FLAT TOP CONTAINER AND BLANK FOR CONSTRUCTING SAME

Abstract: A flat top, thermoplastic coated, paperboard container having weakened lines formed thereon such that the top may be fully opened by breaking through a weakened line at the front and progressively breaking the weakened lines along the sides upon peeling back the cover panel, to provide ac­ cess to the contents. Provisions are included for covering the weakened lines on the inside of the container to prevent leak­ age.

Description: This invention relates generally to thermoplastic coated paperboard containers and, more particularly, to a blank and a container including a top end closure of an improved construction. Containers for beverages such as milk, cream, other dairy products, juices, and the like, are conventionally constructed from the thermoplastic coated paperboard. Typically, these containers include a top end closure with a folded roof structure adaptable to providing a readily available pouring spout when the contents of the container are to be dispensed. Coated paperboard blanks for constructing such a container are made on converting machines similar to those disclosed by US-A-2,682,208 and US-A-63,731,600. After construction, the blanks are processed by forming, filling and sealing machines, such as those disclosed by US-A-3,303,761, US-A-3,918,236, US-A-3,398,659 or US-A-4,193,833, to produce the formed, filled and sealed containers of the type referred to above and shown and described in US-A-3,270,940, or US-A-4,422,570. While this type of container has been generally satisfactory for liquid products, it is desirable to utilize a similar square or rectangular thermoplastic coated paperboard container for frozen juices with a modified top closure arrangement which is adaptable to being fully opened, in lieu of using a conventional cylindrical paperboard container with a removable metal or solid plastic top cover. Such a modified top closure arrangement is desirable also for containing and providing access to "spoonable" products, such as yogurt and puddings. One example of a satisfactory top closure of a substantially fully openable type is shown and described in US-A-4,397,415. Further, EP-A-0 141 491 discloses a container wherein the three weakened lines associated with the side panels and the front panel, respectively, are provided in a distance from the score lines on which the respective edge fold-in panels are folded. This design results in a container having a rather rigid top end closure since the three free edges of the cover panel are reinforced by the fold-in edge panels. Further, there is no risk of liquid leaking from the closed container in the area of the weakened or perforated lines since the same are well inwardly of the free edges of the top end closure. Also US-A-2,294,964 discloses another known flat top paper board container wherein weakened or perforated lines extend partly along score lines at the upper ends of the side panels of the container body and the front panel thereof. This known container comprises a portion of the top end closure which remains closed when the rest of the top end closure is opened by breaking the weakened lines. Further, the stability of the top end closure of the known container is weakened by the weakened lines surrounding the major portion of the top end there being no reinforcing elements comparable to the fold-in edge panels of the claimed container. Additionally, the perforated lines of the known container mostly lying directly at the edges of the top end closure involve the risk of leakage of liquid from the container through the perforations of the weakened lines. It is the object of the invention to provide a thermoplastic coated paperboard container including improved top closure means for providing the above mentioned desirable fully openable feature for particular products. This object according to the invention is accomplished by a flat top thermoplastic coated container comprising: body panels including front and back panels and a pair of side panels; a pair of side fold-in edge panels integrally connected by first and second horizontal score lines to the top end of said pair of side panels and folded on said first and second horizontal score lines inwardly toward one another; a front fold-in edge panel integrally connected by a third horizontal score line to the top end of said front panel and folded inwardly on said third horizontal score line; a cover panel integrally connected by a fourth horizontal score line to said back panel and folded on said fourth score line onto and secured to said side fold-in edge panels and said front fold-in edge panel; and first to third weakened lines associated with each of said fold-in edge panels with the third weakened line associated with said front fold-in panel being adapted to be manually broken to permit further breaking of said first and second weakened lines associated with said side fold-in edge panels by the manual lifting of said cover panel, characterized in that the side fold-in edge panels are connected to the top of the side panels by their associated first and second weakened lines and are folded inwardly on these weakened lines and that a layer of one of aluminum foil, thermoplastic film and hot melt is covering the first and second horizontal weakened lines associated with said side fold-in edge panels and the third horizontal score line and secured to segments of the immediately adjacent panel surfaces. Further, the object underlying this invention is accomplished by constructing a flat top container from a thermoplastic coated container blank for constructing a flat top container, said blank comprising: body panels including front and back panels and a pair of side panels; a pair of side fold-in edge panels integrally connected by first and second horizontal score lines to the top end of said pair of side panels and folded on said first and second horizontal score lines inwardly toward one another; a front fold-in edge panel integrally connected by a third horizontal score line to the top end of said front panel and foldable inwardly on said third horizontal score line; a cover panel integrally connected by a fourth horizontal score line to said back panel and foldable on said fourth score line onto and securable to said side fold-in edge panels and said front fold-in edge panel; and first to third weakened lines associated with each of said fold-in edge panels with the third weakened line associated with said front fold-in panel being adapted to be manually broken to permit further breaking of said first and second weakened lines associated with said side fold-in edge panels by the manual lifting of said cover panel of a closed container made from said blank, characterized in that the side fold-in edge panels are connected to the top of the side panels by their associated first and second weakened lines and are foldable inwardly on these weakened lines and that a layer of one of aluminum foil, thermoplastic film and hot melt is covering the first and second horizontal weakened lines associated with said side fold-in edge panels and the third horizontal score line and secured to segments of the immediately adjacent panel surfaces. An advantage of the invention is to provide an improved thermoplastic coated paperboard container suitable for being filled with a juice concentrate and then frozen, or with foodstuffs of a somewhat solid consistency. A further advantage of the invention is to provide a square or rectangular paperboard container including an improved, conveniently fully openable flat top closure arrangement. A still further advantage of the invention is to provide a flat top container having a lift flap and a cover panel having a perforated portion covered with a foil patch, a thermo-plastic film, or a thermoplastic hot melt. Still another advantage of the invention is to provide alternate embodiments of a flat top container wherein the cover panel may be one of a full panel top for maximum "billboard", or overlapping panel segments which may be converted with minimal scrap. Other advantages of the invention will become more apparent when reference is made to the following drawings and related description. In the drawings, Figure 1 is a fragmentary layout view of the inside surface of a coated paperboard container blank used to construct a container having a top end closure in accordance with the present invention; Figure 2 is a fragmentary layout view of the outside surface of a blank after it is side seamed from the blank illustrated in Figure 1; Figures 3 and 4 are enlarged fragmentary perspective views illustrating sequentially the steps involved in forming the flat top end closure; Figure 5 is a fragmentary perspective view showing the container of Figure 4 after the top closure has been sealed closed and then opened; Figure 6 is a fragmentary layout view of the inside surface of an alternate embodiment blank from which a container embodying the invention may be erected; Figures 7 and 8 are views of the alternate embodiment comparable to the Figures 4 and 5 of the preferred embodiment; Figures 9-12 are views of still another embodiment of the invention; and Figures 13-18 are views of still another embodiment of the invention. Referring now to the drawings in greater detail, Figure 1 illustrated a container blank 10 formed in accordance with the principles of the present invention. The container blank 10 is generally divided into three sections including a top end closure 12, a body portion 14, and a conventional flat bottom end closure (not shown). The latter may be any suitable end closure arrangement and is not a part of this invention. The body portion 14 comprises a plurality of integrally connected body panels, namely, a back panel 18, a side panel 20, a front panel 22 and a side panel 24, and a side seam flap or narrow fifth panel 26 formed adjacent the panel 24. The container blank 10 is defined on its longitudinal sides by edges 28 and 30. The body panels 18, 20, 22 and 24, and the side seam flap 26, are defined by vertical score lines 32, 34, 36 and 38. It should be apparent that the body panels may be equal in width and hence, adaptable to forming a square cross-section container, or may be formed much that one pair of alternate body panels is wider than the other pair and, hence, adaptable to forming a rectangular cross-section container. The top end closure 12 comprises a cover panel 40 connected by a score line 42 to the back panel 18, and front edge panel 43 connected by a score line 44 to the top of the front body panel 22. Side edge panels 46 and 48 are connected by perforated lines 50 and 52, respectively, to the fops of the side panels 20 and 24. An arcuate shaped perforated line 54 is formed in the front panel 22, arcing from points adjacent the respective ends of the score line 44 to form a segment 55. An edge panel 56 is connected by a score line 58 to the top of the side seam flap 26. Diagonal score lines 60 and 62 are formed on the edge panel 46, extending from the intersections of the score lines 32/42 and 34/44, respectively. Diagonal score lines 64 and 66 are formed on the edge panel 48, extending from the intersections of the score lines 36/44 and 38/58, respectively. A layer 68 of a suitable material, such as a thermoplastic hot melt, or a strip of either aluminum foil or thermoplastic film, is secured to all the inside surfaces adjacent the perforated lines 50, 52 and 54. Specifically, the top edge 70 of the layer or strip 68 extends from the edge 30 across the panels 56, 48, 43 and 46 at approximately the half heights thereof, and onto the cover panel 40 for a distance approximately the width of the panel 56. The bottom edge 72 of the layer or strip 68 extends from the edge 30 across the panels 26, 24, 22 and 20 on a line below the bottom of the arcuate perforated line 54 an amount approximately equal to the height of the edge 70 above the score line 44. The edge 72 continues onto the back panel 18 the same distance as the top edge 70. The end of the layer or strip 68 is defined by an edge 74 across the score line 42. The container blank 10 illustrated in Figure 1 is first formed into a side seam blank as shown in Figure 2 by rotating the body panel 24 and the side seam flap 26 as a unit about the vertical score line 36, and having the inside surfaces of the body panel 24 come into contact with the inside surface of the body panel 22, with the vertical score line 38 positioned next to the vertical score line 34, and with the inside surface of the side seam flap 26 contacting the inside surface of the body panel 20 adjacent the vertical score line 34. The body panel 18 is then rotated about the vertical score line 32 to bring its inside surface into contact with the inside surface of the body panel 20. The inside surface of the body panel 18 along the portion adjacent the edge 28 comes into contact with the outside surface of the side seam flap 26, and the edge 28 is positioned parallel and aligned with the vertical score line 38. The various members of a bottom end closure will make similar movements. Insofar as the top end closure 12 is concerned, the edge panel 48 overlies the edge panel 43, the edge panel 56 overlies a portion of the edge panel 46, and the cover panel 40 overlies the edge panels 46 and 56. The container blank 10 is then sealed where the inside areas of the body panel 18 and cover panel 40 come into contact with the outside surfaces of the side seam flap 26 and the edge panel 56. In the Figure 1 structure, if desired, in the formation of the side seam blank the side seam panel 26 could be sealed to the outside surface of the adjacent back panel 18, rather than to the inner surface thereof as described above. Inasmuch as the eventual top closure arrangement of the invention is a non-gable, flat top configuration, it has been proven to be more compatible with existing forming, filling and sealing machines to form such top closure first. Then, after filling the container through the open bottom end, the panels associated therewith are closed and sealed in a manner heretofore used for a conventional top closure arrangement. Accordingly, after the side seam blank is opened up into a squared condition, as shown in Figure 3, the various parts of the eventual top end closure 12 are folded on the various score lines and perforated lines in the following manner so as to form the top end structure. The edge panels 46 and 48 are forced inwardly about the respective perforated lines 50 and 52, after which the front edge panel 43 is urged inwardly about the score line 44, followed by the bending of the cover panel 40 about the score line 42. The sealing of the interrelated elements of the top closure 12 is then accomplished by conventional means, such as a sonic or high frequency vibration sealing means. The sealing of the various top end closure elements may also be accomplished by other means, such as gas heat, if desired. Figure 4 illustrates the top end closure 12 structure once the sealing thereof has been effected. In opening the carton, the arcuate segment 55 between the perforated line 54 and the score line 44 pressed inwardly, breaking the perforated line 54 and bending the segment 55 about the score line 44. As the segment 55 and the cover panel 40 are raised further, the edge panels 46 and 48 are pulled away from the side panels 20 and 24, breaking the perforated lines 50 and 52 and providing a completely open top as shown in Figure 5, permitting access to the contents of the container. Referring now to Figures 6-8, there is illustrated an alternate blank embodiment wherein cover panels 76 and 78 of equal height replace the cover and front edge panels 40 and 43 of the Figure 1 structure, resulting in an overlapped end closure as shown in Figure 7. This embodiment opens the same as the Figure 5 arrangement, as illustrated in Figure 8. Figure 9-12 illustrate still another embodiment, wherein the arcuate perforated line 54 and diagonal score lines 62 and 64 of Figures 1 and 6 have been eliminated, and a lift tab 80, cut edges 82 and 84, and a perforated line 86 have been added. The lift tab 80 included an inner portion 88 and an outer portion 90 separated by a score line 92. The top end structure for this embodiment is formed by first pivoting the front edge panel 43 inwardly about the score line 44 between the extended edge panels 46 and 48 and the lift tab 80 outwardly about perforated line 86 (Figure 10). This in made possible by virtue of the cute edge 82 between the edge panels 46 and 42, and the out edge 84 between the edge panels 46 and 48. Thereafter, once the side edge panels 46 and 48 are bent inwardly about the respective perforated lines 50 and 52, and the cover panel 40 is flattened about the score line 42, the outer portion 90 of the lift tab 80 is folded onto the cover panel 40 about the score line 92 and tack welded thereon (Figure 11). When opening, the outer tab portion 90 is lifted and the cover panel 40 is torn back, separating the perforated lines 86, 50 and 52 to fully expose the contents of the container as shown in Figure 12. A still further embodiment is illustrated in Figures 13-18. This embodiment is somewhat similar to the Figures 6-8 arrangement, but with additional provisions for eliminating raw edges in the top closure being exposed to the contents of the sealed container. This is accomplished by substituting panels 94, 96 and 98 for the panels 46, 48 and 78, respectively, of Figure 6. The panel 94 includes a substantially centrally located horizontal score line 100, with diverging score lines 102 and 104 extending from one end of the score line 100 to substantially the corners of the panel 94 adjacent a full area cover panel 106 comparable to the cover panel 40 of Figure 1. The score lines 102 and 104 form a substantially triangular panel 107 with the score line 32. Diverging score lines 108 and 110 extend from the other end of the score line 100 to substantially the corners of the panel 94 adjacent the panel 98, forming a substantially triangular panel 111 with the score line 34. Vertical score lines 112 and 114 extend from the respective ends of the score line 100 upwardly in Figure 13 to the free edge of the panel 94, forming triangular segments 113 and 115 with the respective score lines 104 and 110 and the free edges of the panel 94. The panel 96 is comparable to the panel 94 and includes a substantially centrally located horizontal score line 116, with diverging score lines 118 and 120 extending from one end of the score line 116 to substantially the corners of the panel 96 adjacent an edge panel 122 connected by the score line 58 to the side seam flap 26. The score lines 118 and 120 form a substantially triangular panel 123 with the score line 38. Diverging score lines 124 and 126 extend from the other end of the score line 116 to substantially the corners of the panel 96 adjacent the panel 98, forming a substantially triangular panel 127 with the score line 36. Vertical score lines 128 and 130 extend from the respective ends of the score line 116 upwardly in Figure 13 to the free edge of the panel 96, forming triangular segments 129 and 131 with the respective score lines 120 and 126 and the free edges of the panel 96. The panel 98 includes segments 132, 134 and 136. The segments 132 and 134 are separated by a score line 138 and substantially equal to each other in height, and of substantially the same freight as the panels 94 and 96, the score line 138 being aligned with the free edges of the panels 94 and 96. The segment 136 is separated from the segment 134 by a score line 140 and serves as a lift tab, as will be explained. The same layer 68 as shown in Figures 1, 6 and 9 is secured to all the inside surfaces adjacent the perforated lines 50, 52 and 54. The container blank illustrated in Figure 13 is first formed into a side seam blank as shown in Figure 14, as described above relative to Figure 2, and then opened up into a squared condition, as shown in Figure 15. The various parts of the eventual top end closure are folded on the various score lines and perforated lines in the following manner. In effect, the score lines 100, 116 and 138 are pushed inwardly, collapsing the segments above and below the respective score lines, as shown in Figure 16. Specifically, the outer surfaces of the upper halves of the panels 94 and 96 progressively approach the respective outer surfaces of the lower halves, and the outer surface of the upper segment 134 approaches the outer surface of the lower segment 132. Concurrently, the triangular segments 113, 115, 129 and 131 approach the upper halves of the respective triangular panels 107, 111, 123 and 127. The lift tab 136 is bent around the score line 140 such that its inner surface approaches the inner surface of the segment 134 but, as shown in Figure 17, the free edge portion of the cover panel 106 is caused to be confined and sealed between the adjacent surfaces of the segment 134 and the lift tab 136. Due to the conventional thermoplastic coating on all inside and outside surfaces of the blanks shown in Figures 1, 6, 9 and 13, all contacting surfaces of each of the closed containers shown in Figures 4, 7, 11 and 17 are sealed to each other under heat and pressure or vibration in the end sealing operation. Referring now to Figure 18, in a manner similar to that involved for Figures 5 and 8, manually pressing in the panel segment 55 breaks the weakened line 54, after which lifting is made easy by the tab 136, serving to break the weakened lines 50 and 52 to thereby expose a fully opened top, providing complete access to the contents of the container. It should be realized that a panel somewhat similar to the panel 98 could be used on the blank of Figure 1, in lieu of the panel 43, and visa versa, if desired. It should be apparent that the invention provides a novel and efficient thermoplastic coated paperboard carton which is ideally suited for being filled with a frozen concentrate, such as orange juice, or with a spoonable product, such as yogurt and puddings, for example, and sealed for distribution through the marketing system, and capable of being readily and easily opened by the consumer.

Claims: 1. A flat top thermoplastic coated container comprising: body panels including front (22) and back panels (18) and a pair of side panels (20, 24); a pair of side fold-in edge panels (46, 48) integrally connected by first and second horizontal score lines (50, 52) to the top end of said pair of side panels (20, 24) and folded on said first and second horizontal score lines (50, 52) inwardly toward one another; a front fold-in edge panel (43) integrally connected by a third horizontal score line (44) to the top end of said front panel (22) and folded inwardly on said third horizontal score line (44); a cover panel (40) integrally connected by a fourth horizontal score line (42) to said back panel (18) and folded on said fourth score line (42) onto and secured to said side fold-in edge panels (46, 48) and said front fold-in edge panel (43); and first to third weakened lines (50, 52, 54; 82, 84, 86) associated with each of said fold-in edge panels (43, 46, 88) with the third weakened line (54) associated with said front fold-in panel (43) being adapted to be manually broken to permit further breaking of said first and second weakened lines (50, 52) associated with said side fold-in edge panels (46, 48) by the manual lifting of said cover panel (40), characterized in that the side fold-in edge panels (46, 48) are connected to the top of the side panels (20, 24) by their associated first and second weakened lines (50, 52) and are folded inwardly on these weakened lines (50, 52) and that a layer (68) of one of aluminum foil, thermoplastic film and hot melt is covering the first and second horizontal weakened lines (50, 52) associated with said side fold-in edge panels (46, 48) and the third horizontal score line (44) and secured to segments of the immediately adjacent panel surfaces. 2. The container according to claim 1, wherein said third weakened line (54) is an arcuate line extending downwardly from the third horizontal score line (44), being formed in said front panel (22) and adapted to being pushed inwardly to be broken. 3. The container according to claim 2, wherein said layer (68) also covers said third weakened line (54) and is secured to segments of the immediately adjacent panel surfaces. 4. The container according to claim 1, wherein a lift tab (80) is secured to said front fold-in edge panel (88), wherein said third weakened line comprises two cut edges (82, 84) and a perforated line (86) and wherein said cut edges (82, 84) are separating said respective side fold-in edge panels (46, 48) from said front fold-in edge panel (88). 5. The container according to claim 4, wherein said layer (68) does not cover said perforated line (86). 6. The container according to claim 5, wherein said lift tab (80) includes an inner segment (88) and an outer segment (90), said inner and outer segments (88, 90) being interconnected by a score line (92) formed across the width of said lift tab (80) at a distance away from said third weakened line (82, 84, 86) equal to the height of said front fold-in edge panel, said inner segment (88) being secured between said front fold-in edge panel and said cover panel (40), and said outer segment (90) being folded about said score line (92) onto said cover panel (40) and adapted to being lifted so as to separate said inner segment (88) from said front fold-in edge panel, break said third weakened line (82, 84, 86), and progressively break said first and second weakened lines (50, 52). 7. The container according to claim 3, wherein a pair of diagonal score lines (60, 62, 64, 66) is formed on each of said side fold-in edge panels (46, 48) at the ends thereof, each said pair of diagonal score lines converging in an upwardly direction and forming corner segments sealed between said side fold-in edge panels (46, 48) and said cover panel (40). 8. The container according to claim 5, wherein a diagonal score line is formed on each of said side fold-in edge panels (46, 48) at the end thereof away from said front fold-in edge panel (88) so as to form a corner segment adapted to being sealed between each of said side fold-in edge panels (46, 48) and said cover panel (40). 9. The container according to claim 7 or 8, wherein said corner segments are triangular in shape. 10. The container according to claim 7 or 8, wherein said corner segments are trapezoidal in shape. 11. The container according to claim 7, wherein an additional panel segment is connected by a horizontal score line (100, 116) to each of said side fold-in edge panels, and a pair of diagonal score lines (104, 110, 120, 126) diverging upwardly from the respective ends of the horizontal score line (100, 116) to substantially the corners of the additional panel segment, and adapted to fold onto said respective side fold-in edge panels, thereby eliminating raw edges along the sides of the inside end closure. 12. The container described in claim 7, wherein said front fold-in edge panel (98) consists of three segments (132, 134, 136), two of which are substantially equal in height and equal to the overall height of each each side fold-in edge panel and the additional panel segment, and are folded inwardly onto each other to thereby eliminate a raw edge along the front of the inside end closure, and the third (136) of which serves as a lift tab being folded onto and sealed to the outer surface of the free edge portion of said cover panel (106). 13. A thermoplastic coated container blank for constructing a flat top container, said blank comprising: body panels including front (22) and back panels (18) and a pair of side panels (20, 24); a pair of side fold-in edge panels (46, 48) integrally connected by first and second horizontal score lines (50, 52) to the top end of said pair of side panels (20, 24) and foldable on said first and second horizontal score lines (50, 52) inwardly toward one another; a front fold-in edge panel (43) integrally connected by a third horizontal score line (44) to the top end of said front panel (22) and foldable inwardly on said third horizontal score line (44); a cover panel (40) integrally connected by a fourth horizontal score line (42) to said back panel (18) and foldable on said fourth score line (42) onto and securable to said side fold-in edge panels (46, 48) and said front fold-in edge panel (43); and first to third weakened lines (50, 52, 54; 82, 84, 86) associated with each of said fold-in edge panels (43, 46, 48) with the third weakened line (54) associated with said front fold-in panel (43) being adapted to be manually broken to permit further breaking of said first and second weakened lines (50, 52) associated with said side fold-in edge panels (46, 48) by the manual lifting of said cover panel (40) of a closed container made from said blank, characterized in that the side fold-in edge panels (46, 48) are connected to the top of the side panels (20, 24) by their associated first and second weakened lines (50, 52) and are foldable inwardly on these weakened lines (50, 52) and that a layer (68) of one of aluminum foil, thermoplastic film and hot melt is covering the first and second horizontal weakened lines (50, 52) associated with said side fold-in edge panels (46, 48) and the third horizontal score line (44) and secured to segments of the immediately adjacent panel surfaces.

Inventors: LISIECKI, ROBERT E.
Applicants: EX-CELL-O CORPORATION
Application year: 1987
Main classification: B65D5
IPC codes: B65D5