WO2004110881A1

WO2004110881A1 - Carton with re-closable dispensing opening

Info

Publication number: WO2004110881A1
Application number: PCT/ZA2004/000065
Authority: WO
Inventors: Thomas Johannes Bingle
Original assignee: Thomas Johannes Bingle
Priority date: 2003-06-12
Filing date: 2004-06-11
Publication date: 2004-12-23
Also published as: WO2004110881A8

Abstract

A carton is disclosed which comprises panels (2, 3, 4, 5) constituting the upright side walls of the carton, overlapping flaps (10, 11, 12,13) forming an end closure for one end of the carton and overlapping flaps (6, 7, 9) forming an underlying closure structure for the other end of the carton. The underlying closure structure is covered by an outer closure flap (8). The underlying closure structure includes an inner flap (6) formed with a removable panel (16) which can be detached to leave an opening through which the contents of the container can be dispensed. Between the outer closure flap (8) and the inner flap (6) there is a label comprising a substrate and pressure sensitive adhesive for releasably securing the closure flap (8) to that portion of the inner flap (6) which surrounds the removable panel (16). The substrate conceals the pressure sensitive adhesive layer. Blanks from which the carton can be erected are also disclosed.

Description

CARTON WITH RE-CLOSABLE DISPENSING OPENING

FIELD OF THE INVENTION

THIS INVENTION relates to cartons with re-closable dispensing openings.

BACKGROUND TO THE INVENTION

In my PCT Application No. PCT/ZA01/00150 (published as WO02/070354) I disclose a carton with a re-closable dispensing opening, the carton employing pressure sensitive adhesive for the purpose of re-closing the dispensing opening.

The carton disclosed fulfils its intended purpose but there are in some circumstances technical difficulties in implementing the invention of WO02/070354. A problem arises from the fact that the pressure sensitive adhesive has to be applied to the blank whilst the carton is being erected, filled and closed. Not all packaging lines can be economically adapted to apply the adhesive to the blank immediately before the filled carton is closed.

Applying the adhesive during manufacture of the blank is not possible as the cut blanks are stacked and shipped to the packer in bulk. The loading on the blanks during transport presses them into a block with each blank adhered to the ones on either side thereof. Adjacent blanks are then difficult to separate at the rate required to enable a high speed packaging line to be fed.

The present invention provides a solution to this problem.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of the present invention there is provided a carton which comprises panels constituting the upright side walls of the carton, overlapping flaps forming an end closure for one end of the carton and overlapping flaps forming an underlying closure structure for the other end of the carton, said underlying closure structure being covered by an outer closure flap, said underlying closure structure including an inner flap formed with a removable panel which can be detached to leave an opening through which the contents of the container can be dispensed, and there being, between said outer closure flap and the inner flap, a label comprising a substrate and pressure sensitive adhesive for releasably securing said closure flap to that portion of the inner flap which surrounds said removable panel, said substrate concealing said pressure sensitive adhesive.

In one form said pressure sensitive adhesive releasably secures said substrate to said inner flap, the adhesion between said substrate and the adhesive being greater than between said inner flap and the adhesive.

In another form said substrate is secured by the pressure sensitive adhesive to said outer closure flap, the strength of adhesion between the adhesive and the outer closure flap exceeding the strength of adhesion between the substrate and the adhesive whereby the substrate can be peeled off to leave the adhesive on the outer closure flap.

The label preferably comprises in sequence said substrate, said pressure sensitive adhesive, a film and permanently bonding adhesive securing said film to said outer flap thereby to facilitate peeling the substrate off without detaching the pressure sensitive adhesive from the film.

Said outer closure flap can have a line of weakening therein which bounds a closure tab, said label being secured to said closure tab.

According to a further aspect of the present invention there is provided a blank which comprises wall panels joined to one another along crease lines so that the wall panels can be folded with respect to one another to form a carton, first and second sets of flaps joined along crease lines to said wall panels, said first set of flaps forming a closure for one end of the carton when folded with respect to the wall panels and overlapped with one another, said second set of flaps being joined along crease lines to ends of said wall panels remote from the ends to which said first set of flaps are connected and which second set of flaps, when folded over with respect to the wall panels, form a closure for the other end of the carton, said second set of flaps including a first flap with a weakened line therein bounding a removable panel and a second flap with a line of weakening therein which bounds a closure tab, and a label comprising a substrate with a layer of pressure sensitive adhesive on it for releasably securing said closure tab to that portion of said first flap which surrounds said removable panel.

Preferably said layer of pressure sensitive adhesive is applied only to those portions of the closure tab which, when the carton is erected and the removable panel and closure tab come into register, lie outside the area of said panel.

According to another aspect of the present invention there is provided a blank which comprises wall panels joined to one another along crease lines so that the wall panels can be folded with respect to one another to form a carton, first and second sets of flaps joined along crease lines to said wall panels, said first set of flaps forming a closure for one end of the carton when folded with respect to the wall panels and overlapped with one another, said second set of flaps being joined along crease lines to ends of said wall panels remote from the ends to which said first set of flaps are connected and which second set of flaps, when folded over with respect to the wall panels, form a closure for the other end of the carton, said second set of flaps including a first flap with a weakened line therein bounding a removable panel and a second flap with a line of weakening therein which bounds a closure tab, there being a label comprising a substrate with a layer of pressure sensitive adhesive on one of its faces, the pressure sensitive adhesive releasably securing said substrate to that portion of the first flap which surrounds said removable panel.

A carton is erected using the blank defined in the preceding paragraph by coating one or both of said first and second flaps with permanently bonding adhesive so that the other face of the substrate is permanently adhered to said first flap as said other end of the carton is closed.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:-

Figure 1 illustrates a blank from which a carton can be erected;

Figure 2 illustrates a modified form of the blank of Figure 1 ;

Figure 3 is a pictorial view of a carton during erection using the blank of Figure 1 ;

Figure 4 is a pictorial view of a closed carton using the blank of Figure 1;

Figure 5 is a pictorial view of the carton of Figures 3 and 4 with the closure structure opened;

Figure 6 illustrates a further blank from which a carton can be erected; Figure 7 illustrates a modified form of the blank of Figure 6;

Figure 8 illustrates a carton being erected using the blank of Figure 6;

Figure 9 is a pictorial view of the carton of Figure 6 in a closed condition;

Figure 10 is a pictorial view of the carton of Figure 6 in an opened condition;

Figure 11 illustrates a further blank from which a carton can be erected; Figure 12 illustrates a modified form of the blank of Figure 11 ;

Figure 13 illustrates a carton erected using the blank of Figure 11 just before it is fully closed; Figure 14 illustrates the carton of Figure 3 in a closed condition;

Figure 15 illustrates the carton of Figure 13 partly opened but before a removable panel section is removed;

Figure 16 illustrates a further blank from which a carton can be erected; Figure 17 illustrates, to a larger scale, a detail of the blank of Figure 16;

Figure 18 illustrates a modified form of the blank of Figure 16;

Figure 19 illustrates a further blank from which a carton can be erected;

Figure 20 illustrates a modified form of the blank of Figure 19;

Figure 21 illustrates another blank from which a carton can be erected; Figure 22 illustrates a modified form of the blank of the Figure 21 ; and

Figure 23 illustrates a further modified form of the blank of Figure 21.

DETAILED DESCRIPTION OF THE DRAWINGS

The blank as shown in Figure 1 can be of any material conventionally used in the manufacture of cartons for containing flowable materials such as small uniformly shaped bulk forms (for example pasta) or cereals such as cornflakes.

Suitable materials are paperboard, fibreboard and rigid sheet plastics material, or laminated materials consisting of plastics and paperboard and/or fibreboard combinations.

The blank comprises four wall panels 2, 3, 4 and 5 which are bounded by crease lines 22, 23, 24 and 25. One of the longer free edges of the panel 5 is a free edge and it is joined along its other edge to the panel 4 by way of the crease line 25. An elongate closure tab 1 is joined along the crease line 22 to the panel 2.The crease lines 23, 24, and 25 form the boundaries between the panels 2, 3, 4 and 5. The closure tab 1 can, if desired, be along the edge of the panel 5 instead of along the edge of the panel 2.

A bottom closure structure of the carton is constituted by four flaps 10, 11 , 12 and 13 each of which is joined along a respective crease line 30, 31 , 32 and

33 to one of the shorter edges of each panel 2, 3, 4 and 5. It will be noted that the flaps 11 and 13 are half flaps and the flaps 10 and 12 are full flaps. It is possible for the flaps 10 and 12 to be full flaps or to be sized between half flaps and full flaps provided there iέ a degree of overlap.

Top closure flaps 6, 7, 8 and 9 are joined to the other shorter edges of the panels 2, 3, 4, and 5 along crease lines 26, 27, 28 and 29 respectively.

The flaps 7 and 9 are half flaps. Each has a semi-circular piece thereof cut away. The resulting cut outs are designated 18 and 19. If the flaps 7 and 9 are less than half flaps, the gap between them can replace the cut outs.

The flap 8 can be considered to have two areas 14 and 15, joining one another along an imaginary line 21 which is parallel to the crease line 28.

The flap 6 has a removable panel 16 within the area thereof, the removable panel 16 being joined to the remainder of the flap 6 along a circular weakened line 20. The weakened line can be constituted by a score line or by a line of perforations. The removable panel 16 is shown in the illustrated embodiment as being circular in shape and having a crease line 36 extending diametrically across it. It can, however, also be semi-circular. Generally the shape and size of the cut-outs 18, 19 and of the removable panel 16 are chosen in dependence on the flow characteristics of the carton's contents. Whilst the panel 16 is shown as circular, it can be of any desired shape.

The area 15 of flap 8 has a tab 38 within it, the tab 38 being bounded by a weakened line 42 and by a crease line 37 about which the tab 38 can be bent. The weakened line 42 can be constituted by perforations, by a die cut, by a score line or by a combination of these. The line 37 connects the ends of the line 42.

The tab 38 is larger than the panel 16 for a purpose to be described.

A release tab is designated 45 and is defined between one of free edges of the flap 8 and part of the line 42.

One possible method of erecting the carton will now be described with reference to Figure 3. The blank is folded along the crease lines 22, 23, 24 and 25, and the closure tab 1 adhered to the inside face of the edge zone of the panel 5. This can be done at the carton maker's factory or immediately prior to filling. The bottom flaps 10, 11 , 12 and 13 are then folded about the crease lines 30, 31 , 32 and 33. The flaps 11 and 13 are folded first and permanently bonding adhesive applied to the flap 10. When the flap 10 is folded over it adheres to the flaps 11 and 13.

Permanently bonding adhesive is then applied to the flap 12 and the flap folded over to adhere it to the flap 10.

The carton is filled through the top and then the top is closed by folding the top closure flaps 6, 7, 8, and 9 over about the crease lines 26, 27, 28 and 29 and adhering them together.

It will be understood that the above procedure can be reversed and the carton filled through the bottom.

If the folding procedure of Figure 3 is followed, the half flaps 7, 9 are the first flaps folded. The flap 6 then has permanently bonding adhesive applied to it over the entire area of that face thereof which becomes the lower face after it is folded over, and it is then folded over. The flaps 7 and 9 are permanently secured by the adhesive to the underside of the flap 6. It will be noted that the cut outs 18, 19 come into co-operating relationship and that they together define a composite circular cut out that registers with the removable panel 16.

The flap 8 has either pressure sensitive or permanent bonding adhesive applied to the shaded area designated 15. If permanent bonding adhesive is applied to the area 15, the coated area excludes the tab 38. The whole area 15 need not have adhesive applied to it and the adhesive can be applied in a pattern. The tab 38 has a label 46 (see Figure 5), which comprises a substrate with a layer of pressure sensitive adhesive on it, applied to it. The pressure sensitive adhesive can cover the entire area of the tab 38 but is preferably in a pattern around the edge of the tab 38 as indicated by the shaded area 40. The pressure sensitive adhesive on the area 40 of the flap 8 eventually releasably secures the tab 38 to the flap 6. The label 46 covers the entire area 38 of the tab, inclusive of the area 40, but stops short of the line 42. The label is not shown in Figure 1.

The tab 45 is preferably glued to the flap 6 but this is not essential.

The area 14 of the flap 8 has permanently bonding adhesive applied to it, this adhesive securing the area 14 permanently to the flap 6. Alternatively the top face of the flap 6 can have permanently bonding adhesive applied to an area thereof that comes into co-operating relationship with the area 14 of the flap 8.

The area 14 seals-off the gap which would otherwise exist, when the tab 38 is in its open position, along the top edge of the panel 4 at the crease line 28 and between this panel and the edge of the underlying top closure structure which comprises the flaps 6, 7 and 9.

An alternative way of forming the underlying top closure structure is to fold the flap 6 first. Either the half panels 7, 9, or the flap 6, have permanently bonding adhesive applied before the flaps 7 and 9 are folded over into face-to-face contact with, the flap 6. The flap 8 is the last one to be folded over.

To dispense the contents of the carton, the tab 38 is lifted by prying up or prying loose the release tab 45, or tearing along a tear line that is between the line 42 and the release tab 45 of flap 8. The tab 38 is then folded back on itself about the crease line 37 (see Figure 5). This causes the panel 8 to fail along the line 42. The tab 38 can easily be detached from the flap 6 as the pressure sensitive adhesive on it is, during first opening, covered by the substrate of the label 46. The substrate is removed by the consumer by peeling it from the tab 38 before the pressure sensitive adhesive can be used for its intended purpose. The pressure sensitive adhesive remains affixed to the tab 38 when the substrate of the label 46 is removed. The removable panel 16, which forms the tamper evident feature, is then detached. This can be done by pushing it in to cause the material of the flap 6 to fail along the weakened line 20 and by tearing it out. No spillage of the contents of the carton occurs during this procedure.

Figure 5 shows the carton after opening and with the substrate of the label 46 partly peeled from the tab 38 thus exposing the pressure-sensitive adhesive pattern 40 on the tab 38. Panel 16 has been removed to leave a hole designated 16a.

The carton can be re-closed and resealed by pressing the tab 38 back against the underlying top structure so that the pressure sensitive adhesive 40 is effective releasably to secure the tab 38 to the flap 6 around the periphery of the hole 16a.

The label 46 described above comprises a substrate and the adhesive layer. It can, however, comprise the substrate, the adhesive pattern 40 and a base layer which is secured by permanent adhesive to the tab 38.

Each time the carton is re-opened, the tab 38 has to be peeled back. If the tab 38 develops curl memory from continuous opening it can be slightly bowed in the opposite direction to that in which it is bowed during opening before pressing the tab 38 back against the underlying closure structure.

The blank of Figure 2 differs from the blank of Figure 1 in that the flap 8 of Figure 2 is smaller than the flap of Figure 1. The area 15 can be reduced to the extent that only the tab 38 and area 14 remain and these together constitute the top closure flap.

The blank of Figure 6 differs from the blank of Figure 1 in a number of respects. The mayor difference is that the wall panels 2 and 4 are at least twice as wide as the wall panels 3 and 5. The erected carton is thus rectangular in plan and not square as is the carton of Figures 3 to 5. The other mayor difference is that the flap 8 is differently arranged. More specifically, the tab 38 is to one side of flap 8. The flaps 7 and 9 are shown as full flaps. In some instances where the face panel 4 to side panel 2 has a ratio less than 2:1 , the flaps 7 and 9 can be less than half flaps. The cut outs 18 and 19 are replaced by a circular hole 41.

The area 15 can be cut back to the extent that only the tab 38 and area 14 remain, these together constituting the top closure flap. Figure 7 illustrates the area 15 as being smaller than the area 15 in Figure 6. The carton erected from the blank of Figure 6 is as shown in Figure 9 when closed, is shown in Figure 8 when partly erected and is shown in Figure 10 when opened for dispensing purposes.

The carton Figures 11 to 15 differs from that of Figures 6 to10 only in that tab 38 on flap 8 has been rotated 90 degrees so that the crease line 37 runs pendicular to the imaginary line 21.

The exposed surface of the carton can be printed. It can also totally or in part be covered by a coating such as varnish, with or without a release coating, or a plastics film. All these techniques are commonly used in the packaging industry. The release coating in particular can be patterned when applied to the top of flap 6 so as to regulate the pressure sensitive adhesive's functionality.

In Figures 16 and 17, it is the panel 16 that is covered by a label. The label is designated 50 and comprises a substrate and a layer of pressure sensitive adhesive on the substrate. The pressure sensitive adhesive attaches the label to the panel 16. The label 50 is secured to that surface of the panel 16 which faces upwardly when the carton is erected.

The tab area 38 is bounded by cut lines 52 and 54 which run parallel to another but are spaced apart to provide a gap 56. The gap 56 can be, for example, 2mm wide. At one end the tab 38 is extended by the smaller tab 45 and at the other end is bounded by the crease line 37. There are a number of bridges 58 (Figure 17) between the area 15 and the tab 38.

The blank of Figures 16 and 17 is erected in the same way as that of Figures 1 etc. Final closure after filling comprises coating the flap 6, including the label 50, with permanently adhering adhesive, and then folding the flap 8 down onto the adhesive covered surface of the flap 6. Alternatively the flap 8 can have the adhesive layer applied to it.

The substrate of the label 50 is now permanently adhered to the tab

38.

When the tab 38 is torn along the line 52 simultaneously breaking the bridges 58, the substrate of the label 50, with the pressure sensitive adhesive on it, pulls away from the panel 6. The tab 38 is re-secured when it is pressed down into contact with the flap 6.

It will be understood that the removable panel 16 is pressed out after first opening.

The gap 56 is provided to ensure that even if the label 50 is not accurately positioned over the panel 16, it will not adhere to the part of the panel 8 which is outwardly of the line 54. Figures 18 to 23 show various configurations all of which have the same features as Figures 16 and 17 but in which the tab 38 is of a different shape and/or is positioned differently. Where applicable the same reference numerals as have been used in the preceding Figures are used in these Figures. In each case the label comprises a substrate with pressure sensitive adhesive on it, and the tab

38 is connected to the remainder of the panel 8 along a weakened line.

As described above, the label comprises a substrate and a layer of pressure sensitive adhesive on the substrate. In another form for use in the embodiments of Figures 1 to 15, the label is of more complex construction and comprises the substrate to which the pressure sensitive adhesive is applied, a film and a layer of permanently bonding adhesive which adheres the film to the tab 38. This construction can be used if the adhesion between the pressure sensitive adhesive and the tab 38 is considered insufficient. The nature of the film chosen is such that the pressure sensitive adheres more strongly to it than to the substrate.

Claims

CLAIMS:

1. A carton which comprises panels constituting the upright side walls of the carton, overlapping flaps forming an end closure for one end of the carton and overlapping flaps forming an underlying closure structure for the other end of the carton, said underlying closure structure being covered by an outer closure flap, said underlying closure structure including an inner flap formed with a removable panel which can be detached to leave an opening through which the contents of the container can be dispensed, and there being between said outer closure flap and the inner flap, a label comprising a substrate and pressure sensitive adhesive for releasably securing said closure flap to that portion of the inner flap which surrounds said removable panel, said substrate concealing said pressure sensitive adhesive.

2. A carton as claimed in claim 1 , wherein said pressure sensitive adhesive releasably secures said substrate to said inner flap, the adhesion between said substrate and the adhesive being greater than between said inner flap and the adhesive.

3. A carton as claimed in claim 1 , wherein said substrate is secured by the pressure sensitive adhesive to said outer closure flap, the strength of adhesion between the adhesive and the outer closure flap exceeding the strength of adhesion between the substrate and the adhesive whereby the substrate can be peeled off to leave the adhesive on the outer closure flap.

4. A carton as claimed in claim 3, wherein said label comprises in sequence said substrate, said pressure sensitive adhesive, a film and permanently bonding adhesive securing said film to said outer flap thereby to facilitate peeling the substrate off without detaching the pressure sensitive adhesive from the film.

5. A carton as claimed in claim 3 or 4, wherein said outer closure flap has a line of weakening therein which bounds a closure tab, said label being secured to said closure tab.

6. A blank which comprises wall panels joined to one another along crease lines so that the wall panels can be folded with respect to one another to form a carton, first and second sets of flaps joined along crease lines to said wall panels, said first set of flaps forming a closure for one end of the carton when folded with respect to the wall panels and overlapped with one another, said second set of flaps being joined along crease lines to ends of said wall panels remote from the ends to which said first set of flaps are connected and which second set of flaps, when folded over with respect to the wall panels, form a closure for the other end of the carton, said second set of flaps including a first flap with a weakened line therein bounding a removable panel and a second flap with a line of weakening therein which bounds a closure tab, and a label comprising a substrate with a layer of pressure sensitive adhesive on it for releasably securing said closure tab to that portion of said first flap which surrounds said removable panel.

7. A blank as claimed in claim 6, wherein said layer of pressure sensitive adhesive is applied only to those portions of the closure tab which, when the carton is erected and the removable panel and closure tab come into register, lie outside the area of said panel.

8. A blank which comprises wall panels joined to one another along crease lines so that the wall panels can be folded with respect to one another to form a carton, first and second sets of flaps joined along crease lines to said wall panels, said first set of flaps forming a closure for one end of the carton when folded with respect to the wall panels and overlapped with one another, said second set of flaps being joined along crease lines to ends of said wall panels remote from the ends to which said first set of flaps are connected and which second set of flaps, when folded over with respect to the wall panels, form a closure for the other end of the carton, said second set of flaps including a first flap with a weakened line therein bounding a removable panel and a second flap with a line of weakening therein which bounds a closure tab, there being a label comprising a substrate with a layer of pressure sensitive adhesive on one of its faces, the pressure sensitive adhesive releasably securing said substrate to that portion of the first flap which surrounds said removable panel.

9. A method of erecting a carton using the blank of claim 8 which comprises coating one or both of said first and second flaps with permanently bonding adhesive so that the other face of the substrate is permanently adhered to said first flap as said other end of the carton is closed.