Universal carton blank and method of manufacturing a carton therefrom

Abstract

A universal blank adapted for assembly as a carton by either a top/end load cartoner or locking tab cartoner, and related method of assembly. The universal blank includes one or more minor flaps forming locking tabs and one or more major flaps forming locking slots. The locking tab/slots facilitate assembly with a locking tab cartoner. Alternatively, the universal blank can be processed by a top/end load cartoner by first bonding two of the outer minor panels. Graphics formed on the universal blank present a desired, aesthetically pleasing appearance upon assembly by either cartoning technique. Further, preferred gluing techniques can be employed to promote consistent assembly by a top/end load cartoner.

1 . A method of assembling a carton comprising: 
 a) providing a blank including: 
 a first minor panel,  
 a first major panel connected to the first minor panel,  
 a second minor panel connected to the first major panel opposite the first minor panel,  
 a second major panel connected to the second minor panel opposite the first major panel,  
 a third minor panel connected to the second major panel opposite the second minor panel,  
 first and second major flaps extending from opposite ends of the first major panel, respectively,  
 third and fourth major flaps extending from opposite ends of the second major panel, respectively,  
 wherein at least one of the first, second, third, and fourth major flaps forms a cut, locking slot,  
 first and second minor flaps extending from opposite ends of the second minor panel, respectively,  
 third and fourth minor flaps extending from opposite ends of the third minor panel, respectively,  
 wherein at least one of the first, second, third, and fourth minor flaps forms a locking tab;  
   b) applying glue to one of the first and third minor panels;    c) folding the blank such that the first and third minor panels are aligned, and the glue applied at step b) adheres the first and third minor panels;    d) unfolding the major panels relative to the minor panels to define a carton shell having first and second open ends;    e) folding the first and third minor flaps inwardly relative to the second and third minor panels, respectively, to encompass a portion of the first open end;    f) folding one of the first and third major flaps inwardly over the first and third minor flaps;    g) applying glue to the first or third major flap folded at step f);    h) folding an other of the first and third major flaps inwardly onto the major flap folded at step f), wherein the glue applied at step g) adheres the first and third major flaps;    i) folding the second and fourth minor flaps inwardly relative to the second and third minor panels, respectively, to encompass a portion of the second open end;    j) folding one of the second and fourth major flaps inwardly over the second and fourth minor flaps;    k) applying glue to the second or fourth major flap folded at step j); and    l) folding an other of the second and fourth major flaps inwardly onto the major flap folded at step j), wherein the glue applied at step k) adheres the second and fourth major flaps, resulting in a completed carton;    wherein the completed carton is characterized by the at least one locking tab not being engaged within the at least one locking slot.    
   
   
       2 . The method of  claim 1 , wherein the first minor panel forms the re-closure tab and the second minor panel forms the re-closure slot.  
   
   
       3 . The method of  claim 1 , wherein each of the first, second, third, and fourth minor flaps forms a locking tab.  
   
   
       4 . The method of  claim 3 , wherein: 
 each of the third and fourth major flaps forms a pair of locking slots;    and further wherein the method is characterized by none of the locking tabs being engaged within the locking slots upon formation of the completed carton.    
   
   
       5 . The method of  claim 4 , wherein step f) is characterized by folding the third major flap onto the first and third minor flaps, and step h) is characterized by folding the first major flap onto the third major flap.  
   
   
       6 . The method of  claim 5 , wherein step j) is characterized by folding the fourth major flap onto the second and fourth minor flaps, and step  1 ) is characterized by folding the second major flap onto the fourth major flap.  
   
   
       7 . The method of  claim 1 , wherein upon completion of step h), the first and third minor flaps are covered by the first and third major flaps.  
   
   
       8 . The method of  claim 1 , wherein the major flap folded at step f) has a free leading edge and opposing free side edges, and further wherein upon completion of step h), an entirety of an exterior of the opposing free side edges of the major flap folded at step f) are exteriorly exposed.  
   
   
       9 . The method of  claim 8 , wherein providing a blank includes printing graphics on an exterior of the major flap to be folded at step f), and further wherein the printed graphics encompass the opposing free side edges.  
   
   
       10 . The method of  claim 1 , wherein each of the first and third minor panels has a lateral length defined by opposing first and second ends, and further wherein step b) is characterized by applying a glue bead to one of the first and third minor panels, the glue bead having a length not less than 90% of the lateral length of the minor panel to which the glue bead is applied.  
   
   
       11 . The method of  claim 10 , wherein step b) is further characterized by a first end of the glue bead being spaced not more than 0.4 inch from the first opposing end of the minor panel to which the glue bead is applied.  
   
   
       12 . The method of  claim 10 , wherein the minor panel to which the glue bead is applied forms a glue assist area, and wherein step b) is further characterized by the glue bead extending beyond a lateral length of the glue assist area.  
   
   
       13 . The method of  claim 10 , wherein step b) is characterized by applying the glue bead to the third minor panel.  
   
   
       14 . The method of  claim 1 , wherein step b) is characterized by applying first and second glue beads to one of the first and third minor panels, the glue beads being laterally spaced from one another.  
   
   
       15 . The method of  claim 1 , wherein a partially-closed carton is formed upon completion of step h), the method further comprising: 
 dispensing product into the partially-closed carton following step h).    
   
   
       16 . A method of assembling a carton comprising: 
 a) providing a blank including: 
 a first minor panel,  
 a first major panel connected to the first minor panel,  
 a second minor panel connected to the first major panel opposite the first minor panel,  
 a second major panel connected to the second minor panel opposite the first major panel,  
 a third minor panel connected to the second major panel opposite the second minor panel,  
 first and second major flaps extending from opposite ends of the first major panel, respectively,  
 third and fourth major flaps extending from opposite ends of the second major panel, respectively,  
 wherein at least one of the first, second, third, and fourth major flaps forms a cut, locking slot,  
 first and second minor flaps extending from opposite ends of the second minor panel, respectively,  
 third and fourth minor flaps extending from opposite ends of the third minor panel, respectively,  
 wherein at least one of the first, second, third, and fourth minor flaps forms a locking tab;  
   b) determining an availability of a locking tab cartoner or a top/end load cartoner at a cartoning resource;    c) providing the blank to the cartoning resource based upon the determination at step b); and    d) forming a carton from the blank;    wherein an entirety of the carton has a uniform exterior graphics appearance whether formed by a locking tab cartoner or a top/end load cartoner.    
   
   
       17 . The method of  claim 16 , wherein the method is characterized by using an identical blank for assembly by a top/end load cartoner or a locking tab cartoner.  
   
   
       18 . The method of  claim 16 , wherein a determination is made at step b) that a top/end load caser is available at the cartoning resource, and further wherein step c) includes: 
 applying glue to one of the first and third minor panels;    folding the blank such that the first and third minor panels are aligned and the glue adheres the first and third minor panels resulting in a flattened carton shell;    wherein the flattened carton shell is provided to the cartoning resource as part of step c).    
   
   
       19 . The method of  claim 16 , wherein a determination is made at step b) that a top/end load cartoner is available from the cartoner resource, and further wherein step d) includes: 
 e) providing the blank as a flattened carton shell by: 
 applying glue to one of the first and third minor panels,  
 folding the blank such that the first and third minor panels are aligned, and the glue adheres the first and third minor panels to form the flattened carton shell,  
   f) unfolding the major panels relative to the minor panels to define a carton shell having first and second open ends;    g) folding the first and third minor flaps inwardly relative to the second and third minor panels, respectively, to encompass a portion of the first open end;    h) folding one of the first and third major flaps inwardly over the first and third minor flaps;    i) applying glue to the first or third major flap folded at step h);    j) folding an other of the first and third major flaps inwardly onto the major flap folded at step h), wherein the glue applied at step i) adheres the first and third major flaps;    k) folding the second and fourth minor flaps inwardly relative to the second and third minor panels, respectively, to encompass a portion of the second open end;    l) folding one of the second and fourth major flaps inwardly over the second and fourth minor flaps;    m) applying glue to the second or fourth major flap folded at step  1 ); and    n) folding an other of the second and fourth major flaps inwardly onto the major flap folded at step  1 ), wherein the glue applied at step m) adheres the second and fourth major flaps, resulting in a completed carton.    
   
   
       20 . The method of  claim 16 , wherein a determination is made at step b) that a locking tab cartoner is available at the cartoning resource, and further wherein step d) is characterized by using the locking tab cartoner to form the carton.  
   
   
       21 . A method of assembling cartons, the method comprising: 
 a) providing identical first and second blanks each including: 
 a first minor panel,  
 a first major panel connected to the first minor panel,  
 a second minor panel connected to the first major panel opposite the first minor panel,  
 a second major panel connected to the second minor panel opposite the first major panel,  
 a third minor panel connected to the second major panel opposite the second minor panel,  
 first and second major flaps extending from opposite ends of the first major panel, respectively,  
 third and fourth major flaps extending from opposite ends of the second major panel, respectively,  
 wherein at least one of the first, second, third, and fourth major flaps forms a cut, locking slot,  
 first and second minor flaps extending from opposite ends of the second minor panel, respectively,  
 third and fourth minor flaps extending from opposite ends of the third minor panel, respectively,  
 wherein at least one of the first, second, third, and fourth minor flaps forms a locking tab;  
   b) forming a first carton from the first blank using a locking tab cartoner;    and    c) forming a second carton from the second blank using a top/end load cartoner;    wherein the first and second cartons have a different construction; and further wherein an entirety of the first and second cartons has a uniform exterior graphics appearance.    
   
   
       22 . The method of  claim 21 , wherein step c) includes: 
 applying glue to one of the first and third minor panels; and    folding the blank such that the first and third minor panels are aligned and the glue adheres the first and third minor panels resulting in a flattened carton shell.    
   
   
       23 . A universal blank for assembly as a carton, the blank comprising: 
 a first minor panel;    a first major panel connected to the first minor panel;    a second minor panel connected to the first major panel opposite the first minor panel;    a second major panel connected to the second minor panel opposite the first major panel;    a third minor panel connected to the second major panel opposite the second minor panel;    first and second major flaps extending from opposite ends of the first major panel, respectively;    third and fourth major flaps extending from opposite ends of the second major panel, respectively;    wherein at least one of the first, second, third, and fourth major flaps forms a cut, locking slot;    first and second minor flaps extending from opposite ends of the second minor panel, respectively;    third and fourth minor flaps extending from opposite ends of the third minor panel, respectively;    wherein at least one of the first, second, third, and fourth minor flaps forms a locking tab; and    printed graphics on an exterior face of the blank, the printed graphics including printed segments of the first minor flap and the third major flap such that in a first carton construction, the printed segment of the first minor flap is exteriorly exposed, and in a second carton construction, the printed segment of the third major flap is exteriorly exposed.    
   
   
       24 . The universal blank of  claim 23 , wherein the third major flap includes a free leading edge and opposing, first and second free side edges, and further wherein the printed segment of the third major flap encompasses an entirety of the free side edges.  
   
   
       25 . The universal blank of  claim 24 , wherein the printed segment includes a sub-segment defined by an interior demarcation line that extends from the free leading edge.  
   
   
       26 . The universal blank of  claim 25 , wherein the demarcation line extends adjacent the first free side edge and intersects the free leading edge at a point spaced from the first side edge by a distance of at least 0.065 inch.  
   
   
       27 . The universal blank of  claim 26 , wherein the demarcation line extends from the free leading edge in an angular fashion relative to the first free side edge, defining an included angle of at least 4°.  
   
   
       28 . The universal blank of  claim 23 , wherein the printed graphics further includes a printed segment and an unprinted segment on the third minor panel, the unprinted segment extending to a free leading end of the third minor panel.  
   
   
       29 . The universal blank of  claim 28 , wherein the unprinted segment of the third minor panel encompasses a portion of the re-closure slot formed by the third minor panel.  
   
   
       30 . The universal blank of  claim 23 , wherein the first minor panel and the first major panel are separated by a scoreline, and further wherein a location of the scoreline relative to an opposite end of the first major panel is dictated by a thickness of the blank.  
   
   
       31 . A carton comprising: 
 a first major wall;    a second major wall opposite the first major wall;    opposing side walls connecting opposite sides of the first and second major walls, respectively, to define a carton shell having first and second ends;    a first closure provided at the first end of the carton shell, the first closure including: 
 a first minor flap,  
 a second minor flap,  
 wherein at least one of the minor flaps forms a locking slot,  
 a first major flap,  
 a second major flap,  
 wherein the first major flap forms at least one locking slot,  
 and further wherein the first closure is formed by the first major flap extending over an exterior of the first and second minor flaps and the second major flap extending exteriorly over the first major flap, the first major flap being adhered to the second major flap;  
   a second closure provided at the second end of the carton shell, the second closure including: 
 a third minor flap,  
 a fourth minor flap,  
 a third major flap,  
 a fourth major flap,  
 wherein the second closure is formed by the third major flap extending over an exterior of the third and fourth minor flaps, and the fourth major flap extending exteriorly over the third major flap, the third major flap being adhered to the fourth major flap;  
   wherein the carton is characterized by the locking tab not being engaged within the locking slot.    
   
   
       32 . The method of  claim 31 , wherein each of the first, second, third, and fourth minor flaps form a locking tab.  
   
   
       33 . The carton of  claim 32 , wherein the first major flap forms a pair of locking slots and the third major flap forms a pair of locking slots, and further wherein the carton is characterized by none of the locking tabs being engaged within the locking slots.  
   
   
       34 . The carton of  claim 33 , wherein the locking slots of the first major flap are positioned over the first and second minor flaps, respectively, and the locking slots of the third major flap are positioned over the third and fourth minor flaps, respectively.  
   
   
       35 . The carton of  claim 31 , wherein the first and second minor panels are adhered to one another by a glue line extending at least 90% of a lateral length of the first and second minor panels.  
   
   
       36 . The carton of  claim 31 , wherein upon final assembly, portions of the first major flap, including opposing side edges, are exteriorly exposed relative to the second major flap, and further wherein the first major flap includes printed graphics on the exposed portions.