The present invention relates to a method of placing a carton in a tilt configuration according to the preamble of claim 1. Similarly, the present invention relates to a carton according to the preamble of claim 6.

Enclosed cartons with positioning features for displaying or dispensing articles have been used in the past. A carton as defined in the preamble of claim 6 which is suited to be placed in a tilt configuration as defined in the preamble of claim 1 is disclosed, e.g., in US 2004/0188508 A1. Due to the tilt configuration of the carton, articles accommodated within the carton are more easily accessible to users through the dispenser opening. Articles may therefore be retrieved from the carton interior without necessitating the user to reach into the carton interior. The dispenser flap of this carton extends into the top panel, the exiting end panel and both side panels. The dispenser flap mounting projection is formed in the top panel by a suitably curved frangible line. In its tilt configuration the side panel portions of the dispenser flap embrace the carton side panels adjacent the end panel what makes it cumbersome to correctly place the dispenser flap so as to place the carton in its tilt configuration. Further, the mounting feature sized to receive the dispenser flap mounting projection extends across the entire width of the carton. This, as in many other instances of use of positioning features, negatively affects the structural integrity of the carton. Additionally, many conventional carton positioning assemblies, like that of the named reference, are structurally weak and are relatively easily flattened by excessive weight, and/or may not provide a desired degree of stability for a carton. Accordingly, it is one object of the present invention to provide for a carton of the generic type as defined in the preamble of claim 6 and a method of placing a carton in a tilt configuration as defined in the preamble of claim 1 that allows supporting a relatively large weight without collapsing or deforming significantly.

According to a first aspect of the invention, this object is achieved by a carton as defined in claim 6. Accordingly, the carton of the present invention includes a dispenser located at an exiting end of the carton. The dispenser can be opened by separating the dispenser flap from the exiting end of the carton, thereby forming a dispenser opening at the exiting end. The dispenser flap is then, at its mounting projection, engaged with a mounting feature at the bottom rear of the carton to tilt the carton in a manner such that articles within the carton are urged by gravity toward the exiting end. The dispenser flap comprises at least one fold line extending substantially laterally across the existing end panel along with at least one fold line the dispenser flap mounting projection is to be bent. Also according to the first aspect of the invention, the dispenser flap can be formed such that it is capable of supporting a relatively large weight without collapsing or deforming significantly. The relatively high strength of the dispenser flap allows heavy articles such as beverage containers to be supported in the carton while in the tilt configuration.

The opened exiting end of the opened carton can have one or more retainer walls so that articles are prevented from inadvertently rolling out of the carton, even when the carton is in the tilt configuration.

According to a second aspect of the invention, the method of placing a carton in a tilt configuration according to the present invention as defined in claim 1 comprises providing a carton having a first side panel, a top panel, a second side panel, a bottom panel, an end panel, an exiting end panel, and a dispenser pattern defining a dispenser flap at least in the exiting end panel and in the top panel, separating the dispenser flap from a remainder of the carton, wherein separating the dispenser flap forms a dispenser opening at least in the exiting end panel and in the top panel, and engaging the dispenser flap with a mounting feature proximate to the end panel, wherein the dispenser flap provides a nonzero angle of orientation of the carton with respect to horizontal.

The dispenser flap comprises a mounting projection, and engaging the dispenser flap with the mounting feature comprises inserting the mounting projection in the mounting feature. The dispenser flap comprises at least one fold line extending substantially laterally across the exiting end panel. A plurality of articles can be accommodated within the carton. A carton blank, which is not part of the present invention, may comprise a first side panel, a second side panel, a top panel, a bottom panel, at least one exiting end flap extending along a first marginal area of the blank, at least one end flap extending along a second marginal area of the blank, a dispenser pattern defining a dispenser flap at least in the at least one exiting end flap, the top panel, the first side panel, and the second side panel, and a mounting feature at or adjacent to the at least one end flap sized to receive at least a portion of the dispenser flap.

The at least one exiting end panel of the blank may comprise a first side exiting end flap connected to the first side panel, and a second side exiting end flap connected to the second side panel, the dispenser pattern extending through the first side exiting end flap and the second side exiting end flap. The dispenser pattern may comprise a first fold line extending generally transversely through first side exiting end flap and a second fold line extending generally transversely through the second side exiting end flap. The mounting feature may comprise a breachable line of disruption in the blank.

Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims.

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

FIG. 1 is a plan view of a blank from which a carton according to a first embodiment of the invention is formed.

FIG. 2 is a top perspective view of the carton according to the first embodiment.

FIG. 3 illustrates opening of the dispenser of the first carton embodiment.

FIG. 4 is a perspective view of the dispenser flap of the first carton embodiment.

FIG. 5 is a partial, bottom perspective view of the rear of the first carton embodiment.

FIG. 6 illustrates the first carton embodiment being placed in a tilt configuration.

FIG. 7 is a side view of the first carton embodiment in its tilt configuration.

FIG. 8 is a partial, perspective view of the first carton embodiment in its tilt configuration.

FIG. 9 is a plan view of a blank from which a carton according to a second embodiment of the invention is formed.

FIG. 10 is a top perspective view of the carton according to the second embodiment.

FIG. 11 is a perspective view of the dispenser flap of the second carton embodiment.

FIG. 12 is a partial, bottom perspective view of the rear of the second carton embodiment.

FIG. 13 is a side view of the second carton embodiment in its tilt configuration.

FIG. 14 is a partial, perspective view of the second carton embodiment in its tilt configuration.

For a more complete understanding of the present invention, reference should be made to the following detailed description and accompanying drawings, wherein like or similar reference numerals designate corresponding parts throughout the figures.

The present invention generally relates to cartons having tilt features that enhance the dispensing capabilities of the cartons. The tilt features according to present invention can be used, for example, in cartons that contain articles or other items or products such as, for example, food and beverages. The articles can also include beverage containers such as, for example, cans, bottles, PET containers, or other containers such as those used in packaging foodstuffs. For the purposes of illustration and not for the purpose of limiting the scope of the invention, the following detailed description describes generally cylindrical beverage containers as disposed within the carton embodiments. In this specification, the terms "lower," "bottom," "upper" and "top" indicate orientations determined in relation to fully erected and upright cartons.

FIG. 1 is a plan view of a blank 8 used to form a carton 190 (illustrated in FIG. 2) according to a first embodiment of the invention. The blank 8 comprises a first side panel 10 foldably connected to a top panel 20 at a first transverse fold line 21, a second side panel 30 foldably connected to the top panel 20 at a second transverse fold line 31, and a bottom panel 40 foldably connected to the first side panel 10 at a third transverse fold line 41. An adhesive flap 50 may be foldably connected to the second side panel 30 at a fifth transverse fold line 51. A handle 26 can be included in the top panel 20.

The first side panel 10 is foldably connected to a first side exiting end flap 12 and a first side end flap 14. The top panel 20 is foldably connected to a top exiting end flap 22 and a top end flap 24. The second side panel 30 is foldably connected to a second side exiting end flap 32 and a second side end flap 34. The bottom panel 40 is foldably connected to a bottom exiting end flap 42 and a bottom end flap 44. The exiting end flaps 12, 22, 32, 42 extend along a first marginal area of the blank 8, and may be foldably connected along a first longitudinally extending fold line 62. The end flaps 14, 24, 34, 44 extend along a second marginal area of the blank 8, and may be foldably connected along a second longitudinally extending fold line 64. The longitudinally extending fold lines 62, 64 may be straight fold lines, or, the fold lines 62, 64 may be offset at one or more locations to account for, for example, blank thickness. When the carton 190 is erected, the exiting end flaps 12, 22, 32, 42 close a front or exiting end of the carton 190, and the end flaps 14, 24, 34, 44 close a back end of the carton 190.

A dispenser pattern 100 is formed in the blank 8 and defines a dispenser 150 in the erected carton (FIG. 2). The dispenser pattern 100 can generally be formed from, for example, tear lines or other lines of disruption that allow the dispenser 150 to be opened. When the dispenser 150 is opened, a dispenser flap 155 removed during opening of the dispenser 150 may be used to place the carton 190 in its tilt configuration.

The dispenser pattern 100 comprises a first end tear line 108 that extends through the first side exiting end flap 12, and a second end tear line 128 that extends through the second side exiting end flap 32. The first and second end tear lines 108, 128 have obliquely extending center sections that transition at each end into generally laterally extending sections. The first and second end tear lines 108, 128 define an end retainer wall 125 in the erected carton 190 (FIG. 2).

The first end tear line 108 extends to a point at or adjacent to a first side tear line 102 that extends generally obliquely through the first side panel 10. The second end tear line 128 extends to a point at or adjacent to a second side tear line 122 that extends generally obliquely through the second side panel 30. A first generally longitudinally extending tear line 104 extends between a point at or adjacent to the first side tear line 102 and an opening feature 106 in the top panel 20. A second generally longitudinally extending tear line 124 extends between a point at or adjacent to the second side tear line 122 and the opening feature 106. A first tilt fold line 132 extends from the first end tear line 108 to an edge of the first side exiting end flap 12. A second tilt fold line 134 extends from the second end tear line 128 to an edge of the second side exiting end flap 32. In accordance with a first exemplary embodiment, a mounting feature 136 is formed at the fold line 64 between the bottom panel 40 and the bottom end flap 44. The mounting feature 136 cooperates with the dispenser flap 155 to tilt the carton 190 (FIG. 7). First and second oblique score lines 26, 28 are formed in the top exiting end flap 22. The oblique score lines 26, 28 allow the dispenser flap 155 to deform at the top exiting end flap 22 allowing the dispenser flap 155 to be removed more easily during opening of the dispenser 150.

Referring again to FIG. 1, the tear lines 102, 104, 108, 122, 124, 128 of the dispenser pattern 100 can be formed from continuous or substantially continuous tear lines formed by, for example, scores, cuts, gaps, cut/creases, perforations, offset cuts, and combinations thereof. If cuts are used to form the tear lines 102, 104, 108, 122, 124, 128 the cuts may be, for example, interrupted by breachable nicks. The tilt fold lines 132, 134 can be, for example, creases, cut/creases, interrupted cuts, scores, or other lines of disruption in the blank 8. The mounting feature 136 can in general be any breachable line of disruption in the blank 8 that allows an opening to be formed, preferably without necessitating the use of a tool, at the feature. For example, the mounting feature 136 can have the form of a tear line, a continuous cut, or a cut interrupted by breachable nicks. An elongate continuous or interrupted aperture can also be used to form the mounting feature 136.

FIG. 2 is a perspective view of the erected carton 190. The carton 190 can be erected from the blank 8 by, for example, applying glue to the adhesive flap 50 and folding the blank 8 so that the adhesive flap 50 comes into contact with the bottom panel 40. To complete the carton 190, the exiting end flaps 12, 22, 32, 42 are folded inwardly and glued or otherwise adhered in place to form an exiting end panel 120, and the end flaps 14, 24, 34, 44 are folded inwardly and glued or otherwise adhered to form an end panel 130. Containers C (shown in FIG. 7) or other articles may be placed in the carton 190 at any time prior to forming either or both of the end panels 120, 130. In the erected carton 190, the dispenser pattern 100 defines the dispenser flap 155 that is used as a tilt element for the carton.

As shown in FIG. 2, the first and second end tear lines 108, 128 define a generally U-shaped retainer wall 125 in the exiting end panel 120. When the dispenser flap 155 is removed, the retainer wall 125 at least partially occludes the exiting end of the carton 190 to prevent containers or other articles from inadvertently rolling out of or otherwise exiting the carton 190.

FIG. 3 illustrates opening of the dispenser 150 of the carton 190. The carton dispenser 150 may be opened by inserting a finger or other object into the opening feature 106. The opening feature 106 can include, for example, scores, continuous cuts and/or cuts interspersed with nicks, or other breachable lines of disruption, in order to provide relatively easy access to the dispenser 150. The dispenser flap 155 is then removed by tearing along the tear lines 102, 104, 108, 122, 124, 128 (FIG. 1). The oblique scores 26, 28 on the sides of the dispenser flap 155 allow the flap to deform slightly at its edges so that it is more easily pulled from the carton 190.

FIG. 4 is a perspective view of the dispenser flap 155 after removal from the exiting end of the carton 190 during opening of the dispenser 150. The dispenser flap 155 serves as a tilt element for the carton 190, as is discussed in detail below. In accordance with the first exemplary embodiment, the detached dispenser flap 155 includes a mounting projection 162, a rear wall 164, and a base 166 that may be oriented generally perpendicular to the mounting projection 162. The mounting projection 162 is bendable with respect to the rear wall 164 about the tilt fold line lines 132, 134.

FIG. 5 is a bottom perspective view of the rear of the carton 190. As shown in FIG. 5, the mounting feature 136 is disposed at the bottom rear of the carton 190, and is at or adjacent to the bottom panel 40 and the end panel 130. The mounting feature 136 is sized to receive the mounting projection 162 of the dispenser flap 155.

FIG. 6 illustrates the carton 190 being placed in the tilt configuration. In order to place the carton 190 in the tilt configuration, the mounting projection 162 is first folded or bent about the tilt fold line lines 132, 134 so that it is adjacent to or abutting the rear wall 164, as shown in FIG. 6. The folded mounting projection 162 is then inserted into the mounting feature 136 until the base 166 of the flap 155 abuts the bottom panel 40. The mounting projection 162 has a tapered shape that facilitates its insertion into the mounting feature 136. The carton 190 is shown with its bottom side up in FIG. 6 for the purposes of illustration. In practice, a user may place the carton 190 in the tilt configuration while the carton 190 is upright, in order to prevent articles from escaping through the dispenser opening 152 (FIG. 7) formed during removal of the dispenser flap 155. Alternatively, the dispensing opening 152 can be covered while the carton 190 is inverted.

FIG. 7 is a side view of the carton 190 in the tilt configuration, and FIG. 8 is a partial, perspective view of the carton 190 in the tilt configuration. As shown in FIG. 7, the dispenser flap 155 leaves a dispenser opening 152 when removed from the exiting end of the carton 190, and also provides the carton 190 with a tilt angle α when engaged with the mounting feature 136. The tilt angle α causes containers C housed within the carton 190 to roll, slide, or otherwise advance toward the exiting end of the carton 190 by the action of gravity. The shape of the dispenser flap 155, and accordingly the angle α, can be varied according to the desired dispenser opening 152 left by removal of the flap 155, and/or according to the desired tilt angle α. For example, the angle α can be at least about three degrees. In other embodiments, the angle α is at least about five degrees.

According to the above embodiment, containers in the rear or back end of the carton 190 are advanced by the action of gravity to a front or exiting end of the carton 190, without necessitating the user to reach into the carton. This provides a user ease of access to articles within the carton. Also according to the above embodiment, the "corner cutout" form of the dispenser flap 155 is capable of supporting a relatively large carton weight without collapsing, and provides a stable tilt platform for the carton.

FIG. 9 is a plan view of a blank 208 used to form a carton 390 (illustrated in FIG. 10) according to a second embodiment of the invention. The blank 208 comprises a first side panel 210 foldably connected to a top panel 220 at a first transverse fold line 221, a second side panel 230 foldably connected to the top panel 220 at a second transverse fold line 231, and a bottom panel 240 foldably connected to the second side panel 230 at a third transverse fold line 241. An adhesive flap 250 may be foldably connected to the first side panel 210 at a fifth transverse fold line 251. A handle 226 can be included in the top panel 20. The carton blank 208 and carton 390 may be generally similar to the carton blank 8 and carton 190 discussed above, respectively, and like or similar reference numbers in the two embodiments indicate like elements.

A dispenser pattern 300 is formed in the blank 8 and defines a dispenser 350 in the erected carton (FIG. 10). The dispenser pattern 300 can generally be formed from tear lines or other lines of disruption that allow all or a portion of the dispenser 350 to be opened. When the dispenser 350 is opened, a dispenser flap 355 removed during opening of the dispenser is used to place the carton 390 in its tilt configuration.

The dispenser pattern 300 comprises a first end tear line 308 that extends obliquely through the first side exiting end flap 212, and a second end tear line 328 that extends obliquely through the second side exiting end flap 232. The first and second end tear lines 308, 328 have obliquely extending sections that terminate in generally laterally extending sections. The first and second end tear lines 308, 328 define end retainer walls 325, 327 in the erected carton 390 (FIG. 10).

The first end tear line 308 extends to a point at or adjacent to a first side tear line 302 that extends generally laterally through the first side panel 210. The second end tear line 328 extends to a point at or adjacent to a second side tear line 322 that extends generally laterally through the second side panel 230. A first generally longitudinally extending tear line 304 extends between a point at or adjacent to the first side tear line 302 and an opening feature 306 in the top panel 220. A second generally longitudinally extending tear line 324 extends between a point at or adjacent to the second side tear line 322 and the opening feature 306. A first tilt fold line 332 extends from the first end tear line 308 to an edge of the first side exiting end flap 212. A second tilt fold line 334 extends from the second end tear line 328 to an edge of the second side exiting end flap 232. In accordance with the second exemplary embodiment, a mounting feature 336 is formed at the fold line 264 between the bottom panel 240 and the bottom end flap 244.

A tear-away section 322 may be formed in the bottom exiting end flap 240. The tear away section 322 is shaped to align with the first and second end tear lines 308, 328 in the erected carton 390. The tear-away section 322 in the bottom exiting end flap 242 allows articles in the bottom of the carton 390 to be accessed through the exiting end of the carton 390 when the dispenser flap 155 is removed from the carton 390 (FIG. 10).

The tear lines 302, 304, 308, 322, 324, 328 of the dispenser pattern 300 can be formed from continuous or substantially continuous tear lines formed by, for example, scores, creases, cuts, gaps, cut/creases, perforations, offset cuts, and combinations thereof. If cuts are used to form the tear lines 302, 304, 308, 322, 324, 328, the cuts may be, for example, interrupted by breachable nicks. The tilt fold lines 332, 334 can be, for example, creases, cut/creases, scores, or other lines of disruption in the blank 208. The mounting feature 336 can comprise a breachable line of disruption such as, for example, a tear line, a continuous cut, or a cut interrupted by breachable nicks. An elongate aperture can also be used to form the mounting feature 336.

FIG. 10 is a perspective view of the erected carton 390. Containers C (shown in FIG. 13) or other articles may be placed in the carton 390 at any time prior to forming either or both of the end panels 320, 330. In the erected carton 390, the dispenser pattern 300 forms the dispenser flap 355 that is used as a tilt element for the carton. The carton 390 may be opened by inserting a finger or other object into the opening feature 306 and tearing along the tear lines 302, 304, 308, 322, 324, 38 (FIG. 9), thereby removing the dispenser flap 355. The tear lines 308, 328 define the end retainer walls 325, 327 in the exiting end panel 320. When the dispenser flap 355 is removed, the end retainer walls 325, 327 prevent containers or other articles from inadvertently rolling out of or otherwise exiting the carton 390.

FIG. 11 is a perspective view of the dispenser flap 355 after its removal from the exiting end of the carton 390. The detached dispenser flap 355 includes a mounting projection 362, a rear wall 364, and a base 366 that extends generally perpendicularly to the mounting projection 362. The mounting projection 362 is bendable with respect to the rear wall 364 about the first and second tilt fold line lines 332, 334.

FIG. 12 is a bottom perspective view of the rear of the carton 390. As shown in FIG. 12 and in accordance with the second exemplary embodiment, the mounting feature 336 is disposed at the bottom rear of the carton 390 at or adjacent to the bottom panel 240 and to the end panel 320. The mounting feature 336 is sized and shaped to receive the mounting projection 362 of the dispenser flap 355.

The carton 390 may be placed in the tilt configuration in a manner similar to the carton 190 (illustrated in FIG. 6). In order to place the carton 390 in the tilt configuration, the mounting projection 362 is first folded or bent about the tilt fold line lines 332, 334 so that it is adjacent to or abutting the rear wall 364 of the dispenser flap 355. The folded mounting projection 362 is then inserted into the mounting feature 336 until the base 366 of the flap 355 abuts the bottom panel 240. The mounting projection 362 has a tapered shape that facilitates its insertion into the mounting feature 336. In practice, a user may place the carton 390 in the tilt configuration while the carton 390 is upright, in order to prevent articles from escaping through the dispenser opening 352 (FIG. 13) formed during removal of the dispenser flap 355. The user may also invert the carton 390 and cover the dispenser opening 352 to prevent escape of articles from the carton.

FIG. 13 is a side view of the carton 390 placed in the tilt configuration, and FIG. 14 is a partial, perspective view of the carton 390 in the tilt configuration. As shown in FIG. 13, the dispenser flap 355 provides the carton 390 with a tilt angle β. The tilt angle β causes containers C housed within the carton 390 to roll, slide, or otherwise advance toward the exiting end of the carton 390 by the action of gravity. The shape of the dispenser flap 355, and accordingly the size of the tilt angle β, can be varied according to a desired shape of the dispenser opening 352 left by removal of the flap 355, and/or according to the desired tilt angle β. For example, the tilt angle β can be at least about three degrees. In other embodiments, the tilt angle β is at least about five degrees.

The cartons 190, 390 discussed in this specification are designed to accommodate twelve generally cylindrical 12 ounce beverage containers C in two rows (extending horizontally in FIGS. 7 and 13) and six columns (extending vertically in FIGS. 7 and 13). This arrangement is known as a 2x6 configuration. Other types of articles, however, can be accommodated within cartons according to the present invention. These articles can include beverage containers such as bottles and PET containers, as well as other containers cylindrical in shape, such as those used in packaging foodstuffs. Any other like containers holding non-food items or products, such as motor oil, lubricants, etc. can be held and automatically positioned in this type of carton. The principles of the present invention are also applicable to alternative arrangements of articles, including 3x4, 4x3, 2x4, 2x5, 4x6, 4x5, 3x6, 5x6, etc.

In the exemplary embodiments discussed above, the blanks may be formed from materials such as clay coated newsprint (CCN) and solid unbleached sulfate (SUS) board. In general, the blanks may be constructed of paperboard, having a caliper of at least about 14, so that it is heavier and more rigid than ordinary paper. The blanks, and thus the cartons, can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The first and second sides of the blanks can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.

A tear line can be any substantially linear, although not necessarily straight, line of disruption that facilitates tearing therealong. Specifically, but not for the purpose of narrowing the scope of the present invention, tear lines include: a cut that extends partially into the material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of cuts that extend completely through the material, with adjacent cuts being spaced apart slightly so that small somewhat bridge-like pieces of the material (e.g., 'nicks') are defined between adjacent cuts. The nicks are broken during tearing along the tear line. Such a tear line that includes nicks can also be referred to as a cut line, since the nicks typically are a relatively small in relation to the cuts.

The term "line" as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines.

In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line. In contrast, where nicks are present in a cut line (e.g., tear line), typically the nicks will not be overly large or overly numerous in a manner that might cause a reasonable user to incorrectly consider the subject cut line to be a fold line.

The above embodiments may be described as having one or more panels adhered together by glue. The term "glue" is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place.

The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected embodiments of the invention, but it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed in the appended claims.