US20130341384A1

US20130341384A1 - Resealable Carton and Method of Forming the Same

Info

Publication number: US20130341384A1
Application number: US13/888,962
Authority: US
Inventors: Raymond Fisher; Don Scott
Original assignee: Malnove Packaging Solutions
Current assignee: Malnove Packaging Solutions
Priority date: 2012-05-07
Filing date: 2013-05-07
Publication date: 2013-12-26

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 1 a and 1 b 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 1 a and 1 b 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 1 a and 1 b 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 2 a and 2 b and third and four embossed areas 2 c and 2 d that are formed with an embossing tool. A first scored area 2 e having a scored pattern is formed between the first and second embossed areas 2 a and 2 b. The first embossed areas 2 a, 2 b and the first scored area 2 e are together foldably connected as a fold to an end of the second panel 2. The area 2 e 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 2 f having a scored pattern is formed between the third and fourth embossed areas 2 c and 2 d. The third and fourth embossed areas 2 c and 2 d and the second scored area 2 f are together foldably connected as a fold to the other end of the second panel 2. The area 2 f 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 3 a and 3 b at respective ends thereof. The first and second dust flaps 3 a and 3are foldably connected to respective ends of the third panel 3. The first and second dust flaps 3 a and 3 b are configured to fold into the emboss/deboss panels described herewith to form a sift proof carton. The first and second dust flaps 3 a and 3 b 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 3 b can easily fold inward to create the sift proof carton. The first and second dust flaps 3 a and 3 b 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 3 a is configured to match a shape of the second embossed area 2 b and a shape of the first debossed area 4 a. A shape of the second dust panel 3 b is configured to match a shape of the fourth embossed area 2 d and a shape of the third debossed area 4 c.
The fourth panel 4 includes first and second debossed areas 4 a and 4 b at an end thereof and third and fourth 4 c and 4 d debossed areas at the other end thereof that are formed with a debossing tool. A third scored area 4 e having a scored pattern is formed between first and second debossed areas 4 a and 4 b. The first and second debossed areas 4 a and 4 b and the third scored area 4 e are shaped opposite to the first and second embossed areas 2 a and 2 b and the first scored area 2 e, 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 4 f having a scored pattern is formed between the third and fourth debossed areas 4 c and 4 d. The third and fourth debossed areas 4 c and 4 d and the fourth scored area 4 f are shaped opposite to the third and fourth embossed areas 2 c and 2 d and the second scored area 2 d, 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 4 a, 4 b and the third scored area 4 e are together foldably connected as a flap to the end of the fourth panel 4. The third and fourth embossed areas 4 c and 4 d and the fourth scored area 4 f 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 5 a and 5 b at respective ends thereof. The third and fourth dust flaps 5 a and 5 b are foldably connected to the respective ends of the fifth panel 5. The third and fourth dust flaps 5 a and 5 b are configured to fold into the emboss/deboss panels described herewith to form a sift proof carton. The third and fourth dust flaps 5 a and 5 b are not connected to the folds at the respective ends of the fourth panel 4 so that the third and fourth dust flaps 5 a and 5 b can easily fold inward to create the sift proof carton. The third and fourth dust flaps 5 a and 5 b 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 5 a is configured to match a shape of the first embossed area 1 b and a shape of the second debossed area 4 b. A shape of the fourth dust panel 5 b is configured to match a shape of the third embossed area 2 c and a shape of the fourth debossed area 4 d.
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 2 g) for the peel and reseal opening in the second panel 2 is formed by a first cut pattern 2 h, a second cut pattern 2 i and a third cut pattern 2 j. The second cut pattern 2 i is offset from the first cut pattern 2 h. The third cut pattern joins the first cut pattern 2 h and the second cut pattern 2 i. For example, the first cut pattern 2 h may be a 50% cut that cuts from the inside of the carton. The second cut pattern 2 i 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 2 g. 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 2 g. A portion of the cutout 2 g is foldably attached to the second panel 2. In another example embodiment, the cut patterns may be formed such that the cutout 2 g is completely removed from the panel 2. The cutout 2 g may have any desired shape, for example, a dog-bone shape for a carton of dog bones. Furthermore, the cutout 2 g 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 2 g 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 2 g 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 2 k 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 2 g 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 2 k 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 2 k. 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 4 a and 4 b and the first scored area 4 e 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 4 a and 4 b and the first scored area 4 e (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 4 a and 4 b and the first scored area 4 e from FIG. 4 is folded first. The first and second dust flaps 3 a and 5 a are folded in, after an adhesive or glue pattern is applied to the outside of the flap including the first and second embossed areas 4 a and 4 b and the first scored area 4 e. The tab 1 a is automatically folded with dust flap 5 a because the exterior surface of the tab 1 a is adhered with adhesive or glue to the interior surface of the first dust flap 5 a. Another adhesive or glue pattern is applied to the outside of the folded first and second dust flaps 3 a and 5 a and the first scored area 4 e, which has not been covered by the dust flaps 3 a and 5 a. The first and second debossed areas 2 a and 2 b and the first scored area 2 e are folded together as a flap onto the folded dust flaps 3 a and 5 a and the first scored area 4 e 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 1 a glued on the inside of dust flap 5 a and tab 1 b glued on the inside of dust flap 5 b. The second panel 2 is a main body part that carries the unique reverse and/or perforated cuts 2 h, 2 i and 2 j, and the opening 2L created thereby when and peel and reseal label 2 k and the cutout 2 g is lifted. FIG. 6 is shown without the cutout 2 g so that the inside of the carton and the opening 2L can be displayed.
As shown in FIG. 7, when the label 2 k is pulled up it opens the opening 2L in the second panel 2 and lifts with it the cutout 2 g if present. The inside of the label 2 k 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 2 g adheres to the inside of the label 2 k and fits back into the opening 2L when the carton is resealed. The edges of the label 2 k around the cutout 2 g 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 2 g may be removed and only the label 2 k 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 2 k is applied to a top of the box on the second panel 2, the label 2 k 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.