Carton packaging system

Abstract: A product package is disclosed which comprises a carton 10 and a dispensing device 12. The carton, which is typically formed of coated board, has an opening region 20 defined by a line of weakness 24. The dispensing device 12 has a cusp 34 which, when urged against the opening region 20, causes rupture of the line of weakness 24. The dispensing device 12 may then be secured to the carton 10 by means of a screw-threaded portion 32 of its body. The dispensing device 12 has an openable cap 44 to allow product to be dispensed from the carton to it.

Description: The use of cartons for packaging consumer products is widespread. The products thus packaged include detergents, foods, and many others. The cartons are typically formed from a blank of material folded to form a container and sealed to retain the product. A problem with such cartons is that they tend to be difficult to open without spilling some of the product, a particular disadvantage where the nature of the product is such that contact with human skin should be avoided. Additionally, once opened, cartons typically fail to provide any means by which the product may be satisfactorily dispensed in a controlled manner, free from mess. Various solutions to these problems have been proposed. For example, in GB-A-2210359 and EP-A-0543119, and many others, there is disclosed cartons having integral pouring spouts which may be opened in a controlled manner and provide a spout through which the product may be readily dispensed. However, such devices add significantly to the cost of each carton produced. An alternative solution has been to provide a device which can penetrate and be retained on a carton so as to provide a dispensing spout. Examples are disclosed in GB-A-1173866, WO-A-9200883, US-A-5090596, and many others. Clearly, such devices must be provided with a sharp element to pierce or cut the material of the carton. In practice, if the sharp element is sufficiently sharp as to be capable of entering the carton readily, it can also constitute a hazard to the user. It is an aim of the present invention to provide a carton system which does not suffer from the increased unit cost associated with a fixed spout, yet which is easy to use with a minimum of hazard. According to a first aspect of the invention there is provided a carton system for a product comprising a carton and a dispensing device characterised in that: the carton is formed from a blank of material in which is formed an opening region defined by a line of weakness; in that the dispensing device comprises a body having a flow passage therethrough and a rupturing formation, the rupturing formation being adapted to penetrate the carton at the opening region such that the flow passage communicates with the interior of the carton to allow its contents to be dispensed therethrough; and in that the dispensing device comprises a threaded portion by means of which the dispensing device can be removably secured to the carton for use. Thus, as compared with a conventional carton, each carton used in the present invention requires only a line of weakness to be formed. Since the dispensing device may be transferred from one carton to another the additional unit cost, compared with a conventional carton, is minimal. Additionally, the line of weakness facilitates rupture of the carton, so avoiding the need to provide the dispensing device with a sharp and potentially dangerous formation, while enabling easy access by a user and providing a reliable pouring spout. The product packaged in a system of the present invention may be in many forms including liquid, gel or granular solid. The blank is typically formed of a laminated board. The particular board composition is determined primarily by the nature of the product that the carton is intended to store. The board may comprise an outer layer and an inner composite layer between which is disposed a board layer of cellulosic material. For example, the outer layer may be PE, and the composite layer may be EVOH/PE. Such a material may be suitable for use with a liquid detergent product. Such a board material is conventional, so the blank may be formed by a step carried out by an existing machine for carton blank production, and a separate or integrated step in which the line of weakness is formed. The line of weakness may be constituted by a line of reduced thickness of the material of the blank. Were a foil laminated material to be used to form the blank, such a line of weakness could be formed by mechanical stamping, scoring or etching. However, where a material as defined in the last-preceding paragraph is used, the line of weakness is advantageously formed by laser etching, which offers greater control over the disposition, cross-section, and depth of line formed. In particularly preferred embodiments, the line of weakness is formed to penetrate the outer layer and substantially or entirely through the board layer, but not so far as to penetrate through the composite layer. The line of weakness may be a closed curve. More preferably, it includes at least one interruption at which the integrity of the board is preserved. Since rupture is resisted at such an interruption, once open, the material of the opening region will not become detached and fall into the carton. The composition of the blank within the opening region is typically substantially identical to the composition of the blank outside of the opening region. Thus, the entire blank (including the opening region) can be formed from a unitary piece of material. A carton system embodying the invention is particularly, but not exclusively, applicable to gable-top cartons, the opening region being formed, for example, in a sloping surface of the gable, or in a gable end. The dispensing device has, by preference, an externally threaded portion shaped and dimensioned for engagement with the periphery of the opening region following rupture thereof. By this arrangement, the dispensing device may be threadingly engaged with the carton. Additionally, the thread serves to align and locate the dispensing device in position on the carton, and interengagement of the thread and the board of the carton may provide a primary seal between the device and the carton. Preferably, the thread is formed on a tapered core which increases in diameter away from the rupturing formation. The thread may have one or more regions of increased depth remote from the rupturing formation. Such a region or regions may be continuous or may comprise a plurality of discrete regions. In some embodiments, the dispensing device carries a secondary sealing means for enhancing the fluid-resistant seal with an external surface of the carton. This arrangement is especially advantageous in combination with the above-mentioned threading. The secondary sealing means may be formed integrally with the body of the dispensing device. Typically, the dispensing device carries a closure by means of which the flow passage may be selectively closed, so allowing the carton to be effectively resealed after opening. The body may be tubular, the flow passage typically being coaxial with the body. In such embodiments, the dispensing device may have an inner portion which, in use, penetrates within the carton and an outer portion which, in use, projects from the carton. A shroud may surround the outer portion. A flexible plastics sealing element may be disposed in contact with or integral with the shroud, this being advantageous in that the sealing element can be compressed between the shoulder and the material of the carton. Such compression can be readily achieved if the inner portion is provided with an external thread extending at least partially along its length. A carton system embodying the invention may further incorporate retaining means for retaining the dispensing means with the carton prior to use. Thus, the system can be conveniently packaged for sale as a complete product. The retaining means may comprises an overcap for mounting on the carton within which the dispensing device may be stored, and optionally positively held, prior to use. In such embodiments, the overcap may have indicia for measuring a quantity of liquid dispensed from the carton, and may have a spout for pouring product. An embodiment of the invention will now be described in detail, by way of example, with reference to the accompanying drawings in which: Figure 1 shows a carton system embodying the invention is a condition in which it might be sold; Figure 2 shows the carton system of Figure 1 in a condition ready for use in dispensing product; Figure 3 is a front view of a dispensing device for use with the embodiment of Figure 1; Figure 4 is a part-sectional side view of the dispensing device of Figure 3; Figure 5 is a plan of a blank for the carton of the embodiment of Figure 1; Figures 6 and 7 are more detailed views, respectively form one side and from above, of the overcap shown in Figure 1; Figure 8 is a side view of an alternative dispensing device which can be used with the carton system of Figure 1; and Figure 9 is a view of a small section of a threaded part of the body of Figure 8, viewed in the direction of arrow A. With reference to the drawings, a carton system embodying the invention comprises a gable-top carton 10, a dispensing device 12 and an overcap 14. The carton 10 is of a general design, well known for use in packaging liquid products, liquid fabric detergent compositions being one example of many such products. The carton 10 is formed from an initially flat blank, as shown in Figure 5. The blank is formed of a laminated board which is folded and secured by heat sealing to form the carton, in a substantially conventional manner. In this embodiment, the board has an outer layer of PE and an inner composite layer of EVOH/PE. However, the invention is applicable to a system in which the carton is formed from a wide range of other materials. In the present embodiment, an opening region 20 is formed in a diagonally upwardly directed face 22 of the carton 10. The opening region 20 is defined by a generally circular line of weakness 24 formed in the blank by laser etching. There is a small interruption in the line of weakness shown at 26. This is disposed to be uppermost when the carton 10 is standing in its normal upright orientation. The line of weakness 24 constitutes a line at which the thickness of the material of the blank is reduced by a controlled amount. This must be sufficient to weaken the material to allow the opening region to be ruptured when required by a user, but must retain sufficient strength to ensure that rupture will not occur accidentally during transit or storage. In the present embodiment, this can be achieved by etching through the outer layer, and substantially or entirely through the board, but without weakening the composite layer. As shown more clearly in Figures 3 and 4, the dispensing device comprises an integral body of plastics material having a flow passage through it. The body has a carton piercing portion 30 formed as a cylindrical tube coaxial with an axis A of the body. An open end of the tube constitutes an inlet for the flow passage. The open end is formed with a face which is offset by approximately 30° to the axis so as to form a rounded cusp at 34. The carton piercing portion 30 projects from an intermediate part 32 of the body which has an external thread 36. The diameter of the intermediate part 32 and the thread increases from the piercing portion 30, and its pitch decreases from the piercing portion 30. The variation along the thread 36 facilitates alignment of the dispensing device 12 upon the carton 10, and enhances the seal formed between the thread 36 and the material of the carton. Several radial apertures 38 extend through the intermediate part to communicate with the flow passage, these permitting product to be dispensed from the carton when only a small amount of product remains at insufficient depth to enter at the open end. The body extends from the intermediate part 32 generally as a smooth cylinder, as shown at 40 to terminate at an outlet of the flow passage. An outer end portion of the cylinder has reduced wall thickness and onto this is mounted a closure assembly comprising a skirt 42 secured to the body and a cap 44, secured to the skirt, for hinging movement between a closed position in which it seals the flow passage and an open position in which it allows a free flow of product therethrough, this latter condition being shown in Figure 2. The skirt 42 is secured to the body such that it can be rotated about it. This permits the cap 44 to me moved to a convenient orientation whereby it does not impede flow of product from the carton 10, irrespective of the rotational orientation of the body. A shroud 50 is carried on the body. The shroud 50 is a thin-walled body of rotation and is disposed coaxially with the body. The shroud has an upper circular opening at 52 which surround the body at its cylindrical section 40. From there, the shroud 50 curves outwardly to a cylindrical portion which surrounds the body and extends to the intermediate part 32 to be disposed radially outwardly of an upper part of the external thread 36. A secondary sealing element 54 of resilient plastics materials is carried on the body immediately adjacent the shroud 50. This may be formed integrally with the shroud 50 or, as in the present embodiment, may be a separate component. The secondary sealing element 54 has an annular web region 56 which extends between the body and the shroud 50 to form a seal therebetween, an end portion of the shroud 50 being received within a retaining groove 58 of the secondary sealing element 54. Outwardly of the shroud 50, the secondary sealing element 54 has a sealing lip 60 which extends radially and axially away from the shroud 50. With reference to Figure 1, a complete product package embodying the invention includes and overcap 14 mounted on the carton 10 and in which the dispensing device 12 is contained. There is substantially no limitation to the shape or configuration of the overcap 14, other than it must be sufficiently large to contain the dispensing device 12 and must meet the dimensional and aesthetic requirements for a package appropriate to the product. An example of a suitable overcap is shown in greater detail in Figures 5 and 6. The overcap 14 is made of a transparent or translucent material in order that the dispensing device 12 is visible through it. The overcap 14 can serve a dual purpose. It is provided with gradations, shown at 70, in order that it can be used as a measuring container for obtaining a required dose of the product, in an orientation as shown in Figure 6. Additionally, it has a pouring spout 72 to facilitate pouring of liquid from it. In this embodiment, the overcap 14 has side walls 74 each of which, when mounted on the carton 10, lies adjacent a respective gable end of the carton 10. Within each side wall 74 there is formed a depressed zone 76, which projects into the gable end so as to retain the overcap 14 in position on the carton 10. A product package embodying the invention will typically be sold in a form substantially that shown in Figure 1. For use, the overcap 14 is first removed. The cusp 34 is then urged against the opening region 20 to cause rupture around the line of weakness 24. The dispensing device 12 is then pushed towards the carton, whereupon the thread 36 of the intermediate portion 32 engages with and seals against the periphery of the carton material where it has ruptured. Rotation of the dispensing device then causes it to be drawn towards the carton until the sealing lip 60 of the secondary sealing element 54 comes into contact with it. Rupture does not take place at the interruption 26 of the line of weakness 24 so the material of the opening region 20 remains attached to the surrounding carton at this point. In order to dispense a quantity of the product from the carton 10, the cap 44 is moved to its open condition, as shown in Figure 2. A quantity of the product can then be poured from the carton, passing through the flow passage of the dispensing device 12. It will be understood that the cusp 34 is not sharp. Its function is not to cut the material of the carton 10, but simply to concentrate applied force to- the line of weakness 24. In practice, the cusp may be omitted, the end face of the tube being transverse to the axis. With reference now to Figure 8, an alternative dispensing device, suitable for use with a carton such as that of Figure 5 comprises a body of plastics material with a flow passage running axially through it. The body comprises a one-piece, hollow, generally cylindrical outer part 100, on a free end of which is carries a re-closable cap 102. The hollow interior of the outer part defines a part of a flow passage which can be selectively sealed or opened by means of the cap 102. The body has walls formed from a single thickness of plastic material. The body has a tapered threaded portion 104 extending from the cylindrical outer part 100. The taper is at an angle of approximately 15° and the thread 108 has a pitch of approximately 3mm. An end surface of the tapered threaded part 104 remote from the flange portion 120 is cut at an angle approximately 15° from a right angle with respect to the axis of the body such one side of the body projects beyond the other, to form a cusp at 106. Intermediate the tapered threaded portion 104 and the cylindrical outer part 100, there is a radially projecting flange portion 120. A plurality of slots 110,112 are formed which extend radially through the material of the body. There are two groups of slots 110,112. A first group 112 extend such that each has a centre line which lies in alignment with the cusp 106. The second group 110 is circumferentially opposite. Each of the slots 110,112 extends through the material of the body between adjacent turns of the thread 108, as shown in Figure 9. The thread 108 has portions 114 of increased depth on its turns closest to the flange portion 120. These are generally in alignment with the groups of slots 110, 112. When viewed from the end face, these portions 114 present readily extending curved "wing" porions of the thread. In use, the cusp 106 is urged against the line of weakness in the carton 22, sufficiently firmly to cause the carton to rupture along the line of weakness. The body can then be screwed into the hole thus formed in the carton. As compared with the embodiment described above, the present embodiment may, in some circumstances, be less likely to tear the material of the carton due to the lesser angle of the taper of the thread. Furthermore, the projections 108 of the thread aid retention of the body on the carton, without disadvantages which could arise through increasing the thread depth along its entire length. Also, in this embodiment, a primary seal is formed between the thread and the aperture in the carton, with a separate external sealing member being rendered unnecessary. There are many possible variations to these embodiments without deviation from the scope of this invention. For example, the line of weakness may define an opening region which is other than circular. Additionally, more than one interruption may be provided, it being believed that both of these variations can be employed to control the speed of rupture of the line of weakness, and the strength of the opening region prior to rupture.

Claims: A carton system for a product comprising a carton (10) and a dispensing device (12) characterised in that : the carton (10) is formed from a blank of material in which is formed an opening region defined by a line of weakness (24); in that the dispensing device (12) comprises a body having a flow passage therethrough and a rupturing formation (34), the rupturing formation being adapted to penetrate the carton (10) at the opening region such that the flow passage communicates with the interior of the carton (10) to allow its contents to be dispensed therethrough; and in that the dispensing device (12) comprises a threaded portion (36) by means of which the dispensing device (12) can be removably secured to the carton (10) for use. A carton system according to claim 1 in which the blank is formed of cellulosic material. A carton system according to claim 2 in which the material of the blank is board laminated with an outer layer and a composite inner layer. A carton system according to any preceding claim in which the line of weakness (24) is constituted by a line of reduced thickness of the material of the blank. A carton system according to claim 4 in which the line of weakness (24) is formed by laser etching. A carton system according to any preceding claim in which the composition of the blank within the opening region is substantially identical to the composition of the blank outside of the opening region. A carton system according to any preceding claim in which the carton is a gable-top carton, the opening region being formed in a sloping surface (22) of the carton top. A carton system according to any preceding claim in which the threaded portion (36) of the dispensing device (12) is shaped and dimensioned for engagement with the periphery of the opening region following rupture thereof. A carton system according to any preceding claim in which the dispensing device carries a secondary sealing means (60) for forming a fluid-resistant seal with an external surface (22) of the carton (10). A carton system according to any preceding claim in which the dispensing device (12) carries a closure (22,24) by means of which the flow passage may be selectively closed. A carton system according to any one of claims 1 to 7 in which the body is tubular and the flow passage is coaxial with the body. A carton system according to claim 11 in which the dispensing device (12) has an inner portion which, in use, penetrates within the carton and an outer portion which, in use, projects from the carton, there being a shroud carried on the body forming a shoulder between the inner and outer portions. A carton system according to claim 12 in which a flexible plastics secondary sealing element (60) is disposed in contact with the shoulder. A carton system according to claim 12 or claim 13 in which the inner portion carries an external thread (36) extending at least partially along its length. A carton system according to claim 14 in which the external (36) thread forms a fluid-resistant seal with the carton in use. A carton system according to any one of claims 1 to 11 in which the dispensing device (98) comprises a single-walled tubular moulding. A carton system according to claim 16 in which the moulding has a tubular body part (100) and an externally threaded part (104). A carton system according to any preceding claim further incorporating retaining means for retaining the dispensing means with the carton prior to use. A carton system according to claim 18 in which the retaining means comprises an overcap (14) for mounting on the carton (10). A carton system according to claim 19 in which the overcap (14) has indicia (70) for measuring a quantity of product dispensed from the carton (10). A carton system according to any preceding claim in which the line of weakness (24) is a closed curve. A carton system according to any one of claims 1 to 19 in which the line of weakness in discontinuous, having one or more interruptions (26). A carton system according to any one of claims 1 to 19 in which the line of weakness is generally circular and has two interruptions (26) disposed diametrically opposite one another. A packaged product comprising a carton system according to any preceding claim in which is contained a product being in the form of one of a liquid, a gel or a granular solid.

Inventors: HILL REBECCA JANE, LAW BRIAN ROBERT, SHEPPARD JOHN EDWARD, YOUNG DAVID IAIN, HILL, REBECCA JANE, LAW, BRIAN ROBERT, SHEPPARD, JOHN EDWARD, YOUNG, DAVID IAIN
Applicants: UNILEVER NV, UNILEVER PLC, UNILEVER N.V.
Application year: 1996
Main classification: B65D5
IPC codes: B67B7, B65D5