WO2000075025A1

WO2000075025A1 - Method and apparatus for producing a reclosable opening and pouring device for carton boxes with a liner

Info

Publication number: WO2000075025A1
Application number: PCT/US2000/015172
Authority: WO
Inventors: David C. Ours; David L. Bradley
Original assignee: Kellogg Company
Priority date: 1999-06-07
Filing date: 2000-06-01
Publication date: 2000-12-14
Also published as: AU5457700A

Abstract

Dispensing assembly for a carton having a liner. A pour spout or flap is mounted to a dispensing opening to pivot between an open and closed positions. The unfilled liner is bonded with a mandrel and clamp to the pour spout or flap in a way that when the spout or flap is initially opened, that portion of the liner bonded thereto separates from the rest of the liner, providing access to the contents thereof.

Description

METHOD AND APPARATUS FOR PRODUCING A RECLOSABLE OPENING AND POURING DEVICE FOR

CARTON BOXES WITH A LINER

Background

This invention relates to the packaging of dry particulate foods such as ready-to-eat ("RTE") cereal. More specifically, this invention relates to lined cartons of the type known as a bag-in-a-box with reclosable dispensing means connected to the liner or bag in such a way that a portion thereof is separated from the liner upon initial opening of the dispensing means to provide access to the contents of the carton.

The use of cartons with liner bags for dry particulate products such as RTE cereal is well known. Such cartons are usually formed from a blank of paperboard or similar material comprising sidewalls with top and bottom flaps.

The liner is a plastic or coated paper bag which holds the particulate product.

The liner can be filled and sealed before or after being placed inside an open carton, the flaps of which are then folded and sealed. Access to the contents of such cartons involves breaking the seal between the top flaps of the carton and pulling open the sealed liner bag.

Resealing is often difficult and incomplete leading to a loss of freshness of the product. RTE cereal, for example, has a low moisture content and readily absorbs moisture from the air leading to a loss of crispness. Dispensing devices such as pour spouts have been proposed to control the discharge of particulate product and minimize exposure to the atmosphere.

However, when a carton with a pour spout contains a filled and sealed liner bag, the bag must be manually torn or cut with a knife or scissors when the spout is first opened. This arrangement has several drawbacks not the least of which is manually cutting or tearing of the liner bag. Once opened, and as the contents are depleted, the liner bag and its contents slide and shift positions in the carton which can cause the opened portion of the liner to become misaligned with the pour spout opening thereby hindering dispensing of product from the carton. This also causes product to drop between the carton and the liner.

U.S. Patent 2,998,788 relates to bag-in-a-box packaging where a liner is sandwiched between a metal spout and a precut flap in the carton side wall. A cut-out in the side wall above the flap allows the insertion of a knife to cut the liner and open the spout. The liner is bonded to the spout and the carton flap using a heated anvil which is inserted into an empty, lined carton. This particular approach, similar to other existing approaches, is limited in that the spouts provided therein are physically configured in such a way so to provide limited protection of the RTE product from ambient moisture, and further require specific manipulation for initially opening/piercing of the container.

Summary of the Invention

The present invention is therefore directed towards producing an improved bag-in-a-box carton where the bag or liner is physically configured in the box in such a way so as to provide placement of a reclosable pour device which readily facilitates initial opening or piercing of the package, yet offers superior protection from ambient moisture. More specifically, the carton has a reclosable pour device having a dispensing flap or pour spout which comes into contact with the unfilled, unsealed liner when it is placed in the container such that the liner is sealed to the dispensing flap or spout in such a way that the liner is not ruptured, but upon initial opening of the flap or spout, that portion of the liner bonded thereto separates from the liner to provide access to the contents of the carton.

A preferred carton has a pivotable pour spout mounted to a dispensing flap. A front panel of the pour spout is bonded to a portion of the bag once it is placed into the box (but before it is filled and sealed) without rupturing the bag such that when initially opened, that portion partly separates from the rest of the liner, thereby providing access to the contents of the carton. Hence, as the pour spout is manually opened for the first time, the portion of the bag bonded to the front panel separates from the remainder of the bag to create an opening, yet remains integral with the pivot axis. It is preferred that the liner is also bonded to an area defining the periphery of the dispensing flap to maintain positioning of the bag and a tight seal upon closing of the flap. In other words, the portion of the liner that separates from the liner corresponds to the size of the dispensing opening, and reclosure of the pour spout fills the opening to minimize contact of the contents with the outside atmosphere, thereby reducing exposure to ambient moisture. The liner remains integral at the bottom of the dispensing opening (i.e. along the pivot axis) to maintain alignment, and preferably the liner is also bonded around the margins of the pour opening to prevent product from falling between the bag and the box. It is preferred to heat seal the liner along the top and side edges of the dispensing flap or front panel in such a way that weakened tear lines are created in the liner, but without rupturing the liner, to facilitate initial opening of the flap or pour spout. The tear lines are in the vicinity of and are preferably aligned with the tear or perforation lines of the dispensing flap to facilitate opening and to maintain a tight seal upon reclosure. That portion of the liner that adheres to the carton adjacent to the dispensing flap can be heat sealed or spot adhered to the carton.

Description of the Drawings

The present invention will be more fully understood from the following description and the accompanying drawings wherein:

Fig. 1A is a plan view of a pour spout of the invention opened up and laid flat.

Fig. IB is a plan view of the other side of the pour spout of Fig. 1 A. Fig. 2 is a plan view of the assembly of Fig. IB turned over with the pour spout folded over a fitment which defines a dispensing opening shown in phantom. Fig. 3 is a perspective view of the pour spout assembly of Fig. 2 shown folded and partly open.

Fig. 4 is a perspective view of a carton with access to a dispensing assembly of the invention.

Figs. 5 and 6 are perspective views of a dispensing assembly of the invention partly open and fully open. Fig. 7 is a plan view showing the assembly of Fig. 1 A with the pour spout folded under a fitment (Fig. 2 turned over) and positioned on the interior of a flat carton blank.

Fig. 8A is a perspective view, broken away, of the interior of a dispensing assembly of the invention.

Figs. 8B and 8C are cross-sectioned views taken along lines 8B-8B and 8C-8C of Fig.8A.

Fig. 8D is a cross-sectional view of laminated foil used to promote bonding. Figs. 9 and 10 are perspective views of an alternate dispensing assembly show closed and open.

Fig. 1 1 is a front view of the assembly of Figs. 9 and 10 shown fully open.

Fig. 12 is a cross-sectional view taken along line 12-12 of Fig. 9. Fig. 13 is a flow diagram of the process for sealing a liner to the pour spout assembly with the mandrel assembly.

Fig. 14 is a perspective eye view of the process shown in Fig. 13 as depicted in a double package mandrel assembly.

Description

According to the present invention, a portion of an unfilled and unsealed liner is brought into contact with and bonded to the inner wall of the front panel of a pour spout or a flap mounted in a dispensing opening in a side panel or end wall of a carton or carton blank. A mandrel assembly, acting in concert with a substantially opposed clamping assembly can be used to closely contact the open liner to the dispensing flap or pour spout. An adhesive or adhesive system is provided between the liner and the dispensing flap or front panel of the pour spout to promote bonding.

Fig. 13 is a flow diagram of the general process for preparing the lined cartons of the invention. Although further detailed in the discussion relating to Fig. 14, infra, the method begins by providing a carton blank, step 350, and adding a spout to the carton blank indicated as step 352. Step 352 contemplates the use of a positioning assembly such as a mandrel and clamping device. Separately, the liner will be formed as a bag around the mandrel, which is then brought into contact with the inside portion pour spout and possibly the adjacent area of the carton blank surrounding the pour spout. The carton blank is then folded around the mandrel by a folding assembly known in the art. Last, the liner is then adhered to the carton and spout in step 360. The liner is filled, (step 362), sealed, (step 364), and the lined carton is then completely closed, (step 366), with the filled and sealed liner inside.

Fig. 14 is directed to a preferred embodiment of the invention, wherein packaging is accomplished using a double package maker, the basic assembly and operation of which are well known in the art.

In a preferred embodiment according to Fig. 13, a preformed carton having a pour spout is provided, i.e., steps 350, 352 and a portion of 358 (folding of carton) are completed prior to insertion of the liner bag which has been formed around the mandrel as provided in Step 358. Thus, following the dotted lines, a carton blank 350 is provided with a pour spout 352 as provided above. The carton blank is then folded to form a carton having at least one of the top or bottom ends. Separately, the liner has been formed into a bag around a mandrel as in step 356, and the liner bag is inserted into carton through an open top or bottom end thereof as in step 358. The process then continues as in Fig. 13, such that the liner bag is adhered to the carton spout 360, filled 362, sealed 364 and the carton closed 366. In this embodiment, the liner can be brought into contact with the carton/pour spout using a mandrel/clamping assembly or other device such as a vacuum.

In a preferred embodiment shown in Fig. 14, the carton is prepared from packaging material 402 which are formed (not shown) into foldable blanks 406 and bundle 404, as known in the art. Once taken from the bundle 404, each blank is positioned by a position assembly (not pictured) which secures a fitment to the blank 406. The double package maker described in Fig. 14 includes a mandrel 410, which is rotated and positioned by mandrel wheel 416, similarly known in the art of double package makers. The package maker may be of any variety such as a vertical-type or horizontal -type. A preferred horizontal double bag maker is the Series PKD machine commercially available from Robert Bosch GmbH of Stuttgart, Germany. A preferred vertical filler is the SIG RSK.

Liner material 400 is cut into sized sheets 412, wrapped 414 around mandrel 410 to form bag 401 , and is longitudinally sealed 409 and transversely sealed at the bottom portions 411 to form a bag. The mandrel 410 with the bag then rotates to a position to receive foldable blank 406 and the blank is folded 408 around mandrel 410 along lines 413 such that an open carton (418) is formed around the bag 411. Once folded, mandrel 410 acts in concert with a clamping assembly having first and second clamping elements that are closeably (not pictured) opposed to each other in order to bring bag 401, carton blank 408 and fitment into maximized contact for effectuation of hot melt adhesives by the preferred heat supplied by a heat source. In a preferred embodiment, heat is supplied by a heat source attached to the mandrel 410, which heats the mandrel which in turn melts the adhesive. Thereafter, the assembly is sent towards location 418 where the bottom of the carton 417 is closed, after which the liner 413 is filled with product at 420, and sealed at 422, the box additionally manipulated at 424, and carton 417 is closed at 426. The present invention contemplates the above process utilizing multiple adhesive systems such as hot melt (which might further employ any variety of heating methodologies, including, but not limited to conduction, convection, or by activating the sealant with electromagnetic or sonic energy, through induction heating, etc.) or cold seals such as non-heat activated adhesives or pressure sensitive adhesives.

Hot-melt adhesives are 100% solids and are applied in hot, molten form. They set fast when heat is removed and can be preapplied and reactivated later by the application of heat. Hot melt adhesives are typically formulated with a backbone polymer such as ethylene-vinyl acetate or polyethylene. The main polymer is usually let down with a diluent such as wax to improve melt flow properties. Antioxidants may be added since the adhesive is applied hot and is subject to oxidation. Tackifiers can also be added to improve hot tack and viscosity. Other materials can be added to influence the melt temperature, and colorants may be added to make the adhesive more visible.

Hot-melt adhesives are readily available from numerous sources. INSTANT LOK® hot melt adhesives from National Starch and Chemical Corporation of Bridgewater N . 08807 are suitable for use in the invention. Although the preferred embodiment contemplates the use of induction, heat may be provided via the mandrel 410 or by the clamping assembly. For example, sonic energy transmission (transmitted from either mandrel 410 or the clamping assembly), may be used to activate any of the multiple adhesive systems. Moreover, the cooperation between mandrel 410 and the clamping assembly may simply provide physical contact necessary to complete cold or hot seals as required in the multiple adhesive systems.

In a preferred embodiment, the hot melt adhesive is heated by induction. In this embodiment, an activatable hot melt adhesive is applied between the liner and the dispensing flap or front panel, and heat is applied to the interface of the liner, the dispensing flap such as by induction heating. Activation of the hot melt adhesive can also be accomplished by inclusion of a heat generating substance in or positioned such that the hot melt adhesive to generate the heat necessary to activate the hot melt adhesive to bond the liner to the dispensing flap or front panel. Such heat generating substances include metal foils such as aluminum foil, which may be laminated on one or both sides to a hot melt adhesive, metal salts such as magnesium chloride, chromium nitrate, aluminum chloride and the like, which are mixed with the hot melt adhesive; and metal particles such as iron or aluminum powder mixed with or flocked onto the hot melt adhesive applied to the flap or front panel.

When using magnetic particles such as iron, a magnet can be employed to orient the particles and promote bonding with the liner, e.g., to aid in creating a tearable seam to facilitate opening of the spout. The metal salts and metal particles are used in amounts sufficient to activate the adhesive when external bonding energy is applied. Metal foil laminates are preferred heat promoters because of their ease of application and activation. A typical metal foil laminate includes aluminum foil, generally vacuum metalized aluminum on a polyester film, with a linear low density polyethylene adhesive on one or both sides. Curwood Inc., of Oshkosh, WI 54903, provides CURLAM® Grade 5432 film which has an adhesive on one side of the film. It is preferred to coat both sides of the film with an adhesive which enables the use of induction heating to bond the foil laminate to the front panel and the liner at the same time.

Induction heating equipment is widely used in the packaging field and suitable units for use in the invention are available from Lepel Corporation of Edgewood, NY 1 1717 and Amertherm, Inc. of Scottsville, NY 14546.

The intensity and duration of the induction field required to bond the liner to the front panel depends on the composition of the heat activatable adhesive. For example, an aluminum foil laminated with linear, low density polyethylene generally achieves its sealing temperature in 0.9 to 1.2 seconds when exposed to a Lepel, LEPAK, Jr. 750 watt induction sealer. An adhesive having a resin base including about 5 to 10 weight percent metallic salt, such as chromium nitrate or aluminum chloride, generally reaches its sealing temperature in under 2.0 seconds when placed in an 800 watt GE microwave oven operating at 900 to 1100 kHz.

Other induction heating systems and heat activatable adhesives can be adapted to the present invention. For example, an induction heating system for sealing packages using magnetic susceptible particles and heat softenable adhesives and high frequency alternating magnetic fields is disclosed in U.S. Pat.3 ,879,247 which is incorporated herein by reference. Polymer systems for sealing containers which can be activated by electromagnetic energy frequencies of 0.1 - 30,000 MHZ, including radio frequency and microwave heating, are disclosed in U.S. Pat. 4,787,194 which is incorporated herein by reference. RF sealable, non-foil acrylate based polymers for packaging applications are disclosed in U.S. Patent 4,660,354 (Example 1) and W0 95/03939 which are also incorporated herein by reference.

Heat sealing the liner to a flap or the front panel of the pour spout preferably locally weakens the liner to facilitate separation of a portion of the liner upon initial opening of the pour spout or flap. In one embodiment, this can be accomplished by attaching a metal foil laminate to the front panel of the pour spout or to the fitment which defines the dispensing opening. The foil can be configured so as to concentrate heat at the edges of the dispensing opening which crates a weakened or thinned tear line without breaking the seal of the bag. A preferred liner is biaxially oriented, laminated high density polyethylene film. Such films will tear easily in the longitudinal or machine direction and to impart better tearability in the transverse direction, fillers such as finely divided calcium carbonate, silica, diatomaceous earth and the like can be added to the film. A suitable film can have two high density polyethylene layers containing 15% by weight finely divided silica in the inner layer and 10% in the outer layer.

In another embodiment, a fitment defining a dispensing opening, preferably with a cut-out piece, is positioned by a positioning assembly between the liner and the front panel of a pour spout. Positioning of the fitment may be accomplished, through a variety of systems which position the fitment between the liner and the carton, and will ideally be affixed to the carton with a hot melt adhesive. Positioning the fitment in this manner defines a focused seal area around the periphery of the dispensing opening and provides a weakened seal line which facilitates separation from the liner. Other methods of scoring a liner include applying a metal containing substance, such as a metal foil or a metal ink, directly to the liner, and then exposing the liner to an induction field.

Referring now to Figs. 4-6 of the drawing, the dispensing assembly of the invention, shown generally by reference numeral 3, is mounted to a dispensing opening in carton 1. Carton 1 includes side walls 42, end walls 43 and top flaps 40 and 41. The carton bottom is defined by similar flaps which are folded over and adhered to each other (not shown).

A sealed plastic liner bag 15 with particulate product such as RTE cereal is in carton 1. Access panel 5, which is perforated on three sides from end wall 43 so as to pivot around axis 2, carries the pour spout which includes front panel 6 and side panels 7 (Fig. 3).

Access to pour spout 3 can be gained by removing strip 5 between perforated lines 4 via pull tab 5" thus exposing an upper portion of front panel

6 (Figs. 4 and 5). Alternatively, panel 5 can abut a cut line in end wall 43 which can be covered by a peel off tape which can be removed for initial opening of the pour spout 3. Resealable peel-off tape can cover panel 5 and the surrounding areas to insure freshness.

In the embodiment shown in Figs. 1 -3, the pour spout assembly has side panels 7 joined to front panel 6 along fold lines 31. Side panels 7 have stepped portions 7" and ears 38 which interact with end wall 43 and cuts 2" to define the open and closed positions of the pour spout. Side panels 7 have curved embossed areas T to stiffen or reinforce the panels 7 for closing the pour spout and diagonal embossed lines 8 to allow the stepped portions 7" to flex if necessary to fit between side wall 42 and end wall 43 at 2". Front panel 6 in integral with fitment 100 via panel 104. Fitment 100 has upper and lower margin portions 1 1 1 and 105 , respectively, side members 102 and a cut-out piece having a central section 126 and vertical side pieces 127 which extend into side members 102 (Fig. IB) to define dispensing opening 109 along line 131' as shown in dotted lines under bonding member 9 (Fig. 2).

Front panel 6 has a tab 306 which releasably interlocks with tab 112 and panel 1 14 having slits 114' of upper margin portion 1 11 when spout panel 6 is folded over fitment 100 (Fig. 2).

In one embodiment, upper margin portion 1 1 1 can have laterally extending flexible tabs (now shown) that interact with stepped portions 7" and cut-outs adjacent ears 38 (not shown) to hold the spout in the open and closed positions. Ears 38 prevent pull-out of the spout. Stepped portions 7" slide through cuts 2" in end wall 43.

When the pour spout is folded over fitment 100 (Fig. 2), connecting panel 104 ties on top of lower margin portion 105 and front panel 6 covers central section 126 of cut-out 126/127 and pivots at line 6" which is aligned with the bottom of opening 109. Oval cut-out 104' along line 6" facilitates flexing and bending of the pour spout. Side members 127 are folded at right angles to panel 6 and cut-out 126/127 fits into dispensing opening 109 defined by fitment 100 when the pour spout is closed. The pour spout and fitment can be spot glued or otherwise affixed to the interior of carton end wall 43 via upper portion 11 1 and lower portion 105. One side member 102 can be wider to provide an area 102' (Figs. 1A and B) to spot or hard glue to the interior of carton side 42 before the carton is 5 erected. This insures that side members 102 will stay flat against the interior side walls of the carton when erected so as not to interfere with the insertion of a filled and sealed bag.

The top of opening 109 is V-shaped and the upper corners provide areas of reduced resistance to initiate separation of the liner bonded to cut-out 10 126/127 from liner 15 itself.

A preferred bonding member 9 (Figs. 1 A and 2) is a metal foil laminate having an outer member 131 and an inner member 133. As shown in Fig. 8D, a preferred member 9 includes a layer of metal foil 9a such as aluminum foil or vacuum metalized aluminum adhered to polyester layer 9b. Adhesive 15 layers 9c and 9e flank both sides of the polyester/foil laminate. Linear low density polyethylene adhesive layers define the outermost layers 9d and 9f. The overall thickness of member 9 is about 5 mils.

Bonding member 9 can be adhered to fitment 100 in a number of ways. It can be fully glued in place using a pressure sensitive, heat activated or other 20 adhesive. It can also be spot glued for later full gluing by actuating adhesive layer 9d or 9f at the same time the other layer is bonded to liner 15.

Margin portions 111 and 105 and side members 102 surround opening 109. Inner member 133 corresponds to opening 109 and is connected to outer member 131 via perforation line 131' about the periphery of opening 109. Inner member 133 has score lines 134 and 134' in the shape of inner member 133 to concentrate heat for bonding around the periphery of line 131'.

This creates a weakened seal line in the area of line 131' to facilitate initial opening of the pour spout, especially at the upper corners of opening 109 where cut-out members 126 and 127 meet along fold line 101.

Outer member 131 has a series of graduated fingers or cuts 132 which help to distribute bonding heat over the area of member 131 and away from the outer edges to prevent the formation of weak spots when liner 15 is bonded to the area surrounding opening 109 to maintain alignment of the liner with the pour spout. Fingers 132 also cooperate with score lines 134 and 134' to concentrate bonding heat along line 131' to form a thinner or weakened tear line in liner 15. In the embodiment shown in Fig. 7, liner 15 is bonded to outer member 131 in an area between fingers 132 and line 131' and to inner member 133 in the areas defined by line 131' and score lines 134 and 134'. Referring to Figs. 13 and 14, in order to bring liner bag 15 into contact with pour spout 3, an unfilled bag is positioned within the carton by mandrel assembly 410, which is tightly wrapped around the mandrel assembly 410 by virtue of a bag forming device.

Once tightly wrapped, a longitudinal seal 409 and a bottom transverse seal 411 is effectuated by a sealer. Liner bag 15 is forced tightly against the interior of the carton and fitment 100. (Figs. 7 and 8-A-C), such that fitment 100 is situated between liner bag 15 and the carton (Fig. 6). While in this state, the carton 408 (Fig. 14) enters a heating zone, which preferably includes an induction heater such as the is Model XP20 made by Ameritherm Inc. To insure that liner 15 reaches into the corners formed when cut-out side members 127 are folded at a right angle to center section 126 along line 101 (Figs. 1 A and B), means can be employed to put pressure on the product in liner 15 so as to cause it to settle neatly into the corners. For example, a plunger tool (not pictured) can be used to force the sealed liner into the recesses of the carton.

Heat delivered via induction heater 21 heats inner and outer members 131 and 133 which in turn activates adhesive layers corresponding to layers 9d and 9f of Fig. 8D. Adhesive layer 9d adheres member 9 to cut-out 126/127, side members 102 and margin portions 105 and 1 1 1. See Figs. 1A and B. Because heat generated by foil layer 9a becomes concentrated as shown and described in Fig.7, a thinning of liner 15 occurs at 128 (Figs. 8B and C) around the edges of cut-out 126/127 to facilitate initial opening of the pour spout. While liner 15 is thinned along line 131', the seal of the bag is not broken until the pout spout is opened by the consumer. To open the pour spout of Figs. 1-7, tab 5" is pulled to remove section 5'.

This exposes tab 306 of front panel 6 which extends above access panel 5. Insertion of one or more fingers behind tab 306 will cause the liner to begin to tear at the upper corners of center section 126 where they join side sections 127 along fold line 101. Continued pulling separates panel 5 along lines 2' and the liner along line 131' until it reaches the bottom corners of center section 126 when the spout is fully open. Liner 15 remains connected to outer member 131 where it is attached to side members 102 and margin portions 105 and 111. In the embodiment shown, spout side panels 7 pivot in and out between a narrow space defined by side members 102 and carton side walls 42 without coming into contact with liner 15.

Upon closing of the spout, cut-out 126/127 fits neatly back into dispensing opening 109 defined by side members 102 and margin portions 105 and 1 11 of fitment 100 to minimize invasion of exterior air. When closed, recess 7" of the side panels slip behind cuts 2" to maintain closure of the spout. For added holding power, tab 306 interlocks with members 1 12 and 1 14 providing a "snap" closure to insure freshness. Figs. 9-12 show an alternate embodiment wherein pour door 202 with a recessed center section 203 snaps into frame 204 which is mounted to a dispensing opening 214 in end wall 43 of carton 1.

Metal foil laminate 205 (similar to member 9) is perforated along line 205' and is adhered to the interior of end wall 43 over opening 214. Liner 15 is adhered via laminate 205 using the process of Fig. 19 to the interior end wall 43 surrounding opening 214 and to recessed portion 203 of door 202. When pour door 202 is lifted up the first time, portion 15' separates from liner 15 along line 205' providing access to the contents thereof. Initial separation of portion 15' takes place where opening 214 is pointed (at 206) which offers less resistance than trying to tear an entire side at one time.

Liner 15 and its contents remain aligned with opening 214 because the liner 15 is adhered via member 205 to end wall 43 around opening 214.

This application hereby incorporates by reference the following applications, United States Patent application Serial No. 09/213,100, filed on December 17, 1998, which is a continuation-in-part of application Serial No. 09/150,966 filed September 10, 1998 which is a continuation-in-part of application Serial No. 09/050, 533 filed March 30, 1998, which claims priority from Provisional application Serial No. 60/069,859 filed December 17, 1997.

Claims

CLAIMSWe claim:

1. In a process for making a carton having a dispensing flap wherein an open, unfilled liner is inserted into an open, unfilled carton, the improvement comprising bonding said liner to said dispensing flap whereby upon initial opening of said dispensing flap that portion of said liner bonded to said dispensing flap separates from the remaining portion of said liner providing access to the contents of said carton when filled with product and sealed.

2. Process of claim 1, wherein: said unfilled liner is bonded to said dispensing flap by forming a bag having only one open end around a mandrel and clamping said bag to said dispensing flap carton.

3. In a process for making a carton wherein an open, unfilled liner is inserted into an open, unfilled carton, said carton having a dispensing opening in a side wall thereof and pour spout means mounted in said dispensing opening including a front panel, the improvement comprising: bonding said unfilled liner to said front panel whereby upon initial opening of the pour spout, that portion of the liner bonded to said front panel separates from the remainder of said liner providing access to the interior of the liner.

4. Process of claim 3, wherein: said bonding of said liner to said dispensing flap is effectuated through the use of a mandrel and clamping assembly.

5. Process of claim 4 wherein said front panel is provided with a bonding promoter to promote the bonding of said liner to said front panel, wherein means are employed to deliver bonding energy to the interface between said front panel and said liner.

6. Process of claim 5 wherein said means to deliver heat energy comprises an induction heater.

7. In a process for making a carton wherein an open, unfilled liner adapted to contain particulate product is inserted into an open, unfilled carton having side and end walls, an access panel severably connected to one end wall of said carton, a fitment having a cut-out defining a dispensing opening and having an upper margin portion and a pour spout having side panels and a front panel; the improvement comprising: bonding of said unfilled liner to said flap through the use of a mandrel and clamping assembly.

8. Process of claim 7 wherein said fitment is provided with means to promote bonding of said liner to said fitment and means are employed to deliver bonding energy to the interface between said fitment and said liner.

9. In a process for making carton wherein an open, unfilled liner adapted to contain particulate product is inserted into an open, unfilled carton having a fitment having a cut-out defining a dispensing opening and having upper margin portion and lower margin portion adjacent said cut-out and wherein said pour spout has side panels and a front panel pivoting between open and closed positions about the base of said front panel, the improvement comprising: bonding an unfilled liner to said front panel and to said carton through the use of a mandrel and clamping assembly, whereby said liner is inserted inside the carton such that said fitment is sandwiched between said liner and said carton.

10. Process of claim 9 wherein a bonding promoter is applied to said cut-out and to said fitment adjacent said cut-out to promote bonding of the liner.