U.S. patent application number 11/150440 was filed with the patent office on 2005-10-13 for carton blank and carton formed therefrom.
Invention is credited to Walsh, Joseph C..
Application Number | 20050224564 11/150440 |
Document ID | / |
Family ID | 26689461 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050224564 |
Kind Code |
A1 |
Walsh, Joseph C. |
October 13, 2005 |
Carton blank and carton formed therefrom
Abstract
A carton blank and a carton formed therefrom wherein the formed
carton is fluid impervious and is provided with a pour spout but
retains the fluid imperviousness of the carton until the pour spout
is opened and wherein the pour spout has wing portions located
between an inner and an outer layer of the carton and free to move
relative thereto.
Inventors: |
Walsh, Joseph C.; (Boulder,
CO) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
P.O. BOX 7037
ATLANTA
GA
30357-0037
US
|
Family ID: |
26689461 |
Appl. No.: |
11/150440 |
Filed: |
June 10, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11150440 |
Jun 10, 2005 |
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10027744 |
Dec 20, 2001 |
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10027744 |
Dec 20, 2001 |
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09220065 |
Dec 23, 1998 |
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09220065 |
Dec 23, 1998 |
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09017108 |
Jan 31, 1998 |
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09017108 |
Jan 31, 1998 |
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08934269 |
Sep 19, 1997 |
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5857614 |
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Current U.S.
Class: |
229/117.27 ;
229/117.3; 229/117.31; 229/215 |
Current CPC
Class: |
B65D 5/6623 20130101;
B65D 5/743 20130101; B65D 5/6602 20130101; B65D 5/744 20130101 |
Class at
Publication: |
229/117.27 ;
229/117.31; 229/117.3; 229/215 |
International
Class: |
B65D 005/56; B65D
005/72 |
Claims
What is claimed:
1. A carton blank comprising: an outer layer comprising a generally
rectangular sheet of a relatively rigid material; said outer layer
having a plurality of cut and fold lines formed therein for
dividing said outer layer into a plurality of panels; said outer
layer having at least one top panel integral with at least a first
sidewall panel and joined thereto by a fold line; said at least a
first sidewall panel being integral with a second sidewall panel
and a third sidewall panel and joined thereto by opposite fold
lines; a first weakened portion formed in said at least a first
sidewall panel adjacent to said fold line between said at least one
top panel and said at least a first sidewall panel; a fold line in
said at least a first sidewall panel extending between said
opposite fold lines and spaced from said first weakened portion; a
second weakened portion formed in said at least a first sidewall
panel and located between said first weakened portion and said fold
line between said opposite fold lines; said second weakened portion
being mounted for pivotal movement relative to said at least a
first sidewall panel; a pour spout having a central body portion, a
first wing portion extending from one side of said central body
portion and a second wing portion extending from the other side of
said central body portion; said central body portion of said pour
spout being united with said second weakened portion for movement
therewith so that said central body portion and said first and
second wing portions cooperate to form said pour spout; an inner
layer comprising a generally rectangular sheet of a relatively
flexible fluid impervious material; and at least portions of said
inner layer being secured to at least portions of said outer layer
and at least other portions of said inner layer being secured to at
least portions of said central body portion of said pour spout.
2. A carton blank as in claim 1 wherein: said pour spout having an
outer surface and an inner surface; at least portions of said outer
surface of said central body portion being secured to at least
portions of said second weakened portion with said first wing
portion being superposed over but not secured to said second
sidewall panel and said second wing portion being superposed over
but not secured to said third sidewall panel; at least portions of
said inner surface of said central body portion being secured to at
least portions of said inner layer; and said first wing portion
being joined to said central body portion by a fold line and said
second wing portion being joined to said central body portion by a
fold line.
3. A carton blank as in claim 2 and further comprising: a third
weakened portion; said third weakened portion being formed in a
portion of said inner layer; said third weakened portion comprising
a plurality of cut lines; continuous portions of said inner layer
on either side of each of said cut lines being secured to portions
of said pour spout to retain the fluid imperviousness of said inner
layer.
4. A carton blank as in claim 3 wherein: at least portions of said
first and second weakened portions being in a coinciding
relationship; and at least one of said plurality of cut lines of
said third weakened portion being parallel to but spaced from said
at least portions in said coinciding relationship.
5. A carton blank as in claim 4 wherein: a second one of said
plurality of cut lines of said third weakened portion being
parallel to but spaced from said fold line joining said central
body portion and said first wing portion of said pour spout; and a
third one of said plurality of cut lines of said third weakened
portion being parallel to but spaced from said fold line joining
said central body portion and said second wing portion of said pour
spout.
6. A carton blank as in claims 5 wherein: said continuous portions
being secured only to portions of said central body portion of said
pour spout; and said first and second wing portions being located
between but not secured to portions of said outer and inner
layers.
7. A carton blank as in claim 1 and further comprising: said
plurality of panels comprising at least a plurality of top panels
joined by fold lines to adjacent sidewall panels, a front panel and
a back panel; at least one continuous strip of a relatively
flexible material superposed at least over said top panels and
portions of said opposite sidewall panels said front panel and said
back panel adjacent to said fold lines joining said top panels and
said opposite sidewall panels; said front panel and said back
panel; and at least portions of said at least one continuous strip
of a relatively flexible material being secured only to at least
portions of said inner layer.
8. A carton blank as in claim 7 and further comprising: a third
weakened portion; said third weakened portion being formed in a
portion of said inner layer; said third weakened portion comprising
a plurality of cut lines; continuous portions of said inner layer
on either side of each of said cut lines being secured to portions
of said pour spout to retain the fluid imperviousness of said inner
layer.
9. A carton blank as in claim 8 wherein: said continuous portions
being secured only to portions of said central body portion of said
pour spout; and said first and second wing portions being located
between but not secured to portions of said outer and inner
layers.
10. A carton blank as in claim 1 and further comprising: said outer
layer having an outer surface and an inner surface; said inner
layer having an outer surface and an inner surface; said pour spout
having an outer surface and an inner surface; at least portions of
said outer surface of said central body portion of said pour spout
being secured to at least portions of said inner surface of said
second weakened portion for movement therewith; and a sharp point
on each of said first and second wing portions so that when said
central body portion of said pour spout moves outwardly said sharp
points will penetrate and form openings in said inner layer so that
said at least portion of said inner layer secured to said central
body portion of said pour spout will tear away from other portions
of said inner layer during the formation of said pour spout.
11. A pour spout for a carton wherein the carton has a plurality of
sidewall panels and top and bottom panels with a first sidewall
panel having a pair of spaced apart fold lines joining the first
sidewall panel to a second sidewall panel and a third sidewall
panel comprising: an outer layer formed from a relatively rigid
material; said first sidewall panel having another fold line
joining said first sidewall panel to a top panel; a first weakened
portion formed in said-first sidewall panel adjacent to said
another fold line; a second weakened portion formed in said first
sidewall panel and located so that at least a portion of said
second weakened portion coincides with at least a portion of said
first weakened portion; a pour spout having a central body portion,
a first wing portion extending from one side of said central body
portion and a second wing portion extending from the other side of
said central body portion; said central body portion of said pour
spout being secured to said second weakened portion with said first
wing portion superposed over but not secured to at least a portion
of said second sidewall panel and said second wing portion
superposed over but not secured to at least a portion of said third
sidewall panel; a generally rectangular sheet of a relatively
flexible fluid impervious material superposed over said outer layer
and said pour spout so that said pour spout is located between said
outer and inner layers; and at least portions of said inner layer
being secured to at least portions of said outer layer and at least
other portions of said inner layer being secured to at least
portions of said central body portion of said pour spout.
12. A pour spout for a carton as in claim 11 and further
comprising: said first and second wing portions being located
between said outer and inner layers and mounted for movement
relative thereto.
13. A pour spout for a carton as in claim 12 and further
comprising: a third weakened portion; said third weakened portion
being formed in a portion of said inner layer; said third weakened
portion comprising a plurality of cut lines; continuous portions of
said inner layer on either side of each of said cut lines being
secured to portions of said pour spout to retain the fluid
imperviousness of said inner layer.
14. A pour spout for a carton as in claim 13 wherein: at least
portions of said first and second weakened portions being in a
coinciding relationship; and at least one of said plurality of cut
lines of said third weakened portion being parallel to but spaced
from said at least portions in said coinciding relationship.
15. A pour spout for a carton as in claim 14 wherein: a second one
of said plurality of cut lines of said third weakened portion being
parallel to but spaced from said fold line joining said central
body portion and said first wing portion of said pour spout; and a
third one of said plurality of cut lines of said third weakened
portion being parallel to but spaced from said fold line joining
said central body portion and said second wing portion of said pour
spout.
16. A pour spout for a carton as in claim 15 wherein: said
continuous portions being secured only to portions of said central
body portion of said pour spout.
17. A pour spout for a carton as in claim 13 wherein: said
continuous portions being secured only to portions of said central
body portion of said pour spout.
18. A pour spout for a carton as in claim 17 wherein: said pour
spout having an outer surface and an inner surface; at least
portions of said outer surface of said central body portion being
secured to at least portions of said second weakened portion with
said first wing portion being superposed over, but not secured to
said second sidewall panel and said second wing portion being
superposed over but not secured to said third sidewall panel; at
least portions of said inner surface of said central body portion
being secured to at least portions of said inner layer; and said
first wing portion being joined to said central body portion by a
fold line and said second wing portion being joined to said central
body portion by a fold line.
19. A pour spout for a carton as in claim 11 and further
comprising: said outer layer having an outer surface and an inner
surface; said inner layer having an outer surface and an inner
surface; said pour spout having an outer surface and an inner
surface; at least portions of said outer surface of said pour spout
being secured to at least portions of said inner surface of said
second weakened portion for movement therewith; at least portions
of said outer surface of said central body portion of said pour
spout being secured to at least portions of said inner surface of
said second weakened portion for movement therewith; and a sharp
point on each of said first and second wing portions so that when
said central body portion of said pour spout moves outwardly said
sharp points will penetrate and form openings in said inner layer
so that said at least portion of said-inner layer secured to said
central body portion of said pour spout will tear away from other
portions of said inner layer during the formation of said pour
spout.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 09/220,065 filed Dec. 23, 1998, for Carton
Blank and Carton Formed Therefrom of Joseph C. Walsh which is a
continuation-in-part of U.S. patent application Ser. No. 09/017,108
filed Jan. 31, 1998, for Carton Blank And Carton Formed Therefrom
of Joseph C. Walsh (now abandoned) which application is a
continuation-in-part of U.S. patent application Ser. No. 08/934,269
filed Sep. 19, 1997, for Carton Blank and Carton Formed Therefrom
of Joseph C. Walsh (now U.S. Pat. No. 5,857,614), all of which are
hereby specifically incorporated by reference for all that is
disclosed therein.
FIELD OF THE INVENTION
[0002] This invention is directed generally to a carton blank and
carton formed therefrom and more particularly to a leakproof carton
from which the materials contained therein may be readily
removed.
BACKGROUND OF THE INVENTION
[0003] There are many kinds of leakproof cartons on the market. The
vast majority of these cartons have an outer layer formed from a
relatively rigid material for protection and an inner layer formed
from a relatively flexible material for providing the leakproof
qualities. When it is desired to remove the material in the carton,
it is necessary to first open the outer layer, and then open the
inner layer. Also, the inner layer generally is not secured to the
outer layer so access to the inner layer sometimes presents a
problem. This is particularly true in leakproof cartons that are
designed to hold only one serving. Another problem relates to the
formation of a pour spout in such cartons.
BRIEF DESCRIPTION OF THE INVENTION
[0004] This invention provides a leakproof carton comprising an
outer layer formed from a relatively rigid material and an inner
layer formed from a relatively flexible fluid impervious material
which carton is readily opened in one simultaneous operation so
that the material therein may be readily removed. Also, the parts
of the outer and inner layer adjacent to the opening remain secured
together to facilitate further the removal of the material
contained therein. The invention also provides a carton blank from
which the carton is formed.
[0005] The invention also provides a carton blank and a carton
formed therefrom which carton is fluid impervious and is provided
with a pour spout so that the carton retains its fluid
imperviousness until the pour spout is opened.
[0006] In a preferred embodiment of the invention, the carton blank
comprises a unitary sheet of a relatively rigid material having an
inner surface and an outer surface, a left side edge, a right side
edge, a top edge and a bottom edge. The unitary sheet of a
relatively rigid material has a length extending from the top edge
to the bottom edge and a width extending from the left side edge to
the right side edge. The unitary sheet of relatively rigid material
has a plurality of cut and fold lines for dividing the unitary
sheet of a relatively rigid material in a conventional manner into
a plurality of panels including into a back wall panel, a front
wall panel, opposite sidewall panels, a glue tab panel and top and
bottom panels extending outwardly in opposite directions from the
front wall, back wall and opposite sidewall panels. The glue tab
panel has a top edge and a bottom edge. The carton blank also
comprises a generally rectangular sheet of a relatively flexible
fluid impervious material having an inner surface and an outer
surface, a central body portion, a top body portion, a bottom body
portion, a left side edge, a right side edge and top and bottom
edges. The central body portion of the rectangular sheet of a
relatively flexible fluid impervious material is secured to
opposite portions of the unitary sheet of a relatively rigid
material. Linearly extending weakened portions are formed in at
least portions of the unitary sheet of a relatively rigid material
that is secured to the central body portion. At least portions of
the generally rectangular sheet of a relatively flexible fluid
impervious material are easily separated along a line opposite to
the linearly extending opening means. The at least portions are
joined together by adhesive to preserve the integrity of the
generally rectangular sheet of a relatively flexible fluid
impervious material but to permit the separation thereof.
[0007] In a preferred embodiment of the invention, the relatively
flexible fluid impervious material comprises a plastic material.
The generally rectangular sheet of a plastic material comprises a
separate first portion and a separate second portion with at least
portions of one of the separate first and second portions overlying
at least portions of the other of the first and second portions. A
continuous portion of the first portion is secured to a continuous
portion of the second portion to preserve the integrity of the
generally rectangular sheet of a plastic material. At least a
portion of the continuous portions is located opposite to the
linearly extending weakened portions to permit the separation of
the first and second portions simultaneously with the outer
layer.
[0008] In another preferred embodiment of the invention, the
rectangular sheet of a relatively flexible fluid impervious
material comprises a laminate of a paper material and a plastic
material with the paper material being secured to opposite portions
of the unitary sheet of a relatively rigid material. The generally
rectangular sheet of a relatively flexible fluid impervious
material comprises a separate first portion and a separate second
portion. Each of the separate first and second portions has an edge
portion with the edge portions being in a face to face relationship
and located opposite to the linearly extending opening means. At
least all of the edge portions of the paper portions are secured
together to preserve the integrity of the generally rectangular
sheet of a relatively flexible fluid impervious material but to
permit separation of the first and second portions simultaneously
with the outer layer.
[0009] In another preferred embodiment of the invention, the
generally rectangular sheet of a relatively flexible fluid
impervious material comprises a laminate of a generally rectangular
sheet of a relatively flexible paper material and a plastic
material wherein the plastic material comprises a separate first
portion and a separate second portion. At least portions of one of
the separate first and second portions overlies at least portions
of the other of the separate first and second portions. A
continuous portion of the first portion is secured to a continuous
portion of the second portion to preserve the integrity of the
generally rectangular sheet of a relatively flexible fluid
impervious material. At least a portion of the continuous portions
is located opposite to the linearly extending weakened portions to
permit the separation of the first and second portions
simultaneously with the outer layer.
[0010] In another preferred embodiment of the invention, the
conventional panel portions have a front wall panel, a back wall
panel and at least one sidewall panel portion having opposite side
edges. The front and back wall panels are integral with one of the
opposite side edges and are joined to the at least one sidewall
panel portion by a fold line. The linearly extending weakened
portions of the outer layer extend from a location in one of the
front and back wall panels to a location in the other of the front
and back wall panels.
[0011] In another preferred embodiment of the invention, the carton
formed from the carton blank is provided with a pour spout. One of
the sidewall panels has opposite substantially parallel side edges
formed by a portion of the fold lines. Linearly extending weakened
portions, similar to those described above, have at least one
portion extending between the opposite side edges and terminate in
opposite ends. The opposite side edges are formed as linearly
extending weakened portions extending from the opposite ends. Spout
forming material is provided and has a central portion and two wing
portions integral with the central portion and extending outwardly
on either side thereof. At least a portion of the central portion
is secured to at least a portion of the central body portion of the
generally rectangular sheet secured to opposite portions of the
opposite side edges.
[0012] A carton formed from the above described carton blanks
comprises an outer layer formed from the relatively rigid material
and having linearly extending weakened portions formed in at least
parts thereof and an inner layer formed from the relatively
flexible fluid impervious material and having a central body
portion secured to opposite portions of the outer layer. The
central body portion has a weakened portion along a line opposite
to the linearly extending weakened portions so that one opening can
be. simultaneously formed in the outer and inner layers.
[0013] In all of the above cartons, the outer and inner layers are
in a sealed together relationship in the areas adjacent to the
opening.
[0014] In another preferred embodiment of the invention, the carton
blank comprises an outer layer comprising a generally rectangular
sheet of a relatively rigid material and having a plurality of cut
and fold lines formed therein for dividing the outer layer into
conventional panels. At least one top panel is integral with at
least a first sidewall panel and is joined thereto by a fold line.
The at least a first sidewall panel is integral with a second
sidewall panel and a third sidewall panel and is joined thereto by
opposite fold lines. A first weakened portion is formed in the at
least sidewall panel adjacent to the fold line between the at least
one top panel and the at least a first sidewall panel. A fold line
is formed in the at least a first sidewall panel extending between
the opposite fold lines and spaced from the first weakened portion.
A second weakened portion is formed in the at least a first
sidewall panel and is located between the first weakened portion
and the fold line between the opposite fold lines which fold line
provides for pivotal movement relative to the at least a first
sidewall panel. A pour spout is provided and has a central body
portion, a first wing portion extending from one side of said
central body portion and a second wing portion extending from the
other side of said central body portion. The central body portion
of the pour spout is united with the second weakened portion for
movement therewith so that the central body portion and the first
and second wing portions cooperate to form a pour spout. The carton
blank also has an inner layer comprising a generally rectangular
sheet of a relatively flexible fluid impervious material. At least
portions of the inner layer are secured to at least portions of the
outer layer and at least other portions of the inner layer are
secured to at least portions of the central body portion of the
pour spout.
[0015] The pour spout has an outer surface and an inner surface
with at least portions of the outer surface of the central body
portion being secured to at least portions of the second weakened
portion with the first wing portion being superposed over but not
secured to the second sidewall panel and the second wing portion
being superposed over but not secured to the third sidewall panel.
At least portions of the inner surface of the central body portion
are secured to at least portions of the inner layer. The first wing
portion is joined to the central body portion by a fold line and
the second wing portion is joined to the central body portion by a
fold line.
[0016] A third weakened portion, is formed in a portion of the
inner layer and comprises a plurality of cut lines. Continuous
portions of the inner layer on either side of each of the cut lines
are secured to portions of the central body portion of the pour
spout to retain the fluid imperviousness of the inner layer. At
least portions of the first and second weakened portions are in a
coinciding relationship and at least one of the plurality of cut
lines of the third weakened portion is parallel to but spaced from
the at least portions in the coinciding relationship.
[0017] A second one of the plurality of cut lines of the third
weakened portion is parallel to but spaced from the fold line
joining the central body portion and the first wing portion of the
pour spout and a third one of the plurality of cut lines of the
third weakened portion is parallel to but spaced from the fold line
joining the central body portion and the second wing portion of the
pour spout.
[0018] In another preferred embodiment of the invention, the
conventional panels comprise at least a plurality of top panels
joined by fold lines to adjacent sidewall panels, a front panel and
a back panel. At least one continuous strip of a relatively
flexible material is superposed at least over the top panels and
portions of the opposite sidewall panels the front panel and the
back panel adjacent to the fold lines joining the top panels and
the opposite sidewall panels, the front panel and the back panel;
and at least portions of the continuous strip of a relatively
flexible material is secured to at least portions of the inner
layer.
[0019] A carton formed from the above-described carton blank
comprises an outer layer formed from a relatively rigid material
and has at least first, second and third sidewall panels wherein
one of the fold lines joins the first sidewall panel to a top
panel. A first weakened portion is formed in the first sidewall
panel adjacent to such fold line. A second weakened portion is
formed in the first sidewall panel and is located so that at least
a portion of the second weakened portion coincides with at least a
portion of the first weakened portion. A pour spout is provided and
has a central body portion, a first wing portion extending from one
side of the central body portion and a second wing portion
extending from the other side of the central body portion. The
central body portion of the pour spout is secured to the second
weakened portion with the first wing portion superposed over but
not secured to at least a portion of the second sidewall panel and
the second wing portion superposed over but not secured to at least
a portion of the third sidewall panel.
[0020] An inner layer comprising a generally rectangular sheet of a
relatively flexible fluid impervious material has at least portions
thereof secured to at least portions of the outer layer and at
least other portions of the inner layer secured to at least
portions of the central body portion of the pour spout. The first
and second wing portions are located between but not secured to the
outer and inner layers and are mounted for movement relative
thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Various embodiments of the invention are illustrated in the
drawing in which:
[0022] FIG. 1 is a top plan view of a carton blank of this
invention;
[0023] FIG. 2 is a perspective view of a carton formed from the
carton blank of FIG. 1 in an opened position;
[0024] FIG. 3 is a cross-sectional view taken on the line 3-3 of
FIG. 1 of one embodiment of the carton blank of this invention;
[0025] FIG. 4 is a cross-sectional view similar to FIG. 3 of
another embodiment of the carton blank of this invention; and
[0026] FIG. 5 is a cross-sectional view similar to FIG. 3 of
another embodiment of the carton blank of this invention;
[0027] FIG. 6. is a partial top plan view of another embodiment of
a carton blank of the invention;
[0028] FIG. 7 is a top plan end of FIG. 6;
[0029] FIG. 8 is a perspective view of a portion of a carton formed
from the carton blank of FIG. 6;
[0030] FIG. 9 is a partial side elevational view of a portion of
FIG. 8 showing the spout partially opened;
[0031] FIG. 10 is a schematic illustration of apparatus for use in
forming carton blanks of this invention;
[0032] FIG. 11 is a top plan view of a portion of the outer surface
of the continuous strip of a relatively rigid material having cut
and fold lines formed therein;
[0033] FIG. 12 is a top plan view of a portion of the inner surface
of the carton blank after the continuous sheet of a relatively
flexible material and the coating of adhesive has been applied
thereto;
[0034] FIG. 13 is a top plan view wherein the pour spout has been
applied to the illustration in FIG. 12;
[0035] FIG. 14 is a top plan view of a portion of the inner surface
of a carton blank of this invention;
[0036] FIG. 15. is a cross-sectional view taken on the line 15-15
of FIG. 14;
[0037] FIG. 16 is a view in cross-section to show the relationship
between the wing portions of the pour spout and the outer and inner
layers; and
[0038] FIG. 17 is a perspective view of a carton of this invention
with the pour spout opened.
DETAILED DESCRIPTION OF THE INVENTION
[0039] In FIG. 1, there is illustrated a carton blank 2 having an
outer layer comprising a unitary sheet 4 of a relatively rigid
material, such as a composite material described in U.S. Pat. No.
4,254,173 to Peer, Jr., which is incorporated herein by reference
thereto, a conventional paperboard or other materials having
similar characteristics. The unitary sheet 4 is provided with a
plurality of fold lines 6 and cut lines 8 to form a front panel 10,
a back panel 12, opposite sidewall panels 14 and 16, a glue tab
panel 18, top panels 20 and bottom panels 22. The glue tab panel 18
also has a fold line 24. The unitary sheet 4 has a top edge 26, a
bottom edge 28, a left side edge 30 and a right side edge 32. It is
understood that the unitary sheet may have other
configurations.
[0040] The unitary sheet 4 is provided with linearly extending
weakened portion which as illustrated in FIG. 1 comprises
conventional perforated lines 34 in the front panel 10, the back
panel 12 and the sidewall panel 16 which also has fold lines 36.
Also, perforated lines 38 are formed in two of the top panels 20.
All of these perforated lines 34, fold lines 36 and perforated
lines 38 function to provide an opening as described below.
However, it is understood that other types of conventional opening
means may be employed within the concepts of this invention.
[0041] The carton blank 2 also has an inner layer comprising a
generally rectangular sheet 50, preferably of a fluid impervious
material, having a central body portion 52 located between the
lines 54 and 56 that is secured to opposite portions of the unitary
sheet 4 by a suitable adhesive 58. Portions of the edge portions of
the generally rectangular sheet 50 coincide with the top edge 26,
the bottom edge 28, the left side edge 30 and the right side edge
32. The generally rectangular sheet 50 has a weakened portion 60,
by various means some of which are described below, at least part
of which is located opposite to portions of the linearly extending
perforated lines 34 for purposes described below. The weakened
portion 60 is illustrated in FIG. 1 by a dashed line.
[0042] One preferred embodiment of the invention is illustrated in
FIG. 3. The generally rectangular sheet 50 comprises a plastic
material 70 laminated to a relatively flexible paper material 72 by
a suitable adhesive 74. The generally rectangular sheet 50 has a
first portion 76 and a second portion 78 having edges 80 and 82 in
a face to face relationship which are located to form the weakened
portion 60. The plastic material 70 can be a polypropylene material
or any other type of material having similar characteristics. The
paper material 72 can be formed from Kraft or recycled fibers or
any other materials having similar characteristics. The central
body portion 52 of the paper material 64 is secured to opposite
portions of the unitary sheet 4, illustrated in FIG. 3 as the back
panel 12, by a suitable adhesive 58 wherein a portion of the
adhesive 58 is located between the side edges 80 and 82 to preserve
the integrity of the generally rectangular sheet 50 of a relatively
flexible fluid impervious material and to permit separation of the
first and second portions 76 and 78 as described below.
[0043] Another preferred embodiment of the invention is illustrated
in FIG. 4. The generally rectangular sheet 50 comprises a plastic
material 70 comprising a first portion 86 and a second portion 88
laminated to the paper material 72, comprising a unitary sheet, by
the adhesive 74. The paper material 72 is provided with a series of
perforations 90 to provide the weakened portion 60. The adhesive 74
joins the first and second portions 86 and 88 along a continuous
line 92 to preserve the integrity of the generally rectangular
sheet 50 of a relatively flexible fluid impervious material. The
adhesive 74 preferably comprises a hot melt adhesive so, if the
outer surface of the plastic material 70 is provided with a heat
sealing adhesive, the overlying portions 94 will be sealed together
to further ensure the integrity of the generally rectangular sheet
50. However the perforations 90 and the adhesive 74 and the
overlying portions 94 permit separation of the generally
rectangular sheet 50 along the lines 90 and 92 for purposes
described below.
[0044] Another preferred embodiment of the invention is illustrated
in FIG. 5. The generally rectangular sheet 50 comprises the plastic
material 70 comprising a first portion 96 and a second portion 98.
The central body portion 52 of the first and second portions 96 and
98 is secured to the unitary sheet 4 by the adhesive 58 which joins
the first and second portions 96 and 98 along the continuous line
100 to preserve the integrity of the generally rectangular sheet 50
of a relatively flexible fluid impervious material. Also, the
adhesive 58 preferably comprises a hot melt adhesive so, if the
outer surface of the plastic material 70 is provided with a heat
sealing adhesive, the overlying portions 102 will be sealed
together to further ensure the integrity of the generally
rectangular sheet 50. However, the continuous line 100 and the
overlying portions 102 permit separation of the generally
rectangular sheet 50 for purposes described below.
[0045] In FIG. 2, there is illustrated an opened carton 104 having
an outer layer 106 and an inner layer 108 formed from any of the
embodiments of the invention such as those illustrated in FIGS.
3-5. The carton blank 2 is folded around the fold lines 6 and 18 to
form an open ended enclosure (not shown). The bottom panels 22 and
the corresponding bottom portion of the generally rectangular sheet
50 are folded and sealed together to form a carton having one open
end (not shown) which is then filled with the desired material and
the top panels 20 and the corresponding top portion of the
generally rectangular sheet 50 are folded together and sealed to
form the filled carton (not shown). When it is desired to remove
the material from the carton, pressure is applied to the portion of
the sidewall 16 enclosed by the fold lines 36 and the perforated
line 34 and the outer and inner layers 106 and 108 are opened
simultaneously along the linearly extending opening means 34 and
the weakened portion 60 and folded back along the fold lines 38 to
provide an opening 110. The portions of the outer and inner layers
106 and 108 adjacent to the opening 110 are sealed together by the
adhesives 58 and 74.
[0046] In FIGS. 6-8, there is illustrated another preferred
embodiment of the invention for forming a pour spout in a carton.
The portions of the invention in FIGS. 6-8 that correspond to
portions of the invention in FIGS. 1-5 have been identified with
the same reference numerals.
[0047] In FIGS. 6 and 7, there is illustrated a portion of another
preferred carton blank 120 that comprises a unitary sheet 4 of a
relatively rigid material and a generally rectangular sheet 50 of a
relatively flexible fluid impervious material, as described
above.
[0048] A spout forming piece 122 of a relatively rigid material is
provided and has a central portion 124 and two wing portions 126
and 128. The spout forming piece 122 is formed from a material such
as that described in the Peer, Jr. patent, a conventional
paperboard or a relatively rigid plastic material, such as
polypropylene or polyester. Perforated lines 130 and 132 form
opposite side edges for the sidewall panel 16 in a portion of the
fold lines 6 of the unitary sheet 4 of a relatively rigid material
and another fold line 134 is also formed therein. The central
portion 124 is secured to that portion of the generally rectangular
sheet 50 of a relatively flexible fluid impervious material secured
to the portion of sidewall panel 16 between the perforated lines
130 and 132, the weakened portion 34 and the fold line 134.
[0049] A fold line 140 connects wing portion 126 to the central
portion 124 and a fold line 141 connects wing portion 128 to the
central portion 124. Cut out portions 142, 144, 146 and 148 in the
central portion 124 and the wing portions 126 and 128 function to
provide sharp, pointed projections 150 and 152 for purposes
described below. Stop portions 154 and 156 limit the outward
movement of the wing portions 126 and 128. The wing portions 126
and 128 are not secured to any other portion of the carton blank
120.
[0050] The operation of a carton 160 formed from the carton blank
120 is illustrated in FIGS. 8 and 9. In FIG. 8, the carton blank
has been folded to form the carton 160 which has been filled with a
desired product and sealed. The wing portions 126 and 128 are
adjacent to portions of the front 10 and back 12 panels. When it is
desired to remove portions of the product from the carton 160, a
finger (not shown) is placed against the portion of the unitary
sheet 4 of a relatively rigid material defined by the lines 34 and
36 and sufficient force is applied to move these portions inwardly.
This operation breaks the weakened portions 34 and part of 60. The
finger is then moved against a portion of the central portion 124
and an outwardly directed force is applied thereto to move the
sharp pointed projections 150 and 152 into contact with and to
pierce portions of the generally rectangular sheet 50 of a
relatively flexible fluid impervious material. The continued
outward movement of the central portion 124, as indicated by the
arrow 162, also moves the portion of the unitary sheet 4 of a
relatively rigid material outwardly breaking the perforations 130
and 132 and pivoting around the fold line 134. The generally
rectangular sheet 50 of a relatively flexible fluid impervious
material also splits along a line corresponding to the perforations
130 and 132. The wing portions 126 and 128 also move outwardly to
provide the side portions of the pour spout in cooperation with the
central portion 124.
[0051] In FIG. 10, there is a schematic illustration of apparatus
for making a preferred embodiment of the carton blank of this
invention. A continuous strip 170 of a relatively rigid material,
such as that disclosed in the Peer, Jr. patent, conventional
paperboard or other materials having similar characteristics, is
pulled from a roll 172 of such material and passes between cutting
and creasing rolls 174 where substantially all of the cut and fold
lines for the carton blanks are made. In a preferred embodiment,
the only cut line not made is the cut line between successive
carton blanks. The cut and creased continuous strip 176 has an
outer surface 178 and an inner surface 180 and is passed under a
plurality rolls 182 from which a plurality of continuous strips 184
of a relatively flexible material, such as a Kraft paper or other
materials having similar characteristics, are superposed in a
spaced apart relationship over the cut and creased continuous strip
176. The continuous strips 184 have an outer surface (not shown)
facing the inner surface 180 and an inner surface 186 and leave
portions of the cut and creased continuous strip 176 exposed. The
cut and creased continuous strip 176 and the plurality of
continuous strips 184 pass through hot melt adhesive applying rolls
188 and 190 whereat a conventional hot melt adhesive at
temperatures between about 350.degree. F. and 400.degree. F. is
applied to at least portions of the inner surface 186 of the
continuous strips 184 and to at least portions of the exposed
portions of the inner surface 180 of the cut and creased continuous
strip 176. The adhesive coated cut and creased continuous strip 176
and the adhesive coated continuous strips 184 pass beneath a roll
192 which deposits a pour spout 194, described move fully below,
over a portion of the adhesive coated continuous strip 176. The
adhesive coated cut and creased continuous strip 176, the
continuous strips 184 and the pour spout 194 pass beneath a roll
196 from which a continuous strip 198 of a relatively flexible
fluid impervious material, such as a plastic film of a polyethylene
material or other plastic materials having similar characteristics
or a plastic coated paper material or other materials having
similar characteristics, is superposed over the adhesive coated
continuous strip 176, the continuous strips 184 and the pour spout
194. In a preferred embodiment of the invention, the continuous
strips 170 and 198 have the same width in a cross machine direction
and are sufficiently wide so that they can be cut in half to form
adjacent carton blanks. The continuous strip 198 has an outer
surface (not shown) facing the adhesive coated cut and creased
continuous strip 176, the adhesive coated continuous strips 184 and
the pour spouts 194 and also an inner surface 200.
[0052] All of the above described materials then pass between
laminating rolls 202 and 204 to form the laminated product 206
described more fully below. In a preferred embodiment of the
invention, the laminating rolls 202 and 204 provide a pulling force
to pull the continuous strips 170, 184 and 198 from the rolls 172,
182 and 192. Also, the rolls 174, 188, 190 and 198 may be
independently driven to move at the same velocity as the continuous
strips 170, 184 and 198 which is preferable between about 300 and
100 feet per minute. The laminated product 206 then moves into
processing apparatus 208 wherein a portion of the continuous strip
198 is secured to a portion of the pour spout 194 and the cuts are
made to form the individual carton blanks which are then
collected.
[0053] In FIG. 11, there is illustrated a portion 220 of the cut
and creased continuous strip 176 having cut lines 222 and fold
lines formed therein to form top panels 226, a first sidewall panel
228, second sidewall panel 230 and third sidewall panel 232. A
first weakened portion 234 is formed in the first sidewall panel
228 by a plurality of perforated cut lines 236. A second weakened
portion 238 is formed in the first sidewall panel 228 by a
plurality of perforated cut lines 240 and one of the perforated cut
lines 236. The second weakened portion 238 is pivotally mounted on
the first sidewall panel 228 by a fold line 242. The perforated cut
lines 240 are extensions of the fold lines 224 forming the first
sidewall panel 228 and terminate at the one perforated cut line
236.
[0054] In FIG. 12, one of the continuous strips 184 has been
superposed over a portion of the inner surface 180 to cover the top
panels 226, the fold lines 224 between the top panels 226 and the
first, second and third sidewall panels 228, 230 and 232 adjacent
to the fold lines 224. Portions of the continuous strip 184, the
sidewall panels 228, 230 and 232 and the second weakened portion
238 are coated with the adhesive 244. The first weakened portion
234, the portion 246 of the second sidewall panel 230 and the
portion 248 of the third sidewall panel 232 are not coated with the
adhesive 244. It is understood that the continuous strip 184 may be
omitted to form a carton blank as illustrated in the portion
illustrated in FIG. 5 above.
[0055] In FIG. 13, a pour spout 194 has been superposed over
portions of the first, second and third sidewall panels 228, 230
and 232. The pour spout 194 has a central body portion 250, a first
wing portion 252 and a second wing portion 254. A fold line 256
between the central body portion 250 and the first wing portion 252
permits pivotal movement therebetween. A fold line 258 between the
central body portion 250 and the second wing portion 254 permits
pivotal movement therebetween. The central body portion 250
overlies and is secured to the second weakened portion 238. The
first wing portion 252 overlies the non-adhesive coated portion 246
and the second wing portion 254 overlies the non-adhesive coated
portion 248. As illustrated in FIG. 15, the pour spout 194 is
formed from a lamination of a conventional paperboard 262,
preferably formed from bleached Kraft fibers and having a thickness
of about 0.015 inch laminated by a suitable adhesive to a film 264
of a polyester material having a thickness of about 0.0005 inch and
the exposed surface thereof is coated with a coating layer 266 of a
polyethylene material or a material having similar characteristics.
In another embodiment, the pour spout 194 is formed from a
relatively rigid fluid impervious material such as a polyethylene
having a thickness of about 0.012 in or other materials having
similar characteristics. Each of the first and second wing portions
246 and 248 has an abutment 260 to limit the outward movement of
the pour spout 194.
[0056] In FIG. 14, the continuous strip 198 of a relatively
flexible fluid impervious material is secured to the adhesive
coated portions of the continuous strip 184 and the sidewall panels
228, 230 and 232. A third weakened portion 270 is formed in a
portion of the continuous strip 198 overlying the central body
portion 250 of the pour spout. The third weakened portion 270 is
formed by a plurality of, cut lines 272, 274 and 276, which cut
lines can be perforated lines, which are continuous and wherein one
end of the cut line 272 intersects with one end of the cut line 274
and one end of the cut line 276 intersects with the other end of
the cut line 274 and are formed by a heated cutting apparatus (not
shown) so that, as the cut lines 272, 274 and 276 are made, a
continuous portion 278 of the continuous strip 198 on one side of
the cut lines 272, 274 and 276 is secured to the underlying
portions of the coating layer 266 of the central body portion 250
of the pour spout and another continuous portion 280 on the other
side of the cut lines 272, 274 and 276 is secured to the underlying
portions of the central body portion 250 of the pour spout. This
preserves the integrity of the continuous strip 198 of a relatively
flexible fluid impervious material. In another embodiment of the
invention, a coating of a suitable adhesive material, such as a
conventional hot or cold melt adhesive, may be applied to the
portions 278 and 280 instead of using the heat from the heated
cutting apparatus. When the adhesive coating is applied to the
portions 278 and 280 a non-heated cutting apparatus may be used. No
portion of the first and second wing portions 252 and 254 is
secured to either of the continuous strips 170 and 198, as
illustrated in FIG. 16, so that the first and second wing portions
252 and 254 are free to move relative to the continuous strips 170
and 198 but are contained between them. This prevents the first and
second wing portions 252 and 254 from being displaced as the carton
is filled with the desired material.
[0057] The heated cutting apparatus forming the cut lines 272, 274
and 276 and the sealed portions 278 and 280 is set at a temperature
capable of performing the above described functions. If the
continuous strip 198 of a relatively flexible fluid impervious
material is a polyethylene having a melt point of about 290.degree.
F., the heated cutting apparatus preferably has a temperature at
least as great as 290.degree. F. but preferably higher. The central
body portion 250 of the pour spout is particularly suited for this
operation. The coated layer 266 of a polyethylene material is
compatible to the continuous strip 198 of a relatively flexible
fluid impervious material so that the heated cutting apparatus will
cut through the two polyethylene layers and seal together the two
polyethylene layers at the portions 278 and 280. The film 264 of a
polyester material has a higher melt point so that, as the heated
cutting apparatus makes the cut lines 272, 274 and 276 and the
sealed together portions 278 and 280, it does not melt through the
film 264 of the polyester material to preserve the integrity of the
fluid impervious lining.
[0058] A carton 290 formed from a carton blank described above is
illustrated in FIG. 17 with the pour spout 194 in the opened
position. The pour spout 194 is moved to the opened position by
placing a finger tip (not shown) against the first weakened portion
234 and pushing inwardly. As the first weakened portion 234 moves
inwardly the seal 278 between the continuous strip 198 and the
central body portion 250 adjacent to the first weakened portion 234
is broken to allow the first weakened portion 234 to move inwardly.
After the first weakened portion 234 has been moved inwardly a
sufficient distance, the finger tip is placed against the portion
280 of the continuous strip 198 secured to the central body portion
250 and an outwardly directed force is applied thereto. This moves
the central body portion 250 and the second weakened portion 238
outwardly and gradually breaks the seal between the continuous
portion 278 and the central body portion 250 to allow the first and
second wing portions 252 and 254 to be moved outwardly. The
abutments 260 limit the outer movement of the first and second wing
portions 252 and 254. After the desired amount of material has been
removed from the carton 290, an inwardly directed force is applied
to the pour spout 194. The inward movement of the first and second
wing portions 252 and 254 is limited by the secured together
portions 292 and 294 of the continuous strips 170 and 198.
[0059] It is contemplated that the inventive concepts herein
described may be variously otherwise embodied and it is intended
that the appended claims be construed to include alternative
embodiments of the invention except insofar as limited by the prior
art.
* * * * *