Abstract:
The invention relates to a packaging blank and container having an integral reclosable pour spout which provides enhanced seals, and promotes accurate placement of the pour spout during construction. The blank provides a pour spout assembly having a skewed fold line that facilitate folding operations and promotes accurate positioning of the pour spout, a detachable access tab that promotes sealing and provides tamper evidence, and a novel pour spout assembly that promotes directional and controlled pouring of articles. The invention further relates to a container formed from the blank.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates to a packaging blank with features which enhance the seal of a container having a directional pour spout formed from the blank at an edge of a side panel, while improving the ease with which the pour spout is opened and closed. The invention further includes features which improve manufacturing efficiencies. The blank further improves accuracy of placement of the pour spout assembly during folding operations to thereby improve manufacturing quality. 
         [0002]    The invention further relates to a container formed from the blank having a rear panel and a side panel, wherein a pour spout assembly enhances sealing between the rear panel and side panel to thereby prevent sifting and infestation. Still further, the blank and container minimize scrap sheet material (i.e., sheet scrap) while enhancing efficiencies during the opening and closing of the pour spout. 
         [0003]    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. 
         [0004]    Today, the initial construction of packaging blanks into containers is managed in the facilities of the blank manufacturer. For example, the blanks are formed from sheets and then the blanks are separated. Next at least one flap (e.g., a glue flap) is secured to at least one panel of the blank during a folding and gluing 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 and sealing of the container is typically managed in the facilities of the article manufacturer. 
         [0005]    Manufacturers employ a variety of automated equipment that is capable of folding and gluing the blank to form an open-ended 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, gluing, 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). 
         [0006]    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 encounter problems with sealing. 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. Further, infestation plagues many known containers during storage. Thus, there is a need for a container having a reclosable pour spout that provides superior sealing characteristics. 
         [0007]    Moreover, conventional blanks capable of forming containers having integral pour spouts often fail to provide directional pouring, i.e., controlled product flow. Thus, there is a need for a container having a reclosable pour spout that provides directional pouring of articles. 
         [0008]    Known containers having reclosable pour spouts are typically 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. 
         [0009]    Known blanks capable of forming a container having an integral pour spout formed solely from paperboard typically include pour spout assembly panels integral with the blank. An attractive option for forming containers having integral pour spouts includes providing blanks that include pour spout assemblies connected to one edge of the blank. Unfortunately, multiple folding operations are required to construct these containers. Further, the addition of the pour spout assembly requires that manufacturers fold multiple layers of sheet material upon one another, resulting in bulges at critical joints in the resulting container. Specifically, the pour spout assembly is folded such that multiple layers of paperboard are formed at the intersection of, for example, the manufacturer&#39;s glue joint and a side panel. 
         [0010]    When constructing containers from known blanks having a pour spout assembly, the sheet material connecting the pour spout assembly to the blank is folded against itself when securing a side panel to a front or rear panel with a glue flap to form a manufacturer&#39;s glue joint. The layering of sheet material increases the amount of force acting on the glue joint which could lead to rupture and unintended dispersal of the contents of the container (i.e., broken seal). The stacking or layering of the sheet material may further result in bulging that disrupts the in-line processing of the blank into the container. For example, non-flat or non-planar blanks may be discharged or unintentionally removed from a conveyor or work station by one or more of the machinery elements (e.g., suction arms) performing folding or gluing operations. Thus there is a need for a blank capable of forming a container that minimizes layers of sheet material at critical joints. 
         [0011]    Moreover, blanks having integral pour spout assembly panels require multiple complicated folding operations which oftentimes result in inaccurate placement of the pour spout assembly panel. In other words, the pour spout assembly, and specifically the spout body interior panel may not correspond to a spout body intermediate panel or a spout body reinforcing panel in a side panel of the blank. Thus, there is a need for a blank that promotes accurate placement of the pour spout components on the blank proper. 
         [0012]    The incorporation of extension panels having pour spout assemblies into a blank creates numerous problems for manufacturers that incorporate in-line processes. The modification of existing equipment is time consuming and expensive. Existing in-line processes incorporate machines that are capable of forming sheets defining a number of blanks, breaking the sheets into the blanks, and folding the paperboard blanks to form the container. Thus, there is a further need for a packaging blank capable of forming a container having an integral pour spout, wherein the blank is 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.” 
         [0013]    Advantageously, the present invention provides a blank capable of forming a container having an integral reclosable pour spout formed of paperboard, and a container formed from the blank that improves sealing operations, increases the economies of manufacturing (i.e., non-disruptive folding and gluing operations), minimizes rupture, and prolongs structural integrity of the pour spout. 
       SUMMARY OF THE INVENTION 
       [0014]    In one aspect, the invention is a blank comprising a front panel having first and second side panels connected to opposite edges of the front panel, a spout body reinforcing panel and a detachable access tab defined by the first side panel (the pour spout reinforcing panel defining at least one retention tab), a rear panel connected to the front panel by the second side 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 assembly panel connected to the rear panel by the glue flap. As configured, the blank is capable of being folded such that portions of the pour spout assembly panel correspond with the spout body reinforcing panel to form a reclosable pour spout upon construction of a container. 
         [0015]    The blank further provides an outer top closure panel, an inner top closure panel, an outer bottom closure panel, an inner bottom closure panel, a first top closure flap, a second top closure flap, a first bottom closure flap, and a second bottom closure flap. 
         [0016]    The pour spout assembly panel comprises a spout connection panel connected to and extending from the glue flap, a spout body interior panel connected to and extending from the spout connection panel, and first and second spout side panels extending laterally from opposite edges of the spout body interior panel. The first and second spout side panels each define at least one retention tab. 
         [0017]    The lower edge of the second spout side panel is arcuate-shaped and extends below a lower edge of the first spout side panel and the spout body interior panel. This configuration facilitates directional pouring of articles contained within the container formed from the packaging blank. 
         [0018]    The blank also includes a spout body intermediate panel connected to the rear panel and positioned substantially above the glue flap. The spout body intermediate panel defines at least one retention tab that corresponds with the retention tab of the spout body reinforcing panel upon construction of the packaging blank into the container. The configuration facilitates the opening and closing of the pour spout. 
         [0019]    The blank also includes a glue tab connected to the rear panel. The glue tab defines at least one channel and at least one retention tab for guiding the movement of the pour spout, and for facilitating the opening and secure closing of the pour spout. 
         [0020]    The packaging blank also includes an outer top closure panel, an inner top closure panel, an outer bottom closure panel, an inner bottom closure panel, a first inner top closure flap, a second inner top closure flap, a first inner bottom closure flap, and a second inner bottom closure flap. 
         [0021]    The invention also provides a reclosable container having a directional integral pour spout. The container includes a bottom panel and first and second side panels secured to opposite edges of the bottom panel. The first side panel defines a spout body reinforcing panel and a detachable access tab. The container further includes a front panel and a rear panel. 
         [0022]    Still further the container includes a top closure panel, a top closure flap, and a pour spout assembly. The pour spout assembly is positioned at an edge of the first side panel and the rear panel. The pour spout assembly has at least one retention tab for securing the pour spout assembly against the first side panel. 
         [0023]    The bottom panel includes an outer bottom closure panel, an inner bottom closure panel, a first inner bottom closure flap, and a second inner bottom closure flap. The top panel includes an outer top closure panel, an inner top closure panel, a first inner top closure flap, and a second inner top closure flap. 
         [0024]    The pour spout assembly includes a spout connection panel, a spout body intermediate panel, a spout body interior panel, and first and second spout side panels extending laterally from opposite edges of the spout body interior panel. A lower edge of the second spout side panel is arcuate-shaped and extends below a lower edge of the first spout side panel and the spout body interior panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    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: 
           [0026]      FIG. 1  is a top plan view of the blank of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which multiple embodiments of the invention are shown. This invention may, however, be embodied in 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. Further, like numbers with the prime notation refer to like or similar elements of the structure. 
         [0028]    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. The term “unitary sheet” refers to material having a broad, continuous surface so connected that it is possible to pass from any one point of the surface to any other point without leaving the surface. Sheet may also refer to separate pieces of, for example, paperboard used to form blanks. 
         [0029]    It will be understood by those skilled in the art that the term “container” as used herein refers to various embodiments of the present structure for retaining a variety articles as formed from the various embodiments of the blank described below. 
         [0030]    The term “panel” used in conjunction with the blank and container of the present invention refers to the major component part of a blank or container, and defines the major partition elements of the blank or container. 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 blank or container element that is typically hinge-connected along a free edge of a panel or another flap. 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. 
         [0032]    It will be understood by those skilled in the art that the terms “top panel” and “bottom panel” may also refer to “bottom panel” and “top panel” dependent upon the perspective of the individual viewing the apparatus. It will also be appreciated that the term “top” implies the opposite of “bottom.” 
         [0033]    With reference to the orientation of the blank in  FIG. 1 , it will be understood that the terms “internal surface” and “external surface” may be referred to as “inside surface” and “outside surface.” Stated differently, the term internal surface implies the surface of the container closest to the interior of the container. Thus, it will be understood that the term external surface implies the side of the container opposite the internal surface (i.e., the side farthest from the interior of the container). 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&#39;s logo). 
         [0034]    Further, 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 or container structure, respectively. 
         [0035]    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. 
         [0036]    It will be understood by those skilled in the art that the term “score” refers to a crease along which the adjacent components or portions of a component of the blank are folded without cracking or breaking to form a container. It will be understood that the term “cut-score” and “reverse 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. 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. 
         [0037]    It will be further understood that the term “score line” or “fold line” refers to a crease along which the adjacent components of a blank are folded without cracking or breaking to form a container. The term “secured” may refer to adhered with adhesive (e.g., glue) or bonded with heat. 
         [0038]    As used in conjunction with a score, cut-score, reverse cut-score, perforations, score line, or fold line, the term “skew” or “skewed” refers to one of the above that is slanted or oblique with respect to a vertical axis of the blank. Stated differently, the term refers to a score, cut-score, reverse cut-score, perforations, score line, or fold line that is neither perpendicular nor parallel to another line or plane in the blank. 
         [0039]    The term “substantially rectangular” is meant to succinctly describe a simple geometric shape approximating a rectangle. 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 polygonal” is meant to describe a simple geometric shape approximating a closed plane figure bounded by straight lines. 
         [0040]    The term “substantially parallel” is meant to describe the spatial relationship between, for example, one panel and another panel, wherein the relationship is approximately parallel. 
         [0041]    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., cereal, grain, consumables, etc.). It will be understood, however, that “article” may also refer to any number of goods such as individually packaged consumables for humans and animals, as well as individually packaged non-consumables. 
         [0042]    An overall view of an embodiment of a blank  10  capable of forming a container  11  having a reclosable pour spout  12  of the invention is set forth at  10  in the top plan view of  FIG. 1 . In one aspect, the invention is a blank  10  comprising a substantially rectangular front panel  13  having first and second side panels  14 ,  15  connected to opposite edges of the front panel  13 , a spout body reinforcing panel  16  and a detachable access tab  17  defined by the first side panel  14  (wherein the pour spout reinforcing panel defines at least one retention tab  18 ), a substantially rectangular rear panel  20  connected to the front panel  13  by the second side panel  15 , a glue flap  21  connected to an edge of the rear panel  20  opposite the edge to which the second side panel  15  is connected, and a pour spout assembly panel  22  connected to the rear panel  20  by the glue flap  21 . As configured, the blank  10  is capable of being folded such that portions of the pour spout assembly panel  22  correspond with the spout body reinforcing panel  16  to form a reclosable pour spout upon construction of a container  11 . Accordingly, portions of the pour spout assembly panel  22  accurately position and secure the pour spout within an interior of the container  11  and substantially adjacent to an edge of the first side panel  14 . 
         [0043]    The blank  10  further provides an outer top closure panel  27  connected to an upper edge of the front panel  13 , an inner top closure panel  28  connected to an upper edge of the rear panel  20 , an outer bottom closure panel  29  connected to a lower edge of the front panel  13 , an inner bottom closure panel  30  connected to a lower edge of the rear panel  20 , a first top closure flap  31  connected to an upper edge of the first side panel  14 , a second top closure flap  32  connected to an upper edge of the second side panel  15 , a first bottom closure flap  33  connected to a lower edge of the first side panel  14 , and a second bottom closure flap  34  connected to a lower edge of the second side panel  15 . 
         [0044]    The packaging blank  10  consists essentially of a one-piece blank, wherein the one-piece blank has an external planar side and an internal planar side. For advertising and promotional considerations, the external planar side is preferably finished (i.e., includes printed material or related identifying indicia). In one embodiment, the packaging blank  10  is formed of paperboard. 
         [0045]    The pour spout assembly panel  22  comprises a spout connection panel  39  connected to and extending from the glue flap  21 , a spout body interior panel  40  connected to and extending from the spout connection panel  39 , and first and second spout side panels  41 ,  42  extending laterally from opposite edges of the spout body interior panel  40 . The first and second spout side panels each define at least one retention tab  43 . The retention tabs  18 ,  43  of the spout body reinforcing panel  16  and the first and second spout side panels correspond with one another upon construction of the packaging blank  10  into the container  11  to facilitate the opening and closing of the pour spout  12 . 
         [0046]    The lower edge of the second spout side panel  42  is arcuate-shaped and extends below a lower edge of the first spout side panel  41  and the spout body interior panel  40 . This configuration facilitates directional pouring of articles contained within the container  11  formed from the packaging blank  10 . 
         [0047]    The blank  10  also includes a spout body intermediate panel  47  connected to the rear panel  20  and positioned substantially above the glue flap  21 . The spout body intermediate panel defines at least one retention tab  48  that corresponds with the retention tab  18  of the spout body reinforcing panel  16  upon construction of the packaging blank  10  into the container  11 . The configuration facilitates the opening and closing of the pour spout  12 . Upon construction of the container  11 , the retention tabs  18 ,  48  prevent the pour spout from advancing beyond the plane of the first side panel  14  without sufficient force applied by a user to open the pour spout  12 . This feature prevents unintended dispensing of articles from within the container  11 . 
         [0048]    The blank  10  also includes a glue tab  49  connected to the rear panel  20  and positioned substantially above the spout body intermediate panel  47 . The glue tab  49  defines at least one channel  50  and at least one retention tab  51  for guiding the movement of the pour spout  12 , and for facilitating the opening and secure closing of the pour spout  12 . 
         [0049]    The pour spout assembly panel  22  includes at least one score line  52  that is skewed relative to a vertical axis of the blank  10 . The skewed score line facilitates the folding and gluing of the blank  10  and also facilitates the accurate positioning of the pour spout within an interior of the container  11  upon construction. The packaging blank  10  may also include score lines, cut-scores, reverse cut-scores, and perforations that facilitate the formation of the container  11 . 
         [0050]    The packaging blank  10  also includes an outer top closure panel  27  connected to an upper edge of the front panel  13 , an inner top closure panel  28  connected to an upper edge of the rear panel  20 , an outer bottom closure panel  29  connected to a lower edge of the front panel  13 , an inner bottom closure panel  30  connected to a lower edge of the rear panel  20 , a first inner top closure flap  31  connected to an upper edge of the first side panel  14 , a second inner top closure flap  32  connected to an upper edge of the second side panel  15 , a first inner bottom closure flap  33  connected to a lower edge of the first side panel  14 , and a second inner bottom closure flap  34  connected to a lower edge of the second side panel  15 . 
         [0051]    In one embodiment, portions of the first inner top closure flap  31 , the second inner top closure flap  32 , the first inner bottom closure flap  33 , the second inner bottom closure flap  34 , the inner top closure panel  28 , and the inner bottom closure panel  30  include glue assist perforations formed in the respective flaps and panels. 
         [0052]    The invention also provides a reclosable container  11  having a directional integral pour spout. The container  11  includes at least one substantially rectangular bottom panel  113 , and substantially rectangular first and second side panels  114 ,  115  secured to opposite edges of the bottom panel. The first and second side panels  114 ,  115  define substantially parallel planes, and the first side panel  114  defines a spout body reinforcing panel  116  and a detachable access tab  117 . The container  11  further includes a substantially rectangular front panel  118  connected to the bottom panel  113  and to respective edges of the first and second side panels  114 ,  115 , a substantially rectangular rear panel  120  secured to the bottom panel and to respective edges of the first and second side panels. The front and rear panels  118 ,  120  define substantially parallel planes. 
         [0053]    Still further the container  11  includes at least one substantially rectangular top closure panel  123  secured to respective edges of the front and rear panels, at least one top closure flap  124  connected to a top edge of the first side panel, and a pour spout assembly  125  secured to the first side panel. The pour spout assembly  125  is positioned at an edge of the first side panel  114  and the rear panel  120 . The pour spout assembly has at least one retention tab  126  for securing the pour spout assembly against the first side panel. As configured, the pour spout assembly  125  is opened upon removal of the detachable access tab  117  and closed upon securing the retention tab  126  against the first side panel  114 . 
         [0054]    The bottom panel  113  includes an outer bottom closure panel  127  connected to a lower edge of the front panel  118 , an inner bottom closure panel  128  connected to a lower edge of the rear panel  120 , a first inner bottom closure flap  129  connected to the first side panel  114 , and a second inner bottom closure flap  130  connected to the second side panel  115 . 
         [0055]    The top panel  123  includes an outer top closure panel  134  connected to an upper edge of the front panel  118 , an inner top closure panel  135  connected to an upper edge of the rear panel  120 , a first inner top closure flap  136  connected to the first side panel  114 , and a second inner top closure flap  137  connected to the second side panel  115 . 
         [0056]    The pour spout assembly  22  includes a spout connection panel  140  secured to the first side panel  114 , a spout body intermediate panel  141  secured to the spout body reinforcing panel  116 , a spout body interior panel  142  secured to the spout body intermediate panel  141  and connected to the spout body connection panel  140 , and first and second spout side panels  143 ,  144  extending laterally from opposite edges of the spout body interior panel  142 . The first and second spout side panels  143 ,  144  each define at least one retention tab  45 . Accordingly, the retention tabs of the spout body reinforcing panel, and the first and second spout side panels correspond with one another to facilitate the opening and closing of the pour spout. 
         [0057]    A lower edge of the second spout side panel  144  is arcuate-shaped and extends below a lower edge of the first spout side panel and the spout body interior panel. This configuration facilitates directional pouring of articles contained within the container  11 . The second spout side panel  144  extends to an intermediate portion of the spout body reinforcing panel  116 . 
         [0058]    The first spout side panel  143  extends substantially parallel to the rear panel  120  and the second spout side panel  144  extends at an angle of between about 35 and 50 degrees relative to the first spout side panel when the spout is opened to provide directional and controlled pouring of articles in the container  11 . 
         [0059]    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.