GABLE TOP CONTAINER WITH FOLDABLE RIDGE

Abstract: A coated paperboard container (22) and a blank (20) for constructing the container is disclosed as including a body portion (24) having an upper end that is closed by a folded top end closure (26) which includes closure panels (52, 54, 56, 58) and seal lips (60, 62, 64, 66) having a construction that enhances foldability and sealing. Front and back gable panels (54, 58) of the top end closure are each flanked by a pair of triangular inner roof panels (53, 55, 57, 59) that have different sizes than each other so as to facilitate folding of a top seal (32) provided by the seal lips from a vertical position in a direction toward the smaller inner roof panels. Inner seal lips (62, 66) are each connected to one pair of the inner roof panels by a single score line (63, 67) and outer seal lips (60, 64) are likewise each connected to outer roof panels of the closure by a single score line (61, 65). The unequal size of the inner roof panels on opposite sides of each gable panel is provided by inclined score line portions that connect the smaller inner roof panels and the inner seal lips. The inclined score line portions and the score line between the outer seal lip and the outer roof panel adjacent the smaller inner roof panels are wider than the other score lines so as to further facilitate folding the top seal from a vertical position toward the smaller inner roof panels into either a "slant top" or a "flat top" container.

Description: Gable Top Container With Foldable Ridge TECHNICAL FIELD This present invention relates to a coated paper- board container and to a blank for constructing the container- so as to include a body portion having a top end closed by a folded top end closure of an improved construction. BACKGROUND ART Containers for beverages such as milk, cream, other dairy products, juices, and the like are conventional- ly constructed from thermoplastic coated paperboard. One type of these containers includes a top end closure with a folded gable roof having a vertically projecting seal at the roof ridge for sealing the container and providing a pouring spout when the contents of the container are to be dispensed. Stacking of such containers requires the use of separating trays intermediate different layers due to the vertically projecting seals of their top end closures. Also, storage space is lost in stacking these containers due to the empty space resulting .from the configuration of the top end closure. Such containers are shown by U.S. Patents 3,116,002 and 3,120,335. Another type of the containers includes flat top end closures that are folded and have a flat seal projecting from a centerline of the closure with an outer end that is releasably secured to the rest of the closure generally adjacent one of its sides. Various releas- able securements are provided for releasing the flat seals to permit them to be opened and to thereby provide spout for dispensing the beverages. U.S. Patents 3,869,078 and 3,892,347 disclose such flat top end closures. A further type of container is disclosed by United States Published Patent application B 461,257, published January 13, 1976, now U.S. Patent 4,078,715, issued March 14, 1978, and includes a top end closure with an inclined seal that includes a harder score line on one side of the seal for facilitating folding ' of the seal from a vertical position to the inclined position. United States Patents 4,012,997 and 4,093,115 disclose a container folding method and the container made by the method wherein certain roof panels of the top end closure are provided with double score lines extending along¬ side each other. Folding of a top seal of the end closure from a vertical position to a flat position requires the application of a downward force along the lower double score line on one side of the top seal and the application of another force to bend the top seal downwardly. Each additioή- al application of force for folding the top end closure requires an additional folding tool on the folding mechanism and is thus accompanied by additional expense. Coated paperboard blanks for constructing each type of container described above are made on converting machines like those disclosed by U.S. Patents- 2,682,208 and 3,731,600. After construction of the blanks to form the containers, appli- cation of heat or high frequency vibration applied by clamping pressure to interengaged portions of the blanks provides seal¬ ing of the containers. DISCLOSURE OF THE INVENTION An object of the present invention is to provide an improved coated paperboard container and a blank for constructing the container to include a top end closure comprised of a folded roof and a top seal for sealing the roof, and wherein the construction of the top end closure enhances foldability of the top 'seal from a vertical position. In carrying out the above object and other objects of the invention, the blank from which the constainer is con¬ structed includes a pair of triangular gable panels whose opposite sides are connected to a pair of triangular inna_= __ roof panels that are of a different--size than each other. An inner seal lip associated with each pair of inner roof panels is connected-thereto by an associated single score line. A pair of outer roof panels of the top end closure are likewise connected to associated outer seal lips by "associated single score lines. Folding of the top seal which is defined by the inner and outer seal lips is facili¬ tated in a direction toward the smaller inner roof panels so as to enable the top closure to be constructed into a slant top closure or a flat top closure. The closure can also be constructed as a straight up closure without any folding of the top seal. Terminal edges of the outer seal lips extend alongside each other after construction of the top end clo¬ sure and the inner seal lips are folded during each construc- tion so that terminal edge portions of each inner seal lip extend parallel to each other inwardly from the terminal edges of the outer seal iips. The container is constructed from a coated paper- board blank so as to include a body portion having a pair of side panels connected by front and back panels. As disclosed the back panel is secured to one of the side panels by a seam flap with a heat bond during construction of the container. A bottom end of the constructed container includes a bottom end closure that closes the lower side of the container body portion while folded closure panels and seal lips at the uppe end of the container body portion form the folded roof and the top seal of the invention. A preferred embodiment of a blank for constructing a container in accordance with the present invention includes a single score line that connects one of the outer seal panel and the associated outer roof panel at a lower elevation than the apices of the front and back gable panel, and each single score line between' the inner seal lips and the associated pair of inner roof panels thereof includes an inclined score line portion. Upper ends of the inclined score line portions intersect with the apices of the associated -gable panels and lower ends of the inclined score line portions are located adjacent the opposite ends of the dropped score line in the constructed condition of the top end closure formed by the blank. The inner roof panels on one side of the top seal of the constructed end closure are of a smaller size than the inner roof panels on the other side of the top seal. Seal- ing of the top seal is performed with the inner and outer seal lips located in a generally vertical position. Each of the inclined score line portions between the smaller triangu¬ lar inner roof panels and- their associated inner seal lips and the dropped score line between the one outer seal lip and its associated outer roof panel are preferably wider than the other score lines of the top end closure. This construction of the container blank facilitates folding of the top seal from the vertical position to either an inclined position for providing a slant top or a horizontal position where the top seal is adhesively bonded to the adjacent outer roof panel to provide a flat top end closure. Regard¬ less of whether the top seal is used to make a vertical top, a slant top, or a flat top end closure," the terminal edges of the outer seal lips extend alongside each other and the folded inner seal lips have their terminal edges likewise extending alongside each other located inwardly from the terminal edges of the outer seal lips. In the preferred construction of the blank having the dropped score line and inclined score line portions that are wider than the other score lines of the top end closure, the outer seal lip and outer roof panel connected by the dropped score line are located between the two smaller triangular inner roof panels in the flat condition of the blank prior to construction. A seam flap that connects the other outer roof panel and one of the larger inner roof panels is thus located on the opposite side of the top seal from the smaller inner roof panels toward which the top seal is capable of being bent. Such an arrangement of the top seal panels and seal lips enhances the seal'provided by the container blank. The objects, features and advantages of the present invention are readily apparent from the following description of the best mode for carrying out the invention when taken in connection with the accompanying drawings. * BRIEF DESCRIPTION OF DRAWINGS Figure 1 is a view of a coated paperboard container blank used to construct a container having a top end closure with a roof and a top seal in accordance with the present inventio ; Figure 2 is a partial view of a container constructe from the blank of Figure 1 and shows the top seal of the top end closure in a vertical position where sealing thereof is performed; Figure 3 is a bottom plan view showing a bottom end closure of the constructed container; Figure 4 is a view of the container after the top seal has been bent from the vertical position of Figure 2 to the inclined position shown in order to provide a slant top seal for the top end closure; and Figure 5 is a view of the container after the top seal kas been bent' from the vertical position of Figure 2 to the flat position shown and releasably secured in order to provide a flat top seal for the top end closure. BEST MODE OF CARRYING OUT THE INVENTION A thermoplastic coated paperboard blank indicated by reference numeral 20 in Figure 1 is constructed according to the preferred embodiment of the invention to provide a carton or container 22 as shown in part in Figure 2. A tubular body portion 24 of the container 22 has a top end closed by a top end closure 26 (Figure 2) of the invention and also has a bottom end closed by a bottom end closure 28 (Figure 3) . The container blank 20, as shown in Figure 1, includes various scores or score lines along which the blank is folded to provide the container body portion 24, the slant top end closure 26, and the bottom end closure 28. Inter¬ mediate its upper and lower ends, the blank 20 includes a rectangular side panel 34 connected to a rectangular front panel 36 which is itself • connected to another rectangular side panel 38. A rectangular back panel 40 is also connected to the side panel 38 and is secured to a seam flap 42 connected to the side panel 34 during construction of the order to form a tubular configuration. Securement of the seam flap 42 to the back panel 40 is provided by heat wit a clamping pressure- utilized to bond the thermoplastic coating of the container blank portions to each other.- The bottom end closure 28 is formed after the construction of the container blank into its tubular shap by folding the various triangular and rectangular panels 4 44, 45, 46, 47, 48, 49 and 50 and then bonding these pane to each other. A lower end 42a of seam flap 42 is secure to the panel 50 during the formation of the container bla into its tubular configuration. Inward folding of the triangular panels 44 and 48 toward each other then pulls triangular panels 43, 45 and 47, 49 connected thereto int an overlying relationship therewith as the rectangular pa 46 and 50 are concomitantly pulled inwardly to overlie th triangular panels in a generally planar relationship to fo the end closure. The end closure 28, as can be seen in Figure 3, is of the tucked in type with a portion 50a of panel 50 extending past a centerline B of the closure bene a flap 46a of panel 46. A high frequency vibration sealin apparatus such as the one disclosed by U.S. Patent 3,912,5 or a conventional heat sealing apparatus is utilized to se the end closure whose various portions have one, two, thre and four layers of the carton material respectively indica by letters a, b, c and d. It should also be noted that th bottom end closure 28 may also be of the "non-tuck in" typ wherein the panel 50 terminates at the centerline B of thi closure. The top end closure 26 is formed from the contai blank 20 shown in Figure 1 after construction thereof into the tubular configuration described above and after format of the bottom end closure 28 and filling of the partially constructed container with its contents. The roof 30 of t top end closure includes a rectangular .outer roof panel 52 connected to the body portion side panel 34, a front trian lar gable panel 54 connected to the body portion front pan 36, an outer roof panel 56 connected to the body portion s panel 38, and a back triangular gable panel 58 connected t { _ OM the body portion back panel 40. Triangular inner roof panels 53 and 55 respectively connect the front triangular gable panel 54 with pouring spout portions 52a and 56a of the outer roof panels. Likewise, triangular inner roof panels 57 and 59 of the constructed container respectively connect the back triangular gable panel 58 with the outer roof panels 56 and 52, the latter connection being made by an upper portion 42b of the seam flap which is bonded to panel 59. The top seal 32 of top end closure 26 includes a rectangular outer seal lip 60 shown in Figure 1 as projecting from the outer roof panel 52 and connected thereto by a single score line 61. A front inner seal lip 62 is connected by a single score line 63 to the inner roof panels 53 and 55 that are connected to the front triangular gable panel 54. An outer seal lip 65 of the slant top seal projects from the out-er roof panel 56 and is connected thereto by a single score line 65. A back inner seal lip 66 is connected by a single score line 67 to the.inner roof panels 57 and 59 that are connected to the back triangular- gable panel 58. Ends of the inner and outer seal lips are also connected to each other as shown. Construction of the top end closure 26 begins by inward folding of the triangular gable panels 54 and 58 shown in Figure 1 toward each other with the container blank in its tubular configuration. This folding moves the inner roof panels 53, 55 and 57, 59 respectively connected to gable panels 54 and 58 in an overlying relationship thereto and pulls the outer roof panels 52 and 56 downwardly * into their inclined orientation so as to cooperatively provide the roof ridge A (Figure 2) from which the top seal 32 projects. The bond along seal 32 is formed by application of either heat or high frequency vibration together with a clamping action that seals the contents of the container. Each bond not only seals the outer seal lips 60 and 64 to each other but also secures the outer seal lips to the folded inner seal lip 66 therebetween which is connected to the back triangular gable panel 58 shown in Figure 1 by the inner roof panels 57 and 59. Outer seal lips 60 and 64 are also secured to each other by the bond but may be prevented from forming a with the inner seal lip 62 associated with the front trian lar gable panel 54 shown in Figure 1 by coating of an abhe ive material applied to the inner seal lip 62 as shown at and to the outer seal lips 60 and 64 as shown at 72 and 74 This abhesive coating may be made of any suitable material such as a silicone based material, and permits the sealed end closure 26 to be opened from its closed condition of F ure 2 to an open condition where a conventional pouring sp (not shown) is provided to dispense the contents of the container. Outer seal lips 60 and 64 as seen in Figure 1 ha respective straight outer terminal edges 60a and 64a. Bot outer roof panels 52 and 56 have the same height projectin from their associated body portion side panels 34 and 38 a the score lines that interconnect these panels are located slightly above the score lines that connect the triangular gable panels 54 and 58 with the front and back panels 36 a 40 to enhance foldability. As seen in Figure 1, inner seal lips 62 and 66 i elude respective terminal edges 62a and 66a that may have somewhat blunt V shapes forming associated vertices 86 and 88. Opposite ends 90 and 92 of inner seal lip 62 are resp tively connected to the outer seal lips 60 and 64 adjacent their coatings of abhesive material indicated by 72 and 74 Likewise, opposite ends 94 and 96 of inner seal lip 66 are respectively connected to outer seal lip 64 and outer seal lip 60, the latter connection being at the top seam flap e 42b. Intermediate its ends, inner seal lip 62 includes a score line 98 extending between its terminal edge vertex 8 and the adjacent front gable panel inclined edge intersect or apex 80. Likewise, inner seal lip 66 includes a score line 100 extending between its terminal edge vertex 88 and. the adjacent back gable panel inclined edge intersection 8 During sealing of the top seal 32, the inner seal lips fol along their respective score lines 98 and 100 so as to be located between the outer seal lips 60 and 64. Referring once again to Figure 1, the single sco line 65 that connects the outer roof panel 56 and the oute seal lip 64 is positioned at a dropped or lower elevation L3RE. _OΓ.-.PI than the gable apices 80 and 84 and the single score line 61 that connects the outer roof panel 52 and the outer seal lip 60. The combined height of outer roof panel 52 and outer seal lip 60 is the same as the combined height of outer roof panel 56 and outer seal lip 64. The score line 65 that connects the outer roof panel 5.6 and the outer seal lip 64 is wider than the score line 61 that connects the outer roof panel 52 and the outer seal lip 60 in order to facilitate folding of the top seal after construction of the container as will be more fully hereinafter described. Each of the front and back gable panels 54 and 58 of blank 20f shown in Figure 15 has its base angles 54a, 54b, and 58a, 58b equal to each other. As such, the intersection or apices 80 and 84 of the gable panels where the intersecting edges 78, 79 and 82, 83 meet are located centrally between the opposite ends 90, 92 and 94, 96 of the inner seal lips 62 and 66. Each single score line 63 and 67 that connects the associ¬ ated inner seal lip 62 or 66 with the adjacent inner roof panels 53, 55, or 57, 59 includes an inclined portion whose upper end extends to the adjacent gable apex 80 or 84 and whose lower end is connected to the adjacent end of the score line 65. The inclined score line portions 63 and 67 like the score line 65 are wider than the other score lines so as to also facilitate the folding of the top seal from a vertical position as is more fully hereinafter described. It should also be noted that the terminal edges 62a and 66a of the inner seal lips 62 and 66 are of a symmetrical shape on oppo¬ site sides of their central vertices 86 and 88. The constructed container 22 can be utilized with its top seal 32 extending vertically as shown in Figure 2. It is also possible to fold the top seal 32 to an inclined, position by the application of a force F as shown in Figure 4 in order to provide a slant top seal. Folding of the top seal 32 to the slant top position shown in Figure 4 is facilitated by the wider and dropped score line 65 and the wider and inclined portions of score lines 63 and 67. In the slant top condition, the top seal 32 extends toward the smaller inner roof panels 55 and 57 which are partially defined by the inclined score line portions of score lines 63 and 67. Containers 22 can be packed in layers on top of each other to minimize the storage and cargo space neces- sary. As the containers are stacked, their slant top seals 32 will deflect downwardly as shown in Figure 4 from their solid line position to the lower position shown by phantom line. As this deflection takes place, the slant top end clo'sure 26 provides an inherent cushioning effect between the layers of containers to enhance the transportability of the containers without leakage occuring. .Unlike folded gable roof closures with vertically projecting seals, this container does not require any shipping tray intermediate the different layers of stacked containers. No releasable securement of the slant top seal to the rest of the top end closure is necessary as with flat top end closures. The versatility of the container blank 20 shown i Figure 1 is further demonstrated by Figure 5 wherein the to seal 32 is shown folded over to a horizontal position in order to provide a flat top end closure. A force F, impart by use of a suitable tool, bends the top seal 32 toward the side of the container on which the dropped and wide score line 65 is located. The outer seal lip 64 is then releas- ably secured to the outer roof panel 56 by a suitable adhes bond provided in any conventional manner in order to provid the flat top closure. Opening of the constructed flat top end closure of the container 22 thus proceeds by first releasing the top seal 32 from the outer roof panel 56 and then moving the top seal to either the slant position of Figure 4 or the vertical position of Figure 2 followed by opening of the pouring spout in the usual manner. While the best mode for practicing the present invention has herein been disclosed in detail, those skille in the art will recognize various alternative designs and embodiments for practicing the present invention as defined by the following claims.

Claims: We claims 1. A blank for constructing a container, the blank comprising: body portion panels including front and back panels and a pair of side panels one of which connects the front and back panels; bottom end closure panels con¬ nected to lower ends of the body portion panels; top end closure panels connected to upper ends of the body portion • panels; said top end closure panels including front and back gable panels respectively connected to the upper ends of the front and back panels of the body portion and also including a pair of outer roof panels respectively connected to the upper ends of the side panels of the body portion; a pair of triangular inner roof panels located on opposite sides of each gable panel; the inner roof panels of each pair being of a different size than each other; top seal lips including a pair of inner seal lips respectively connected to the inner roof panels associated with each gable panel; a single score line connecting each inner seal lip and the associated inner roof panels; said top seal lips also including a pair of outer seal lips respectively connected to the outer roof panels; a single score line connecting each outer seal lip and the associated outer roof panel; and the outer seal lips having terminal edges whose heights are selected so as to extend generally alongside each other upon construction of a top end closure and a top seal by folding of said top end closure panels and said top seal lips. 2. A blank as in Claim 1 wherein each gable panel includes a pair of unequal base angles so as to provide the different size of each inner roof panel on its opposite sides. 3. A blank as in Claim 1 wherein one of the outer seal lips and the associated outer roof panel have the single score line therebetween located lower than the single score line between the other " outer seal lip and outer roof panel, said lower single score line being wider than the single score line between said other outer seal lip and outer roof panel, each of said single score lines between the inner seal lips and the associated inner roof panels including a wide portion and a narrow portion, said wide score line portions having inclined orientations with upper ends that intersect with apices of the associated gable panels and lower ends that are located adjacent the oppo- site ends of said wide score line in the constructed condition of the top end closure. 4. A blank as in Claim 1 wherein the single score line between one outer seal lip and roof panel is located below the single score line between the other outer seal lip and roof panel. 5. A blank for constructing a container,, the bla comprising: body portion panels including front and back panels and a pair of side panels one of which connects the " front and back panels; bottom end closure -panels connected to lower ends of the body portion panels; top end closure panels connected to upper ends of the body portion panels; said top end closure panels including front and back gable panels respectively connected to the upper ends of the front and back panels of the body portion and also includ- ing a pair of outer roof panels respectively connected to the upper ends of the side panels of the body portion; each of said gable panels including a pair-of equal base angles and an upper apex; a pair of triangular inner roof panels located on opposite sides of each gable panel; the inner roof panels ' of each pair being of a different size than each other; top seal lips including a pair of inner seal lips respectively connected to the inner roof panels associated with each gable panel; a single score line conne ing each inner seal lip and the associated inner roof panel said top seal lips also including a pair of outer seal lips respectively connected to the outer roof panels; a single score line connecting each outer seal lip and the associate outer roof panel; one single score line that connects the outer seal lip. and the outer roof panel connected to said one side panel of the body portion being located below the apices of the gable panels and being wider than the other single score line connecting the other outer seal lip and outer roof panel; each of the smaller inner roof panels being located adjacent one end of the wide score line; each of the single score lines connecting the inner seal lips and the associated inner roof panels including a wide score line portion connected to one end of the wide score line between the one outer seal lip and outer roof panel; and the outer seal lips having terminal edges whose heights are selected so as to extend generally alongside each other upon construc tion of a top end closure and a top seal by folding of said top end closure panels and said top seal lips. 6. A blank for constructing a container, the blank comprising: body portion panels including front and back panels and a pair of side panels one of which connects the front and back panels; bottom end closure panels con¬ nected to lower ends of the body portion panels; top end closure panels connected to upper ends of the body portion panels; said top end closure panels including front and back gable panels respectively connected to the upper ends of the front and back panels of the body portion and also including a pair of outer roof panels respectively connected to the upper ends of the side panels of the body portion; each of said gable panels including a pair of equal base angles and an upper apex; a pair of triangular inner roof panels locate on opposite sides of each gable panel; the inner roof panels of .each pair being of a different size than each other; top seal lips including a pair of inner seal lips respectively connected to the inner roof panels associated with each gable panel; a single score line connecting each inner seal lip and the associated inner roof panels; said top seal lips also including a pair of outer seal lips respectively connec ed to the outer roof panels; a single score line connecting each outer seal lip and the associated outer roof panel; one single score line that connects the outer seal lip and the outer roof panel connected to said one side panel being wider and located' below the other single score line that connects ' the other outer seal lip and outer roof panel; each of the smaller inner roof panels being located adjacent one end of said lower and wider score line; each of the single score lines connecting the inner seal lips and the associate inner roof panels including an inclined score line portion URΪ Ofl'.PI to to to H H tn O tπ o tn o tn the inner seal lips and the associated inner roof panels including a wide portion and a narrow portion, said wide score line portions having inclined orientations with upper ends that intersect with apices of the gable panels and lower ends connected to opposite ends of the lower and wider score line that connects the outer seal lip and outer roof panel on the side of the top seal where the smaller inner roof panels are located. 9. A container as in Claim 7 wherein the single score line between one outer seal lip and outer roof panel is located below the single score line between the other outer seal lip and outer roof panel. 10. A container comprising: a body portion in¬ cluding front and back panels and a pair of side panels- which connect the front and back panels; a bottom end closure including folded panels connected to lower ends of the body portion panels; a top end closure including top closure panels connected to upper ends of the body portion panels to provide a folded roof and also including a top seal including seal.lips connected to the top closure panels and sealed to each other to provide the top seal; said top closure panels including front and back gable panels respectively connected to upper ends of the front and back panels of the body portion and also including a pair of outer roof panels respectively connected to the upper ends of the side panels of the body portion on opposite sides of the top seal; each of said gable panels including a pair of equal base angles and an apex; a pair of triangular inner roof panels flanking each gable panel; the inner roof panels on one side of the top seal being of a smaller size than the inner roof panels on the other side thereof; said top seal including a pair of inner seal lips respectively connected to the inner roof panels associ¬ ated with each gable panel; a single score line connecting each inner seal lip and the associated inner roof panels; said top seal also including a pair of outer seal lips res¬ pectively connected to the outer roof panels; a single score line connecting each outer seal lip and the associated o ter ' BU EA-T OMPI _ WIPO μ- H tn O tn

Inventors: LISIECKI R
Applicants: EX CELL O CORP
Application year: 1979
Main classification: B65D5
IPC codes: B65D5