CA2316195A1 - Four-panel paperboard carton with integrated pour spout - Google Patents
Four-panel paperboard carton with integrated pour spout Download PDFInfo
- Publication number
- CA2316195A1 CA2316195A1 CA002316195A CA2316195A CA2316195A1 CA 2316195 A1 CA2316195 A1 CA 2316195A1 CA 002316195 A CA002316195 A CA 002316195A CA 2316195 A CA2316195 A CA 2316195A CA 2316195 A1 CA2316195 A1 CA 2316195A1
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- Prior art keywords
- spout
- chute
- flap
- carton
- sides
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/72—Contents-dispensing means
- B65D5/74—Spouts
- B65D5/741—Spouts for containers having a tubular body
- B65D5/743—Spouts formed by deforming or tearing scored or incised parts of the side-wall of containers
- B65D5/744—Spouts formed by deforming or tearing scored or incised parts of the side-wall of containers combined with swivelling devices having a bottom-wall and two side-walls
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Cartons (AREA)
Abstract
A carton, formed from a unitary blank, comprises four panels (22, 24, 26, 28) interconnected by fold creases (14, 16, 18, 20) to form a rectangular tube. At the end of the tube, a set of four flaps (32, 34, 36, 38, 46, 48, 50, 52) are folded upon each other to form ends of the carton. A spout is formed in one of the four flaps to facilitate the pouring of the content.
Description
I
FOUR-PANEL PAPERBOARD CARTON WITH INTEGRATED POUR SPOUT
BACKGROUND OF THE INVENTION
TECHNICAL FIELD
The invention relates to paperboard cartons and, in particular, to a paperboard carton having an integrally-formed paperboard pour spout. The invention is especially applicable to cartons for granular and particulate products including, but not limited to, pet litter, laundry detergent, dishwashing detergent, and food stuffs (e.g. sugar, rice, cereals, dry pet food).
BACKGROUND ART
It is known to supply particulate products, especially detergents, in a carton with a tear strip around three sides of the carton. When the tear strip is removed, the upper portion of the carton becomes a hinged Iid. A disadvantage of this type of carton is that it usually requires a liner, both to allow the carton to be filled above the level of the tear strip and to provide stacking strength. Also, it is usual to include a separate scoop in the carton for dispensing its contents. These additional items increase production costs.
An alternative approach is to provide a pour spout to facilitate the dispensing of the contents. In some cases, a plastic or metal pour spout is installed in one wall of the carton.
The carton may be a typical four-panel carton, i.e. having front, rear and side panels, each with flaps at opposite ends which are folded down in succession to form a parallelepiped box. Such a carton is relatively inexpensive to produce but installation of the plastic or metal pour spout requires special and expensive production equipment.
These disadvantages have been addressed by making cartons with integral pour spouts formed from the paperboard material. The specification of United States patent number 5,531,376 (Brink et al) issued July 1996 discusses limitations of such integral pour spouts, including lack of durability, the absence of tactile or audible feedback indicative of positive reclosure, the inability to prevent spillage or sifting of the contents of the container in the area of the pour spout, and the excessive use of paperboard in the construction of the spout.
A basic carton requires four panels and their end flaps, which can be formed from a rectangular blank. Hitherto, cartons with integral pour spouts have used at least one additional panel and in some cases two additional panels. Thus, Brink et al's carton has two extra panels which are used to form the pouring spout and so requires excessive paperboard as compared with the basic four-panel carton. Furthermore, these additional fifth and sixth panels are quite intricate and involve multiple folds, which complicates the folding and gluing process required to take the blank and produce from it the "knock-s down" which will then be shipped to the filler. A further disadvantage of Brink et al's carton is that the side pieces of the spout protrude into the interior of the carton during the filling operation and hence can interfere with the filling and/or be damaged by the contents. Moreover, the carton requires an extra flap of material which must be folded down during assembly of the carton to provide a means of holding and aligning the spout sides during use. This increases the footprint of the basic blank and also incurs extra production expense.
U.S. patent number 4,194,677 (Wysocki) discloses a carton with an integral pouring spout formed from a unitary blank without an additional flap. The pouring spout is deployed through an opening formed by removal of a cover piece in an overlying end flap. As the spout is deployed for the first time, its sides or wings engage the edges of the opening and are folded inwards. Because these edges are parallel, each side/wing engages the edges along substantially the whole of its length, requiring a significant force to deploy the spout, with increased risk of damage to the spout lip by the user's fingertip. Also, the spout sides are relatively low, as compared with the height of the opening, leading to risk of spillage, and folding them through substantially 90 degrees each time they are deployed leads to rapidly reduced resiliency and increased likelihood of sifting between the spout sides and the engaged edges of the opening.
U.S. patent number 2,989,224 (Umanoffj also discloses a carton with an integral pouring spout deployed through an opening in an overlying end flap. The spout has a chute or tongue portion and opposed sides. The side edges of the tongue or chute portion converge so that it is narrower at its distal end. The edges of the opening diverge. As a result, the force required to deploy the spout for the first time will be less than required to deploy Wysocki's spout, but Umanoff's deployed spout, being relatively wide and converging, will be more susceptible to spillage and collapsing of the spout, especially after repeated use. Other disadvantages include the fact that the spout is only one ply of the material, the abscence of a cover for the spout, and the absence of something to prevent the spout from being pushed into the carton when it is being closed.
Also, because the spout is located in the top of the carton, a greater opening angle is requires and the carton must be tipped further when pouring.
SUMMARY OF THE INVENTION:
The present invention seeks to eliminate, or at least mitigate, the disadvantages of such known cartons and provide an improved paperboard carton with an integral pour spout.
According to one aspect of the present invention, there is provided a carton, formed from a unitary blank, comprising four panels (22,24,26,28) interconnected by fold creases (14,16,18,20) to form a rectangular tube, a first set of four flaps (32,34,36,38) at one end of the tube and a second set of four flaps (46,48,50,52) at an opposite end of the tube, the flaps of each set being folded in succession to form respective ends of the carton, the second set of flaps having a combination of fold creases and cut-lines defining a spout chute (92) and two spout sides (94,96), the chute having three edges defined by three fold creases (98,100,102) and a fourth edge defined by a cut-line (104), a middle one (98) of the three fold creases attaching the chute hingably to the first flap (50) and each of the other fold creases (100,102) attaching a respective one of the spout sides (94,96) hingably to the chute (92), each spout side having distal edges defined by cut-lines, the second (52) of said second set of flaps overlying the first flap (50) and having three conjoined cut-lines (84) and a hinge fold crease (86) defining a spout opening member (82), the spout opening member having a perimeter circumscribing the underlying spout chute (92), the spout chute (92) and spout sides (94,96) being coplanar with said first flap (50), and the spout chute (92) being attached to the spout opening member (82) so that when the spout opening member (82) is hinged outwardly, a resulting opening (82') in the second flap (52) will allow the spout chute (92) to pass therethrough but the spout sides (94,96) will engage edges of the opening (82') and pivot inwardly towards each other to form sides of the spout, the third flap (48) and fourth flap (46) of the second set of end flaps (46,48,50,52) being configured so as not to obscure the opening (82'), and retaining means (120,,1202) for retaining the spout in the deployed position, the retaining means comprising an intermediate part (120,,1202) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (120,1202) engages an edge portion (105,,1052) of a hole (117) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part ( 1201,1202) through the hole, and, when the intermediate part is outside the carton, flexing towards its original position so that said intermediate part ( 120, ,1202) engages the edge portion exteriorly to resist closing of the spout until sufficient closing force is applied to the spout chute (92).
Each edge portion may be delimited by a crease to act as a hinge and allow flexing of the edge portion.
The edge portion may also serve as an abutment for a stop, for limiting outward travel of the deployed spout.
According to a second aspect of the present invention, there is provided a carton blank for forming a parallelepiped carton with an integral pour spout. The blank comprises a rectangle of paperboard, corrugated board, or like material having two parallel main fold creases and four transverse parallel fold creases defining four panels and a gluing strip arranged in sequence. A first set of four flaps are each connected to a respective one of the four panels by a first of the main fold creases, and a second set of four flaps are each connected to the four panels by the other main fold crease. The flaps are separated by cuts to allow each to hinge about the associated one of the main fold creases. A first of the first set of flaps has cut-lines and fold creases defining a spout chute and two spout sides. The chute has three edges defined by three conjoined fold creases and a fourth edge defined by a cut-line. A middle one of the three fold creases attaches the chute hingably to the end flap. Each of the other fold creases of the three attaches one of the side portions hingably to the chute. Distal edges of the side portions are defined by a series of cut-lines. The arrangement is such that hinging of the chute outwardly from the first flap, and hinging of the spout sides inwardly towards each other, forms the spout.
A second one of the first set of flaps has cut-lines and a fold crease defining a spout opening member having a perimeter that, when superimposed upon the chute, will circumscribe the chute. When the spout opening member is hinged outwardly, an opening so formed will allow passage of the spout chute therethrough but the spout sides will engage the edges of the opening and be forced to hinge inwards. Retaining means ( I201,1202) for retaining the spout in the deployed position comprises an intermediate part (120,,1202) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (1201,1202) engages an edge portion WO 99!32361 PCT/US98/27372 ( 105, ,1052) of a hole ( 117) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part ( 120, ,1202) through the hole, and, when the intermediate part is outside the carton, flexing towards its original position so that said intermediate part (120" 1202) engages the edge 5 portion exteriorly to resist closing of the spout until sufficient closing force is applied to the spout chute (92) .
When the blank is folded and glued to form the carton, the end flap having the hinged tab is folded outside the end flap having the spout chute and sides.
The hinged tab is attached (conveniently adhered) to the chute. When the hinged tab and chute are hinged outwardly, the spout sides engage respective edges of the opening left by the hinged tab and pivot inwardly towards each other to form the spout.
Preferably, at least one of the spout side members has means for engaging an adjacent edge of the opening to limit outward travel of the chute, and means for retaining the spout in the open position.
Such engaging means may comprise a stop formed by a notch in the edge portion of the spout side member.
The cutscore defining the fourth edge of the spout chute may still attach the spout chute to the first flap until severed during deployment.
Preferably, during manufacture, material is removed from adjacent each spout side portion to provide clearance for the forming of the spout sides during initial deployment and repetitive operation of the spout.
A third flap of the second set of flaps may have cutscores defining a removable cover piece, the perimeter of which will circumscribe the hinged tab when the third flap is folded down over the second flap. The removable cover piece will be removed before deploying the spout for the first time.
Alternatively, the removable cover piece may be omitted and the flap containing the hinged tab, exposed. A removable adhesive label may be adhered over the hinged tab to prevent sifting of the product through the cutscores defining the hinged tab, and the knockout for the user's finger. The adhesive label will be removed before first use.
The fourth flap does not contain any components of the spout and is sized so that it does not overlie the spout components.
FOUR-PANEL PAPERBOARD CARTON WITH INTEGRATED POUR SPOUT
BACKGROUND OF THE INVENTION
TECHNICAL FIELD
The invention relates to paperboard cartons and, in particular, to a paperboard carton having an integrally-formed paperboard pour spout. The invention is especially applicable to cartons for granular and particulate products including, but not limited to, pet litter, laundry detergent, dishwashing detergent, and food stuffs (e.g. sugar, rice, cereals, dry pet food).
BACKGROUND ART
It is known to supply particulate products, especially detergents, in a carton with a tear strip around three sides of the carton. When the tear strip is removed, the upper portion of the carton becomes a hinged Iid. A disadvantage of this type of carton is that it usually requires a liner, both to allow the carton to be filled above the level of the tear strip and to provide stacking strength. Also, it is usual to include a separate scoop in the carton for dispensing its contents. These additional items increase production costs.
An alternative approach is to provide a pour spout to facilitate the dispensing of the contents. In some cases, a plastic or metal pour spout is installed in one wall of the carton.
The carton may be a typical four-panel carton, i.e. having front, rear and side panels, each with flaps at opposite ends which are folded down in succession to form a parallelepiped box. Such a carton is relatively inexpensive to produce but installation of the plastic or metal pour spout requires special and expensive production equipment.
These disadvantages have been addressed by making cartons with integral pour spouts formed from the paperboard material. The specification of United States patent number 5,531,376 (Brink et al) issued July 1996 discusses limitations of such integral pour spouts, including lack of durability, the absence of tactile or audible feedback indicative of positive reclosure, the inability to prevent spillage or sifting of the contents of the container in the area of the pour spout, and the excessive use of paperboard in the construction of the spout.
A basic carton requires four panels and their end flaps, which can be formed from a rectangular blank. Hitherto, cartons with integral pour spouts have used at least one additional panel and in some cases two additional panels. Thus, Brink et al's carton has two extra panels which are used to form the pouring spout and so requires excessive paperboard as compared with the basic four-panel carton. Furthermore, these additional fifth and sixth panels are quite intricate and involve multiple folds, which complicates the folding and gluing process required to take the blank and produce from it the "knock-s down" which will then be shipped to the filler. A further disadvantage of Brink et al's carton is that the side pieces of the spout protrude into the interior of the carton during the filling operation and hence can interfere with the filling and/or be damaged by the contents. Moreover, the carton requires an extra flap of material which must be folded down during assembly of the carton to provide a means of holding and aligning the spout sides during use. This increases the footprint of the basic blank and also incurs extra production expense.
U.S. patent number 4,194,677 (Wysocki) discloses a carton with an integral pouring spout formed from a unitary blank without an additional flap. The pouring spout is deployed through an opening formed by removal of a cover piece in an overlying end flap. As the spout is deployed for the first time, its sides or wings engage the edges of the opening and are folded inwards. Because these edges are parallel, each side/wing engages the edges along substantially the whole of its length, requiring a significant force to deploy the spout, with increased risk of damage to the spout lip by the user's fingertip. Also, the spout sides are relatively low, as compared with the height of the opening, leading to risk of spillage, and folding them through substantially 90 degrees each time they are deployed leads to rapidly reduced resiliency and increased likelihood of sifting between the spout sides and the engaged edges of the opening.
U.S. patent number 2,989,224 (Umanoffj also discloses a carton with an integral pouring spout deployed through an opening in an overlying end flap. The spout has a chute or tongue portion and opposed sides. The side edges of the tongue or chute portion converge so that it is narrower at its distal end. The edges of the opening diverge. As a result, the force required to deploy the spout for the first time will be less than required to deploy Wysocki's spout, but Umanoff's deployed spout, being relatively wide and converging, will be more susceptible to spillage and collapsing of the spout, especially after repeated use. Other disadvantages include the fact that the spout is only one ply of the material, the abscence of a cover for the spout, and the absence of something to prevent the spout from being pushed into the carton when it is being closed.
Also, because the spout is located in the top of the carton, a greater opening angle is requires and the carton must be tipped further when pouring.
SUMMARY OF THE INVENTION:
The present invention seeks to eliminate, or at least mitigate, the disadvantages of such known cartons and provide an improved paperboard carton with an integral pour spout.
According to one aspect of the present invention, there is provided a carton, formed from a unitary blank, comprising four panels (22,24,26,28) interconnected by fold creases (14,16,18,20) to form a rectangular tube, a first set of four flaps (32,34,36,38) at one end of the tube and a second set of four flaps (46,48,50,52) at an opposite end of the tube, the flaps of each set being folded in succession to form respective ends of the carton, the second set of flaps having a combination of fold creases and cut-lines defining a spout chute (92) and two spout sides (94,96), the chute having three edges defined by three fold creases (98,100,102) and a fourth edge defined by a cut-line (104), a middle one (98) of the three fold creases attaching the chute hingably to the first flap (50) and each of the other fold creases (100,102) attaching a respective one of the spout sides (94,96) hingably to the chute (92), each spout side having distal edges defined by cut-lines, the second (52) of said second set of flaps overlying the first flap (50) and having three conjoined cut-lines (84) and a hinge fold crease (86) defining a spout opening member (82), the spout opening member having a perimeter circumscribing the underlying spout chute (92), the spout chute (92) and spout sides (94,96) being coplanar with said first flap (50), and the spout chute (92) being attached to the spout opening member (82) so that when the spout opening member (82) is hinged outwardly, a resulting opening (82') in the second flap (52) will allow the spout chute (92) to pass therethrough but the spout sides (94,96) will engage edges of the opening (82') and pivot inwardly towards each other to form sides of the spout, the third flap (48) and fourth flap (46) of the second set of end flaps (46,48,50,52) being configured so as not to obscure the opening (82'), and retaining means (120,,1202) for retaining the spout in the deployed position, the retaining means comprising an intermediate part (120,,1202) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (120,1202) engages an edge portion (105,,1052) of a hole (117) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part ( 1201,1202) through the hole, and, when the intermediate part is outside the carton, flexing towards its original position so that said intermediate part ( 120, ,1202) engages the edge portion exteriorly to resist closing of the spout until sufficient closing force is applied to the spout chute (92).
Each edge portion may be delimited by a crease to act as a hinge and allow flexing of the edge portion.
The edge portion may also serve as an abutment for a stop, for limiting outward travel of the deployed spout.
According to a second aspect of the present invention, there is provided a carton blank for forming a parallelepiped carton with an integral pour spout. The blank comprises a rectangle of paperboard, corrugated board, or like material having two parallel main fold creases and four transverse parallel fold creases defining four panels and a gluing strip arranged in sequence. A first set of four flaps are each connected to a respective one of the four panels by a first of the main fold creases, and a second set of four flaps are each connected to the four panels by the other main fold crease. The flaps are separated by cuts to allow each to hinge about the associated one of the main fold creases. A first of the first set of flaps has cut-lines and fold creases defining a spout chute and two spout sides. The chute has three edges defined by three conjoined fold creases and a fourth edge defined by a cut-line. A middle one of the three fold creases attaches the chute hingably to the end flap. Each of the other fold creases of the three attaches one of the side portions hingably to the chute. Distal edges of the side portions are defined by a series of cut-lines. The arrangement is such that hinging of the chute outwardly from the first flap, and hinging of the spout sides inwardly towards each other, forms the spout.
A second one of the first set of flaps has cut-lines and a fold crease defining a spout opening member having a perimeter that, when superimposed upon the chute, will circumscribe the chute. When the spout opening member is hinged outwardly, an opening so formed will allow passage of the spout chute therethrough but the spout sides will engage the edges of the opening and be forced to hinge inwards. Retaining means ( I201,1202) for retaining the spout in the deployed position comprises an intermediate part (120,,1202) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (1201,1202) engages an edge portion WO 99!32361 PCT/US98/27372 ( 105, ,1052) of a hole ( 117) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part ( 120, ,1202) through the hole, and, when the intermediate part is outside the carton, flexing towards its original position so that said intermediate part (120" 1202) engages the edge 5 portion exteriorly to resist closing of the spout until sufficient closing force is applied to the spout chute (92) .
When the blank is folded and glued to form the carton, the end flap having the hinged tab is folded outside the end flap having the spout chute and sides.
The hinged tab is attached (conveniently adhered) to the chute. When the hinged tab and chute are hinged outwardly, the spout sides engage respective edges of the opening left by the hinged tab and pivot inwardly towards each other to form the spout.
Preferably, at least one of the spout side members has means for engaging an adjacent edge of the opening to limit outward travel of the chute, and means for retaining the spout in the open position.
Such engaging means may comprise a stop formed by a notch in the edge portion of the spout side member.
The cutscore defining the fourth edge of the spout chute may still attach the spout chute to the first flap until severed during deployment.
Preferably, during manufacture, material is removed from adjacent each spout side portion to provide clearance for the forming of the spout sides during initial deployment and repetitive operation of the spout.
A third flap of the second set of flaps may have cutscores defining a removable cover piece, the perimeter of which will circumscribe the hinged tab when the third flap is folded down over the second flap. The removable cover piece will be removed before deploying the spout for the first time.
Alternatively, the removable cover piece may be omitted and the flap containing the hinged tab, exposed. A removable adhesive label may be adhered over the hinged tab to prevent sifting of the product through the cutscores defining the hinged tab, and the knockout for the user's finger. The adhesive label will be removed before first use.
The fourth flap does not contain any components of the spout and is sized so that it does not overlie the spout components.
The sequence in which the flaps are folded down can vary. In some cases, a minor or short flap is folded down first followed by an opposite short flap and then third and fourth major or wide flaps. In other cartons, particularly those used for dishwasher detergent, one of the wider flaps is folded first, followed by the two smaller flaps and then the other wider flap. The positioning of the spout components should take into account the folding sequence so that the flap containing the spout chute and sides is inside the flap containing the spout opening member. When the spout is being deployed, the sides of the pouring spout which hitherto lie flat inside the box, i.e. coplanar with the chute and remaining areas of the flap, will be folded inwards by the outer edges of the second panel and hence will fold through approximately 90° relative to the plane of the flap. The respective outer edges of the sides may have shoulders which will serve to provide a resilient locking of the pouring spout in the open position and notches defining stops to abut the interior of the carton and limit the outward travel of the pour spout chute.
In this specification, the word "cutscore" embraces both continuous cuts which do not penetrate the board completely and a series of short cuts which penetrate the board completely but alternate with uncut parts. The latter form of cutscore is also known as "cut-and-nick" .
Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings, of preferred embodiments of the invention which are described by way of example only.
BRIEF DESCRIPTION OF DRAWINGS:
Figure 1 is a plan view of a blank for a carton having an integral pour spout;
Figure 2 is an enlarged view of three end flaps of the blank of Figure 1, showing the components of the pour spout;
Figure 3 shows a partially assembled carton and illustrates a typical sequence in which the end flaps containing the spout components may be folded;
Figure 4 is a perspective view of the completely assembled carton, with its spout cover in place, prior to first use;
Figure 5 is a cutaway perspective view of the interior of the carton showing the pour spout before it is deployed for the first time;
In this specification, the word "cutscore" embraces both continuous cuts which do not penetrate the board completely and a series of short cuts which penetrate the board completely but alternate with uncut parts. The latter form of cutscore is also known as "cut-and-nick" .
Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings, of preferred embodiments of the invention which are described by way of example only.
BRIEF DESCRIPTION OF DRAWINGS:
Figure 1 is a plan view of a blank for a carton having an integral pour spout;
Figure 2 is an enlarged view of three end flaps of the blank of Figure 1, showing the components of the pour spout;
Figure 3 shows a partially assembled carton and illustrates a typical sequence in which the end flaps containing the spout components may be folded;
Figure 4 is a perspective view of the completely assembled carton, with its spout cover in place, prior to first use;
Figure 5 is a cutaway perspective view of the interior of the carton showing the pour spout before it is deployed for the first time;
Figure 6 is a detail view showing, enlarged, a part of the carton blank of Figure 2;
Figure 7 is a detail view of the pouring spout before deployment;
Figures 8A-8D are a series of cross-sectional detail views taken from above on line A-A of Figure 7 and illustrating deployment of the spout;
Figures 9A-9E are a series of cross-sectional detail side views taken on line B-B
of Figure 8 and illustrating deployment of the spout;
Figure 10 is a perspective view of the carton showing the spout fully deployed;
Figure 11 is a cutaway perspective view of the interior of the carton showing the spout fully deployed;
Figure 12 is a cross-sectional detail view taken on line VIII-VIII of Figure 11 and showing the spout fully deployed;
Figure 13 is a plan view of a blank incorporating modifications;
Figure 14 is an enlarged view corresponding to Figuie 2 but of a modification in which an outer cover is omitted:
Figure 15 is a plan view of three end flaps illustrating a modification to the shape of the spout and surrounding opening; and Figure 16 is a perspective view of an assembled carton with the spout of Figure 15 deployed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the invention will now be described with reference to Figures 1-14. Figure 1 shows a rectangular carton blank having two parallel longitudinal fold creases 10 and 12 and four transverse fold creases 14, 16, 18 and 20 defining four rectangular panels, namely, in succession, a bottom panel 22, a front panel 24, a top panel 26 and a rear panel 28. The front panel 24 and rear panel 28 are rectangular, whereas the bottom panel 22 and top panel 26 are oblong, their longer edges attached to the~adjacent panels. An elongate gluing tab 30 extends along the free edge of rear panel 28 and is attached to it by a fold crease 20.
A set of four end flaps 32, 34, 36 and 38 along one longitudinal edge of the blank are attached to the panels 22, 24, 26 and 28, respectively, by sections of the fold crease 12. The end flaps 32, 34, 36 and 38 are separated from each other by cuts 44, 42 and 40, WO 99/32361 PC'T/US98/27372 respectively. A similar set of four end flaps 46, 48, 50 and 52 are provided along the opposite longitudinal edge of the blank and attached to panels 22, 24, 26 and 28, respectively, by sections of fold crease 10. The end flaps 46, 48, 50 and 52 are separated from each other by cuts 54, 56 and 58, respectively. The components of the integral pour spout are provided in the end flaps 50 and 52 and a spout outer cover or sealing patch is provided in end flap 48.
As shown in more detail in Figure 2, the spout outer cover 60 is formed by offset cutscores including a first cut portion 62 extending perpendicular to the fold crease 10 joining the end flap 48 to the front panel 24 and adjacent the edge defined by the cut 56..
Two parallel offset cut-lines 64 and 66 extend from opposite ends of offset cut 62, and away from the cut 56, to define a rectangular cover portion 68. At their distal ends, the offset cut-lines 64 and 66 converge but do not meet. An arcuate cut 70 joins the ends of the offset cut-lines 64 and 66 to form a generally semicircular end tab 72 which is attached to the rectangular portion 68 by a fold crease 74. A generally C-shaped cut 76 connecting respective ends of the cut 70 forms a knockout tab 78. During manufacture, the knockout tab 78 will be removed leaving a hole 80 (see Figure 3).
The carton is a side-load carton. When the carton is assembled, as shown in Figure 3, the end panel 48 containing the spout outer cover 60 is the "last down" or outermost of the end panels. The penultimate end flap, when assembled, is end flap 52, which has a spout opening member 82 formed by cut-lines 84 on three sides and a fold crease 86 on the fourth side (Figure 2). At the edge furthest from fold crease 86, an additional cutscore or cut-and-nicked line 88 forms with the cut-line 84 a D-shaped knockout 90.
The inner surface of the D-shaped knockout 90 may be removed during manufacture leaving a hole 90', or its outer surface may ~be glued to the inner face of spout outer cover 60 which, following assembly, will overlie it. Hence, removal of the outer cover 60 will tear out the knockout tab 90, leaving a D-shaped finger recess 90' which will enable the user to insert a finger tip beneath the edge of the spout opening member 82 and pry it outwards, severing the nicks of cut-lines 84 and hinging the spout opening member 82 about fold crease 86.
This deploys the spout which, as will now be described, is formed in the adjacent or underlying end panel 50 when the carton is assembled.
End panel 50 contains the components of the spout itself, namely a spout chute portion 92 and two spout side portions 94 and 96, respectively, attached to opposite sides thereof. The spout chute portion 92 is defined by three fold creases 98, 100 and 102, respectively, and a cut-line 104. The fold creases 100 and 102 join the spout chute 92 to side portions 94 and 96, respectively.
The second side portion 96 is similar to the first side portion 94 and so will not be described. The components of the side portions are identified by the same reference numbers but with the subscripts 1 and 2, respectively.
Spout side portion 94 is defined by the fold crease 100 and a series of contiguous cut-line segments, namely an initial cut-line segment 106, extending from one end of, and collinear with, fold crease 98, a second cut-line segment 108, extending at an obtuse angle to fold crease 98 towards the fold crease 10, a third cut-line segment 1101 which extends parallel to fold crease 100, and a final cut-line segment 112, which joins the third cut-line segment 110, to the other end of fold crease 100. Final cut-line segment 112, has a special profile which provides certain functions when the spout is deployed. In particular, at its end adjacent the outer edge of the side portion 94, cut-line 112, has a notch 114, forming a stop surface 116, substantially parallel to cut-line segment 108, adjacent the distal edge of the side portion. A medial segment 118, of cut-line 112, is concave, providing clearance when the spout is being deployed. A shoulder portion 1201 is formed between the concave segment 1181 and the notch 114, . The distance between the peak of shoulder portion 1201 and the joint between fold creases 98 and 102 (which will constitute a pivot or hinge fulcrum later) is slightly greater than the length of fold crease 100, for reasons which will become apparent later.
As shown more clearly in Figure 6, a short segment 107 of profiled cut-line 1121, between an end of fold crease 100 and the junction between cut-lines 1121 and 1241 is inclined relative to chute hinge fold crease 98, so as to form a second shoulder 109, in the upper edge of spout side 94, adjacent side hinge fold crease 100. Hence, the distance between main hinge fold crease 98 and the apex of second shoulder 109, also is slightly greater than the length of fold crease 100.
An additional pair of cut-lines 1221 and 124, define, with profiled cutscore 112,, a knockout 1261, removal of which will take place during manufacture of the blank.
If desired, a hole can be provided in the top panel 26 (Figure 1) to take a handle in a manner which is well-known and so will not be described here.
Knockouts 78, 126, and 1262 are removed during formation of the blank, leaving corresponding holes 80, 126,' and 1262' . (If desired, knockout 90 could also be removed at this stage). The blank then is folded about fold creases 14 and 18 and the elongate tab 30 is glued to the inside of the edge of the bottom panel 22. In this knocked-down, flat 5 condition, the carton is shipped to the filler, i.e. the company which will be assembling the carton and filling it with the product.
Prior to filling, the final assembly and gluing of the carton will take place.
The sequence is as follows:-1. The knocked-down flat cartons are stacked in the hopper of a form-fill-seal 10 machine. Individual blanks are "picked off" the stack and opened into a tubular rectangular body with open ends at the top and bottom. The end flaps 48, 50, and 52 which will form the spout can be at the top or the bottom depending upon the way the machine operates, and/or the particular kind of machine being used.
2. The end flaps 32, 34, 36 and 38, which do not form the spout, are folded down -- first the two inside minor flaps (32 and 36), then inside major flap 38 and lastly the outside major flap 34 -- and glued to form an open carton.
3. The open carton is filled with product via the open top. This is a side-load carton so, when it is being filled, the end flaps 46, 48, 50 and 52 will be open at the top. When in use, however, the carton will have these end flaps at one side.
Generally, the fill level will be controlled so that, when the carton is filled, sealed and upright, the product level will be lower than the bottom of the spout unit. In practice, the product level may be slightly higher during filling to allow for settling during shipping. It should be appreciated that, in use, the spout can still be deployed, without undue spillage, even if there is product behind it.
4. The end flaps 46, 48, 50 and 52 then are folded and glued to close the carton. In this case, it is important that the flaps be folded in the correct sequence because they define the spout. As illustrated in Figure 3, the minor end flaps and 50 are folded first. Glue will be applied to the outer surface of end flap using any conventional gluing pattern. Glue will also be applied to the outer surface of end flap 50 but, because this end flap contains the spout components, the glue must be applied to certain parts only. In particular, glue will be applied to the perimeter of the end flap 50 avoiding the side portions 94 and 96. Glue will also be applied to the spout chute portion 92. It is important to avoid allowing glue in the area of end flap 50 that will be contacted by D-shaped piece 90 when end flap 52 is folded down.
5. Major end flap 52 will be folded down and its inner surfaces will adhere to the minor end flaps 46 and 50. The inner surface of the spout opening member will adhere to the outer surface of spout chute 92. (If desired/preferred, the outer surface of spout chute 92 may be perforated to improve adhesion, especially if the paperboard has a gloss finish).
6. , Glue will be applied to the perimeter of the outer surface of major end flap 52 taking care to avoid glue on the area which will be overlaid by the spout outer cover 60 when major end flap 48 is folded down. Glue will also be applied to D-shaped knockout tab 90. (Unless it has been removed previously, i.e. during manufacture of the blank.) (If desired/preferred, the outer surface of knockout tab 90 may be perforated to improve adhesion.) It should be appreciated that, if the D-shaped piece 90 has been knocked out during manufacture of the blank, it would be important to avoid allowing glue into the recess during gluing of the end panel 52.
7. Finally, the major end flap 48 is folded down and adheres to subjacent major flap 52. D-shaped knockout tab 90 adheres to the interior face of the spout outer cover 60 at a position adjacent its cutscore 62, i.e. well away from the hole 80. Typically, compression arrangements will be used to hold the carton together and apply pressure to the end flaps to ensure that the adhesion is satisfactory.
8. The sealed carton, as shown in Figure 4, will then be packed and shipped.
It should be noted that; as illustrated in Figure 5, when the carton is being filled, the side portions 94 and 96 do not protrude into the interior of the carton and interfere with the filling process. Rather, both the side portions 94 and 96 and the chute portion 92 are flat and coplanar with the end flap 50.
The carton will be used in the orientation shown in Figures 4, 10 and 16, i.e.
rotated through 90 degrees relative to the filling position so that the spout is in the side of the carton, near its top. Deployment of the pouring spout the first time will be described with reference also to Figures 7, 8A-8D and 9A-9E. In order to use the product, the user will insert a fingertip into the hole 80 (Figure 4), beneath the end 72 of spout outer cover 60, and grasp and tear out the spout outer cover 60, exposing the spout opening member 82. Removal of spout outer cover 60 will also remove the D-shaped tab 90 (adhered thereto) from underlying end flap 52 to leave a hole or recess 90' . Inserting a fingertip into the hole 90' (Figure 2), the user will pull the spout opening member 82, outwards and downwards bringing with it the spout chute portion 92 because they are adhered together.
Cut-line 84 is a complete cut so it is not necessary to tear the spout opening member 82 free of its surrounding end flap 52. The spout chute portion 92 is slightly smaller than the spout opening member 82, so it will pass through the opening 82' left by removal of the spout opening member 82.
As the spout chute portion 92 hinges outwards about fold crease 98, the spout side portions are automatically deployed. Thus, as shown in Figures 8A-8D, side portions 94 and 96 will engage the edges of the opening 82' and be forced to fold inwards about fold creases 100 and 102, respectively. Because the opening 82' is only slightly larger than the chute portion 92, the side portions 94 and 96 will fold until they are approximately perpendicular to the chute portion 92 to define the sides of the pouring spout, as shown in Figures 10 and 11.
Fold crease 74 defining the D-shaped end tab 72 of the spout outer cover 60 is optional.
The concavely curved sections 118, and 1182 of the upper edge profiles of side portions 94 and 96, respectively, provide clearance so that the side portions do not foul the edges 105, and 1052, respectively, of opening 107 during the first part of the travel of the chute portion 92. As can be seen more clearly from Figure 12, which shows only side portion 94, the shoulder 120, will engage the edge portion 1051 of the opening 107 which serves as a flexible striking plate in that it has sufficient resilience to deflect resiliently and allow the shoulder 120, to pass through the opening 107 as shown in Figure 9B.
Likewise, the edge portion 1052 will deflect resiliently to allow shoulder 1202 of side portion 96 to pass through the opening 107 in a similar manner. The material of the carton may be sufficiently thin and flexible for the edge portions 105, and 1052 to flex sufficiently.
However, short creases 121, and 1212, respectively, (similar to fold creases) may be provided to partition the edge portions 1051 and 1052 and form hinges, to allow the edge portions 1051 and 1052 to deflect more easily.
Figure 7 is a detail view of the pouring spout before deployment;
Figures 8A-8D are a series of cross-sectional detail views taken from above on line A-A of Figure 7 and illustrating deployment of the spout;
Figures 9A-9E are a series of cross-sectional detail side views taken on line B-B
of Figure 8 and illustrating deployment of the spout;
Figure 10 is a perspective view of the carton showing the spout fully deployed;
Figure 11 is a cutaway perspective view of the interior of the carton showing the spout fully deployed;
Figure 12 is a cross-sectional detail view taken on line VIII-VIII of Figure 11 and showing the spout fully deployed;
Figure 13 is a plan view of a blank incorporating modifications;
Figure 14 is an enlarged view corresponding to Figuie 2 but of a modification in which an outer cover is omitted:
Figure 15 is a plan view of three end flaps illustrating a modification to the shape of the spout and surrounding opening; and Figure 16 is a perspective view of an assembled carton with the spout of Figure 15 deployed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the invention will now be described with reference to Figures 1-14. Figure 1 shows a rectangular carton blank having two parallel longitudinal fold creases 10 and 12 and four transverse fold creases 14, 16, 18 and 20 defining four rectangular panels, namely, in succession, a bottom panel 22, a front panel 24, a top panel 26 and a rear panel 28. The front panel 24 and rear panel 28 are rectangular, whereas the bottom panel 22 and top panel 26 are oblong, their longer edges attached to the~adjacent panels. An elongate gluing tab 30 extends along the free edge of rear panel 28 and is attached to it by a fold crease 20.
A set of four end flaps 32, 34, 36 and 38 along one longitudinal edge of the blank are attached to the panels 22, 24, 26 and 28, respectively, by sections of the fold crease 12. The end flaps 32, 34, 36 and 38 are separated from each other by cuts 44, 42 and 40, WO 99/32361 PC'T/US98/27372 respectively. A similar set of four end flaps 46, 48, 50 and 52 are provided along the opposite longitudinal edge of the blank and attached to panels 22, 24, 26 and 28, respectively, by sections of fold crease 10. The end flaps 46, 48, 50 and 52 are separated from each other by cuts 54, 56 and 58, respectively. The components of the integral pour spout are provided in the end flaps 50 and 52 and a spout outer cover or sealing patch is provided in end flap 48.
As shown in more detail in Figure 2, the spout outer cover 60 is formed by offset cutscores including a first cut portion 62 extending perpendicular to the fold crease 10 joining the end flap 48 to the front panel 24 and adjacent the edge defined by the cut 56..
Two parallel offset cut-lines 64 and 66 extend from opposite ends of offset cut 62, and away from the cut 56, to define a rectangular cover portion 68. At their distal ends, the offset cut-lines 64 and 66 converge but do not meet. An arcuate cut 70 joins the ends of the offset cut-lines 64 and 66 to form a generally semicircular end tab 72 which is attached to the rectangular portion 68 by a fold crease 74. A generally C-shaped cut 76 connecting respective ends of the cut 70 forms a knockout tab 78. During manufacture, the knockout tab 78 will be removed leaving a hole 80 (see Figure 3).
The carton is a side-load carton. When the carton is assembled, as shown in Figure 3, the end panel 48 containing the spout outer cover 60 is the "last down" or outermost of the end panels. The penultimate end flap, when assembled, is end flap 52, which has a spout opening member 82 formed by cut-lines 84 on three sides and a fold crease 86 on the fourth side (Figure 2). At the edge furthest from fold crease 86, an additional cutscore or cut-and-nicked line 88 forms with the cut-line 84 a D-shaped knockout 90.
The inner surface of the D-shaped knockout 90 may be removed during manufacture leaving a hole 90', or its outer surface may ~be glued to the inner face of spout outer cover 60 which, following assembly, will overlie it. Hence, removal of the outer cover 60 will tear out the knockout tab 90, leaving a D-shaped finger recess 90' which will enable the user to insert a finger tip beneath the edge of the spout opening member 82 and pry it outwards, severing the nicks of cut-lines 84 and hinging the spout opening member 82 about fold crease 86.
This deploys the spout which, as will now be described, is formed in the adjacent or underlying end panel 50 when the carton is assembled.
End panel 50 contains the components of the spout itself, namely a spout chute portion 92 and two spout side portions 94 and 96, respectively, attached to opposite sides thereof. The spout chute portion 92 is defined by three fold creases 98, 100 and 102, respectively, and a cut-line 104. The fold creases 100 and 102 join the spout chute 92 to side portions 94 and 96, respectively.
The second side portion 96 is similar to the first side portion 94 and so will not be described. The components of the side portions are identified by the same reference numbers but with the subscripts 1 and 2, respectively.
Spout side portion 94 is defined by the fold crease 100 and a series of contiguous cut-line segments, namely an initial cut-line segment 106, extending from one end of, and collinear with, fold crease 98, a second cut-line segment 108, extending at an obtuse angle to fold crease 98 towards the fold crease 10, a third cut-line segment 1101 which extends parallel to fold crease 100, and a final cut-line segment 112, which joins the third cut-line segment 110, to the other end of fold crease 100. Final cut-line segment 112, has a special profile which provides certain functions when the spout is deployed. In particular, at its end adjacent the outer edge of the side portion 94, cut-line 112, has a notch 114, forming a stop surface 116, substantially parallel to cut-line segment 108, adjacent the distal edge of the side portion. A medial segment 118, of cut-line 112, is concave, providing clearance when the spout is being deployed. A shoulder portion 1201 is formed between the concave segment 1181 and the notch 114, . The distance between the peak of shoulder portion 1201 and the joint between fold creases 98 and 102 (which will constitute a pivot or hinge fulcrum later) is slightly greater than the length of fold crease 100, for reasons which will become apparent later.
As shown more clearly in Figure 6, a short segment 107 of profiled cut-line 1121, between an end of fold crease 100 and the junction between cut-lines 1121 and 1241 is inclined relative to chute hinge fold crease 98, so as to form a second shoulder 109, in the upper edge of spout side 94, adjacent side hinge fold crease 100. Hence, the distance between main hinge fold crease 98 and the apex of second shoulder 109, also is slightly greater than the length of fold crease 100.
An additional pair of cut-lines 1221 and 124, define, with profiled cutscore 112,, a knockout 1261, removal of which will take place during manufacture of the blank.
If desired, a hole can be provided in the top panel 26 (Figure 1) to take a handle in a manner which is well-known and so will not be described here.
Knockouts 78, 126, and 1262 are removed during formation of the blank, leaving corresponding holes 80, 126,' and 1262' . (If desired, knockout 90 could also be removed at this stage). The blank then is folded about fold creases 14 and 18 and the elongate tab 30 is glued to the inside of the edge of the bottom panel 22. In this knocked-down, flat 5 condition, the carton is shipped to the filler, i.e. the company which will be assembling the carton and filling it with the product.
Prior to filling, the final assembly and gluing of the carton will take place.
The sequence is as follows:-1. The knocked-down flat cartons are stacked in the hopper of a form-fill-seal 10 machine. Individual blanks are "picked off" the stack and opened into a tubular rectangular body with open ends at the top and bottom. The end flaps 48, 50, and 52 which will form the spout can be at the top or the bottom depending upon the way the machine operates, and/or the particular kind of machine being used.
2. The end flaps 32, 34, 36 and 38, which do not form the spout, are folded down -- first the two inside minor flaps (32 and 36), then inside major flap 38 and lastly the outside major flap 34 -- and glued to form an open carton.
3. The open carton is filled with product via the open top. This is a side-load carton so, when it is being filled, the end flaps 46, 48, 50 and 52 will be open at the top. When in use, however, the carton will have these end flaps at one side.
Generally, the fill level will be controlled so that, when the carton is filled, sealed and upright, the product level will be lower than the bottom of the spout unit. In practice, the product level may be slightly higher during filling to allow for settling during shipping. It should be appreciated that, in use, the spout can still be deployed, without undue spillage, even if there is product behind it.
4. The end flaps 46, 48, 50 and 52 then are folded and glued to close the carton. In this case, it is important that the flaps be folded in the correct sequence because they define the spout. As illustrated in Figure 3, the minor end flaps and 50 are folded first. Glue will be applied to the outer surface of end flap using any conventional gluing pattern. Glue will also be applied to the outer surface of end flap 50 but, because this end flap contains the spout components, the glue must be applied to certain parts only. In particular, glue will be applied to the perimeter of the end flap 50 avoiding the side portions 94 and 96. Glue will also be applied to the spout chute portion 92. It is important to avoid allowing glue in the area of end flap 50 that will be contacted by D-shaped piece 90 when end flap 52 is folded down.
5. Major end flap 52 will be folded down and its inner surfaces will adhere to the minor end flaps 46 and 50. The inner surface of the spout opening member will adhere to the outer surface of spout chute 92. (If desired/preferred, the outer surface of spout chute 92 may be perforated to improve adhesion, especially if the paperboard has a gloss finish).
6. , Glue will be applied to the perimeter of the outer surface of major end flap 52 taking care to avoid glue on the area which will be overlaid by the spout outer cover 60 when major end flap 48 is folded down. Glue will also be applied to D-shaped knockout tab 90. (Unless it has been removed previously, i.e. during manufacture of the blank.) (If desired/preferred, the outer surface of knockout tab 90 may be perforated to improve adhesion.) It should be appreciated that, if the D-shaped piece 90 has been knocked out during manufacture of the blank, it would be important to avoid allowing glue into the recess during gluing of the end panel 52.
7. Finally, the major end flap 48 is folded down and adheres to subjacent major flap 52. D-shaped knockout tab 90 adheres to the interior face of the spout outer cover 60 at a position adjacent its cutscore 62, i.e. well away from the hole 80. Typically, compression arrangements will be used to hold the carton together and apply pressure to the end flaps to ensure that the adhesion is satisfactory.
8. The sealed carton, as shown in Figure 4, will then be packed and shipped.
It should be noted that; as illustrated in Figure 5, when the carton is being filled, the side portions 94 and 96 do not protrude into the interior of the carton and interfere with the filling process. Rather, both the side portions 94 and 96 and the chute portion 92 are flat and coplanar with the end flap 50.
The carton will be used in the orientation shown in Figures 4, 10 and 16, i.e.
rotated through 90 degrees relative to the filling position so that the spout is in the side of the carton, near its top. Deployment of the pouring spout the first time will be described with reference also to Figures 7, 8A-8D and 9A-9E. In order to use the product, the user will insert a fingertip into the hole 80 (Figure 4), beneath the end 72 of spout outer cover 60, and grasp and tear out the spout outer cover 60, exposing the spout opening member 82. Removal of spout outer cover 60 will also remove the D-shaped tab 90 (adhered thereto) from underlying end flap 52 to leave a hole or recess 90' . Inserting a fingertip into the hole 90' (Figure 2), the user will pull the spout opening member 82, outwards and downwards bringing with it the spout chute portion 92 because they are adhered together.
Cut-line 84 is a complete cut so it is not necessary to tear the spout opening member 82 free of its surrounding end flap 52. The spout chute portion 92 is slightly smaller than the spout opening member 82, so it will pass through the opening 82' left by removal of the spout opening member 82.
As the spout chute portion 92 hinges outwards about fold crease 98, the spout side portions are automatically deployed. Thus, as shown in Figures 8A-8D, side portions 94 and 96 will engage the edges of the opening 82' and be forced to fold inwards about fold creases 100 and 102, respectively. Because the opening 82' is only slightly larger than the chute portion 92, the side portions 94 and 96 will fold until they are approximately perpendicular to the chute portion 92 to define the sides of the pouring spout, as shown in Figures 10 and 11.
Fold crease 74 defining the D-shaped end tab 72 of the spout outer cover 60 is optional.
The concavely curved sections 118, and 1182 of the upper edge profiles of side portions 94 and 96, respectively, provide clearance so that the side portions do not foul the edges 105, and 1052, respectively, of opening 107 during the first part of the travel of the chute portion 92. As can be seen more clearly from Figure 12, which shows only side portion 94, the shoulder 120, will engage the edge portion 1051 of the opening 107 which serves as a flexible striking plate in that it has sufficient resilience to deflect resiliently and allow the shoulder 120, to pass through the opening 107 as shown in Figure 9B.
Likewise, the edge portion 1052 will deflect resiliently to allow shoulder 1202 of side portion 96 to pass through the opening 107 in a similar manner. The material of the carton may be sufficiently thin and flexible for the edge portions 105, and 1052 to flex sufficiently.
However, short creases 121, and 1212, respectively, (similar to fold creases) may be provided to partition the edge portions 1051 and 1052 and form hinges, to allow the edge portions 1051 and 1052 to deflect more easily.
As can be seen from Figures 11 and 12, the edge portions 1051 and 1052, respectively, provide the abutments for stops 1161 and 1162, respectively. Consequently, as the spout reaches full deployment, the stops 116, and 1162 will abut the edge portions 1051 and 1052 and prevent further outward travel of the spout chute 92 as shown in Figure 9C. In this position, the side portions 94 and 96 form the sides of the spout so that the product can be poured without undue spillage.
An advantage of the abutments 1051 and 1052 being formed in the edge of the hole left by the spout chute and sides, rather than in a different flap, is that they are automatically accurately aligned with the stops 1161 and 1162, respectively, and shoulders 120,, 1202, 1091 and 1092, respectively.
As can be seen from Figures 9C and 10, in the fully-deployed position, the shoulders 1201 and 1202 engage the edge portions 1051 and 1052 of opening 107 in flap 50 to resist closure of the spout again. To close the spout again, the user must apply sufficient pressure to the spout to cause the shoulders 1201 and 1202 to deflect the edge portions 1051 and 1052 inwardly as shown in Figures 9D and 9E and pass through the opening 107. Once the spout has been fully closed again as shown in Figure 9A, it will be held closed by interengagement between the second pair of shoulders 1091 and 1092 defined by inclined edges 1071 and 1072, respectively, in the profiled upper edges 1121 and 1122 of the spout sides and the inner surfaces of abutment edge portions 1051 and 1052, respectively, perhaps assisted to some extent by frictional engagement between the distal edge of chute portion 92 and the edge of the opening it left in end flap 50, and between opening member 82 and its opening 82' . This interengagement occurs as a natural consequence of the nature of the cutscores 84 and 104. It should be noted that the cutscores comprise a number bf so-called nicks or discontinuities in the cut so that, when the cut-score is severed, there will be a pip of material left behind which will act as a frictional locking device when the pouring spout is re-closed.
It should also be noted that the spout configuration is designed so as to reduce sifting. in particular, the hole 80 left by knockout 78 is well away from the holes left by knockouts 1261 and 1262 and knockout 90, so that, for the contents to sift through the holes (or the cutscores if the knockout 90 has not yet been removed) it will have to take a somewhat labyrinthine path to escape from the carton. It should be kept in mind that some of the products for which this carton will be used could be very fine and so it is important to avoid sifting.
Not all carton assembly machines use the gluing and folding sequence described above. Figure 13 illustrates one of many alternative arrangements of the end flaps containing the spout components so as to accommodate other gluing and folding sequences.
Most of the components of the carton shown in Figure 13 are identical to those in Figure 1 and so have the same reference numbers. Whereas the carton of Figure 1 had the top panel 26 in the middle of the blank, the carton of Figure 13 has the top panel 26, and its attached end flaps 36 and 50 at the end of the blank, i.e. transposed with the bottom panel 22 and its attached end flaps 32 and 46. Nevertheless, once the blank has been folded to form the knocked-down carton, the outer cover 60 and spout opening member 82 will still be adjacent the end flap 50 carrying the spout chute 92 and side portions 94 and 96. The end flaps 50, 52 and 48 will be folded and glued in the appropriate order with the flap 50 innermost, flap 52 next down, and flap 48 outermost.
To accommodate other folding and gluing sequences, the components of the spout would be located on the appropriate flap to ensure that the innermost and outermost components of the spout came together in the correct order when they were folded and glued.
Figure 13 also illustrates that glue strip or elongate tab 30 might be large enough to form a reinforcing panel 26A similar in size to top panel 26. Panels 26 and 26A have similar rectangular holes 130 and 130A, respectively. When the carton is assembled, panel 26A will lie inside, and be glued to, top panel 26 and holes 130 and 130A will be aligned to receive a handle in known manner.
Figure 14 illustrates yet another modification, involving omission of the removable spout outer cover 60. Components corresponding to those in Figure 2 have the same reference numbers. The spout opening member 82 is provided, as before, in major end flap 52. Spout chute 92 and side portions 94 and 96, though similar to those of Figure 2, are provided in the adjacent end portion of the other major end flap 48, and rotated through 90 degrees as compared with the corresponding components of Figure 2, i.e.
relative to fold crease 10. The intermediate minor end flap 50 is foreshortened so that it does not obscure or interfere with the deployment of the spout. As before, after filling, the carton will be closed by folding minor end flap 50 down first, major end flap 48 down second, and major end flap 52 down last. As before, the spout opening member 82 will be glued to the underlying spout chute portion 92 and the spout will be deployed in the same way as the spout of the carton of Figures 1 to 13. In order to protect against product sifting through the spout components during shipping, a label 125 (shown in broken lines 5 in Figure 14) may be glued over the spout opening member 82 and the hole left by removal of the knockout tab 90. Any suitable pressure-sensitive adhesive might be used for this label. The label will be removed by the user, before first use, to expose the spout opening member 82.
It should be noted that, although the foregoing describes the end flaps containing 10 the spout components being folded down after the carton has been filled, they could be folded and glued before filling, and the other set of end flaps 32, 34, 36, and 38 are folded and glued after filling.
Yet another modification will now be described with reference to Figures 15 and 16 in which components that are identical to components of Figures 1 - 14 have the same 15 reference number. Those components that correspond but have been modified have the same reference numbers as the corresponding components in Figures 1- 14 but with an asterisk. Referring to Figure 15, which corresponds to Figure 2, the outer cover 60 is identical to that of the carton of Figure 2. The shape of the spout chute 92*
differs in that its edge distal from the hinge fold crease 98 is castellated, with a rectangular medial extension 140. The knockouts 1261 * and 1262* differ in shape because each of the cutscores segments 1241* and 1241 extends as a continuation of the cut-line 142 defining the outer edge of the spout portion 92*. Also, the upper (in use) edges of the side portions 94* and 96* have a section 144,/1442 extending parallel to the cut-line 142*.
The upper edges 1441 and 1442 merge smoothly into the notches 1141* and 1142*, respectively, forming shoulders 1201* and 1202*, respectively.
The spout opening member 82* differs in that it is cut away at its corners to leave a central extension portion 146 at its edge distal from the hinge fold crease 86*. Either side of the extension portion 146, the spout opening member 82* has notches 148, and 1482 leaving protrusions 1501 and 1502, respectively, at opposite sides of the spout opening member 82*. When the spout opening member 82* has been opened, the opening left in the end flap 52 will have an indent 1521 left by the lug 1501 and a depending spur 1541 left by the notch 148, . A similar indent 1522 and spur 1542 will be left by protrusion 1502 and notch 1482, respectively.
As can be seen in Figure 16, when the spout is deployed, the sides 94* and 96*
engage in the indents 1521 and 1522, respectively, and are preventing from hinging inwards by spurs 1541 and 1542, respectively. This ensures that the sides cannot be folded inwards accidentally during use, thereby losing their resilience with a resulting deterioration of the anti-sifting seal between the sides and the edges of the opening.
One advantage of the present invention is that the pouring spout is provided using material within the confines of the basic rectangular four-panel blank. In volume production this results in significant reduced cost. Other advantages of cartons embodying the present invention are as follows:
The spout sides are not deployed before use and so do not interfere with, and are not subject to possible damage during the form, fill and seal operations.
The knockout holes are positioned so as to provide a labyrinthine path to inhibit sifting of the contents.
No extra material, outside the usual four-panel blank, is required to form the spout, which reduces cost.
The avoidance of a tear strip and associated cutscores improves moisture vapour transmission rates as compared with tear strip opening cartons.
The elimination of a tear strip opening required to dispense the contents reduces the material cost.
The spout sides are never folded beyond a right angle to the chute so their fold creases retain their resilience. Consequently, the sides will be urged resiliently against the outer edges of the surrounding opening during deployment and maintain a relatively good seal against sifting -- which is not the case in known cartons where the sides are pre-folded at angles up to 180 degrees during manufacture.
Gluing of the spout chute to the spout opening member forms a two ply reinforced, relatively stiff spout which is particularly advantageous because the spout must be repeatedly opened by grasping the spout chute/spout opening member.
In those embodiments where the outer cover 60 is provided, leaving the knockout 90 in place until it is removed with the outer cover means that there is no opening through which the contents may sift during shipping.
WO 99/323b1 PCT/US98/27372 An advantage of embodiments of the invention in which the sides of the opening left by the opening member 82 diverge is that the spout sides are folded gradually as the spout is deployed. By contrast, those of the spout disclosed in US 4,194,677, would immediately engage the edges of the opening along substantially their entire length, which would require a much greater force to fold the spout sides. Moreover, because the spout opening is wider at the top, the spout has greater flow capability. Because the spout sides are not folded through the full 90 degrees, they retain their resiliency better - resulting in a better seal against the edges of the opening even after repeated operations.
An advantage of embodiments in which each spout side has an edge extending at an acute angle to the adjacent hinge fold crease is that the sides of the deployed spout may be higher, affording better control over pouring and a more robust spout.
An advantage of having the abutment stop defined by an edge extending at an acute angle to the adjacent fold crease, i.e. generally parallel to the inclined portion of first edge 108, is that the spout can open to a greater angle while leaving adequate material for strength. Hence, before the spout is deployed, these abutments do not unnecessarily extend the width of the cut-lines towards the edges of the flap, which could lead to weakness in view of the limited material available in that area.
An advantage of the flexible abutments 105, and 1052 is that the force required to open and close the spout may be reduced while permitting the use of heavier gauge, and hence more rigid or stiffer, sheet stock. Hinging of the abutments about creases 121, and 1212 during repetitive inward and outward travel requires less force and hence reduced wear and tear on the cooperating parts, at least as compared with previously-known cartons which rely upon distortion of one or other of the interengaging parts.
Also, the stop surfaces abut more than just the edges 107, and 1072 of the opening and inhibit the abutments from hinging at their fold creases 1211 and 1212 so that the stop surfaces cannot pass.
It should also be noted that formation of the abutments 1051 and 1052 from the same flap as the spout chute and sides ensures their correct positioning with respect to each other since it avoids reliance upon the alignment of overlapping flaps for proper positioning.
It should also be appreciated that, because the abutments 105, and 1052 protrude into the opening from above, the wings or sides of the spout, being cut from the material WO 99/323b1 PCT/US98/27372 at the sides of the opening 82, can extend the full height of the spout, affording better pour control and a stronger structure.
Advantageously, the inclined cut-line segments 1071 and 1072 tend to direct the spout sides or wings outwardly into contact with the edges of the opening 82 which helps to prevent sifting of particulate material therebetween, even after repeated operations.
It should also be noted that, as the second pair of shoulders 109 and 1092 pass by the flexible abutment edge portions 105, and 1052 during closing, there is a click, giving audible feedback to the user that the pouring spout is properly closed.
An advantage of providing the spout components in a minor flap is that the integrity of the major flaps is maintained which, in a side load carton, add to the stacking strength of the carton, allowing the elimination of a liner or a reduction in board thickness which could result in significant cost savings.
Although embodiments of the invention have been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only and not to be taken by way of the limitation, the scope of the present invention being limited only by the appended claims.
An advantage of the abutments 1051 and 1052 being formed in the edge of the hole left by the spout chute and sides, rather than in a different flap, is that they are automatically accurately aligned with the stops 1161 and 1162, respectively, and shoulders 120,, 1202, 1091 and 1092, respectively.
As can be seen from Figures 9C and 10, in the fully-deployed position, the shoulders 1201 and 1202 engage the edge portions 1051 and 1052 of opening 107 in flap 50 to resist closure of the spout again. To close the spout again, the user must apply sufficient pressure to the spout to cause the shoulders 1201 and 1202 to deflect the edge portions 1051 and 1052 inwardly as shown in Figures 9D and 9E and pass through the opening 107. Once the spout has been fully closed again as shown in Figure 9A, it will be held closed by interengagement between the second pair of shoulders 1091 and 1092 defined by inclined edges 1071 and 1072, respectively, in the profiled upper edges 1121 and 1122 of the spout sides and the inner surfaces of abutment edge portions 1051 and 1052, respectively, perhaps assisted to some extent by frictional engagement between the distal edge of chute portion 92 and the edge of the opening it left in end flap 50, and between opening member 82 and its opening 82' . This interengagement occurs as a natural consequence of the nature of the cutscores 84 and 104. It should be noted that the cutscores comprise a number bf so-called nicks or discontinuities in the cut so that, when the cut-score is severed, there will be a pip of material left behind which will act as a frictional locking device when the pouring spout is re-closed.
It should also be noted that the spout configuration is designed so as to reduce sifting. in particular, the hole 80 left by knockout 78 is well away from the holes left by knockouts 1261 and 1262 and knockout 90, so that, for the contents to sift through the holes (or the cutscores if the knockout 90 has not yet been removed) it will have to take a somewhat labyrinthine path to escape from the carton. It should be kept in mind that some of the products for which this carton will be used could be very fine and so it is important to avoid sifting.
Not all carton assembly machines use the gluing and folding sequence described above. Figure 13 illustrates one of many alternative arrangements of the end flaps containing the spout components so as to accommodate other gluing and folding sequences.
Most of the components of the carton shown in Figure 13 are identical to those in Figure 1 and so have the same reference numbers. Whereas the carton of Figure 1 had the top panel 26 in the middle of the blank, the carton of Figure 13 has the top panel 26, and its attached end flaps 36 and 50 at the end of the blank, i.e. transposed with the bottom panel 22 and its attached end flaps 32 and 46. Nevertheless, once the blank has been folded to form the knocked-down carton, the outer cover 60 and spout opening member 82 will still be adjacent the end flap 50 carrying the spout chute 92 and side portions 94 and 96. The end flaps 50, 52 and 48 will be folded and glued in the appropriate order with the flap 50 innermost, flap 52 next down, and flap 48 outermost.
To accommodate other folding and gluing sequences, the components of the spout would be located on the appropriate flap to ensure that the innermost and outermost components of the spout came together in the correct order when they were folded and glued.
Figure 13 also illustrates that glue strip or elongate tab 30 might be large enough to form a reinforcing panel 26A similar in size to top panel 26. Panels 26 and 26A have similar rectangular holes 130 and 130A, respectively. When the carton is assembled, panel 26A will lie inside, and be glued to, top panel 26 and holes 130 and 130A will be aligned to receive a handle in known manner.
Figure 14 illustrates yet another modification, involving omission of the removable spout outer cover 60. Components corresponding to those in Figure 2 have the same reference numbers. The spout opening member 82 is provided, as before, in major end flap 52. Spout chute 92 and side portions 94 and 96, though similar to those of Figure 2, are provided in the adjacent end portion of the other major end flap 48, and rotated through 90 degrees as compared with the corresponding components of Figure 2, i.e.
relative to fold crease 10. The intermediate minor end flap 50 is foreshortened so that it does not obscure or interfere with the deployment of the spout. As before, after filling, the carton will be closed by folding minor end flap 50 down first, major end flap 48 down second, and major end flap 52 down last. As before, the spout opening member 82 will be glued to the underlying spout chute portion 92 and the spout will be deployed in the same way as the spout of the carton of Figures 1 to 13. In order to protect against product sifting through the spout components during shipping, a label 125 (shown in broken lines 5 in Figure 14) may be glued over the spout opening member 82 and the hole left by removal of the knockout tab 90. Any suitable pressure-sensitive adhesive might be used for this label. The label will be removed by the user, before first use, to expose the spout opening member 82.
It should be noted that, although the foregoing describes the end flaps containing 10 the spout components being folded down after the carton has been filled, they could be folded and glued before filling, and the other set of end flaps 32, 34, 36, and 38 are folded and glued after filling.
Yet another modification will now be described with reference to Figures 15 and 16 in which components that are identical to components of Figures 1 - 14 have the same 15 reference number. Those components that correspond but have been modified have the same reference numbers as the corresponding components in Figures 1- 14 but with an asterisk. Referring to Figure 15, which corresponds to Figure 2, the outer cover 60 is identical to that of the carton of Figure 2. The shape of the spout chute 92*
differs in that its edge distal from the hinge fold crease 98 is castellated, with a rectangular medial extension 140. The knockouts 1261 * and 1262* differ in shape because each of the cutscores segments 1241* and 1241 extends as a continuation of the cut-line 142 defining the outer edge of the spout portion 92*. Also, the upper (in use) edges of the side portions 94* and 96* have a section 144,/1442 extending parallel to the cut-line 142*.
The upper edges 1441 and 1442 merge smoothly into the notches 1141* and 1142*, respectively, forming shoulders 1201* and 1202*, respectively.
The spout opening member 82* differs in that it is cut away at its corners to leave a central extension portion 146 at its edge distal from the hinge fold crease 86*. Either side of the extension portion 146, the spout opening member 82* has notches 148, and 1482 leaving protrusions 1501 and 1502, respectively, at opposite sides of the spout opening member 82*. When the spout opening member 82* has been opened, the opening left in the end flap 52 will have an indent 1521 left by the lug 1501 and a depending spur 1541 left by the notch 148, . A similar indent 1522 and spur 1542 will be left by protrusion 1502 and notch 1482, respectively.
As can be seen in Figure 16, when the spout is deployed, the sides 94* and 96*
engage in the indents 1521 and 1522, respectively, and are preventing from hinging inwards by spurs 1541 and 1542, respectively. This ensures that the sides cannot be folded inwards accidentally during use, thereby losing their resilience with a resulting deterioration of the anti-sifting seal between the sides and the edges of the opening.
One advantage of the present invention is that the pouring spout is provided using material within the confines of the basic rectangular four-panel blank. In volume production this results in significant reduced cost. Other advantages of cartons embodying the present invention are as follows:
The spout sides are not deployed before use and so do not interfere with, and are not subject to possible damage during the form, fill and seal operations.
The knockout holes are positioned so as to provide a labyrinthine path to inhibit sifting of the contents.
No extra material, outside the usual four-panel blank, is required to form the spout, which reduces cost.
The avoidance of a tear strip and associated cutscores improves moisture vapour transmission rates as compared with tear strip opening cartons.
The elimination of a tear strip opening required to dispense the contents reduces the material cost.
The spout sides are never folded beyond a right angle to the chute so their fold creases retain their resilience. Consequently, the sides will be urged resiliently against the outer edges of the surrounding opening during deployment and maintain a relatively good seal against sifting -- which is not the case in known cartons where the sides are pre-folded at angles up to 180 degrees during manufacture.
Gluing of the spout chute to the spout opening member forms a two ply reinforced, relatively stiff spout which is particularly advantageous because the spout must be repeatedly opened by grasping the spout chute/spout opening member.
In those embodiments where the outer cover 60 is provided, leaving the knockout 90 in place until it is removed with the outer cover means that there is no opening through which the contents may sift during shipping.
WO 99/323b1 PCT/US98/27372 An advantage of embodiments of the invention in which the sides of the opening left by the opening member 82 diverge is that the spout sides are folded gradually as the spout is deployed. By contrast, those of the spout disclosed in US 4,194,677, would immediately engage the edges of the opening along substantially their entire length, which would require a much greater force to fold the spout sides. Moreover, because the spout opening is wider at the top, the spout has greater flow capability. Because the spout sides are not folded through the full 90 degrees, they retain their resiliency better - resulting in a better seal against the edges of the opening even after repeated operations.
An advantage of embodiments in which each spout side has an edge extending at an acute angle to the adjacent hinge fold crease is that the sides of the deployed spout may be higher, affording better control over pouring and a more robust spout.
An advantage of having the abutment stop defined by an edge extending at an acute angle to the adjacent fold crease, i.e. generally parallel to the inclined portion of first edge 108, is that the spout can open to a greater angle while leaving adequate material for strength. Hence, before the spout is deployed, these abutments do not unnecessarily extend the width of the cut-lines towards the edges of the flap, which could lead to weakness in view of the limited material available in that area.
An advantage of the flexible abutments 105, and 1052 is that the force required to open and close the spout may be reduced while permitting the use of heavier gauge, and hence more rigid or stiffer, sheet stock. Hinging of the abutments about creases 121, and 1212 during repetitive inward and outward travel requires less force and hence reduced wear and tear on the cooperating parts, at least as compared with previously-known cartons which rely upon distortion of one or other of the interengaging parts.
Also, the stop surfaces abut more than just the edges 107, and 1072 of the opening and inhibit the abutments from hinging at their fold creases 1211 and 1212 so that the stop surfaces cannot pass.
It should also be noted that formation of the abutments 1051 and 1052 from the same flap as the spout chute and sides ensures their correct positioning with respect to each other since it avoids reliance upon the alignment of overlapping flaps for proper positioning.
It should also be appreciated that, because the abutments 105, and 1052 protrude into the opening from above, the wings or sides of the spout, being cut from the material WO 99/323b1 PCT/US98/27372 at the sides of the opening 82, can extend the full height of the spout, affording better pour control and a stronger structure.
Advantageously, the inclined cut-line segments 1071 and 1072 tend to direct the spout sides or wings outwardly into contact with the edges of the opening 82 which helps to prevent sifting of particulate material therebetween, even after repeated operations.
It should also be noted that, as the second pair of shoulders 109 and 1092 pass by the flexible abutment edge portions 105, and 1052 during closing, there is a click, giving audible feedback to the user that the pouring spout is properly closed.
An advantage of providing the spout components in a minor flap is that the integrity of the major flaps is maintained which, in a side load carton, add to the stacking strength of the carton, allowing the elimination of a liner or a reduction in board thickness which could result in significant cost savings.
Although embodiments of the invention have been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only and not to be taken by way of the limitation, the scope of the present invention being limited only by the appended claims.
Claims (21)
1. A carton, formed from a unitary blank, characterized by four panels (22,24,26,28) interconnected by fold creases (14,16,18,20) to form a rectangular tube, a first set of four flaps (32,34,36,38) at one end of the tube and a second set of four flaps (46,48,50,52) at an opposite end of the tube, the flaps of each set being folded in succession to form respective ends of the carton, the second set of flaps having a combination of fold creases and cutlines defining a spout chute (92) and two spout sides (94,96), the chute having three edges defined by three fold creases (98,100,102) and a fourth edge defined by a cut-line (104), a middle one (98) of the three fold creases attaching the chute hingably to the first flap (50) and each of the other fold creases (100,102) attaching a respective one of the spout sides (94,96) hingably to the chute (92), each spout side having distal edges defined by cut-lines, the second (52) of said second set of flaps overlying the first flap (50) and having three conjoined cut-lines (84) and a hinge fold crease (86) defining a spout opening member (82), the spout opening member having a perimeter circumscribing the underlying spout chute (92), the spout chute (92) and spout sides (94,96) being coplanar with said first flap (50), and the spout chute (92) being attached to the spout opening member (82) so that when the spout opening member {82) is hinged outwardly, a resulting opening (82') in the second flap (52) will allow the spout chute (92) to pass therethrough but the spout sides (94,96) will engage edges of the opening (82') and pivot inwardly towards each other to form sides of the spout, the third flap (48) and fourth flap (46) of the first set of end flaps (46,48,50,52) being configured so as not to obscure the opening (82'), retaining means (120 1,120 2,105 1,105 2) for retaining the spout in the deployed position, the retaining means comprising an intermediate part (120 1,120 2) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (120 1,120 2) engages an edge portion (105 1,105 2) of a hole (107) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part (120 1,120 2) through the hole and, when outside the carton, said intermediate part (120 1,120 2) engages said edge portion of the hole exteriorly to resist closing of the spout until sufficient closing force is applied to the opening member (82).
2. A carton according to claim 1, characterized in that said edge portions (105 1, 105 2) comprise protuberances protruding into said opening and delimited by creases (121 1, 121 2) permitting said flexing.
3. A carton according to claim 1, characterized in that at least one of the spout sides has means (116) for limiting outward travel of the spout chute (92).
4. A carton according to claim 2, characterized in that said limiting means (116) comprises a stop formed in an edge portion of the spout side distal from its fold crease (100, 102), the stop being so disposed as to abut said edge portion (105 1, 105 2) interiorly.
5. A carton according to claim 1, characterized in that said at least one of the spout sides has a second intermediate part (109 1, 109 2) disposed adjacent the spout chute, said second intermediate part (109 1, 109 2) for engaging the flexible edge portion (105 1, 105 2) during closure of the spout, said edge portion flexing to allow entry of said second intermediate part (109 1, 109 2) and returning such that said second intermediate part (109 1, 109 2) engages said edge portion (105 1, 105 2) interiorly to retain said spout closed.
6. A carton according to claim 1, characterized in that said third flap (48) is folded outside the second flap (52) and has a portion overlying the spout opening member (82), said portion comprising a removable spout cover piece (60), said cover piece having a perimeter circumscribing the underlying spout opening member (82), such that removal of the cover piece (60) provides access to the spout opening member (82) for opening thereof.
7. A carton according to claim 1, characterized in that neither the third flap (48) nor the fourth flap (46) has a portion overlying the spout opening member (82), the second flap (52) is outermost and a removable label (119) is adhered to said second flap, obscuring and sealing the spout opening member (82) cutscores (84), the adhered label being removable for first use.
8. A carton according to claim 1, characterized in that the cut-lines (84) defining the spout opening member (82*) have undulations (152,154) at respective corners of the spout opening member (82*) remote from the hinge fold crease (86*), each undulation forming, when the spout opening member (82*) has been opened, a notch (148 1, 148 2) in an upper edge of said resulting opening (82') in the second flap, respective upper edges of the spout sides, when deployed, each engaging in a respective one of the notches (148 1, 148 2).
9. A carton according to claim 1, characterized in that the conjoined cut-lines (84) comprise a first cut-line (84 1) and a second cut-line (84 2) extending one from each end of said hinge fold crease (86) and diverging so that the spout opening member (82) and said resulting opening (82') are wider at their respective ends distal from said hinge fold crease (86) than at the hinge fold crease (86) itself, such that the spout sides (94,96), during deployment, engage corresponding edges of said opening (82') gradually and pivot inwardly .
10. A carton as claimed in claim 9, characterized in that said each spout side comprises a first edge (106, 108, 110) and a second edge (118), the first edge (108) extending from one end of the adjacent one of said other fold creases (100,102) and the second edge extending from an opposite end of said adjacent one of said fold creases.
11. A carton blank for forming a parallelepiped carton with an integral pour spout, said blank characterized by a rectangle of paperboard, corrugated board, or like material having two parallel main fold creases and four transverse parallel fold creases defining four panels and a gluing strip arranged in sequence, a first set of four flaps each connected to a respective one of the four panels by a first of the main fold creases, and a second set of four flaps each connected to the four panels by the other main fold crease, the flaps being separated by cuts to allow each to hinge about the associated one of the main fold creases, a first of said first set of flaps having cut-lines and fold creases defining a spout chute and two spout sides, the chute having three edges defined by three conjoined fold creases and a fourth edge defined by a cut-line, a middle one of the three fold creases attaching the chute hingably to the end flap, each of the others of the three fold creases attaching one of the side portions hingably to the chute, distal edges of the side portions being defined by a series of cut-lines, the arrangement being such that hinging of the chute outwardly from the first flap, and hinging of the spout sides inwardly towards each other, forms the spout, a second of said first set of flaps having cut-lines and a fold crease defining a spout opening member having a perimeter that, when superimposed upon the chute, will circumscribe the chute, so that, when the spout opening member is hinged outwardly, an opening so formed will allow passage of the spout chute therethrough but the spout sides will engage the edges of the opening and be forced to hinge inwards, the blank further comprising retaining means (120 1, 120 2, 105 1, 105 2) for retaining the spout in the deployed position, the retaining means comprising an intermediate part (120 1 , 120 2) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (120 1, 120 2) engages an edge portion (105 1, 105 2) of a hole (117) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part (120 1, 120 2) through the hole and, when outside the carton, said intermediate part (120 1, 120 2) engages said edge portion of the hole exteriorly to resist closing of the spout until sufficient closing force is applied to the spout chute (92).
12. A carton blank according to claim 11, characterized in that said edge portions (105 1, 105 2) comprise protuberances protruding into said opening and delimited by creases (121 1, 121 2) permitting said flexing.
13. A carton blank according to claim 11, characterized in that at least one of the spout sides has means (116) for limiting outward travel of the spout chute (92).
14. A carton blank according to claim 12, characterized in that said limiting means (116) comprises a stop formed in an edge portion of the spout side distal from its fold crease, the stop being so disposed as to abut said edge portion (105 1, 105 2) interiorly.
15. A carton blank according to claim 11, characterized in that said at least one of the spout sides has a second intermediate part (1091,1092) disposed adjacent the spout chute, said second intermediate part (109 1, 109 2) for engaging the flexible edge portion (105 1, 105 2) during closure of the spout, said edge portion flexing to allow entry of said second intermediate part (109 1, 109 2) and returning such that said second intermediate part (109 1, 109 2) engages said edge portion (105 1, 105 2) interiorly to retain said spout closed.
16. A carton blank according to claim 11, characterized in that a third flap of said first set of end flaps has cutlines defining a removable cover piece the perimeter of which will circumscribe the spout opening member when the third flap is folded over the second flap.
17. A carton blank according to claim 11, characterized in that neither of the third and fourth flaps will obscure said opening when the carton has been assembled, and a label is adhered to the second flap, the label extending over and sealing the spout opening member, the label being removable to expose the spout opening member.
18. A carton blank according to claim 11, characterized in that the cut-lines defining the spout opening member have undulations (152,154) at respective corners of the spout opening member remote from the hinge fold crease, each undulation forming, when the spout opening member has been opened, a notch in an upper edge of said opening, respective upper edges of the spout sides, when deployed, each engaging in a respective one of the notches.
19. A carton as claimed in claim 1, characterized in that said first of the flaps that contains the spout chute and sides comprises a minor flap.
20. A carton blank according to claim 11, characterized in that knockout holes are provided adjacent upper edges of the side portions to provide clearance for the folding spout sides during initial deployment.
21. A carton, formed from a unitary blank, characterized by four panels (22,24,26,28) interconnected by fold creases (14,16,18,20) to form a rectangular tube, a first set of four flaps (32,34,36,38) at one end of the tube and a second set of four flaps (46,48,50,52) at an opposite end of the tube, the flaps of each set being folded in succession to form respective ends of the carton, the second set of flaps having a combination of fold creases and cutlines defining a spout chute (92) and two spout sides (94,96), the chute having three edges defined by three fold creases (98,100,102) and a fourth edge defined by a cut-line (104), a middle one (98) of the three fold creases attaching the chute hingably to the first flap (50) and each of the other fold creases (100,102) attaching a respective one of the spout sides (94,96) hingably to the chute (92), each spout side having distal edges defined by cut-lines, the spout chute (92) and spout sides (94,96) being coplanar with said first flap (50) prior to first deployment, the arrangement being such that, when the spout opening member (82) is hinged outwardly, a resulting opening (82') in the second flap (52) will allow the spout chute (92) to pass therethrough but the spout sides (94,96) will engage edges of the opening (82') and pivot inwardly towards each other to form sides of the spout, the third flap (48) and fourth flap (46) of the first set of end flaps (46,48,50,52) being configured so as not to obscure the opening (82'), the carton further comprising retaining means (120 1, 120 2, 105 1, 105 2 for retaining the spout in the deployed position, the retaining means comprising an intermediate part (120 1, 120 2) of at least one of said spout sides (94,96) configured so that, during deployment of the spout, said intermediate part (120 1, 120 2) engages an edge portion (105 1, 105 2) of a hole (107) in the first flap (50) left by deployment of the chute (92) and sides (94,96), said edge portion flexing resiliently to allow passage of the intermediate part (120 1, 120 2) through the hole and, when outside the carton, said intermediate part (120 1,120 2) engages said edge portion of the hole exteriorly to resist closing of the spout until sufficient closing force is applied to the opening member (82).
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US99682397A | 1997-12-23 | 1997-12-23 | |
| US08/996,823 | 1997-12-23 | ||
| PCT/US1998/027372 WO1999032361A1 (en) | 1997-12-23 | 1998-12-23 | Four-panel paperboard carton with integrated pour spout |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2316195A1 true CA2316195A1 (en) | 1999-07-01 |
Family
ID=25543348
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002316195A Abandoned CA2316195A1 (en) | 1997-12-23 | 1998-12-23 | Four-panel paperboard carton with integrated pour spout |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU2203899A (en) |
| CA (1) | CA2316195A1 (en) |
| WO (1) | WO1999032361A1 (en) |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3096011A (en) * | 1962-09-04 | 1963-07-02 | Sonoco Products Co | Container with pouring spout |
| US4194677A (en) * | 1978-06-23 | 1980-03-25 | Champion International Corporation | Carton with pour spout made from the carton material |
| US4168003A (en) * | 1978-07-24 | 1979-09-18 | Champion International Corporation | Carton having pour spout with cover strip |
| US5141150A (en) * | 1990-01-25 | 1992-08-25 | Seal Spout Corporation | Pouring spout |
| SE9100007L (en) * | 1991-12-30 | 1992-07-01 | Lars Dahlman | DEVICE FOR ELECTROMAGNETIC SCREENING ON SCREENS |
| US5531376A (en) * | 1995-08-14 | 1996-07-02 | Packaging Corporation Of America | Paperboard container with integral paperboard pour spout |
-
1998
- 1998-12-23 CA CA002316195A patent/CA2316195A1/en not_active Abandoned
- 1998-12-23 WO PCT/US1998/027372 patent/WO1999032361A1/en active Application Filing
- 1998-12-23 AU AU22038/99A patent/AU2203899A/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| WO1999032361A1 (en) | 1999-07-01 |
| AU2203899A (en) | 1999-07-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |