Abstract:
The present invention provides a container with an integrated spout and a method for forming the container. The container includes an inner panel that defines a spout and an outer panel that defines an orifice. The width of the spout exceeds the width of the orifice. The outer panel may include a first tab adjacent to the orifice to provide access to the spout. The outer panel may also include a second tab that temporarily occludes the orifice. The orifice may be exposed when the spout on the inner panel is accessed and the second tab is at least partially detached by extracting the spout. An integrated spout on the inner panel, the width of which exceeds the width of the orifice on the outer panel, reduces the cycle time and cost of manufacturing containers with a spout and prevents the container contents from bypassing the spout upon pouring.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims the benefit of U.S. Provisional Patent Application No. 60/536,904 filed Jan. 16, 2004, where this provisional application is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to containers, and more specifically, containers with pour spouts.  
         [0004]     2. Description of the Related Art  
         [0005]     Heretofore prior art solids dispensing pour spouts for containers used stamped steel or injection molded plastic spouts that required special box manufacturing steps. Attempts to create an integrated spout container, i.e., one that formed the spout from the container material, provided a solution to the excess manufacturing steps but resulted in a spout that undesirably permitted dispensed solids to bypass the spout. Thus, a need arose to provide an integrated spout solution that minimized the solids bypass problem of the prior art.  
       BRIEF SUMMARY OF THE INVENTION  
       [0006]     The invention provides for an integrated solids dispensing pour spout for use in solids dispensing containers and methods for fabricating a container having the same. The invention comprises a first panel defining a spout and a second panel defining an orifice. During use of the invention, the first panel is overlapped by the second panel to permit a portion of the spout to emerge from the orifice upon application of a bias force to the spout. In a container application, the first panel is defined as an inner panel and the second panel is defined as an outer panel. The lateral centerline of the spout is aligned with the lateral centerline of the orifice and further positioned so that the spout may emerge through the orifice upon application of a tension force to the spout.  
         [0007]     As previously described, the first panel defines the spout. The spout remains contiguous with the first panel at a lower hinge segment; otherwise, it is separate or separable from the first panel. The spout comprises a central portion from which first and second lateral wings hingedly extend. Each lateral wing has a perimeter edge comprising a lower edge segment (which may include a lateral edge segment) and an upper edge segment. The central portion may be discrete or may be characterized as the area of intersection between the first and second lateral wings. A maximum spout width is identified as “SW max ”, and represents the maximum distance from the first wing edge to the second wing edge prior to deployment of the spout.  
         [0008]     Also as previously described, the second panel defines an orifice. The orifice has a lower perimeter edge segment generally corresponding in length to the lower hinge segment of the spout. Lateral and upper perimeter edge segments complete the definition of the orifice, where the lateral perimeter edge segments are generally rectilinear and preferably converge towards the lower edge segment. The lateral perimeter edge segments also define a maximum orifice width, “OW max ”, which is less than “SW max ”. As will be described in more detail below, this feature causes the hinged first and second wings to fold towards the central portion when the spout is pivotally extended through the orifice.  
         [0009]     Operation of the invention requires that the first and second panels be overlapped so that the lower hinge of the spout is generally congruent with the lower edge segment of the orifice. As an upper portion of the spout is caused to emerge from the orifice, the first and second wings are caused to fold by the partial obstruction provided by the orifice lateral perimeter edge segments, i.e., “OW max ” is less than “SW max ”. Because of the compound angles involved and the regular surface of the wings, there is a high degree of latitude for selection of the orifice angle (the angle formed between the orifice lateral perimeter edge and centerline) and the spout angle (the angle formed between the lateral hinge and the centerline). Thus, a “wide” spout and a “narrow” spout can be used with the same orifice geometry, or vice versa. The degree of spout extension through the orifice is only limited by the depth of the wings (wing depth is defined as the arc length of the wing to orifice edge contact area as determined from the lower hinge thereof) and/or any over-extension prevention feature as described below.  
         [0010]     A feature of the invention is the interaction between the first and second panels when establishing a spout. By forming a notch in each wing&#39;s upper edge segments, and ensuring that the length of each wing&#39;s lower edge segment is generally equal to or greater than the length of each lateral perimeter edge segment, over-extension of the spout can be prevented by the interference between the spout notches and upper perimeter edge segments of the orifice. Note that selective positioning of the first panel relative to the second panel can create such over-rotation interference even though the length of the wing&#39;s lower edge segment may be less than that of the orifice lateral perimeter edge segment. Thus, functional interference between the spout and the orifice overrides dimensional limitations in some circumstances. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  is a schematic plan view of a prior art container blank incorporating a conventional pour spout;  
         [0012]      FIG. 2  is a schematic plan view of a container blank incorporating a first embodiment of the invention;  
         [0013]      FIG. 3  is an enlarged view of the spout portion of the first embodiment shown in  FIG. 2 ;  
         [0014]      FIG. 4  is an enlarged view of the pull tab portion of the first embodiment shown in  FIG. 2 ;  
         [0015]      FIG. 5  is a registered composite overlay of  FIGS. 3 and 4  wherein the relative relationship between the spout portion and the pull tab portion of the first embodiment is shown;  
         [0016]      FIG. 6  is a perspective view of a container incorporating the first embodiment of the invention after extension of the spout portion;  
         [0017]      FIG. 7  is a side elevational view in perspective of the container of  FIG. 6  incorporating the first embodiment of the invention after extension of the spout portion;  
         [0018]      FIG. 8  is a front elevational view of the container of  FIG. 6  incorporating the first embodiment of the invention after extension of the pull tab portion and the spout portion;  
         [0019]      FIG. 9  is a perspective view with cut-out to reveal the interior of the container of  FIG. 6  illustrating the engagement of an overextension feature with the container; and  
         [0020]      FIG. 10  is a partial front elevational view of a spout provided in accordance with an alternative embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     The following discussion is presented to enable a person skilled in the art to make and use the invention. Various modifications to the preferred embodiment will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention as defined by the appended claims. Thus, the present invention is not intended to be limited to the embodiment shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.  
         [0022]     Turning then to the several Figures wherein like numerals indicate like parts, and more particularly to  FIG. 2 , a plan view of a corrugated container blank incorporating an embodiment of the invention is shown. Container blank  10  is preferably constructed from 40 pound basis corrugated material having a “B” flute size, and has general dimensions of 22″ by 39″, with the corrugation running in the vertical direction. End panel  12   a  defines spout  20  while end panel  12   b  defines orifice  50 , which when container blank  10  is formed into a container  10 ′ such as shown in  FIG. 5 , is non-permanently occluded by tab “A”  52  and tab “B”  60 .  
         [0023]     In  FIG. 3 , which is a detailed view of spout  20 , the elements thereof will now be described. Spout  20  comprises central portion  22 , and lateral wings  30   a  and  30   b . To permit the required deflection of wings  30   a  and  30   b , lateral hinge segments  24   a  and  24   b  are provided at the interface between central portion  22  and wings  30   a/b , and comprise a plurality of perforations formed in the container blank. Those persons skilled in the art will appreciate that the use of perforations may not be necessary in all instances; if wings  30   a  and  30   b  are constructed from a sufficiently pliable or resilient material, there may not be a need to localize the stress in order to achieve deflection of the wings. However, since the illustrated embodiment is constructed from corrugated paperboard and the axis of pivot is askew to the direction of corrugation, perforations are considered desirable.  
         [0024]     Spout  20  is hingedly linked to panel  12   a  at lower hinge segment  26 , which is also characterized as comprising a plurality of perforations. Again, the use of perforations to enhance the functionality of the described embodiment is considered desirable in view of the materials used, however, their presence is not required depending upon material selection and spout geometry. Alternatives to perforation include scoring.  
         [0025]     Each wing  30   a/b  further includes lower edge segment  32   a/b , lateral edge segment  34   a/b , stop edge segment  44   a/b , upper edge segment  36   a/b  and recess edge segment  38   a/b , respectively. Each wing also comprises an over-extension prevention feature in the form of notch  42   a/b , which comprises stop edge segment  44   a/b  and cut-back edge segment  46   a/b . As will be described below, the over-extension prevention feature prevents unintended extension of spout  20  from orifice  50  defined by panel  12   b . Recess edge segments  38   a/b  of wings  30   a/b  and recess edge segment  28  of central portion  22  may be formed to accommodate the intrusion of tab “A”  52  as will be described below.  
         [0026]     In an alternate embodiment of the present invention as illustrated in  FIG. 10 , wings  30   a/b  may be joined directly by a singular hinge segment  24 , thereby obviating the need for a central portion. In this embodiment, wings  30   a/b  may be hingedly connected to the inner panel at least at a portion of wing lower segments  32   a/b , about which the spout may rotate into the extended position. In this embodiment of the present invention, when the spout is extended, wings  30   a/b  interact with the orifice to form a “V” geometry hinged at hinge segment  24 . Although such a configuration still permits use of the invention, the volume of dispensed solids will be reduced and clogging of the spout may increase depending upon the shape and size of the dispensed solids. Through incorporation of a central portion with moderately inclined wings, the size of the dispensing orifice can be maximized.  
         [0027]     Panel  12   b  defines orifice  50  as shown in  FIG. 4  and as previously described. While only orifice  50  is desirable for operation of spout  20 , the illustrated embodiment includes occluding tab “A”  52  and tab “B”  60 , which have been perforated for consumer breach in order to access spout  20  after purchase of the container comprising the embodiment. For convenience, reference to an “edge” applies to both the tab edge and the orifice edge, since they are common to one another.  
         [0028]     Turning then to tab “B”  60 , it has lower hinge segment  62 , which is characterized as comprising a plurality of perforations to permit hinged movement of tab “B”  60 . Tab “B”  60  also includes lower lateral perimeter edge segments  64   a/b  and upper lateral perimeter edge segments  66   a/b . In addition, it has common perimeter  68 , which corresponds to common perimeter  58  of tab “A”  52 . In turn, tab “A”  52  has lateral perimeter edge segments  56   a/b  as well as upper hinge segment  54 , which is characterized as comprising a plurality of perforations to permit hinged movement of tab “A”  52 . With respect to all tab edge segments (this does not apply to perforated hinge segments), it is understood that the perforations are such that a consumer may easily breach the frangible connection created thereby to cause either tab “A”  52  or tab “B”  60  to pivot about its respective hinge.  
         [0029]     Turning to  FIGS. 5 through 9 , operation of the invention will now be described. As shown best in  FIG. 5 , when panel  12   b  is overlapped and bonded to panel  12   a  (note that no portion of spout  20  or orifice  50  is bonded), the resulting alignment creates a symmetrical overlay of spout  20  and orifice  50  about an imaginary vertical centerline. In addition, lower hinge segment  26  of spout  20  is generally superposed over lower hinge segment  62  of tab “B”  60  (note that slight displacement of lower hinge segment  26  relative to lower hinge segment  62  is permissible and accounts for reduced interference; as used herein, “generally superposed” includes this relationship). In addition, both wings  30   a  and  30   b  extend beyond lower lateral perimeter edge segments  64   a  and  64   b , respectively.  
         [0030]     When a consumer of the contents of container  10 ′ desires to access the contents, sufficient inward pressure is applied to tab “A”  52  so as to cause lateral perimeter edge segments  56   a/b , and common perimeter  58  to fail. Because inward pivoting of tab “A”  52  is unrestricted by spout  20  (recall that spout  20  includes recess segments  28  and  38   a/b ), both tab “B”  60  and spout  20  are now accessible and extendable by the consumer.  
         [0031]      FIG. 6  is a perspective view of a container  10 ′ according to one embodiment of the present invention after extension of the spout portion. As illustrated in  FIG. 6 , the consumer will pull at common perimeter  68  of tab “B”  60  and recess edge segment  28  of central portion  22 , causing failure of lower lateral perimeter edge segments  64   a/b  and upper lateral perimeter edge segments  66   a/b , resulting in the outward pivoting of tab “B”  60 . In addition, spout  20  will pivot about lower hinge segment  26 , causing inward pivoting of wings  30   a/b  about their respective lateral hinge segments  24   a/b . As outward pivoting of spout  20  continues, wings  30   a/b  continue to ride against lower lateral perimeter edge segments  64   a/b  until notches  42   a/b , and particularly stop edge segments  44   a/b , engage upper lateral perimeter edge segments  66   a/b , respectively.  FIG. 7  is a side elevational view in perspective of the container of  FIG. 6  after extension of the spout portion. As illustrated in  FIG. 7 , further outward pivoting of spout  20  is arrested, while beneficially retaining the proximate arrangement between wings  30   a/b , and respective lower lateral perimeter edge segments  64   a/b .  FIG. 8  is a front elevational view of the container of  FIG. 6  after extension of the pull tab portion and the spout portion. As illustrated in  FIG. 8 , when the spout  20  is extended, the recess edges  38   a/b  of the two opposing wings and the recess edge  28  of the central portion are formed to guide the container contents toward the recess edge  28  of the central portion and prevent the contents from bypassing the spout when poured.  
         [0032]      FIG. 9  is a perspective view with cut-out to reveal the interior of the container of  FIG. 6  in order to further illustrate the engagement of an overextension feature with the container.  FIG. 9  shows a view from the interior of the container, depicting the interference between notches  42   a/b  and upper lateral perimeter edge segments  66   a/b  at stop edge segments  44   a/b  to prevent overrotation of the spout  20 . In addition, because only outward pivotal motion is arrested by notches  42   a/b , when the consumer is finished with dispensing the contents of the container, spout  20  may be pivoted inwardly, thereby minimizing external interference due to an extended spout and generally restricting unintentional escapement of the container contents.  
         [0033]     All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.  
         [0034]     From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.