Abstract:
A box with a sliding opening has an integral liner to keep pourable contents fresh and dry. The box has a slide that is moveable by a user&#39;s thumb across the opening to open and close the box and the liner during the same operation. The user in one motion can either open the box and the liner to pour out the contents or close the box and the liner so the contents do not spill out. Advantageously, the box is formed from a single blank piece of paper or cardboard stock, and a single planar sheet of moisture impervious material liner is placed onto the blank and folded in a particular sequence such that the slide ends up inside the box for easy assembly with a resulting sealed liner bag inside.

Description:
BACKGROUND 
       [0001]    The present disclosure relates to packaging for pourable materials, and in particular, to a box with a slide opening and an integral liner for containing and dispensing pourable items such as cereal or other foodstuffs. 
         [0002]    A wide range of pourable products such as dry cereals, powdered laundry soap and many others are dispensed in cardboard boxes. To access the contents, a user must generally open the top of the box. Sometimes the contents are held in a wax paper or other plastic-type bag inside the box and that bag must be torn open after opening the box. To store contents and maintain their freshness or dryness and limit exposure to humid ambient air, a user folds over the bag to close the bag and closes the box when possible which typically has an awkward, difficult to manipulate closure, particularly in the case of traditional breakfast cereal boxes. 
         [0003]    Standard cereal boxes are typically delivered in a tube-shaped standard folding carton, partially assembled and collapsed condition. When manufacturing boxes in large quantities, e.g. for mass distributed breakfast cereals, it is preferable to have the box delivered to the end-manufacturer as a folded flat. Automated machinery at the food processor opens up the flat carton, folds and secures top or bottom flaps to form a box with an open end. Next the machinery fills the box with product, and the box is closed to complete packaging. 
         [0004]    Applicant has developed packages of new and differing functionality which offer significant improvements in dispensing product yet maintaining the processing same as standard folding cartons with conventional high speed machinery, over the prior art. Applicant is the named inventor on numerous U.S. patents directed to specialty packaging including U.S. Pat. Nos. 6,116,499, 6,273,332, 6,360,942, 6,435,402, 6,945,449, 7,040,528, 7,156,286 and 7,743,973, and application Ser. No. 12/686,252 filed Jan. 12, 2010. These patents and the pending application show the progression of Applicant&#39;s innovative packaging designs, and how they have evolved to become friendlier to the high-speed form, fill, and seal machines used by major food processing companies in producing hundreds of packages per minute. 
         [0005]    While Applicant&#39;s packages described in existing patents offer many advantages over the prior art, there remains a need for a mass producible box with a sealed bag inside, for storing and maintaining the required liner by cereal MFG companies, while providing dispensing portions of the contents and re-closing the box with ease. The need exists for a box for containing pourable items where the liner bag is conveniently constructed along with the box, and a liner bag inside which can be opened and closed as the box is opened and closed by a convenient slide opener. 
       SUMMARY 
       [0006]    A box having an integral liner containing pourable items, and a method of packaging and dispensing pourable products, such as cereal, is disclosed. A box having an integral liner is formed from a foldable box blank. The foldable box blank has a plurality of sides coupled together, each of the sides corresponding to a side of the box when folded. In one embodiment, the foldable box blank is preferably made of cardboard material. 
         [0007]    A first side of the box blank has a side opening, which serves as the opening through which pourable product will be dispensed. Coupled to the first side opening, a slide allows the box to be opened and closed when the package is used. It is anticipated that the slide may be coupled to the first side prior to assembly, and in this manner, the package may be constructed specifically from a single flat piece of box blank stock. Alternatively, the side opening can be located virtually anywhere on the box convenient for pouring. 
         [0008]    As freshness is a desired characteristic of goods contemplated to be dispensed from the box, a bag substantially sealed inside the box is contemplated as part of the package. In one exemplary embodiment, the bag may be made from a moisture impervious material, including a heat-sealable plastic-type material known to skilled persons for maintaining the freshness and dryness of contained items, or any material which satisfies these purposes. Typically the moisture impervious material substantially covers the box blank prior to assembly of the package. The moisture impervious material has a perforated portion, defining an opening, overlaying the side opening of the box, which may be sealed together. By sealing the openings of the box and bag, a substantially air-tight re-sealable package is produced. The union of the openings also prevents product or other material from lodging between the bag and box. 
         [0009]    Once the box blank and moisture impervious material have been folded into the box and bag, respectively, forming the package, product may be introduced into the package. It is anticipated that product may be introduced during the folding process by leaving one side, in one embodiment a top or bottom side, open for the introduction of product. Once product is introduced into the package, the remaining side may be closed, sealing the package until opened by a user. Glue or a similar adhesive may also be used to attach selected portions of the bag, notably around the opening, to the box blank. Using the integral liner also eliminates the empty corners found in conventional cereal boxes with bags, and thus makes it possible for manufacturers to use smaller boxes saving on paper and the environment. 
         [0010]    Completing the method, to use the package, a user moves the slide opening to expose the bag inside the box. In one embodiment, it is anticipated the slide will have a first portion adapted to slide along the first side of the box, and a second portion adapted to extend away from the box top. It is also anticipated that the slide may comprise a tab allowing a user to actuate the slide more easily. In an alternative embodiment, a removable patch (not shown) may also be sealed over the perforated portion. 
         [0011]    Upon first use of the slide, the box opening is exposed along with the section of the bag to be opened. A user may remove the section of the bag, which is typically surrounded by perforations, to access the product. In addition to the perforated opening being located overlaying the box opening, in one embodiment, a tab may be present adjacent the perforated portion of the bag to facilitate removal. Once the portion of the bag surrounded by perforations is removed, with the slide in an open configuration, product may be poured through the side opening. 
         [0012]    Once a desired amount of pourable product is dispensed from the box, a user may move the slide to a position covering the side opening and the opening in the bag, which will close the box and bag with one movement. Without further actions by the user such as folding over the bag or clipping it closed, freshness of the pourable product in the package will be preserved. Due to the position of the opening on the side of the box and tabbed slide, the slide may be engaged with a user&#39;s thumb in one embodiment. In order to prevent the portion of the slide covering the opening from dislocating from the box, the slide may be equipped with one or more stops adapted to limit sliding movement of the slide. 
         [0013]    In one alternative embodiment, it is anticipated that the sheet of moisture impervious material may be in a folded condition prior to the steps of sealing opposing edges of the moisture impervious material to form a bag and attaching the bag to the box blank. In this embodiment, the folded sheet of moisture impervious material also has an opening defined by perforations adapted to overlay the side opening. It is anticipated that the method of use of the assembled package in this embodiment will be substantially the same as in other embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a flat pattern view of the blank from which an embodiment of the box is made. 
           [0015]      FIG. 2  is a perspective view of the blank and the liner material adapted to cover the blank, also showing an initial assembly step. 
           [0016]      FIG. 3  is a perspective view of the blank and liner material, also showing subsequent assembly steps. 
           [0017]      FIG. 4  is a plan view of the partially assembled box showing the lifting flap in one embodiment of the invention and a portion of the liner material cut away for clarity of illustration. 
           [0018]      FIG. 5  is a front perspective view of the box showing assembly of the lifting flap and hidden components of the lifting flap in dashed line. 
           [0019]      FIG. 6  is a front perspective view of the box showing the lifting flap in a closed configuration. 
           [0020]      FIG. 7  is an inverted front perspective view of the box being filled from the bottom with pourable product. 
           [0021]      FIG. 8  is a front perspective view of the box showing operation of the slider and lifting flap. 
           [0022]      FIG. 9  is a perspective view of an alternative embodiment of the invention showing a liner separate from a blank having adhesive areas. 
           [0023]      FIG. 10  is a perspective view of a liner folded and adhered to a blank by compression, and hot rollers sealing edges of the liner forming a bag. 
           [0024]      FIG. 11  is a front perspective view of the box showing the sealed bag inside the box prior to closing the box bottom. 
           [0025]      FIG. 12  is a front perspective view of the box prior to filling and closing the box. 
           [0026]      FIG. 13  is an inverted front perspective view of the box being filled from the bottom with pourable product. 
           [0027]      FIG. 14  is an inverted front perspective view of the bottom of the bag being hot sealed prior to closing. 
       
    
    
     DESCRIPTION 
       [0028]      FIG. 1  illustrates one embodiment of a die cut paper or cardboard blank  10  that may be used to form the box  12 . The blank  10  has a top end  14  and a bottom end  16  and is scored for folding between a first minor side  18 , a first major side  20 , a second minor side  22  and a second major side  24 , all generally rectangular in shape. The first minor side  18  includes flap  26  and aperture  28  and is attached to the first major side  20  by fold line  30 . The first major side  20  includes major flaps  32  and  34  and is connected to second minor side  22  by fold line  36 . The second minor side  22  includes flaps  38  and  40  and is connected to second major side  24  by fold line  42 . The second major side  24  includes flaps  44  and  46  and is connected to the overlapping flap or manufacturer&#39;s joint  48  (which includes aperture  49 ) by fold line  50 . 
         [0029]    Still referring to  FIG. 1 , the slider retention portion  52  is attached to the first minor side  18  along fold lines  54  and  56  with a slotted opening  58 . The slider retention portion  52  is formed with aperture  60  and includes the stopper tabs  62  and  64  and a minor flap  65 . The slider retention portion  52  is attached to the slider  66  along perforated lines  68  and  70 . The slider  66  includes the slide  72  which is connected along fold lines  76  and  78  to the lifting flap  74  and includes the tab  80  configured for engagement by a user&#39;s thumb when folded, and small cutouts  81  in the minor sides  18 ,  22 , and  48  to provide easy access to the tab  80 . The lifting flap  74  is attached to the attachment portion  82  along fold line  84 . The slider  66  is formed with aperture  90  and includes tabs  86  and  88 . The minor flaps  26 ,  38 ,  40  rather than being entirely separated from the major flaps  32 ,  34 ,  44 , and  46  have instead a line of weakness or are perforated. Additionally, the minor flaps  26 ,  38 ,  40 , and  65  have a fold line  67  the function of which is explained below. 
         [0030]      FIG. 2  illustrates an embodiment with the liner  100  shown prior to being affixed to the blank  10 . The liner  100  includes an opening  112  and a liner flap  102 . The liner flap  102  is attached to a connector portion  106  connecting it with the liner  100  and removable liner portion  104 . The liner  100  is connected to the removable liner portion  104  with a perforation line  104   a.  As can be appreciated from  FIG. 2 , pulling flap  102  away from the liner  100  removes the removable liner portion  104  along perforation line  104   a.  The liner  100  is preferably made of a plastic, waxed paper, or other materials known to persons skilled in the art for containing pourable items in a box in a fresh or dry state. The apertures,  28 ,  49 ,  60 , and  90 , and liner opening  112  are all compatible in shape, although not necessarily the same shape, such that when the four openings are aligned as discussed herein, a path is provided from the interior of the box to the exterior. 
         [0031]    Still referring to  FIG. 2 , construction of the box  12  begins with folding the slider  66  over onto the slider retention portion  52  along perforated lines  68 ,  70 . Referring to  FIG. 3 , the overlapping slider  66  and slider retention portion  52  are then folded over onto minor side  18  along fold line  56 . The liner  100  is then affixed to the blank  10  and glued or otherwise adhered to the blank  10  to secure the liner  100  thereto such that the liner opening  112  is placed substantially in alignment with aperture  28  of the first minor side  18 . As shown in  FIG. 4 , in one embodiment, the liner  100  extends about a half inch (0.5 in.) beyond the top end  14 , the bottom end  16 , and about that same distance into the overlapping flap  48  and extending over onto portions of slider retention portion  52  and the slider  66 . In one embodiment a series of small glue dots, not shown, are deposited on the blank  10 , particularly near the aperture  28  to ensure proper alignment is maintained, as well as across the remainder of the blank  10 . 
         [0032]    To continue box assembly, the slide  72  is situated between the slider retention portion  52  and the liner  100  with the slide  72  in communication with the liner flap  102 . Further, the overlapping flap  48  is folded along fold line  50  so that it is approximately perpendicular to second major side  24  and then similarly folding between second major side  24  and second minor side  22  along fold line  42 , folding between second minor side  22  and first major side  20  along fold line  36  and then folding between first major side  20  and first minor side  18  along fold line  30 . The overlapping flap  48  is then glued or otherwise adhered to the first minor side  18  to form a generally rectangular box  12  as shown in  FIG. 5 . 
         [0033]      FIG. 6  shows the box  12  further assembled with flaps  32 ,  44  and  38  folded over and glued or otherwise adhered together to close the top of the box  12 . The lifting flap  74  is also folded over onto the folded flaps  32  and  44  with the attachment portion  82  glued or otherwise adhered thereto.  FIG. 6  also shows the tab  80  on the lifting flap  74 . 
         [0034]      FIG. 7  shows the box  12  being filled from the bottom with pourable product prior to final assembly, which is one method of filling the assembled box  12 . Final assembly of the box  12  is accomplished by folding over flaps  26  and  40 , and then flaps  46  and  34 , which are then glued or otherwise adhered together to close the bottom of the box  12  to hold the pourable product. As mentioned above, flaps  26  and  40  may be scored with fold lines  67 , which helps retain all the cereal or other product and prevents dust or small particles of product from being released from the box as it is closed. Assembling the package in this manner creates a box with a sealed, air-tight liner bag inside to keep the cereal or other pourable product dry and fresh. 
         [0035]      FIG. 8  shows a manner of dispensing pourable product from the box  12  following removal of the liner cover  104  from the liner  100 . The tab  80  is lifted by a user&#39;s thumb in the direction of the arrow  120  to move the slide  72  upward to align the aperture  90  with the aperture  28  on the first minor side  18 . The stopper members  62 ,  64  prevent advance of the slide  72  beyond the first minor side  18  by engaging the tabs  86 ,  88  on the slide  72 . The liner opening  112  is created by pulling the liner flap  102 . The pourable product within the box  12  is then dispensed from the box  12  through the liner opening  112  and out through apertures  90  and  28 . Pushing down on the tab  80  in the opposite direction of the arrow  120  moves the slide  72  back down to close the aperture  28  and also to close the liner opening  112 . 
         [0036]    In some embodiments, it may be preferable to prepare the liner  100  and blank  10  for assembly by passing the blank  10  and liner  100  through hot rollers or other sealing apparatus under pressure. Referring to  FIGS. 9-14 , an alternative method of forming and attaching the liner  100  and assembling the box  12  is shown. In  FIG. 9 , the liner  100  is folded along fold line  36  as the overlapping slider  66  and slider retention portion  52  are folded over onto minor side  18  along fold line  56  (See,  FIG. 3 ). 
         [0037]    Adhesive strips  114  incorporated onto the surface of the unassembled blank  10  are designed to hold the liner  100  in position as the blank  10  is folded into a three-dimensional box  12 . Although adhesive strips are contemplated, alternative embodiments may employ adhesive in spots, not shown, across predetermined portions of the box blank, or in another configuration to support the bag in position. 
         [0038]    Referring to  FIG. 10 , with the liner  100  folded over the blank  10 , hot pressure is applied to seal the liner  100 . In one embodiment, the liner  100  may be passed through a hot rolling mechanism. 
         [0039]    As shown in  FIG. 11 , the liner  100  is glued and closed proximal the top of the box prior to assembly of the flaps  32 ,  44 , and  38 , which are folded over and glued or otherwise adhered together to close the top of the box  12 , along with the lifting flap  74  which is folded over onto the folded flaps  32  and  44  with the attachment portion  82  glued or otherwise adhered thereto (See  FIGS. 5-6 ). In this manner of assembly, in one alternative embodiment, the side of the liner  100  adjacent the bottom of the blank  10  is left unsealed. In one embodiment, due to adhesion with the blank  10 , as the blank  10  is folded into a three dimensional box, the liner  100  at the bottom of the box  12  opens to accommodate pourable product as shown in  FIG. 12 . 
         [0040]    Referring to  FIGS. 13 and 14 , pourable product is introduced into the box  12  in the same manner as the embodiment shown in  FIG. 7 . In this embodiment, the liner  100  is not adhered to flaps  26 ,  40 ,  34 , and  46  prior to introduction of the pourable product. Rather, the product is introduced into the box  12 , and thereafter a hot roller or other mechanism is brought to bear against the liner  100 , to seal it. Once the liner  100  is sealed, flaps  26 ,  40 ,  34  and  46  are closed to create an assembled box  12  having a pourable product contained by a sealed liner  100  therein. 
         [0041]    While particular forms of the invention have been illustrated and described, it will also be apparent to those skilled in the art that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited except by the full breadth and scope of the appended claims.