APPARATUSES AND METHODS FOR A CARTON OPENING ARRANGMENT

Abstract

Methods and apparatuses are disclosed for processing cartons that include steps such as embossing the top opening of cartons for packaging liquid food. Embossing the top opening of cartons may reduce the force required to open the carton in both vertical and horizontal direction and minimize the amount of fibers remaining in the pouring spout after the carton has been opened.

Claims

1. A carton blank for a gable-top carton, the carton blank comprising: a pre-laminated paperboard sheet; a plurality of crease lines; a top portion configured to become a sealing fin on a folded packaging container, the top portion comprising a rectangular fin panel and a plurality of rectangular portions, the rectangular fin panel positioned between the plurality of rectangular portions; and an embossed pattern printed along the rectangular fin panel and a portion of one of the rectangular portions of the top portion of the carton blank, the embossed pattern configured to reduce the force required to open the folded packaging container.

2. The carton blank of claim 1, wherein the pre-laminated paperboard sheet further comprises a central layer comprising a paperboard material and an outer layer comprising a polyethylene material.

3. The carton blank of claim 1, wherein the embossed pattern comprises a plurality of rows, each row comprising a plurality of x-shaped marks.

4. The carton blank of claim 3, wherein the embossed pattern has two rows.

5. The carton blank of claim 3, wherein each x-shaped mark in the plurality of x-shaped marks has a height of approximately 4 mm.

6. The carton blank of claim 1, wherein the embossed pattern comprises a plurality of rows, each row comprising a plurality of ovals.

7. The carton blank of claim 6, wherein each oval of the plurality of ovals has a height of approximately 2 mm and a width of approximately 45 mm.

8. The carton blank of claim 1, further comprising a compressed spot positioned approximately in the center of the embossed pattern.

9. The carton blank of claim 8, wherein the compressed spot comprises a triangular shape.

10. The carton blank of claim 9, wherein the triangular shape has a height of approximately 7 mm, a first dimension of approximately 20 mm, and a second dimension of approximately 18 mm.

11. A packaging container for packaging liquid food, the packaging container comprising: a pre-laminated paperboard material, the pre-laminated paperboard material comprising an outer layer comprising a polyethylene material; a container body, the container body comprising a closed bottom end; a top portion, the top portion extending from the container body opposite the closed bottom end and forming a roof-like configuration; and a sealing fin, wherein the sealing fin comprises a front sealing portion on a front side a back sealing portion on a back side of the sealing fin, a first side rectangular portion opposite a second side rectangular portion, and a front rectangular fin panel opposite a back rectangular fin panel, wherein the front sealing portion comprises an embossed pattern extending along the front rectangular fin panel and a portion of one of the rectangular portions, wherein the back sealing portion comprises the polyethylene material, and wherein the embossed pattern is configured to reduce the force required to open the packaging container.

12. The packaging container of claim 11, further comprising a compressed spot positioned approximately in the center of the embossed pattern.

13. The packaging container of claim 11, further comprising a central layer comprising a paperboard material.

14. The packaging container of claim 11, wherein the embossed pattern has two rows, each row comprising a plurality of x-shaped marks.

15. The packaging container of claim 11, wherein the embossed pattern has three rows, each row comprising a plurality of ovals.

16. The packaging container of claim 11, further comprising a pouring spout, the pouring spout formed by opening the front side of the sealing fin along the embossed pattern while the back side of the sealing fin remains sealed.

17. A method for processing a gable-top carton, the method comprising: printing a plurality of carton blanks on a pre-laminated paperboard sheet; creasing each of the plurality of carton blanks such that each of the plurality of carton blanks comprise a plurality of crease lines; printing an embossed pattern along a top portion of the plurality of creased carton blanks; and cutting a single carton blank from the plurality of creased carton blanks.

18. The method of claim 17, further comprising compressing a compressed spot positioned approximately in the center of the embossed pattern.

19. The method of claim 18, wherein the compressed spot comprises a triangular shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 is a perspective view of a carton from the prior art showing the sealing fin area prior to closing and heat-sealing.

[0030] FIG. 2 is a plan view of a carton blank from the prior art.

[0031] FIG. 3A is a perspective view of a carton with a gable-shaped cover from the prior art in a closed condition.

[0032] FIG. 3B shows the same carton from the prior art as that illustrated in FIG. 3A, but illustrating the first step for opening the pouring opening.

[0033] FIG. 3C is a broken-away perspective top view onto the gable-shaped cover of the carton from the prior art after it has been completely opened.

[0034] FIG. 4 is a broken-away side view of the upper region of a blank from the prior art as shown in FIG. 3A, in a flat condition, with the fold lines and the sealing areas of low adhesive force.

[0035] FIG. 5 is a side view of another embodiment from the prior art, the view being similar to that shown in FIG. 4, in accordance with the above-described embodiment.

[0036] FIGS. 6A-6B depict a portion of an embodiment of a blank carton with an embossed pattern according to the present solution.

[0037] FIGS. 7A-7B depict a portion of another embodiment of a blank carton with an embossed pattern according to the present solution.

DETAILED DESCRIPTION

[0038] Embodiments of the solution disclosed herein are directed to various techniques for adhering surfaces in a carton, such as replacing the use of an adhesive surface at the top of the gable top carton, with a step of embossing this area to adhere the surfaces together. In some examples, the benefit of embossing may be twofold. First, the defined embossed marks (e.g., x-shaped marks, circular marks, oval marks) help reduce the force required to open the carton in both vertical and horizontal directions. Second, an area in the pouring spout can be fully compressed, as shown in FIGS. 6A and 7A, to ensure that little to no fibers remain in the pouring spout after the carton has been opened, which avoids contamination of the product.

[0039] In some embodiments, the method of embossing the carton may involve printing on cartons being in the form of pre-laminated sheets. The pre-laminated sheets can comprise a central layer of paperboard and outer layers of polyethylene. After being printed on, the cartons can be creased such that several crease lines are formed. The crease lines may be configured to be folded such that the top of the carton that is opposite a closed bottom, the top resembles a roof, the side walls are opposite each other, and the front wall is opposite the back wall. After the cartons are creased, the cartons can be embossed along the part of each rectangular section 340, 440 and along the length of the first and second rectangular fin panel 332, 334, 432, 434. The embossed patterns are described further below. Once the cartons are embossed, the pre-laminated sheets can be cut into individual carton blanks. In certain embodiments, each carton blank can comprise a sealing flap that includes a polyethylene material (e.g., low-density polyethylene (LDPE)). After the pre-laminated sheets are cut, the cartons can be folded along the crease lines and heat can be applied to the sealing flap to melt the polyethylene material such that the sealing flap seals against the interior-facing surface of the front wall.

[0040] Referring to FIGS. 6A-6B, a portion of an embodiment of an embossed carton blank 300 according to the present solution is shown. The general structure of the carton blank may be similar to the prior art carton blank shown in FIGS. 4-5. When the carton blank 300 is folded, it may have a similar configuration as the prior art carton depicted in FIGS. 3A-3C. In certain embodiments, the embossed carton blank 300 can comprise front and back walls 304, 306, side walls 310, rectangular fin panels 332, 334, rectangular portions 340, 348, a plurality of crease lines 312, 314, 319, 321, 336, 344, triangular back-folding panels 326, and triangular end panels 322. In some embodiments, the plurality of crease lines may include vertical crease lines 336, two diagonal crease lines 319, 321 and a score 344. At the top of the carton 300, the front and back walls 304, 306 can be folded along a crease line 312 which extends across the front wall 304 and back wall 306 and the two side walls 310. The crease lines 314 can be configured to form each of the corners of the carton 300.

[0041] In some embodiments of the present solution, the carton blank can have main roof panels 318, 320 which can be extensions of the front and back walls 304, 306. The main roof panels 318, 320 may each comprise a diagonal crease line 319, 321 and a triangular folding panel 327. When opening the top of the carton, these diagonal crease lines 319, 320 can support and guide the carton to fold along the diagonal crease lines 319, 320, which can make it easier for the consumer to open the carton. The carton blank can have triangular end panels 322, 324 and triangular back-folding panels 326. A crease line or score 344 in the carton blank can be parallel to the crease line 312 and can define the sealing fin along the ridge of the sealed gable-top carton. In certain embodiments, on the opposite side of the crease line 344 from the triangular back-fold panels 326, the carton blank can have rectangular fin panels 332, 334 adjacent the end panel 322 At the apex of the triangular end panel 322, a vertical crease line 336 can be provided between the rectangular panels 332, 334. In some embodiments, a similar vertical crease line can be provided between the rectangular panels at the apex of the triangular end panel (not shown) opposite the other triangular end panel 322. The main roof panels 318, 320 can include rectangular portions 340, 348 which extend above the edges 342 of the fin panels 332, 334, as shown in FIGS. 6A-6B.

[0042] This embodiment of the embossed carton blank 300 according to the present solution may have an embossed pattern 346 that can comprise two rows of x-shaped marks. In certain embodiments, the embossed pattern 346 can extend from a portion of one rectangular portion 340 along the rectangular fin panels 332, 334 and to a portion of the other rectangular portion 348. In some embodiments, each x-shaped mark can have a height of approximately 4 mm, such that when the rows are printed on the rectangular panels 332, 334 and rectangular portions 340, 348 there is approximately 1 mm between the lowermost portion of the bottom row of x-shaped marks and the score 344. If the embossed portion 346 crosses the score 344, there is a risk of compromising the seal when the top of the carton is sealed in a filling machine. Although two rows of x-shaped marks are shown in FIGS. 6A-6B, there can be less or more than two rows embossed onto the carton. Additionally, the height of the x-shaped marks can be greater than or less than 4 mm.

[0043] FIG. 6A shows an embodiment of the embossed carton blank 300 according to the present solution with a fully compressed triangular area 350 that overlaps the vertical crease line 336 (FIG. 6B) between the two rectangular fin panels 332, 334. As described above, this fully compressed area 350 prevents fibers from contaminating the product when the carton is opened. In some embodiments, the fully compressed area 350 can comprise a height of approximately 7 mm, a first width of approximately 20 mm, and a second width of approximately 18 mm. Although the compressed area 350 is shown in a triangular shape with specific dimensions, the compressed area 350 can comprise different dimensions and/or different shapes.

[0044] Referring to FIGS. 7A-7B, another embodiment of an embossed carton blank 400 according to the present solution is shown. The embossed carton blank 400 may have a similar structure as the embodiment shown in FIGS. 6A-6B and the prior art embodiments shown in FIGS. 4-5. When the carton blank 400 is folded, it may have a similar configuration as the prior art carton shown FIGS. 3A-3C. In certain embodiments, the embossed carton blank 400 can comprise front and back walls 404, 406, side walls 410, rectangular fin panels 432, 434, rectangular portions 440, 448, a plurality of crease lines 412, 414, 419, 421 436, 444, triangular back-folding panels 426, triangular folding panels 427, and triangular end panels 422. In some embodiments, the plurality of crease lines may include vertical crease lines 436, a score 444, and diagonal crease lines 419, 421. This embodiment of the embossed carton blank 400 may have an embossed pattern 446 that can comprise three rows of ovals. In certain embodiments, each oval may have a height of approximately 2 mm and a width of approximately 45 mm. These dimensions allow for the lowermost portion of the ovals to be 1 mm from the score 444.

[0045] As shown in FIG. 7A, this embodiment of the embossed carton blank 400 can also include a fully compressed area 450 overlapping the vertical crease line 436. Although three rows of ovals are shown in FIGS. 7A-7B, there can be less or more than three rows embossed onto the carton. Additionally, the height and width of the ovals can be greater than or less than 2 mm and 45 mm, respectively. Also, the compressed area 450 can comprise different dimensions and/or different shapes than shown in FIG. 4A.

[0046] Although an x-shaped embossed pattern and an oval embossed pattern are shown, the embodiments described herein can comprise a variety of suitable shapes for sealing a carton. Moreover, the embodiments/examples disclosed herein may comprise differently shaped compression areas with different dimensions and a different number of rows.

Terminology

[0047] Any patents and applications and other references noted above, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the disclosure can be modified, if necessary, to employ the systems, functions, and concepts of the various references described herein to provide yet further implementations.

[0048] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0049] While certain embodiments have been described, these embodiments have been presented by way of example only and are not intended to limit the scope of protection. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. For example, the actual steps or order of steps taken in the disclosed processes may differ from those shown in the figure. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.

[0050] Although the present disclosure includes certain embodiments, examples and applications, it will be understood by those skilled in the art that the present disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments or uses and obvious modifications and equivalents thereof, including embodiments which do not provide all of the features and advantages set forth herein. Accordingly, the scope of the present disclosure is not intended to be limited by the described embodiments, and may be defined by claims as presented herein or as presented in the future.

[0051] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, or steps. Thus, such conditional language is not generally intended to imply that features, elements, or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Likewise the term “and/or” in reference to a list of two or more items, covers all of the following interpretations of the word: any one of the items in the list, all of the items in the list, and any combination of the items in the list. Further, the term “each,” as used herein, in addition to having its ordinary meaning, can mean any subset of a set of elements to which the term “each” is applied. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, refer to this application as a whole and not to any particular portions of this application.

[0052] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0053] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.