CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/334,220, filed on April 25, 2022.

INCORPORATION BY REFERENCE

[0002] The disclosure of U.S. Provisional Patent Application No. 63/334,220, filed on April 25, 2022, is hereby incorporated by reference for all purposes as if set forth in its entirety.

BACKGROUND

[0003] The present disclosure generally relates to cartons for holding and dispensing articles.

SUMMARY

[0004] According to one aspect, the disclosure is generally directed to a carton for holding and dispensing at least one article, the carton comprising a plurality of panels extending at least partially around an interior of the carton and comprising a top panel, a bottom panel, a front panel, and at least one back panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels and forming at least one closed end of the carton, and a dispenser for accessing the interior of the carton, the dispenser comprising a plurality of dispenser flaps at least partially separably connected to the top panel such that the dispenser is reconfigurable between a first configuration, in which the plurality of dispenser flaps is foldably connected to the top panel, and a second configuration, in which one or more of the dispenser flaps is separated from the top panel.

[0005] According to another aspect, the disclosure is generally directed to a blank for forming a carton for holding and dispensing at least one article, the blank comprising a plurality of panels for extending at least partially around an interior of the carton formed from the blank and comprising a top panel, a bottom panel, a front panel, and at least one back panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels for forming at least one closed end of the carton formed from the blank, and a dispenser for accessing the interior of the carton formed from the blank, the dispenser comprising a plurality of dispenser flaps at least partially separably connected to the top panel such that the dispenser is reconfigurable between a first configuration, in which the plurality of dispenser flaps is foldably connected to the top panel, and a second configuration, in which one or more of the dispenser flaps is separated from the top panel. [0006] According to another aspect, the disclosure is generally directed to a method of forming a carton for holding and dispensing at least one article, the method comprising obtaining a blank, the blank comprising a plurality of panels comprising a top panel, a bottom panel, a front panel, and at least one back panel, the blank further comprising a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the blank further comprising a dispenser comprising a plurality of dispenser flaps at least partially separably connected to the top panel. The method further comprises positioning the plurality of panels extending at least partially around an interior of the carton and such that the dispenser is reconfigurable between a first configuration, in which the plurality of dispenser flaps is foldably connected to the top panel, and a second configuration, in which one or more of the dispenser flaps is separated from the top panel, and overlapping the plurality of end flaps to form at least one closed end of the carton.

[0007] Those skilled in the art will appreciate the above-stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] 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 disclosure.

[0009] Fig. 1 is a plan view of an exterior surface of a blank used to form a carton according to an exemplary embodiment of the disclosure.

[0010] Fig. 1A is an enlarged view of a portion of the blank of Fig. 1.

[0011] Fig. 2 is a perspective view of a carton formed from the blank of Fig. 1 according to an exemplary embodiment of the disclosure.

[0012] Fig. 3 is a perspective view of the carton of Fig. 2, with the dispenser of the carton in a first configuration.

[0013] Fig. 4 is a perspective view of the carton of Fig. 2, with the dispenser of the carton in a second configuration.

[0014] Corresponding parts are designated by corresponding reference numbers throughout the drawings. DETAILED DESCRIPTION

[0015] Cartons according to the present disclosure can accommodate articles of numerous different shapes. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes articles such as gloves (e.g., nitrile, latex, rubber, other polymeric materials, or gloves formed from other materials), tissues, sheets or barriers, wipes, cloths, or other household/medical/industrial products for being sequentially dispensed from such cartons. It will be understood that the articles can be different products, such as paper towels, napkins, sanitary or disinfecting wipes, etc., without departing from the disclosure.

[0016] In this specification, the terms “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright cartons. As described herein, cartons can be formed from blanks by overlapping multiple panels, portions, and/or end flaps. Such panels, portions and/or end flaps may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure.

[0017] Fig. 1 is a plan view of an exterior surface 101 of a blank, generally indicated at 103, used to form a container or carton 105 (Fig. 2) according to an exemplary embodiment of the disclosure. As described further herein, the carton 105 can be provided with a dispenser 109 for accessing an interior 107 of the carton 105 and dispensing one or more articles held in the interior 107 of the carton 105. The dispenser 109 can be formed of materials that have enhanced sustainability comparable to other materials. For example, in some embodiments, the dispenser 109 can be comprised of paperboard. In some embodiments, the dispenser 109 can be devoid of polymeric materials such as plastic, e.g., plastic films..

[0018] As shown in Fig. 1, the blank 103 can have a longitudinal axis LI and a lateral axis L2, and a plurality of panels for extending at least partially around the interior 107 of the carton 105 formed from the blank 103. In the illustrated embodiment, the plurality of panels of the carton blank 103 can include a front side panel or front panel 121, a top side panel or top panel 123 foldably connected to the front panel 121 at a lateral fold line 125, and a bottom panel 127 foldably connected to the front panel 121 at a lateral fold line 129. A first back panel 131 can be foldably connected to the top panel 123 at a lateral fold line 133, and a second back panel 135 can be foldably connected to the bottom panel 127 at a lateral fold line 137. It will be understood that one or both of the back panels 131, 135 can be considered an end flap foldably connected to a respective panel of the plurality of panels.

[0019] The blank 103 can also include a plurality of end flaps for forming at least one closed end of the carton 105. The end flaps can include a first front side end flap 139 foldably connected to the front panel 121 at a respective portion of a longitudinal fold line 141, a first top side end flap 143 foldably connected to the top panel 123 at a respective portion of the longitudinal fold line 141 , and a first bottom side end flap 145 foldably connected to the botom panel 127 at a respective portion of the longitudinal fold line 141.

[0020] As also shown, an atachment end flap 147 can be foldably connected to the end flap 143 at a lateral fold line 149. The end flaps 139, 143, 145, 147 can be a first plurality of end flaps extending along a first marginal portion of the blank for being at least partially overlapped to form a first closed end 111 of the carton 105 formed from the blank 103. In some embodiments, the end flaps 147, 143 can be considered foldably connected portions of a single end flap, e.g., a base portion and a distal portion of such end flap. In some embodiments, the fold line 149 can be collinear with or form a portion of the fold line 133.

[0021] Similarly, a second front side end flap 151 , a second top side end flap 153, and a second bottom side end flap 155 can be foldably connected to opposite ends of the respective panels 121, 123, 127 at respective portions of a longitudinal fold line 157. An atachment end flap 159 can also be foldably connected to the end flap 153 at a lateral fold line 161. The end flaps 151, 153, 155, 159 can be a second plurality of end flaps extending along a second marginal portion of the blank 103 and for being at least partially overlapped to form a second closed end 113 of the carton 105 formed from the blank 103. In some embodiments, the end flaps 153, 159 can be considered foldably connected portions of a single end flap, e.g., a base portion and a distal portion of such end flap. In some embodiments, the fold line 161 can be collinear with or form a portion of the fold line 133.

[0022] The blank 103 also includes dispenser features for forming the dispenser 109 of the carton 105. With additional reference to Fig. 1A, such dispenser features can include a first dispenser flap 163, a second dispenser flap 165 (broadly, “third dispenser flap”), a third dispenser flap 167 (broadly, “second dispenser flap”), and a fourth dispenser flap 169, each in at least partial feeing relation with one another.

[0023] In the illustrated embodiment, the first dispenser flap 163 can be at least partially separably connected to the top panel 123 at a curved tear line 171, the second dispenser flap 165 can be at least partially separably connected to the top panel 123 at a curved tear line 173, the third dispenser flap 167 can be foldably connected to a first dispenser panel 175 at a longitudinal fold line 177, and the fourth dispenser flap 169 can be foldably connected to a second dispenser panel 179 at a longitudinal fold line 181.

[0024] Each dispenser panel 175, 179 can be at least partially separably connected to the top panel 123 at a respective curved tear line 183, 185. As shown, and as described further herein, the third dispenser flap 163 can be at least partially separable from the top panel 123 at a respective pair of at least partially curved cuts 187, 189 that intersect or extend adjacent endpoints of the fold line 177, and the fourth dispenser flap 169 can be at least partially separable from the top panel 123 at a respective pair of at least partially curved cuts 191, 193 that intersect or extend adjacent endpoints of the fold line 181. [0025] With continued reference to Fig. 1A, the dispenser features 109 can be arranged such that endpoints of the tear line 183 are positioned proximate or intersecting endpoints of the respective cuts 187, 189, the other endpoints of the respective cuts 187, 189 are positioned proximate or intersecting endpoints of the respective tear lines 171, 173, the other endpoints of the respective tear lines 171, 173 are positioned proximate or intersecting endpoints of the respective cuts 191, 193, and the other endpoints of the respective cuts 191, 193 are positioned proximate or intersecting endpoints of the tear line 185. Such arrangement of the lines of weakening 171, 173, 183, 185, 187, 189, 191, 193 can form a generally elliptical line of weakening around the dispenser features to facilitate removal thereof, as described further herein. It will be understood that the lines of weakening associated with the dispenser features can form a different arrangement, e.g., circular, square, trapezoidal, etc., without departing from the disclosure.

[0026] In the illustrated embodiment, the third dispenser flap 167 can include a base portion 195 foldably connected to the dispenser panel 175 at the longitudinal fold line 177, and a distal portion 197 foldably connected to the base portion 195 at a longitudinal fold line 199. Similarly, the fourth dispenser flap 169 can include a base portion 201 foldably connected to the dispenser panel 179 at the longitudinal fold line 181 and a distal portion 203 foldably connected to the base portion 201 at a longitudinal fold line 205.

[0027] The dispenser flaps 163, 165, 167, 169 can be arranged such that the distal portion 197 of the dispenser flap 167 can be at least partially separable from the dispenser flaps 163, 165 at respective oblique tear lines 207, 209 that intersect each other and respective endpoints of the longitudinal fold line 199. The base portion 203 of the dispenser flap 169 can likewise be at least partially separable from the respective dispenser flaps 163, 165 at respective oblique tear lines 211, 213 that intersect each other and respective endpoints of the fold line 205. The dispenser flaps 163, 165 can be at least partially separated at a curved line of weakening 215 that extends from the intersection of the tear lines 207, 209 to the intersection of the tear lines 211, 213. In some embodiments, one or more of the tear lines 207, 209, 211, 213 can include a relief cut to facilitate relative separation of the dispenser features.

[0028] Referring additionally to Fig. 2, formation of the carton 105 from the blank 103 will be described according to an exemplary embodiment of the disclosure. The blank 103 can be positioned with the exterior surface thereof in contact with a supporting surface, e.g., in a face-down orientation, and with an interior surface of the blank 103 facing upwardly. The panels 121, 123, 127, 131, 135 can be folded at the fold lines 125, 129, 133, 137 at least partially around the interior 107 of the carton 105 and to position the front panel 121 and the back panels 131 , 135 in generally spaced and parallel relation and to position the top panel 123 and the bottom panel 127 in generally spaced and parallel relation. The back panels 131, 135 can be positioned in at least partially overlapping relation and secured to one another with an adhesive, for example glue. In some embodiments, the back panel 131 can be positioned overlapping the back panel 135. In other embodiments, the back panel 135 can be positioned overlapping the back panel 131.

[0029] The end flaps 139, 143, 145 can be folded at respective portions of the fold line 141 into at least partially overlapping relation to form the first closed end 111 of the carton 105. The end flap 147 can be folded at the fold line 149 into at least partial overlapping relation with respective portions of the back panels 131, 135. For example, in some embodiments, an exterior surface of the attachment flap 147 can be positioned in at least partial face-to-face contact with an interior surface of the back panel 135.

[0030] Similarly, the end flaps 151, 153, 155 can be folded at respective portions of the fold line 157 into at least partially overlapping relation to form the second closed end 113 of the carton 105, with the end flap 159 folded at the fold line 161 into at least partial overlapping relation with respective portions of the back panels 131, 135. For example, in some embodiments, an exterior surface of the attachment flap 159 can be positioned in at least partial face-to-face contact with an interior surface of the back panel 135.

[0031] ft will be understood that one or more articles G can be loaded into the interior 107 of the carton

105 before both ends 111, 113 of the carton 105 are closed. In the illustrated embodiment, the articles G can be gloves, e.g., nitrile or other polymeric gloves, though the articles can include one or more other household/medical/industrial products without departing from the disclosure.

[0032] In the erected configuration of the carton 105, the dispenser 109 can be presented facing upwardly from the top panel 123 to be engaged/operated by a user in a plurality of modalities or configurations.

[0033] With additional reference to Fig. 3, in a first configuration of the dispenser 109, the dispenser flaps 1 3, 165, 167, 169 can be at least partially separated from one another at the respective lines of weakening 207, 209, 211, 213, 215, and the dispenser flaps 167, 169 can be at least partially separated from the top panel 123 at the respective cuts 187, 189, 191, 193. In some embodiments, initial separation of the respective dispenser flaps from one another can be caused by at least partially pressing down thereupon by a user.

[0034] In such a configuration, one or more of the dispenser flaps 163, 165, 167, 169 can be moved relative to the top panel 123 to at least partially expose an opening 115 into the interior 107 of the carton 107 to provide access to the articles G in the interior 107 of the carton 105. For example, the end flap 163 can be at least partially folded upwardly relative to the top panel 123 at the tear line 171, the end flap 165 can be at least partially folded upwardly relative to the top panel 123 at the tear line 173, the end flap 167 can be at least partially folded upwardly relative to the top panel 123 and the dispenser panel 175 at the fold line 177, and/or the end flap 169 can be at least partially folded upwardly relative to the top panel 123 and the dispenser panel 179 at the fold line 181. In some embodiments, the distal portion 1 7 of the end flap 167 can be folded at least partially upwardly relative to the base portion 195 thereof at the fold line 199, and/or the distal portion 203 of the end flap 169 can be at least partially folded upwardly relative to the base portion 201 thereof at the fold line 181.

[0035] In this regard, upon at least partial exposure of the opening 115 into the interior 107 of the carton 105 via relative movement of one or more of the dispenser flaps 163, 165, 167, 169, one or more of the articles G can be withdrawn through the opening 115 to the exterior environment for subsequent use.

[0036] It will be understood that one or more of the edges and faces of the dispenser flaps 163, 165,

167, 169 can provide at least partial resistance to withdrawing one or more of the articles G from the interior 107 of the carton 105, e.g., via frictional or other interfering engagement with the respective articles G. In one embodiment, the engagement of one or more of the dispenser flaps 163, 165, 167, 169 can at least partially separate adjacent articles G in the interior 107 of the carton 105 to provide a controlled and serialized dispensing of articles G from the carton 105. In one embodiment, one or more of the dispenser flaps 163, 165, 167, 169 can be at least partially biased downward toward the interior 107 of the carton 105 to facilitate such engagement with the articles G.

[0037] When one or more dispensing operations with regard to the carton 105 are complete, it will be understood that one or more of the dispenser flaps 163, 165, 167, 169 can be urged toward the interior 107 of the carton 105, e.g., to minimize the opening 115 into the interior 107 of the carton 105 and to provide a tucked arrangement/profile for the features of the dispenser 109.

[0038] Referring additionally to Fig. 4 a second configuration of the dispenser 109 is illustrated in which one or more of the dispenser flaps 163, 165, 167, 169 is separated and removed from the top panel 123 at the respective tear lines 171, 173, 183, 185 and respective cuts 187, 189, 191, 193 in order to maximize the size of the opening 115 into the interior 107 of the carton 105. Such access to the articles G in the carton 105 may be desirable, for example, in emergent situations in which rapid access to the articles G is needed. Such a situation could arise for example, in a busy medical or clinical environment in which multiple personnel may need to access the articles G in rapid succession and/or in bulk. In some embodiments, the carton 105 may be provided in an outer container, e.g., a rigid container with a top opening, such that the removal of one or more of the dispenser flaps 163, 165, 167, 169 avoids obscuring the top opening of the outer container.

[0039] The second configuration of the dispenser 109 is also advantageous as it provides selectivity to the opening 115 into the carton 105, e.g., by providing the operator the option to remove a desired arrangement or number of dispenser flaps from the top panel 123. For example, an operator may choose to separate less than all of the dispenser flaps 163, 165, 167, 169 from the top panel 123 at the respective tear lines 171, 173, 183, 185 and cuts 187, 189, 191, 193 in order to provide a size and arrangement for the opening 115 of their choosing.

[0040] In view of the foregoing, the blank 103/carton 105 provides a carton for dispensing one or more articles in a selectively reconfigurable manner via a dispenser 109 that allows for dispensing of articles according to a first configuration or a second configuration to adapt to changing environments.

[0041] The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the cartons, to function at least generally as described above. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

[0042] In accordance with the above-described embodiments of the present disclosure, 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 disclosure, 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.

[0043] As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits 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 tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the spaced apart slits to be replaced with a continuous slit, a continuous score, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. Also, a tear line can be a series of cut scores passing completely, or partially, through the material, that are separated by nicks.

[0044] The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

[0045] The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.