Tear Away Packaging

Abstract

A box is disclosed that comprises a plurality of panels and flaps substantially enclosing an inner space and a tear initiator. A first side panel and a connecting flap at least partially overlapping with the first side panel. The tear initiator includes a first cut in the first side panel and a second cut in the connecting flap adjacent and offset from the first cut to enable an opening to be formed through the first side panel and the connecting flap upon application of force at the tear initiator to open the box.

Claims

1. A box comprising: a plurality of panels and flaps substantially enclosing an inner space; a first side panel; and a connecting flap at least partially overlapping with the first side panel; and a tear initiator including a first cut in the first side panel and a second cut in the connecting flap adjacent and offset from the first cut to enable an opening to be formed through the first side panel and the connecting flap upon application of force at the tear initiator to open the box.

2. The box of claim 1 wherein the connecting flap covers the first cut of the first side panel and the first side panel covers the second cut of the connecting flap.

3. The box of claim 1 further comprising an adhesive disposed between the connecting flap and the first side panel extending over each of the first cut and second cut.

4. The box of claim 1 wherein the first cut extends through the first side panel along a length of the first cut and the second cut extends through the connecting flap along a length of the second cut.

5. The box of claim 1 wherein the second cut does not overlap with the first cut.

6. The box of claim 1 wherein the first cut and second cut are arcuate, the second cut having a different orientation than the first cut.

7. The box of claim 1 further comprising an end flap attached to the first side panel, wherein the first cut is arcuate to direct tearing in the first side panel from the first cut and toward the end flap upon application of force at the tear initiator.

8. The box of claim 7 wherein the second cut is arcuate to direct tearing in the connecting flap from the second cut and toward the end flap upon application of force at the tear initiator.

9. The box of claim 1 wherein the first side panel is positioned outward of the connecting flap relative to the inner space.

10. The box of claim 1 further comprising one or more end flaps at least partially closing an end of the box, the one or more end flaps attached to the first side panel such that tearing the box from the tear initiator causes tearing along the one or more end flaps.

11. The box of claim 10 further comprising a second side panel and a third side panel opposite the second side panel, a first end flap of the one or more end flaps connected to the second side panel by a first line of weakness and a second end flap of the one or more end flaps connected to the third side panel by a second line of weakness to facilitate tearing of the first end flap and second end flap from the second side panel and third side panel.

12. (canceled)

13. The box of claim 11 wherein a section of the first end flap adjacent the first side panel is cut from the second side panel and a section of the second end flap adjacent the first side panel is cut from the third side panel.

14. A box comprising: a first side panel; a second side panel opposite the first side panel; a third side panel extending between the first side panel and the second side panel; a first end flap extending from the first side panel; and a second end flap connected to the second side panel and at least partially overlapping with the first end flap, the first end flap including an extension portion extending outward beyond the third side panel to permit a user to grasp the extension and apply force to the extension portion to detach the first end flap and second end flap from the first side panel and second side panel.

15. The box of claim 14 further comprising a third end flap connected to the third side panel, the third end flap at least partially overlapping with the first end flap and attached to the first end flap by an adhesive, the third end flap having a cut therein to direct tearing in the third end flap upon application of force to the extension portion to detach the first end flap and second end flap.

16. The box of claim 15 wherein the cut is arcuate to direct tearing of the third end flap away from the third side panel.

17. The box of claim 14 wherein the second end flap overlies the first end flap.

18. The box of claim 14 further comprising: a first line of weakness along the connection between the first side panel and first end flap; and a second line of weakness along the connection between the second side panel and second end flap.

19. The box of claim 18 wherein the first line of weakness includes a first plurality of scores extending partially through the box, wherein the second line of weakness includes a second plurality of scores extending partially through the box.

20. The box of claim 14 wherein the first plurality of scores includes a first score extending inward from the third side panel, wherein the second plurality of scores includes a second score extending inward from the third side panel.

21. The box of claim 14 wherein a section of the connection between first end flap and first side panel adjacent the third side panel is cut and a section of the connection between the second end flap and second side panel adjacent the third side panel is cut.

22-40. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0005] FIG. 1 is a perspective view of a box having tear features to facilitate opening of the box.

[0006] FIG. 2A is a schematic diagram of a blank for the box of FIG. 1.

[0007] FIG. 2B is a schematic diagram showing alignment of the first cut and second cut of a tear initiator of an embodiment of a box similar to FIG. 1

[0008] FIGS. 3A-3E show a progression of the assembled box of FIG. 1 being opened using the tear features.

[0009] FIG. 4 is a perspective view of a box according to another embodiment, the box having a tab to tear open the box.

[0010] FIG. 5 is a schematic diagram of a blank for the box of FIG. 4.

[0011] FIGS. 6A-6D show a progression of the assembled box of FIG. 4 being opened using the tear features.

DETAILED DESCRIPTION

[0012] With respect to FIG. 1, packaging such as a box 100 is shown having a tear initiator 102. The tear initiator 102 is a portion of the box 100 where force is to be applied (e.g., with a finger) to form an opening to the interior of the box 100. Once the opening is formed, force may be applied to a tear portion 104 of the box 100 to detach (e.g., tear) the tear portion 104 away from the remainder of the box 100. For example, the user may grasp the tear portion 104 using the opening formed at the tear initiator 102 and pull the tear portion 104 to at least partially separate the tear portion 104 from the remainder of the box 100.

[0013] With reference also to FIG. 2A, the box 100 is formed from a sheet 106 formed into a plurality of walls substantially enclosing an interior space and held together by an adhesive. The sheet 106 may be formed of a material that can be torn by hand, for example, a cellulose or plastic material. As examples, the sheet 106 may be a paperboard, cardboard, corrugate, and/or other paper-based material. The sheet 106 may also include cellulose coated with other materials such as plastics, polymers, films, and the like. The sheet 106 may have a thickness in the range of about 0.012 inches to about 0.030 inches. As one example, the sheet 106 has a thickness of about 0.014 (or 18 point). The sheet 106 may include multiple layers laminated together. As one example, the sheet 106 includes multiple paper-based layers laminated together with a clay coating and ink disposed on an outer surface thereof.

[0014] The tear initiator 102 is formed in a sidewall 108 of the box 100 including a first side panel 110 and a connecting flap 112. The first side panel 110 and the connecting flap 112 at least partially overlap to connect the first side panel 110 to the connecting flap 112. An adhesive (e.g., a glue) is disposed between an outer surface 114 of the connecting flap 112 and an inner surface 116 of the first side panel 110 to secure the connecting flap 112 to the first side panel 110.

[0015] The tear initiator 102 includes a first cut 118 in the first side panel 110 and a second cut 120 in the connecting flap 112. The cut 118 may extend entirely through the first side panel 110 and the cut 120 may extend entirely through the connecting flap 112 to make it easier to tear an opening in the sidewall 108. In some forms, the cut 118 extends partially through the first side panel 110, for example, 50%-99% of the way through the first side panel 110. In some forms, the cut 120 extends partially through the connecting flap 112, for example, 50%-99% of the way through the connecting flap 112. When the first side panel 110 and connecting flap 112 are secured together, the cut 118 of the first side panel 110 is adjacent to and offset from the cut 120 of the connecting flap 112 such that the cuts 118, 120 do not overlap or form an opening directly through the sidewall 108. In other words, the openings of the cuts 118, 120 are adjacent but misaligned such that a portion of the first side panel 110 covers the cut 120 in the connecting flap 112 and a portion of the connecting flap 112 covers the cut 118 in the first side panel 110. The cuts 118, 120 are close enough to one another, however, that force applied to the first side panel 110 at the first cut 118 applies force at the second cut 120 to cause tearing in the first side panel 110 and connecting flap 112 to form an opening therethrough. For example, the cuts 118, 120 may be offset from one another by a distance in the range of about 0.0156 inches to about 0.125 inches. As one example, the cuts 118 are offset from one another by a minimum distance of 0.03125 inches.

[0016] The adhesive may be disposed between the first side panel 110 and the connecting flap 112 such that the adhesive extends over the first cut 118 and/or second cut 120. In some embodiments, the adhesive surrounds the first cut 118 and/or second cut 120. For instance, the adhesive is disposed about the opening of the first cut 118 to fill the gap between the first side panel 110 and connecting flap 112. The adhesive thus inhibits ingress into the box 100 through the first cut 118 and between the first side panel 110 and connecting flap 112. The adhesive may also be disposed about the opening of the second cut 120 to fill the gap between the first side panel 110 and connecting flap 112. The adhesive thus inhibits ingress into the box 100 through the second cut 120 and between the first side panel 110 and connecting flap 112. The adhesive may be disposed along the length of the first side panel 110 on the inner surface 116 that contacts the connecting flap 112 to secure the first side panel 110 and connecting flap 112 along the length of the box 100. The adhesive may additionally or alternatively be disposed along the length of the connecting flap 112 that contacts the inner surface 116 of the first side panel 110. The adhesive may form a seal between the first side panel 110 and connecting flap 112 to inhibit ingress or egress (e.g. of debris) therebetween. The adhesive may be applied in a single line or in multiple lines. For example, the adhesive may be applied as multiple lines extending in parallel to one another along the length of the first side panel 110 and/or connecting flap 112.

[0017] In some embodiments, adhesive is applied in glue regions 122, 124 to secure the connecting flap 112 and the first side panel 110 together. The first glue region 122 of the connecting flap 112 includes adhesive to secure the first side panel 110 to the connecting flap 112 and to form a seal therebetween to inhibit ingress or egress. The first glue region 122 of adhesive may extend along a substantial portion (e.g., 75%-100%) of the height of the connecting flap 112. The adhesive in the first glue region 122 secures the first side panel 110 to the connecting flap 112 when the first side panel 110 is pressed against the adhesive on the first glue region 122 during assembly.

[0018] The second glue region 124 extends longitudinally over the first cut 118 and the second cut 120 when the first side panel 110 is pressed against the adhesive of the second glue region 124. The adhesive of the second glue region 124 extends over the cuts 118, 120, for example, to inhibit unintentional opening of the cuts, e.g., during handling, transit, and storage. For example, the adhesive of the second glue region 124 keeps the portions of the first side panel 110 on opposite sides of the cut 118 from flexing or shifting too far from one another, which could cause the cut 118 to open. The adhesive of the second glue region 124 similarly keeps the portions of the connecting flap 112 on opposite sides of the cut 120 from flexing or shifting too far from one another, which could cause the cut 120 to open. The adhesive of the second glue region 124 also ensures that the portions of the connecting flap 112 and the first side panel 110 having the cuts 118, 120 are adhered together to ensure proper tearing at the tear initiator 102 (e.g., from the first and second cuts 118, 120) when force is applied thereto to open the box. The adhesive of the second glue region 124 also aids to hold the first side panel 110 and connecting flap 112 together so that the first side panel 110 covers the cut 120 of the connecting flap 112 and the connecting flap 112 covers the cut 118 of the first side panel 110 to thereby close the cuts 118, 120 and inhibit debris from passing through the cuts 118, 120. In other words, the adhesive of the second glue region 124 keeps the cuts 118, 120 offset from one another, ensuring the cuts 118, 120 are not aligned to inhibit debris from passing through the cuts 118, 120. In some forms, the adhesive of the second glue region 124 may fill the cuts 118, 120 to seal the cuts 118, 120 closed and inhibit debris from passing therethrough.

[0019] The first cut 118 of the first side panel 110 may be shaped to direct tearing in the first side panel 110 and adhesive upon application of force at the tear initiator 102. The first cut 118 may be, as examples, curved, triangular, rectangular, or angled. As one example, the first cut 118 may have an arcuate shape. The ends of the first cut 118 may be adjacent the end of the box 100 to direct tearing toward the end of the box 100 as force is applied thereto. The ends of the first cut 118 may be spaced from the first end flap 160 to ensure the first side panel 110 remains intact (e.g., not unintentionally torn) during production and distribution but close enough to permit users to tear the first side panel 110 with ease when intending to open the box 100. The ends of the first cut 118 may be spaced from the first end flap 160 by a distance in the range of about 0.08 to 0.2 inches. As one example, the ends of the first cut 118 are 0.167 inches from the first end flap 160.

[0020] The second cut 120 of the connecting flap 112 may be shaped to direct tearing in the connecting flap 112 and adhesive upon application of force at the tear initiator 102. The second cut 120 may be, as examples, curved, triangular, rectangular, or angled such as V-shaped. As one example, the second cut 120 may have an arcuate shape. The ends of the second cut 118 may be adjacent the end of the box 100 to direct tearing toward the end of the box 100. The ends of the second cut 120 may be spaced from the edge of the connecting flap 112 to ensure the connecting flap 112 remains intact (e.g., not unintentionally torn) during production and distribution but close enough to the edge to permit users to tear the connecting flap with ease when intending to open the box 100. The ends of the second cut 120 may be spaced from the edges of the connecting flap 112 by a distance in the range of about 0.08 to 0.2 inches. As one example, an end of the second cut 120 is 0.144 inches from an end edge 112A. As one example, an end of the second cut 120 is 0.097 inches from a side edge 112C of the connecting flap 112.

[0021] The first cut 118 may span a substantial portion of the width of the first side panel 110 and the second cut 120 may span a substantial portion of the width of the connecting flap 112 which may aid in directing tearing outward toward the first and second lines of weakness 178, 180 as discussed below.

[0022] The second cut 120 may have a different shape than the first cut 118, for example, a different arcuate shape. Forming the second cut 120 to have a different arcuate shape than the first cut 118 aids to ensure that the first cut 118 and second cut 120 do not overlap even if they are offset from one other. In other words, the cuts 118, 120 have different sizes and positions to be offset from one another without overlapping when the box 100 is assembled. By not overlapping, the cuts 118, 120 do not form a hole through the sidewall 108 box 100, which inhibits ingress and egress through the sidewall 108. For example, the radius of the second cut 120 may be different than that of the cut 118. For instance, the arcuate shape of the second cut 120 may have a greater radius than that of the first cut 118 so that the ends of the second cut 120 extend outward of and do not overlap with the first cut 118. Due to the larger radius of the second cut 120, an end of the second cut 120 may be truncated such that the second cut 120 is asymmetrical along the length of the box 100 and relative to the first cut 118. Cut 118 may be smaller than cut 120 and be spaced further from the edge such that a greater force is required to tear cut 118 to inhibit unintentional tearing. When a user applies sufficient force at the first cut 118, the force also causes tearing from the second cut 120.

[0023] The first cut 118 may include one or more bridges 119 (e.g., two) that extend across the cut 118 to aid in keeping the first side panel 110 intact and resist unintentional tearing from the cut 118. In some forms, the first cut 118 does not include any bridges 119 but instead the first side panel 110 is cut along the entire length of the first cut 118 (e.g., bridges 119 are omitted). The second cut 120 may include one or more bridges 121 (e.g., two) that extend across the cut 120 to aid in keeping the connecting flap 112 intact and resist unintentional tearing from the cut 120. In some forms, the second cut 120 does not include any bridges 121 but instead the connecting flap 112 is cut along the entire length of the second cut 120 (e.g., bridges 121 are omitted). In other embodiments, the cuts 118, 120 may have more or fewer bridges. For example, regarding FIG. 2B, a schematic view of cuts 118A, 120A of a box 100A similar to that of FIG. 1 is shown according to another embodiment, with FIG. 2B showing the cuts 118A, 120A of the connecting flap 112A and first side panel 110A relative to one another when assembled. As shown, the cuts 118A, 120A are adjacent one another, but do not overlap. The first cut 118A has five bridges 119A and the second cut 120A has four bridges 121A. The bridges 119A, 121A of the first and second cuts 118A, 120A are arranged such that the bridges 119A of the first cut 118A are offset or out of alignment (e.g., radial alignment) with the bridges 121A of the second cut 120A, which aids to avoid unintentional tearing in the first and second cuts 118A, 120A, e.g., during transit and handling. For example, the bridges 121A of the second cut 120A are positioned between two bridges 119A of the first cut 118A so that the bridges 119A, 121A alternate with one another.

[0024] In other embodiments the cuts 118, 120 may have different shapes such as triangular, rectangular, or angled or V-shaped cuts. The cut 118 of the first side panel 110 may be adjacent the cut 120 of the connecting flap 112. The cut 120 of the connecting flap 112 may be larger in size than the cut 118 of the first side panel 110 to facilitate tearing upon application of force by a user. Including a cut 120 having a larger size than the cut 118 of the first side panel 110 may also inhibit the cuts 118, 120 from overlapping, e.g., so that there is no opening entirely through the sidewall 108 to inhibit ingress into and egress out of the box 100 through the cuts 118, 120.

[0025] With reference to FIG. 2A, a sheet 106 of the box 100 is shown as a blank before the box 100 is assembled. The sheet 106 includes a sidewall portion 144, a first end flap portion 146, and a second end flap portion 148. The sidewall portion 144 may be creased at fold lines 156 to form the first side panel 110, second side panel 150, third side panel 152, fourth side panel 154, and connecting flap 112. The sidewall portion 144 may be folded along the fold lines 156 when assembling the box 100.

[0026] The first end flap portion 146 includes a plurality of cut lines 158 that form a first end flap 160, a second end flap 162, a third end flap 164, and a fourth end flap 166 which connect, respectively, to an end of the first side panel 110, second side panel 150, third side panel 152, fourth side panel 154. The second end flap portion 148 includes a plurality of cut lines 168 that form a fifth end flap 170, a sixth end flap 172, a seventh end flap 174, and an eighth end flap 176 which connect, respectively, to an opposite end of the first side panel 110, second side panel 150, third side panel 152, fourth side panel 154. The end flaps are separated from the side panels by the fold lines 156 about which the end flaps may be folded.

[0027] The connection between the second end flap 162 and the second side panel 150 includes a first line of weakness 178 to reduce the force needed to separate the second end flap 162 from the second side panel 150. The connection between the fourth end flap 166 and the fourth side panel 154 includes a second line of weakness 180 to reduce the force needed to separate the fourth end flap 166 from the fourth side panel 154. The first and second lines of weakness 178, 180 may include perforations. The perforations may include a plurality of scores that extend partially through the sheet 106, for example, 50% of the way through the material. Using scores that only extend partially through the sheet 106 weakens the connection to facilitate tearing but without forming an opening through the box 100 through which objects may enter the box 100. In some forms, the perforations extend through the sheet 106.

[0028] The first and second lines of weakness 178, 180 may include a plurality of scores separated by uncut portions of the box 100. The scores and uncut portions may have lengths in the range of about 0.03125 inches to about 0.1875 inches. In some forms, the length of the scores are the same as the length of the uncut portions. In some forms, the length of the scores are different from the length of the uncut portions. For example, the scores may be longer than the uncut portions. As one example, the scores may have a length of about 0.125 inches while the uncut portions have a length of about 0.0625 inches. As one example, the scores and uncut portions each have a length of about 0.125 inches.

[0029] In some embodiments, an initial tear section 182 of the first line of weakness 178 (e.g., the end adjacent the first side panel 110) includes a cut in the box 100 to aid in beginning a tear along the first line of weakness 178 from the first side panel 110. The cut of the initial tear section 182 may extend entirely through the box 100. The cut of the initial tear section 182 may extend inward from the edge of the second end flap 162 adjacent the first end flap 160 along a portion of the first line of weakness 178. Similarly, an initial tear section 184 of the second line of weakness 180 (e.g., the end adjacent the first side panel 110 when assembled) may include a cut in the box 100 to aid in beginning a tear along the second line of weakness 180 from the first side panel 110. The cut of the initial tear section 184 may extend entirely through the box 100. The cut of the initial tear section 184 may extend inward from the edge of the fourth end flap 166 adjacent the connecting flap 112 along a portion of the second line of weakness 180. The first end flap 160 is adjacent the initial tear sections 182, 184 to close the opening of the cuts in the initial tear sections 182, 184 from ingress. In some forms, the cuts of the initial tear section 182 and initial tear section 184 extend partially through the box 100 (e.g., 50% of the way through sheet 106). The cuts of the initial tear sections 182, 184 may be scores having a longer or shorter length than the remainder of the first and second lines of weakness 178, 180.

[0030] The connecting flap 112 may have ends 112A, 112B that taper inward as connecting flap 112 extends from the fourth side panel 154. The tapered connecting flap 112 provides clearance for the first and fifth end flaps 160, 170 when folded inward during assembly.

[0031] To assemble the box 100 from the blank sheet 106, the sidewall portion 144 is folded at the fold lines 156 (e.g., to a 90 degree angle) to position the first side panel 110, second side panel 150, third side panel 152, fourth side panel 154 at angles relative to one another. An adhesive may be applied to the outer surface 114 of the connecting flap 112 and the connecting flap placed in overlapping engagement with the first side panel 110 to secure the connecting flap 112 to the first side panel 110. The adhesive may be applied over the entire outer surface 114 of the connecting flap 112. The adhesive may be applied to the outer surface 114 to ensure the adhesive extends about the cuts 118, 120 as discussed above. The adhesive may be applied between the connecting flap 112 and first side panel 110 to form a seal along the length of the sidewall 108 to inhibit objects from entering or exiting the box 100 between the connecting flap 112 and first side panel 110.

[0032] The first end flap 160 and third end flap 164 are folded inward. Adhesive may be applied to the outer surfaces 160A, 164A of the first end flap 160 and third end flap 164 to secure these flaps to the fourth end flap 166 that gets folded inward over the first end flap 160 and third end flap 164. Additionally or alternatively, adhesive is applied to the fourth end flap 166 to contact the outer surfaces 160A, 164A of the first and third end flaps 160, 164 when the fourth end flap 166 is folded over the first and third end flaps 160, 164. Adhesive may be applied to the outer surface 166A of the fourth end flap 166 to secure the fourth end flap 166 to the second end flap 162 when the second end flap 162 is folded inward over the fourth end flap 166. Additionally or alternatively, adhesive is applied to the second end flap 162 to contact the outer surface 166A of the fourth end flap 166 when the second end flap 162 is folded over the fourth end flap 166. The first, second, third, and fourth end flaps 160, 162, 164, 166 are thus secured together by adhesive and form at least a portion of the tear portion 104. For instance, when the box 100 is torn from the cuts 118, 120, the tear extends toward the first end flap 160 causing the first end flap 160 and a portion of the first side panel 110 to separate from the remainder of the box 100. The tear may extend along the first and second lines of weakness 178, 180 toward the third end flap 164. The third end flap 164 may remain secured to the third side panel 152 to keep the tear portion 104 attached to the remainder of the box 100 while permitting access to the interior of the box 100 (e.g., the product therein). Keeping the tear portion 104 connected to the box 100 permits the box 100 to remain a single unit even upon opening. The box 100 can thus be disposed (e.g., recycled) as a single piece after use. Keeping the tear portion 104 connected to the box 100 also makes it easier to cleanup the box upon use as there is only one piece to collect when cleaning up.

[0033] In an alternative approach, the fourth end flap 166 is folded inward first, with the first and third end flaps 160, 164 being folded over the fourth end flap 166. Adhesive is applied to secure the fourth end flap 166 to the first and third end flaps 160, 164. For instance, adhesive may be applied to the outer surface 166A of the fourth end flap 166 to contact the inner surfaces of the first and third end flaps 160, 164. Or, adhesive is applied to the inner surfaces of the first and third end flaps 160, 164 to secure the first and third end flaps 160, 164 to the fourth end flap 166. The second end flap 162 is folded inward over the first and third end flaps 160, 164. Adhesive is applied to secure the second end flap 162 to the first and third end flaps 160, 164. For instance, adhesive may be applied to the inner surface of the second end flap 162 to contact the second end flap 162 to the first and third end flaps 160, 164. Or, adhesive may be applied to the outer surfaces 160A, 164A of the first end flap 160 and third end flap 164 to secure these flaps to the second end flap 162 upon the second end flap 162 being folded over the first and third end flaps 160, 164.

[0034] The second end flap portion 148 may be folded and secured together similar to the approaches of the first end flap portion 146 discussed above. For example, the fifth and seventh end flaps 170, 174 may be folded inward with adhesive disposed on the outer surfaces thereof. The eighth end flap 176 may be folded inward over the fifth and seventh end flaps 170, 174 to secure the eighth end flap 176 thereto. Adhesive may be disposed on the outer surface of the eighth end flap 176 and the sixth end flap 172 folded over the eighth end flap 176 to secure the sixth end flap 172 thereto.

[0035] A product may be inserted into the interior 190 (see FIG. 3E) of the box 100 before the first end flap portion 146 or second end flap portion 148 are closed. The product may be a food product, for example, macaroni noodles and a cheese packet.

[0036] With reference to FIGS. 3A-3E, the box 100 is shown progressively being opened using the tear initiator 102 to at least partially detach the tear portion 104 from the box 100. With respect to FIG. 3A, an inward force in direction 186 is applied at the tear initiator 102 of the first side panel 110. The force may be applied by a user with their finger pressing inward on the tear initiator 102. The inward force causes tearing in a region 111 of the first side panel 110 (see FIG. 2A) and a region 113 of the connector flap 112 (see FIG. 2A) from the cuts 118, 120 toward the first end flap 160.

[0037] With respect to FIGS. 3B-3D, a force on the tear portion 104 is applied in direction 188 to continue tearing the tear portion 104 from the remainder of the box 100. For example, a user may grasp the tear portion 104 by extending a finger through an opening 179 at the cuts 118, 120 and squeezing the first end flap portion 146. The force causes tearing along the initial tear sections 182, 184 of lines of weakness 178, 180. The force may continue to be applied in direction 188 to tear along the length of the lines of weakness 178, 180.

[0038] With respect to FIG. 3E, upon tearing along the lines of weakness 178, 180, the tear portion 104 may be pivoted about the connection of the third end flap 164 to the third side panel 152 to access the interior 190 of the box 100, for example, to remove a product therein. In some forms, the box 100 may generally remain together as a single component such that the box 100 may be recycled. In other words, all of the components of the box 100 may remain together while also permitting access to the contents of the box 100.

[0039] With respect to FIG. 4, a box 200 is provided according to another embodiment that has an extension or tab 202. The tab 202 may be grasped by a user and pulled to at least partially detach a tear portion 204 to provide access to the interior of the box 200. The box 200 is similar in many respects to the box 100 described above such that the differences are highlighted.

[0040] The box 200 has a plurality of walls substantially enclosing an interior space 254 (see FIG. 6D) in which product may be disposed. With reference also to FIG. 5 which shows the box 200 as a blank before assembly, the box 200 is formed of a sheet 206 that is folded and held together by adhesive. The box 200 includes a sidewall portion 208, a first end flap portion 210, and a second end flap portion 212.

[0041] The sidewall portion 208 and second end flap portion 212 are similar to the sidewall portion 144 and second end flap portion 148 of the box 100. The sidewall portion 208 includes a first side panel 214, second side panel 216, third side panel 218, fourth side panel 220, and connecting flap 222. Compared to box 100 of the first embodiment, in box 200, a connecting flap 222 of the sidewall portion 208 has a smaller width that overlaps with a smaller portion of the first side panel 214 when assembled. The first side panel 214 and connecting flap 222 also do not include the cuts of the tear initiator as in box 100.

[0042] The first end flap portion 210 includes a first end flap 224, a second end flap 226, a third end flap 228, and a fourth end flap 230 that are connected, respectively, to the first side panel 214, second side panel 216, third side panel 218, and fourth side panel 220. The sheet 206 includes a fold line 232 about which the first end flap 224, second end flap 226, third end flap 228, and fourth end flap 230 can be folded relative to the sidewall portion 208.

[0043] The connection between the second end flap 226 and the second side panel 216 includes a first line of weakness 234 to reduce the force needed to separate the second end flap 226 from the second side panel 216. The connection between the fourth end flap 230 and the fourth side panel 220 includes a second line of weakness 236 to reduce the force needed to separate the fourth end flap 230 from the fourth side panel 220. The first and second lines of weakness 234, 236 may include perforations. The perforations may include a plurality of scores that extend partially through the sheet 206, for example, 50% of the way through the material. Using scores that only extend partially through the sheet 206 weakens the connection to facilitate tearing, but without forming an opening through the box 200 through which objects may enter the box 200. In some forms, the perforations extend through the sheet 106.

[0044] The first and second lines of weakness 234, 236 may include a plurality of scores separated by uncut portions of the box 200. The scores and uncut portions may have lengths in the range of about 0.03125 inches to about 0.1875 inches. In some forms, the length of the scores are the same as the length of the uncut portions. In some forms, the length of the scores are different from the length of the uncut portions. For example, the scores may be longer than the uncut portions. As one example, the scores may have a length of about 0.125 inches while the uncut portions have a length of about 0.0625 inches. As one example, the scores and uncut portions each have a length of about 0.125 inches.

[0045] In some embodiments, an initial tear section 238 of the first line of weakness 234 (e.g., the end adjacent the first side panel 214) includes a cut in the box 200 to aid in beginning a tear along the line of weakness 234. The cut of the initial tear section 238 may extend entirely through the box 200. The cut of the initial tear section 238 may extend inward from the edge of the second end flap 226 adjacent the first end flap 224 along a portion of the first line of weakness 234. Similarly, an initial tear section 240 of the second line of weakness 236 (e.g., the end adjacent the first side panel 214 when assembled) includes a cut extending entirely through the box 200 to aid in beginning a tear along the line of weakness 236. The cut of the initial tear section 240 may extend entirely through the box 200. The cut of the initial tear section 240 may extend inward from the edge of the fourth end flap 230 adjacent the connecting flap 222 along a portion of the second line of weakness 236. The first end flap 224 is adjacent the initial tear sections 238, 240 to close the opening of these cuts from ingress. In some forms, the cuts of the initial tear section 238 and initial tear section 240 extend partially through the box 200 (e.g., 50% of the way through sheet 206).

[0046] The first end flap 224 includes a cut 242. The cut 242 may extend entirely through the first end flap 224, which makes it easier to tear away a portion of the first end flap 224 as the tear portion 204 is detached by pulling on the tab 202 of the fourth end flap 230. The cut 242 of the first end flap 224 may be shaped to direct tearing in the first end flap 224 and adhesive disposed thereon. The cut 242 may be, as examples, curved, triangular, rectangular, or angled such as V-shaped. As one example, the cut 242 may have an arcuate shape. The ends of the cut 242 may extend toward an edge of the first end flap 224 to direct tearing toward the edge. The ends of the cut 242 may be spaced from the edge of the first end flap 224 to ensure the first end flap 224 remains intact (e.g., not unintentionally torn) during production and distribution but close enough to permit users to tear the first end flap 224 with ease when intending to open the box 200. The ends of the cut 242 may be spaced from the side edges 224A, 224B of the first end flap 224 by a distance in the range of about 0.08 inches to about 0.2 inches. As one example, the ends of the cuts are each spaced 0.13 inches from the respective side edge 224A, 224B. The cut 242 may include one or more bridges 243 that extend across the cut 242 to aid in keeping the first end flap 224 intact and resist unintentional tearing from the cut 242. In some forms, the cut 242 does not include any bridges 243 but instead the first end flap 224 is cut along the entire length of the cut 242 (e.g., bridges 243 are omitted).

[0047] An adhesive may be applied to the outer surface 244 of the first end flap 224 to secure the first end flap 224 to the fourth end flap 230, which is folded over the first end flap 224. The adhesive may extend about the cut 242 to fill the gap between the first end flap 224 and fourth end flap 230 (which covers the opening of the cut 242) and inhibit objects from entering the box 200 between the first and fourth end flaps 224, 230 and the cut 242. An adhesive may also be applied to the outer surface 246 of the third end flap 228 to secure the third end flap 228 to the fourth end flap 230, which is folded over the third end flap 228. Additionally or alternatively, adhesive is applied to the fourth end flap 230 to contact the outer surfaces 244, 246 of the first end flap 224 and third end flap 228 when the fourth end flap 230 is folded over the first end flap 224 and third end flap 228.

[0048] The fourth end flap 230 has an outer surface 248 on which adhesive is disposed to secure the second end flap 226 thereto when the second end flap 226 is folded over the fourth end flap 230. Additionally or alternatively, adhesive is applied to the second end flap 226 to contact the outer surface 248 of the fourth end flap 230 when the second end flap 226 is folded over the fourth end flap 230.

[0049] The fourth end flap 230 includes the tab 202 which extends outward beyond the sidewall portion 208 of the box 200 to make it easier for a user to grasp the tab 202 to open the box 200. For instance, as shown in FIG. 4, the tab 202 extends outward beyond the first side panel 214. The distance the tab 202 extends from outward of the first side panel 214 may be adjusted to provide a sufficient size to enable a user to firmly grasp the tab 202 and apply force thereto to tear the tear portion 204 of the box 200. As an example, the tab may extend outward a distance in the range of 0.15 to 0.4 inches. As an example, the tab 202 extends outward a distance of 0.211 inches. The tab 202 has a convex shape that protrudes outward of the first side panel 214, however, in other embodiments the tab 202 may have other shapes.

[0050] In some forms, the tab 202 is bent downward to extend along the first side panel 214. The tab 202 may be removably secured to the first side panel 214, for example, with an adhesive. The tab 202 may extend along the first side panel 214 in the range of about 0.5 inches to about 3 inches. The tab 202 may be detached from the first side panel 214 by a user when opening the box. The user may grasp and pull the tab 202 to tear the tear portion 204 of the box 200. The increased length of the tab 202 may make it easier for the user to grasp and apply force to tear the tear portion 204.

[0051] With reference to FIGS. 6A-6D, the box 200 is shown progressively being opened using the tab 202 to at least partially detach the tear portion 204 from the remainder of the box 100. With respect to FIG. 6A, a force in direction 250 is applied to the tab 202. The force may be applied by a user grasping the tab 202 with their fingers and pulling the tab 202 in direction 250 while holding the box 200. The force causes tearing in the first and second lines of weakness 234, 236 which causes the ends of the second end flap 226 and fourth end flap 230 to separate (e.g., tear away) from the sidewall portion 208.

[0052] With respect to FIG. 6B, as force is continued to be applied in direction 250, the tear portion 204 continues to separate from the sidewall portion 208 along the lines of weakness 234, 236. Because the first end flap 224 is secured to the fourth end flap 230 with adhesive, applying force to the fourth end flap 230 also applies force to the first end flap 224 in direction 250. This force causes tearing in region 225 of the first end flap 224 from the cut 242 away from the first side panel 214. The cut 242 reduces the force needed to lift the tab 202 and fourth end flap 230 from the sidewall portion 208 because the cut 242 provides a line of weakness in the first end flap 224. The cut 242 permits a portion 223 (see FIG. 6C) of the first end flap 224 to be more easily separated from the remainder of the first end flap 224. The cut 242 also reduces the length of tearing in the first end flap 224 to separate the portion 223 therefrom. The cut 242 further may direct tearing from the ends of the cut 242 toward the edge(s) of the first end flap 224.

[0053] With respect to FIGS. 6C, as the force is applied to the tab 202, the portion 223 of the first end flap 224 is torn away and completely separated from the remainder of the first end flap 224 that remains connected to the first side panel 214. The portion 223 of the first end flap 224 that is torn away remains secured to the fourth end flap 230 by the adhesive. The force may continue to be applied in direction 250 to tear along the length of the lines of weakness 234, 236.

[0054] With respect to FIG. 6D, upon tearing along the lines of weakness 234, 236, the tear portion 204 may be pivoted about the connection of the third end flap 228 to the third side panel 218 to access the interior of the box 200, for example, to remove a product therein. In some forms, the box 200 may generally remain together as a single component such that the box 200 may be recycled. In other words, all of the components of the box 200 may remain together while also permitting access to the contents of the box 200.

[0055] Uses of singular terms such as a, an, are intended to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms comprising, having, including, and containing are to be construed as open-ended terms. It is intended that the phrase at least one of as used herein be interpreted in the disjunctive sense. For example, the phrase at least one of A and B is intended to encompass A, B, or both A and B.

[0056] While there have been illustrated and described particular embodiments of the present invention, those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.