Patent Publication Number: US-7210612-B2

Title: Carton blank, carton and method of forming the carton

Description:
This application is a divisional of U.S. patent application Ser. No. 09/972,575, filed Oct. 5, 2001, now U.S. Pat. No. 7,036,714 which is a continuation-in-part of U.S. patent application Ser. No. 09/607,197 filed Jun. 28, 2000, now U.S. Pat. No. 6,386,438 issued May 14, 2002, for CARTON BLANK, CARTON AND METHOD OF FORMING THE CARTON of Walsh et al. and claims the benefit of U.S. provisional patent application Ser. No. 60/244,716 filed Oct. 30, 2000, for CARTON BLANK, CARTON AND METHOD OF FORMING THE CARTON of Walsh et al., all of which are hereby incorporated by reference for all that is disclosed therein. 
    
    
     FIELD 
     The disclosure herein is directed generally to a carton blank and a carton formed therefrom. 
     BACKGROUND 
     In order to protect moisture sensitive materials in a carton, there have been many kinds of fluid impervious cartons developed to protect such moisture sensitive materials from deleterious elements such as the humidity in the air. The vast majority of these leakproof cartons have an outer layer formed from a relatively rigid material and an inner layer formed from a relatively flexible fluid impervious material to provide the moisture protection. When it is desired to remove an amount of the material in the carton, it is necessary to open both the outer and inner layers. It is desirable that an opening be formed in both the outer and inner layers at the same time. Also, it is desirable that such an opening be located so that it is not necessary to make an oversized carton so that none of the material in the carton is spilled during the opening thereof. Another desired advantage is that the structures associated with making the opening be of a nature that such structures may be returned to substantially the original position to further protect the material remaining in the carton. 
     SUMMARY 
     A carton blank having an outer layer of a relatively rigid material, a first inner layer of a relatively rigid material superposed over a portion of the outer layer and a second inner layer of a relatively flexible layer of a fluid impervious material is provided with first and second weakened portions so that, after a carton has been formed from the carton blank, filled with a desired material and sealed, the first weakened portion may be broken to form a flip top lid which when moved in an arcuate path will gradually sever the second weakened portion to form an opening in the carton so that an amount of the desired material may be removed from the carton. 
     The carton also may include a feature which allows the flip top lid to be securely re-closed after initial opening of the lid. The re-closing feature may include a hinge member which is originally formed within a wall of the container. A portion of the hinge member may be attached, e.g., by gluing, to a portion of the lid such that, when the lid is initially opened, the hinge member is severed from the container wall, thus leaving a hole in the wall. When the lid is re-closed, the hinge member is able to engage within the opening formed in the container wall, thus releasably securing the lid in the closed position. Alternatively, the hinge may be retained on the container wall while a panel portion is removed from the wall via attachment to the lid. In this manner, when the lid is re-closed, the panel portion on the lid may engage with the hinge portion located on the container wall in order to releasably secure the lid in the closed position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Illustrative and presently preferred embodiments are illustrated in the accompanying drawings in which: 
         FIG. 1  is a top plan view of the outer surface of a carton blank; 
         FIG. 2  is a top plan view of the inner surface of a carton blank with parts broken away; 
         FIGS. 3–5  are top plan views illustrating different steps in the formation of the top portion of a carton from a carton blank; 
         FIG. 6  is a enlarged portion of  FIG. 5  illustrating one of the weakened portions; 
         FIG. 7  is a perspective view of a closed carton; 
         FIG. 8  is a perspective view of a partially opened carton; and 
         FIG. 9  is an enlarged perspective view of a opened carton wherein the flip top lid is being retained in an opened position; 
         FIG. 10  is a schematic elevational view with parts in section of a portion of the top of a carton prior to the formation of the opening therein; 
         FIG. 11  is a schematic elevational view with parts in section and wherein the flip top lid has been formed and is partially opened; and 
         FIG. 12  is a schematic elevational view with parts in section and wherein the flip top lid is being held in the opened position. 
         FIG. 13  is a partial perspective view of a closed carton having a stay closed feature. 
         FIG. 14  is a plan view of an insert member forming a part of the carton of  FIG. 13 . 
         FIG. 15  is a partial cross-sectional view taken along the line  15 — 15  in  FIG. 13 . 
         FIG. 16  is a partial cross-sectional view similar to  FIG. 15 , but showing the carton in a partially open condition. 
         FIG. 17  is a partial cross-sectional view similar to  FIGS. 15 and 16 , but showing the carton in a further open condition. 
         FIG. 18  is a partial cross-sectional view similar to  FIGS. 15–17 , but showing the carton after it has been re-closed. 
         FIG. 19  is a plan view of an insert member used in a carton having an alternative stay closed feature. 
         FIG. 20  is a partial cross-sectional view, similar to  FIGS. 15–18 , but showing a carton including the insert member of  FIG. 19  in a partially open condition. 
         FIG. 21  is a partial cross-sectional view similar to  FIG. 20 , but showing the carton in a further open condition. 
         FIG. 22  is a partial cross-sectional view similar to  FIGS. 20 and 21 , but showing the carton after it has been re-closed. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1–22 , in general, illustrate a method of opening and closing a container  280 ,  480 . The method includes providing the container  280 ,  480  having a body portion having at least one wall  322 ,  422 ; a lid  382 ,  482  movably attached to the body portion; a panel  352 ,  354 ,  454  formed in the at least one wall of the body portion. The panel  352 ,  354 ,  454  may be attached to the lid  382 ,  482 . The method may further include moving the lid  382 ,  482  to an open position by applying an opening force thereto, wherein the opening force causes the panel  352 ,  354 ,  454  to separate from the at least one wall  322 ,  422 , thereby forming a hole  356 ,  456  in the at least one wall  322 ,  422 ; moving the lid  382 ,  482  to a closed position by applying a closing force thereto and releasably retaining the lid  382 ,  482  in the closed position by engaging at least a portion of the panel  352 ,  354 ,  454  with at least a portion of the wall  322 ,  422 . 
       FIGS. 1–22 , further illustrate, in general, a container  280 ,  480  having a body portion having at least one wall  322 ,  422  and a lid  382 ,  482  movably attached to the body portion. The container  280 ,  480  may include a first condition before the container  280 ,  480  has initially been opened, a second open condition and a third re-closed condition. In the first condition, a panel  352 ,  354 ,  454  is attached to both the at least one wall  322 ,  422  of the body portion and the lid  382 ,  482 . In the second condition, the panel  352 ,  354 ,  454  remains attached to the lid  382 ,  482  but has been removed from the at least one wall member  322 ,  422 , thus leaving a hole  356 ,  456  in the at least one wall  322 ,  422 . In the third condition, at least a portion of the panel  352 ,  354 ,  454  is releasably engaged with at least a portion of the wall  322 ,  422 . 
       FIGS. 1–22 , further illustrate, in general, a method of opening and closing a container  280 . The method may include providing the container  280  having a body portion having at least one wall  322 ; a lid  282  movably attached to the body portion and a hinge  352  movably attached to the lid  282 . The method may further include moving the lid  282  to an open position by applying an opening force thereto; moving the lid  282  to a closed position by applying a closing force thereto and releasably retaining the lid  282  in the closed position by engaging at least a portion of the hinge  352  with at least a portion of the wall  322 . 
       FIGS. 1–22 , further illustrate, in general a container  282  capable of moving between ah open condition and a closed condition. The container  282  may include a body portion having at least one wall  322 ; a lid  282  movably attached to the body portion and hinge  352  movably attached to the lid  282 . In the closed condition, at least a portion of the hinge  352  is engaged with at least a portion of the wall  322 . 
       FIGS. 1–22 , further illustrate, in general a method of opening and closing a container  280 ,  480 . The method may include providing the container  282  having a body portion having at least one wall  322 ,  422 ; a lid  282 ,  382  movably attached to the body portion; a hinge portion  352 ,  452  and a stationary portion  354 ,  422 . The hinge portion  352 ,  452  is movably attached to the stationary portion  354 ,  422  via a score line  350 ,  441 . The hinge portion  352 ,  452  is aligned with the stationary portion  354 ,  422 . The method further includes moving the lid  282 ,  482  to an open position by applying an opening force thereto, wherein the opening force causes the hinge portion  352 ,  452  to misalign with the stationary portion  354 ,  422 ; moving the lid  282 ,  482  to a closed position by applying a closing force thereto and using the hinge portion  352 ,  452  to releasably retain the lid  282 ,  482  in the closed position. 
       FIGS. 1–22 , further illustrate, in general a container  280 ,  480  capable of moving between an open condition and a closed condition. The container  280 ,  480  may include a body portion having at least one wall  322 ,  422 ; a lid  282 ,  482  movably attached to the body portion; a hinge portion  352 ,  452  and a stationary portion  354 ,  422 . The hinge portion  352 ,  452  is movably attached to the stationary portion  354 ,  422  via a score line  350 ,  441 . The container  280 ,  480  includes a first condition before the container  280 ,  480  has initially been opened, a second open condition and a third re-closed condition. In the first condition, the hinge portion  352 ,  452  is aligned with the stationary portion  354 ,  422 . In the second condition, the hinge portion  352 ,  452  is misaligned with the stationary portion  354 ,  422 . In the third condition, the hinge portion  352 ,  452  releasably retains the lid  282 ,  482  in the re-closed condition. 
     Having thus described the container and method in general, they will now be described in further detail. 
     In  FIG. 1 , there is illustrated the outer surface of a carton blank  2 . The carton blank  2  has an outer layer which comprises a generally rectangular sheet of a relatively rigid material such as paperboard, a composite materials comprising a plastic film laminated to paperboard or any other conventional material used in forming cartons and has a plurality of integral sidewall panels  4 ,  6 ,  8  and  10  which are joined together by fold lines  12 ,  14  and  16  and a glue tab panel  18  integral with the sidewall panel  10  and joined thereto by a fold line  20 . A plurality of bottom panels  22 ,  24 ,  26  and  28  are integral with the sidewall panels  4 ,  6 ,  8  and  10  and are joined thereto by fold lines  30 ,  32 ,  34  and  36  and are separated from each other by cut lines  38 ,  40  and  42 . A plurality of top panels  44 ,  46 ,  48  and  50  are integral with the sidewall panels  4 ,  6 ,  8  and  10  and are joined thereto by fold lines  52 ,  54 ,  56  and  58  and are separated from each other by cut lines  60 ,  62 ,  64  and  66 . The cut lines  60  and  62  are spaced apart to form an opening  68  therebetween. The top panel  44  has a pair of spaced apart opposite fold lines  70  and  72  and an arcuate shaped perforated line  74  which, when broken, forms a tab portion  76 . The top panel  48  has a pair of spaced apart opposite fold lines  78  and  80  and an arcuate shaped perforated line  82  which, when broken, forms a tab portion  84 . A first weakened portion  86  has a first end point  88  in the fold line  56  and a second end point  90  in the fold line  14 . A second weakened portion  92  has a first end point  94  in the fold line  52  and a second end point  96  in the fold line  12 . A third weakened portion  98  extends between the second end points  90  and  96  and is shaped as a frustum of a V. As illustrated in  FIG. 1 , the weakened portions  86 ,  92  and  98  form portions  4 a,  6 a and  8   a  in the sidewall panels  4 ,  6  and  8 . An opening tab  100  is formed in the sidewall panel  6  by a perforated line  102  and extensions  104  and  106  thereof which extensions  104  and  106  are parallel to but spaced slightly from portions of the fold lines  12  and  14 . A tab portion  108  extends from a fold line  110  for purposes described below. 
     In  FIG. 2 , there is illustrated the inner surface of a carton blank  2 . The portions illustrated in  FIG. 2  that correspond to  FIG. 1  have been identified with the same reference numerals. A first inner layer comprising a generally rectangularly shaped insert  120  has a partial sidewall panel  122  superposed over a portion of the sidewall panel  6 ; a partial sidewall panel  124  superposed over a portion of the sidewall panel  4  and a partial sidewall panel  126  superposed over a portion of the sidewall panel  8 . The partial sidewall panel  124  and the partial sidewall panel  126  are integral with the partial sidewall panel  122  and are joined thereto by the fold lines  128  and  130  which are substantially superposed over portions of the fold lines  12  and  14 . The insert  120  has an upper edge  132  that is spaced slightly from the fold line  54  and portions of the fold lines  52  and  56  and a lower edge  134 . The portion of the partial sidewall panel  122  adjacent to the lower edge  134  is secured to the opposite facing inner surface of the sidewall panel  6  by a suitable adhesive  136 . The first inner layer or insert  120  is preferably formed from the same type of material as the outer layer. 
     A second inner layer of the carton blank  2  comprises a generally rectangular sheet  140  of a fluid impervious material comprising a central body portion  142  that is superposed over at least portions of the portions of the sidewall panels  4 ,  6 ,  8  and  10  located between but spaced slightly from the fold lines  52 ,  54 ,  56  and  58  and the fold lines  30 ,  32 ,  34  and  36  and a corresponding portion of the glue tab panel  18  and all of the insert  120 . The generally rectangular sheet  140  is preferably formed from a plastic material, such as polyethylene, a kraft paper covered with polyethylene or other materials having similar characteristics. At least portions of the central body portion  142  are secured to facing portions of the insert  120  and the sidewall panels  4 ,  6 ,  8  and  10  and the glue tab panel  18 . The generally rectangular sheet  140  has a top portion  144  that extends from the central body portion  142  and is superposed over at least portions of the top panels  44 ,  46 ,  48  and  50  and the glue tab panel  18 . In one example of a preferred embodiment, the top portion  144  is superposed over and secured to an elongated strip  146  of a relatively flexible material, such as a kraft paper or other materials having similar characteristics. The generally rectangular sheet  140  had a bottom portion  148  that extends from the central body portion  142  and is superposed over at least portions of the bottom panels  22 ,  24 ,  26  and  28  and the glue tab panel  18 . The bottom portion  148  is superposed over and secured to a strip  150  of a relatively flexible material as described above. In some instances, the strips  146  and  150  may be omitted so that the top  144  and bottom  148  portions comprise only portions of the sheet  140  of a fluid impervious material. As illustrated in  FIG. 2 , two of the edges of the generally rectangular sheet  140  are located in alignment with the edge of the glue tab panel  18  and the edge of the sidewall panel  4  but in some instances such edges may be offset a desired distance. 
       FIGS. 3–5  illustrate steps in forming a closed and sealed end for a carton formed from the carton blank  2  described in relation to  FIGS. 1 and 2 . The sidewall panels  4 ,  6 ,  8  and  10  are folded around the fold lines  12 ,  14  and  16  and secured together by a suitable arrangement between the glue tab panel  18  and a portion of the sidewall panel  4  or portions of the sheet  140  associated with the structures to form an open ended structure (not shown). The bottom panels  22 ,  24 ,  26  and  28  and the bottom portion  148  with or without the strip  150  have been folded and secured together to form a closed fluid impervious bottom end for the carton. The carton is then filled with a desirable material and the top portion  144  with or without the strip  146  has been folded and sealed together to form a closed fin joint. The fin joint is formed from the top portion  144  that extends upwardly from a common plane formed by the fold lines  52 ,  54 ,  56  and  58  and comprises portions of the generally rectangular sheet  140  that extend from the sidewall panels  4 ,  6 ,  8  and  10  to form an open top portion. The portions of the generally rectangular sheet adjacent to the open top portion are secured together to form two sealed together layers having a central section  160  and two opposite end sections  162  and  164 . The extensions of the top portion  144  from the sidewall panels  4  and  8  are also formed into generally horizontal portions  166  and  168  that lie in a common plane generally parallel to the above-described common plane. The generally horizontal portions  166  and  168  comprise a single thickness of the generally rectangular sheet  140 . The extensions of the top portion  144  from the sidewall panels  6  and  10  and the glue tab panel  18  are also formed into triangular end sections  152  and  154  illustrated in  FIGS. 3 and 4  by two reference numerals which comprise two thicknesses of the generally rectangular sheet  140 . The triangular end sections  152  and  154  also lie in a plane parallel to the common planes described above. As illustrated in  FIG. 3 , the central section  160  and the end sections  162  and  164  of the fin joint have been folded over so that they lie substantially in the common plane formed by the fold lines  52 ,  54 ,  56  and  58 . Therefore, the fin joint has a central section comprising the central section  160  and the portions  166  and  168  and two opposite end sections comprising the end sections  162  and  164  and the triangular portions  152  and  154 . In  FIG. 4 , the top panel  44  is folded around fold line  52  until it is superposed over a major portion of the central section comprising the central body portion  160  and the portions  166  and  168  but is not secured thereto. The top panel  50  is then folded around fold line  58  so that it is superposed over a portion of the top panel  44  and the end sections  154  and  164  are sandwiched in between. These portions are not adhesively secured together. The top panel  46 , preferably at the same time, is folded around fold line  54  so that it is superposed over a portion of the top panel  44  and the open portion formed by the cut line  60  and the end sections  154  and  162  are sandwiched in between. These portions are not adhesively secured together. The structure prior to folding over the top panel  46  is illustrated in  FIG. 5 . The top panel  48  is then folded around fold line  56  until it is superposed over the top panels  44  and  50  and the central portion of the top panel  44 . At least the facing portions of the top panels  48 ,  46 ,  50  and  44  are secured together. The fold lines  78  and  80  are superposed over the fold lines  70  and  72  and the tab portions  76  and  84  extend in opposite directions. 
     In  FIG. 6 , there is illustrated part of the structures for forming the flip top lid for the carton as described below. The generally rectangular sheet  140  is superposed over the inner surface of the outer layer of the carton blank  2  of  FIG. 2  and is secured thereto by a suitable adhesive illustrated by the dotted portion. The generally rectangular sheet  140  also is superposed over the generally rectangular first inner layer or insert  120 . A weakened portion  170  having end portions  172  and  174  is formed in the generally rectangular sheet  140 . In an exemplary preferred embodiment, the length of the weakened portion  170  between the end portions  172  and  174  is less than the distance between the fold lines  72  and  80  as illustrated in  FIG. 6 . The weakened portion  170  is surrounded by an adhesive, illustrated by the more heavily dotted area, to preserve the fluid tightness between the portion of the generally rectangular sheet  140  and the first inner layer or insert  120 . The weakened portion  170  may comprise a cut line or a perforated line and may be formed using a heated cutting apparatus (not shown) so that, as the weakened portion  170  is made, the portions of the generally rectangular sheet  140  surrounding the weakened portion  170  are secured to the first inner layer or insert  120 . In another exemplary embodiment, a coating of a suitable adhesive, such as a conventional hot or cold melt adhesive, may be used as long as the fluid impervious characteristic of the second inner layer or generally rectangular sheet  140  is maintained. The weakened portion  164  is preferably located as close as possible to the upper edge  132  of the first inner layer or insert  120  for purposes described below. The location of the weakened portion  164  as shown in  FIG. 6  is for illustration purposes only. 
     A carton  180  formed from the carton blank  2  of  FIGS. 1 and 2  and having its top portion formed as illustrated in  FIGS. 3–5  is illustrated in  FIGS. 7–9 . In  FIG. 7 , the carton  180  is one that has been filled with the desired material as described above. In  FIG. 8 , the flip top lid  182  having portions  4   a ,  6   a  and  8   a  secured from the sidewall panels  4 ,  6  and  8  and the tab portion  108  has been partially opened. As illustrated in  FIG. 8 , the opening tab  100  has been removed by applying a force thereto at the fold line  14  and severing it along the perforated lines  104 ,  102 ,  98  and  106 . Another force has been applied to the tab  108  to sever the outer layer along the perforated lines  86  and  92 . At the same time, the force separates the weakened portion  170  since the portion  162  located between the folded over top panel  46  and the top panel  44  applies the force to the weakened portion  170 . The tab portion  84  has separated along the score line  82  as the flip top lid  182  moves upwardly in a pivoted manner through an arcuate path defined by the fold lines  78  and  80 . The pivotal movement of the flip top lid  182  is continued until the outer surface (not numbered) of the tab portion  84  faces the outer surface (not numbered) of the tab portion  76 . This pivotal movement is generally about 120 degrees. In  FIG. 9 , the flip top lid  182  is held in an opened position by the cooperation between outer surfaces of the tab portions  76  and  84  which generally is about 90 degrees so that an amount of the desired material may be removed from the carton  180 . After an amount of the desired material has been removed from the carton  180 , a force is applied to the flip top lid  182  to return it generally to the position illustrated in  FIG. 7  but with the opening tab  100  removed. 
       FIGS. 10–12  illustrate the location of the various components at different times during the formation of the opening in the carton  180 . In  FIG. 10 , the carton  180  has not been opened. In  FIG. 11 , the carton  180  has been partially opened. In  FIG. 12 , the carton  180  has been fully opened and the flip top lid  182  is being held in an opened position so that an amount of the desired material may be removed from the carton  180 . In  FIG. 12 , the flip top lid  182  has been moved to a partially opened position. Part of the weakened portion  170  has been severed. The portion of the weakened portion  170  between the panels  6  and  6   a  and part of the weakened portion  170  between the panels  4  and  4   a  and  8  and  8   a  has been separated. Since the end sections of the fin joint are sandwiched between portions of the top panels  44  and  46 , a force is applied to the end sections  152  and  162  and portions of the portions  166  and  168  of the fin joint to pull these portions downwardly through the opening  68  formed by the cut line  60 . In  FIG. 12 , the weakened portion  170  has been completely severed and a large portion of the end sections  152  and  162  and the portions  166  and  168  of the fin joint have been moved through the opening  68 . As described above, the contact between the outer surfaces of the tab portions  76  and  84  holds the flip top lid  182  in the opened position so that an amount of the desired material may be removed from the carton  180 . In  FIGS. 10–12 , the strips  146  and  150  of a relatively flexible material are not shown but would be included in an exemplary preferred embodiment. 
       FIGS. 13–18  illustrate a carton  280 . The carton  280  may be substantially identical to the carton  80  previously described with respect to  FIGS. 1–12 , except that the carton  280  is provided with a flip top lid  382  having a feature to allow the lid to be securely re-closed after initial opening, as will be described in further detail below. Because the carton  280  is similar in many aspects to the carton  80 , the same reference numerals are used in  FIGS. 13–18  to refer to like features illustrated in  FIGS. 1–12 . 
     As noted above, the carton  280  may be formed in a substantially identical manner to that described with respect to the carton  80  previously described with respect to  FIGS. 1–12 . With reference to  FIG. 13 , the carton  280  may, however, include an insert member  320  which is modified relative to the insert member  120  previously described with respect to the carton  80 .  FIG. 14  illustrates the modified insert member  320  in further detail. 
     Referring now to  FIG. 14 , the insert member  320  may have a partial sidewall panel  322 ; a partial sidewall panel  324  and a partial sidewall panel  326 . The partial sidewall panel  324  and the partial sidewall panel  326  may be integral with the partial sidewall panel  322  and may be joined thereto by the fold lines  328  and  330 . The insert member  320  has an upper edge  332 . The insert member  320  may, for example, be formed from the same material as previously described with respect to the insert member  120 . A cutout portion  340  may be provided in the partial sidewall panel  322  of the insert member  320  as shown. The cutout portion  340  may generally be defined by an upper cut line  342  and a lower cut line  344 . The cut lines  342 ,  344  may extend completely through the material forming the insert member  320  such that, together, the cut lines  342 ,  344  will form an opening  356  in the insert member  320  after the cutout portion  340  is removed, as will be described in further detail herein. A pair of uncut areas may be located between the cut lines  342  and  344  forming retention tabs  346  and  348 . The retention tabs  346 ,  348  serve to retain the cutout portion to the remainder of the insert member  320  during manufacture of the carton  280  in a manner as will be described in further detail herein. 
     With continued reference to  FIG. 14 , a score line  350  may be provided as shown, dividing the cutout portion  340  into an upper (as viewed in  FIG. 14 ) hinge portion  352  and a lower stationary portion  354 . The cutout portion  340  may, for example, have a height “a” of about 1.0 inch and a width “b” of about 1.5 inches and may, for example, be generally elliptical is shape. The score line  350  may, for example, be located a distance “c” of about 0.6 inch above the lower edge of the cutout  340 . The lower edge of the cutout  340 , in turn, may be located a distance “d” of about 1.85 inch below the upper edge  332  of the insert member  320 . 
     The insert member  320  may be assembled into the carton blank  2  in substantially the same manner as previously described with respect to the insert member  120 , see  FIG. 2 . When assembling the insert member  320 , however, adhesive  360 ,  FIG. 15 , may be supplied between the insert member stationary portion  354 ,  FIG. 14 , and the carton blank sidewall panel  6 ,  FIG. 2 . In addition, although the rectangular sheet  140  may be secured to the insert member  320  around the periphery of the cutout portion  340 , the sheet  140  is not secured to the cutout portion  340  itself. Securing the rectangular sheet  140  to the insert member  320  and to the remainder of the carton blank  2  may be accomplished using a conventional glue or by any other conventional attachment mechanism. 
     After the insert member  320  has been attached to the carton blank  2 , as described above, the carton blank may be erected into the carton  280 , as illustrated in  FIG. 13 .  FIG. 15  is a cross-sectional view of the carton  280 , taken along the line  15 — 15  of  FIG. 13 .  FIGS. 13 and 15  both illustrate the carton  280  before the flip top lid  382  has initially been opened.  FIGS. 16–18  illustrate a sequence of operations through which the flip top lid  382  is opened and then re-closed. 
     The carton  280  may be initially opened in generally the same manner as the carton  80 , previously described. Specifically, to initially open the carton  280 , the opening tab  100 ,  FIGS. 13 and 15 , may be removed. The tab  108  may then be pulled upwardly, severing the outer layer of the carton  280  along the perforated lines  86  and  92 , to the position illustrated in  FIG. 16 . Referring now to  FIG. 16 , it can be seen that the movement described above has also caused the cutout portion  340  to separate from the insert member  320 , due to the adhesive  360  located between the flip top lid  382  and the stationary portion  354  of the cutout portion  340 . Specifically, with reference to  FIG. 14 , the upward movement of the flip top lid  382  has caused the retention tabs  346  and  348  to tear, thus allowing the cutout portion  340  to completely separate from the remainder of the insert member  320 . Referring again to  FIG. 16 , the upward movement of the flip top lid  382  also causes the hinge portion  352  of the cutout portion  340  to bend about the score line  350 , due to the interaction between the hinge portion  352  and the upper edge of the opening  356 . As can be appreciated from  FIG. 16 , although separation of the cutout portion  340  forms the opening  356  through the insert member  320 , the sheet  140  still spans the opening  356 . 
       FIG. 17  illustrates the flip top lid  382  in a further opened condition. Referring to  FIG. 17 , it can be seen that the hinge portion  352  is completely disengaged from the opening  356 , but still maintains a nonaligned orientation with respect to the stationary portion  354 . The hinge portion  352  is biased toward this nonaligned orientation due to the score line  350  and the bending action imposed on the hinge portion  352  during opening of the lid  382 , as illustrated in  FIG. 16 . 
     After the desired amount of product has been dispensed from the open carton  280 , the flip top lid  382  may be re-closed. This re-closed condition is illustrated in  FIG. 18 . As can be seen from  FIG. 18 , when the flip top lid is returned to its closed position, the hinge portion  352  will engage beneath the upper edge of the opening  356 . This engagement, in turn, causes the lid  382  to resist reopening and, thus, tends to maintain the lid in its closed condition, as illustrated in  FIG. 18 . 
     When it is desired to reopen the flip top lid  382 , e.g., to dispense further product from the container  280 , the tab  108  may again be pulled upwardly, thus causing the flip top lid  382  to once again move through the sequence illustrated in  FIGS. 16 and 17 . As can be appreciated from the above, the cutout portion  340  serves to maintain the flip top lid  382  in its closed position after the lid has initially been opened but allows the lid to be reopened when desired. 
     It is noted that, in addition to holding the lid in its closed position, the stay-closed feature described above also results in an audible “click” when the lid reaches its closed position. This click is caused when, as the lid is moving downwardly to its closed position, the hinge portion  352  springs into the opening  356 . This feature is beneficial in that it provides a user of the carton  280  with an audible signal indicating that the lid has reached its fully closed position. The audible click discussed above is caused, in part, by the hinge portion  352  springing past the edge of the opening  356 . The volume of the audible click is also, however, enhanced by the hinge portion  352  forcefully contacting the sheet  140 , as illustrated in  FIG. 18 . Accordingly, the existence of the sheet  140  in the vicinity of the opening  356  enhances the audible signal provided. 
     The existence of the sheet  140  in the vicinity of the opening  356  is also advantageous in that it seals the opening  356  and, thus, prevents product housed withing the carton  280  from exiting the carton through the opening  356 . The existence of the sheet  140  is further advantageous in that it prevents the hinge portion  352  from penetrating too far into the opening  356 , see  FIG. 16 . In some situations, such excessive penetration by the hinge portion  352  may interfere with proper reopening of the flip top lid  382 . As can be appreciated with reference to  FIG. 16 , in limiting the penetration by the hinge portion  352 , the sheet  140  imposes a resilient force (in the direction of the arrow  362 ) on the flip top lid  382 . This resilient force causes the flip top lid  382  to be biased toward its closed position until the hinge portion  352  disengages from the opening  356  during opening of the flip top lid  382 . This biasing of the flip top lid, in turn, causes the flip top lid to tend to remain in its closed position until a sufficient opening force is applied and, thus, serves to resist accidental opening of the flip top lid  382 . 
     Although, as described above, the existence of the sheet  140  is beneficial in many respects, the carton  280  may, alternatively, be manufactured without the sheet  140 . In this case, a relatively small section of material may be provided in order to cover the opening  356 . This small section of material may be attached, e.g., by gluing, to the partial sidewall panel  322  of the insert member  320 ,  FIG. 14 , in the vicinity of the opening  356 . The small section of material may, for example, be formed from the same material as the sheet  140 . 
     The stay closed feature described above is extremely advantageous in that it is easy to manufacture. Specifically, the use of the cutout  340  does not require that any extra folds be provided in the insert member  320 . Such folds add complexity when erecting a carton and it is, thus, desirable to minimize them. Referring, for example, to  FIG. 17 , it can be seen that the hinge portion  352  is partially folded about the score line  350 . In other words, the hinge portion  352  is non-aligned with the stationary portion  354 . This non-aligned configuration enables the hinge portion  352  to spring into the opening  356  when the flip top lid  382  is re-closed (see  FIG. 18 ) and, thus, is important to proper operation of the stay closed feature. As can be appreciated with respect to  FIGS. 15 and 16 , this folding of the hinge portion  352  is caused by the opening of the flip top lid  382 . In other words, before the flip top lid is initially opened ( FIG. 15 ), the hinge portion  352  is not folded about the score line  350 . Rather, the opening force supplied to the flip top lid  382  by a user causes the folding to occur. Accordingly, the fold does not have to be formed on the production line for forming the carton  280 . This, in turn, simplifies the carton forming process. 
     The described stay closed feature is further advantageous in that no additional material is required in its formation. Specifically, as described above, the cutout portion  340 , which includes the hinge portion  352 , is removed from an existing portion of the insert member  320 . Accordingly, no additional material is required to form the cutout portion  340 . Additionally, because the cutout portion  340  is located on the inside of the flip top lid panel  6   a , it is never readily visible to a consumer of the product packaged within the carton  280 . Accordingly, the design of the stay closed feature described herein facilitates the aesthetic appearance of the carton. 
     It is noted that, although the stay-closed feature has been described in conjunction with the stay open feature of  FIGS. 1–12  for illustration purposes, it is to be understood that either the stay closed feature or the stay open feature could, alternatively, be used independently of each other. It is further noted that, although, for illustration purposes, the stay closed feature is illustrated as being elliptical in shape, it could, alternatively, be any other shape, such as rectangular or round. 
       FIGS. 19–22  illustrate an alternative embodiment of the stay closed feature in which the hinge portion remains attached to the insert member. Referring first to  FIG. 19 , an insert member  420  may be provided which is similar to the insert member  320  previously described with respect to  FIGS. 13–18 . The insert member  420  may have a partial sidewall panel  422 ; a partial sidewall panel  424  and a partial sidewall panel  426 . The partial sidewall panel  424  and the partial sidewall panel  426  may be integral with the partial sidewall panel  422  and may be joined thereto by the fold lines  428  and  430 . The insert member  420  has an upper edge  432 . The insert member  420  may, for example, be formed from the same material as previously described with respect to the insert members  120  and  320 . A latch mechanism  440  may be provided in the partial sidewall panel  422  of the insert member  420  as shown. The latch mechanism  440  may generally be defined by an upper score line  441 , a first cut line  442  and a second cut line  444 . A third cut line  450  may extend across the latch mechanism  440  and intersecting both the first and second cut lines  442 ,  444 , as shown, dividing the latch mechanism  440  into an upper (as viewed in  FIG. 19 ) hinge portion  452  and a lower stationary portion  454 . The cut lines  442 ,  444 ,  450  may extend completely through the material forming the insert member  420  such that, together, the cut lines  442 ,  444 ,  450  will form an opening  456  in the insert member  420  after the stationary portion  454  is removed, as will be described in further detail herein. A pair of uncut areas may be located within the cut line  450  forming retention tabs  446  and  448 . A further retention tab  449  may be provided between the first and second cut lines  442 ,  444 , as shown. The retention tabs  446 ,  448 ,  449  serve to retain the stationary portion  454  to the remainder of the hinge portion  452  and the remainder of the insert member  420  during manufacture of a carton embodying the insert member  420 . 
     The insert member  420  may be assembled into the carton blank  2  in substantially the same manner as previously described with respect to the insert member  320 . Specifically, when assembling the insert member  420 , adhesive  460 ,  FIG. 20 , may be supplied between the insert member stationary portion  454  and the carton blank sidewall panel  6 ,  FIG. 2 . In a manner similar to that described with respect to the insert member  320 , the rectangular sheet  140  may be secured to the insert member  420  around the periphery of the latch mechanism  440  but not to the latch mechanism itself. Securing the rectangular sheet  140  to the insert member  420  and to the remainder of the carton blank  2  may be accomplished using a conventional glue or by any other conventional mechanism. 
     After the insert member  420  has been attached to the carton blank  2 , as described above, the carton blank may be erected into a carton  480  having a flip top lid  482 , as illustrated in  FIGS. 20–22 .  FIGS. 20–22 , in a similar manner to  FIGS. 16–18 , illustrate a sequence of operations through which the flip top lid  482  is opened and then re-closed. 
     The carton  480  may be initially opened in generally the same manner as the cartons  80  and  280 , previously described. Specifically, to initially open the carton  480 , the opening tab  100 ,  FIGS. 13 and 15 , may be removed. The tab  108 , e.g.,  FIG. 20 , may then be pulled upwardly, severing the outer layer of the carton  480  along the perforated lines  86  and  92 , to the position illustrated in  FIG. 20 . Referring now to  FIG. 20 , it can be seen that the movement described above has also caused the stationary portion  454  to separate from the insert member  420 , due to the adhesive  460  located between the flip top lid  482  and the stationary portion  454  of the cutout portion  440 . Specifically, with reference to  FIG. 19 , the upward movement of the flip top lid  482  has caused the retention tabs  446 ,  448  and  449  to tear, thus allowing the stationary portion  454  to completely separate from the remainder of the insert member  420 . Referring again to  FIG. 20 , the upward movement of the flip top lid  482  also causes the hinge portion  452  to bend about the score line  441 . As can be appreciated from  FIG. 20 , although separation of the stationary portion  454  and bending of the hinge portion  452  about the score line  441  forms the opening  456  through the insert member  420 , the sheet  140  still spans the opening  456 . 
       FIG. 21  illustrates the flip top lid  482  in a further opened condition. Referring to  FIG. 21 , it can be seen that the hinge portion  452  maintains a nonaligned orientation with respect to the remainder of the insert member partial sidewall panel  422 . The hinge portion  452  is biased toward this nonaligned orientation due to the score line  441  and the bending action imposed on the hinge portion  452  during opening of the lid  482 , as illustrated in  FIG. 20 . 
     After the desired amount of product has been dispensed from the open carton  480 , the flip top lid  482  may be re-closed. This re-closed condition is illustrated in  FIG. 22 . As can be seen from  FIG. 22 , when the flip top lid is returned to its closed position, the hinge portion  452  will engage above the upper edge of the stationary portion  454 . This engagement, in turn, causes the lid  482  to resist reopening and, thus, tends to maintain the lid in its closed condition. 
     When it is desired to reopen the flip top lid  382 , e.g., to dispense further product from the container  480 , the tab  108  may again be pulled upwardly, thus causing the flip top lid  482  to once again move through the sequence illustrated in  FIGS. 20 and 21 . As can be appreciated from the above, the latch mechanism  440  serves to maintain the flip top lid  482  in its closed position after the lid has initially been opened. 
     As in the embodiment of  FIGS. 13–18 , the existence of the sheet  140  in the vicinity of the opening  456  is advantageous in that it seals the opening  46  and, thus, prevents product housed withing the carton  480  from exiting the carton through the opening  456 . Although the existence of the sheet  140  is beneficial in many respects, the carton  480 , like the carton  280 , may, alternatively, be manufactured without the sheet  140 . In this case, a relatively small section of material may be provided in order to cover the opening  456 . This small section of material may be attached, e.g., by gluing, to the partial sidewall panel  422  of the insert member  420 ,  FIG. 19 , in the vicinity of the opening  456 . The small section of material may, for example, be formed from the same material as the sheet  140 . 
     As in the embodiment of  FIGS. 13–18 , the stay closed feature of  FIGS. 19–22  is extremely advantageous in that it is easy to manufacture. Specifically, the use of the latch mechanism  440  does not require that any extra folds be provided in the insert member  420 . Such folds add complexity when erecting a carton and it is, thus, desirable to minimize them. Referring, for example, to  FIG. 21 , it can be seen that the hinge portion  452  is partially folded about the score line  441 . In other words, the hinge portion  452  is non-aligned with the remainder of the partial sidewall panel  422  of the insert member  420 . This non-aligned configuration enables the hinge portion  452  to spring into contact with the stationary portion  454  when the flip top lid  482  is re-closed (see  FIG. 22 ) and, thus, is important to proper operation of the stay closed feature. As can be appreciated with respect to  FIG. 20 , this folding of the hinge portion  452  is caused by the opening of the flip top lid  482 . In other words, before the flip top lid is initially opened, the hinge portion  452  is not folded about the score line  441 . Rather, the opening force supplied to the flip top lid  482  by a user causes the folding to occur. Accordingly, the fold does not have to be formed on the production line for forming the carton  480 . This, in turn, simplifies the carton forming process. 
     The described stay closed feature is further extremely advantageous in that no additional material is required in its formation. Specifically, as described above, the latch mechanism  440 , which includes the hinge portion  452 , is removed from an existing portion of the insert member  420 . Accordingly, no additional material is required to form the latch mechanism  440 . 
     It is noted that, although the stay-closed feature of  FIGS. 19–22  has been described in conjunction with the stay open feature of  FIGS. 1–12  for illustration purposes, it is to be understood that either the stay closed feature or the stay open feature could, alternatively, be used independently of each other. It is further noted that, although, for illustration purposes, the stay closed feature of  FIGS. 19–22  is illustrated as being elliptical in shape, it could, alternatively, be any other shape, such as rectangular or round. 
     It is contemplated that the concepts herein described may be variously otherwise embodied and it is intended that the appended claims be construed to include alternative embodiments except insofar as limited by the prior art.