FLOATING ROLL END HOLDERS

Abstract

A container includes a plurality of panels connected together at fold lines to extend at least partially around an interior space, including a top panel, a front panel, a bottom panel and a back panel. A plurality of end flaps, each end flap foldably connected to a respective one of the panels, are overlapped with one another to enclose an end of the interior space. One of the end flaps includes a roller flap foldably connected thereto, the roller flap extending inward into the interior space for suspending a roll of material thereon.

Description

REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/767,618 filed on Nov. 15, 2018, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

2. Field of the Invention

The present disclosure relates to packaging, and more particularly to roll holders for dispensing rolled material such as foil, wrap material, and the like.

3. Description of Related Art

Traditional roll dispensers have plastic inserts on either end, facing inward. A roll of material such as foil, wrapping material, or the like, is suspended end to end between the plastic inserts. This allows the roll of material to roll relative to the dispenser so a user can remove a desired amount of material from the dispenser. Typically the rest of the dispenser is made of paper board or the like, and the plastic inserts must be assembled and/or adhered into the dispenser.

The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved rolled material dispensers. This disclosure provides a solution for this need.

SUMMARY OF THE INVENTION

A container includes a plurality of panels connected together at fold lines to extend at least partially around an interior space, including a top panel, a front panel, a bottom panel and a back panel. A plurality of end flaps, each end flap foldably connected to a respective one of the panels, are overlapped with one another to enclose an end of the interior space. One of the end flaps includes a roller flap foldably connected thereto, the roller flap extending inward into the interior space for suspending a roll of material thereon.

The roller flap can include a plurality of panels forming a z-shape in cross-section. The roller flap can include an adhesive panel adhered to the bottom panel wherein corresponding edges of the adhesive panel and the bottom panel are offset from one another by a gap. The roller flap can include a top panel that is foldably connected to and is adhered to a respective end flap. The front panel can include a tuck panel. A front closure panel can be foldably attached to the bottom panel and is cooperative with the tuck panel to close or open the interior space.

The plurality of end flaps can include a bottom end flap foldably connected to the bottom panel, where the bottom end flap is the end flap that includes the roller flap foldably connected thereto. A back end flap can be foldably connected to the back panel. A top end flap can be foldably connected to the top panel. A front end flap can be foldably connected to the front panel. A second plurality of end flaps can be included at an opposite end of the panels from the first plurality of end flaps. Each end flap of the second plurality of end flaps can be foldably connected to a respective one of the panels, wherein the end flaps of the second plurality of end flaps are overlapped with one another to enclose an end of the interior space opposite the first plurality of end flaps. A second plurality of end flaps can include a bottom flap having a second roller flap foldably connected thereto, the second roller flap extending inward into the interior space for suspending a roll of material thereon. A roll of material can be suspended on the first and second roller flaps in the interior space.

A blank for a container includes a plurality of panels and a plurality of end flaps as described above.

These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIG. 1 is a plan view of an exemplary embodiment of a blank constructed in accordance with the present disclosure, showing the panels and end flaps;

FIG. 2 is a plan view of the blank of FIG. 1, showing the roller flaps adhered for palletization;

FIG. 3 is a perspective view of the blank of FIG. 1 with the roller panel formed into a support for a roll of material;

FIG. 4 is a perspective view of the blank of FIG. 1, showing the blank formed into a dispenser suspending a roll of material in the interior space; and

FIG. 5 is perspective view of the dispenser of FIG. 4, showing the dispenser open for dispensing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a blank in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of blanks in accordance with the disclosure, or aspects thereof, are provided in FIGS. 2-5, as will be described. The systems and methods described herein can be used to improve floating end roll containers.

The blank 100 for a container 101 (shown in FIG. 4) includes a plurality of panels connected together at fold lines to extend at least partially around an interior space 103 (identified in FIG. 3), including a top panel 102 connected to a front panel 104 along a fold line 106, a bottom panel 108 connected to a back panel 110 along a fold line 112. The back panel 110 is connected to the top panel 102 along fold line 114. The front panel 104 includes a frangible panel 116 connected thereto along a perforation line 118. A front closure panel 120 is foldably attached to the bottom panel 108 along a fold line 122. The front closure panel 120 includes a reinforcement panel 124 foldably connected thereto along a fold line 126. With the reinforcement panel 124 adhered to the front closure panel 120 (as shown in FIGS. 3-4), the front closure panel 120 is cooperative with the frangible panel 116 to close or open the interior space 103. The five moon shaped areas 117 shown on the closure panel 120 in FIG. 1 are glue dot areas, to ease the opening feature. The outlines of the five moon shaped areas 117 are partial cuts, so that when a consumer pulls off the frangible panel 116 and breaks the perforation line 118, only half of the material detaches from panel 120 for a clean look once open.

A plurality of end flaps, each end flap foldably connected to a respective one of the panels 102, 104, 108, 110, are configured to be overlapped with one another to enclose an end of the interior space 103 as shown in FIGS. 3-4. The plurality of end flaps includes a bottom end flap 128 foldably connected to the bottom panel 108 along a fold line 130. A back end flap 132 is foldably connected to the back panel 110 along a fold line 134. A top end flap 136 is foldably connected to the top panel 102 along fold line 138. A front end flap 140 is foldably connected to the front panel 104 along the fold line 142. A front closure panel end flap 144 is foldably connected to the front closure panel 120 along a fold line 146.

A second plurality of respective end flaps 148, 152, 156, 160, 164 is foldably connected by respective fold lines 150, 154, 158, 162, 166 at an opposite end of the respective panels 108, 110, 102, 104, 120 from the first plurality of end flaps 128, 132, 136, 140, 144. The end flaps of the second plurality of end flaps 148, 152, 156, 160, 164 are ultimately overlapped with one another to enclose an end of the interior space 103 opposite the first plurality of end flaps 128, 132, 136, 140, 144.

Each of the bottom end flaps 128, 148 includes a respective roller flap 168, 170 foldably connected thereto, the roller flap 168, 170 extending inward into the interior space 103 when the container 101 is constructed as shown in FIG. 3-4 for suspending a roll 172 of material thereon. Each roller flap 168, 170 includes a plurality of panels 174, 176, 78 forming a z-shape in cross-section when assembled as shown in FIG. 2. Each roller flap 168, 170 includes an adhesive panel 180 that is adhered to the bottom panel 108 when forming the container 101. The z-shaped cross-section of the panels 174, 176, 178 forms along fold lines 182, 186, 188, 190 when erecting the container 101 because corresponding edges, i.e., fold lines 182, 150, of the adhesive panel 180 and the bottom panel 108 are offset from one another by a gap G identified in FIG. 2. Each roller flap 168, 170 includes a top panel 184 that is foldably connected to and is adhered to a respective bottom end flap 128, 148. The fold lines 186 can be pre-broken, e.g., in two places.

The reinforcement panel 124 can be folded along the fold line 126 and adhered to the front closure panel 120. The fold line 192 connecting each roller flap 168, 170 to its respective bottom end flap 128, 148 can be folded and the adhesive panel 180 of each roller flap 168, 170 can be adhered to the respective bottom end flap 128, 148. This results in the palletized form of the blank 100 shown in FIG. 2. For example, the blank 100 can be made in a first facility and processed into the palletized form shown in FIG. 2.

Bulk blanks 100 can be palletized and shipped to a second facility, for example, where the blanks are formed into containers 101 as follows. The bottom panel 108 is folded into position along the fold line 112. The bottom end flap 128 is folded into position along fold line 130. This forces the roller flap 168 into the z-shape. The closure panel 120 can be folded into position along the fold line 126 and its end flap 144 can be adhered to the bottom end flap 128. A roll 172 of material can be placed in the interior space 103 and one end thereof can be suspended on the roller flap 168. Then the bottom end flap 148, second roller flap 170, and second end flap 164 can be positioned and adhered at the second end of the container 101 in a similar manner as that described above, wherein the second end flap 164 is placed in the center of the roll 172 sot that both ends of the roll 172 are suspended by the roller flaps 168, 170 for easy dispensing of the rolled material from the container 101 without the rolled material contacting the sides of the container 101.

The top panel 102 can be folded into position along the fold line 114, and the front panel 104 can be folded into position along the fold line 106 so that the respective end flaps 136, 140, and 156, 160 can be folded into position, overlapped and adhered to form a lid portion of the container 101. The frangible panel 116 can be adhered to an outer surface of the reinforcement panel 124. A consumer can tear away the perforation line 118, open the lid portion as shown in FIG. 5, and access the rolled material, and re-close the lid portion.

The methods and systems of the present disclosure, as described above and shown in the drawings, provide for floating roll end holders with superior properties including forming the roll holders from a common blank and material with the dispenser. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.

Claims

1. A container comprising:

a plurality of panels connected together at fold lines to extend at least partially around an interior space, including a top panel, a front panel, a bottom panel and a back panel; and

a plurality of end flaps, each end flap foldably connected to a respective one of the panels, wherein the end flaps are overlapped with one another to enclose an end of the interior space, wherein one of the end flaps includes a roller flap foldably connected thereto, the roller flap extending inward into the interior space for suspending a roll of material thereon.

2. The container as recited in claim 1, further comprising a roll of material suspended on the roller flap in the interior space.

3. The container as recited in claim 1, wherein the roller flap includes a plurality of panels forming a z-shape in cross-section.

4. The container as recited in claim 1, wherein the roller flap includes an adhesive panel adhered to the bottom panel wherein corresponding edges of the adhesive panel and the bottom panel are offset from one another by a gap.

5. The container as recited in claim 1, wherein the roller flap includes a top panel that is foldably connected to and is adhered to a respective end flap.

6. The container as recited in claim 1, wherein the front panel includes a tuck panel.

7. The container as recited in claim 6, further comprising a front closure panel foldably attached to the bottom panel and cooperative with the tuck panel to close or open the interior space.

8. The container as recited in claim 1, wherein the plurality of end flaps includes:

a bottom end flap foldably connected to the bottom panel, where the bottom end flap is the end flap that includes the roller flap foldably connected thereto;

a back end flap foldably connected to the back panel;

a top end flap foldably connected to the top panel; and

a front end flap foldably connected to the front panel.

9. The container as recited in claim 8, wherein the plurality of end flaps is a first plurality of end flaps and further comprising a second plurality of end flaps at an opposite end of the panels from the first plurality of end flaps, wherein each end flap of the second plurality of end flaps is foldably connected to a respective one of the panels, wherein the end flaps of the second plurality of end flaps are overlapped with one another to enclose an end of the interior space opposite the first plurality of end flaps.

10. The container as recited in claim 9, wherein the roller flap is a first roller flap and wherein the second plurality of end flaps includes a bottom flap having a second roller flap foldably connected thereto, the second roller flap extending inward into the interior space for suspending a roll of material thereon.

11. The container as recited in claim 10, further comprising a roll of material suspended on the first and second roller flaps in the interior space.

12. A blank for a container comprising:

a plurality of panels connected together at fold lines configured for extending at least partially around an interior space, including a top panel, a front panel, a bottom panel and a back panel; and

a plurality of end flaps, each end flap foldably connected to a respective one of the panels, wherein the end flaps are configured to be overlapped with one another to enclose an end of the interior space, wherein one of the end flaps includes a roller flap foldably connected thereto, the roller flap configured to extend inward into the interior space for suspending a roll of material thereon.

13. The blank as recited in claim 12, wherein the roller flap includes a plurality of panels configured to form a z-shape in cross-section.

14. The blank as recited in claim 12, wherein the roller flap includes an adhesive panel adhered to the bottom panel wherein corresponding edges of the adhesive panel and the bottom panel are offset from one another by a gap.

15. The blank as recited in claim 12, wherein the roller flap includes a top panel that is foldably connected to and is adhered to a respective end flap.

16. The blank as recited in claim 12, wherein the front panel includes a tuck panel.

17. The blank as recited in claim 16, further comprising a front closure panel foldably attached to the bottom panel and cooperative with the tuck panel to close or open the interior space.

18. The blank as recited in claim 12, wherein the plurality of end flaps includes:

a bottom end flap foldably connected to the bottom panel, where the bottom end flap is the end flap that includes the roller flap foldably connected thereto;

a back end flap foldably connected to the back panel;

a top end flap foldably connected to the top panel; and

a front end flap foldably connected to the front panel.

19. The blank as recited in claim 18, wherein the plurality of end flaps is a first plurality of end flaps and further comprising a second plurality of end flaps at an opposite end of the panels from the first plurality of end flaps, wherein each end flap of the second plurality of end flaps is foldably connected to a respective one of the panels, wherein the end flaps of the second plurality of end flaps are configured to be overlapped with one another to enclose an end of the interior space opposite the first plurality of end flaps.

20. The blank as recited in claim 19, wherein the roller flap is a first roller flap and wherein the second plurality of end flaps includes a bottom flap having a second roller flap foldably connected thereto, the second roller flap configured to extend inward into the interior space for suspending a roll of material thereon.