Note: Descriptions are shown in the official language in which they were submitted.
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CARTON WITH POUR SPOUT
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.
61/193,067, filed on October 27, 2008, the entire disclosure of which is
incorporated herein by reference.
BACKGROUND
[0002] The disclosure generally relates to cartons for storing and dispensing
materials, and methods blanks for forming such cartons. It is desirable to
provide
a carton that can easily be converted from a closed configuration for storing
materials to an open configuration for pouring the materials out of the
carton. It
also desirable to provide a carton that can be easily and securely reclosed
after
being opened. Additional objects and desires will become apparent from the
following disclosure, drawings and claims.
SUMMARY
[0003] The disclosure generally relates to cartons suitable for storing and
dispensing material such as, for example, granular or pelletal material, and
methods of erecting such cartons from a carton blank. The material can be
stored
inside the carton within a bag, or the material can be stored without a bag.
[0004] According to an embodiment, a carton can comprise a front panel, a
rear panel, a first side panel, a second side panel opposite the first side
panel, a
bottom panel, a top panel comprising a first side top flap and a second side
top
flap, and a front top end panel foldably connected to the front panel, the
first side
top flap and the second side top flap. The carton can be constructed such
that,
when the carton is in a closed configuration, the front top end panel extends
inwardly from the front panel towards an interior of the carton, the second
side top
flap partially overlaps the first side top flap, and the first side top side
flap and the
second side top side flap lie over the front top end panel. The carton can be
placed in an open configuration in which a spout is formed in a top of the
carton
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and defines an opening for pouring contents from the carton. The front top end
panel can be folded outwardly away from the interior of the carton to form a
front
lip of the spout, and portions of the first and second top side flaps form
side walls
of the spout.
[0005] According to another embodiment, a carton can comprise a front panel,
a rear panel, a first side panel, a second side panel opposite the first side
panel, a
bottom panel, a top panel, and a front top end flap or panel foldably
connected to
the front panel. The top panel can comprise a first side top flap and a second
side
top flap. The first side top flap can include a first flap section, a second
flap
section and a first break line between the first flap section and the second
flap
section. The second side top flap can include a third flap section, a fourth
flap
section and a second break line between the third flap section and the fourth
flap
section. When the carton is in a closed configuration, the front top end panel
extends inwardly from the front panel towards an interior of the carton
beneath the
first side top flap and the second side top flap, and the second side top flap
partially overlaps the first side top flap, or the first side top flap
partially overlaps
the second side top flap. The carton can be placed in an open configuration in
which a spout is formed in a top of the carton and defines an opening for
pouring
contents from the carton. When the carton is in the open configuration, the
front
top end flap or panel is folded outwardly away from the interior of the carton
and
forms a front lip of the spout. Additionally, when the carton is in the open
configuration, the first flap section and the second flap section are detached
from
each other along the first break line, the third flap section and the fourth
flap
section are detached from each other along the second break line, and the
first flap
section and the third flap section extend transversely to the second flap
section
and the fourth flap section, thereby forming side walls of the spout.
[0006] According to other embodiments, blanks for forming the cartons are
disclosed.
[0007] Additional features and advantages will be appreciated from the
following detailed description, drawings and claims.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a plan view of a carton blank with an outer or print side of
the
blank facing upward.
[0009] FIGS. 2 and 3 are perspective views of a carton erected from the blank
of FIG. 1, wherein the carton is in a closed configuration.
[00010] FIG. 4 is a bottom view of the carton of FIGS. 2 and 3.
[00011] FIGS. 5 and 6 show the carton of FIGS. 2 and 3 in an open
configuration for pouring contents out of the carton.
[00012] FIG. 7 shows the carton of FIGS. 2 and 3in a reclosed configuration.
[00013] FIG. 8 is a plan view of a carton blank according to another
embodiment with an outer or print side of the blank facing upward.
[00014] FIG. 9 is a perspective view of a carton erected from the blank of
FIG.
8, wherein the carton is in a closed configuration.
[00015] FIG. 10 shows the carton of FIG. 9 in an open configuration for
pouring contents out of the carton.
[00016] FIG. 11 shows the carton of FIG. 9 in a reclosed configuration.
[00017] FIG. 12 is a plan view of a carton blank according to another
embodiment with an outer or print side of the blank facing upward.
[00018] FIG. 13 is a perspective view of a carton erected from the blank of
FIG. 12, wherein the carton is in a closed configuration.
[00019] FIG. 14 is a bottom view of the carton of FIG. 12.
[00020] FIGS. 15 and 16 show the carton of FIG. 12 in an open configuration
for pouring contents out of the carton.
[00021] FIG. 17 shows the carton of FIG. 12 in a reclosed configuration.
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[00022] FIG. 18 is a plan view of a carton blank according to yet another
embodiment with an outer or print side of the blank facing upward.
[00023] FIG. 19 is a perspective view of a carton erected from the blank of
FIG. 18, wherein the carton is in a closed configuration.
[00024] FIG. 20 is a bottom view of the carton of FIG. 19.
[00025] FIGS. 21 and 22 show the carton of FIG. 19 in an open configuration
for pouring contents out of the carton.
[00026] FIG. 23 is a perspective view of a carton of FIG. 19 in a reclosed
configuration.
[00027] FIG. 24 is a plan view of a carton blank according to yet another
embodiment with an outer or print side of the blank facing upward.
[00028] FIG. 25 is a perspective view of a carton erected from the blank of
FIG. 24, wherein the carton is in a closed configuration.
[00029] FIG. 26 is a bottom view of the carton of FIG. 25.
[00030] FIGS. 27 and 28 show the carton of FIG. 25 in an open configuration
for pouring contents out of the carton.
[00031] FIG. 29 shows the carton of FIG. 25 in a reclosed configuration.
DETAILED DESCRIPTION
[00032] The disclosure generally relates to cartons suitable for storing and
dispensing material such as, for example, granular or pelletal material, and
methods of erecting such cartons from a carton blank. For purposes of
illustration
and not limitation, the detailed description below describes several
embodiments
of the invention within the context of a carton with a pour spout for
dispensing
material from the carton. Further, references herein to "end," "side,"
"front,"
"rear," "bottom," and "top" refer to orientations or positions of elements
when the
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carton is erected and disposed in an upright orientation. The terms "upper,"
"lower," "vertical," "horizontal," "lateral," and "oblique," and any
variations
thereof, generally refer to the location and/or orientation of an element or
line with
respect to a drawing figure in which it appears. Reference characters shared
among the various embodiments disclosed herein indicate similar parts.
[00033] Referring now in more detail to the drawing figures, wherein like
reference characters indicate like parts throughout the several views, FIG. 1
illustrates a carton blank 1 from which a carton 200 (FIG. 2) may be erected.
The
blank 1 is shown with its outside or print side up. The blank 1 includes a
front
panel 10, a first side panel 20, a second side panel 30, a rear closure flap
40, and a
rear flap 50. Horizontal fold lines 16, 18 form top and bottom edges,
respectively,
of the panels 10, 20, 30 and the flaps 40, 50. The first and second side
panels 20,
30 are foldably connected to opposite sides of the front panel 10 along
vertical
fold lines 12, 14, respectively. The rear closure flap 40 is foldably
connected to
the first side panel 20 along a vertical fold line 22. The rear flap 50 is
foldably
connected to the second side panel 30 along a vertical fold line 32. Each of
the
panels 10, 20, 30 and flaps 40, 50 are substantially rectangular in shape.
However, other shapes are possible.
[00034] A first side top flap 80 and a first bottom flap 90 are foldably
connected to the first side panel 20 along the fold lines 16, 18,
respectively. A
front top end panel 60 and a front bottom end flap 70 are foldably connected
to the
front panel 10 along the fold lines 16, 18, respectively. A second side top
flap 100
and a second bottom flap 110 are foldably connected to the second side panel
30
along the fold lines 16, 18, respectively. The front top end panel 60 is also
foldably connected to the first and second side top flaps 80, 100 along the
fold
lines 12, 14, respectively. A rear top end flap 120 and a rear bottom end flap
130
are foldably connected to the rear flap 50 along the fold lines 16, 18,
respectively.
The flaps 70, 80, 90, 100, 110, 130 and the front top end panel 60 are
generally
rectangular in shape, however other shapes are possible.
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[00035] The first side top flap 80 includes a first break line 86 extending
substantially vertically between the laterally extending outer edge of the
first side
top flap 80 and the fold line 16. The first break line (e.g., cut and/or tear
line) 86
includes a cut segment 86a extending from the laterally extending outer edge
of
the first side top flap 80 and a perforated segment 86b extending from the cut
segment 86a to the fold line 16. The break line 86 divides the first side top
flap 80
into a first side top flap section 82 and a second side top flap section 84.
The
second side top flap 100 includes a second break line 106 extending
substantially
vertically between the laterally extending outer edge of the second side top
flap
100 and the fold line 16. The second break line 106 includes a cut segment
106a
extending from the laterally extending outer edge of the second side top flap
100
and a perforated segment 106b extending from the cut segment 106a to the fold
line 16. The break line 106 divides the second side top flap 100 into a third
side
top flap section 102 and a fourth side top flap section 104. The first side
top flap
80 optionally includes adhesive regions 88 in the first side top flap section
82 for
releasably adhesively attaching the first and second side top flaps 80, 100
together
at the first and third side top flap sections 82, 102 in overlapping fashion.
The
adhesive regions 88 may be defined by score patterns or partial cut patterns
89
extending partially through the thickness of the blank 1 (into the page). The
releasable adhesive attachment between the first and third side top flap
sections
82, 102 may be provided in any suitable manner.
[00036] Opposite edges of the front top end panel 60 are foldably connected to
the first and second side top flaps 80, 100 by the fold lines 12, 14,
respectively.
The front top end panel 60 includes a substantially triangular center section
62, a
substantially triangular first side section 64 foldably connected to the
center
section 62 along a first oblique fold line 63, and a substantially triangular
second
side section 66 foldably connected to the center section 62 along a second
oblique
fold line 65. The oblique fold lines 63, 65 extend between the fold line 16
and the
laterally extending outer edge of the front top end panel 60, and converge
towards
each other as they extend from the fold line 16.
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[00037] A closure feature, or female locking member/receptacle 140 is
optionally provided in the front panel 10. The closure feature 140 includes an
arcuate tear line 142, a vertical cut line or tear line 144 extending
downwardly
from the arcuate tear line 142, and a v-shaped fold line 146 positioned below
the
cut line 144.
[00038] Referring to FIGS. 2 -4, the blank 1 can be erected into a carton 200.
In FIGS. 2 and 3, the carton 200 is in a closed configuration. Referring to
FIGS. 2
and 3, the side panels 20, 30 are folded inwardly along the fold lines 12, 14,
respectively, such that the first and second side panels 20, 30 extend
substantially
parallel to each other and perpendicularly to the front panel 10. The rear
closure
flap 40 is folded inwardly along the fold line 22 so as to extend
substantially
parallel to the front panel 10. The rear flap 50 is folded inwardly along the
fold
line 32 so as to overlap the rear closure flap 40 and extend substantially
parallel to
the front panel 10. The rear flap 50 and the rear closure flap 40 together
from a
rear panel 170 (FIG. 3) of the carton 200, extending substantially parallel to
the
front panel 10. The rear closure flap 40 may be adhesively or otherwise
attached
to the inner side of the rear panel 50.
[00039] Still referring to FIGS. 2 and 3, the center section 62 of the front
top
end panel 60 is folded inwardly along the fold line 16, and the first and
second
side sections 64, 66 of the front top end panel 60 are folded over the center
section
62 along the respective oblique fold lines 63, 65 such that the front top end
panel
60 is folded towards the interior of the carton 200. The rear top end flap 120
is
folded inwardly along the fold line 16 towards the interior of the carton 200.
The
first and second side top flaps 80, 100 are folded along the fold line 16 such
that
the second side top flap 100 partially overlaps the first side top flap 80 and
the
first and second side top flaps 80, 100 lie over the front top end panel 60
and the
rear top end flap 120. The first and second side top flaps 80, 100 are secured
together such as by way of adhesive material at adhesive regions 88, and
adhesive
material between the second and fourth side top flap sections 84, 104, so that
the
first and second side top flaps 80, 100 form a top panel 150 extending between
the
first and second side panels 20, 30 and the front and rear panels 10, 170. The
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second and fourth side top flap sections 84, 104 may be attached to each other
in a
more permanent manner than the first and third side top flap sections 82, 102,
such as by a more secure adhesive attachment. The top panel 150 extends
substantially perpendicularly to the front panel 10, the rear panel 170, and
the first
and second side panels 20, 30. The first and third side top flap sections 82,
102
are positioned adjacent to each other in the top panel 150 to form a partially
detachable portion of the top panel 150.
[00040] As shown in FIG. 4, the front bottom end flap 70 and the rear bottom
end flap 130 are folded inwardly along the fold line 18, and the first and
second
bottom flaps 90, 110 are folded inwardly along the fold line 18 over the front
bottom end flap 70 and the rear bottom end flap 130 such that the second
bottom
flap 110 overlaps the first bottom flap 90. The first and second bottom flaps
90,
110 form a bottom panel 160 extending substantially parallel to the top panel
150.
The first and second bottom flaps 90, 110 may be adhesively or otherwise
secured
together.
[00041] FIGS. 5 and 6 show the carton 200 in an open configuration for
pouring contents therefrom. In the open configuration, the first and third
side top
flap sections 82, 102 are separated from the second and fourth top panel
sections
84, 104, respectively, along the respective break lines 86, 106 and are folded
outwardly along the fold line 16 so as to extend transversely to the second
and
fourth side top flap sections 84, 104, which form a remainder of the top panel
150.
The center section 62 of the front top end panel 60 is folded outwardly along
the
fold lines 16, 63, 65, and the first and second side sections 64, 66 of the
front top
end panel 60 are folded outwardly along the fold lines 63, 65, 12, 14, such
that the
front top end panel 60 extends transversely between the first and third side
top
flap sections 82, 102. The center section 62 extends outwardly and upwardly
from the front panel 10, and the first and second side sections 64, 66 extend
rearwardly and outwardly from the center section 62 to the first and third
side top
flap sections 82, 102, respectively. The first and third side top flap
sections 82,
102 and the front top end panel 60 thereby form a spout 170 having an opening
172 at the top of the carton 200. The first and third side top flap sections
82, 102
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form first and second side walls of the spout 170, and the front top end panel
60
forms a front spout lip 174. The second and fourth side top flap sections 84,
104
are adhesively secured such that they are not opened with the spout 170.
Contents
within the carton 200 can be poured out of the spout 170 though the opening
172.
The lip 174 is configured to direct the flow of contents as they are poured
out of
the spout 170.
[00042] FIG. 7 shows the carton 200 in an optional reclosed configuration. In
the configuration of FIG. 7, the top panel 150 is reclosed after the carton
has been
used in the open configuration of FIGS. 5 and 6. The first and third side top
flap
sections 82, 102 are folded inwardly along the fold line 16 such that the
third side
top flap section 102 partially overlaps the first side top flap section 82.
The center
section 62 of the spout 170 is folded downwardly about the fold line 16, and
the
first and second side sections 64, 66 of the spout 170 are folded inwardly and
downwardly over the center section 62 along the respective oblique fold lines
63,
65. Thus, the lip 174 of the spout 170 extends downwardly, substantially
parallel
to the front panel 10. The tear line 144 in the front panel is broken to form
an
arcuate opening 145, and the outer tip 175 (FIGS. 5-7) of the spout 170 is
secured
in the opening 145, thereby closing the spout 170 and securing the top panel
150
in a closed configuration. The fold lines 144, 146 allow the front panel 10 to
flex
in the vicinity of the fold lines 144, 146 to facilitate inserting the tip 175
into the
opening 145. The spout 170 may be reopened by reversing the closing procedure.
[00043] FIG. 8 shows a carton blank 202 according to another embodiment,
from which a carton 400 (FIG. 9) may be erected. The blank 202 is similar to
the
blank 1 of the previous embodiment, with the exception that the blank 202
includes first and second side top flaps 300, 310 instead of the previously
described side top flaps 80, 100, and the front panel 10a may lack (or it may
include) the closure feature 140 of the previous embodiment.
[00044] The first side top flap 300 includes a first break line 306 extending
substantially vertically from the laterally extending outer edge of the first
side top
flap 300, and a third oblique fold line 308 extending obliquely from the first
break
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line 306 to an intersection point of the fold lines 12, 16. The break line 306
and
the third oblique fold line 308 divide the first side top flap 300 into a
first side top
flap section 302 and a second side top flap section 304. The second side top
flap
310 includes a second break line 316 extending substantially vertically from
the
laterally extending outer edge of the second side top flap 310, and a fourth
oblique
fold line 318 extending obliquely from the second break line 316 to an
intersection point of the fold lines 14, 16. The break line 316 and the fourth
oblique fold line 318 divide the second side top flap 300 into a third side
top flap
section 312 and a fourth side top flap section 314. The first side top flap
300
includes adhesive regions 88 in the first side top flap section 302 for
releasably
adhesively attaching the first and third side top flap sections 302, 312
together.
[00045] FIG. 9 shows the carton 400 erected, in a closed configuration, from
the blank 202. The carton 400 is similar to the carton 200 of the previous
embodiment, with the exception of the top panel 350, and optionally the front
panel 10a. As shown in FIG. 8, the first and second side top flaps 300, 310
are
folded along the fold line 16 such that the second side top flap 310 partially
overlaps the first side top flap 300 and the first and second side top flaps
300, 310
lie over the front top end panel 60 and the rear top end flap 120. The first
and
third side top flap sections 302, 312 of the first and second side top flaps
300, 310,
respectively, may be releasably secured together by adhesive material at the
adhesive regions 88, and the second and fourth side top flap sections 304, 314
may be more permanently secured together (such as by a more permanent
adhesive attachment) such that the first and second side top flaps 300, 310
form
the top panel 350 extending between the first and second side panels 20, 30
and
the front and rear panels 10, 170. The top panel 350 extends substantially
perpendicularly to the front panel 10, the rear panel 170, and the first and
second
side panels 20, 30. The first and third side top flap sections 302, 312 are
positioned adjacent to each other in the top panel 350 to form a partially
detachable portion of the top panel 350.
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[00046] FIG. 10 shows the carton 400 in an open configuration for pouring
contents therefrom. In the open configuration, the first and third side top
flap
sections 302, 312 are separated from the second and fourth top panel sections
304,
314, respectively, along the respective break lines 306, 316 and are folded
outwardly along the fold line 16 so as to extend transversely to the second
and
fourth side top flap sections 304, 314, which form a remainder of the top
panel
350. The center section 62 of the front top end panel 60 is folded outwardly
along
the fold lines 16, 63, 65, and the first and second side sections 64, 66 of
the front
top end panel 60 are folded outwardly along the fold lines 63, 65, 12, 14,
such that
the front top end panel 60 extends transversely between the first and third
side top
flap sections 302, 312. The center section 62 extends outwardly and upwardly
from the front panel 10a, and the first and second side sections 64, 66 extend
rearwardly and outwardly from the center section 62 to the first and third
side top
flap sections 302, 312, respectively. The first and third side top flap
sections 302,
312 and the front top end panel 60 thereby form a spout 370 having an opening
372 at the top of the carton 400. The first and third side top flap sections
302, 312
form first and second side walls of the spout 370, and the front top end panel
60
forms a front spout lip 374. The second and fourth side top flap sections 304,
314
are adhesively secured such that they are not opened with the spout 370.
Contents
within the carton 400 can be poured out of the spout 370 though the opening
372.
The lip 374 is configured to direct the flow of contents as they are poured
out of
the spout 370.
[00047] FIG. 11 shows the carton 400 in an example of a reclosed
configuration, upon the carton being reclosed from the open configuration of
FIG.
10. The first and third side top flap sections 302, 312 are folded inwardly
along
the fold line 16 such that the third side top flap section 312 partially
overlaps the
first side top flap section 302, the center section 62 of the spout 370 is
folded
rearwardly about the fold line 16, and the first and second side sections 64,
66 of
the spout 370 are folded inwardly and forwardly over the center section 62
along
the respective oblique fold lines 63, 65. Thus, the lip 374 of the spout 370
extends
rearwardly, substantially parallel to the top panel 350, and lies below the
first and
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third side top flap sections 302, 312. The top panel 350 and the spout 370 are
thereby secured in a closed configuration. Other reclosed configurations,
generally such as the one discussed for the prior embodiment, may be used.
[00048] FIG. 12 shows a carton blank 502 according to yet another
embodiment, from which a carton 600 (FIG. 13) may be erected. The blank 502
includes the front panel lOa from the embodiment of FIGS. 8-11, and the first
side
panel 20, the second side panel 30, the rear closure flap 40, the rear flap
50, and
the first bottom flap 90 of the two previous embodiments.
[00049] A first side top flap 540 and the first bottom flap 90 are foldably
connected to the first side panel 20 along the fold lines 16, 18,
respectively. A
front top end flap 560 and a front bottom end flap 570 are foldably connected
to
the front panel 10a along the fold lines 16, 18, respectively. A second side
top
flap 550 and a second bottom flap 510 are foldably connected to the second
side
panel 30 along the fold lines 16, 18, respectively. A rear top end flap 520
and a
rear bottom end flap 530 are foldably connected to the rear flap 50 along the
fold
lines 16, 18, respectively.
[00050] The first side top flap 540 includes a first break line 546 extending
substantially vertically from the laterally extending outer edge of the first
side top
flap 540, and a third arcuate fold line 547 extending from the first break
line 546.
The first break line 546 and the third arcuate fold line 547 divide the first
side top
flap 540 into a first side top flap section 542 and a second side top flap
section
544. The second side top flap 550 includes a second break line 556 extending
substantially vertically from the laterally extending outer edge of the second
side
top flap 550, and a fourth arcuate fold line 557 extending from the second
break
line 556. The second break line 556 and the fourth arcuate fold line 557
divide
the second side top flap 550 into a third side top flap section 552 and a
fourth side
top flap section 554. The second side top flap 550 includes adhesive regions
88 in
the third side top flap section 552 for releasably adhesively attaching the
first and
third side top flap sections 542, 552 of the first and second side top flaps
540, 550,
respectively, together in overlapping fashion.
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[00051] Still referring to FIG. 12, the rear top end flap 520 includes an
adhesive region 522 for securing the first side top flap 540 to the rear top
end flap
520. Because the second side top flap 550 is configured lie over the rear top
end
flap 520 and the first side top flap 540 is configured to overlap the second
side top
flap 550 in the erected carton 600, the second side top flap 550 includes a
corner
cutout section 553 configured to allow the adhesive region 552 to contact the
first
side top flap 540 in the carton 600. The front bottom end flap 570 and the
rear
bottom end flap 530 include respective adhesive regions 572, 532 for securing
the
front bottom end flap 570 and the rear bottom end flap 530 to the first bottom
flap
90. Because the second bottom flap 510 is configured lie over the front bottom
end flap 570 and the rear bottom end flap 530, and the first bottom flap 90 is
configured to overlap the second bottom flap 510 in the erected carton 600,
the
second bottom flap 510 includes corner cutout sections 512 configured to allow
the adhesive regions 572, 532 to contact the first bottom flap 90 in the
carton 600.
[00052] The front top end flap 560 includes a center section 562, a first side
section 564 foldably connected to the center section 562 along a first arcuate
fold
line 563, and a second side section 566 foldably connected to the center
section
562 along a second arcuate fold line 565. The arcuate fold lines 563, 565
extend
between the fold line 16 and the laterally extending outer edge of the front
top end
flap 560, and converge towards each other as they extend from the fold line
16.
[00053] Referring to FIGS. 13 and 14, the blank 502 can be erected into a
carton 600. In FIGS. 13 and 14, the carton 600 is in a closed configuration.
Referring to FIG. 13, the carton 600 includes the front panel 10a, side panels
20,
30 and a rear panel 170 (not shown in this embodiment) of the previous
embodiment of FIGS. 8-11. The front top end flap 560 is folded inwardly along
the fold line 16, and the first and second side sections 564, 566 of the front
top
end flap 560 are folded inwardly along the respective oblique fold lines 563,
565
such that the front top end flap 560 is folded towards the interior of the
carton 600
and the first and second side sections 564, 566 extend transversely to the
center
section 562. The rear top end flap 520 is folded inwardly along the fold line
16
towards the interior of the carton 200. The first and second side top flaps
540, 550
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are folded along the fold line 16 such that the first side top flap 540
partially
overlaps the second side top flap 550 and the first and second side top flaps
540,
550 lie over the front top end panel 560 and the rear top end flap 520. The
first
and third side top flap sections 542, 552 of the first and second side top
flaps 540,
550, respectively, may be releasably secured together by adhesive material at
the
adhesive regions 88, and the second and fourth side top flap sections 544, 554
may be more securely attached together, such as by a more permanent adhesive.
The first side top flap 540 may be secured to the rear top end flap 520 via
attachment to the adhesive region 522. The first and second side top flaps
540,
550 thereby form a top panel 555 extending between the first and second side
panels 20, 30 and the front and rear panels 10a, 170. The top panel 555
extends
substantially perpendicularly to the front panel 10a, the rear panel 170, and
the
first and second side panels 20, 30.
[00054] Referring to FIG. 14, the front bottom end flap 570 and the rear
bottom
end flap 530 are folded inwardly along the fold line 18, and the first and
second
bottom flaps 90, 510 are folded inwardly along the fold line 18 over the front
bottom end flap 570 and the rear bottom end flap 530 such that the first
bottom
flap 90 overlaps the second bottom flap 510. The first bottom flap 90 is
secured
to the front bottom end flap 570 and the rear bottom end flap 530 at adhesive
regions 572, 532. The first and second bottom flaps 90, 510 form a bottom
panel
515 extending substantially parallel to the top panel 555.
[00055] FIGS. 15 and 16 show the carton 600 in an open configuration for
pouring contents therefrom. In the open configuration, the first and third
side top
flap sections 542, 552 are partially separated from the second and fourth top
panel
sections 544, 554, respectively, along the respective break lines 546, 556 and
are
folded outwardly along the third and fourth arcuate fold lines 547, 557,
respectively, so as to extend transversely to the second and fourth side top
flap
sections 544, 554, which form a remainder of the top panel 555. The front top
end
flap 560 is folded outwardly along the fold line 16 such that the front top
end
panel 560 extends upwardly between the first and third side top flap sections
542,
552. The center section 562 extends upwardly substantially parallel to front
panel
14
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10a, and the first and second side sections 564, 566 extend rearwardly and
substantially perpendicularly to the center section 562. The first and third
side top
flap sections 542, 552 and the front top end panel 560 thereby form a spout
590
having an opening 592 at the top of the carton 600. The first and third side
top
flap sections 542, 552 form first and second side walls of the spout 590, and
the
front top end panel 560 forms a front spout lip 594. The second and fourth
side
top flap sections 544, 554 are secured such that they do not open with the
spout
590. Contents within the carton 600 can be poured out of the spout 590 though
the opening 592. The lip 594 is configured to direct the flow of contents as
they
are poured out of the spout 590.
[00056] FIG. 17 shows the carton 600 in a reclosed configuration. In the
configuration of FIG. 17, the top panel 555 is reclosed after the carton has
been
used in the open configuration of FIGS. 15 and 16. The first and third side
top
flap sections 542, 552 are folded inwardly along the fold line 16 such that
the first
side top flap section 542 partially overlaps the third side top flap section
552, and
the lip 594 of the spout 590 is folded inwardly about the fold line 16,
beneath the
first and second side top flap sections 542, 552. Thus, the spout 590 and the
top
panel 550 are returned to a closed configuration.
[00057] FIG. 18 shows a carton blank 702 according to another embodiment,
from which a carton 800 (FIG. 19) may be erected. The blank 702 includes a
rear
panel 710, a first side panel 20, a second side panel 30, a front closure flap
704,
and a front flap 780. Horizontal fold lines 16, 18 form top and bottom edges,
respectively, of the panels 710, 20, 30 and the flaps 704, 780. The first and
second side panels 20, 30 are foldably connected to opposite sides of the rear
panel 710 along vertical fold lines 712, 714, respectively. The front closure
flap
704 is foldably connected to the first side panel 20 along a vertical fold
line 22.
The front flap 780 is foldably connected to the second side panel 30 along a
vertical fold line 32.
[00058] A first side top flap 740 and a first bottom flap 790 are foldably
connected to the first side panel 20 along the fold lines 16, 18,
respectively. A
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rear top end flap 760 and a rear bottom end flap 770 are foldably connected to
the
rear panel 710 along the fold lines 16, 18, respectively. A second side top
flap
750 and a second bottom flap 110 are foldably connected to the second side
panel
30 along the fold lines 16, 18, respectively. A front top end flap 720 and a
front
bottom end flap 730 are foldably connected to the front flap 780 along the
fold
lines 16, 18, respectively.
[00059] The rear panel 710 includes arcuate fold lines 713, 717 extending
adjacent to the fold lines 712, 714, respectively, and defining respective
gripping
regions 715, 719 at the lateral edges of the rear panel 710.
[00060] The front top end flap 720 includes a center section 722, a first side
section 724 foldably connected to the center section 722 along a first arcuate
fold
line 723, and a second side section 726 foldably connected to the center
section
722 along a second arcuate fold line 725. The arcuate fold lines 723, 725
extend
between the fold line 16 and the laterally extending outer edge of the front
top end
flap 720, and converge towards each other as they extend from the fold line
16.
[00061] Still referring to FIG. 18, the first side top flap 740 includes a
first
break line 746 (e.g., a cut line and/or score line) extending substantially
vertically
from the laterally extending outer edge of the first top flap 740, and a third
arcuate
fold line 747 extending from the first break line 746. The first break line
746 and
the third arcuate fold line 747 divide the first top flap 740 into a first top
flap
section 742 and a second top flap section 744. The second top flap 750
includes a
second break line 756 (e.g., a cut line and/or score line) extending
substantially
vertically from the laterally extending outer edge of the second top flap 750,
and a
fourth arcuate fold line 757 extending from the second break line 756. The
second break line 756 and the fourth arcuate fold line 757 divide the second
side
top flap 750 into a third side top flap section 752 and a fourth side top flap
section
754. The first side top flap 740 includes adhesive regions 88 in the first
side top
flap section 742 for releasably adhesively attaching the first and third side
top flap
sections, 742, 752 of the first and second side top flaps 740, 750,
respectively,
together in overlapping fashion. The first and third side top flap sections
742, 752
16
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include respective V-notches 745, 755 in their laterally extending outer
edges.
The V-notches 745, 755 are configured to interlockingly engage each other, as
will be described later.
[00062] The rear top end flap 760 includes an adhesive region 762 for securing
the second side top flap 750 to the rear top end flap 760. Because the second
side
top flap 750 is configured overlap the first side top flap 740 and the first
side top
flap 740 is configured to lie over the rear top end flap 760 in the erected
carton
800, and the first side top flap 740 includes a corner cutout section 746
configured
to allow the adhesive region 762 to contact the second side top flap 750 in
the
carton 800. The rear bottom end flap 770 and the front bottom end flap 730
include respective adhesive regions 772, 732 for securing the rear bottom end
flap
770 and the front bottom end flap 730 to the second bottom flap 110. Because
the
first bottom flap 790 is configured lie over the front bottom end flap 730 and
the
rear bottom end flap 770, and the second bottom flap 110 is configured to
overlap
the first bottom flap 790 in the erected carton 800, the first bottom flap 790
includes corner cutout sections 795 configured to allow the adhesive regions
732,
772 to contact the second bottom flap 110 in the carton 800.
[00063] Referring to FIGS. 19 and 20, the blank 702 can be erected into the
carton 800. In FIGS. 19 and 20, the carton 800 is in a closed configuration.
Referring to FIG. 19, the side panels 20, 30 are folded inwardly along the
fold
lines 712, 714, respectively, such that the first and second side panels 20,
30
extend substantially parallel to each other and perpendicularly to the rear
panel
710. The front closure flap 704 is folded inwardly along the fold line 22 so
as to
extend substantially parallel to the rear panel 710. The front flap 780 is
folded
inwardly along the fold line 32 so as to overlap the front closure flap 704
and
extend substantially parallel to the rear panel 710. The front flap 780 and
the rear
closure flap 704 together from a front panel 785 of the carton 800, extending
substantially parallel to the rear panel 710. The front closure flap 704 may
be
adhesively or otherwise attached to the inner side of the front panel 780. The
rear
panel 710 is creased along the fold lines 713, 717 such that the gripping
regions
17
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715, 719 extend transversely to the remainder of the rear panel 710, thereby
facilitating gripping of the rear panel 710 by a person's hand.
[00064] Still referring to FIG. 19, the front top end flap 720 is folded
inwardly
along the fold line 16 towards the interior of the carton, and the first and
second
side sections 724, 726 of the front top end flap 720 are folded inwardly along
the
respective oblique fold lines 723, 725 such that that the front top end flap
720 is
folded towards the interior of the carton 800 and the first and second side
sections
724, 726 extend transversely to the center section 722. The rear top end flap
760
is folded inwardly along the fold line 16 towards the interior of the carton
800.
The first and second top flaps 740, 750 are folded along the fold line 16 such
that
the second side top flap 750 partially overlaps the first side top flap 740
and the
first and second side top flaps 740, 750 lie over the front top end flap 720
and the
rear top end flap 760. The first and third side top flap sections 742, 752 of
the
first and second side top flaps 740, 750, respectively, may be releasably
secured
together by adhesive material at the adhesive regions 88, and the second and
fourth side top flap sections 744, 754 may be more permanently secured
together,
such as by a more permanent adhesive material. The second side top flap 750
may be secured to the rear top end flap 760 at the adhesive region 762. Thus,
the
first and second side top flaps 740, 750 form a top panel 758 extending
between
the first and second side panels 20, 30 and the front and rear panels 785,
710. The
top panel 758 extends substantially perpendicularly to the front panel 785,
the rear
panel 710, and the first and second side panels 20, 30. The first and third
side top
flap sections 742, 752 are positioned adjacent to each other in the top panel
758 to
form a partially detachable portion of the top panel 758.
[00065] Referring to FIG. 20, the rear bottom end flap 770 and the front
bottom
end flap 730 are folded inwardly along the fold line 18, and the first and
second
bottom flaps 790, 110 are folded inwardly along the fold line 18 over the rear
bottom end flap 770 and the front bottom end flap 730 such that the second
bottom flap 110 overlaps the first bottom flap 790. The second bottom flap 110
is
secured to the rear bottom end flap 770 and the front bottom end flap 730 at
18
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adhesive regions 772, 732. The first and second bottom flaps 790, 110 form a
bottom panel 796 extending substantially parallel to the top panel 758.
[00066] FIGS. 21 and 22 show the carton 800 in an open configuration for
pouring contents out of the carton. In the open configuration, the first and
third
side top flap sections 742, 752 are partially separated from the second and
fourth
side top flap sections 744, 754, respectively, along the respective break
lines 746,
756 and are folded outwardly along the third and fourth arcuate fold lines
747,
757, respectively, so as to extend transversely to the second and fourth side
top
flap sections 744, 754, which form a remainder of the top panel 758. The front
top end flap 720 is folded outwardly along the fold line 16 such that the
front top
end panel 720 extends upwardly between the first and third side top flap
sections
742, 752. The center section 722 extends upwardly substantially parallel to
front
panel 780, and the first and second side sections 724, 726 extend rearwardly
and
substantially perpendicularly to the center section 722. The first and third
side top
flap sections 742, 752 and the front top end panel 720 thereby form a spout
797
having an opening 798 at the top of the carton 800. The first and third side
top
flap sections 742, 752 form first and second side walls of the spout 797, and
the
front top end panel 720 forms a front spout lip 799. The second and fourth
side
top flap sections 744, 754 are secured such that they do not open with the
spout
797. Contents within the carton 800 can be poured out of the spout 797 though
the opening 798. The lip 799 is configured to direct the flow of contents as
they
are poured out of the spout 797.
[00067] FIG. 23 shows the carton 800 in a reclosed configuration, wherein the
carton is reclosed after being used in the open configuration shown in FIGS.
21
and 22. In the reclosed configuration, the first and third side top flap
sections 742,
752 are folded inwardly along the fold line 16 such that the first side top
flap
section 742 partially overlaps the third side top flap section 752, and the
front
spout lip 799 is folded inwardly about the fold line 16, beneath the first and
third
side top flap sections 742, 752. The V-notches 745, 755 are interlocked with
each
other to secure the first and third side top flap sections 742, 752 together.
Thus,
the spout 797 and the top panel 758 are returned to a closed configuration.
19
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[00068] FIG. 24 illustrates a carton blank 902, according to another
embodiment, that can be erected into a carton 1000 (FIG. 25). The blank 902 is
similar to the blank 702, except that the blank 902 includes first and second
side
top flaps 840, 850 in place of the previous first and second side top flaps
740, 750,
a front top end flap 820 in place of the previous front top end flap 720, and
a
second bottom flap 810 in place of the previous second bottom flap 110. The
second bottom flap 810 is similar to the previous bottom flap 710, but
includes a
notch 812 in its laterally extending outer edge to facilitate gripping of the
second
bottom flap 810.
[00069] The front top end flap 820 includes a center section 822, a first side
section 824 foldably connected to the center section 822 along a first arcuate
fold
line 823, a second side section 826 foldably connected to the center section
822
along a second arcuate fold line 825, and a bottom section 828 positioned
below
the center section 822 and the first and second sections 824, 826, and
connected
thereto along a concave fold line 827. The arcuate fold lines 823, 825 extend
from the concave fold line 827 towards the laterally extending outer edge of
the
front top end flap 820, and converge towards each other as they extend from
the
concave fold line 827.
[00070] Still referring to FIG. 24, the first side top flap 840 includes a
first
break line 846 (e.g., a cut line and/or score line) extending substantially
vertically
from the laterally extending outer edge of the first side top flap 840, and a
third
arcuate fold line 847 extending from the first break line 846. The first break
line
846 and the third arcuate fold line 847 divide the first side top flap 840
into a first
top flap section 842 and a second top flap section 844. The second top flap
850
includes a second break line 856 (e.g., a cut line and/or score line)
extending
substantially vertically from the laterally extending outer edge of the second
top
flap 850, and a fourth arcuate fold line 857 extending from the second break
line
856. The second break line 856 and the fourth arcuate fold line 857 divide the
second top flap 850 into a third top flap section 82 and a fourth top flap
section
854. The second side top flap 850 includes adhesive regions 88 in the third
side
top flap section 852 for releasably adhesively attaching the first and third
side top
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flap sections 842, 852 together in overlapping fashion. The first and third
side top
flap sections 842, 852 include respective notches 845, 855 in their laterally
extending outer edges. The notches 845, 855 are configured facilitate opening
of
the first and third flap sections 845, 855 as will be described later. Because
the
first side top flap 840 is configured to overlap the second side top flap 850
and the
second side top flap 850 is configured to lie over the rear top end flap 760
in the
erected carton 1000, the second side top flap 850 includes a corner cutout
section
859 that allows the first side top flap 840 to be attached to the adhesive
region
762.
[00071] FIGS. 25 and 26 show the carton 1000 erected, in a closed
configuration, from the blank 902. The carton 1000 is similar to the previous
carton 800, except that the carton 1000 includes a top panel 858 (FIG. 25) and
a
bottom panel 896 (FIG. 26). Referring to FIG. 25, the front top end flap 820
is
folded inwardly along the fold line 16 towards the interior of the carton
1000, and
the first and second side sections 824, 826 of the front top end flap 820 are
folded
inwardly along the respective oblique fold lines 823, 825 such that that the
front
top end flap 820 is folded towards the interior of the carton 1000 and the
first and
second side sections 824, 826 extend transversely to the center section 822
and the
bottom section 828. The rear top end flap 760 is folded inwardly along the
fold
line 16 towards the interior of the carton 1000. The first and second side top
flaps
840, 850 are folded along the fold line 16 such that the first side top flap
840
partially overlaps the second side top flap 850 and the first and second side
top
flaps 840, 850 lie over the front top end flap 820 and the rear top end flap
760.
The first and third side top flap sections 842, 852 of first and second side
top flaps
840, 850, respectively, may be releasably secured together by adhesive
material at
the adhesive regions 88, and the second and fourth side top flap sections 844,
854
may be more permanently secured together, such as by a more permanent
adhesive material. The first side top flap 840 may be secured to the rear top
end
flap 760 at the adhesive region 762. Thus, the first and second side top flaps
840,
850 form a top panel 858 extending between the first and second side panels
20,
30 and the front and rear panels 785, 710. The top panel 858 extends
substantially
21
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perpendicularly to the front panel 785, the rear panel 710, and the first and
second
side panels 20, 30. The first and third side top flap sections 842, 852 are
positioned adjacent to each other in the top panel 858 to form a partially
detachable portion of the top panel 858. The notch 845 in the first side top
flap
section 842 is exposed in the top panel 858, allowing the first side top flap
section
842 to be easily gripped by a person's hand.
[00072] Referring to FIG. 26, the rear bottom end flap 770 and the front
bottom
end flap 730 are folded inwardly along the fold line 18, and the first and
second
bottom flaps 790, 810 are folded inwardly along the fold line 18 over the rear
bottom end flap 770 and the front bottom end flap 730 such that the second
bottom flap 810 overlaps the first bottom flap 790, and the notch 812 is
exposed.
The second bottom flap 810 is secured to the rear bottom end flap 770 and the
front bottom end flap 730 at adhesive regions 772, 732. The first and second
bottom flaps 790, 810 form a bottom panel 896 extending substantially parallel
to
the top panel 858.
[00073] FIG. 28 shows the carton 1000 in an open configuration for pouring
contents out of the carton. In the open configuration, the first and third
side top
flap sections 842, 852 are partially separated from the second and fourth top
panel
sections 844, 854, respectively, along the respective break lines 846, 856 and
are
folded outwardly along the third and fourth arcuate fold lines 847, 857,
respectively, so as to extend transversely to the second and fourth side top
flap
sections 844, 854, which form a remainder of the top panel 858. The center
section 822, the first side section 824 and the second side section 826 of the
front
top end flap 820 are folded upwardly along the concave fold line 827 such that
the
bottom section 828 of the front top end panel 720 extends substantially
horizontally (perpendicularly to the front panel 780), and the center section
822,
the first side section 824 and the second side section 826 extend upwardly
from
the bottom section 828 between the first and third side top flap sections 842,
852.
The first and second side sections 824, 826 extend rearwardly and transversely
to
the center section 822. The first and third side top flap sections 842, 852
and the
front top end panel 820 thereby form a spout 897 having an opening 898 at the
top
22
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of the carton 1000. The first and third side top flap sections 842, 852 form
first
and second side walls of the spout 897, and the front top end panel 820 forms
a
front spout lip 899. The second and fourth side top flap sections 844, 854 are
secured such that they do not open with the spout 897. Contents within the
carton
1000 can be poured out of the spout 797 though the opening 898. The lip 899 is
configured to direct the flow of contents as they are poured out of the spout
897.
[00074] FIG. 29 shows the carton 1000 in a reclosed configuration, wherein the
carton 1000 is reclosed after being used in the open configuration shown in
FIG.
28. In the reclosed configuration, the first and third side top flap sections
842, 852
are folded inwardly along the fold line 16 such that the first side top flap
section
842 partially overlaps the third side top flap section 852, and the center
segment
and the first and second side segments 824, 826 of the front spout lip 899 are
folded downwardly about the concave fold line 827, beneath the first and third
side top flap sections 842, 852. The notches 845, 855 may be interlocked with
each other to secure the first and third top flap sections 842, 852 together.
Thus,
the spout 897 and the top panel 858 are returned to a closed configuration.
[00075] In some embodiments described and shown herein, the second side top
flap partially overlaps the first side top flap when the carton is in the
closed
configuration, such that the third and fourth side top flap sections partially
overlap
the first and second side top flap sections. In other embodiments, the first
side top
flap partially overlaps the second side top flap when the carton is in the
closed
configuration, such that the first and second side top flap sections partially
overlap
the third and fourth side top flap sections. It should be appreciated,
however, that
in any of the embodiments, it is possible to reverse the overlapping
arrangement
of the first and second side top flaps, and thus the overlapping arrangement
of the
side top flap sections.
[00076] In some instances in the foregoing, attaching parts together is
described with reference to specific features and methods. However, the
attaching
may be carried out in any suitable manner, such as, but not limited to,
through the
use of adhesive material.
23
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[00077] The term "break line" is used throughout the specification. A break
line may be any suitable line of disruption, such as a tear line and/or a cut
line
(e.g., a slit). The term "fold line" is used throughout the following
description. It
is noted that, unless stated otherwise, the term "fold line" can include any
at least
somewhat line-like arranged, although not necessarily straight, form of
weakening
that facilitates folding therealong; and a tear line can be any at least
somewhat
line-like arranged, although not necessarily straight, form of weakening that
facilitates tearing therealong. More specifically, but not for the purpose of
narrowing the scope of the present invention, conventional fold lines include:
a
crease, such as formed by folding; a score line, such as formed with a blunt
scoring knife, or the like, which creates a crushed portion in the material
along the
desired line of weakness; a slit that extends partially into the material
along the
desired line of weakness, and/or a series of spaced apart slits that extend
partially
into and/or completely through the material along the desired line of
weakness; or
various combinations of these features. The term "tear line" is also used
throughout the specification. More specifically, but not for the purpose of
narrowing the scope of the present invention, conventional tear lines include
a slit
that extends partially into the material along the desired line of weakness, a
series
of spaced apart slits that extend partially into and/or completely through the
material along the desired line of weakness, or any combination of these
features.
[00078] The foregoing disclosure provides illustrative embodiments of the
invention and is not intended to be limiting. As understood by those of skill
in the
art, the overall invention encompasses other embodiments not specifically
enumerated herein. For example, although the cartons shown in the form of a
parallelpipedal box, they can alternatively be shaped differently, and
likewise the
various detachable sections, panel sections, panels and flaps described herein
can
be shaped and arranged differently.
24
