Inventors: Sara Falcon, Alyssa Smith, Linh Kooc

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 1 19(e) of United States provisional applications serial number 61/496,635 filed on June 14, 201 1 and 61/528,774 filed on August 30, 2011, both of which are hereby incorporated by reference in their respective entireties.

BACKGROUND

[0002] The invention consists of a folded carton structure with a seal end flap. The seal end flap may be constructed such that a primary tab is revealed when the seal end flap is folded over. The primary tab and the resultant seal end flap may rest opposite each other such that the consumer can grip each with a separate hand and pull the package apart.

[0003] The invention allows the user easy access into a sealed carton structure, without the use of a tool. The invention allows the consumer to open the package without tearing through the structure, leaving a cleaner appearance to the opened package. The invention provides audible cueing during opening to enhance the opening experience.

[0004] The invention consists of a folded carton structure and with a seal end flap. The folded carton structure may house the product, whereas the seal end flap may be used to keep the structure closed.

[0005] The carton structure may have secondary tabs that keep the structure closed along any open sides. The secondary tabs may be any shape or size, and one or multiples may be used per open side of the carton structure.

[0006] The junction where the secondary tab meets the folded carton structure may be smooth towards the seal end of the structure. The junction where the secondary tab meets the folded carton structure may have a sharp undercut on the side that is farthest from the seal end. The sharp junction may allow the tab to key into the insert hole locking it in place. This keying action may provide security by snuggly holding the folded carton structure together. The smooth junction may allow the tab to exit the insert hole easily in the direction of the opening feature. The combination of smooth and sharp junctions may allow the structure to remain securely in the closed position until the opening feature is engaged. The combination of smooth and sharp junctions gives directionality to the opening of the carton structure as it easily opens in the direction of pull once the opening feature is engaged.

[0007] The seal end flap may consist of two layers of board that are sealed together along a side of the carton structure, securing the carton structure together. The seal end flap may extend from the carton structure along a crease on one layer and a perforation along the second layer. One layer of the seal end flap may have a cut out area which is not sealed. When the seal end flap is folded along the crease, the cut out area, or primary tab, may be exposed creating a pull tab to open the package. The primary tab and the resultant seal end flap may be pulled in opposite directions to break the perforations on the second seal layer, thus opening the package.

[0008] The invention may contain multiple audible redundant cues that aid the consumer in understanding how to open the package and add to the overall opening experience. The action of the primary tab releasing from the seal end flap may create an audible click that adds to the element of surprise as the primary tab seems to "pop" from the seal end flap. The action of breaking the small tacked areas of the perforation may provide a series of satisfying "pop" sounds as the package is opened.

[0009] The present application is directed to paperboard packages and, more particularly, to easy-opening features for paperboard packages. Manufacturers and retailers of consumer goods, such as pharmaceuticals, software, electronics, health and beauty products and the like, typically package their products in tamper resistant security packages. For example, many consumer goods are packaged in blister or clamshell packages formed by positioning a consumer good in a flanged blister made from various polymeric and/or paperboard materials and sealing the flanged blister between two paperboard substrates. Consumers have voiced disapproval of such packages because of the difficulty of opening the same and the potential for being cut on a rough edge especially of plastic blisters. Packages may therefore be made based largely on paperboard, for example, NATRALOCK packages. Packaging made primarily of paperboard is more sustainable than packaging made from petroleum- based plastics. The paperboard used in such packages may be tear-resistant as described in commonly assigned US Patent No. 7, 144,635.

[0010] Some packages may include a paperboard card and a polymeric blister. Other packages may not use a polymeric blister. In any case it would be

advantageous to have a package that protects its contents well but is fairly easy to open.

SUMMARY

[0011] In one aspect a packaging structure is disclosed which includes a first panel and a second panel made of sheet material and hingedly attached to one another either directly or through intermediate panels, wherein the packaging structure is initially shut but can be opened by tearing certain parts of the package.

[0012] Other aspects of the disclosed package will become apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Fig . 1 is a plan view of a blank for a package;

[0014] Fig . 2 is a perspective view of a step in assembling the package;

[0015] Fig . 3 is a perspective view of a further step in assembling the package;

[0016] Fig . 4 is a perspective view of a finished package;

[0017] Fig . 5 is a perspective view of a step in opening the package;

[0018] Fig . 6 is a perspective view of a step in opening another package;

[0019] Fig . 7 is a perspective view of the opened package;

[0020] Fig . 8 shows alternative forms of certain package features; [0021] Fig. 9 is a plan view of a blank for another package; and

[0022] Figs. 10A and 10B are detail views of certain features of the package of Fig. 9.

DETAILED DESCRIPTION

[0023] As various embodiments of the package are described, reference will be made to Figures 1-10. Certain parts of the packages are denoted by reference numerals. Where there is more than one of the same feature, generally only one will be denoted by a reference numeral. Typically in these Figures, where a top plan view is shown for a blank of material, solid lines usually indicate periphery or cuts, and dashed lines usually indicate crease, score, or fold lines. In perspective views, solid lines typically show edges, while dashed lines typically show hidden or partially obscured features. Where assembly steps are described, these steps are exemplary and are not to be limiting as to the sequence of operations used to arrive at the final package. Also, directions such as up, down, top, bottom, front, back, etc. are used for convenience in describing the package and are not meant to be limiting. In most cases the packages described here are made from one blank (that is, the cut sheet parts from which the package components are made by folding and other steps). However, it should be understood that blanks may be provided instead as more than one part. The word "panel" will often be used to describe a piece of sheet material such as paperboard, particularly with respect to a blank from which the package is made. However, "panel" may also be used to describe a region of a piece of material, for example a portion of the material that is in a first plane, connected across a fold line with the same material in a second plane. Since panels are sometimes superimposed, for example, creating a two-layer structure, like features or panels will sometime coincide, in which cases, descriptions may call out the number identifying the feature closer to the viewer, that is, the feature visible in a particular Figure.

[0024] Fig. 1 shows a plan view of a blank 10 for forming a package 12. Although a blister may be used as part of the package, the example here does not use a blister. The package may have a back panel 20 and a front panel 40 hingedly connected through a base panel 30 which may include one or more subpanels, and one or more base side panels 35. Back panel 20 and front panel 40 may each be connected to a sealing flap 21, 41 which may comprise a hang hole 22, 42. A reinforcing layer of paperboard or other material may be placed between the front and back sealing flaps 21, 41, for example at the hang hole location, as described in PCT/US08/066517. The front panel 40 may have an aperture 44 to receive a portion of a product item 100, or a blister (not shown). The back panel 20 may have an aperture 24 to receive a portion of a product item 100, or a blister (not shown).

[0025] Each of the back panel 20 and front panel 40 may include hingedly attached wing or side panels 25, 45 attached along hinge or fold lines 26, 46 which may be linear or curved and which may include scores, perforations, or other features to facilitate forming the package, according to manufacturing preference. Other hinge or fold lines (not all labeled) may be included between the various panels. Either or both the side panels 25, 45 may include slots 27 to receive tabs 47.

[0026] Fig. 2 shows a perspective view of the blank 10 in a partially assembled configuration, with back panel 20 and front panel 40 folded toward each other in a hinging action about the base panel 30. Also shown in Fig. 2 are the side panels 25, 45 being bent inward slightly.

[0027] Fig. 3 shows a perspective view of the blank 10 in a further assembled configuration, with the back panel 20 and front panel 40 moved closer together and the side panels 25, 45 overlapping to some extent. In the distant side panels, the tab 47 is shown inserted through slot 27, while in the nearer side panels 25, 45 the tab 47 is not yet inserted into the slot 27. As shown in Fig. 3, the distant openings or cutouts 25A, 45 A may be provided in the overlapping side panels 25, 45 to provide a viewport or touch port for a customer to see or touch the product, which may be inserted into the package at some point before the package is sealed shut. To close and seal the package once the contents are placed inside, the back panel 20 and front panel 40 may be brought closer together, any additional tabs 47 inserted through corresponding slots 27, and the sealing flaps 21, 41 joined together by heat sealing, adhesive, staples, or other suitable method. This forms the package 12 shown in Fig. 4. To better show side panel 25 in Fig. 4, side panel 45 is illustrated not quite covering side panel 25, as if the panels were not quite closed yet. However in the completely closed package, the side panels 45 may in fact (depending on the design) overlap side panels 25 sufficiently to cover or nearly cover or hide side panels 25. One or more means such as tape (for example a tape 'dot' 49A provided with a perforation for easier separation) or glue 49B may optionally be used to better secure together the side panels 25, 45. If such securing means are used, they may be sized, shaped, or positioned to provide some strength without making the package too difficult to open in the steps illustrated in Figs. 5-7.

[0028] The package in Fig. 4 may include a pull tab 50 extending upward from back panel 20 (or alternately from front panel 40) into sealing flap 21. An optional cutout 54 may be provided in sealing flap 21 adjacent to the pull tab 50 to enable a customer to more readily grasp the edge of the pull tab 50.

[0029] One way to start opening package 12 is shown in Fig. 5. The user may flex sealing flap 21 (and the attached ply of sealing flap 41) backwards in order to help release the pull tab 50 from the perforations 52 joining it to the remainder of sealing flap 21. Then, as shown in Fig. 7, the customer may continue to pull on pull tab 50 so that the perforations 56 between sealing flap 21 and back panel 20 are severed. This allows back panel 20 to pivot away from front panel 40. The tabs 47 may then disengage from slots 27 and allow the package to fully open. The action of breaking the perforation may provide a series of satisfying "pop" sounds as the package is opened.

[0030] Another way to start opening package 12 is shown in Fig. 6, where a user may grasp pull tab 50 and draw it away from the plane of sealing flap 21, thereby starting a tear to separate the upper edge of the pull tab 50. To facilitate the user's grasping pull tab 50, an optional cutout 54 may be provided through sealing flap 21 (or through sealing flaps 21 and 41). Such a cutout may better enable a user's fingers to gain access to the edge of pull tab 50.

[0031] As shown in Fig. 8, the tabs 47 may be formed with a geometry that holds side panels 25, 45 securely closed when the sealing flaps 21, 41 are joined together.

However, the geometry of tabs 47 may allow the tabs to fairly easily release from slots 27 once the back panel 20 has been separated from the sealing flap 41. For example, as shown in Fig. 8A, tab 47 may have a lower edge 47A with at least a slight 'downward' slope relative to the edge of side panel 45 which may tend to more securely engage slot 27. Thus when the package is assembled with the sealing flaps 21, 41 joined together, tab lower edge 47A may resist a lateral pulling force "A" that might otherwise tend to pull the tab 47 out of slot 27. However, when the package is being opened as shown in Figs. 5-7, the force against tab 47 may be a pivoting force "B" (about pivot point or pivot line "P" for example that may coincide with or be proximate to one or more fold lines of the package) in which case the 'downward' slope of lower edge 47 A may allow tab 47 to 'rotate' out of slot 27. Likewise the 'downward' slope of upper edge 47B may allow it to readily rotate out of slot 27.

[0032] The tab 47 may be shaped according to manufacturing preference, for example to provide a tab that provides a desired resistance to opening either by lateral force or pivoting force. For example, an alternative tab 48 is shown in Fig. 8B that may have a lower edge 48A with at least a slight 'downward' slope relative to the edge of side panel 45 that may tend to securely engage slot 27. Thus when the package is assembled with the sealing flaps 21, 41 joined together, tab lower edge 48A may resist a lateral pulling force "A" that might otherwise tend to pull tab 48 out of slot 27. Likewise tab upper edge 48B have at least a slight upward slot to more securely engage slot 27, and resist a lateral pulling force "A" that might otherwise tend to pull tab 48 out of slot 27.

[0033] However, when the package is being opened as shown in Figs. 5-7, the force against tab 48 may be a pivoting force "B" (about pivot point or pivot line "P" for example that may coincide with or be proximate to one or more fold lines of the package) in which case the 'downward' slope of lower edge 48A may allow tab 48 to 'rotate' out of slot 27. However, the 'upward slope of upper edge 48B instead of smoothly rotating out of slot 27, may resist removal from slot 27. Tab 48 may thereby provide a more secure package, but one which may be more difficult to open. Thus tabs 47, 48 (or other or additional tabs if provided) may be designed according to manufacturing preference to adjust the package closure strength as well as the ease of opening once the user starts the pivoting motion of Figs. 5-7.

[0034] Fig. 9 shows a plan view of a blank 1 1 for forming a package, similar in many respects to the package shown in the earlier Figures. In blank 11, however, tabs 47C are provided which are shaped to more securely fit into slots 27. Tabs 47C may be shaped so that once secured into slots 27, a tab 47C must be torn from its associated side panel 45 in order to open the package.

[0035] Fig. 10A shows a detail of geometry of tab 47C including its lower edge 47A and upper edge 47B which will fit securely into slot 27 and be difficult or impossible to remove from slot 27 without tearing loose the tab. Thus when the package is assembled with the sealing flaps 21, 41 joined together, the tab lower edge 47 A and tab upper edge 47B may resist any forces that might otherwise pull the tab 47C out of slot 27. When the package is being opened (for example as shown in Figs. 5-7), tab 47C must be torn from side panel 45 in order to open the package.

[0036] The perforations between tab 47C and wing panel 45 may be designed to more strongly hold together at the tab upper edge 47B that is further from pivot point or pivot line "P" (for example, shallower cuts, or cuts from one surface only, or more material between cuts) while the perforations at the tab lower edge 47A that is closer to pivot point or pivot line "P" may be designed to less strongly hold together (for example deeper cuts, or cuts from both surfaces, or cuts with less material between cuts). Thus the perforations may be designed so that it is somewhat difficult (e.g., a more secure package) to start tearing the tab (which may occur toward the tab upper edge 47B), but once the tear has started, it may progress without undue effort by the user.

[0037] The card blank 10, 1 1 and package 12 may be formed of a sheet material such as paperboard, which may be made of or coated with materials to increase its strength. An example of such a sheet material is EASYSEAL paperboard made by

MeadWestvaco Corporation. The sheet material may have a heat sealable coating, for example to allow a heat seal to be created between the back sealing flap 21 and front sealing flap 41. Alternately, other forms of adhesive may be used to seal these flaps together. It should be noted that the use of tear resistant materials, and/or in more than one layer, help to improve the tamper- and theft-resistance of the package.

[0038] Package 12 may be used to enclose either a loose item of merchandise, or an inner carton enclosing merchandise. For example, a manufacturer may have an existing well established carton with a well-recognized brand image, but lacking adequate security. Such a carton may have a premium appearance, for example custom graphics, metallization, embossing, or other premium features. By placing the existing premium carton inside package 12, additional tamper and theft resistance may be provided. Furthermore once package 12 is opened the premium package is still intact. Thus a manufacturer may wish to enclose an existing carton within package 12.

[0039] The packages disclosed herein may be made from one or several blanks (that is, the cut sheet parts from which the package components are made by folding and other steps). However, it should be understood that certain unitary blanks may be provided instead as more than one part, and certain blanks may be combined into single blanks, while still arriving at the same finished package.

[0040] Where more than one blank is used, the blanks may be assembled in various stages, including assembling a unitary blank into a package, assembling separate blanks and then joining them to form a package, and joining two or more blanks together, for example by heat sealing, gluing, mechanical fastening, or otherwise and then forming the combined blanks into the package.

[0041] It should be understood that additional foldover panels may be included in the package blanks for further reinforcing the packages.