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 to avoid risking tearing the box liner. The user can open the box and the liner to pour out the contents in one motion and easily close and seal the box and the liner so the contents do not spill out. Advantageously, the box is formed from a single blank piece of cardboard or similar stock, and a single planar sheet of moisture impervious material adhered onto the blank which folds with the blank to form a sealed liner or bag, such that the slide ends up inside the box for easy assembly with a resulting sealed bag inside.

Description:
[0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 13/1775,779, filed on Jul. 1, 2011. 
     
    
     BACKGROUND 
       [0002]    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. 
         [0003]    A wide range of pourable products such as dry cereals, small cookies or crackers, pet foods, powdered laundry soap and many others are held in and dispensed from cardboard box containers. Often, to preserve the freshness of food products and prevent leakage of fine particle food and other products, these boxes enclose a sealed waxed paper or plastic bag for holding the manufactured product. While effectively containing and preserving the manufactured products, opening such a container is a cumbersome process. A user must open the top of the box and then manipulate and tear open the bag held within. If the sealed top of the bag is not carefully torn open, the bag may rip down the side, spilling product. 
         [0004]    Conventional folding cartons are also ill suited for re-closure, especially since users customarily dispense only a portion of the contents at a time. After opening the box and dispensing some of the product, users must attempt to re-close the bag by folding or rolling up the open top. This must be done with the bag in the box (if removed, the bag may deform and no longer fit), and results in a partially closed unsealed bag prone to spilling product between the bag and the box. 
         [0005]    The containers themselves are also difficult to close. Typical closures are the cartons flaps glued onto each during manufacture. For commercial cereal boxes, after opening, to close the box users must open a slit in the flap and bend the flap of the box top to insert a tab in the slit. Opening the box top frequently results in tearing and ruining the closure. Also, the slit must be opened along a perforation, which frequently results in tearing it to the edge of a flap also rendering the closure inoperable. Even if the slit is preserved and the tab carefully inserted therein, the closure is prone to unwanted opening. 
         [0006]    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 distribution of breakfast cereals, it is preferable to have the box delivered to the filling machine 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 filling machine fills the box with product, and then glue closes the box to be a ready consumer package. 
         [0007]    Applicant has developed packages of new and differing functionality which offer significant improvements in dispensing, closing and reopening yet maintaining the manufacturing and filling process the same as standard folding cartons which work with conventional high speed machinery, over the prior art, and keeping the look of a standard carton for the consumer&#39;s familiarity. 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. 
         [0008]    While Applicant&#39;s display package design and the technology 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 manufacturing 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 the liner bag can be opened and closed as the box is opened and closed by a convenient slide opener. The need also exists for a box capable of maintaining high speed production manufacturing that can actually be manufactured by the food companies because it offers the economical advantage of high volume mass production. 
       SUMMARY 
       [0009]    A box having an integral liner for containing pourable items and a method of packaging and dispensing pourable products, such as cereal in a high speed production line that is friendly to existing packaging machinery, is disclosed. A box having an integral liner is thrilled 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. The foldable box blank is preferably made of single sheet cardboard or similar material, which may be stamped to create fold lines and perforations. 
         [0010]    A first side of the box blank has a dispensing and closing mechanism technology serving 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. The slide may be coupled to the first side prior to assembly, allowing the package to be constructed specifically from a single flat piece of box blank stock for high speed line assembly. Additionally, the box opening can be placed virtually anywhere on the box convenient for pouring. This box design, while incorporating a dispensing mechanism, is made the same way as conventional boxes already on the market with the same advantages of mass production. It offers a convenient side pouring feature and recloses without tearing the box or the bag in it, thereby avoiding the problems of reclosing an opened and/or damaged bag, and the likelihood of destroying the tab and slot closure on a conventional box top. 
         [0011]    As moisture and dust proof along with freshness is a desired and necessary characteristic of the goods contemplated to be held in and dispensed from the box, a bag substantially sealed inside the box forms part of the package. 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 materials known and used in conventional cardboard box sealed bags which satisfies these purposes. 
         [0012]    Typically the moisture impervious material substantially covers the box blank prior to package assembly. Opposing sides of the moisture impervious material may be brought together beyond the edge of the box blank to form two layers that are sealed. By also sealing the bottom or top edge of the moisture impervious material, and folding the blank into a box shape, a bag with an opening adjacent the open top or bottom of the box is automatically formed. 
         [0013]    The moisture impervious material preferably has a perforated portion, defining an opening, overlaying and aligned with the side opening of the box. The opening of the moisture impervious material liner and the side opening of the box are preferably sealed together to prevent product from lodging between the bag and the box after initial opening. The moisture impervious material may also extend past the slide, and substantially past an edge of the box blank corresponding to the bottom or top of a completed box. By sealing the openings of the box and bag, once the moisture impervious material is completely sealed to hold product, a substantially air-tight re-sealable package is produced. 
         [0014]    As discussed, once the fold or manufacturing joint is sealed, the blank is ready to be formed the same way as a conventional box by first sealing the bottom or the top portion of the liner and then the bottom or top portion of the blank, ready to be filled and to be sealed to form a complete package. Once product is introduced into the package, it may be closed and sealed 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. 
         [0015]    Completing the method, to use the package, a user lifts open the slide opening to expose the opening in 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. 
         [0016]    Conventional boxes require users to carefully separate the glued together box top flaps often resulting in tearing, and having no ability to reclose the interior sealed bag. In contrast the present invention simply requires that a user lifts up on the lid, thereby opening the slide, with the optional additional step of removing a tab over the slide sealing the interior bag, e.g. pushing in the perforated area, for dispensing products from the inner bag. 
         [0017]    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. 
         [0018]    Once a desired amount of pourable product is dispensed from the box, a user may push close the opener to close the box and cover the inner bag. 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. 
         [0019]    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. 
         [0020]    In a second alternative embodiment method of packaging and dispensing pourable product a box blank is formed having a plurality of sides coupled together, including a first side having a side opening coupled to a slide covering the side opening. A sheet or liner of moisture impervious material is attached to the box blank, substantially covering it. The liner has an opening overlaying the side opening. An adhesive may be applied to a predetermined portion of the sheet for attaching to another portion of the sheet for forming a sealed tube from which the sealed bag is formed. 
         [0021]    The box blank is then formed into a box with the liner forming a bag inside the box. Thereafter the bottom edges of the liner may be sealed forming a sealed bag inside the box. In this manner, a multiplicity of the boxes may be stacked in a collapsed configuration for later use prior to opening the boxes from the collapsed configuration for filling with the pourable product. The bag is then filled with the pourable product, and the top of the bag sealed. Thereafter, a user may open and close the box in the manner according to the first embodiment. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a flat pattern view of the blank from which an embodiment of the box is made. 
           [0023]      FIG. 2  is a perspective view of the blank and the liner material adapted to cover the blank, also showing an initial assembly step. 
           [0024]      FIG. 3  is a perspective view of the blank and liner material, also showing subsequent assembly steps. 
           [0025]      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. 
           [0026]      FIG. 5  is a front perspective view or the box showing assembly of the lifting flap and hidden components of the lifting flap in dashed line. 
           [0027]      FIG. 6  is a front perspective view of the box showing the lifting flap in a dosed configuration. 
           [0028]      FIG. 7  is an inverted front perspective view of the box being filled from the bottom with pourable product. 
           [0029]      FIG. 8  is a front perspective view of the box showing operation of the slider and lifting flap. 
           [0030]      FIG. 9  is a perspective view of an alternative embodiment of the invention showing a liner separate from a blank having adhesive areas. 
           [0031]      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. 
           [0032]      FIG. 11  is a front perspective view of the box showing the sealed bag inside the box prior to closing the box bottom. 
           [0033]      FIG. 12  is a front perspective view of the box prior to filling and closing the box. 
           [0034]      FIG. 13  is an inverted front perspective view of the box being filled from the bottom with pourable product. 
           [0035]      FIG. 14  is an inverted front perspective view of the bottom of the bag being hot sealed prior to closing. 
           [0036]      FIG. 15  is a perspective view of a second embodiment of a blank and liner material adapted to cover the blank, also showing an initial assembly step. 
           [0037]      FIG. 16  is a perspective view of the second embodiment with the blank adhered to the liner and partially folded. 
           [0038]      FIG. 17  is a perspective view of the second embodiment in a further folded position, showing the liner being sealed. 
           [0039]      FIG. 18  is a perspective view of the box according to the second embodiment being filled from the top with pourable product. 
       
    
    
     DESCRIPTION 
       [0040]      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 told 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 . 
         [0041]    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. 
         [0042]      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. 
         [0043]    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 . 
         [0044]    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 . 
         [0045]      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 . 
         [0046]      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. 
         [0047]      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 . 
         [0048]    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 ). 
         [0049]    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. 
         [0050]    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. 
         [0051]    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 . 
         [0052]    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. 
         [0053]    Referring to  FIG. 15 , the box blank  10  according to a second embodiment is shown. In this embodiment, several areas of adhesion  114  are disposed on the box blank  10 . Preferably, the areas of adhesion  114  are formed inside the perimeter of the first major side  20  and the second major side  24 . 
         [0054]    Still referring to  FIG. 15 , a sheet or liner  200  of moisture impervious material according to the second embodiment is shown. The liner  200  is sized and oriented to have a first edge  202  aligned at the junction between second major side  24  and overlapping flap  48 , and to have second edge  204  overhanging the first minor side  18  of the box blank  10 . 
         [0055]    Still referring to  FIG. 15 , the liner  200  is adhered to the box blank  10  at the areas of adhesion  114 . With the first edge  202  and the second edge  204  of the liner  200  in proper alignment, the removable liner portion  104  will align with apertures  28 ,  60  on the box blank  10 . 
         [0056]    Referring to  FIGS. 15 and 16 , after the liner  200  is adhered to the box blank  10 , the liner  200  and the box blank  10  are folded along fold line  1 . As shown in  FIG. 16 , the liner  200  and the box blank  10  also have areas of adhesion  214 ,  216 . The areas of adhesion  214 ,  216  are located proximal the first edge  202  of the liner  200  and on overlapping flap  48  of the box blank  10 . 
         [0057]    Still referring to  FIG. 16 , after the liner  200  and the box blank  10  are folded along fold line  1 , the liner  200  and the box blank  10  are then folded along fold line  2 . By folding the liner  200  and the box blank  10  along fold line  2 , the area of adhesion  214  on overlapping flap  48  adheres to first minor side  18 , and the area of adhesion  216  proximal first edge  202  of the liner  200  adheres to the second edge  204  of the liner  200 , thereby forming the liner  200  into a sealed tube  218 . 
         [0058]    Referring to  FIG. 17 , after the liner  200  and the box blank  10  have been folded along fold line  1  and then along fold line  2 , and the sealed tube  218  created, a double-layered bottom portion  206  of the liner  200  remains extending beyond the box blank  10 . The layers of the bottom portion  206  are sealed together by a sealing roller  208  or similar mechanism. In the illustrated embodiment the sealing roller  208  creates two parallel sealed lines  210  on the liner  200 , although other sealing patterns are contemplated according to preference. 
         [0059]    Still referring to  FIG. 17 , sealing the bottom portion  206  forms an air tight bag with an open top. Sealing the sides of the liner  200  by folding it according to  FIGS. 15 and 16 , and the adhesive area  216  adhering to the overhanging edge  204  of the liner  200 , forms the sealed bag  220  (see  FIG. 18 ). This eliminates the extra steps of independently sealing the sides of the liner  100  according to the first embodiment, described in paragraph 0045 and shown in  FIG. 10 . By forming the sealed bag  220  and box  212  initially in a collapsed configuration, multiple collapsed boxes  212  can be stacked before being individually folded open and filled with the pourable product  38 . 
         [0060]    Referring to  FIG. 18 , a second embodiment box  212  including the sealed bag  200  is shown being filled from the to with pourable product  38 . Once the pourable product  38  is in the sealed bag  220 , it may be sealed at the top to contain the pourable product  38  in an airtight manner. 
         [0061]    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 he 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.