Blank for Forming a Carton and a Method of Inserting Empty Hollow Cores Back into the Carton

Abstract

A blank formed from cellulosic fibers is disclosed which is capable of being constructed into a carton. The carton is capable of housing a plurality of roll products, such as rolls of paper towels or rolls of toilet paper. Each of the roll products is wound onto a hollow core made from cellulosic fibers. The carton has a dispensing opening through which the roll products can be individually removed. The carton also has an empty hollow core insertion opening through which an empty hollow core can be inserted back into the carton for the purpose of being recycled along with the empty carton. A method of inserting the empty hollow cores back into the carton is also disclosed.

1 . A blank for forming a carton having a dispensing opening and an empty hollow core insertion opening, comprising:
 a) an adhesive tab;   b) a back panel located adjacent to said adhesive tab and having a top and a bottom;   c) a first vertical fold line positioned between said adhesive tab and said back panel;   d) a top panel located adjacent to said back panel and having a top and a bottom;   e) a second vertical fold line positioned between said back panel and said top panel;   f) a front panel located adjacent to said top panel and having a top and a bottom;   g) a third vertical fold line positioned between said top panel and said front panel;   h) a bottom panel located adjacent to said front panel and having a top and a bottom;   i) a fourth vertical fold line positioned between said front panel and said bottom panel;   j) a back panel top flap located adjacent to said top of said back panel;   k) a back panel bottom flap located adjacent to said bottom of said back panel;   l) a top panel top flap located adjacent to said top of said top panel;   m) a top panel bottom flap located adjacent to said bottom of said top panel;   n) a front panel top flap located adjacent to said top of said front panel;   o) a front panel bottom flap located adjacent to said bottom of said front panel;   p) a bottom panel top flap located adjacent to said top of said bottom panel;   q) a bottom panel bottom flap located adjacent to said bottom of said bottom panel;   r) a first horizontal fold line disposed between said back panel and said back panel top flap, between said top panel and said top panel top flap, between said front panel and said front panel top flap, and between said bottom panel and said bottom panel top flap;   s) a second horizontal fold line disposed between said back panel and said back panel bottom flap, between said top panel and said top panel bottom flap, between said front panel and said front panel bottom flap, and between said bottom panel and said bottom panel bottom flap;   t) a first tear panel formed in both said back panel top flap and in said front panel top flap, said first tear panel having a pair of portions which extends partially into said back panel and partially into said front panel, said first tear panel intersecting said first horizontal fold line, and when said first tear panel is removed a dispensing opening is formed into said carton; and   u) a second tear panel formed in said back panel and aligned adjacent to said second horizontal fold line, said second tear panel having a central axis aligned perpendicular to said back panel, and when said second tear panel is removed an empty hollow core insertion opening is formed into said carton.   
     
     
         2 . The blank of  claim 1  further comprising a third tear panel formed in said front panel and aligned adjacent to said second horizontal fold line, said third tear panel having a central axis aligned perpendicular to said front panel, and when said third tear panel is removed another insertion opening is formed into said carton through which an empty hollow core can be inserted. 
     
     
         3 . The blank of  claim 2  wherein said central axes of said second and third tear panels are coaxially aligned. 
     
     
         4 . The blank of  claim 1  wherein said empty hollow core has a diameter and said second tear panel has a circular configuration with a diameter at least equal to said diameter of said empty hollow core. 
     
     
         5 . The blank of  claim 3  wherein said second tear panel has a diameter of at least 1.5 inches and said second tear panel is circumscribed by a perforation line. 
     
     
         6 . The blank of  claim 1  wherein said blank is folded and assembled into a six sided enclosed carton capable of housing a plurality of roll products, and each of said roll products has a hollow core upon which multiple sheets of said roll product are wound. 
     
     
         7 . The blank of  claim 6  further comprising a fourth tear panel formed in said top panel, said fourth tear panel having a central axis aligned perpendicular to said top panel, and when said fourth tear panel is removed a viewing opening is formed into said carton through which a consumer can view the roll products housed in said carton. 
     
     
         8 . The blank of  claim 7  further comprising a fifth tear panel formed in said top panel, said fifth tear panel having a central axis aligned perpendicular to said top panel, and when said fifth tear panel is removed a handle opening is formed which allows a consumer to carry said carton. 
     
     
         9 . The blank of  claim 6  wherein said top panel top flap has a pair of spaced apart slits formed therein which create a pivotable flap. 
     
     
         10 . A carton formed from cellulose fibers and having a dispensing opening and an empty hollow core insertion opening, said carton capable of housing a plurality of generally cylindrically shaped products formed from cellulose fibers, each of said products being wound upon a hollow core formed from cellulose fibers and having a common diameter, said carton comprising:
 a) a top panel;   b) a bottom panel aligned opposite to said top panel;   c) a pair of end walls each being located between said top panel and said bottom panel;   d) a front panel and a back panel each being located between said top panel and said bottom panel and adjacent to each of said pair of end walls;   e) a first tear panel formed in one of said pair of end walls and having a pair of portions which extend partially into said back panel and partially into said front panel, and when said first tear panel is removed a dispensing opening is formed into said carton; and   f) a second tear panel formed in said back panel, said second tear panel having a diameter at least equal to said common diameter of each of said hollow cores, and when said second tear panel is removed an empty hollow core insertion opening is formed into said carton which allow an empty hollow core to be inserted back into said carton once one of said products has been removed from said carton.   
     
     
         11 . The carton of  claim 10  wherein said second tear panel has a diameter which is greater than said common diameter of each of said hollow cores. 
     
     
         12 . The carton of  claim 10  wherein said second tear panel has a circular configuration with a central axis which is located within about 3 inches of said top tear panel and diagonally away from said dispensing opening. 
     
     
         13 . The carton of  claim 12  wherein said second tear panel is located at a greater distance from said bottom panel than said dispensing opening when said carton is resting on said bottom panel. 
     
     
         14 . The carton of  claim 10  further comprising a third tear panel formed in said front panel, said third tear panel having a diameter which is equal to said diameter of said second tear panel. 
     
     
         15 . The carton of  claim 10  further comprising an inspection opening formed in said top panel which is sized to allow a person to insert at least one finger through said opening and touch an adjacent roll product housed in said carton, said opening being covered by a flap, and said flap being releasably secured to said top panel by an adhesive. 
     
     
         16 . The carton of  claim 10  further comprising a fourth tear panel formed in said top panel, and when said fourth tear panel is removed a viewing opening is formed into said carton through which a consumer can view said products housed in said carton. 
     
     
         17 . The carton of  claim 10  further comprising a fifth tear panel formed in said top panel, and when said fifth tear panel is removed a handle opening is formed which allows a consumer to carry said carton. 
     
     
         18 . The carton of  claim 10  wherein one of said pair of end walls contains a rotatable flap having a free end that can be rotated to expose an opening into said carton through which a person can insert a thumb and index finger so as to physically touch at least one of said roll products housed in said carton, and said flap can be rotated back to a closed position wherein said free end is inserted into a slit to reclose said carton. 
     
     
         19 . A method of inserting an empty hollow core having a common diameter back into a carton, each of said hollow cores having a product wound upon it, said method comprising the steps of:
 a) inserting a plurality of said products into said carton and sealing said carton, said carton having a top panel, a bottom panel aligned opposite to said top panel, a pair of end walls each being located between said top panel and said bottom panel, a front panel and a back panel each being located between said top panel and said bottom panel and adjacent to each of said pair of end walls, a first tear panel formed in one of said pair of end walls and having a pair of portions which extend partially into said back panel and partially into said front panel, and when said first tear panel is removed a dispensing opening is formed into said carton which provides access to at least one of said products housed within said carton, and a second tear panel formed in one of said front and back panels, said second tear panel having a diameter at least equal to said common diameter of each of said hollow cores, and when said second tear panel is removed an empty hollow core insertion opening is formed into said carton which allow an empty hollow core to be inserted back into said carton once one of said products has been removed from said carton;   b) removing said first tear panel to obtain a dispensing opening into said carton;   c) removing said second tear panel to obtain an insertion opening;   d) removing one of said products from said carton;   e) removing said product wound upon said hollow core to obtain an empty hollow core; and   f) inserting said empty hollow core back into said carton through said insertion opening.   
     
     
         20 . The method of  claim 19  wherein said carton and each of said hollow cores is formed from cellulose fibers, and said method further comprises recycling said carton containing one or more of said empty hollow cores. 
     
     
         21 . The method of  claim 19  further comprising forming said second tear panel in said back panel and forming a third tear panel in said front panel, said third tear panel having a diameter at least equal to said common diameter of each of said hollow cores, and when said third tear panel is removed, another empty hollow core insertion opening is formed into said carton which allows an empty hollow core to be inserted back into said carton once one of said products has been removed from said carton.