Abstract:
Cartons with semi-rigid or rigid box-like container sections, along with attached plastic or polymeric reclosable flexible material structures, are disclosed. The resulting containers with reclosable flexible material are intended to be formed so as to be easily filled and closed. Furthermore, methods and apparatus for the manufacture of these cartons are disclosed.

Description:
[0001]    This application claims priority under 35 U.S.C. §119(e) of U.S. provisional application Ser. No. 61/417,643, filed Nov. 29, 2010, the disclosure of which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE DISCLOSURE 
       [0002]    1. Field of the Disclosure 
         [0003]    This disclosure pertains to a container or carton with a semi-rigid or rigid box section with a reclosure header from flexible web reclosure material and an unfolded box blank that has top and side panels and bottom flaps to form the box bottom. The disclosure further relates to the method and machinery used in the manufacture thereof. 
         [0004]    2. Description of the Prior Art 
         [0005]    In the prior art, the use of a plastic flexible header and reclosure in combination with a rigid or semi-rigid box structure is a developing field. The container, as well as the machinery and method for the production thereof, is disclosed in U.S. patent application Ser. Nos. 12/922,537; 12/922,540; 12/922,541; and 12/922,547, all entitled “Carton with Plastic Reclosable Header” and filed on Sep. 14, 2010, the disclosures of all of which are hereby incorporated by reference. While the container, as well as the machinery and method of production thereof, has been found to be satisfactory and well-adapted to its intended purposes, further improvements are sought, particularly with regard to the shape and type of the resulting package. 
       OBJECTS AND SUMMARY OF THE DISCLOSURE 
       [0006]    It is therefore an object of the present disclosure to improve the container of the type with a rigid or semi-rigid box structure in combination with a plastic header and a reclosable zipper. 
         [0007]    It is therefore a further object of the present disclosure to provide a container of the type described above with an alternate improved shape and stackability. 
         [0008]    These and other objects are attained by providing web reclosure material and an unfolded flat box blank that has top and side panels and bottom flaps to form the box bottom, where one panel of the box blank has a cut-out and attaching over the panel web reclosure material, after which the box blank with the attached web reclosure material is separated into individual units. Thereafter, the box blank can be folded and formed into the resulting container with a reclosure header (and filled, when required) and wherein the reclosure header is attached to only one or an uneven number of sides of the box. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawing, wherein: 
           [0010]      FIG. 1  is a side schematic of an embodiment of the machinery and apparatus of the present disclosure. 
           [0011]      FIG. 2  is a top schematic of an embodiment of the machinery and apparatus of the present disclosure. 
           [0012]      FIG. 3  is a side schematic of a further embodiment of the machinery and apparatus of the present disclosure. 
           [0013]      FIG. 4  is a top schematic of a further embodiment of the machinery and apparatus of the present disclosure. 
           [0014]      FIG. 5A  illustrates an alternate assembly of an embodiment of the unfolded flat blanks and web reclosure material of the present disclosure. 
           [0015]      FIG. 5B  is a cross-sectional view along plane  5 B- 5 B of  FIG. 5A . 
           [0016]      FIG. 6A  is a side schematic of a further embodiment of the machinery and apparatus of the present disclosure. 
           [0017]      FIG. 6B  is a top schematic of a further embodiment of the machinery and apparatus of the present disclosure. 
           [0018]      FIG. 7  is a further schematic of the embodiment of the machinery and apparatus shown in  FIGS. 6A and 6B . 
           [0019]      FIG. 8  is a further schematic illustrating the filling process of inverted containers in an embodiment of the present disclosure. 
           [0020]      FIGS. 9A through 9F  are perspective views of various embodiments of the cardboard container of the present disclosure. 
           [0021]      FIG. 10A  is a perspective view of a still further embodiment of the cardboard container of the present disclosure. 
           [0022]      FIG. 10B  is a perspective view of the cardboard container of  FIG. 10B , shown with a folded header. 
           [0023]      FIG. 10C  is a cross-sectional view of the cardboard container of  FIG. 10A . 
           [0024]      FIG. 10D  is a partial cross-sectional view of the cardboard container of  FIG. 10B , showing the zipper sealed to the outside of the folded film. 
           [0025]      FIG. 10E  is a partial cross-sectional view of the cardboard container of  FIG. 10B , showing the zipper sealed to the inside of the folded film. 
           [0026]      FIGS. 11A and 11B  are perspective views showing the order of assembly of a cardboard container of the present disclosure. 
           [0027]      FIG. 12A  is a plan view of an embodiment of the unfolded box blank with attached web reclosure material of the present disclosure. 
           [0028]      FIG. 12B  is a plan view illustrating the assembly step of the cardboard container of  FIG. 12A . 
           [0029]      FIG. 13A  is a diagram of a portion of the assembly method and apparatus of an embodiment of the reclosable material of the present disclosure. 
           [0030]      FIGS. 13B ,  13 C and  13 D are cross-sectional diagrams of the engagement of the zipper or reclosure mechanism in an embodiment of the present disclosure. 
           [0031]      FIG. 14A  is a diagram of a portion of an alternative assembly method and apparatus of the web reclosure material of the present disclosure. 
           [0032]      FIG. 14B  is a cross-sectional diagram of the engagement of the zipper or reclosure mechanism and web material of  FIG. 14A  in an alternative embodiment of the present disclosure. 
           [0033]      FIGS. 15A through 15F  are cross-sectional views of different arrangements of the web reclosure material to form a header. 
           [0034]      FIG. 15G  illustrates the method of assembly of an embodiment of the header of the present disclosure. 
           [0035]      FIGS. 16A-16F  are cross-sectional views illustrating further embodiments of the zipper structure of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one can see that  FIGS. 1 and 2  are respective top and side schematic views of a machinery and apparatus  10  for the production of cartons  1000 , as illustrated hereinafter at  FIGS. 9A-11B . Apparatus  10  includes a magazine  12  which holds a stack  14  of flattened unfolded blanks  16  (or rigid or semi-rigid unfolded flat box sections) which are eventually folded to form the semi-rigid or rigid box portions or panels  1002  (sides and bottom) of cartons  1000 . Preferably, the blanks  16  have been cut and formed prior to being supplied to magazine  12 , there are instances wherein the cut-out section area is perforated for removal of these sections later in the manufacturing process, such as after the attachment of the web reclosure material. A bottom feed belt  20 , configured around rolls  22 ,  24  sequentially pulls a single blank  16  through the feed gate  18  which is formed at the bottom of the magazine  12 . The feed gate  18  allows the thickness of only one blank  16  to pass through at a time. The series or sequence of blanks  16  progressing through apparatus  10  can be seen on both  FIG. 1  and  FIG. 2 . The blanks  16  are passed by bottom feed belt  12  to the nip formed between rollers  24 ,  26  and further to the nip formed between rollers  28 ,  30  so as to be engaged between lower and upper main conveyor pull belts  40 ,  42 . Lower main conveyor pull belt  40  is configured around rollers  28 ,  38 . Similarly, upper main conveyor pull belt  42  is configured around rollers  30 ,  32 ,  34 . Lower and upper main conveyor pull belts  40 ,  42  are set at a different speed from the bottom feed belt  20  so as to control and fix the gap between successive blanks  16 . Alter the position of the blanks  16  has been adjusted, the blanks  16  are delivered to roller  42  where it is joined to polymeric web reclosure material  44 . Web reclosure material  44  is formed from zipper  54  and web or film material  55  that are joined at roller  46  and attached to each other at sealing or attaching station  58 . Zipper  54  may have sliders mounted on it at slider mounting station  56 . Polymeric web reclosure material  44  is positioned over and held in place against the blanks  16 . However, as shown in  FIGS. 5A and 5B , other embodiments may join the blank  16 , the web material  55  (illustrated as two separate sheets  55 ′ and  55 ″) and the zipper material  54  simultaneously. If the web reclosure material is delivered above the flat unfolded blanks  16  and attached thereto, the resulting combination typically will have to be inverted before filling. If the reclosable material is delivered below the blanks  16 , typically no inversion is necessary. 
         [0037]      FIG. 1 , as well as  FIG. 3 , further includes an inserts with illustrations of an alternative embodiments wherein the web reclosure material  44 , instead of being provided with continuous zipper, is provided with pre-applied zipper sections or segments  54 ′, in either the machine or transverse direction, which are then indexed to fit over the blanks  16 . 
         [0038]    As shown in  FIGS. 3 and 4 , other methods of delivering the blank  16  to the (lower) main conveyor pull belt  40  may be used, such as positioning the blanks  16  on the conveyor pull belt  40  by vacuum pick-up and placing devices  50 . In the embodiment of  FIGS. 3 and 4 , the blanks  16  could be delivered to the conveyor pull belt  40  from a location adjacent to the conveyor pull belt  40  rather than in-line with the conveyor pull belt  40 . 
         [0039]    In both the embodiments of  FIGS. 1 and 2  and of  FIGS. 3 and 4 , the web reclosure material or film  44  is attached to the blanks  16 , preferably by one or more seal bars  52 . Alternately, this attachment may be done by adhesive and element  52  would be implemented as an adhesive applicator. Seal bar  52  would typically include at least one seal bar which is rectangular and would attach the web reclosure material  44  to the blank  16  in a single operation. Some applications, however, may require more than one operation. Seal bar  52  may be reciprocal and may travel horizontally, synchronized with the conveyor pull belt  40  and then return to seal the succeeding blank  16 . This is typically more efficient than an intermittent (“stop-and-go”) travel of the conveyor pull belt  40  and typically provides more dwell time for the seal bar  52  thereby improving seal quality. At the location of seal bar  52 , side rollers  52 A move the unfolded blanks  16  and roller  62 , synchronized to roller  52 A, moves the web reclosure material  44 . 
         [0040]    After the web reclosure material  44  is sealed to the blank  16 , the blanks  16  along with the attached reclosure material  44 , are transported by conveyor pull belt  40  under rollers  62 ,  64 , and a cross-seal is formed in the web reclosure material  44  and the web reclosure material  44  (which is still a continuous sheet connected to a series of blanks  16 ) is cut by cutter  66  (cutter  66  typically also forming the cross seal). The resulting cartons  1000  (the combination of blank  16 , web reclosure material  55  and zipper material  54 ), still in a flat unfolded configuration, are separated from each other and stacked, or otherwise prepared for subsequent transportation and/or assembly. An alternate embodiment may use web reclosure material  44  with transverse perforated lines (or other lines of weakness) between subsequent cartons  1000  so as to form a continuous belt of blank boxes with attached web reclosure material, and which are then stacked in a zig-zag configuration on top of each other. 
         [0041]    Alternative embodiments are shown in  FIGS. 6A and 6B  wherein the stock rigid or semi-rigid material  13  of blanks  16  is provided from spool  17  and cut and shaped at shaping station  19  to form blanks  16 . In this illustrated embodiment, initially the center section and the unusable sides of the rigid or semi-rigid stock material are cut out, and the various score lines (for subsequent folding) are formed. The central section that joins successive blanks  16  is also scored to keep the unfolded blanks attached to each other until they are later separated. However, if the blanks  16  are completely separated, side rollers can be used to move them from one station to another.  FIG. 6A  further includes an inset with an illustration of an alternative embodiment wherein the web reclosure material  44  is provided with pre-applied zipper sections or segments  54 ′ which are then indexed to fit over the blanks  16 . 
         [0042]    Subsequently, as shown in  FIGS. 7 and 8 , at the same location or at a different location, including a different or separate geographic location, a form-and-hill operation will take place wherein the flat cartons  1000 , including the blank  16 , the web reclosure material  44  and the zipper material  54  will be folded to form the completed cartons  1000  with a storage volume.  FIGS. 7 and 8  illustrate the filling of the cartons  1000 . The unfolded box blanks  16  with attached web reclosure material  44  are loaded from the side with contents  2000  after which the side and bottom panels are folded and attached to each other to form the filled carton  1000 . Alternately, the bottom flaps of the carton  1000  can be folded, closed and attached to each other and the filling done through the zipper or other reclosure  54 . In any event, the filled carton  1000  is typically provided with tamper-evident construction. In some instances, one of the zipper flanges may be left at least partially unattached or unsealed to the web material at a specific location or opening, the unit filled through that unattached area opening, after which the zipper flange and the web reclosure material are re-attached and sealed to each other thereby closing the opening. The resulting packages are shown in  FIG. 9A-9F , and  10 A- 10 E wherein completed cartons  1000  have a rigid or semi-rigid bottom  1003  (formed from flaps  1020 ,  1022  in  FIGS. 11A and 11B ), four rigid or semi-rigid sides  1004 ,  1006 ,  1008 ,  1010  and top  1012  comprising a rigid or semi-rigid frame-type structure  1014  around a central opening  1016  which is covered with web reclosure material  44  and zipper  54 . Additionally, as shown in  FIG. 9E , a band  1018  can be placed around and attached to the carton  1000 . Similarly, as shown in  FIG. 9F , a cardboard or similar rigid or semi-rigid lid  1100  can be placed over the top of carton  1000  in order to protect the contents, provide further tamper evidence, and further aid in the shipping and storage of cartons  1000 . As shown in  FIGS. 9A-9F  and  10 A- 10 F, the sealing or attachment of the web reclosure material  44  to the completed carton  1000  takes place on one side of the panel (the top) or three panels (two sides and top, i.e. on an uneven number of panels of carton  1000 ). Additionally, as shown in  FIGS. 9D ,  10 B,  10 D and  10 E, the web reclosure material  44  can, after attachment, be configured to be folded flat against the top  1012  of carton  1000 . 
         [0043]    The blanks  16  may be made of carton or fibrous materials, rigid or semi-rigid polymers, or any other rigid or semi-rigid materials. The blanks  16  may be coated or laminated on either side or both with polymers, may provide moisture or oxygen barriers, or may be biodegradable. As shown in  FIGS. 12A and 12B , the blanks  16  may have any number of panels and many different arrangements of bottom flaps and different was of folding and attaching these together to form the bottom of the container  1000 . The various panels are separated by score lines to provide for accurate folding of the blank  116  thereby forming the container. While typically, only one panel of the blank  16  may require an opening such as central opening  1016 , more openings would be provided and, while the web reclosure material  44  would typically be attached only to an uneven number of sides, there are applications wherein it may also be attached to an even number of sides of the blank  16 . 
         [0044]    The web and reclosure mechanism and/or zipper  55  may be delivered attached to each other from a spool or assembled in front of the machine from separate reclosure and web material spools (see  FIGS. 5A and 5B ). The web material  55  is typically flexible polymeric material, which may include, but is not limited to, polyethylene, polypropylene or other polymers. The web material could have eyemarks, be delivered in a flat or folded configuration, have folds above or below the zipper  54  or both, wherein the folds could then be provided with features such as handles, tear-away compartment, spouts or funnels, be provided with tear lines or lines of weakened resistance, or be provided with peel seal material. When the web material  55  and the zipper  54  are delivered attached to each other, the zipper could be attached to the web reclosure material in separate, discrete sections, in which case the zipper  54  could be attached to the web material in the film-delivered direction (i.e., machine direction) or at an angle to the Film-delivered direction, such as the transverse direction. If the web material  55  is delivered in one web, it will have a tear line  57  (see  FIGS. 15A and 17 ) or line of weakened resistance below the zipper  54  to provide access to the contents  2000  of the carton  1000 . The tear line  57  will typically be formed in the machine direction, with a first interlocking element of zipper  54  attached to the web reclosure material  44  on a first side of the tear line  57  and a second interlocking element of zipper  54  attached to web material  55  on a second side of tear line  57 . However, if the web material  55  is delivered as two webs  55 ′,  55 ″, as shown in  FIG. 5 , there is no need for such a line of weakness as access is provided between the two webs. 
         [0045]    The zipper or reclosure material  54  is typically a zipper, but may also include hook-and-eye or adhesive constructions. The zipper  54  may have on of many constructions such as, but not limited to, a zipper operated by a slider  65  (see  FIGS. 10A and 16E ), a zipper with flanges above or below the zipper (the flanges of which may or may not be attached to each other, and may include tear lines  59 ,  61  as shown in  FIG. 15C , the zipper structure being formed as shown in  FIG. 15G ). A string zipper, a double zipper, a tamper-evident zipper, a zipper with bent or uneven length flanges, a zipper with pre-applied spot seals, a zipper with a line of weakened resistance, a zipper with a peel seal (see peel seal  66  in  FIG. 16B ), a leak-resistant zipper, a zipper with wedges, a zipper with stabilizing post, a zipper with guide ribs, a pinch grip pull zipper or a clicker zipper may also be implemented. The zipper  54  could be attached to the web material  55  in several different ways, from above or below the web material as illustrated in  FIGS. 10D ,  10 E,  13 A,  14 A,  15 D and  15 E. Additionally, particularly if the web material  55  is delivered as a single web, the zipper  54  may be placed astride a line of weakness  57  as shown in  FIG. 15D . 
         [0046]    The zipper  54  can be delivered interlocked or in unlocked, separated sections, and can have several variations. The zipper  54  can be attached to a flat web material  55  as shown in  FIG. 15A , or to a web material  55  with a pre-formed fold  63  and tear-lines  59 ,  61  above the interlocking zipper elements as shown in  FIG. 15C . If the zipper  54  delivered separate and unlocked, it can be delivered from above or below the web material  55  as shown in  FIGS. 13A and 14A , after which, when the zipper  54  is aligned and interlocked, a fold  63  is formed above or below the zipper  54 , as shown in  FIGS. 13C and 14B . Alternately, zipper  54  can be delivered with different flange arrangements such as shown in  FIGS. 15A and 15B , so as to be positioned in a stand-up configuration above the web material  55 . Typically, the zipper base (if a string zipper) or the zipper flanges are attached to the web material  55  at different times. The resulting construction is the same, but the method and sequence of attachment of the zipper  54  to the web material  55  is different. If a fold  63  is formed in the web material  55  as previously indicated, the zipper  54 , instead of being attached to the inside of the fold  63 , can be attached to the outside of the fold  63 , so that the fold  63  is positioned below the zipper interlocking elements and the zipper flange. Typical zipper configurations illustrative of this are shown in  FIGS. 15D and 15E . 
         [0047]    In this way, a container  1000  is provided. 
         [0048]    Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.