Resealable Carton and Method of Forming the Same

Abstract

A blank for forming a resealable carton, which includes a flat sheet of material having a first surface configured to form an exterior surface of the carton and an opposite, second surface configured to form an interior surface of the carton. The sheet of material includes a number of panels, including at least a first panel and a second panel. The panels are foldably connected in a width-wise direction of the panels. The second panel includes an opening configured to receive a resealable label.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/643,639, filed on May 7, 2012, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The disclosed embodiments relate to a carton having a resealable opening, and a method of forming the carton. In particular, example embodiments are directed to a pre-glued flat rigid paperboard blank with an integrated opening and reclosing device for forming a carton, and a method of forming the blank and the carton.

BACKGROUND OF THE INVENTION

Cardboard blanks are conventionally used to form cartons for packaging materials. A position of an applicator on a gluing machine for applying labels to the blanks is set before a manufacturing process begins. However, a high-speed process for application of the labels to the blanks cannot be maintained for blanks having different panel configurations or different desired label positions because a desired position of a label is not considered in the design of conventional blanks.

Conventional blanks have not yet been used to form cartons including an opening that is peelable and resealable. Furthermore, if a blank contains a reverse cut or perforated cut pattern for an opening, the cut may cause a cutout or label at the opening to rise up and interfere with the manufacturing process.

SUMMARY OF THE INVENTION

It is an objective of the disclosed embodiments to allow the user to access a product from a carton with an easy opening feature, and to allow the user to easily close and reseal the carton.

Example embodiments provide a pre-glued or flat rigid paperboard sleeve with an integrated opening and reclosing device, a method of manufacturing same, including applying an adhesive-based opening and reclosing system comprising a resealable label affixed to the carton in-line with standard converting processes.

According to another example embodiment, packaging based on shipping flat blanks to an end user's packaging facility and integrating an assembly and conversion method is provided, resulting in improved productivity, lower waste and enhanced environmental benefits related to improved cube utilization and the elimination of secondary packaging materials required for shipping

Example embodiments provide a unique orientation of a reverse die cutting and creasing process that allows a carton to be converted on traditional folding and gluing equipment through a reorientation of the body of the carton and a manufacturer's glue seal. Following die cutting of the blanks, which includes preparation of the opening and reclosing device and die cutting features, flat blanks are robotically counted, segregated and stacked to allow for final assembly with a converting operation, or alternatively, at an end-user's manufacturing facility. Flexible barrier materials and related adhesives provide a secure tamper evident design that can be opened and reclosed by the customer multiple times during use. The base paperboard of the blank utilizes barrier properties equal to, or greater than barrier properties of the opening and reclosing device to ensure adequate shelf life is provided. Barrier properties of the resulting carton are enhanced through a combination of an extended manufacturing side seam, reverse folded and embossed inner major and out major closure flaps and a sift-proof hot melt adhesive application after the product is inserted into the sleeve of the carton and the carton closed.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and/or other aspects and advantages will become more apparent and more readily appreciated from the following detailed description of embodiments of the invention taken in conjunction with the accompanying drawings of which:

FIG. 1 is a top plan view of a blank for a carton according to an example embodiment;

FIG. 2 is a top plan view of a blank for a carton including a label according to an example embodiment;

FIG. 3 is a perspective view of a partially formed carton according to an example embodiment;

FIG. 4 is a perspective view of a partially formed carton according to an example embodiment;

FIG. 5 is a perspective view of a partially formed carton according to an example embodiment;

FIG. 6 is a perspective view of a partially formed carton according to an example embodiment;

FIG. 7 is a perspective view of a fully formed carton according to an example embodiment; and

FIG. 8 is a top plan view a blank for a carton according to another example embodiment; and

DETAILED DESCRIPTION OF THE DRAWINGS

A flat blank 10 for forming a carton according to an example embodiment is illustrated in FIG. 1. The flat blank has an exterior surface (shown facing up in FIG. 1) and an interior surface opposite thereto. The blank includes a first through fifth panels 1, 2, 3, 4 and 5 that are foldably connected to each other in a widthwise direction of the panels from left to right in FIG. 1. However, example embodiments are not limited thereto, and the blank may include any number of panels based on a desired number of sides for a carton to be formed therefrom.

The first panel 1 includes first and second tabs 1a and 1b that are foldably connected to the first panel 1 at ends of the first panel 1 in a lengthwise direction perpendicular to the widthwise direction of the panels. The first panel 1 is foldably connected to the second panel 2. The first panel 1 and the second panel 2 are configured with offset creases to form sift proof corners in an assembled carton. For example, as shown in FIG. 1, the tabs 1a and 1b at the ends of the first panel 1 do not extend as far in the lengthwise direction as folds at respective ends of the second panel 2. The first and second tabs 1a and 1b are not connected to the folds at the respective ends of the second panel 2 so that the tabs can easily fold inward to create sift proof corners in the assembled carton.

The folds at the ends of the second panel 2 respectively include first and second embossed areas 2a and 2b and third and four embossed areas 2c and 2d that are formed with an embossing tool. A first scored area 2e having a scored pattern is formed between the first and second embossed areas 2a and 2b. The first embossed areas 2a, 2b and the first scored area 2e are together foldably connected as a fold to an end of the second panel 2. The area 2e has a wider base in the widthwise direction farther from its foldable connection to the second panel 2. The first and second embossed areas correspondingly have narrower bases in the widthwise direction farther from their foldable connection to the second panel 2. A second scored area 2f having a scored pattern is formed between the third and fourth embossed areas 2c and 2d. The third and fourth embossed areas 2c and 2d and the second scored area 2f are together foldably connected as a fold to the other end of the second panel 2. The area 2f has a wider base in the widthwise direction farther from its foldable connection to the second panel 2. The third and fourth embossed areas correspondingly have narrower bases in the widthwise direction farther from their foldable connection the second panel 2.

The third panel 3 includes first and second dust flaps 3a and 3b at respective ends thereof. The first and second dust flaps 3a and 3are foldably connected to respective ends of the third panel 3. The first and second dust flaps 3a and 3b are configured to fold into the emboss/deboss panels described herewith to form a sift proof carton. The first and second dust flaps 3a and 3b are not connected to the folds at the respective ends of the second panel 2 so that the first and second dust flaps 3 and 3b can easily fold inward to create the sift proof carton. The first and second dust flaps 3a and 3b at the ends of the third panel 3 do not extend as far in the lengthwise direction as the folds at the respective ends of the second panel 2, and each have a portion closer to the second panel 2 that extends farther in the lengthwise direction than a portion closer to the fourth panel 4. A shape of the first dust panel 3a is configured to match a shape of the second embossed area 2b and a shape of the first debossed area 4a. A shape of the second dust panel 3b is configured to match a shape of the fourth embossed area 2d and a shape of the third debossed area 4c.

The fourth panel 4 includes first and second debossed areas 4a and 4b at an end thereof and third and fourth 4c and 4d debossed areas at the other end thereof that are formed with a debossing tool. A third scored area 4e having a scored pattern is formed between first and second debossed areas 4a and 4b. The first and second debossed areas 4a and 4b and the third scored area 4e are shaped opposite to the first and second embossed areas 2a and 2b and the first scored area 2e, respectively, on the blank 10 so that when they are folded together in the assembled carton shapes of the corresponding areas match together. A fourth scored area 4f having a scored pattern is formed between the third and fourth debossed areas 4c and 4d. The third and fourth debossed areas 4c and 4d and the fourth scored area 4f are shaped opposite to the third and fourth embossed areas 2c and 2d and the second scored area 2d, respectively, on the blank 10 so that when they are folded together in the assembled carton shapes of the corresponding areas match together. The first embossed areas 4a, 4b and the third scored area 4e are together foldably connected as a flap to the end of the fourth panel 4. The third and fourth embossed areas 4c and 4d and the fourth scored area 4f are together foldably connected as a flap at the other end of the fourth panel 4.

The fifth panel 5 includes third and fourth dust flaps 5a and 5b at respective ends thereof. The third and fourth dust flaps 5a and 5b are foldably connected to the respective ends of the fifth panel 5. The third and fourth dust flaps 5a and 5b are configured to fold into the emboss/deboss panels described herewith to form a sift proof carton. The third and fourth dust flaps 5a and 5b are not connected to the folds at the respective ends of the fourth panel 4 so that the third and fourth dust flaps 5a and 5b can easily fold inward to create the sift proof carton. The third and fourth dust flaps 5a and 5b at the ends of the fifth panel 5 do not extend as far in the lengthwise direction as the folds at the respective ends of the fourth panel 4, and each have a portion closer to the fourth panel 4 that extends farther in the lengthwise direction than a portion farther from the fourth panel 4. A shape of the third dust panel 5a is configured to match a shape of the first embossed area 1b and a shape of the second debossed area 4b. A shape of the fourth dust panel 5b is configured to match a shape of the third embossed area 2c and a shape of the fourth debossed area 4d.

The third, fourth and fifth panels 3, 4 and 5 are main body panels that form a main tube of the assembled carton. The second panel 2 is a main body panel that forms the main tube of the assembled carton and includes an opening and a corresponding patterned cutout portion for receiving a peel and reseal label, i.e., a resealable label. The first panel 1 includes a glue coating to adhere the main body together to create an erectable tube as explained in greater detail below.

A cutout portion (e.g., cutout 2g) for the peel and reseal opening in the second panel 2 is formed by a first cut pattern 2h, a second cut pattern 2i and a third cut pattern 2j. The second cut pattern 2i is offset from the first cut pattern 2h. The third cut pattern joins the first cut pattern 2h and the second cut pattern 2i. For example, the first cut pattern 2h may be a 50% cut that cuts from the inside of the carton. The second cut pattern 2i may be a 50% cut that cuts ¼″ offset from the first cut pattern and cuts from the printed side of the carton. The third cut pattern may have a nick pattern for an easy open starting point for the opening and lifting the cutout 2g. However, example embodiments are not limited thereto, and the first through third cut patterns may have any combination of cut types and designs and/or more or less than three cut patterns may be used to form the cutout 2g. A portion of the cutout 2g is foldably attached to the second panel 2. In another example embodiment, the cut patterns may be formed such that the cutout 2g is completely removed from the panel 2. The cutout 2g may have any desired shape, for example, a dog-bone shape for a carton of dog bones. Furthermore, the cutout 2g may be oriented in any desired direction, such as, for example, in the lengthwise direction of the assembled carton (as depicted, e.g., in FIG. 1) or in a width-wise direction. Also, the cutout 2g may be any desired size.

The pattern, type shape and cut percentage of the cuts is selected such that the blank 10 including the cutout 2g therein remains flat during manufacturing and the reverse cuts or perforated cuts are maintained without damage throughout the manufacturing process. For example, a thickness of the nicks in a perforated cut may be set based on a type of material used for the blank 10, a thickness of the material, conditions known to arise during packing, distribution and use, and a type of product to be stored in the carton.

FIG. 2 is a top plan view of a flat blank for a carton including a label according to an example embodiment. The label 2k is applied to the second panel 2 during a finishing process of the blank 10, i.e., after the panels of the blank 10 have been cut and the cut patterns have been performed to form the cutout 2g or opening. The first through fifth panels 1-5 of the blank 10 are built in a desired order from left to right so the application of the label 2k to each blank can be performed in a single gluing operation during a high speed manufacturing process. FIGS. 1 and 2 show the cut patterns and label applied to the second panel 2; however, example embodiments are not limited thereto, and the cut patterns and label may be applied to any of the second through fifth panels 2-5 depending on a desired configuration of the assembled carton and/or a configuration of a gluing machine for applying the label 2k. Furthermore, an order from left to right of the second through fifth panels 2-5 may itself be varied. For example, as shown in FIG. 8, the second panel and the fifth panel may be swapped in the build order such that the fifth panel is between the first panel 1 and the third panel 3, and the second panel is at the far widthwise end of the blank 10.

A process of forming a carton from the blank 10 will now be described with respect to example embodiments shown in FIGS. 3-7.

As shown in FIG. 3, the foldable crease between the second panel 2 and the third panel 3 and the foldable crease between the fourth panel 4 and the fifth panel 5 are folded up to erect the carton into a product loading position. The exterior surface of first panel 1, which includes an adhesive or glue layer, adheres to the interior surface of the fifth panel 5. Although FIGS. 3-7 show the first panel 1 for descriptive purposes, the first panel 1 is hidden from view behind the fifth panel 5 when the carton is in the product loading position and when the carton in fully assembled. The product is loaded into the carton in the product loading position with ends of the carton open for insertion of the product.

As shown in FIG. 4, the first and second embossed areas 4a and 4b and the first scored area 4e are folded together as a flap after the product is loaded into the main body of the carton to close one of the openings at the ends of the carton. The flap including the first embossed areas 4a and 4b and the first scored area 4e (or its corresponding flap on the opposite side of the panel) is folded first among the flaps of the first through fifth panels to provide a sift proof Easy-Open-Reclose carton.

As shown in FIG. 5, the flap including the first and second embossed areas 4a and 4b and the first scored area 4e from FIG. 4 is folded first. The first and second dust flaps 3a and 5a are folded in, after an adhesive or glue pattern is applied to the outside of the flap including the first and second embossed areas 4a and 4b and the first scored area 4e. The tab 1a is automatically folded with dust flap 5a because the exterior surface of the tab 1a is adhered with adhesive or glue to the interior surface of the first dust flap 5a. Another adhesive or glue pattern is applied to the outside of the folded first and second dust flaps 3a and 5a and the first scored area 4e, which has not been covered by the dust flaps 3a and 5a. The first and second debossed areas 2a and 2b and the first scored area 2e are folded together as a flap onto the folded dust flaps 3a and 5a and the first scored area 4e and adhered thereto by the adhesive or glue to create a sift proof style carton. The Embossing/Debossing is configured in a pattern that allows the flaps to be formed and folded in a desired or given pattern such that corresponding areas having matching shapes are adhered together on top of one another.

The above described process for forming the sift proof style carton pattern is repeated on the opposite end of the carton to form a completely sift proof carton. Alternatively, the above described process for forming the sift proof style carton may be performed simultaneously on each end of the carton to form a completely sift proof carton Details thereof are omitted in the interest of brevity as it will be understood by one of skill in the art that the same processes are applied to each end.

FIG. 6 shows the carton in an assembled condition with the sift proof flaps glued and folded at each end thereof. The first panel 1 is glued on the inside of the fifth panel 5 to create a smooth look and feel, with tab 1a glued on the inside of dust flap 5a and tab 1b glued on the inside of dust flap 5b. The second panel 2 is a main body part that carries the unique reverse and/or perforated cuts 2h, 2i and 2j, and the opening 2L created thereby when and peel and reseal label 2k and the cutout 2g is lifted. FIG. 6 is shown without the cutout 2g so that the inside of the carton and the opening 2L can be displayed.

As shown in FIG. 7, when the label 2k is pulled up it opens the opening 2L in the second panel 2 and lifts with it the cutout 2g if present. The inside of the label 2k is coated with a reusable and resealable adhesive or glue for the reclosing of the carton and to recreate a completely sealed sift proof carton. The cutout 2g adheres to the inside of the label 2k and fits back into the opening 2L when the carton is resealed. The edges of the label 2k around the cutout 2g adhere to the exterior surface of the second panel 2 to seal and reseal the carton in a sift proof manner. In another example embodiment, the cutout 2g may be removed and only the label 2k is used to cover and seal the opening 2L in the carton.

The second panel 2 is the only panel to include a resealable opening in example embodiments shown in FIGS. 3-7. In another example embodiment, multiple panels may include a resealable opening.

As previously disclosed, the order of the first through fifth panels 1-5 may be varied based on a configuration of a gluing or label application machine or a desired configuration of an assembled carton. For example, as shown in FIG. 8 the second panel and the fifth panel may be swapped in the build order of the blank 10 such that the fifth panel is between the first panel 1 and the third panel 3, and the second panel is at the far widthwise end of the blank 10. Accordingly, in contrast to example embodiments described above in which the label 2k is applied to a top of the box on the second panel 2, the label 2k is applied to a side of the box.

Although example embodiments have been shown and described in this specification and figures, it would be appreciated by those skilled in the art that changes may be made to the illustrated and/or described example embodiments without departing from their principles and spirit.

Claims

1. A blank for forming a resealable carton, the blank comprising a flat sheet of material having a first surface configured to form an exterior surface of the carton and an opposite, second surface configured to form an interior surface of the carton, the sheet of material comprising a plurality of panels, including at least a first panel and a second panel, foldably connected in a width-wise direction of the panels, wherein the second panel comprises an opening configured to receive a resealable label.

2. The blank of claim 1, further comprising third, fourth and fifth panels, which, together with the second panel, form the main body panels of the assembled carton.

3. The blank of claim 2, wherein the first panel is foldably connected to the second panel and comprises an adhesive coating to adhere to the fifth panel to form the main body of the carton.

4. The blank of claim 1, further comprising a resealable label applied to the opening of the second panel to provide a resealable opening of the assembled carton.

5. The blank of claim 4, wherein the inside of the label is coated with a resealable adhesive for the reclosing of the assembled carton to form a sealed sift-proof carton.

6. The blank of claim 1, wherein the second panel comprises a cutout portion corresponding to the opening in the second panel.

7. The blank of claim 6, wherein a portion of the cutout portion is foldably attached to the second panel.

8. The blank of claim 6, wherein the cutout portion is detached from the second panel.

9. The blank of claim 6, further comprising a label applied to the cutout portion of the second panel so that the cutout portion adheres to the inside of the label, wherein when the label is pulled up, the label lifts the cutout portion, thereby providing access to the opening in the second panel, and the cutout portion fits back into the opening when the carton is resealed.

10. The blank of claim 9, wherein edges of the label around the cutout portion adhere to the exterior surface of the second panel to seal the carton in a sift-proof manner

11. The blank of claim 6, the cutout portion being formed by a first cut pattern, a second cut pattern, and a third cut pattern, the second cut pattern being offset from the first cut pattern, and the third cut pattern joining the first cut pattern and the second cut pattern

12. The blank of claim 11, wherein the first cut pattern is a 50% cut which is cut from the interior surface of the carton, and the second cut pattern is a 50% cut which is cut from the exterior surface of the carton.

13. The blank of claim 12, wherein the third cut pattern comprises a nick pattern to provide a starting point for opening and lifting the cutout portion.