Abstract:
A carton includes a spout dispenser formed in a top panel of the carton. The spout dispenser is formed from a spout section of a side top flap adhered to an end top flap. Pivoting the spout section away from the top panel causes part of the end top flap to be pulled through an aperture through which product can be dispensed.

Description:
BACKGROUND  
       [0001]     Dispensing cartons are known. Such cartons typically have a top panel formed from flaps that are separable to open the top of the carton. The contents of the carton can then be dispensed from the open carton top. Such cartons, however, typically are not easily closed once opened, and may not provide for easy dispensing of the carton contents. One solution to this problem is to include a pivotable dispenser that can be opened for dispensing the carton contents and then closed for storage. Conventional pivotable dispensers, however, may be difficult to open and/or to place in a dispensing configuration. Many conventional dispensers also require a metal or plastic insert spout piece to form the dispensing portion of the carton, which may increase costs and/or complexity of manufacture.  
       SUMMARY  
       [0002]     According to a first aspect of the invention, a carton comprises a first side panel, a first end panel, a second side panel, a second end panel, a bottom panel and a top panel. The top panel comprises a first end top flap, a first side top flap overlying the first end top flap and having an aperture formed therein, and a second side top flap overlying the first side top flap. The first end top flap is adhered to the underside of the second side top flap through the aperture in the first side top flap. A plurality of lines of disruption in the second side top flap define in part a pivotable dispenser in the top panel.  
         [0003]     The pivotable dispenser may be placed in a dispensing configuration by breaching the plurality of lines of disruption in the second side top flap and pulling the dispenser open. An access flap can be defined in the dispenser to allow a user to insert a finger into the top panel and thereby access the dispenser. Accessing and opening the dispenser can be performed using a relatively simple motion.  
         [0004]     According to a second aspect of the invention, the first end top flap can include a spout section having wing portions. The wing portions can engage inside edges of the aperture in the first side top flap to secure the dispenser in the dispensing configuration. Locking cuts may be formed in the top panel in which the wing portions can be removably engaged to further secure the dispenser in the dispensing configuration. The dispenser can be closed by pressing the dispenser back into the top panel.  
         [0005]     According to a third aspect of the invention, the spout dispenser can be formed from the top flaps of the carton such that no additional inserts or pieces etc. are required.  
         [0006]     Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description, taken in conjunction with the drawings and from the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0007]     According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.  
         [0008]      FIG. 1  is a plan view of a first side of a blank used to form a carton having a pivotable spout dispenser according to a first embodiment of the invention.  
         [0009]      FIG. 2  is a perspective view of a partially erected carton.  
         [0010]      FIGS. 3A and 3B  are perspective views of the erected carton.  
         [0011]      FIG. 4  is a partial top plan view of the spout dispenser.  
         [0012]      FIG. 5  illustrates the spout dispenser being opened.  
         [0013]      FIG. 6  illustrates the spout dispenser being opened.  
         [0014]      FIG. 7  is an end view of the carton with the spout dispenser opened and in a dispensing configuration.  
     
    
     DETAILED DESCRIPTION  
       [0015]     The present invention generally relates to dispensing or pour features for cartons. The present invention can be used, for example, in cartons that contain articles or other products such as, for example, food and beverages. The articles can also include particulate products such as, for example, rice, beans, sugar, and other pourable dry products. In this specification, the relative terms “bottom,” “side,” “end,” and “top” may indicate orientations determined in relation to fully erected and upright cartons.  
         [0016]      FIG. 1  is a plan view of a blank  8  used to form a carton  190  having a pivotable spout dispenser  160  (illustrated in  FIGS. 3A and 3B ) according to a first embodiment of the invention. The blank  8  comprises a first side panel  10 , a first end panel  20  connected to the first side panel  10  at a first transverse fold line  21 , a second side panel  30  foldably connected to the first end panel  20  at a second transverse fold line  31 , and a second end panel  40  foldably connected to the second side panel  30  at a third transverse fold line  41 . An adhesive panel  50  may be foldably connected to the first side panel  10  at a fourth transverse fold line  51 .  
         [0017]     The first side panel  10  is foldably connected to a first side top flap  12  and a first side bottom flap  14 . The first end panel  20  is foldably connected to a first end top flap  22  and a first end bottom flap  24 . The second side panel  30  is foldably connected to a second side top flap  32  and a second side bottom flap  34 . The second end panel  40  is foldably connected to a second end top flap  42  and a second end bottom flap  44 . The top flaps  12 ,  22 ,  32 ,  42  extend along a first or top marginal portion of the blank  8 , and may be foldably connected along a first longitudinal fold line  62 . The bottom flaps  14 ,  24 ,  34 ,  44  extend along a second or bottom marginal portion of the blank  8 , and may be foldably connected along a second longitudinal fold line  64 . The longitudinal fold lines  62 ,  64  may be straight fold lines, or may be offset at one or more locations to account for, for example, blank thickness. When the carton  190  is erected, the top flaps  12 ,  22 ,  32 ,  42  close a first or top opening of the carton  190 , and the bottom flaps  14 ,  24 ,  34 ,  44  close a second or bottom opening of the carton  190 .  
         [0018]     A spout dispenser pattern  100  is formed in the blank  8 . According to an aspect of the invention, the spout dispenser pattern  100  includes lines of disruption formed in the first side top flap  12 , the first end top flap  22 , and the second side top flap  32 . The spout dispenser pattern  100  defines the pivotable spout dispenser  160  in the erected carton  190  ( FIGS. 3A and 3B ).  
         [0019]     Referring to  FIG. 1 , the spout dispenser pattern  100  includes an aperture  110  formed from a plurality of lines of disruption in the first side top flap  12 . The aperture  100  is defined by spaced side cut lines  112 , an end cut line  114 , and an arcuate end cut line  116 . The cut lines  112  define shoulders  118  on either side of the aperture  110 . The cut lines  112 ,  114 ,  116  of the exemplary embodiment define the opening or aperture  110  in the first side top flap  12 . Alternatively, the lines  112 ,  114 ,  116  could be breachable lines of disruption (e.g. tear lines) in the flap  12  defining a knockout panel (not illustrated). The knockout panel could be removed during erection of the blank  8  or during use of the carton  190 .  
         [0020]     In the first top end flap  22 , a pair of dogleg-shaped cut-crease lines  128  (e.g., fold lines) extend from a distal end of the flap  22  to the first longitudinal fold line  62 . A longitudinally extending cut-crease fold line  130  extends through a medial portion of the first top end flap  22  and across the cut-crease lines  128 . The lines  128 ,  130  define a central portion  120 , first and second wing portions  122 , and a base  124  in the first end top flap  22 . The central portion  120  is foldably connected to the base  124  at the fold line  130 . At the first end top flap  22 , the longitudinal fold line  62  can include a cut-crease section  132 .  
         [0021]     In the second side top flap  32 , a spout section  138  is defined by a plurality of lines of disruption. The spout section  138  includes a central spout portion  140  and first and second wing portions  142  defined by dogleg-shaped interior side cut-crease lines  148  (e.g., fold lines), spaced exterior side cut-space lines  149  (e.g., tear lines), and a laterally extending end fold line  152 . An access flap  144  is defined by an arcuate cut-space line  145  (e.g., tear line) connecting the side cut-space lines  149  and a lateral fold line  150 . Oblique locking cuts  154  extend outwardly from the exterior side cut-space lines  149 .  
         [0022]     The lines  128 ,  130 ,  148  may be formed from, for example, cut-crease lines having 100% cuts (i.e., cuts that extend through the entire blank) in  FIG. 1 , or partial cuts may also be used. Cut-space lines, for example, may also be used to form the lines  128 ,  130 ,  148 . The lines  145 ,  149  are breachable lines of disruption that may be, for example, cut-space lines having 100% cuts or partial cuts. Cut-crease lines, for example, may also be used to form the lines  145 ,  149 .  
         [0023]     An exemplary process of erecting the carton  190  will be discussed with reference to  FIGS. 1 and 2 . Referring to  FIG. 1 , adhesive may be applied to the exterior side of the adhesive panel  50  and/or to the interior side of the second end flap  40 . The blank  8  is folded about the transverse fold lines  21  and  41  to bring the exterior side of the adhesive flap  50  into contact with the interior or underside of the second end panel  40 . The panels  40 ,  50  are thereby adhered together. The resulting article is then “opened” to have a generally closed tubular structure.  
         [0024]     In order to close the top of the carton, adhesive is applied to the exterior side of the first end top flap  22  between the dogleg shaped cut-crease lines  128  and/or to the interior or underside of the spout section  138  of the second side top flap  32 , between the dogleg shaped interior side cut-crease lines  148 . Adhesive may also be applied to the underside of part of or the entirety of the exterior side of the first side top flap  12  except in the area of the shoulders  118 . Alternatively or in addition to adhesive applied to the first side top flap  12 , adhesive may be applied to the entirety of or part of the underside of the second side top flap  32  outside of the area defined by the lines  145 ,  149 ,  152 , and so that the shoulders  118  are not adhered to the second side top flap  32 . Adhesive may be applied to the entirety of or part of the upper surface of the second end top flap  42 .  
         [0025]     The top flaps  12 ,  22 ,  32 ,  42  may be closed by folding the first and second end top flaps  22 ,  42  down as shown in  FIG. 2 . The first side top flap  12  is then folded over onto the end top flaps  22 ,  42  so that the side flap  12  overlies the end flaps  22 ,  42 . The first side top flap  12  may be adhered to the second end top flap  42  at any desired location or locations. The underside of the first side top flap  12  may be adhered to the upper side of the first end top flap  22  in the area of the base  124 .  
         [0026]     The second side top flap  32  is folded over the first side top flap  12  so that the flap  32  overlies the flap  12 . The underside of the second side top flap  32  may be adhered to the exterior or upper side of the first side top flap  12  in areas outside of the spout section  138 . The upper or exterior side of the central portion  120  may be adhered to the underside of the central spout portion  140  of the second side top flap  32  through the aperture  110 .  
         [0027]     The bottom flaps  14 ,  24 ,  34 ,  44  may then be folded and adhered together to close the bottom of the carton. The resultant carton  190  is illustrated in  FIGS. 3A and 3B . Dispensable product may be loaded into the carton  190  before closing both ends of the carton. If the contents of the carton  190  are to be held within a bag or other vessel, the bag (not shown) may be inserted into the partially closed carton before closing both ends of the carton.  
         [0028]     Referring to  FIGS. 3A and 3B , the top flaps  12 ,  22 ,  32 ,  42  are adhered together to form a top panel  170 , and the bottom flaps  14 ,  24 ,  34 ,  44  are adhered together to form a bottom panel  180 . The dispenser pattern  100  (illustrated in  FIG. 1 ) in the top flaps  12 ,  22 ,  32  defines a pivotably (e.g., hingedly or foldably) attached spout dispenser  160  in the top panel  170 .  FIG. 4  is a top plan view of a portion of the top panel  170  illustrating the pivotable dispenser  160  in detail. As shown in  FIG. 4 , the dispenser  160  can be formed entirely from the top flaps  12 ,  22 ,  32  comprising the top panel  170 .  
         [0029]     Referring to  FIGS. 1-4 , the shape of the central portion  120  in the first end top flap  22  generally corresponds to the shape of the central spout portion  140  of the spout section  138 , and the upper surface of the central portion  120  is adhered to the underside of the central spout portion  140  through the aperture  110  in the first end top flap  12 . The wings  122  of the first end top flap  22  may remain unadhered to any other part of the carton  190 .  
         [0030]      FIGS. 5-7  illustrate an exemplary process of opening of the dispenser  160 . Referring to  FIG. 5 , a user inserts a finger, tool or other object into the top panel  170  at the access flap  144 . The top panel  170  tears along the arcuate breachable line  145  as the access flap  144  is pressed inwardly.  
         [0031]     Referring to  FIG. 6 , the top panel  170  is further torn along the breachable lines  149  as the central spout portion  140  and wing portions  142  in the second side top panel  32  are pivoted outwardly about the fold line  152 . The central portion  120  in the first end top flap  22  is adhered to the central spout portion  140  and the portion of the first end top flap  22  beyond the fold line  130  also pivots outwardly. This movement pulls the central portion  120  of the first end top flap  22  through the aperture  110  in the first side top panel  12 . At the same time, contact with the sides of the aperture  110  causes the wings  122  in the first end top flap  22  to be folded inwardly at the lines  128  with respect to the central portion  120 .  
         [0032]      FIG. 7  illustrates the pivotable spout dispenser  160  opened and in its dispensing configuration, thereby forming a dispenser opening  165 . Friction between the wings  122  and the interior edges of the aperture  110  serves to maintain the dispenser  160  in its dispensing configuration. If desired, the spout dispenser  160  can be pivoted open further so that the wings  122  engage the locking cuts  154 . The pivotable dispenser  160  can be reclosed by simply pushing the dispenser  160  back towards the top panel  170 . The shoulders  118  at each side of the aperture  110  project inwardly to partially occlude the aperture  110 , and abut the wing portions  142  to prevent the dispenser  160  from being pressed too far in through the aperture  110 .  
         [0033]     According to the above-described embodiments, cartons can be provided with dispensers that are simple in construction, and that are easily opened and reclosed. The carton provides a relatively simple, one-step action for opening and dispensing product from the carton. The spout dispenser is formed from the top flaps of the carton and no additional inserts or pieces are required.  
         [0034]     In the exemplary embodiment discussed above, the blank is formed from clay coated newsprint (CCN). In general, the blank may be constructed of paperboard, having a caliper of at least about 14, so that it is heavier and more rigid than ordinary paper. The blank, and thus the carton, can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above.  
         [0035]     The first and second sides of the blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blank may then be coated with a varnish to protect any information printed on the blank. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.  
         [0036]     In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening or disruption in a blank that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present invention, fold lines include: score lines, creases, cuts that extend partially into a material along a desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness, and various combinations of these features.  
         [0037]     For purposes of the description presented herein, the term “line of disruption” can be used to generally refer to either a cut line, a crease line, a tear line, or a fold line formed in the material (or a combination of at least one cut line, tear line, fold line, etc.). A breachable line of disruption is a line of disruption that is intended to be breached during ordinary use of the carton. An example of a breachable line of disruption is a tear line.  
         [0038]     A tear line can be any form of weakening that facilitates tearing therealong. Specifically, but not for the purpose of narrowing the scope of the present invention, tear lines include: a cut that extends partially into the material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features.  
         [0039]     The term “line” as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines.  
         [0040]     The above embodiments may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place.  
         [0041]     In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections.  
         [0042]     It will be understood by those skilled in the art that while the present invention has been discussed above with reference to preferred embodiments, various additions, modifications, and variations can be made thereto without departing from the spirit and scope of the present invention as set forth in the following claims.