US20050109827A1

US20050109827A1 - Dryer sheet and cleansing article dispensing cartons and die-cut blanks for making the same

Info

Publication number: US20050109827A1
Application number: US10/720,496
Authority: US
Inventors: Chris Martin
Original assignee: Martin Chris L.
Current assignee: Sun Products Corp
Priority date: 2003-11-24
Filing date: 2003-11-24
Publication date: 2005-05-26

Abstract

Die-cut blanks for forming folding cartons and corresponding cartons for housing sheeted cleaning articles, particularly for dryer sheets, are disclosed. The blanks and cartons include a fully enclosed access flap and lapping glue flap.

Description

BACKGROUND

The disclosure herein relates to folding carton blanks and cartons for dispensing cleansing articles such as dryer sheets, pocket handkerchiefs, napkins, facial tissues, powdered surfactants, detergents, and wet wipes.

SUMMARY

Novel carton blanks, cartons and methods for making the same are disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, and a hinge coincident with a panel score line.
FIG. 2 is a top view of a carton blank similar to FIG. 1 and including a finger notch.
FIG. 3 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the top panel running from common endpoints, zipper cuts on the front panel, and a hinge coincident with a panel score line.
FIG. 4 is a top view of a carton blank similar to FIG. 3 and including a finger notch.
FIG. 5 is a top view of a carton blank with a glue flap adjacent to a major panel, zipper cuts on the front and top panels, and a hinge coincident with a panel score line.
FIG. 6 is a top view of a carton blank similar to FIG. 5 and including a finger notch.
FIG. 7 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the front and top panels running from multiple end points, and a hinge coincident with a panel score line.
FIG. 8 is a top view of a carton blank similar to FIG. 7 and including a finger notch.
FIG. 9 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the front and top panels running from common end points, and a hinge coincident with a panel score line.
FIG. 10 is a top view of a carton blank similar to FIG. 9 and including a finger notch.
FIG. 11 is a top view of a carton blank with a glue flap adjacent to a major panel, zipper cuts on the front and top panels, and a hinge not coincident with a panel score line.
FIG. 12 is a top view of a carton blank similar to FIG. 11 and including a finger notch.
FIG. 13 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the front and top panels running from multiple end points, and a hinge not coincident with a panel score line.
FIG. 14 is a top view of a carton blank similar to FIG. 13 and including a finger notch.
FIG. 15 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the front and top panels running from common end points, and a hinge not coincident with a panel score line.
FIG. 16 is a top view of a carton blank similar to FIG. 15 and including a finger notch.
FIG. 17 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, and a hinge not coincident with a panel score line.
FIG. 18 is a top view of a carton blank similar to FIG. 17 and including a finger notch.
FIG. 19 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the top panel running from common endpoints, zipper cuts on the front panel, and a hinge not coincident with a panel score line.
FIG. 20 is a top view of a carton blank similar to FIG. 19 and including a finger notch.
FIG. 21 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, and a hinge coincident with a panel score line.
FIG. 22 is a top view of a carton blank similar to FIG. 21 and including a finger notch.
FIG. 23 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the top panel running from common endpoints, zipper cuts on the front panel, and a hinge coincident with a panel score line.
FIG. 24 is a top view of a carton blank similar to FIG. 23 and including a finger notch.
FIG. 25 is a top view of a carton blank with a glue flap adjacent to a minor panel, zipper cuts on the front and top panels, and a hinge coincident with a panel score line.
FIG. 26 is a top view of a carton blank similar to FIG. 25 and including a finger notch.
FIG. 27 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the front and top panels running from multiple end points, and a hinge coincident with a panel score line.
FIG. 28 is a top view of a carton blank similar to FIG. 27 and including a finger notch.
FIG. 29 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the front and top panels running from common end points, and a hinge coincident with a panel score line.
FIG. 30 is a top view of a carton blank similar to FIG. 29 and including a finger notch.
FIG. 31 is a top view of a carton blank with a glue flap adjacent to a minor panel, zipper cuts on the front and top panels, and a hinge not coincident with a panel score line.
FIG. 32 is a top view of a carton blank similar to FIG. 31 and including a finger notch.
FIG. 33 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the front and top panels running from multiple end points, and a hinge not coincident with a panel score line.
FIG. 34 is a top view of a carton blank similar to FIG. 33 and including a finger notch.
FIG. 35 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the front and top panels running from common end points, and a hinge not coincident with a panel score line.
FIG. 36 is a top view of a carton blank similar to FIG. 35 and including a finger notch.
FIG. 37 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, and a hinge not coincident with a panel score line.
FIG. 38 is a top view of a carton blank similar to FIG. 37 and including a finger notch.
FIG. 39 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the top panel running from common endpoints, zipper cuts on the front panel, and a hinge not coincident with a panel score line.
FIG. 40 is a top view of a carton blank similar to FIG. 39 and including a. finger notch.
FIG. 41 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, a hinge coincident with a panel score line, and lacking a tuck tab score line.
FIG. 42 is a top view of a carton blank with a glue flap adjacent to a major panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, a hinge not coincident with a panel score line, a finger notch, and lacking a tuck tab score line.
FIG. 43 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, a hinge coincident with a panel score line, and lacking a tuck tab score line.
FIG. 44 is a top view of a carton blank with a glue flap adjacent to a minor panel, reverse cuts on the top panel running from multiple endpoints, zipper cuts on the front panel, a hinge not coincident with a panel score line, a finger notch, and lacking a tuck tab score line.
FIG. 45 is an isometric view of a carton made from the blank in FIG. 1 in a closed configuration.
FIG. 46 is an isometric view of a carton made from the blank in FIG. 2 in a closed configuration.
FIG. 47 is an isometric view of a carton made from the blank in FIG. 1 in an open configuration.
FIG. 48 is an isometric view of a carton made from the blank in FIG. 2 in an open configuration.
FIG. 49 is an isometric view of a carton made from the blank in FIG. 4 in a closed configuration.
FIG. 50 is an isometric view of a carton made from the blank in FIG. 5 in a closed configuration.
FIG. 51 is an isometric view of a carton made from the blank in FIG. 6 in a closed configuration.
FIG. 52 is an isometric view of a carton made from the blank in FIG. 7 in a closed configuration.
FIG. 53 is an isometric view of a carton made from the blank in FIG. 8 in a closed configuration.
FIG. 54 is an isometric view of a carton made from the blank in FIG. 16 in a closed configuration.
FIG. 55 is an isometric view of a carton made from the blank in FIG. 17 in a closed configuration.
FIG. 56 is an isometric view of a carton made from the blank in FIG. 20 in a closed configuration.
FIG. 57 is an isometric view of a carton made from the blank in FIG. 21 in a closed configuration.
FIG. 58 is an isometric view of a carton made from the blank in FIG. 24 in a closed configuration.
FIG. 59 is an isometric view of a carton made from the blank in FIG. 25 in a closed configuration.
FIG. 60 is an isometric view of a carton made from the blank in FIG. 26 in a closed configuration.
FIG. 61 is an isometric view of a carton made from the blank in FIG. 27 in a closed configuration.
FIG. 62 is an isometric view of a carton made from the blank in FIG. 36 in a closed configuration.
FIG. 63 is an isometric view of a carton made from the blank in FIG. 37 in a closed configuration.
FIG. 64 is an isometric view of a carton made from the blank in FIG. 40 in a closed configuration.
FIG. 65 is a perspective view of a carton made from the blank in FIG. 1 in an opened configuration and filled with a plurality of sheet articles.

DETAILED DESCRIPTION

The present disclosure relates to a folding box for dispensing articles, such as a cardboard box construction for dispensing dryer sheets, pocket handkerchiefs, napkins, facial tissues, or the like. The folding box may be of a rectangular- or hexahedral-shaped dispensing box. The box can be made of a one piece, rigid, but foldable material. The carton or box can be folded to give four body-forming surfaces and two end closure surfaces.
One form of a folding box blank prepared from a sheet material and processed with a die is illustrated in FIG. 1 as blank 10. In describing this blank and other blanks, it should be understood that a blank has two opposite surfaces—an “outer” surface and an “inner” surface. The outer surface can be suitable for imprinted graphics and also corresponds to the outer surface of a carton. The inner surface can include graphics such as aesthetic design, color or graphics that might be associated with coupons or other promotional information, but otherwise may be an unprinted surface. Different inks and coatings, of course, produce different surface characteristics on the paperboard. Cartons can be constructed from the blanks by folding the blank manually or with the use of automated equipment. An example of a carton is illustrated in FIG. 45 and generally denoted by reference numeral 60.
Coatings
Cartons and blanks can have films, laminations, and coatings on both, either, or neither of the inner and outer surfaces. Both the inner and outer surfaces may be coated with a film of material if desired. In the case of the outer surface, the coating can be chosen to be compatible with printing graphic inks for displaying labels, product information, pictures, and the like. In some instances, the outer surface may not have a coating, for example if labels and other packaging markings are applied by adhesive labels and the like. The inner surface may also be coated with a film as this may reinforce and preserve the integrity of the carton or blank material. In some instances, the inner surface will not have a coating.
The coating selected will depend upon the intended use for the container. By way of example, the inner surface may be coated with one-half millimeter of extruded or laminated low density polyethylene (LDPE) and one millimeter of extruded or laminated high density polyethylene (HDPE). By way of another example, the inner surface may be coated with a millimeter of grease barrier. Also by way of example, the outer surface may be coated with a metalized polyester. Metalized polymers are especially helpful for giving printed materials on the outer surface a metallic or vibrant appearance for marketing purposes and reading clarity.
When a coating is applied to a surface of the blank/carton, it can provide a barrier to perfumes and surfactants. Furthermore, the coating can help strengthen a substrate material for example fiberboard. For example, when paperboard is used, it may include on the inside or outside a printed barrier obtained by fluorochemical treatment to provide wet strength for the flap. The thickness of the paperboard or other material may be whatever is desired such as a thickness in the range from 2 to 30 mils in thickness, or 18 to 22 mils in thickness preferably 20 point.
It is contemplated that a variety of substrate materials may be used for forming the cartons including raw and recycled fiberboard material, raw and recycled fibrous material, raw and recycled paperboard, raw and recycled plastics such as polyethylene, polypropylene, polybutylene, and any other material capable of receiving score lines. The substrate materials used can come pre-coated or a coating may be applied to the substrate at any time. Examples of pre-coated substrates include clay coated recycled paperboard, solid bleached sulfate paperboard, poly-coated solid bleached sulfate paperboard, foil-coated paperboard (recycled and virgin), film coated paperboard (such as metalized polyesters laminated to paperboard substrates), wax-coated paperboard, and various other kinds of paperboard that have been treated, e.g., with special additives such as grease inhibitors. Other examples of paperboard substrate include solid bleached board (SBB), solid unbleached board (SUB), folding box board (FBB), and white lined chipboard (WLC).
Blanks
Die-cut carton blanks can be packaging container blanks of a selected shape and style provided with grooves, scores, perforations or cutting lines and, possibly, punched out portions. The blank is used to produce a carton or carton component. Blanks can also be referred to as any die cut, scored and corner cut section of a sheeted-substrate in a flat to be formed into a rigid box or part thereof. Blanks can also be referred to as a folding carton after cutting and scoring but before folding and gluing. Die-cut blanks can be manufactured at blanking stations in press machinery. A diecutting press allows automatic separation of the die cut blank from a sheet of substrate. A diecutting press with blanking and stripping stations can convert stacked sheets into stacked diecut blanks.
Turning to FIG. 1, a blank 10 is illustrated with primary score lines 111, 112, 113, 114, 115, and 116. The blank 10 also includes two cutoffs 119 and 120. The primary score lines (also called fold lines or creases) and cutoffs (also called the outer perimeter of the die line or outer perimeter) demarcate or otherwise perimeterally define various body-forming panels and flaps. Lapping glue flap 125 (also called glue flap or glue lap) is demarcated by score line 111 and cutoff 119. Major panel 121 is demarcated by score lines 111, 112, 115, and 116. Score lines 115 and 116 also demarcate a separation between major panel 121 and a pair of major flaps 131 and 132 respectively. Minor panel 122 is defined by score lines 112, 113, 115, and 116. Score lines 115 and 116 also demarcate a separation between the minor panel and a pair of minor flaps 133 and 134 respectively. A second major panel 123 is demarcated by score lines 113, 114, 115, and 116. Score lines 115 and 116 demarcate a separation between second major panel 123 and a second pair of major flaps 135 and 136. A second minor panel 124 is demarcated by score lines 114, 115, 116, and cutoff 120. Score lines 115 and 116 also demarcate a separation between a second pair of minor flaps 137 and 138.
The major and minor panels have been enumerated and sometimes referred to as first and second types of major and minor panels. It is contemplated for convenience and brevity that any first major panel could be called a second major panel and visa versa, while any first minor panel could be called a second minor panel and visa versa. This principle also applies when referring to flaps, fold lines, score lines, and the like. Such terminology usually depends on an artisan's reading frame for any given drawing.
Depending upon the desired presentation and function of a package folded and formed from blank 10, it may be convenient to refer to the various panels and flaps relative to their display orientation. In one desired orientation, panel 121 may be thought of as the “bottom” panel. Bottom panel 121 also has a first end wall or cover flap 131 and a second end wall or cover flap 132 separated from bottom panel 121 by score lines 115 and 116 respectively. Bottom panel 121 is adjacent a lapping glue flap 125 along score line 111. Bottom panel 121 is also adjacent a “rear” panel 122 along score line 112. Rear panel 122 has a first side wall 133 and a second side wall 134 and is separated from both by score lines 115 and 116 respectively. Adjacent the rear panel 122 along score line 113 is a “top” panel 123 having a first end wall or cover flap 135 and a second end wall or cover flap 136 separated from top panel 123 by score lines 115 and 116 respectively. Adjacent top panel 123 along score line 114 is a “front” panel 124. The front panel 124 also has a first side wall 137 and a second side wall 138 separated from front panel 124 by score lines 115 and 116 respectively. Front panel 124 terminates at cutoff 120. The lapping glue flap 125 adjacent the bottom panel 121 terminates at cutoff 119.
As displayed in FIG. 1, blank 10 includes major flaps 131, 132, 135, and 136 which in this example have symmetrical appearance. Major flaps 131 and 132 are approximately equal in dimension to major flaps 135 and 136. In this example, the dimensions of the major flaps are sufficiently elongated that they will overlap with one another when the carton made from the blank is closed. In other examples, the dimensions of the major flaps can be shortened to dimensions corresponding to flaps that do not overlap when the assembled carton made from the blank is closed.
With respect to minor flaps 133, 134, 137, and 138, it is unnecessary that these flaps have symmetrical appearance with each other. As seen in an example depicted in FIG. 1, each pair of minor flaps has a similar dimension but each minor flap pair differs in dimension to the other minor flap pair. The relative dimensional shape between pairs of minor flaps may differ to accommodate filling equipment which places articles in the assembled carton. Lapping glue flap 125 in this example has a trapezoidal shape. In other examples, the lapping glue flap may have a rectangular shape.
Perforated Rules and Other Glue Assists
Perforated rules (or glue assists) and other affixing means for adhesive assistance augment the effectiveness of adhesives applied to carton and blank surfaces. Glue assists can involve techniques to break through the clay coating, varnish coatings, UV coatings or other types of barriers existing on a surface to which adhesive will be applied. In an example when the substrate surface is paperboard, glue assists can aid water soluble glue in penetrating through the soluble fibers of the inner core of the board. Perforated rules can be created in a carton or blank surface by a series of knives placed into a die. These knives are set at different heights corresponding to the amount of penetration into the substrate surface. Perforated rules can be of a variety of styles such as dashes, hashes, x-type, and so forth. Perforated rules can be created from any multitude of combinations of teeth & spaces in millimeters and in inches at any desired depth so long as the depth does not penetrate through the entire blank material.
In some examples, affixing means for adhesive assistance are provided. The affixing means for adhesive assistance may exist on one or more of any end closure flap, lapping glue flap, and inner surface of a body-forming panel. In some examples, perforated rules exist on one or more of any end closure flap, lapping glue flap, and inner surface of a body forming panel.
A perforated rule cut can give the glue more adhesion between two glued surfaces. The perforated rules also add to the actual surface area that the glue has to adhere to. This exposed area must be formed in a way that exposes fibers or furrows that stay open through the gluing process. When the substrate surface has a grain, a cross grain cut will tend to stay open were a with grain cut will tend to close. Another example of glue assists arises from laser etched surfaces. Laser etching removes at least a portion of a coating material on a glueable area of the carton blank.
Another feature appearing in FIG. 1 is a plurality of perforated rules (or glue assists) 180. Perforated rules in blank 10 are found in major flaps 131 and 132, minor flaps 133, 134, 137, and 138 and in lapping glue flap 125. Perforated rules 180 are generally understood in the art to be a series of cuts or punches which allow an applied glue to adhere to more than the surface of a flap or panel. The perforated rules enable the applied glue to adhere to a fiberboard material or other suitable substrate material that may be untreated or that may be coated with films.
The variety of styles and forms of perforated rules may also be referred to as affixing means for adhesive assistance. The affixing means provided on the carton blanks depicted can be generally referred to also as adhesive means 180. The use of perforated rules and affixing means for adhesive assistance are optionally included in the blanks herein described. For brevity, all depicted examples are depicted as having perforated rules on all flaps which are to receive glue on the exterior surface. The perforated rules enhance the security of the assembled cartons' structure and improve longevity. However, it is contemplated that in all the blanks/cartons herein depicted, the blanks/cartons could be prepared without the perforated rules (or affixing means for adhesive assistance) and assembled into corresponding cartons.
Access Flap & Reverse Cuts
The folding cartons and blanks include a fully enclosed access flap (or access hatch or access panel) which may be opened and closed by a consumer. The access hatch enables a consumer to open a portion of the container with a human hand and remove articles in the container followed by closing the hatch with minimal effort. When the access flap is opened, the carton I is capable of dispensing sheeted fabric softening articles or sheeted cleaning articles. Furthermore, the access hatch together with the other panels and flaps enclose the articles in the container during shipping and storage. A fully enclosed access flap may be formed and located within the combined surfaces of two body-forming panels therby being fully enclosed by those same body-forming panels.
The access flap may be demarcated by a plurality of lines of separation (also called spaced apart lines of separation, lines of weakness, tear lines, weakened lines of separation, pre-weakened portions of a panel, cuts, and perforation cuts). The lines of separation may demarcate portions of an access flap so that when the lines of separation are severed, a fully enclosed access flap may be movable between a closed postion closing an access opeining into the interior of a carton and an open position allowing the insertion of a humand hand to retrieve various desired articles from the interior of the carton. In addition, the access flap may be rectangular-, hexagaonal-, or irregular hexagonal-shaped.
In the preceding paragraphs, the enumerated features associated with blank 10 have been described relative to the score lines which define portions of the blank and along which they are folded during the construction of the container. The example of blank 10 also includes an access flap 150 which can be defined by lines of separation 151, 152, 153, 154, 157 and 158. Lines 151, 152, 153, 154 are two pairs of partially die cut (or reverse cut or half cut or reverse out or half out or double-cut scores) lines. In the example depicted in FIG. 1, lines 151 and 153 appear substantially parallel and spaced apart by about ¼ inch (or 0.6 cm) and constitute one flank of the access flap 150. Lines 152 and 154 also appear substantially parallel and spaced apart by about ¼ inch (or 0.6 cm), and again constitute another flank of the access flap 150. The reverse cuts can taper to a common point such as 159 and 160. In this example, lines 151 and 152 are partial cuts through the outer surface of the blank 10 while lines 153 and 154 are partial cuts through the inner surface or opposite side of the blank 10. Lines 151 and 152 as displayed in blank 10 are on the outer perimeter portion of the access flap 150 while lines 153 and 154 are on the inner perimeter portion of the access flap 150.
In another example, (not illustrated) line 151 can be interchanged with line 153 and line 152 can be interchanged with line 154 so that the outside surface cut is on the inner perimeter portion of the access flap and the inside cut is on the outer perimeter portion of the access flap. In yet another example, (not illustrated) line 151 can be coincident with score line 115 and line 152 can be coincident with score line 116.
In the example depicted in FIG. 1, lines 151 and 153 run from line end points 141 and 143 respectively to conjoin or otherwise meet at a first tear point 159. Lines 152 and 154 run from line end points 142 and 144 respectively to conjoin or otherwise meet at a second tear point 160. In blank 10, tear points 159 and 160 are coincident with score line 114 and line end points 141, 142, 143, and 144 are coincident with score line 113. The tear points and line end points can be coincident with score lines or can be at locations not coincident with score lines. Examples with tear points and line end points at various positions are contemplated and discussed more fully hereafter.
Access Flap and Zipper Cuts
Another example of a cut which may demarcate the access flap is a zipper cut. Zipper cuts (also called zipper rules, staggered perforated cut lines, tear edges, and tear rules) conveniently control the direction of tear through the substrate material. Zipper cuts exist in a variety of styles that vary in angle, length, and gap between cuts and may be selected according to requirements such as thickness of the material, grain direction, and other criteria. In addition, zipper cuts conveniently assist reclosure of an access flap when the access flap is tucked behind the side edges of a panel. This forms a latching and sealing action minimizing inadvertent opening of the reclosed carton during subsequent handling.
Again, referring to the example depicted in FIG. 1, the access flap 150 is further demarcated by lines of separation 157 and 158 which are zipper cuts through the outer and inner surfaces of blank 10. In this example, the zipper cut lines 157 and 158 can be characterized by “herringbone” foraminations or slit lines in the separating lines of the access flap. Other examples (not illustrated for brevity) of zipper cut style may be applicable to the blanks and cartons.
Tuck Tab
In some examples, the blanks/cartons have a tuck tab (or lip). A tuck tab may constitute or further define one flank of an access flap and usually the flank which can be partially or completely concealed behind a panel when the access flap is relcosed. A tuck tab may also function to assist the consumer when initially opening the container. A tuck tab itself may be demaracted itself by a tuck tab cut extenting between a plurality of spaced apart lines of separation. The tuck tab may also be demarcated by a score line such as a tuck tab score. In some examples, the tuck tab score is colinear with portions of a tuck tab cut.
Returning to the example displayed in FIG. 1, the blank 10 further includes a tuck tab 170. The tuck tab 170 in this example is demarcated by tuck tab score line 171 and tuck tab cut 172. Tuck tab cut 172 extends between first and second tuck tab score line end points 173 and 174 which can be coaxial with tuck tab score line 171. Line 157 runs between tuck tab end point 173 and tear point 159. Line 158 runs between tuck tab end point 174 and tear point 160.
In some examples, the tuck tab is not perimeterally defined by visible lines of demarcation. Referring to the example in FIG. 41, a blank 50 is displayed with an alternative tuck tab (or lip end) 179. As can be seen, the example of blank 50 differs from the example of blank 10 in that blank 50 does not have tuck tab score line 171. Instead, the access flap 150 illustrated in FIG. 41 includes a lip end 179 demarcated by cut 172. It is contemplated that blank and carton configurations which lack the tuck tab score line 171 will be preferable for erected cartons with smaller quantities of articles and shorter minor panels.
In some examples, one or more of spaced apart lines of separation form an obtuse angle with a tuck tab score line. In other examples, one or more of spaced apart lines of separation form a perpendicular angle with a tuck tab score line.
Segments
Blank 10 and other exemplary blanks described herein can been described as including lines of separation divided up into a plurality of definable segments. As can be observed in FIG. 1, four segments 165, 166,167, and 168 are displayed around the perimeter of access flap 150. One segment 165 incorporates lines of separation 151 and 153 which each stretch from a first point to a second point. Segment 165 may be termed the first side first segment of lines of separation. A second segment 165 incorporates lines of separation 152 and 154 which also each stretch from a first point to a second point. Segment 166 may be termed the second side first segment of lines of separation. A third segment 167 corresponds in distance between first and second points of line 157 and may be termed the first side second segment of lines of separation. A fourth segment 168 corresponds in distance between first and second points of line 158 and may be termed the second side second segment of lines of separation. As can be appreciated from the drawings and description herein, the segments 165, 166, 167, and 168 correspond merely to the whichever type of line of separation is selected to span a given distance.
In one example, a fully enclosed access flap is perimeterally defined by a hinge, a pair of segments that may be partial cuts, a pair semgents that may be zipper cuts, and a tuck tab cut.
Finger Notch
In some examples, the blanks/cartons have a finger notch. A finger notch may facilitate grasping of a tuck tab or an end of an access flap to assist a consumer in opening the erected carton. In some examples the finger notch may be defined by an arcuate cut beginning at a finger notch cut point substantially coincident with a tuck tab cut and ending at a second finger notch cut substantially coincident with the tuck tab cut.
Referring to the example depicted in FIG. 2, blank 11 includes the features of blank 10 and a finger notch (or finger tab or thumb tab or access flap assistance tab) 175. The finger notch 175 is demarcated by a finger notch cut 176 which intersects the tuck tab cut 172 at a first finger notch end point 177 and a second finger notch end point 178. In the example depicted in FIG. 2, the finger notch 175 appears hemispherical-(or arch-) shaped; however, the finger notch can take the form of other shapes (for brevity, not depicted) including squares, rectangles, polygons, irregular polygons, ellipsoids, and ovals so long as the shape provides space for a finger or instrument to grasp the tuck tab 170. Again referring to example in FIG. 2, it is contemplated that lapping glue flap 125 can extend behind the entire gap of finger notch 175 area and further extend behind the tuck tab 170. In other examples (not depicted) the lapping glue flap 125 can extend behind the entire gap of finger notch 175 area and not substantially extend behind the tuck tab 170.
Variations of the Access Flap
The access flap for the blanks/cartons can have a variety of appearances and properties. These properties can vary depending upon the nature of the lines of separation which perimeterally demarcate the access flap.
In one example depicting blank 12 in FIG. 3, the lines of separation can terminate at a common end points. Therein, lines 151 and 153 run from common line end point 145 to conjoin or otherwise meet at a first tear point 159. Lines 152 and 154 run from common line end point 146 to conjoin or otherwise meet at a second tear point 160. In blank 12, tear points 159 and 160 are coincident with score line 114 and common line end points 145 and 146 are coincident with score line 113. Blank 13 in FIG. 4 displays an access flap 150 with common line end points 145 and 146 where the second minor panel 124 also includes a finger notch 175.
In another example, the lines of separation may be continuous segments of zipper cuts. Turning to FIG. 5, a blank 14 has an alternative access flap 190 wherein the lines of weakness 191 and 192 are continuous zipper cuts running from line end points 145 and 146 to tuck tab end points 173 and 174 respectively. Blank 15 in FIG. 6 displays an access flap 190 with common line end points 145 and 146 where the second minor panel 124 also includes a finger notch 175.
In still another example, the lines of separation may be continuous segments of partially die cut lines. Turning to FIG. 7, a blank 16 has an alternative access flap 194 including lines of separation 195, 196, 197, and 198. Lines 195, 196, 197, and 198 are two pairs of partially die cut lines. Lines 195 and 197 which are substantially parallel and spaced apart by about ¼ inch (or 0.6 cm) constitute one flank of the access flap 194. Lines 196 and 198 which are also substantially parallel and spaced apart by about ¼ inch (or 0.6 cm) constitute another flank of the access flap 194. Lines 195 and 196 are partial cuts through the outer surface of the blank 16 while lines 197 and 198 are partial cuts through the inner surface or opposite side of the blank 16. Lines 195 and 196 as displayed in blank 16 are on the outer perimeter portion of the access flap 194 while lines 197 and 198 are on the inner perimeter portion of the access flap 194. Blank 17 in FIG. 8 is similar to blank 16 but also includes a finger notch 175.
In like manner as mentioned in a previous example, lines 195 could be interchanged with line 197 and line 196 could be interchanged with line 198 so that the outside surface cuts are on the inner perimeter portion of the access flap and the inside cuts are on the outer perimeter portion of the access flap.
Now turning to blank 18 in FIG. 9, therein, lines 195 and 197 run from common line end point 145 to conjoin or otherwise meet at a first tear point 159. Lines 196 and 198 run from common line end point 146 to conjoin or otherwise meet at a second tear point 160. In blank 18, tear points 159 and 160 are coincident with tuck tab score line 171 and common line end points 145 and 146 are coincident with score line 113. The blank 19 illustrated in FIG. 10 is similar to blank 18 and includes finger notch 175.
The tear points and line end points can be coincident with score lines or can not be coincident with score lines. In one example (not depicted), tear points 159 and 160 are not coincident with score line 114. In another example illustrated in FIG. 11, line end points 141 and 143 are not coincident with score line 113, but are instead coincident with score line 117. In still another example (not illustrated) line end points
Hinge
A hinge demarcates one side of an access flap in the blanks and cartons. The hinge functions as a axial pivot along which the access flap pivots as the consumer opens and closes an erected carton.
In the example depicted in FIG. 1, blank 10 contains a hinge 139 that is also coincident with score line 113. Hinge 139 runs between line end points 141 and 142 while running perpendicular to score lines 115 and 116. In another example, the hinge is not coincident with a panel separating score line. Referring to blank 20 in FIG. 11, hinge 140 traverses a portion of the second major panel 123 but is not coincident with score line 113. Hinge 140 may be a die pressed score line which traverses panel 123 from score line 115 to score line 116 (not illustrated) or may be abbreviated (or shortened) such as score line 117 in blank 20. Score line 117 runs from common line endpoint 147 to common line endpoint 148 in a substantially perpendicular orientation to score lines 115 and 116. In other examples, the hinge 140 traverses a portion of the second major panel but at an angle to one of the score lines. In other examples, the hinge location and score line 117 can be placed in various locations across the second major panel 123 making the access flap larger or smaller.
Now turning to the example blank 20 in FIG. 11 has an abbreviated form of access flap 190 with hinge 140 coincident with score line 117. Blank 21 in FIG. 12 shows a similar blank further including a finger notch 175.
Blank 22 in FIG.13 has an abbreviated form of access flap 194 with hinge 140 coincident with score line 117 and a plurality of line end points 141, 142, 143, and 144. Blank 23 in FIG. 14 shows a similar blank further including a finger notch 175.
Blank 24 in FIG. 15 has an abbreviated form of access flap 194 with hinge 140 coincident with score line 117 and common line end points 147 and 148. Blank 25 in FIG. 16 shows a similar blank further including a finger notch 175.
Blank 26 in FIG. 17 has an abbreviated form of access flap 150 with hinge 140 coincident with score line 117 and a plurality of line end points 141,142, 143, and 144. Blank 27 in FIG. 18 shows a similar blank further including a finger notch 175.
Blank 28 in FIG. 19 has an abbreviated form of access flap 150 with hinge 140 coincident with score line 117 and common line end points 147 and 148. Blank 29 in FIG. 20 shows a similar blank further including a finger notch 175.
Lapping Glue Flap Location
Before a carton is erected and filled with articles, a corresponding blank can be folded. In this process of preparing the blank, a lapping glue flap can be treated with an adhesive and brought into contact with another portion of the blank. The lapping glue flap's dimensions and location can be altered as needed. As disclosed in the examples, this lapping glue flap mechanically reinforces both the stability of the dispensing box but in some examples, also assists in reinforcing the front panel for consumer operation of the access flap.
By way of example, the lapping glue flap may adjoin different body-forming panels and be of different lengths. The lapping glue flap may be foldably attached along an edge of a body-folding panel. In many examples, the lapping glue flap overlaps at least a portion of a body-forming panel lateral to a fully enclosed access flap so that when a consumer separates the access flap from one or more of the body-forming panels to open a carton, the overlapped portion of the body-forming panel remains attached to the lapping glue flap. Furthermore, in these and other examples, the lapping glue flap overlaps at least a portion of a fully enclosed access flap.
As illustrated in the example of FIG. 1, blank 10 has a lapping glue flap 125 located next to the first major panel 121. In another example depicted in FIG. 21, blank 30 includes a major panel 121 demarcated by score lines 112, 115 and 116 and by cutoff 127. A second minor panel 124 is demarcated by score lines 114, 115, 116, and 118. Lapping glue flap 126 is demarcated by score line 118 and cutoff 128. The arrangement of blank 30 differs from the previously described blank 10 in that the lapping glue flap 126 is now on the opposite end of the blank and adjacent to the second minor panel 124 along score line 118.
Placement of lapping glue flap 126 in blank 30 will result in an assembled carton in which the lapping glue flap 126 is adhered to major panel 121, whereas the arrangement placing the lapping glue flap 125 of blank 10 will result in an assembled carton in which the lapping glue flap 125 is adhered to minor panel 124. In both blank 10 and blank 30, the lapping glue flaps are adhered to the interior surface of the respective panels 124 and 121 respectively. In either arrangements depicted in FIG. 1 and FIG. 21, the lapping glue flaps 125 and 126 could be adhered to the outside surface of panel 124 and panel 121 respectively. In another example, blank 31 illustrated in FIG. 22, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124 and including a finger tab 175.
In some examples such as blanks 10 and 30, lapping glue flaps may span the entire width of a panel. In other examples (not illustrated for brevity) lapping glue flaps may span only a portion of the width of the a panel. In still other examples, a lapping glue flap can be capable of receiving a continuous glue seam in contrast with a glue seam that is interrupted. This is not to suggest that the glue seam that ultimately is applied must be continuous, only that the lapping glue flap itself can be continuous and uninterrupted so that a continuous glue seam can be applied.
Blank 32 illustrated in FIG. 23, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with access flap 150 and common line end points 145 and 146. Blank 33 illustrated in FIG. 24 is similar to blank 32 and includes a finger tab 175.
Blank 34 illustrated in FIG. 25, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with access flap 190. Blank 35 illustrated in FIG. 26 is similar to blank 34 and includes a finger tab 175.
Blank 36 illustrated in FIG. 27, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with access flap 194 and a plurality of line end points 141,142, 143, and 144. Blank 37 illustrated in FIG. 28 is similar to blank 36 and includes a finger tab 175.
Blank 38 illustrated in FIG. 29, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with access flap 194 and common line end points 145 and 146. Blank 39 illustrated in FIG. 30 is similar to blank 38 and includes a finger tab 175.
Blank 40 illustrated in FIG. 31, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124 with abbreviated access flap 190. Blank 41 illustrated in FIG. 32 is similar to blank 40 and includes a finger tab 175.
Blank 42 illustrated in FIG. 33 shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with abbreviated access flap 194 and a plurality of line end points 141, 142, 143, and 144. Blank 43 illustrated in FIG. 34 is similar to blank 42 and includes a finger tab 175.
Blank 44 illustrated in FIG. 35, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with abbreviated access flap 194 and common line end points 145 and 146. Blank 45 illustrated in FIG. 36 is similar to blank 44 and includes a finger tab 175.
Blank 46 illustrated in FIG. 37, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with abbreviated access flap 150 with hinge 140 and a plurality of line end points 141, 142, 143, and 144. Blank 47 illustrated in FIG. 38 is similar to blank 46 and includes a finger tab 175.
Blank 48 illustrated in FIG. 39, shows the arrangement of lapping glue flap 126 adjacent to minor panel 124, with abbreviated access flap 150 and common line end points 145 and 146. Blank 49 illustrated in FIG. 40 is similar to blank 48 and includes a finger tab 175.
FIG. 41 displays blank 50. As can be seen, blank 50 differs from other blanks in that it does not have tuck tab score line 171. Instead blank 50 has an alternate tuck tab 179 or end lip 179. Blank 51 displayed in FIG. 42 is similar to blank 50 and includes a finger notch 175 with an abbreviated access flap 150 extending to hinge 140.
Turning to FIG. 43, a carton 52 is displayed similar to carton 50 but lapping glue flap 126 appears on the opposite side of the blank. Therein, lapping glue flap 126 is adjacent minor panel 124. FIG. 44 illustrates blank 53 which is similar to blank 52 and includes a finger notch 175 with an abbreviated access flap 150 extending to hinge 140.
In some examples, the lapping glue flap may be adhered to the outside surface of a panel and in other examples, the lapping glue flap may be adhered to the inside surface of a panel.
Dimensions
Dimensions of the major and minor panels and concomitant dimensions of the major and minor flaps change or are adjusted to accommodate the articles which will fill the box. The dimensions of the first and second major panels are altered depending upon the amount of surface area of the article, i.e., the surface area of the sheet articles. The dimensions of the first and second minor panels are altered depending upon the quantity of the article, i.e., the number of articles in the stack of sheets. In the example of a stack of sheet articles, the sheets may be folded thus reducing the requisite surface area of the first and second major panels but increasing the surface area of minor panels (and therefore the height of the filled carton).
It may be apparent then that whether a panel is termed the major or minor panel, the blank and carton may have major panels which are smaller than its minor panels and the blank or carton may have major panels which are larger than its minor panels. It is sufficed to say that the panel dimensions are adjustable to accommodate the packaged article(s) for the assembled carton.
The size and dimensions of the carton may vary depending upon the nature of the articles that are to be stored in the carton. In some examples, the carton may be a hexahedral-shape. In other examples, the carton may be parallelepipedal-shaped. For examples of rectangular shaped cartons, the height of a carton can correspond to the width of the first and second minor panels, the length of a carton can correspond to the distance between score lines 115 and 116, and the width of the carton can correspond to the width of the first and second major panels. In the example of blanks and cartons which will be used to produce cartons filled with dryer sheets, any quantity of sheets may be accommodated. For a 40 sheet carton example, the height of the carton could be about 1¼ inches (3.2 cm), the length about 7 inches (17.8 cm), and the width about 4¼ inches (10.8 cm). For a 80 sheet carton example, the height could be expected to about 2 inches (5.1 cm). For a 120 sheet carton example, the height would typically be in the range of about 2¼ inches (5.7 cm) to 2¾ inches (7 cm) and the length and width about the same as for the 40 sheet carton example. For a 160 sheet carton example, the height could be about 3⅜ inches (8.6 cm) and the length and width the about same as for the 40 sheet carton example. For a 200 sheet carton example, the height could be about 4 inches (10.2 cm) and the length and width the about same as for the 40 sheet carton example. For a 240 sheet carton example, the height could be about 3⅜ inches (11.7 cm) and the length and width the about same as for the 40 sheet carton example. It should be understood that the height and width of the panels can be changed to accommodate whatever sized article(s) may be desired to fill the carton.
Methods of Assembling Folding Cartons
Blank structures disclosed also enhance the production speed or efficiency during the folding, erection, filling, closing and sealing phases of the manufacturing operation. Blanks prepared from the die-cut press can be fed to an assembly line preparatory to carton filling. In some examples, the blank has already received a printed graphic and/or coating. During this stage of manufacture, a stack of blanks can be loaded into a magazine. Each blank may be taken from the magazine and fed through a folding machine (often called a “fodler-gluer”) in a manner so that an adhesive is applied to the lapping glue flap. After an adhesive is applied, the lapping glue flap is then folded adjacent a panel and adheres to that panel. The entire blank can be made flat again for loading into a magazine to be processed at a filling line.
Depending upon the surface characteristics of the particular carton blank being folded and glued, a glue must be selected which provides the best combination of adhesive strength and low cost. Examples of glues which might be utilized include cold glues including cold-resin glues as well has hot glues. The adhesive may be applied in any acceptable conventional manner including by rotary disc or spot glue injectors.
When some cold-resin glues are used with ordinary clay-coated paperboard, those cold-resin glues usually penetrate the clay coating and ink to impregnate the fibrous mass of the carton blank. The result is a bond sufficient to “pull fiber”, i.e., sufficient to tear the paperboard of one or both glued together panels of the carton blank, when the carton is stressed or opened at that glue seam.
In one such exemplary method, an erected carton 60 illustrated in FIG. 45 is formed from the blank 10 depicted in FIG. 1. The carton 60 is formed by adhering lapping glue flap 125 (now 225 in the carton) to second minor panel 124 (now 224 in the carton). As has been previously articulated, lapping glue flaps (or flaps), minor flaps, and major flaps may optionally include perforated rules of any style or affixing means for adhesive assistance. The perforated rules or affixing means for adhesive assistance can help facilitate the adhesive in penetrating the surface of the fiberboard or other material including any coating. When the flaps include perforated rules or affixing means for adhesive assistance then glue can be applied to the area or areas of the flaps which include the perforated rules or affixing means for adhesive assistance. However, when the flaps include perforated rules or affixing means for adhesive assistance, then glue can be applied to the area or areas of the flaps which include and do not include the perforated rules or affixing means for adhesive assistance.
It should also be noted that when glue is applied to the lapping glue flap, the entire surface of the lapping glue flap can be covered by the adhesive or in other examples, a bead of glue which does not cover an entire surface may be applied. The advantage of the bead is realized in that when the carton is assembled, the adhering panel will also overlap with a portion of the lapping glue flap and having adhesive between the access flap and the lapping glue flap may make opening the access flap more difficult. It is still contemplated that adhesive applied over the surface area of a lapping glue flap which overlaps with a portion of the access flap can still be practiced and in some respects may be advantageous. In examples where a continuous glue seam is applied along the lapping glue flap, less wear on the fabricating equipment results and reduces maintenance costs. This inherently also results in greater efficiency as the equipment is less prone to fail and more cartons can be processed.
The partially assembled carton with an adhesively applied lapping glue flap can be stored as a flat resting packing in a conventional way such as in the magazine of a cardboard box producing machine. The folding and assembling of such a prefabricated packaging can be carried out in conventional ways, whereby the flat box form can be folded and erected into a desired angular position and various articles may be added to the carton in filling lines. Once filled, any unfolded remaining side end walls can be folded and additional adhesive applied to appropriate areas followed by closure of the remaining side end walls to seal or close the filled carton. When sheeted articles are the desired articles to fill the carton, various configurations of the sheets can be stacked in various manners. In one example, the sheeted articles are interfolded. In another example, the sheeted articles are not interfolded.
In another step of an exemplary method, the carton is squared and minor flaps from one side of the carton (such as 134 now 234 and 138 now 238 or 133 now 233 and 137 now 237) are folded inwardly. Selection of which side of minor flaps is folded first is chosen by an operator and conventionally set on the equipment in the filling lines.
For filled cartons, another step in the exemplary process typically involves placement of the desired articles inside the erected carton. The filling lines can place articles such as sheets in the carton. The loading of the package with dryer sheets, handkerchiefs, napkins or the like, can be done by inserting the same from the carton's side prior to closing all of the end side walls.
Still another exemplary process step with the carton filled (or if an empty carton is desired unfilled), involves closing any remaining minor flaps from the second side of the carton. A pair of minor flaps such as 134 now 234 and 138 now 238 or 133 now 233 and 137 now 237 are folded inwardly typically at right angles to their adjoining panels.
Another step in the exemplary method involves application of an adhesive to the minor flaps. This step can be performed simultaneously or in a series of steps to minor flaps on both sides of the carton. Inside major flaps 131 (now 231) and 132 (now 232) are folded into and adhere to the nearby minor flaps. Finally, glue is also applied (again in any acceptable conventional manner) to the inside major flaps 231 and 232 and outside major flaps 135 (now 235) and 136 (now 236) are folded in to adhere to the inside major flaps 231 and 232 respectively. It is contemplated that inside major flaps 231 and 232 can be outside major flaps and outside major flaps 235 and 236 can be inside major flaps depending on how the configuration of blanks and cartons are desired. In such an example, the outside major flaps are folded in the last step and adhered to the inside major flaps.
In an another method for constructing cartons, an erected carton formed from the blank 30 illustrated in FIG. 20 is depicted in FIG. 56. The carton 80 is formed by in part by a step of adhering lapping glue flap 126 (now 226) to first major panel 121 (now 221). In another step of this exemplary method, the carton is squared and minor flaps from one side of the carton (such as 134 now 234 and 138 now 238 or 133 now 233 and 137 now 237) are folded inwardly. For filled cartons, the next step in the process typically involves placement of the desired articles inside the erected carton. With the carton filled, minor flaps from the second side of the carton (such as 134 now 234 and 138 now 238 or 133 now 233 and 137 now 237) are folded inwardly typically at right angles to their adjoining panels.
Another step in this exemplary process includes applying adhesive to the minor flaps. Inside major flaps 131 (now 231) and 132 (now 232) are folded into and adhere to the nearby minor flaps. Next, glue is also applied to the inside major flaps 231 and 232 and outside major flaps 135 (now 235) and 136 (now 236) are folded in to adhere to the inside major flaps 231 and 232 respectively.
As can be seen in FIG. 45, wherein reference numerals corresponding to those of FIG. 1 are 100 greater, the lapping glue flap 225 desirably extends no more than about 20% of the distance from the score cutoff 220 to the score line 214. In some instance is may be preferable to have a lapping glue flap 219 which extends as much as about 50% of the distance from the score cutoff 220 to the score line 214. It is contemplated that the lapping glue flap 219 can span a distance from about 10% to about 50% so of the distance from the score cutoff 220 to the score line 214.
As can be seen in FIG. 56, the lapping glue flap 226 desirably extends no more than about 20% or so of the distance from the score cutoff 227 to the score line 212. In some instances is may be preferable to have a lapping glue flap 226 which extends as much as about 100% of the distance from the score cutoff 227 to the score line 212. It is contemplated that the lapping glue flap 226 can span a distance from about 10% to about 100% so of the distance from the score cutoff 220 to the score line 214.
Cartons
Folding cartons can be containers for sales, storage and shipping packages of various designs which are delivered ready-to-use in flat form or are already squared and filled and ready for distribution. Folding cartons can be prepared from blanks of predetermined configurations. In light of some of the illustrated blanks produced here as examples and some of the blanks not illustrated a number of cartons can be constructed.
All of the blanks previously described can be erected into cartons of corresponding configurations (blanks 10-53 would correspond with cartons 60-103). The blanks depicted and the cartons that follow are but a few examples of the scope of the forms which can be practiced. For brevity, cartons corresponding to the blanks illustrated are illustrated only to assist the reader and one skilled in the art. However, it is contemplated that a carton can be folded and constructed from each of the blanks disclosed herein as well as others which have features described but not illustrated.
Again for brevity but by way of illustrating how the cartons appear, a number of cartons which correspond to some of the blanks will be described. To assist the reader, the enumerated features of the cartons are numbered so that they correspond to the enumerated features of the blanks. Inasmuch, the features of the cartons have a value equal to the number of the feature displayed in the blanks plus a value of 100 (hence, a primary fold line 111 in a blank corresponds to a primary fold line 211 in a carton).
An example of an unfilled carton is illustrated in FIG. 45. Carton 60 comprises primary fold lines 211, 212, 213, 214, 215, and 216. Carton 60 also includes two cutoffs 219 and 220. The primary fold lines (also called score lines) and cutoffs demarcate or otherwise perimeterally define various panels and flaps. Lapping glue flap 225 (also called glue flap or lapping glue flap) is demarcated by fold line 211 and cutoff 219. Major panel 221 is demarcated by fold lines 211, 212, 215, and 216. Fold lines 215 and 216 also demarcate a separation between major panel 221 and a pair of major flaps 231 and 232 (not illustrated) respectively. Minor panel 222 is defined by fold lines 212, 213, 215, and 216. Fold lines 215 and 216 also demarcate a separation between the minor panel and a pair of minor flaps 233 and 234 respectively (not illustrated). A second major panel 223 is demarcated by fold lines 213, 214, 215, and 216. Fold lines 215 and 216 demarcate a separation between second major panel 223 and a second pair of major flaps 235 and 236 (not illustrated) respectively. A second minor panel 224 is demarcated by score lines 214, 215, 216, and cutoff 220. Fold lines 215 and 216 also demarcate a separation between a second pair of minor flaps 237 and 238 (not illustrated). Carton 60 further has the feature that the lapping glue flap 225 is adhered to the inside surface of the second minor panel 224.
Depending upon the desired presentation and function of a carton, it may be convenient to refer to the various panels and flaps relative to their display orientation. In one desired orientation, panel 221 may be thought of as the “bottom” panel. Bottom panel 221 also has a first end wall or cover flap 231 and a second end wall or cover flap 232 (not illustrated) separated from bottom panel 221 by score lines 215 and 216 respectively. Bottom panel 221 is adjacent a lapping glue flap 225 along score line 211. Bottom panel 221 is also adjacent a “rear” panel 222 along score line 212. Rear panel 222 has a first side wall 233 (not illustrated) and a second side wall 234 (not illustrated) and is separated from both by score lines 215 and 216 respectively. Adjacent the rear panel 222 along score line 213 is a “top” panel 223 having a first end wall or cover flap 235 and a second end wall or cover flap 236 (not illustrated) separated from top panel 223 by score lines 215 and 216 respectively. Adjacent top panel 223 along score line 214 is a “front” panel 224. The front panel 224 also has a first side wall 237 (not illustrated) and a second side wall 238 (not illustrated) separated from front panel 224 by score lines 215 and 216 respectively. Front panel 224 terminates at cutoff 220. The lapping glue flap 225 adjacent the bottom panel 221 terminates at cutoff 219.
Turning to FIG. 46 carton 61 is further described as having a finger notch (or finger tab or thumb tab) 275 demarcated by a finger notch cut 276 which intersects the tuck tab cut 272 at a first finger notch end point 277 and a second finger notch end point 278. In the example depicted of carton 61, the finger notch 275 appears hemispherical-(or arch-) shaped; however, the finger notch can take the form of other shapes (for brevity, not depicted) including squares, rectangles, polygons, irregular polygons, ellipsoids, and ovals so long as the shape provides space for a finger or instrument to grasp the tuck tab 270. It is contemplated that lapping glue flap 225 can extend behind the entire gap of finger notch 275 area and further extend behind the tuck tab 270. In other examples (not depicted) the lapping glue flap 225 can extend behind the entire gap of finger notch 275 area and not substantially extend behind the tuck tab 270.
FIG. 47 displays carton 60 in an open box configuration where the lines of separation have all been severed. In the open configuration, it is possible to see minor flaps 234 and 238 as well as portions of the lapping glue flap 226. FIG. 48 displays carton 61 in an open box configuration and also including a finger notch 275 and a larger portion of lapping glue flap 226.
Turning to FIG. 49, a carton 64 has an alternative access flap 290 wherein the lines of weakness 291 and 292 are continuous zipper cuts running from line end points 245 and 246 to tuck tab end points 273 and 274 respectively. Carton 65 in FIG. 50 displays an access flap 290 with common line end points 245 and 246 where the second minor panel 224 also includes a finger notch 275.
Now in FIG. 51, a carton 66 is displayed with an alternative access flap 294 including lines of separation 295, 296, 297, and 298. Lines 295, 296, 297, and 298 are two pairs of partially die cut lines. Lines 295 and 297 which are substantially parallel and spaced apart by about {fraction (1/4)} inch (or 0.6 cm) constitute one flank of the access flap 294. Lines 296 and 298 which are also substantially parallel and spaced apart by about ¼ inch (or 0.6 cm) constitute another flank of the access flap 294. Lines 295 and 296 are partial cuts through the outer surface of the carton 66 while lines 297 and 298 are partial cuts through the inner surface or opposite side of the carton 66. Lines 295 and 296 as displayed in carton 66 are on the outer perimeter portion of the access flap 294 while lines 297 and 298 are on the inner perimeter portion of the access flap 294. Carton 67 in FIG. 52 is similar to blank 66 but also includes a finger notch 275.
Now turning to carton 68 in FIG. 53, another aspect of the access flap 294 can be observed. Therein, lines 295 and 297 run from common line end point 245 to conjoin or otherwise meet at a first tear point 259. Lines 296 and 298 run from common line end point 246 to conjoin or otherwise meet at a second tear point 260. In carton 68, tear points 259 and 260 are coincident with tuck tab score line 271 and common line end points 245 and 246 are coincident with score line 213.
The carton 76 illustrated in FIG. 54 has an abbreviated form of access flap 250 with hinge 240 coincident with score line 217 and a plurality of line end points 241, 242, 243, and 244. Carton 77 in FIG. 55 shows a similar carton further including a finger notch 275.
Now turning to FIG. 56, carton 80 assembled from blank 30 includes a major panel 221 demarcated by score lines 212, 215 and 216 and by cutoff 227. A second minor panel 224 is demarcated by score lines 214, 215, 216, and 218. Lapping glue flap 226 is demarcated by score line 218 and cutoff 228. Placement of lapping glue flap 226 in carton 80 results in an assembled carton in which the lapping glue flap 226 is adhered to major panel 221, whereas the arrangement placing the lapping glue flap 225 of carton 60 results in an assembled carton in which the lapping glue flap 225 is adhered to minor panel 224. Carton 81 depicted in FIG. 57 shows a carton similar to carton 80 and including a finger notch 275.
In cartons depicted herein (such as carton 60 and 80) the lapping glue flaps 225 and 226 may be adhered to the interior surface of the respective panels (such as panels 224 and 221 respectively). While in either arrangement the lapping glue flaps 225 and 226 could be adhered to the outside surface of a panel (again, panels 224 and 221 respectively).
Carton 84 illustrated in FIG. 58, shows the arrangement of lapping glue flap 226 adhered to major panel 221, with access flap 290. Carton 85 illustrated in FIG. 59 is similar to carton 84 and includes a finger tab 275.
Carton 86 illustrated in FIG. 60, shows the arrangement of lapping glue flap 226 adhered to major panel 221, with access flap 294 and a plurality of line end points 241, 242, 243, and 244. Carton 87 illustrated in FIG. 61 is similar to carton 86 and includes a finger tab 275.
Turning to FIG. 62, a carton 96 is depicted and shows the arrangement of lapping glue flap 226 adhered to major panel 221, with abbreviated access flap 250 with hinge 240 and a plurality of line end points 241, 242, 243, and 244. Carton 97 illustrated in FIG. 63 is similar to carton 96 and includes a finger tab 275.
Now turning to the example found in FIG. 64, a carton 100 is illustrated. As can be seen, carton 100 differs from some of the other depicted cartons in that it lacks tuck tab score line 271. In some examples, the tuck tab is not perimeterally defined by visible lines of demarcation. Referring to the example in FIG. 64, a carton 100 is displayed with an alternative tuck tab (or lip end) 279. As can be seen, the example of carton 100 differs from the example of carton 60 in that carton 60 does not have tuck tab score line 271. Instead, the access flap 250 illustrated in FIG. 64 has lip end 179 demarcated by cut 272. It is contemplated that blank and carton configurations which lack the tuck tab score line 271 will be preferable for erected cartons with smaller quantities of articles and shorter minor panels.
As previously articulated, the blanks lacking a tuck tab score line 171 may have lines of separation which vary. Likewise, It is contemplated that carton configurations which lack the tuck tab score line 271 can also have different lines of separation. Furthermore, it is contemplated that cartons lacking tuck tab score line 271 will be preferable for cartons filled with smaller quantities of articles and standing with short minor panels.
Locking Tabs
Another feature convenient to the consumer or end-user for reclosure of an access flap are locking tabs. Locking tabs (also called reclosure assists) may be formed as a result of the consumers first opening of an access flap. The locking tabs function to provide ease of reopening and a neat reclosed appearance while maintaining the access flap in substantially the same plane or planes as the surrounding panel or panels when the carton is reclosed.
The partially cut score lines used as one mode for the lines of separation forming the access flap portions in the top and front panels of the carton as previously mentioned are of the inside-outside double cut score type. This construction provides partial thickness locking tabs (or reclosure assists) of a particularly reliable nature but which are not so stiff as to make the reopening of the cover difficult. They also The partially cut lines of weakness can be cut 5% to 85% of the way through the thickness of a panel; however, a depth of approximately one-half the thickness of the paperboard or other material is preferred.
At least two forms of locking tabs may be used. As illustrated in FIG. 47, locking tabs 229, 230, 261, 262, 263, and 264 are displayed. Ply locking tabs are formed when ply separation occurs along lines of separation. Zipper locking tabs are formed when perforation separation occurs along lines of separation. Ply locking tabs 229 and 230 may be formed whether the lines of separation on a panel are of the partial reverse cut type with the outside cut on the outer perimeter or with the outside cut on the inner perimeter. In addition, ply locking tabs may be formed whether the lines of separation have multiple end points such as 241, 242, 243, and 244 or common end points 245 and 246. When there are common end points, the lock tabs will typically taper to the respective common end points. Ply locking tabs 229 and 230 secure the access flap by either giving the access flap a place to rest (which makes the access flap appear unified with the panel from which it separates) or by overlapping the flap as it passes by the ply locking tabs. Zipper locking tabs 261, 262, 263 and 264 function by realigning the zipper teeth back into a configuration before the perforations were severed.
The access flaps of the several blanks and cartons can be punched out or cut out by other techniques from one or more of the two panel surfaces forming such that the access flaps remain attached to the box along a hinge such as 139 or 140 (when referring to the blanks) and 239 or 240 (when referring to the cartons) which can coincide with fold lines 113, 117, 213, and 217 respectively.
Carton structures disclosed are easily openable and may more simply and reliably be opened by the end user without the need for special tools or appliances, yet which are resistant to the compression loads typically experienced during shipping and handling of the carton.
Opening Operation
Carton structures disclosed may be designed to be easily openable and may more simply and reliably be opened by the end user without the need for special tools or appliances, yet which is resistant to the compression loads typically experienced during shipping and handling of the carton.
As seen in various blanks and cartons described herein, partially cut double-cut scores are formed by way of an inner and outer cut in the paperboard which run parallel to each one another. By so providing these cut score lines, when the end user applies an upward force or opening force on the tuck tab (or pull tab) provided between the pairs of cut score lines, ply separation occurs in the regions between the inner and outer cut score lines. Continued pulling of the pull tab causes complete separation of the opening flap along the lines of separation to allow the end user unobstructed access to the contents of the carton.
The access flaps herein described may be conveniently opened using different techniques. In one technique, a consumer applies pressure toward the interior of the box near a tuck tab cut. Application of sufficient pressure causes the lines of separation in segments 167 and 168 to sever the access flap from the panel in which segments 167 and 168 exist. As the lines of separation in segments 167 and 168 disjoin the access flap from the panel, the consumer lifts the access flap in the direction of the panel with segments 165 and 166 thus further severing segments 167 and 168 until the severance reaches segments 165 and 166. Continued application of an upward force then severs the access flap from the panel in which segments 165 and 166 exist along segments 165 and 166 until the severance stops at a hinge. The access flap can then be closed, reclosed, or reopened while pivoting along the axis of the hinge. The opening of the access flap using this technique does not require a finger notch adjacent the access flap but a finger notch may be incorporated.
In a second technique, a consumer applies an outward pressure from the interior of the box by inserting a finger or fingernail behind the access flap at a tuck tab cut. In this regard, it is preferable to have a finger notch adjacent the access flap to facilitate grasping the access flap. Application of sufficient pressure outwardly causes the lines of separation in segments 167 and 168 to sever the access flap from the panel in which segments 167 and 168 exist. As the lines of separation in segments 167 and 168 disjoin the access flap from the panel, the consumer lifts the access flap in the direction of the panel with segments 165 and 166 thus further severing segments 167 and 168 until the severance reaches segments 165 and 166. Continued application of an upward force then severs the access flap from the panel in which segments 165 and 166 exist along segments 165 and 166 until the severance stops at a hinge. The access flap can then be closed, reclosed, or reopened while pivoting along the axis of the hinge.
The opening of the carton may also be reclosable by means of a double jointed flap which possess a first hinge which allows the entire access flap to pivot and which possesses a second hinge which allows a portion of the access flap to pivot. The double jointing of the flap eases reclosure of the carton as well as assisting in the opening of the flap.
In describing the other techniques of opening, it may be helpful to refer to the procedure in a relative perspective to the carton panels. When it is desired to use one of the fabric softener sheets, the consumer will push against the bottom of an access flap such as 250 or 290. Lines of weakness 257 and 258 will permit severance of the connections between the access flap and the front panel 224 followed by severance of the connections along lines of weakness 251, 252, 253, and 254 between the access flap and the top panel 223 except for score line 213 or 217 wherein the access flap will remain attached to the top panel 223. Once the perforations have been severed, the flap can remain opened as seen in FIGS. 47, 48, and 65. Severance of the lines of weakness creates a product access opening seen in FIG. 65. When the consumer desires to remove a sheet, he/she will hold back the access flap and grasp the fabric softening sheet 298.
Notably, the access flap for opening the carton does not have to extend to the bottom of the front panel or from another perspective, the access flap does not fully extend completely through the panel where opening is initiated.
Dual Mode of Dispensing
In some of the examples of blanks and cartons, an opened carton functions to enable a consumer to grasp articles in multiple ways through a single opening. This dual mode of dispensing gives the end-user the choice of removing single or multiple articles at a time from the open carton. One mode of dispensing is performed by grasping one article at a time. The second mode is a group mode dispensing of a plurality of articles without having to disassociate them from each other.
As illustrated by the example in FIG. 65, a plurality of sheets 298 are illustrated in a filled carton 100. A dispensing carton for stacked sheets is thus provided that enables the end-user to select one sheet from the broader depicted opening or to select a number of sheets from the narrower depicted opening. When a plurality of sheets are removed, the sheets do not have to be disassociated from one another. This example carton is parallelepipedal-shaped and has an irregular hexagon-shaped dispensing opening.
One type of sheet article that could be dispensed from cartons of this disclosure is a fabric softener sheet. Fabric softener sheets have generally been provided to consumers in a variety of forms including rolls where the each sheet is separated by perforations. Fabric softener sheets have also taken the form of stacked interleaved sheets and stacked non-interleaved sheets. Sheets may take various forms, but commonly are rectangular in shape. Some sheets known for use in house-hold products are folded dove tail sheets. Sheets which fill the various configurations of the cartons can be stacked so that they are or are not interfolded and may be woven or non-woven material. Another example of a sheet material is a fibrous polymeric material such as polyester or rayon.
Reclosing Operation
When the consumer has removed the dryer sheet from the carton, the carton may be reclosed by grasping the access flap and pushing it back to an unopened conformation.
In one conformation, the access flap reoccupies the location before the lines of separation were severed such as the carton displayed in FIG. 45. In another conformation, if the access flap is depressed sufficiently that the tuck tab or the bottom edge 272 of an access flap stays behind (or is tucked behind) either the front panel or the lapping glue flap or both (not illustrated). In another conformation, the tuck tab is tucked between the front panel and the lapping glue flap (not illustrated). The convenience and ease associated with reclosing the access flap may be attributable to the operation of hinges such as in the examples with hinge 239 and examples with hinge 240. Furthermore, when score line 214 can act as hinge further easing the reclosure of an access flap.
The tuck tab and lapping glue flap may function as tucking means for permitting opening and reclosing an access flap without disassembly of the carton.
One use of the reclosable access flap is to minimize unwanted escape of perfume into the air when the sheets are not being used and furthermore to help protect the sheet from moisture and other elements in the air.
While the blanks, cartons, and methods have been described and illustrated in conjunction with a number of specific configurations, those skilled in the art will appreciate that variations and modifications may be made without departing from the principles herein illustrated, described, and claimed. The present invention, as defined by the appended claims, may be embodied in other specific forms without departing from its spirit or essential characteristics. The blanks, cartons, and methods described herein are to be considered in all respects as only illustrative, and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A folding carton for dispensing sheeted fabric softening articles or sheeted cleaning articles comprising:

a top body-forming panel,

a front body-forming panel,

a bottom body-forming panel,

a fully enclosed access flap for opening and dispensing sheeted fabric softening articles or sheeted cleaning articles,

said fully enclosed access flap being formed and located within the combined surfaces of said top body-forming panel and said front body-forming panel, and said fully enclosed access flap thereby being fully enclosed by said top body-forming panel with said front body-forming panel,

a lapping glue flap,

said lapping glue flap being foldably attached along an edge of said bottom body-forming panel, and said lapping glue flap being adhered to said front body-forming panel,

said lapping glue flap overlaps at least a portion of said front body-forming panel lateral to said fully enclosed access flap so that when a consumer separates said fully enclosed access flap from said front body-forming panel to open the carton, said overlapped portion of said front body-forming panel remains attached to said lapping glue flap, and

said lapping glue flap also overlaps at least a portion of said fully enclosed access flap.

2. The folding carton of claim 1 further comprising:

a rear body-forming panel,

said bottom body-forming panel separated from said lapping glue flap by a first fold line,

said bottom body-forming panel separated from said rear body-forming panel by a second fold line,

said rear body-forming panel separated from said top body-forming panel by a third fold line,

said top body-forming panel separated from said front body-forming panel by a fourth fold line,

a first pair of end closure flaps adjacent said bottom body-forming panel, one of said first pair of end closure flaps separated from said bottom body-forming panel by a fifth fold line and another of said first pair of end closure flaps separated from said bottom body-forming panel by a sixth fold line,

a second pair of end closure flaps adjacent said rear body-forming panel, one of said second pair of end closure flaps separated from said rear body-forming panel by said fifth fold line and another of said second pair of end closure flaps separated from said rear body-forming panel by said sixth fold line,

a third pair of end closure flaps adjacent said top body-forming panel, one of said third pair of end closure flaps separated from said top body-forming panel by said fifth fold line and another of said third pair of end closure flaps separated from said top body-forming panel by said sixth fold line, and

a fourth pair of end closure flaps adjacent said front body-forming panel, one of said fourth pair of end closure flaps separated from said front body-forming panel by said fifth fold line and another of said fourth pair of end closure flaps separated from said top body-forming panel by said sixth fold line.

3. The folding-carton of claim 1 further comprising:

a plurality of spaced apart lines of separation demarcating portions of said fully enclosed access flap so that when said lines of separation are severed, said fully enclosed access flap is movable between a closed position closing an access opening into the interior of a carton and an open dispensing position allowing the insertion of a human hand to retrieve sheeted fabric softening articles or sheeted cleaning articles from the interior of the carton,

said plurality of spaced apart lines of separation can be divided up into a plurality of definable segments, and

said fully enclosed access flap is further defined to have a tuck tab demarcated in part by a tuck tab cut extending between said plurality of spaced apart lines of separation.

4. The folding carton of claim 3 wherein said tuck tab is further demarcated by a tuck tab score collinear with portions of said tuck tab cut.

5. The folding carton of claim 3 further comprising:

a first hinge by which said access flap is permanently attached to said top body-forming panel, and

a second hinge coincident with said fourth fold line.

6. The folding carton of claim 3 wherein said plurality of spaced apart lines of separation include a pair of partial cuts on outside portions of said top body-forming panel and said front body-forming panel substantially parallel to a pair of reverse cuts on inside portions of said top body-forming panel and said front body-forming panel.

7. The folding carton of claim 6 wherein one of said partial cuts conjoin with one of said reverse cuts at a first tear point and another of said partial cuts conjoin with another of said reverse cuts at a second tear point.

8. The folding carton of claim 7 wherein said first and second tear points are substantially coincident with said fourth fold line.

9. The folding carton of claim 6 wherein said first and second tear points are substantially coincident with said tuck tab cut.

10. The folding carton of claim 6 wherein said plurality of spaced apart lines of separation include a pair of zipper cuts through said top body-forming panel and said front body-forming panel.

11. The folding carton of claim 3 wherein said plurality of spaced apart lines of separation further comprise:

a pair of partial cuts on an outside portion of said top body-forming panel,

a pair of reverse cuts on an inside portion of said top body-forming panel, and

a pair of zipper cuts extending through said front body-forming panel.

12. The folding carton of claim 1 1 wherein said pair of partial cuts and said pair of reverse cuts conjoin at first and second tear points, and

wherein said pair of zipper cuts extend from said first and second endpoints of said tuck tab cut to said first and second tear points.

13. The folding carton of claim 3 wherein a pair of top body-forming panel spaced apart lines of separation run substantially parallel to portions of said fifth fold line and said sixth fold line between said top body-forming panel and said third pair of end closure flaps.

14. The folding carton of claim 3 wherein a pair of front body-forming panel spaced apart lines of separation run substantially parallel to portions of said fifth fold line and said sixth fold line between said top body-forming panel and said fourth pair of end closure flaps.

15. The folding carton of claim 3 wherein a pair of front body-forming panel spaced apart lines of separation form an obtuse angle with said tuck tab score line.

16. The folding carton of claim 5 wherein said first hinge is substantially coincident with said third fold line.

17. The folding carton of claim 5 further comprising:

a seventh fold line,

wherein said seventh fold line traverses said fully enclosed access flap and said first hinge is substantially coincident with said seventh fold line.

18. The folding carton of claim 17 wherein said seventh fold line traverses said top body-forming panel from said fifth fold line to said sixth fold line.

19. The folding carton of claim 1 further comprising:

a finger notch for assisting a consumer's grasp of said tuck tab, and

said finger notch defined by an arcuate cut beginning at a finger notch cut point substantially coincident with said tuck tab cut and ending at a second finger notch cut point substantially coincident with said tuck tab cut.

20. The folding carton of claim 2 further comprising affixing means for adhesive assistance wherein said affixing means for adhesive assistance existing on one or more of: said first pair of end closure flaps, said second pair of end closure flaps, said third pair of end closure flaps, said fourth pair of end closure flaps, said lapping glue flap, and the inner surface of said front body-forming panel.

21. The folding carton of claim 2 further comprising perforated rules existing on one or more of: said first pair of end closure flaps, said second pair of end closure flaps, said third pair of end closure flaps, said fourth pair of end closure flaps, said lapping glue flap, and the inner surface of said front body-forming panel.

22. The folding carton of claim 3 wherein said fully enclosed access flap is perimeterally defined by said first hinge, a pair of partial cuts, a pair of zipper cuts, and said tuck tab cut.

23. The folding carton of claim 1 wherein said fully enclosed access flap has been opened.

24. The carton of claim 1 made of a material selected from the group: raw fiberboard, recycled fiberboard, raw fibrous material, recycled fibrous material, raw paperboard, recycled paperboard, raw polymers, recycled polymers, and organic polymers further including: polyethylene, polypropylene, and polybutylene.

25. The folding carton of claim 1 filled with a stack of sheeted fabric softening articles or sheeted cleaning articles.

26. The folding carton of claim 1 further including a plastic liner, said plastic liner surrounding a plurality of sheeted fabric softening articles or sheeted cleaning articles.

27. A folding carton for dispensing sheeted fabric softening articles or sheeted cleaning articles comprising:

a top body-forming panel,

a front body-forming panel,

a bottom body-forming panel,

a fully enclosed access flap for opening and dispensing sheeted fabric softening articles or sheeted cleaning articles, said fully enclosed access flap being formed and located within the combined surfaces of said top body-forming panel and said front body-forming panel, and said fully enclosed access flap thereby being fully enclosed by said top body-forming panel with said front body-forming panel,

a lapping glue flap, said lapping glue flap being foldably attached along an edge of said bottom body-forming panel, and said lapping glue flap being adhered to said front body-forming panel, said lapping glue flap overlaps at least a portion of said front body-forming panel lateral to said fully enclosed access flap so that when a consumer separates said fully enclosed access flap from said front body-forming panel to open the carton, said overlapped portion of said front body-forming panel remains attached to said lapping glue flap, said lapping glue flap also overlaps at least a portion of said fully enclosed access flap,

a rear body-forming panel, said bottom body-forming panel separated from said lapping glue flap by a first fold line, said bottom body-forming panel separated from said rear body-forming panel by a second fold line, said rear body-forming panel separated from said top body-forming panel by a third fold line, said top body-forming panel separated from said front body-forming panel by a fourth fold line,

a third pair of end closure flaps adjacent said top body-forming panel, one of said third pair of end closure flaps separated from said top body-forming panel by said fifth fold line and another of said third pair of end closure flaps separated from said top body-forming panel by said sixth fold line,

a fourth pair of end closure flaps adjacent said front body-forming panel, one of said fourth pair of end closure flaps separated from said front body-forming panel by said fifth fold line and another of said fourth pair of end closure flaps separated from said top body-forming panel by said sixth fold line,

a plurality of spaced apart lines of separation demarcating portions of said fully enclosed access flap so that when said lines of separation are severed, said fully enclosed access flap is movable between a closed position closing an access opening into the interior of a carton and an open dispensing position allowing the insertion of a human hand to retrieve sheeted fabric softening articles or sheeted cleaning articles from the interior of the carton, said plurality of spaced apart lines of separation can be divided up into a plurality of definable segments, said fully enclosed access flap is further defined to have a tuck tab demarcated in part by a tuck tab cut extending between said plurality of spaced apart lines of separation,

a tuck tab demarcated in part by a tuck tab cut extending between said plurality of spaced apart lines of separation, said tuck tab forming one perimeter portion of said fully enclosed access flap, said tuck tab is further demarcated by a tuck tab score collinear with portions of said tuck tab cut,

a first hinge by which said access flap is permanently attached to said second body-forming panel, and

a second hinge coincident with said fourth fold line.

28. A folding carton blank for assembly into a carton to dispense cleaning or sheeted articles comprising:

a top body-forming panel,

a front body-forming panel,

a bottom body-forming panel,

a fully enclosed access flap for opening and sheeted fabric softening articles or sheeted cleaning articles,

said fully enclosed access flap being formed and located within the combined surfaces of said top body-forming and said front body-forming panels, and said fully enclosed access flap thereby being fully enclosed by said top body-forming panel with said front body-forming panel,

a lapping glue flap, said lapping glue flap being foldably attached along an edge of said bottom body-forming panel,

said lapping glue flap capable of receiving a continuous glue bead parallel to said edge of said bottom body-forming panel.

29. The folding carton blank of claim 28 further comprising:

a rear body-forming panel,

said bottom body-forming panel separated from said lapping glue flap by a first score line,

said bottom body-forming panel separated from said rear body-forming panel by a second score line,

said rear body-forming panel separated from said top body-forming panel by a third score line,

said top body-forming panel separated from said front body-forming panel by a fourth score line,

a first pair of end closure flaps adjacent said bottom body-forming panel, one of said first pair of end closure flaps separated from said bottom body-forming panel by a fifth score line and another of said first pair of end closure flaps separated from said bottom body-forming panel by a sixth score line,

a second pair of end closure flaps adjacent said rear body-forming panel, one of said second pair of end closure flaps separated from said rear body-forming panel by said fifth score line and another of said second pair of end closure flaps separated from said rear body-forming panel by said sixth score line,

a third pair of end closure flaps adjacent said top body-forming panel, one of said third pair of end closure flaps separated from said top body-forming panel by said fifth score line and another of said third pair of end closure flaps separated from said top body-forming panel by said sixth score line, and

a fourth pair of end closure flaps adjacent said front body-forming panel, one of said fourth pair of end closure flaps separated from said front body-forming panel by said fifth score line and another of said fourth pair of end closure flaps separated from said top body-forming panel by said sixth score line.

30. The folding carton blank of claim 28 further comprising:

a plurality of spaced apart lines of separation demarcating portions of said fully enclosed access flap so that when said lines of separation are severed, said fully enclosed access flap is movable between a closed position closing an access opening into the interior of a carton and an open dispensing position allowing the insertion of a human hand to retrieve cleaning or sheeted articles from the interior of the carton,

31. The folding carton blank of claim 30 wherein said tuck tab is further demarcated by a tuck tab score collinear with portions of said tuck tab cut.

32. The folding carton blank of claim 30 further comprising:

a second hinge coincident with said fourth score line.

33. The folding carton blank of claim 30 wherein said plurality of spaced apart lines of separation include a pair of partial cuts on outside portions of said top body-forming panel and said front body-forming panel substantially parallel to a pair of reverse cuts on inside portions of said top body-forming panel and said front body-forming panel.

34. The folding carton blank of claim 33 wherein one of said partial cuts conjoin with one of said reverse cuts at a first tear point and another of said partial cuts conjoin with another of said reverse cuts at a second tear point.

35. The folding carton blank of claim 34 wherein said first and second tear points are substantially coincident with said fourth score line.

36. The folding carton blank of claim 33 wherein said first and second tear points are substantially coincident with said tuck tab cut.

37. The folding carton blank of claim 33 wherein said plurality of spaced apart lines of separation include a pair of zipper cuts through said top body-forming panel and said front body-forming panel.

38. The folding carton blank of claim 30 wherein said plurality of spaced apart lines of separation further comprise:

a pair of partial cuts on an outside portion of said top body-forming panel,

a pair of reverse cuts on an inside portion of said top body-forming panel, and

a pair of zipper cuts extending through said front body-forming panel.

39. The folding carton blank of claim 38 wherein said pair of partial cuts and said pair of reverse cuts conjoin at first and second tear points, and

40. The folding carton blank of claim 30 wherein a pair of top body-forming panel spaced apart lines of separation run substantially parallel to portions of said fifth score line and said sixth score line between said top body-forming panel and said third pair of end closure flaps.

41. The folding carton blank of claim 30 wherein a pair of front body-forming panel spaced apart lines of separation run substantially parallel to portions of said fifth score line and said sixth score line between said top body-forming panel and said fourth pair of end closure flaps.

42. The folding carton blank of claim 30 wherein a pair of front body-forming panel spaced apart lines of separation form an obtuse angle with said tuck tab score line.

43. The folding carton blank of claim 32 wherein said first hinge is substantially coincident with said third score line.

44. The folding carton blank of claim 32 further comprising:

a seventh score line,

wherein said seventh score line traverses said fully enclosed access flap and said first hinge is substantially coincident with said seventh score line.

45. The folding carton blank of claim 44 wherein said seventh score line traverses said top body-forming panel from said fifth score line to said sixth score line.

46. The folding carton blank of claim 28 further comprising:

a finger notch for assisting a consumer's grasp of said tuck tab, and

47. The folding carton blank of claim 29 further comprising affixing means for adhesive assistance wherein said affixing means for adhesive assistance existing on one or more of: said first pair of end closure flaps, said second pair of end closure flaps, said third pair offend closure flaps, said fourth pair of end closure flaps, said lapping glue flap, and the inner surface of said front body-forming panel.

48. The folding carton blank of claim 29 further comprising perforated rules existing on one or more of: said first pair of end closure flaps, said second pair of end closure flaps, said third pair of end closure flaps, said fourth pair of end closure flaps, said lapping glue flap, and the inner surface of said front body-forming panel.

49. The folding carton blank of claim 30 wherein said fully enclosed access flap is perimeterally defined by said first hinge, a pair of partial cuts, a pair of zipper cuts, and said tuck tab cut.

50. The carton blank of claim 28 made of a material selected from the group: raw fiberboard, recycled fiberboard, raw fibrous material, recycled fibrous material, raw paperboard, recycled paperboard, raw polymers, recycled polymers, and organic polymers further including: polyethylene, polypropylene, and polybutylene.

51. The folding carton blank of claim 28 further including a plastic liner, said plastic liner surrounding a plurality of sheeted fabric softening articles or sheeted cleaning articles.

52. A carton made from the blank of claim 28.

53. A partially folded carton made from the blank of claim 28 ready for processing in a filling line wherein said lapping glue flap being adhered to said first body-forming panel.

54. A method of manufacturing a folding carton of claim 1 comprising the steps of:

folding the carton of claim 1, and

adhering said first body-forming panel to said lapping glue flap.

55. A folding carton blank for assembly into a carton to dispense cleaning or sheeted articles comprising:

a top body-forming panel,

a front body-forming panel,

a bottom body-forming panel,

a fully enclosed access flap for opening and sheeted fabric softening articles or sheeted cleaning articles, said fully enclosed access flap being formed and located within the combined surfaces of said top body-forming and said front body-forming panels, said fully enclosed access flap thereby being fully enclosed by said top body-forming panel with said front body-forming panel,

a lapping glue flap, said lapping glue flap being foldably attached along an edge of said bottom body-forming panel, said lapping glue flap capable of receiving a continuous glue bead parallel to said edge of said bottom body-forming panel,

a rear body-forming panel, said bottom body-forming panel separated from said lapping glue flap by a first score line, said bottom body-forming panel separated from said rear body-forming panel by a second score line, said rear body-forming panel separated from said top body-forming panel by a third score line, said top body-forming panel separated from said front body-forming panel by a fourth score line,

a third pair of end closure flaps adjacent said top body-forming panel, one of said third pair of end closure flaps separated from said top body-forming panel by said fifth score line and another of said third pair of end closure flaps separated from said top body-forming panel by said sixth score line,

a fourth pair of end closure flaps adjacent said front body-forming panel, one of said fourth pair of end closure flaps separated from said front body-forming panel by said fifth score line and another of said fourth pair of end closure flaps separated from said top body-forming panel by said sixth score line,

a plurality of spaced apart lines of separation demarcating portions of said fully enclosed access flap so that when said lines of separation are severed, said fully enclosed access flap is movable between a closed position closing an access opening into the interior of a carton and an open dispensing position allowing the insertion of a human hand to retrieve cleaning or sheeted articles from the interior of the carton, said plurality of spaced apart lines of separation can be divided up into a plurality of definable segments, said fully enclosed access flap is further defined to have a tuck tab demarcated in part by a tuck tab cut extending between said plurality of spaced apart lines of separation,

a second hinge coincident with said fourth score line.