U.S. patent application number 10/865323 was filed with the patent office on 2005-12-15 for method of forming a container having an integral pour spout.
Invention is credited to Nelson, Daniel John, Petrelli, J. Anthony.
Application Number | 20050274086 10/865323 |
Document ID | / |
Family ID | 35459054 |
Filed Date | 2005-12-15 |
United States Patent
Application |
20050274086 |
Kind Code |
A1 |
Petrelli, J. Anthony ; et
al. |
December 15, 2005 |
Method of forming a container having an integral pour spout
Abstract
A packaging blank capable of forming a reclosable container
comprises in one embodiment a front panel having opposing side
panels, a rear panel connected to the front panel by the second
side panel, a top panel connected to a top edge of the front panel,
a bottom panel connected to a bottom edge of the front panel, and a
pour spout flap connected to a top edge of the second side panel.
Upon construction the packaging blank provides a reclosable
container having an integral pour spout that is releasably
securable to a portion of the top panel. Still further, the
invention relates to a method of forming the container and a method
of packaging articles in the container.
Inventors: |
Petrelli, J. Anthony;
(Russell, OH) ; Nelson, Daniel John; (Chagrin
Falls, OH) |
Correspondence
Address: |
SUMMA & ALLAN, P.A.
11610 NORTH COMMUNITY HOUSE ROAD
SUITE 200
CHARLOTTE
NC
28277
US
|
Family ID: |
35459054 |
Appl. No.: |
10/865323 |
Filed: |
June 10, 2004 |
Current U.S.
Class: |
53/410 ;
53/133.2; 53/456; 53/564 |
Current CPC
Class: |
B65D 5/745 20130101 |
Class at
Publication: |
053/410 ;
053/456; 053/133.2; 053/564 |
International
Class: |
B65B 061/20 |
Claims
That which is claimed is:
1. A method of packaging articles in a container having a
reclosable pour spout, said method comprising the steps of:
providing a one-piece flexible blank having a front panel, first
and second side panels connected to opposing edges of the front
panel, a rear panel connected to the front panel by the second side
panel, a first bottom panel connected to a bottom edge of the front
panel, a second bottom panel connected to a bottom edge of the rear
panel, a glue flap connected to an edge of the rear panel opposite
the edge to which the second side panel is connected, and a pour
spout flap connected to a top edge of the second side panel;
folding the blank to form a container having an internal packaging
compartment; and positioning articles to be packaged in the
packaging compartment; wherein the container is substantially flat,
yet capable of being constructed into a substantially rectangular
container.
2. A method according to claim 1, wherein the step of folding the
blank comprises: folding the rear panel over the front panel; and
securing the glue flap to an edge of the first side panel such that
the rear panel and front panel, and the first side panel and second
side panel, define substantially parallel planes, respectively.
3. A method according to claim 2, wherein the blank provided
includes: a first bottom flap connected to a bottom edge of the
first side panel; a second bottom flap connected to a bottom edge
of the second side panel; and wherein the step of folding further
comprises: folding the second bottom panel towards the front panel;
folding the first and second bottom flaps against the second bottom
panel; and securing the first and second bottom flaps to the second
bottom panel; the steps performed after the step of securing the
glue flap.
4. A method according to claim 3, wherein the step of folding
further comprises: folding the first bottom panel against the
second bottom panel, first bottom flap, and second bottom flap; and
securing the first bottom panel to the second bottom panel such
that the first bottom flap and second bottom flap are secured
between the first and second bottom panels; the steps performed
after the step of securing the first and second bottom flaps.
5. A method according to claim 1, further comprising the step of
forming a reclosable pour spout after the step of positioning the
articles.
6. A method according to claim 5, wherein the blank provided
includes: a first top panel connected to a top edge of the front
panel, the first top panel having an opening adjacent to the pour
spout flap; and a second top panel connected to a top edge of the
rear panel, the second top panel having an opening adjacent to the
pour spout flap; and a first top flap connected to a top edge of
the first side panel; and the step of forming the reclosable pour
spout comprises: folding the second top panel towards the front
panel such that the second top panel and the first and second
bottom panels define substantially parallel planes; folding the
first top flap against the second top panel; and securing the first
top flap to the second top panel.
7. A method according to claim 6, wherein the step of forming
further comprises: folding the first top panel against the second
top panel and the first top flap such that the openings in the
first and second top panels are in communication; and securing the
first top panel to the second top panel such that the first top
flap is secured between the first and second top panels; the steps
performed after the step of securing the first top flap.
8. A method according to claim 7, wherein the step of folding
further comprises: folding the pour spout flap against the first
top panel; and securing the pour spout flap against the first top
panel such that removal of the pour spout flap from the first top
panel permits the articles in the container to flow through the
openings in the first and second top panels; the steps performed
after the step of securing the first top panel.
9. A method of forming a container having a reclosable pour spout,
said method comprising the steps of: providing a one-piece flexible
blank having a front panel, first and second side panels connected
to opposing edges of the front panel, a rear panel connected to the
front panel by the second side panel, a first top panel connected
to a top edge of the front panel, a second top panel connected to a
top edge of the rear panel, a first bottom panel connected to a
bottom edge of the front panel, a second bottom panel connected to
a bottom edge of the rear panel, a glue flap connected to an edge
of the rear panel opposite the edge to which the second side panel
is connected, and a pour spout flap connected to a top edge of the
second side panel; and folding the blank to form a container having
a reclosable pour spout; wherein the container is substantially
flat, yet capable of being constructed into a substantially
rectangular container.
10. A method according to claim 9, wherein the step of folding the
blank comprises: folding the rear panel over the front panel; and
securing the glue flap to an edge of the first side panel such that
the rear panel and front panel, and the first side panel and second
side panel, define substantially parallel planes, respectively.
11. A method according to claim 10, wherein the step of folding
further comprises: folding the second bottom panel towards the
front panel; and folding the second top panel towards the front
panel such that the second top panel and the second bottom panel
define substantially parallel planes; the steps performed after the
step of securing the glue flap.
12. A method according to claim 11, wherein the blank provided
includes: a first top flap connected to a top edge of the first
side panel; and the step of folding further comprises: folding the
first top flap against the second top panel; and securing the first
top flap to the second top panel; the steps performed after the
step of folding the second top panel.
13. A method according to claim 12, wherein the blank provided
includes: a first bottom flap connected to a bottom edge of the
first side panel; and a second bottom flap connected to a bottom
edge of the first side panel; and the step of folding further
comprises: folding the first and second bottom flaps against the
second bottom panel; and securing the first and second bottom flaps
to the second bottom panel; the steps performed after the step of
securing the first top flap.
14. A method according to claim 13, wherein the step of folding
further comprises: folding the first bottom panel against the
second bottom panel, first bottom flap, and second bottom flap; and
securing the first bottom panel to the second bottom panel such
that the first and second bottom flaps are secured between the
first and second bottom panels; the steps performed after the step
of securing the first and second bottom flaps.
15. A method according to claim 14, wherein the blank provided
includes: an opening defined by the first top panel; and an opening
defined by the second top panel; wherein the step of folding
further comprises: folding the first top panel against the second
top panel and first top flap such that the openings in the first
and second top panels are in communication; and securing the first
top panel to the second top panel such that the first top flap is
secured between the first and second top panels; the steps
performed after the step of securing the first bottom panel.
16. A method according to claim 15, wherein the step of folding
further comprises: folding the pour spout flap against the first
top panel; and securing the pour spout flap to the first top panel
to thereby releasably seal the openings in the first and second top
panels; the steps performed after the step of securing the first
top panel.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a packaging blank. In particular,
the invention relates to a packaging blank for use in automated
processes that is capable of forming a reclosable container having
an integral pour spout that is reclosable. The invention further
relates to a reclosable container formed from the blank having a
tab lock that releasably engages an integral pour spout. Still
further, the invention relates to a method of forming from the
blank a container having enhanced sealing qualities.
BACKGROUND OF THE INVENTION
[0002] As known to those skilled in the art, packaging is typically
formed from packaging blanks, or blanks for short. It will be
understood that as used herein the term "blank" may include
cardboard, rigid paper, flexible plastic, or similar products made
of paperboard or plastic. In particular, the packaging industry
favors the use of one-piece flexible blanks, which are readily
incorporated into automated processes for forming containers.
[0003] Today, the initial construction of packaging blanks into
containers is managed in the facilities of the blank manufacturer.
For example, the blanks are formed and then at least one flap
(e.g., a glue flap) is secured to at least one panel of the blank
during a folding step. The steps accomplished form a substantially
flat container that is capable of being formed into a substantially
rectangular container. The flat, partially-constructed container is
preferred for shipping purposes (i.e., space saving efficiencies
for transportation). The subsequent insertion of articles to be
packaged in the container is typically managed in the facilities of
the article manufacturer.
[0004] Manufacturers employ a variety of automated equipment that
is capable of folding the blank to form a container, inserting
articles into the container, sealing the container, and then
shipping the container by various means of transportation. For
example, manufacturers use in-line processes for accomplishing the
steps of folding, inserting, sealing, and shipping as described
above. For the sake of economic efficiencies, manufacturers prefer
the use of paperboard blanks during automated processes. Thus,
there is a need for providing a packaging blank that is capable of
being formed into a container in automated processes (e.g., in-line
processes).
[0005] The rising popularity of blanks capable of forming
containers having integral pour spouts has created a problem for
manufacturers. These types of containers are most suitable for
packaging foodstuffs such as cereals, baby formula, and other
granular type products. Known containers having reclosable pour
spouts are formed from paperboard blanks and additional mediums
such as plastic or metal. Specifically, the paperboard blanks form
the container structure and plastic, for example, forms the pour
spout. Unfortunately, the requirement of mediums other than
paperboard increases the costs of production for manufacturers.
Stated differently, manufacturers must purchase additional material
to form the pour spout instead of relying on paperboard. Thus,
there is a need for a blank formed solely of, for example,
paperboard that is capable of forming a container having an
integral pour spout.
[0006] Moreover, the requirement for integrating additional mediums
into a paperboard blank to form a pour spout creates numerous
problems for manufacturers that incorporate in-line processes. The
incorporation of, for example, a plastic pour spout into the blank
requires that the manufacturer modify existing equipment to account
for the additional step of securing the plastic pour spout to the
blank. In other words, the manufacturer must incorporate additional
equipment along the processing line to secure the plastic pour
spout to the paperboard blank.
[0007] The modification of existing equipment is time consuming and
expensive. Existing in-line processes incorporate machines that are
capable of folding substantially rectangular paperboard blanks to
form the container. The plastic pour spout often requires the
incorporation of a plastic support panel that extends beyond the
substantially rectangular shape of known blanks. Thus, there is a
further need for a packaging blank capable of forming a container
having an integral pour spout, wherein the blank is substantially
rectangular and capable of being used on existing in-line
equipment. Stated differently, there is a need for a paperboard
blank having an integral spout that is "machine blind".
[0008] As noted, containers having pour spouts are most suitable
for packaging foodstuffs such as cereals and other granular type
products. Known containers fail to provide a sift-proof seal, thus
permitting the articles (e.g., dry baby cereal) in the container to
spill out of the container at the sealed ends. Thus, there is a
need for a container having a reclosable pour spout that provides
superior sealing characteristics.
[0009] Further, the addition of the pour spout requires that
manufacturers incorporate an additional step to the in-line
process, wherein the additional step includes securing the spout
formed of additional mediums (e.g., plastic) during the method of
forming the container. Thus, there is still a further need for a
method of packaging articles in a container having a reclosable
pour spout, wherein the method is conducted along existing in-line
processes.
[0010] Likewise, there exists a need for a method of forming a
container having a reclosable pour spout where the container is
substantially flat, yet capable of being constructed into a
substantially rectangular container, wherein the blank is suitable
for use on in-line processes.
[0011] Advantageously, the present invention provides a blank
capable of forming a container having a reclosable pour spout, and
a method of forming such a container that increases the economies
of manufacturing (i.e., no additional steps) and economies of
material (i.e., no additional medium).
OBJECT AND SUMMARY OF THE INVENTION
[0012] It is therefore an object of the present invention to
provide a blank suitable for use in automated processing.
[0013] Still another object of the invention is the provision of a
blank formed solely of paperboard that is capable of forming a
container having a reclosable pour spout.
[0014] A further object of the invention is to provide a packaging
blank capable of forming a container having an integral pour spout,
wherein the blank is substantially rectangular such that the blank
is capable of being used on existing in-line equipment (i.e., a
machine blind blank).
[0015] Another object of the invention is the provision of a
container having a reclosable pour spout that provides superior
sealing characteristics.
[0016] Yet another object of the invention is the provision of a
method of packaging articles in the container along existing
in-line processes.
[0017] Still another object of the invention is the provision of a
method for forming a container having a reclosable pour spout
suitable for use on in-line processes where the container is
substantially flat, yet capable of being constructed into a
substantially rectangular container.
[0018] The invention meets these objectives with a packaging blank
capable of forming a reclosable container. In particular, the
invention is a packaging blank and a container having a bottom
panel, a first side panel, a second side panel, a front panel, a
rear panel, at least one top panel, and a reclosable pour spout.
Moreover, the invention is a method of packaging articles in a
container having a reclosable pour spout and a method of forming a
container having a reclosable pour spout.
[0019] The foregoing and other objects and advantages of the
invention and the manner in which the same are accomplished will
become clearer based on the following detailed description taken in
conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of a container formed from a
preferred embodiment of the packaging blank.
[0021] FIG. 2 is a fragmentary top plan view of the container
formed from a preferred embodiment of the packaging blank.
[0022] FIG. 3 is a fragmentary perspective view of the container
formed from a more preferred embodiment of the packaging blank
depicting removal of the detachable pour spout tab.
[0023] FIG. 4 is a fragmentary perspective view of the container
formed from the more preferred embodiment of the packaging blank
depicting deformation of the front and rear panels to thereby form
the pour spout.
[0024] FIG. 5 is a fragmentary perspective view of the container
formed from the more preferred embodiment of the packaging blank
depicting articles packaged in the container flowing through
openings in the first and second top panels and over the pour
spout.
[0025] FIG. 6 is a fragmentary top plan view of the container
formed from the more preferred embodiment of the packaging blank
taken along lines 6-6 in FIG. 5.
[0026] FIG. 7 is a fragmentary perspective view of container formed
from the more preferred embodiment of the packaging blank depicting
the tab lock releasably engaging the pour spout.
[0027] FIG. 8 is a top plan view of the preferred embodiment of the
packaging blank.
[0028] FIGS. 9A-9D are perspective views of a method for forming
the container that incorporates the preferred embodiment of the
packaging blank.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings, in which a
preferred embodiment of the invention is shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout.
[0030] As used herein, the term "panel" is used in conjunction with
the packaging blank of the present invention and refers to the
major component part of a folding container and defines the major
partition elements of the blank or container. Those skilled in the
art typically refer to panels that form the top or bottom of a
container as a "major panel." In addition, it will be understood
that the term "product panel" may refer to either the front panel
or rear panel. Those skilled in the art will also appreciate that
panels include edges defined as the line of intersection of two
surfaces or a border. A "free edge" of a panel refers to an edge
that does not intersect with another surface or panel.
[0031] The term "flap" refers to a secondary container element that
is typically hinge-connected along a free edge of a panel or
another flap. Those skilled in the art typically refer to flaps
that form, for example, dust flaps, as "minor panels." It will be
understood that the term "tab" refers to a tertiary element of the
blank or container that is generally hinged to a portion of a free
edge of a panel or flap, or struck from within the plane of a panel
or flap. As used herein, the term "residual" refers to an element
(e.g., a pour spout) resulting from a particular step of removing
an adjacent element (e.g., a tab).
[0032] It will be further understood by those skilled in the art
that the dimensions, or measurements for containers will be
expressed in the order of length (L), width (W), and depth (D),
wherein L is typically the larger dimension at the open end of the
container, W is usually the smaller dimension at the open end of
the container, and D is the distance between the open ends of the
container (e.g., L.times.W.times.D).
[0033] Further, it will also be understood by those of skill in the
art that as used herein, the concept of a panel being "between" two
other panels does not necessarily imply that the three panels or
flaps are contiguous (i.e., in intimate contact). Rather, as used
herein, the concept of one panel being between two other panels is
meant to describe the relative positions of the panels within the
blank structure, respectively.
[0034] Similarly, the concept of a first panel being connected to a
second panel by a third panel, "opposite" the second panel, merely
describes the relative positions of the first and second panels
within the blank structure. It will further be understood that the
term "finished" means coated with a material to produce an
attractive glossy finish. The term "finished" will also be
understood to mean the inclusion of printed material or other
identifying indicia (e.g., a company's logo).
[0035] It will be understood by those skilled in the art that the
term "cut-score" refers to an impression formed by a cutting tool
(e.g., a punch, die, or blade) that extends partially through a
sheet of paperboard or the like. It will be understood by those
skilled in the art that the term "perforations" refers to a series
of holes or impressions formed by a cutting tool (e.g., a punch or
die) that permits easy separation of, for example, panels. It will
be further understood to those skilled in the art that the term
"score lines" refers to a crease along which the adjacent elements
of a blank are folded without cracking or breaking to form a
container. Those skilled in the art will also appreciate that the
term "glue release section" refers to a portion of, for example, a
first panel to which an adhesive is applied such that a second
panel can be secured against the panel having the glue release
section and bearing the adhesive.
[0036] It will also be understood that the term "substantially
rectangular" and "substantially trapezoidal" is meant to succinctly
describe a simple geometric shape approximating a rectangle and
trapezoid, respectively. Similarly, the term "substantially
parallel" is meant to describe the spatial relationship between,
for example, one edge of a panel to another edge of a panel,
wherein the relationship is approximately parallel. The term
"substantially polygonal" is meant to describe a simple geometric
shape approximating a closed plane figure bounded by straight
lines.
[0037] Those skilled in the art will also appreciate that the term
"adjacent" refers to two or more, for example, panels that have a
common border or are in close proximity to one another.
Nevertheless, it will be understood that adjacent may or may not
imply contact, but always implies the absence of anything of the
same kind in between. Furthermore, as used herein, it will be
understood that the term "article" will refer primarily to consumer
products that are packaged for shipment (e.g., consumables,
detergents, granular products, etc.). It will be understood,
however, that "article" may also refer to any number of goods such
as individually packaged consumables.
[0038] An overall view of a preferred embodiment of a packaging
blank 10 capable of forming a reclosable container 17 which
incorporates features of the present invention is set forth in FIG.
8. As depicted in FIG. 8, the packaging blank 10 includes a front
panel 11, a first side panel 12, a second side panel 13, a rear
panel 14, a first top panel 15, a second top panel 16, a first
bottom panel 20, a second bottom panel 21, a pour spout flap 22, a
residual pour spout 23, a detachable pour spout tab 30, a pull tab
42, a first top flap 24, a first bottom flap 25, and a second
bottom flap 26. The blank 10 is preferably a one-piece blank made
of paperboard.
[0039] With reference to FIG. 8 depicting the blank 10, the front
panel 11 includes opposing first and second side panels 12,13. The
rear panel 14 is connected to the front panel 11 by the second side
panel 13. The first top panel 15 is connected to a top edge of the
front panel 11, and the second top panel 16 is connected to a top
edge of the rear panel 14. It will be understood that the blank 10
may include only one top panel 15 that is connected to the top edge
of the front panel 11.
[0040] The first bottom panel 20 is connected to a bottom edge of
the front panel 11. As configured, the first top panel 15 and the
first bottom panel 20 are connected to opposing edges of the front
panel 11. The second bottom panel 21 is connected to a bottom edge
of the rear panel 14 such that the second bottom panel and the
second top panel 16 are connected to opposing edges of the rear
panel. It will be understood that the blank 10 may include only one
bottom panel 20 that is connected to the bottom edge of the front
panel 11.
[0041] The pour spout flap 22 is connected to a top edge of the
second side panel 13 and includes the detachable pour spout tab 30,
the residual pour spout 23, and the pull tab 42. The pull tab 42
and detachable pour spout tab 30 define free edges of the pour
spout flap 22. Specifically, the pour spout flap 22 is positioned
between the first top panel 15 and second top panel 16. More
specifically, the pour spout tab 30 is positioned at a free edge of
the pour spout flap 22. Advantageously, the blank 10 is capable of
being folded such that a portion of the top panel 15 releasably
engages the residual pour spout 23 when the pour spout tab 30 is
detached from the pour spout flap 22. More specifically, a tab lock
31 (discussed herein) provided in the first top panel 15 engages
the residual pour spout 23. Stated differently, the removal of the
detachable pour spout tab 30 permits the first top panel 15
(specifically, the tab lock 31) to releasably engage the pour spout
23 when the pour spout is closed. As depicted in FIGS. 3 and 7,
removal of the detachable pour spout tab 30 permits the opening and
closing of the residual pour spout 23 upon construction of the
container 17.
[0042] The preferred embodiment of the blank 10 also provides a
pour spout flap 22 that includes the pull tab 42 positioned at a
free edge of the pour spout flap. Specifically, the pull tab 42 is
connected to the detachable pour spout tab 30. The pull tab 42
facilitates the removal of the detachable pour spout tab 30 from
the pour spout flap 22 upon construction of the container 17. As
depicted in FIGS. 1 and 2, the pull tab 42 permits a user to grasp
a portion of the pour spout flap 22 and remove the detachable pour
spout tab 30 from the first top panel 15. The pull tab 42 is
defined by a score line 38 in the pour spout flap 22 as shown in
FIG. 8. Specifically, the score line 38 defining the pull tab 42
extends from an edge of the pour spout flap 22 adjacent to the
first top panel 15 to an edge of the pour spout flap adjacent to
the second top panel. Thus, a preferred embodiment of the blank 10
includes a pour spout flap 22 consisting of the detachable pour
spout tab 30, the residual pour spout 23, and the pull tab 42.
[0043] In the preferred embodiment of the blank 10 including the
first top panel 15 and second top panel 16, the blank 10 is capable
of being folded such that the residual pour spout 23 is releasably
secured between the first and second top panels when the detachable
pour spout tab 30 is removed from the pour spout flap 22. As
specifically depicted in FIG. 7, the pour spout 23 is closed (i.e.,
folded downward) and situated between the first and second top
panels 15, 16.
[0044] The blank 10 also includes an external planar side 33 and an
internal planar side 32 as shown in FIG. 8. For advertising and
promotional considerations, the external planar side 33 is
preferably finished (i.e., includes printed material or related
identifying indicia).
[0045] In the preferred embodiment of the blank 10, the front panel
11, rear panel 14, first top panel 15, second top panel 16, first
bottom panel 20, and second bottom panel 21 are substantially
rectangular. The first top flap 24, and first and second bottom
flaps 25, 26 are preferably trapezoidal in shape. Nevertheless, it
will be understood that the front panel 11, rear panel 14, first
and second top panels 15, 16, and first and second bottom panels
20, 21 are not limited to a rectangular shape and may be
trapezoidal in shape. It will also be understood that the first top
flap 24, and first and second bottom flaps 25, 26 are not limited
to a trapezoidal shape and may be triangular or rectangular in
shape.
[0046] In a more preferred embodiment, the first top panel 15 of
the blank 10 defines an opening 34 adjacent to the pour spout flap
22. See FIG. 3. The second top panel 16 may likewise define an
opening 35 adjacent to the pour spout flap 22. In this more
preferred embodiment, the first top panel opening 34 and the second
top panel opening 35 are in communication upon construction of the
container 17. This configuration permits articles 18 to flow freely
from the container 17.
[0047] Referring to FIGS. 3-6, the first top panel 15 includes a
tab lock 31 that is positioned adjacent to the first top panel
opening 34. The tab lock 31 is spaced apart from the pour spout
flap 22 such that the tab lock may releasably engage a portion of
the pour spout flap (i.e., residual pour spout 23) upon
construction of the container 17. See FIG. 7.
[0048] A preferred embodiment of the blank 10 provides a first top
panel 15 that includes an optional detachable sealing tab 40 as
illustrated in FIGS. 2 and 8. The sealing tab 40 occupies the first
top panel opening 34 and provides an additional barrier to prevent
packaged articles 18 from exiting the sealed container 17.
Specifically, the optional sealing tab covers the opening 35 in the
second top panel 16 upon construction of the container 17 as
illustrated in FIG. 2. Stated differently, removal of the sealing
tab 40 forms the first top panel opening 34 as shown more clearly
on the right side of FIG. 2. The sealing tab 40 is connected to the
first top panel 15 by perforations 36. Stated differently, the
detachable sealing tab 40 is formed by perforations 36 in the first
top panel 15. The sealing tab 40 is positioned at a free edge of
the top panel 15 adjacent to the pour spout flap 22. In this
preferred embodiment, the tab lock 31 of the first top panel 15 and
the sealing tab 40 are each defined by perforations 36 in the blank
10. Accordingly, the tab lock 31 is positioned adjacent to the
detachable sealing tab 40. The tab lock 31 is likewise spaced apart
from the pour spout flap 22 such that removal of the detachable
sealing tab 40 permits the tab lock 31 to releasably engage at
least a portion of the pour spout flap 22 (i.e., residual pour
spout 23) upon construction of the container 17 as shown in FIG.
7.
[0049] The first top panel 15 of the preferred embodiment of the
blank 10 may include at least one glue release section 41 formed by
a partial cut 37 in the blank 10. The glue release section 41 is
preferably circular in shape, but may include any number of shapes
(e.g., rectangular). The glue release section 41 is positioned to
secure the pour spout flap 22 to the first top panel 15 upon
construction of the sealed container 17. As illustrated in FIGS. 1,
2, and 9C-9D, the glue release section 41 supports adhesion of the
detachable pour spout tab 30 to the first top panel 15 as discussed
herein with reference to the container 17 formed from the blank
10.
[0050] Referring to FIGS. 3 and 4, the pour spout flap 22 and the
second side panel 13 include score lines 38 that facilitate the
formation of the residual pour spout 23 upon construction of the
container 17. Stated differently, the score lines 38 promote
deformation of the pour spout 23 and second side panel 13 to
readily configure the pour spout for pouring operations. See FIG.
5.
[0051] The detachable pour spout tab 30 and the pour spout 23 are
defined by perforations 36 in the pour spout flap 22 such that
removal of the detachable pour spout tab forms the residual pour
spout. In a preferred embodiment, the residual pour spout 23 is
substantially polygonal in shape. More preferably, the pour spout
23 is polygonal in shape, wherein at least two edges define
substantially parallel edges. As depicted in FIG. 6, the residual
pour spout 23 includes a distal edge that forms an apex of the pour
spout. It will be understood, however, that the pour spout 23 may
be substantially triangular in shape.
[0052] With reference to FIG. 8, the first top flap 24 of the blank
10 is connected to a top edge of the first side panel 12 and
positioned adjacent to the first top panel 15. Embodiments of the
blank 10 are provided to enhance the seals formed at the joints of
the container 17 (e.g., top and bottom). Specifically, in a
preferred embodiment, a portion 43 of the second top panel 16 is
debossed (i.e., lowered) such that the first top flap 24
correspondingly engages the debossed portion of the second top
panel upon construction of the container 17 to thereby form a
sift-proof seal.
[0053] First and second bottom flaps 25, 26 are also provided to
enhance the structural integrity of the container 17. The first
bottom flap 25 is connected to a bottom edge of the first side
panel 12 and positioned adjacent to the first bottom panel 20. The
second bottom flap 26 is connected to a bottom edge of the second
side panel 13 and positioned between the first and second bottom
panels 20, 21.
[0054] Portions 44 of the first bottom panel 20 are preferably
embossed (i.e., raised) such that the first and second bottom flaps
25, 26 correspondingly engage the embossed portions of the first
bottom panel upon construction of the container 17 to thereby form
a sift-proof seal. In similar fashion, portions 45 of the second
bottom panel 21 are debossed such that the first and second bottom
flaps 25, 26 correspondingly engage the debossed portions of the
second bottom panel upon construction of the container 17 to
thereby form a sift-proof seal. As configured upon construction,
the corresponding engagement of the first top flap 24 with the
debossed portion 43 of the second top panel 16, and the
corresponding engagement of the first and second bottom flaps 25,
26 with the respective embossed and debossed portions 44, 45 of the
first and second bottom panels 20, 21 advantageously provides a
sift-proof sealed-end container 17 superior to known
containers.
[0055] With respect to an alternative embodiment of the blank, it
will be understood that the portions 44 of the first bottom panel
20 may be debossed and the portions 45 of the second bottom panel
21 may be embossed.
[0056] The packaging blank 10 also includes a glue flap 50 (also
referred to as a manufacturer's glue joint) connected to an edge of
the rear panel 14 opposite the edge to which the second side panel
13 is connected. The glue flap 50 is preferably rectangular in
shape. It will be understood, however, that the glue flap 50 is not
limited to a rectangular shape and may be trapezoidal in shape.
[0057] Another aspect of the present invention, as illustrated in
FIG. 1, includes a container 17 having an integral pour spout 23
formed from the packaging blank 10. The container 17 includes the
various elements of the blank 10 as described above. For the sake
of clarity, however, the blank elements are described below as
incorporated into the various embodiments of the container 17.
Specifically, a preferred embodiment of the container 17 includes a
first bottom panel 20, a second bottom panel 21, a first side panel
12, a second side panel 13, a front panel 11, a rear panel 14, a
first top panel 15, a second top panel 16, a pour spout flap 22, a
pull tab 42, a detachable pour spout tab 30, a residual pour spout
23, a first top flap 24, a first bottom flap 25, and a second
bottom flap 26. The container 17 is preferably formed from a
one-piece blank 10 made of paperboard. It will be understood that
the container 17 may include only one top panel and one bottom
panel.
[0058] In the preferred embodiment of the container 17, the second
bottom panel 21 is secured to an internal planar side 32 of the
first bottom panel 20 such that both panels define substantially
parallel planes. The first and second side panels 12, 13 are
likewise secured to opposing edges of the bottom panel 20 such that
the side panels define substantially parallel planes. The front
panel 11 is secured to the bottom panel 20 and the respective edges
of the first and second side panels 12, 13. The rear panel 14 is
secured to the bottom panel 20 and to respective edges of the first
and second side panels 12, 13. As configured, the front panel 11
and rear panel 14 define substantially parallel planes.
[0059] The first top panel 15 is secured to respective edges of the
front panel 11 and rear panel 14. As depicted in FIG. 6, the first
top panel 15 defines an opening 34 that is adjacent to a top edge
of the second side panel 13. In a preferred embodiment, the first
top panel 15 includes a tab lock 31 positioned adjacent to the
opening 34 in the first top panel 15 and spaced apart from the top
edge of the second side panel 13. See FIG. 6. Advantageously, the
opening 34 in the first top panel 15 is positioned adjacent to the
pour spout 23 such that the tab lock 31 engages the pour spout upon
closure. The closed configuration seals the opening in the first
top panel 15. See FIG. 7.
[0060] As illustrated in FIG. 2, the first top panel 15 may also
include the detachable sealing tab 40 that occupies the first top
panel opening 34 and covers the second top panel opening 35 upon
construction of the container 17. The sealing tab 40 is connected
to the first top panel 15 by perforations 36 and positioned
adjacent to the tab lock 31. Accordingly, the removal of the
detachable sealing tab 40 permits the tab lock 31 to releasably
engage the pour spout as shown in FIG. 7. Specifically, the tab
lock 31 engages the pour spout 23 once the detachable pour spout
tab 30 is removed (i.e., detached) from the first top panel 15 and
the pour spout flap 22.
[0061] Referring to FIGS. 2-4, at least one glue release section 41
is provided in the first top panel 15 of the container 17. The glue
release section 41 is formed by a partial cut 37 and supports
adhesion of the detachable pour spout tab 30 to the first top panel
15 during initial construction. The glue release section 41 secures
the detachable pour spout tab 30 to the first top panel 15 with an
adhesive for shipping purposes once the container is formed and
filled with articles 18. During operation of the pour spout 23
(i.e., removal of the detachable pour spout tab 30), the glue
release section 41 is separated from the first top panel 15 when
the detachable pour spout tab 30 is detached from the first top
panel and the pour spout is opened.
[0062] As depicted in FIG. 2, the detachable sealing tab 40 is
optional and may be positioned between the pour spout flap 22 and
an opening 35 in the second top panel 16 such that removal of the
detachable pour spout tab 30 and the detachable sealing tab 40
permits a flow of articles 18 from the container 17 as illustrated
in FIG. 5.
[0063] The second top panel 16 is secured to an internal planar
side 32 of the first top panel 15 such that the first and second
top panels 12, 13 define substantially parallel planes. Preferably,
the second top panel 16 defines an opening 35 that is in
communication with the first top panel opening 34. In particular,
the opening 35 in the second top panel 16 is positioned adjacent to
the top edge of the second side panel 13. Advantageously, a portion
43 of the second top panel 16 positioned adjacent to the first side
panel 12 is debossed such that the first top flap 24
correspondingly engages the debossed portion to thereby form a
sift-proof seal.
[0064] The pour spout flap 22 is secured to the top edge of the
second side panel 13. The pour spout flap 22 includes the
detachable pour spout tab 30 and the residual pour spout 23. The
detachable pour spout tab 30 and pour spout 23 are defined by
perforations 36 and positioned adjacent to one another. In a
preferred embodiment, the pour spout flap 22 includes the pull tab
42 connected to the detachable pour spout tab 30. The pull tab 42
facilitates the removal of the detachable pour spout tab 30 from
the first top panel 15 and the pour spout flap 22. The pull tab 42
is defined by at least one score line 38 in the pour spout flap
22.
[0065] The first top flap 24 of the container 17 is connected to a
top edge of the first side panel 12. Specifically, the first top
flap 24 is secured between the first and second top panels 15, 16.
The first bottom flap 25 is connected to a bottom edge of the first
side panel 12 and secured between the first and second bottom
panels 20, 21. The second bottom flap 26 is connected to a bottom
edge of the second side panel 13 such that the second bottom flap
26 is secured between the first and second bottom panels 20, 21. As
discussed above, the first top flap 24 correspondingly engages the
debossed portion 43 of the second top panel 16 to thereby provide a
sift-proof seal in the container.
[0066] Portions 44 of the first bottom panel are embossed to
enhance the quality of the seal in the container 17. As
constructed, the first and second bottom flaps 25, 26
correspondingly engage the embossed portions 44 of the first bottom
panel 20 to form a sift-proof seal. In a similar fashion, portions
45 of the second bottom panel 21 are debossed such that the first
and second bottom flaps 25, 26 correspondingly engage the debossed
portions of the second bottom panel to form a sift-proof seal. The
construction of the container permits corresponding engagement of
the first top flap 24 with the debossed portion 43 of the second
top panel 16. The container further permits the corresponding
engagement of the first and second bottom flaps 25, 26 with the
respective embossed and debossed portions 44, 45 of the first and
second bottom panels 20, 21. In this fashion, the present invention
provides a sift-proof sealed-end container 17 superior to known
containers.
[0067] In a more preferred embodiment of the container 17, portions
44 of the first bottom panel 20 are embossed and portions 45 of the
second bottom panel 21 are debossed. Preferably, the portions 44,
45 are positioned at opposing edges of the respective bottom panels
20, 21. As configured, the first and second bottom flaps 25, 26
correspondingly engage the respective embossed edge portions 44 of
the first bottom panel 20 and the respective debossed edge portions
45 of the second bottom panel 21 during construction of the
container 17. This more preferred embodiment of the container
enhances the sift-proof qualities of the seal.
[0068] Score lines 38 are provided in the pour spout flap 22 and
the second side panel 13 to facilitate the deformation of the front
panel 11, rear panel 14, and second side panel. See FIG. 4. The
score lines facilitate extension of the pour spout 23 to thereby
permit articles 18 in the container 17 to flow through the first
and second top panel openings 34, 35. In other words, the score
lines 38 permit the opening and closing of the pour spout 23.
Further, the score lines 38 permit deformation of the front panel
11, rear panel 14, and second side panel 13 to thereby release the
pour spout 23 from the tab lock 31.
[0069] In the preferred embodiment of the container 17, the front
panel 11, rear panel 14, first top panel 15, second top panel 16,
first bottom panel 20, second bottom panel 21, first side panel 12,
and second side panel 13 are substantially rectangular. The first
top flap 24 and first and second bottom flaps 25, 26 of the
container 17 are preferably trapezoidal in shape. Nevertheless, it
will be understood that the front panel 11, rear panel 14, first
and second top panels 15, 16, first and second bottom panels 20,
21, and first and second side panels 12, 13 are not limited to a
rectangular shape and may be trapezoidal in shape. The rectangular
shape of the panels ensures the substantially rectangular shape of
the container 17. It will also be understood that the first top
flap 24, and first and second bottom flaps 25, 26 are not limited
to trapezoidal shape and may be triangular or rectangular in
shape.
[0070] Another aspect of the invention provides for a method of
packaging articles 18 into a container 17 having a reclosable pour
spout 23 that incorporates the preferred blank 10. Referring to
FIGS. 9A-9D, the method of packaging includes the steps of
providing a one-piece flexible blank 10, folding the blank to form
a container 17 having an internal packaging compartment, and then
positioning articles 18 to be packaged in the packaging
compartment. Advantageously, the container 17 is substantially flat
during the initial steps of the method, yet capable of being
constructed into a substantially rectangular container. Thus, the
container manufacturer may accomplish the initial step of forming a
container, and then ship the container in its flat form to the
article manufacturer (i.e., packager). By doing so, the container
manufacturer enhances transportation efficiencies because the flat
container minimizes required shipping space.
[0071] The preferred embodiment of the one-piece flexible blank 10
provided includes a front panel 11, first and second side panels
12, 13 connected to opposing edges of the front panel, and a rear
panel 14 connected to the front panel by the second side panel 13.
The blank 10 provided further includes a first bottom panel 20
connected to a bottom edge of the front panel 11, a second bottom
panel 21 connected to a bottom edge of the rear panel 14, a glue
flap 50 connected to an edge of the rear panel 14 opposite the edge
to which the second side panel 13 is connected, and a pour spout
flap 22 connected to a top edge of the second side panel 13.
[0072] Upon providing the blank 10, the rear panel 14 is folded
over the front panel 11, and the glue flap 50 is secured to an edge
of the first side panel 12 as depicted in FIG. 9A. The glue flap 50
is secured such that the rear panel 14 and front panel 11, and the
first side panel 12 and second side panel 13 define substantially
parallel planes, respectively.
[0073] Advantageously, the present method of packaging provides for
the formation of a container having greater sealing qualities as
compared to known containers. Those skilled in the art will
appreciate that known methods of forming a container typically
include folding the minor panels toward the packaging compartment,
and then folding the major flaps against the minor panels to form a
seal. In the present invention, the first top panel 15, second top
panel 16, first bottom panel 20, and second bottom panel 21
correspond to the major panels. Further, the first top flap 24,
first bottom flap 25, and second bottom flap 26 of the present
invention correspond to the minor panels. As described herein, the
present method reverses the known method of folding the minor
panels first and then folding the major panels against the minor
panels. Stated differently, the present method of forming the
container is referred to as "reversing the minor".
[0074] Specifically, the present method provides the initial step
of folding two major panels (i.e., second bottom panel 21 and
second top panel 16) downward, and a subsequent step of folding the
minor panels (i.e., first top flap 24, first bottom flap 25, and
second bottom flap 26) against the two previously folded major
panels. The present method also provides a further step of folding
two additional major flaps (i.e., first bottom panel 20 and first
top panel 15) against the minor panels (i.e., first top flap 24,
first bottom flap 25, and second bottom flap 26) and the previously
folded major panels (i.e., second bottom panel 21 and second top
panel 16).
[0075] The present method of stepwise folding a major panel,
folding a minor panel against the major panel, and then folding
another major panel against the minor panel, provides a container
17 having a sift-proof seal at each closed end that surpasses the
sealing qualities of known containers. Moreover, the corresponding
engagement of the first top flap 24 with the debossed portion 43 of
the second top panel 16, and the corresponding engagement of the
first and second bottom flaps 25, 26 with the respective embossed
and debossed portions 44, 45 of the first and second bottom panels
20, 21 as provided in the blank incorporated into the present
method further promotes the sealing qualities of the container.
[0076] The present method as described below will refer to the
elements claimed herein (e.g., first top panel 15 and first top
flap 24) as opposed to major panels and minor panels.
[0077] The blank 10 provided may also include a first bottom flap
25 connected to a bottom edge of the first side panel 12, and a
second bottom flap 26 connected to a bottom edge of the second side
panel 13.
[0078] Once the glue flap 50 is secured to the edge of the first
side panel 12 of the blank 10 provided, the second bottom panel 21
is folded towards the front panel 11. Next, the first and second
bottom flaps 25, 26 are folded against the second bottom panel 21
and secured to the second bottom panel.
[0079] Upon securing the first and second bottom flaps 25, 26 to
the second bottom panel 21, the first bottom panel 20 is folded
against the second bottom panel, first bottom flap 25, and second
bottom flap 26. Thereafter, the first bottom panel 20 is secured to
the second bottom panel 21 such that the first bottom flap 25 and
second bottom flap 26 are secured between the first and second
bottom panels.
[0080] The next step of the preferred method includes positioning
articles 18 to be packaged in the packaging compartment of the
container 17. This step may be accomplished along an in-line
process.
[0081] The preferred method of packaging may also include the step
of forming a reclosable pour spout 23 after articles 18 are
positioned in the container 17. When incorporating the step of
forming the pour spout 23 into the present method, the blank 10
provided may further include a first top panel 15 connected to a
top edge of the front panel 11, a second top panel 16 connected to
a top edge of the rear panel 14, and a first top flap 24 connected
to a top edge of the first side panel 12. The first top panel 15
includes an opening 34 adjacent to the pour spout flap 22, and the
second top panel 16 likewise includes an opening 35 adjacent to the
pour spout flap.
[0082] Referring to FIGS. 9A-9B, the step of forming the reclosable
pour spout 23 includes folding the second top panel 16 towards the
front panel 11, folding the first top flap 24 against the second
top panel, and securing the first top flap to the second top panel.
The second top panel 16 is folded toward the front panel 11 such
that the second top panel and the first and second bottom panels
20, 21 define substantially parallel planes.
[0083] After securing the first top flap 24 to the second top panel
16, the first top panel 15 is folded against the second top panel
and first top flap. See FIG. 9C. The first top panel 15 is folded
such that the openings 34, 35 in the first and second top panels
15, 16 are in communication. The blank 10 depicted in FIGS. 9A-9D
includes the optional sealing tab 40 that occupies the opening 34
in the first top panel 15 and covers the opening 35 in the second
top panel 16 upon construction of the container 17. It will be
understood, however, the same steps are incorporated into the
preferred method whether or not the sealing tab 40 is included in
the blank 10. Next, first top panel 15 is secured to the second top
panel 16 such that the first top flap 24 is secured between the
first and second top panels.
[0084] The final steps of packaging according to the preferred
method are accomplished after the step of securing the first top
panel 15 to the second top panel 16. Specifically, with reference
to FIG. 9D, the step of folding also includes folding the pour
spout flap 22 against the first top panel 15 and securing the pour
spout flap against the first top panel 15. The pour spout flap 22
is secured against the first top panel 15 such that removal of the
pour spout flap from the first top panel permits the articles 18 in
the container 17 to flow through the openings 34, 35 in the first
and second top panels 15, 16.
[0085] The present invention also provides for a method of forming
a container 17 having a reclosable pour spout 23 and enhanced
sealing qualities. The preferred method includes the steps of
providing a preferred embodiment of the blank 10 and folding the
blank to form a container 17 having a reclosable pour spout 23. The
resulting container 17 is substantially flat, yet capable of being
constructed into a substantially rectangular container.
[0086] The preferred embodiment of the blank 10 provided is a
one-piece flexible blank having a front panel 11, first and second
side panels 12, 13 connected to opposing edges of the front panel,
a rear panel 14 connected to the front panel by the second side
panel 13, a first top panel 15 connected to a top edge of the front
panel, and a second top panel 16 connected to a top edge of the
rear panel. The blank 10 provided also includes a first bottom
panel 20 connected to a bottom edge of the front panel 11, a second
bottom panel 21 connected to a bottom edge of the rear panel 14, a
glue flap 50 connected to an edge of the rear panel opposite the
edge to which the second side panel 13 is connected, and a pour
spout flap 22 connected to a top edge of the second side panel.
Still further, the blank 10 provided may include a first top flap
24 connected to a top edge of said first side panel 12, a first
bottom flap 25 connected to a bottom edge of the first side panel,
an opening 34 defined by the first top panel 15, an opening 35
defined by the second top panel 16, and a second bottom flap 26
connected to a bottom edge of the first side panel.
[0087] The step of folding the blank 10 includes folding the rear
panel 14 over the front panel 11, and securing the glue flap 50 to
an edge of the first side panel 12 such that the rear and front
panels 14, 11 and the first and second side panels 12, 13 define
substantially parallel planes, respectively. See FIG. 9A.
[0088] The present method of forming a container likewise provides
for the formation of a container having greater sealing qualities
as compared to known containers. As described above, the present
method reverses the known method of folding the minor panels first
and then folding the major panels against the minor panels.
[0089] Upon securing the glue flap 50 to the first side panel 12,
the second bottom panel 21 is folded towards the front panel 11,
and the second top panel 16 is folded towards the front panel such
that the second top panel and the second bottom panel define
substantially parallel planes.
[0090] After the second top panel 16 is folded toward the front
panel 11, the first top flap 24 is then folded against the second
top panel 16, and the first top flap is secured to the second top
panel. See FIG. 9B. Thereafter, the first and second bottom flaps
25,26 are folded against the second bottom panel 21. Next, the
first and second bottom flaps 25, 26 are secured to the second
bottom panel 21. The steps of folding the first and second bottom
flaps 25, 26 and securing the same to the second bottom panel 21
are performed after the step of securing the first top flap 24 to
the second top panel 16.
[0091] The later steps of folding i.e., after the step of securing
the first and second bottom flaps 25, 26 to the second bottom panel
21 include folding the first bottom panel 20 against the second
bottom panel 26, first bottom flap, and second bottom flap. The
first bottom panel 20 is then secured to the second bottom panel 21
such that the first and second bottom flaps 25, 26 are secured
between the first and second bottom panels.
[0092] The method of forming the container 17 further incorporates
the steps of folding the first top panel 15 against the second top
panel 16 and first top flap 24, and then securing the first top
panel to the second top panel. See FIG. 9B. The step of folding the
first top panel 15 against the second top panel 16 and first top
flap 24 is accomplished such that such that the openings 34, 35 in
the first and second top panels are in communication. The step of
securing the first top panel 15 is performed such that the first
top flap 24 is secured between the first top panel and second top
panel 16.
[0093] Finally, the step of folding incorporates the steps of
folding the pour spout flap 22 against the first top panel 15, and
securing the pour spout flap to the first top panel to thereby
releasably seal the openings 34, 35 in the first and second top
panels 15, 16. See FIGS. 9C-9D.
[0094] In the drawings and specification, there have been disclosed
typical embodiments on the invention and, although specific terms
have been employed, they have been used in a generic and
descriptive sense only and not for purposes of limitation, the
scope of the invention being set forth in the following claims.
* * * * *