Patent Publication Number: US-7913897-B2

Title: Carton with reclosable dispenser

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 60/873,745, filed Dec. 8, 2006, the entire contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND 
     Conventional paperboard cartons are known. Such cartons often include a bag or other vessel held within the interior of the paperboard carton to accommodate the carton contents. The bag may be used to store foodstuffs or other dispensable products. Conventional paperboard cartons, however, may be difficult to open and/or close, and may not close reliably. Conventional cartons may also not allow for neat and reliable dispensing of the carton contents. 
     SUMMARY 
     According to a first embodiment of the invention, a carton comprises a first end panel, a first side panel, a second end panel, a second side panel, a top panel, and a bottom panel. A reclosable dispenser is defined in a top end portion of the carton. The reclosable dispenser can be opened to allow dispensing of the carton contents. 
     According to one aspect of the first embodiment, the size of the dispenser opening can be varied by squeezing the side panels together by varying amounts. The amount of and rate at which product is dispensed can therefore be controlled by the user. 
     According to another aspect of the first embodiment, the carton can be reclosed by a closure tab sized to be received within a closure aperture. 
     According to yet another aspect of the invention, the carton can include a flexible vessel such as a bag in the carton interior. The bag can be used to store product in the carton. 
     Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description, taken in conjunction with the drawings and from the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention. 
         FIG. 1  is a plan view of a blank used to form a carton having a reclosable dispenser according to a first embodiment of the invention. 
         FIG. 2  illustrates the dispensing carton according to the first embodiment of the invention. 
         FIG. 3  illustrates opening of the carton dispenser. 
         FIG. 4  illustrates opening of the carton dispenser. 
         FIG. 5  illustrates opening of a flexible vessel within the carton. 
         FIG. 6  illustrates placing the carton in a dispensing configuration. 
         FIG. 7  illustrates the carton in the dispensing configuration. 
         FIG. 8  illustrates the carton with the dispenser reclosed. 
     
    
    
     DETAILED DESCRIPTION 
     The present embodiments are addressed to reclosable dispensers that allow the contents of cartons to be dispensed from and retained within the cartons. In this specification, the terms “top,” “side,” “end,” and “bottom” are used for clarity of description and to distinguish among elements in the drawings only, and are not intended to limit the scope of the invention except as specifically recited in the appended claims. 
       FIG. 1  is a plan view of a first, exterior side of a blank  8  used to form a carton  150  (illustrated in  FIG. 2 ) having a reclosable dispenser  160  according to a first embodiment of the invention. The blank  8  comprises a first end panel  10  foldably connected to a first side panel  30  at a first transverse fold line  31 , a second end panel  50  foldably connected to the first side panel  30  at a second transverse fold line  51 , and a second side panel  70  foldably connected to the second end panel  50  at a third transverse fold line  71 . An adhesive panel  80  may be foldably connected to the second side panel  70  at a fourth transverse fold line  81 . 
     The first end panel  10  is foldably connected to a first end top flap  16  and a first end bottom flap  18 . The first side panel  30  is foldably connected to a first side top flap  36  and a first side bottom flap  38 . The second end panel  50  is foldably connected to a second end top flap  56  and a second end bottom flap  58 . The second side panel  70  is foldably connected to a second side top flap  76  and a second side bottom flap  78 . The top flaps  16 ,  36 ,  56 ,  76  extend along a first or top marginal area of the blank  8 , and may be foldably connected along a first longitudinally extending fold line  62 . The bottom flaps  18 ,  38 ,  58 ,  78  extend along a second or bottom marginal area of the blank  8 , and may be foldably connected along a second longitudinally extending fold line  64 . 
     The first and second longitudinal fold lines  62 ,  64  may be, for example, generally straight lines of disruption, or, the fold lines  62 ,  64  may be offset at one or more locations to account for, for example, blank thickness or other factors. When the carton  150  ( FIG. 2 ) is erected, the top flaps  16 ,  36 ,  56 ,  76  close a top of the carton  150 , and the bottom flaps  18 ,  38 ,  58 ,  78  close a bottom of the carton  150 . 
     A dispenser pattern  100  is formed from a plurality of lines of disruption in an upper portion of the blank  8 . The dispenser pattern  100  defines the dispenser  160  in the erected carton  150  ( FIG. 2 ). The dispenser pattern  100  comprises a first lower oblique line of disruption  102  extending through the first side panel  30  from adjacent to the longitudinal line of disruption  62  downwardly to adjacent the transverse line of disruption  51 . A second lower oblique line of disruption  102  extends through the second side panel  70  downwardly from adjacent to the longitudinal line of disruption  62  to adjacent the transverse line of disruption  71 . A lower longitudinal or horizontal line of disruption  106  extends through the second end panel  50  adjacent to and between the lower ends of the pair of oblique lines of disruption  102 . A pair of oblique lines of disruption  110  extend from adjacent an upper longitudinal line of disruption  118  downward in an inverse “V” arrangement to the lower longitudinal line of disruption  106 . A transverse line of disruption  112  extends between the oblique lines of disruption  110  upwardly from the longitudinal line  106  to the vertex of the “V”. A first upper oblique line of disruption  116  extends through the first side panel  30  from adjacent the longitudinal line of disruption  62  to adjacent the transverse line of disruption  51 . A second upper oblique line of disruption  116  extends through the second side panel  70  from adjacent the longitudinal line of disruption  62  to adjacent the transverse line of disruption  71 . 
     Still referring to  FIG. 1 , first and second end transverse breachable lines of disruption  120  may extend along the transverse fold lines  51 ,  71 . First and second top transverse breachable lines of disruption  122  extend through the first and second side top flaps  36 ,  76  respectively. The breachable lines of disruption  122  can be, for example, tear lines, and they allow each of the flaps  36 ,  76  to be separated into two sections. A closure aperture  130  is formed in the second side top flap  76 . The closure aperture  130  can be, for example, a breachable line of disruption such as a slit or deep score, or a knockout section of the top flap  76 . A closure tab  132 , which is sized to be received within the closure aperture  130 , is formed at the upper edge of the first side top flap  36 . 
     For purposes of the description presented herein, the term “line of disruption” can be used to generally refer to cuts, scores, tear lines, creases, perforations, overlapping and/or sequential combinations thereof, and other disruptions formed in a blank. A “breachable” line of disruption as disclosed in this specification refers disruptions that are intended to be breached or otherwise torn during ordinary or prescribed use of a carton. A tear line is an example of a breachable line of disruption. A “fold line” is any line of disruption that facilitates folding, bending, hinged movement, etc. of a carton or blank. In the illustrated exemplary embodiment, the lines of disruption  102 ,  110 ,  112  are scores, the lines of disruption  116  are cut-spaces, the lines  120  are 110% cuts, and the lines  31 ,  51 ,  71 ,  81 ,  118  are creases. 
     According to one exemplary method of construction, the carton  150  may be erected by folding the blank  8  flat about the transverse lines of disruption  31 ,  71  so that the exterior side of the adhesive panel  80  contacts the interior side of the first end panel  10 . The first end panel  10  can be adhered to the adhesive panel  80  by, for example, glue, adhesives, or other means. The blank  8  may then be opened to have a generally tubular shape. 
     To close the top of the tubular carton form, the first and second end top flaps  16 ,  56  are folded inwardly, followed by the first side top flap  36 , then the second side top flap  76 . The underside of the second side top flap  76  is adhered to the exterior or upper side of the first side top flap  36 . The underside of the first side top flap  36  may be adhered to one or both of the end top flaps  16 ,  36 . 
     To close the bottom of the tubular carton form, the first and second end bottom flaps  18 ,  58  are folded inwardly, followed by the second side bottom flap  78 , then the first side bottom flap  38 . The underside of the first side bottom flap  38  is adhered to the exterior side of the second side bottom flap  78 . Portions of one or both of the first and second side bottom flaps  38 ,  78  may also be adhered to the first and second end bottom flaps  18 ,  58 . 
       FIG. 2  illustrates the erected carton  150 , which is substantially parallelepipedal in shape. Referring also to  FIG. 1 , in the erected carton  150 , the top flaps  16 ,  36 ,  56 ,  76  form a top panel  170 , and the bottom flaps  18 ,  38 ,  58 ,  78  form a bottom panel  180 . The dispenser pattern  100  defines a dispenser  160  at one upper end of the carton. A bag (not visible in  FIG. 2 ), for example, or other flexible vessel filled with product may be inserted in the carton  150  in a conventional manner at any time before closing the top and bottom of the carton. The product may include, for example, dispensable foodstuffs, detergent, powders, etc. 
       FIGS. 3-6  illustrate opening of the carton dispenser  160  and placing the dispenser  160  in a dispensing configuration. In  FIGS. 3-6 , certain reference numbers may not be visible or included; these reference numbers can be found in  FIG. 1 . Referring to  FIG. 3 , the top panel  170  may be opened by separating the top panel  170  at the first and second side top flaps  36 ,  76  and tearing the top flaps  36 ,  76  into separate sections along the top end tear lines  122 . Sections of the top flaps  36 ,  76  at the dispenser end of the carton  150  may then be pulled outwardly in the direction of the curved arrows as shown in  FIG. 3 . The carton  150  is further separated along the vertically extending lines of disruption  120  at the upper corners of the dispenser  160 . This separation allows the first and second side panels  30 ,  70  to be pivoted outwardly about the oblique lines of disruption  116 . A flexible vessel in the form of a bag  145  is accessible in the partially opened carton  150 . The flexible vessel  145  may be filled with product. 
     Referring to  FIG. 4 , the second end top flap  56  at the dispenser end of the carton  150  is pivoted outwardly about the line of disruption  62  in the direction of the curved arrow. The portion of the end panel  50  connected to the top end flap  56  can also pivot outwardly about the upper longitudinal line of disruption  118  to provide easier access to the bag  145 . 
     Referring to  FIG. 5 , a top portion of the bag  145  is opened. Dispensable product P is disposed within the bag  145 . Referring also to  FIG. 6 , the sides of the carton  150  are squeezed together so that the second end panel  50  deforms at the lines of disruption  106 ,  110 ,  112 ,  134  to form the spout-like dispenser  160 . The first and second side panels  30 ,  70  also deform at the oblique lines of disruption  102 , and the second end flap  56  deforms at the transverse line of disruption  136  to have a “V” profile. These deformations facilitate the dispenser  160  assuming the configuration shown in  FIG. 6 . 
       FIG. 7  illustrates the carton  150  in the dispensing configuration. The carton  150  can be tilted so that dispensable product P in the bag  145  can be dispensed out of the carton through the opening in the top of the flexible vessel  145 . The spout-like dispenser  160  has a generally V-shaped profile that allows the product P to be dispensed in a controlled manner. The side panels  30 ,  70  of the carton  150  can be pressed together to varying degrees, for example, to control the size of the opening of the dispenser  160 . 
     After dispensing product from the carton  150 , the carton can be reclosed as illustrated in  FIG. 8 . The carton  150  may be reclosed by folding the second end top flap  56  inwardly about the line of disruption  62 , and then pulling the side panels  30 ,  70  and the dispenser portions of the side top flaps  36 ,  76  back over the top end of the carton. The closure tab  132  may be engaged with the closure aperture  130  to close the top of the carton  150 . The closure aperture  130  can be a 100% cut such as a slit in which the tab  132  can be received, or a cut interspersed with nicks that can be breached by insertion of the tab  132 . 
     Alternatively, the side top flaps  36 ,  76  can be reclosed by the closure tab  132  and closure aperture  130  and the second end top flap  56  subsequently tucked under the reclosed flaps  36 ,  76 . The carton contents are securely retained by the engaged portions of the side top flaps  36 ,  76  when the carton  150  is in its reclosed configuration. 
     To reopen the dispenser  160 , the closure tab  132  can be disengaged from the closure aperture  130  and the dispenser end of the carton  150  again deformed as shown in  FIG. 6 . The carton  150  can be repeatedly placed in the dispensing configuration and reclosed. Because only a portion of the top flaps  36 ,  76  are opened for dispensing, the carton retains greater rigidity after opening. 
     According to the above-described embodiment of the invention, the reclosable dispenser  160  provides for controlled dispensing of product from the carton  150 . The size of the opening of the dispenser  160  can be selectively varied by the user to any desired degree. After dispensing product, the reclosable dispenser  160  can be reclosed to secure the carton contents after dispensing. 
     In the exemplary embodiment discussed above, the blank may be formed from, for example, clay-coated newsprint (CCN). In general, the blank may be constructed of paperboard and/or paper-based materials, having a caliper of at least about 12, for example, so that it is heavier and more rigid than ordinary paper. The blank, and thus the carton, can also be constructed of other materials having properties suitable for enabling the carton to function at least generally as described above. Solid unbleached sulfate (SUS) board, for example, may be used to form cartons in accordance with the principles of the present invention. 
     The interior and/or exterior sides of the blank can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blank may then be coated with a varnish to protect any information printed on the blank. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blank, or laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
     The term “line” as used herein includes not only straight lines, but also other types of lines such as curved, curvilinear or angularly displaced lines. 
     The above embodiments may be described as having one or panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure paperboard carton panels in place. 
     In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections. 
     It will be understood by those skilled in the art that while the present invention has been discussed above with reference to preferred embodiments, various additions, modifications, and variations can be made thereto without departing from the spirit and scope of the present invention.