispensing openings, 94 and 104 respectively.

Referring now to FIGS. 1, 7 and 9, the blank 10 can optionally contain a pair of fourth tear panels 124 and 126 formed in the bottom panel 40. Each of the pair of fourth tear panels 124 and 126 has a central axis X₃-X₃, see FIG. 7. Each central axis X₃-X₃ of the pair of fourth tear panels 124 and 126 can be coaxially aligned with one of the central axes X₂-X₂, X₂-X₂ of the pair of third tear panels 106 and 108, see FIG. 7. The central axis X₃-X₃ of each of the pair of fourth tear panels 124 and 126 is located within about 3 inches of one of the first and second horizontal fold lines, 64 and 66 respectively. In addition, the central axis X₃-X₃ of each of the pair of fourth tear panels 124 and 126 is located within about 5 inches of one of the first and fourth vertical fold lines, 22 and 46 respectively, when the carton 12 is constructed. Furthermore, one of the pair of fourth tear panels 124 and 126 is located within about 2 inches of the end portion 74 of the first tear panel 68, and the other of the pair of fourth tear panels 124 and 126 is located within about 2 inches of the end portion of one of the pair of second tear panels 96 and 98. In other words, the first of the pair of fourth tear panels 124 and 126 is located adjacent to a first corner 128 and the second of the pair of fourth tear panels 124 and 126 is located adjacent to a second corner 130, see FIG. 9. The corners 128 and 130 are located in the bottom panel 40 across from one another. When at least one of the pair of fourth tear panels 124 and 126 is removed, a fourth opening 132, see FIG. 9, is formed into the carton 12. The fourth opening 132 allows the empty hollow cores 118 to be inserted back into the carton 12.

Each of the fourth openings 132 has a diameter which is at least equal to the external or common diameter d of the empty hollow cores 118 which are designed to pass through it. Desirably, each of the fourth openings 132 should have a diameter which is greater than the diameter d of the empty hollow cores 118 which are designed to pass through it. More desirably, each of the fourth openings 132 should have a diameter which is at least about 0.1 inches larger in diameter than the diameter d of the empty hollow cores 118 which are designed to pass through it. Even more desirably, each of the fourth openings 132 should have a diameter which is at least about 0.2 inches larger in diameter than the diameter d of the empty hollow cores 118 which are designed to pass through it.

Still referring to FIG. 9, the location of the pair of fourth tear panels 124 and 126 is important because when the carton 12 is resting on its back panel 16 and the second tear panels 96 and 98 are removed, the second opening 104 is formed in the carton 12. With the second opening 104 being present, the first roll product 13 can be removed from the carton 12. Once the first roll product 13 is removed, the remaining rolls of product 13 housed in the carton 12 will move downward and/or forward toward the second opening 104. This action will create a void area in the carton 12 approximate the fourth tear panel 126 and will provide an empty space to accommodate the insertion of the empty hollow core 118.

It should be understood that when the first dispensing opening 68 is torn open, the fourth tear panel 124 can be used to insert empty hollow cores 118 back into the carton 12 once the first roll product 13 has been removed via the first dispensing opening 94.

Referring again to FIGS. 1-4, the blank 10 further includes a handle tear panel 134 formed in the top panel 24. The handle tear panel 134 can vary in size and shape. The handle tear panel 134 includes a perforated segment 136 and a non-perforated segment 138. By depressing the perforated segment 136, a portion of the handle tear panel 134 will move downward into the carton 12 and a handle opening 140 is formed, see FIGS. 3 and 4. The perforated segment 136 can be partially or completely folded under the non-perforated segment 138. The handle opening 140 is designed to allow a consumer to insert one, two, three or four fingers through the opening 140 and carry the carton 12 in one hand.

Referring again to FIGS. 1 and 7, the blank 10 can optionally includes one or more weakened areas or lines 142 formed in the first tear panel 68 and/or in the pair of second tear panels 96 and 98. The weakened areas or lines 142 can be aligned parallel to one another, as depicted, or be aligned at an angle to at least one other area or line. The weakened areas or lines 142 can vary in size, shape, thickness, length, etc. Furthermore, a weakened area or line 142 does not have to be continuous. The weakened areas or lines 142 can be randomly positioned or be evenly spaced from an adjacent weakened area or line 142. The weakened areas or lines 142 can include but are not limited to: score lines, fold lines, crease lines, perforation lines, lines of indentations, grooves, areas of indentation, thin areas, etc. The purpose of the weakened areas or lines 142 is to allow the tear panels 68, 96 and 98 to be folded or rolled up into a smaller member and be inserted back into the carton 12 through one of the third or fourth openings, 116 and 132 respectively, see FIG. 7. By inserting the tear panels 68, 96 and 98 back into the carton 12, one can later recycle one hundred percent (100%) of the material used to construct the carton 12. In addition, one can recycle more than just the carton 12 by inserting the empty hollow cores 118 back into the carton 12 so that both the carton 12 and the hollow cores 118 can be recycled. Furthermore, if one can also recycles the used paper towels, one can obtain one hundred percent (100%) recycling of the carton 12 and the roll products 13. This will benefit the environment and reduce the amount of cellulosic material being deposited into landfills.

Referring again to FIGS. 2, 3, 7 and 9, this invention also relates to the carton 12. The carton 12 can be formed from cellulose fibers. One or more similar or different cellulosic fibers can be used to construct the carton 12 as was explained above in reference to the blank 10. The carton 12 is formed by folding, bending, assembling, and/or sealing, taping or interlocking various portions of the blank 10. As explained above, the back panel bottom flap 50, the top panel bottom flap 54, the front panel bottom flap 58 and the bottom panel bottom flap 62 can be configured such that as the blank 10 can be folded into a sleeve and an end wall is automatically formed. This creates a carton 12 which is open at only one end.

The assembled carton 12 has a pair of possible dispensing openings 94 and 104. The carton 12 is capable of housing or temporarily retaining a plurality of generally cylindrically shaped roll products 13 formed from cellulose fibers. Each of the roll products 13 is wound upon an empty hollow core 118 during manufacture. Each of the hollow cores 118 is formed from cellulose fibers and each has an external or common diameter d. The carton 12 includes a top panel 24, a bottom panel 40 aligned opposite to the top panel 24, a pair of end walls 144 and 146 each being located between the top panel 24 and the bottom panel 40. The carton 12 also has a front panel 32 and a back panel 16 each being located between the top panel 24 and the bottom panel 40 and adjacent to each of the pair of end walls 144 and 146. A first tear panel 68 is formed in the front panel 32 of the carton 12. The first tear panel 68 has an end portion 72 which extends into each of the top panel 24 and an end portion 74 which extends into the bottom panel 40. The first tear panel 68 defines a first dispensing opening 94 when removed. The first dispensing opening 94 allows access to at least one of the roll products 13 housed within the carton 12. In other words, the roll products 13 can be individually dispensed from the carton 12 thorough the first dispensing opening 94.

The carton 12 also includes a pair of second tear panels 96 and 98 formed in the top panel top flap 52 and in the bottom panel top flap 60 of the blank 10. These two flaps 52 and 60 form the end wall 146 once the carton 12 is constructed. The pair of second tear panels 96 and 98 cooperates to form a rectangular dispensing opening of similar size to the first dispensing opening 94. The pair of second tear panels 96 and 98 has portions that extend into each of the top and bottom panels, 24 and 40 respectively. The pair of second tear panels 96 and 98 defines a second dispensing opening 104 into the carton 12 when removed. The second dispensing opening 104 allows access to at least one of the roll products 13 housed within the carton 12. In other words, the roll products 13 can be individually dispensed from the carton 12 thorough the second dispensing opening 104.

Referring again to FIGS. 3 and 7, the carton 12 further includes a pair of third tear panels 106 and 108 formed in the top panel 24. The pair of third tear panels 106 and 108 defines a pair of third openings 116, 116, see FIG. 7, into the carton 12 when removed. The empty hollow cores 118 can be inserted back into the carton 12 through one of the pair of third tear panels 116, 116 once one of the roll products 13 has been removed from the carton 12. As explained above, once one of the roll products 13 has been removed from the carton 12, a void space will be present in the carton 12 adjacent to one of the pair of third panels 106 and 108. This void space will allow an empty hollow core 118 to be inserted back into the carton 12.

It should be noted that the integrity of the carton 12 is not compromised or destroyed when either the first dispensing opening 94 or the second dispensing opening 104 is formed in the carton 12. Likewise, the formation of one or both of the pair of third and pair of fourth openings, 116 and 128 respectively, does not compromise or destroy the integrity of the carton 12.

The carton 12 can easily be loaded with roll products 13 by folding the blank 10 along the four vertical fold lines 22, 30, 38 and 46 and bonding the adhesive tab 14 to the bottom panel 40. Simultaneously, the end wall 144 can be automatically formed by the interconnection of the back panel bottom flap 50, the top panel bottom flap 54, the front panel bottom flap 58 and the bottom panel bottom flap 62. An adhesive or glue can be added to the end wall 144 to retain its structure. This action creates a sleeve open at only one end. The roll products 13 can then be inserted into the open end of the carton 12 before the back panel top flap 48, the top panel top flap 52, the front panel top flap 56 and the bottom panel top flap 60 are folded inward and secured together with an adhesive, a glue or by some other means.

The filled carton 12 can be shipped to a retailer where it is made available for sale to the ultimate consumer. The consumer purchases the carton 12 of roll products 13 and takes it home or to a place of business. The consumer will orient the carton 12 to best fit on a shelf, into a closet area, etc. At this time, the consumer can remove one of the first or second tear panels, 68 or 96 & 98 to form either the first dispensing opening 94 or the second dispensing opening 104. For most applications, only one of the first and second dispensing openings, 94 or 104 respectively, need be formed. The finger holes 75 or 105 can facilitate removal of the tear panels 68 and 96 & 98 from the carton 12. The first and second dispensing openings, 94 and 104 respectively, are desirably of the same size and configuration. The carton 12 should be stored such that the roll products 13 are horizontally arranged for easy removal from the first or second dispensing openings, 94 or 104 respectively. The roll products 13 are dispensed from the bottom row. FIG. 9 shows the roll products 13 oriented in a horizontal fashion.

With reference to FIG. 10, one can see that the second dispensing opening 104 is quite larger. For a carton 12 or 12′ containing six or more rolls of paper towels 13, each having a diameter of about 4.5 inches, the second dispensing opening 104 should have a width w, measured parallel to the transverse central axis Y-Y, of at least about 6 inches. Desirably, the width w of the second dispensing opening 104 is at least about 6.5 inches. More desirably, the width w of the second dispensing opening 104 is at least about 7 inches. Even more desirably, the width w of the second dispensing opening 104 is at least about 7.5 inches. Most desirably, the width w of the second dispensing opening 104 is at least about 8 inches. Another way of expressing the width w of the second dispensing opening 104 is to say that the width w is at least about 1.35 times the external or common diameter of the roll product 13. Desirably, the width w of the second dispensing opening 104 is at least about 1.45 times the external or common diameter of the roll product 13. More desirably, the width w of the second dispensing opening 104 is at least about 1.55 times the external or common diameter of the roll product 13. Even more desirably, the width w of the second dispensing opening 104 is at least about 1.65 times the external or common diameter of the roll product 13. Most desirably, the width w of the second dispensing opening 104 is at least about 1.75 times the external or common diameter of the roll product 13.

Referring to FIGS. 4 and 9, since each of the roll products 13 has a soft outer surface, is compressible, exhibits a relatively high coefficient of friction and is relatively light in weight; it will not tend to roll out of the carton 12 under its own weight like an aluminum can. An aluminum can has a very smooth outer circumferential surface with a low coefficient of friction and when it is filled with a liquid it is relatively heavy compared to a roll of paper towels. Because of these differences, it is not necessary to maintain a very high lip 148, or any lip 148, adjacent to either of the first or second dispensing openings, 94 and 104 respectively.

Referring to FIG. 10, an alternative embodiment of a carton 12′ is shown without rolls products 13 so as to better visualize the second dispensing opening 104. In the carton 12′, the second dispensing opening 104 is situated with an edge 150 located flush with an adjacent panel. In FIG. 10, the edge 150 is located flush with the back panel 16. Although the second dispensing opening 104 is shown, it should be understood that the first dispensing opening 94 can be constructed in a similar fashion and the edge 150 would be located adjacent to the end wall 144.

One will also notice in FIG. 10 that the end portions of the second dispensing opening 104 are not semi-circular in configuration as depicted in FIG. 1. Instead, each of the end portions has an arcuate shape that is deepest closer to the back panel 16. This shape facilitates a consumer reaching into the second dispensing opening 104 with one or two hands and inserting a finger into the hollow core 118 of the roll product 13 located adjacent to the second dispensing opening 104. This enables the consumer to remove the roll product 13 by grasping a portion of the hollow core 118. The roll product 13 can be removed using one hand or two hands, whichever is more convenient for the consumer.

Referring now to FIG. 11, a carton 12″ is shown which is similar to the carton 12′ shown in FIG. 10 except for two differences. First, the carton 12″ includes one or more detents 152 positioned along the edge 150. Two detents 152, 152 are depicted. The detents 152 can be integrally formed with the top panel top flap 52, with the bottom panel top flap 60 or with the back panel 16. For example, as the pair of second tear panels 96 and 98 is broken away from the carton 12″, via the perforation lines surrounding the second opening 104, the detents 152, 152 can remain. By “detent” it is meant an upstanding member, a tab, a finger, a shoulder, that will limit, restrict or prevent movement of a roll product 13.

In FIG. 11, a pair of spaced apart detents 152, 152 is depicted. However, any number of detents 152 can be utilized. The size, shape and location of the detent(s) 152 can vary. For example, a detent 152 can be spaced apart from an adjacent detent 152 by a desired distance. Desirably, the distance ranges from between about 1 to 6 inches. More desirably, the detents 152, 152 are spaced at least 2 inches apart from one another. Even more desirably, the detents 152, 152 are spaced at least 1.5 inches apart from one another. For example, for a roll product 13 having a length of from between about 10 to about 12 inches, five or six detents 152 should be effective in preventing the roll product 13 from accidentally rolling out of the carton 12″. The detent(s) 152 will prevent the roll product 13, located immediately adjacent to the second opening 104, from being discharged from the carton 12′ without human assistance. Since the roll products 13 have a soft outer surface which is not exceptionally smooth and therefore has a higher coefficient of friction than say aluminum can, and since the roll products 13 are rather light in weight, they do not have a tendency to roll out of the carton 12, 12′ or 12″ under their own power or initiative.

Referring now to FIG. 12, still another embodiment of a carton 12′″ is shown where the second dispensing opening 104 is situated with a majority of its lower edge 150 flush with the back panel 16. A pair of corner detents 154, 154 is located between the back panel 16 and each of the upstanding bottom panel 40 and the upstanding top panel 24. Each pair of corner detents 154, 154 has a height h₅ which rises above the back panel 16. The size, shape and location of the pair of corner detents 154, 154 can vary. For example, each of the pair of corner detents 154, 154 can have a width w₅, measured along the edge 150, which can range from between about 0.25 inches to about 3 inches for an opening who's largest dimension is 16 inches or less. The height h₅ can range from between about 0.1 inches to about 1 inch. Desirably, each of the pair of corner detents 154, 154 can have a width w₅ which is equal to or less than about 2.5 inches and a height h₅ which is equal to or less than about 0.5 inches. More desirably, each of the pair of corner detents 154, 154 can have a width w₅ which is equal to or less than about 2 inches and a height h₅ which is equal to or less than about 0.4 inches. Even more desirably, each of the pair of corner detents 154, 154 can have a width w₅ which is equal to or less than about 0.75 inches wide and a height h₅ which is equal to or less than about 0.3 inches.

As stated above with reference to FIG. 10, the characteristics of the second dispensing opening 96 & 98 also apply to the first dispensing opening 94 in FIGS. 11 and 12.

Method

A method of recycling empty hollow cores 118 formed from cellulose fibers back into the original package carton 12, 12′ 12″ or 12′″ will now be explained with reference to FIG. 13. A plurality of roll products 13 each formed from cellulosic material and each being wound upon an empty hollow core 118 are housed or retained in the carton 12, 12′, 12″ or 12′″. The carton 12, 12′, 12″ or 12′″ is formed also from cellulose fibers. Desirably, the carton 12, 12′, 12″ or 12′″ is constructed from paperboard. The carton 12, 12′, 12″ or 12′″ can be recycled by itself or in combination with one or more of the empty hollow cores 118 once the roll product 13 has been removed from the hollow cores 118. Each of the hollow cores 118 has a paper product 13, such as paper towels, toilet paper, dry wipes, etc. wound upon it. The roll product 13 usually includes multiple sheet of cellulosic material each separated by a weakened line, such as a perforation line or score line, so that one or more of the sheets can be removed from the roll product 13 at a given time. When all of the sheets are removed, an empty hollow core 118 will remain.

The method includes the steps of inserting a plurality of the roll products 13 into the carton 12, 12′, 12″ or 12′″ and closing and sealing the open end of carton 12, 12′, 12″ or 12′″. The carton 12, 12′, 12″ or 12′″ can then be shipped to a retailer or directly to a consumer. The carton 12, 12′, 12″ or 12′″ has a top panel 24 and a bottom panel 40 aligned opposite to the top panel 24. The carton 12, 12′, 12″ or 12′″ also has a pair of end walls 144 and 146 each being located between the top panel 24 and the bottom panel 40. The carton 12, 12′, 12″ or 12′″ further has a front panel 32 and a back panel 16, each being located between the top panel 24 and the bottom panel 40 and adjacent to each of the pair of end walls 144 and 146. The carton 12, 12′, 12″ or 12′″ also has a first tear panel 68 formed in the front panel 32. The first tear panel 68 has portions that extend into each of the top and bottom panels, 24 and 40 respectively. The first tear panel 68 defines a first opening 94 into the carton 12, 12′, 12″ or 12′″ when it is removed. The first opening 94 provides access to at least one of the roll products 13 housed within the carton 12, 12′, 12″ or 12′″. The carton 12, 12′, 12″ or 12′″ also has a second tear panel (a combination of 96 and 98) formed in the end walls 146. The second tear panel 96 and 98 has portions that that extend into each of the top and bottom panels, 24 and 40 respectively. The second tear panel 96 and 98 defines a second opening 104 into the carton 12, 12′, 12″ or 12′″ when it is removed. The second opening 104 provides access to at least one of the roll products 13 housed within the carton 12, 12′, 12″ or 12′″.

The carton 12, 12′, 12″ or 12′″ further includes a pair of third tear panels 106 and 108 formed in the top panel 24. The pair of third tear panels 106 and 108 defines a pair of third openings 116, 116 into the carton 12, 12′, 12″ or 12′″ when removed. Each of the third openings 116, 116 allow an empty hollow core 118 to be inserted back into the carton 12, 12′, 12″ or 12′″ after at least one full roll of product 13 has been removed from the carton 12, 12′, 12″ or 12′″. At least one roll of product 13 has to be removed from the carton 12, 12′, 12″ or 12′″ to create a void space within the carton 12, 12′, 12″ or 12′″ which will accommodate the insertion of the empty hollow core 118.

The method also includes removing at least one of the third tear panels 106 and 108 from the carton 12, 12′, 12″ or 12′″ to create a third opening 116. After the roll product 13, i.e. paper towels, is removed from the hollow core 118, an empty hollow core 118 remains. The empty hollow core 118 is then inserted back into the carton 12, 12′, 12″ or 12′″ through one of the third openings 116, 116.

The method can also include forming a pair of fourth tear panels 124 and 126 in the bottom panel 40. The pair of fourth tear panels 124 and 126 defines a pair of fourth openings 128, 128 into the carton 12, 12′, 12″ or 12′″ when removed. Each of the fourth openings 128, 128 allow an empty hollow core 118 to be inserted back into the carton 12, 12′, 12″ or 12′″ after at least one full roll of product 13 has been removed from the carton 12, 12′, 12″ or 12′″.

Alternatively, the method can be carried out by removing both of the third tear panels 106 and 108 so as to form two openings 116, 116 into the carton 12, 12′, 12″ or 12′″. After one or more of the empty hollow cores 118 has been inserted back into the carton 12, 12′, 12″ or 12′″, both the carton 12, 12′, 12″ or 12′″ and the empty hollow cores 118 contained therein can be recycled. The recycling can be accomplished using the standard practice for paper products known to those skilled in the recycling art.

Each roll product 13 can be removed from the carton 12, 12′, 12″ or 12′″ through one of the first or second dispensing openings, 94 or 104 respectively, by a consumer using one or two hands. The consumer can reach into the end portions of one of the first or second dispensing openings, 94 or 104 respectively, and physically grab the ends of the roll product 13. Alternatively, the consumer can place an index finger into the opposite ends of the hollow core 118 and pull the roll product through the first or second dispensing openings, 94 or 104 respectively. The roll product 13 being removed from the carton 12, 12′, 12″ or 12′″ will be taken from the bottom row of the roll products 13 contained in the carton 12, 12′, 12″ or 12′″.

While the invention has been described in conjunction with several specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims.

Claims

1. A carton formed from cellulose fibers and having a pair of dispensing openings, said carton capable of housing a plurality of generally cylindrically shaped products formed from cellulose fibers, each of said products wound upon a hollow core formed from cellulose fibers and having a common diameter, said carton comprising:

a) a top panel;

b) a bottom panel aligned opposite to said top panel;

c) a pair of end walls each being located between said top panel and said bottom panel;

d) a front panel and a back panel each being located between said top panel and said bottom panel and adjacent to each of said pair of end walls;

e) a first tear panel formed in said front panel and having portions that extend into each of said top and bottom panels, said first tear panel defining a first dispensing opening when removed which provides access to at least one of said products housed within said carton;

f) a second tear panel formed in one of said end walls and having portions that extend into each of said top and bottom panels, said second tear panel defining a second dispensing opening when removed which provides access to at least one of said products housed within said carton; and

g) a pair of third tear panels formed in said top panel, said pair of third tear panels defining a pair of third openings when removed which allow an empty hollow core to be inserted back into said carton once one of said products has been removed from said carton.

2. The carton of claim 1 wherein one of said pair of third tear panels is located adjacent to a first corner of said top panel and said other pair of third tear panels is located adjacent to a second corner of said top panel, and said first corner is located diagonally across from said second corner.

3. The carton of claim 2 wherein one of said pair of third tear panels has a circular configuration with a central axis which is located with 2 inches of said first tear panel.

4. The carton of claim 3 wherein said other of said pair of third tear panels has a circular configuration with a central axis which is located with 2 inches of said second tear panel.

5. The carton of claim 2 wherein each of said pair of third tear panels has a diameter which is greater than said common diameter of said empty hollow cores.

6. The carton of claim 1 further comprising a pair of fourth tear panels formed in said bottom wall, said pair of fourth tear panels defining a pair of fourth openings when removed which allow an empty hollow core to be inserted back into said carton once at least one of said products has been removed from said carton.

7. The carton of claim 6 wherein each of said third and fourth pairs of tear panels has a central axis and said central axis of each of said pair of third tear panels is coaxially aligned with a central axis of each of said pair of fourth tear panels.

8. The carton of claim 1 wherein each of said first, second and pair of third tear panels includes a plurality of perforations and a handle is positioned in said top panel.

9. The carton of claim 1 wherein one of said first and second openings has an edge located flush with an adjacent panel and a detent is formed along said edge to restrict movement of said product.

10. A blank for forming a carton having a pair of dispensing openings, comprising:

a) an adhesive tab;

b) a back panel located adjacent to said adhesive tab and having a top and a bottom;

c) a first vertical fold line positioned between said adhesive tab and said back panel;

d) a top panel located adjacent to said back panel and having a top and a bottom;

e) a second vertical fold line positioned between said back panel and said top panel;

f) a front panel located adjacent to said top panel and having a top and a bottom;

g) a third vertical fold line positioned between said top panel and said front panel;

h) a bottom panel located adjacent to said front panel and having a top and a bottom;

i) a fourth vertical fold line positioned between said front panel and said bottom panel;

j) a back panel top flap located adjacent to said top of said back panel;

k) a back panel bottom flap located adjacent to said bottom of said back panel;

l) a top panel top flap located adjacent to said top of said top panel;

m) a top panel bottom flap located adjacent to said bottom of said top panel;

n) a front panel top flap located adjacent to said top of said front panel;

o) a front panel bottom flap located adjacent to said bottom of said front panel;

p) a bottom panel top flap located adjacent to said top of said bottom panel;

q) a bottom panel bottom flap located adjacent to said bottom of said bottom panel;

r) a first horizontal fold line disposed between said back panel and said back panel top flap, between said top panel and said top panel top flap, between said front panel and said front panel top flap, and between said bottom panel and said bottom panel top flap;

s) a second horizontal fold line disposed between said back panel and said back panel bottom flap, between said top panel and said top panel bottom flap, between said front panel and said front panel bottom flap, and between said bottom panel and said bottom panel bottom flap;

t) a first tear panel formed in said front panel and having a pair of portions which extends partially into said top panel and said bottom panel, and when said first tear panel is removed a first opening is formed into said carton; and

u) a pair of second tear panels, one of said pair of second tear panels formed in said top panel top flap and having a portion which partially extends into said top panel and said other of said pair of second tear panels formed in said bottom panel top flap and having a portion which partially extends into said bottom panel, and when said pair of second perforations is removed a second opening is formed into said carton.

11. The blank of claim 10 further comprising a pair of third tear panels formed in said top panel, when at least one of said pair of third tear panels is removed a third opening is formed into said carton which allows an empty hollow core to be inserted back into said carton, and each of said third openings has a diameter which is at least equal to said common diameter of said empty hollow core.

12. The blank of claim 11 wherein a pair of third tear panels are formed in said top panel, each of said pair of third tear panels has a central axis which is located within about 3 inches of one of said first and second horizontal fold lines.

13. The blank of claim 10 wherein each of said back panel top flap, said front panel top flap, said top panel top flap and said bottom panel top flap has a height, and said height of each of said top panel top flap and said bottom panel top flap is greater than said height of each of said back panel top flap and said front panel top flap.

14. The blank of claim 10 wherein each of said back panel, said front panel, said top panel and said bottom panel has a width, said width of said back panel is approximately equal to said width of said front panel, and said width of said top panel is approximately equal to said width of said bottom panel, and said width of said back panel is greater than said width of said top panel.

15. The blank of claim 10 wherein said back panel bottom flap and said front panel bottom flap are identical in size and configuration, and said top panel bottom flap and said bottom panel bottom flap are identical in size and configuration.

16. The blank of claim 10 further comprising a pair of fourth tear panels formed in said bottom panel, when at least one of said pair of fourth tear panels is removed a fourth opening is formed into said carton which allows an empty hollow core to be inserted back into said carton, and said fourth opening has a diameter which is at least equal to said common diameter of said empty hollow core.

17. The blank of claim 16 wherein each of said pair of fourth tear panels has a central axis which is located within about 3 inches of one of said first and second horizontal fold lines.

18. A method of recycling empty hollow cores formed from cellulose fibers which are housed in a carton formed from cellulose fibers, each of said hollow cores having a product formed from cellulose fibers wound upon it, said method comprising the steps of:

a) inserting a plurality of said products into said carton and sealing said carton, said carton having a top panel, a bottom panel aligned opposite to said top panel, a pair of end walls each being located between said top panel and said bottom panel, a front panel and a back panel each being located between said top panel and said bottom panel and adjacent to each of said pair of end walls, a first tear panel formed in said front panel and having portions that extend into each of said top and bottom panels, said first tear panel defining a first opening when removed which provides access to at least one of said products housed within said carton, a second tear panel formed in one of said pair of end walls and having portions that extend into each of said top and bottom panels, said second tear panel defining a second opening when removed which provides access to at least one of said products housed within said carton, and a pair of third tear panels formed in said top panel, said pair of third tear panels defining a pair of third openings when removed which permits an empty hollow core to be inserted back into said carton once one of said products has been removed from said carton;

b) removing one of said first and second tear panels to obtain a dispensing opening into said carton;

c) removing at least one of said third tear panels;

d) removing one of said products from said carton;

e) removing said product wound upon said hollow core to obtain an empty hollow core; and

f) inserting said empty hollow core back into said carton through one of said third openings.

19. The method of claim 18 further comprising the step of removing both of said third tear panels.

20. The method of claim 18 further comprising recycling said carton containing one or more of said empty hollow cores.