Package with recloseable dispenser

• US 8,002,171 B2
• Filed: 07/24/2009
• Issued: 08/23/2011
• Est. Priority Date: 07/25/2008
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Pinkstone, Felicia A., Ryan, Michael D., Learn, Angela E.
• Primary Examiner(s): Newhouse; Nathan J
• Assistant Examiner(s): DEMEREE, CHRISTOPHER R
• Application Number:
  US12/508,741
• Publication Number:
  US 20100019022A1
• Time in Patent Office: 760 Days
• Field of Search: 229/131.1, 229/126, 229/133, 229/125.34, 294/262
• US Class Current: 229/122
• CPC Class Codes: B65D 5/563 Laminated linings; Coatings
• CPC Class Codes: B65D 5/606 Bags or bag-like tubes loosely glued to the wall of a "tubular" container
• CPC Class Codes: B65D 5/705 Tearable flaps defined by score-lines or incisions provided in the body of a tubular container made of a single blank
• CPC Class Codes: B65D 77/0433 the inner container being a tray or like shallow container, not formed by folding or erecting one or more blanks B65D81/3862 takes precedence
• CPC Class Codes: B65D 77/10 Container closures formed after filling
• CPC Class Codes: B65D 77/20 by applying separate lids or covers , i.e. flexible membrane or foil-like covers
• CPC Class Codes: Y10T 29/49817 with other than ancillary treating or assembling

Abstract

A package having a dispenser with reclosable features. The package has a reclosable flap that is positionable between an open position for accessing products within the package and a closed position preventing access to products within the package.

Claims

1. A package for holding a product, comprising:

a carton comprising a plurality of panels, the plurality of panels including a dispenser panel;

an inner layer of material attached to an inner surface of the dispenser panel; and

a dispenser flap comprising

an inner flap defined in the inner layer of material;

an outer flap defined in the dispenser panel, the outer flap being attached to the inner flap, and the outer flap being releasably attached to a portion of the inner layer of material adjacent the inner flap; and

an intermediate layer of material disposed between the inner layer of material and the dispenser panel, the intermediate layer of material being adhesively attached to the inner layer of material and the dispenser panel so as to attach the inner layer of material to the dispenser panel;

wherein, in order to open the dispenser flap to provide access to an interior of the carton, the outer flap is at least partially detachable from the dispenser panel and the portion of the inner layer of material adjacent the inner flap, and the inner flap is at least partially detachable from the inner layer of material; and

wherein the outer flap can be reattached to the portion of the inner layer of material adjacent the inner flap in order to close the dispenser flap after the dispenser flap has been opened.

2. The package of claim 1, wherein the inner flap comprises a tab extending through an opening in the dispenser panel, and wherein the tab forms an actuator operable to at least partially detach the inner flap from the inner layer of material.

3. The package of claim 2, wherein the dispenser flap is configured such that at least partially detaching the inner flap from the inner layer of material causes the outer flap to at least partially detach from the dispenser panel and the portion of the inner layer of material adjacent the inner flap.

4. The package of claim 1, wherein the outer flap and the inner flap are at least partially defined by respective tear lines, and wherein the outer flap is at least partially detachable from the dispenser panel and the inner flap is at least partially detachable from the inner layer of material at the respective tear lines.

5. The package of claim 1, wherein the inner layer of material is adhesively attached to the inner surface of the dispenser panel, and the outer flap is adhesively, releasably attached to the portion of the inner layer of material adjacent the inner flap.

6. The package of claim 1, wherein the inner layer of material substantially covers an entire surface area of the inner surface of the dispenser panel.

7. The package of claim 1, wherein the carton comprises a front panel, a back panel, side panels and end panels, and wherein the front panel is the dispenser panel.

8. The package of claim 1, wherein the inner layer of material is a film.

9. The package of claim 8, wherein the inner layer of material is substantially transparent, and wherein the outer flap comprises an opening through which a portion of the inner layer of material is visible.

10. The package of claim 1, wherein the outer flap has a surface area that is greater than a surface area of the inner flap.

11. The package of claim 1, comprising a tray secured to the carton, the tray comprising a bottom wall, side walls and a top opening, wherein:

the dispenser panel and the inner layer of material extend over the top opening; and

the inner layer of material is attached to the tray such that the dispenser panel forms a lid for sealing the top opening.

12. The package of claim 11, wherein:

the dispenser panel is a top panel of the carton;

the carton comprises

a bottom panel having a bottom opening, the bottom panel being spaced from the top panel and extending substantially parallel to the top panel,

a first side panel connected to the top panel and the bottom panel, and extending substantially perpendicular to the top panel,

a second side panel connected to the top panel and extending substantially perpendicular to the top panel,

a third side panel connected to the top panel and extending substantially perpendicular to the top panel,

a fourth side panel connected to the top panel and extending substantially perpendicular to the top panel,

a first closure flap connected to the second side panel and secured in face-to-face contact with the bottom panel,

a second closure flap connected to the third side panel and secured in face-to-face contact with the bottom panel, and

a third closure flap connected to the fourth side panel and secured in face-to-face contact with the bottom panel;

the bottom wall and portions of the side walls extend outwardly from the carton through the bottom opening; and

the tray comprises a flange extending from a top of the side walls and positioned between the top panel and the bottom panel.

13. The package of claim 12, comprising a plurality of retention flaps connected to the bottom panel and positioned adjacent the bottom opening, wherein the retention flaps engage the side walls.

14. The package of claim 12, wherein the first, second and third closure flaps are adhesively attached to the bottom panel.

15. The package of claim 11, wherein the carton is constructed of paperboard and the tray is constructed of plastic.

16. The package of claim 1, wherein:

the dispenser flap comprises an intermediate flap defined in the intermediate layer of material, the intermediate flap being adhesively attached to the outer flap and the inner flap so as to attach the outer flap to the inner flap, and the intermediate flap being releasably attached to the portion of the inner layer of material adjacent the inner flap so as to releasably attach the outer flap to the portion of the inner layer of material adjacent the inner flap;

the intermediate flap is at least partially detachable from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap in order to open the dispenser flap to provide access to the interior of the carton; and

the intermediate flap can be reattached to the portion of the inner layer of material adjacent the inner flap in order to close the dispenser flap after the dispenser flap has been opened.

17. The package of claim 16, wherein the intermediate flap has a surface area that is greater than a surface area of the inner flap.

18. The package of claim 16, wherein the intermediate flap comprises a tab extending through an opening in the dispenser panel, and wherein the tab forms an actuator for at least partially detaching the intermediate flap from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap.

19. The package of claim 18, wherein the dispenser flap is configured such that detaching the intermediate flap from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap causes the outer flap and the inner flap to at least partially detach from the dispenser panel and the inner layer of material, respectively.

20. The package of claim 16, wherein:

the outer flap, the intermediate flap and the inner flap are at least partially defined by respective tear lines; and

the outer flap is at least partially detachable from the dispenser panel, the intermediate flap is at least partially detachable from the intermediate layer of material, and the inner flap is at least partially detachable from the inner layer of material at the respective tear lines.

21. The package of claim 16, wherein the intermediate layer of material and the inner layer of material are adhered together by adhesive.

22. The package of claim 16, wherein the intermediate layer of material substantially covers an entire surface area of the inner surface of the dispenser panel.

23. The package of claim 16, wherein the intermediate layer of material is a biaxially oriented polypropylene material.

24. The package of claim 16, wherein the intermediate layer of material and the inner layer of material are films.

25. The package of claim 24, wherein the intermediate layer of material and the inner layer of material are substantially transparent, and wherein the outer flap comprises an opening through which portions of the inner and intermediate layers of material are visible.

26. The package of claim 25, wherein the inner layer of material is a bag and the intermediate layer of material is a film.

27. The package of claim 1, wherein the dispenser flap is partially separable from the package and pivotable with respect to the package in order to open the dispenser flap.

28. A package assembly for forming a package for holding a product, the package assembly comprising a carton blank assembly comprising:

a carton blank including a plurality of panels foldable to form a carton, the plurality of panels including a dispenser panel;

an inner layer of material attached to an inner surface of the dispenser panel; and

a dispenser flap comprising

an inner flap defined in the inner layer of material and at least partially detachable from the inner layer of material;

an outer flap defined in the dispenser panel and at least partially detachable from the dispenser panel, the outer flap being attached to the inner flap, and the outer flap being releasably attached to a portion of the inner layer of material adjacent the inner flap; and

an intermediate layer of material disposed between the inner layer of material and the dispenser panel, the intermediate layer of material being adhesively attached to the inner layer of material and the dispenser panel so as to attach the inner layer of material to the dispenser panel.

29. The package assembly of claim 28, wherein the inner flap comprises a tab extending through an opening in the dispenser panel, and wherein the tab forms an actuator operable to at least partially detach the inner flap from the inner layer of material.

30. The package assembly of claim 29, wherein the dispenser flap is configured such that at least partially detaching the inner flap from the inner layer of material causes the outer flap to at least partially detach from the dispenser panel and the portion of the inner layer of material adjacent the inner flap.

31. The package assembly of claim 28, wherein the outer flap and the inner flap are at least partially defined by respective tear lines, and wherein the outer flap is at least partially detachable from the dispenser panel and the inner flap is at least partially detachable from the inner layer of material at the respective tear lines.

32. The package assembly of claim 28, wherein the inner layer of material is adhesively attached to the inner surface of the dispenser panel, and the outer flap is adhesively, releasably attached to the portion of the inner layer of material adjacent the inner flap.

33. The package assembly of claim 28, wherein the inner layer of material substantially covers an entire surface area of the inner surface of the dispenser panel.

34. The package assembly of claim 28, wherein the carton comprises a front panel, a back panel, side panels and end panels, and wherein the front panel is the dispenser panel.

35. The package assembly of claim 28, wherein the inner layer of material is a film.

36. The package assembly of claim 35, wherein the inner layer of material is substantially transparent, and wherein the outer flap comprises an opening through which a portion of the inner layer of material is visible.

37. The package assembly of claim 28, wherein the outer flap has a surface area that is greater than a surface area of the inner flap.

38. The package assembly of claim 28, comprising a tray configured to be secured to the carton, the tray comprising a bottom wall, side walls, and a top opening defined within a perimeter of the top edge, wherein:

the dispenser panel is configured to extend over the top opening; and

the inner layer of material is configured to be attached to the tray such that the dispenser panel forms a lid for sealing the top opening.

39. The package assembly of claim 38, wherein:

the dispenser panel is a top panel of the carton blank;

the carton blank comprises

a bottom panel having a bottom opening, the bottom panel being foldable so as to be spaced from and parallel to the top panel,

a first side panel connected to the top panel and the bottom panel, the first side panel being foldable to extend substantially perpendicular to the top panel,

a second side panel connected to the top panel, the second side panel being foldable to extend substantially perpendicular to the top panel,

a third side panel connected to the top panel, the third side panel being foldable to extend substantially perpendicular to the top panel,

a fourth side panel connected to the top panel, the fourth side panel being foldable to extend substantially perpendicular to the top panel,

a first closure flap connected to the second side panel, the first closure flap being foldable into face-to-face contact with the bottom panel,

a second closure flap connected to the third side panel, the second closure flap being foldable into face-to-face contact with the bottom panel, and

a third closure flap connected to the fourth side panel, the third closure flap being foldable into face-to-face contact with the bottom panel;

the bottom wall and portions of the side walls are configured to be received through the bottom opening; and

the tray comprises a flange extending from a top of the side walls and configured to be positioned between the top panel and the bottom panel.

40. The package assembly of claim 39, comprising a plurality of retention flaps connected to the bottom panel and positioned adjacent the bottom opening, wherein the retention flaps engage the side walls.

41. The package assembly of claim 39, wherein the first, second and third closure flaps are adhesively attached to the bottom panel.

42. The package assembly of claim 38, wherein the carton blank is constructed of paperboard and the tray is constructed of plastic.

43. The package assembly of claim 28, wherein:

the dispenser flap comprises an intermediate flap defined in the intermediate layer of material and at least partially detachable from the intermediate layer of material, the intermediate flap being adhesively attached to the outer flap and the inner flap so as to attach the outer flap to the inner flap, and the intermediate flap being releasably attached to the portion of the inner layer of material adjacent the inner flap so as to releasably attach the outer flap to the portion of the inner layer of material adjacent the inner flap.

44. The package assembly of claim 43, wherein the intermediate flap has a surface area that is greater than a surface area of the inner flap.

45. The package assembly of claim 43, wherein the intermediate flap comprises a tab extending through an opening in the dispenser panel, and wherein the tab forms an actuator for at least partially detaching the intermediate flap from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap.

46. The package assembly of claim 45, wherein the dispenser flap is configured such that detaching the intermediate flap from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap causes the outer flap and the inner flap to at least partially detach from the dispenser panel and the inner layer of material, respectively.

47. The package assembly of claim 43, wherein:

the outer flap, the intermediate flap and the inner flap are at least partially defined by respective tear lines; and

the outer flap is at least partially detachable from the dispenser panel, the intermediate flap is at least partially detachable from the intermediate layer of material, and the inner flap is at least partially detachable from the inner layer of material at the respective tear lines.

48. The package assembly of claim 43, wherein the intermediate layer of material and the inner layer of material are adhered together by adhesive.

49. The package assembly of claim 43, wherein the intermediate layer of material substantially covers an entire surface area of the inner surface of the dispenser panel.

50. The package assembly of claim 43, wherein the intermediate layer of material is a biaxially oriented polypropylene material.

51. The package assembly of claim 43, wherein the intermediate layer of material and the inner layer of material are films.

52. The package assembly of claim 51, wherein the intermediate layer of material and the inner layer of material are substantially transparent.

53. The package assembly of claim 43, wherein:

the dispenser flap is configured to be opened by

at least partially detaching the outer flap from the dispenser panel,

at least partially detaching the intermediate flap from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap, and

at least partially detaching the inner flap from the inner layer of material; and

the dispenser flap is configured to be closed after being opened by reattaching the intermediate flap to the portion of the inner layer of material adjacent the inner flap.

54. The package assembly of claim 28, wherein the inner layer of material is a bag and the intermediate layer of material is a film.

55. The package assembly of claim 28, wherein the dispenser flap is partially separable from the carton assembly and pivotable with respect to the carton assembly in order to open the dispenser flap.

56. The method of claim 55, wherein:

the inner flap comprises an actuator tab protruding from an opening in the dispenser panel;

pulling the actuator tab at least partially causes the inner flap to at least partially detach from the inner layer of material and the outer flap to at least partially detach from the dispenser panel and the portion of the inner layer of material adjacent the inner flap.

57. The package assembly of claim 28, wherein:

the dispenser flap is configured to be opened by

at least partially detaching the outer flap from the dispenser panel and the portion of the inner layer of material adjacent the inner flap, and

at least partially detaching the inner flap from the inner layer of material; and

the dispenser flap is configured to be closed after being opened by reattaching the outer flap to the portion of the inner layer of material adjacent the inner flap.

60. The method of claim 57, wherein closing the dispenser flap comprises pivoting the dispenser flap prior to reattaching the outer flap to the portion of the inner layer of material adjacent the inner flap.

58. A method of removing contents from a package, comprising:

providing a package comprising

a carton comprising a plurality of panels, the plurality of panels including a dispenser panel,

an inner layer of material attached to an inner surface of the dispenser panel, and

a dispenser flap comprising

an inner flap defined in the inner layer of material, and

an outer flap defined in the dispenser panel, the outer flap being attached to the inner flap, and the outer flap being releaseably attached to a portion of the inner layer of material adjacent the inner flap; and

an intermediate layer of material disposed between the inner layer of material and the dispenser panel, the intermediate layer of material being adhesively attached to the inner layer of material and the dispenser panel so as to attach the inner layer of material to the dispenser panel;

opening the dispenser flap to provide access to an interior of the carton, wherein opening the dispenser flap comprises at least partially detaching the inner flap from the inner layer of material and at least partially detaching the outer flap from the dispenser panel and the portion of the inner layer of material adjacent the inner flap;

removing contents from the package through the dispenser opening; and

c

losing the dispenser flap, wherein closing the dispenser flap comprises reattaching the outer flap to the portion of the inner layer of material adjacent the inner flap.

59. The method of claim 58, wherein opening the dispenser flap comprises pivoting the dispenser flap.

61. The method of claim 58, wherein the outer flap is releaseably attached to the portion of the inner layer of material adjacent the inner flap with adhesive, and wherein the adhesive is used for reattaching the outer flap to the portion of the inner layer of material adjacent the inner flap.

62. The method of claim 58, wherein:

the outer flap and the inner flap are at least partially defined by respective tear lines; and

at least partially detaching the inner flap from the inner layer of material and at least partially detaching the outer flap from the dispenser panel and the portion of the inner layer of material adjacent the inner flap comprises breaching the respective tear lines.

63. The method of claim 58, wherein:

the package comprises a tray secured to the carton, the tray comprising a bottom wall, side walls and a top opening defined within a perimeter of the top edge;

the dispenser panel and the inner layer of material extend over the top opening; and

the inner layer of material is attached to the tray such that the dispenser panel forms a lid for sealing the top opening.

64. The method of claim 58, wherein:

the dispenser flap comprises an intermediate flap defined in the intermediate layer, the intermediate flap being adhesively attached to the outer flap and the inner flap so as to attach the outer flap to the inner flap, and the intermediate flap being releaseably attached to the portion of the inner layer of material adjacent the inner flap so as to releaseably attach the outer flap to the portion of the inner layer of material adjacent the inner flap;

at least partially detaching the outer flap from the portion of the inner layer of material adjacent the inner flap comprises at least partially detaching the intermediate flap from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap; and

reattaching the outer flap to the portion of the inner layer of material adjacent the inner flap comprises reattaching the intermediate flap to the portion of the inner layer of material adjacent the inner flap.

65. The method of claim 64, wherein the intermediate flap is releaseably attached to the portion of the inner layer of material adjacent the inner flap with adhesive, and wherein the adhesive is used for reattaching the intermediate flap to the portion of the inner layer of material adjacent the inner flap.

66. The method of claim 64, wherein:

the intermediate flap comprises an actuator tab protruding from an opening in the dispenser panel;

pulling the actuator tab at least partially causes the inner flap to at least partially detach from the inner layer of material, the intermediate flap to at least partially detach from the intermediate layer of material and the portion of the inner layer of material adjacent the inner flap, and the outer flap to at least partially detach from the dispenser panel.

67. The method of claim 66, wherein:

the outer flap, the intermediate flap and the inner flap are at least partially defined by respective tear lines; and

at least partially detaching the inner flap from the inner layer of material, at least partially detaching the intermediate flap fromthe intermediate layer of material and the portion of the inner layer of material adjacent the inner flap, and at least partially detaching the outer flap from the dispenser panel comprise breaching the respective tear lines.

68. A package for holding a product, comprising:

a carton comprising a plurality of panels, the plurality of panels including a dispenser panel;

an inner layer of material attached to an inner surface of the dispenser panel; and

a dispenser flap comprising

an inner flap defined in the inner layer of material and at least partially detachable from the inner layer of material;

an outer flap defined in the dispenser panel and at least partially detachable from the dispenser panel, the outer flap being attached to the inner flap, and the outer flap being releaseably attached to a portion of the inner layer of material adjacent the inner flap; and

an intermediate layer of material disposed between the inner layer of material and the dispenser panel, the intermediate layer of material being adhesively attached to the inner layer of material and the dispenser panel so as to attach the inner layer of material to the dispenser panel.

69. The package of claim 68, comprising a tray secured to the carton, the tray comprising a bottom wall, side walls and a top opening, wherein:

the dispenser panel and the inner layer of material extend over the top opening; and

the inner layer of material is attached to the tray such that the dispenser panel forms a lid for sealing the top opening.

70. The package of claim 68, wherein:

the dispenser flap comprises an intermediate flap defined in the intermediate layer and at least partially detachable from the intermediate layer of material, the intermediate flap being adhesively attached to the outer flap and the inner flap so as to attach the outer flap to the inner flap, and the intermediate flap being releasably attached to the portion of the inner layer of material adjacent the inner flap so as to releasably attach the outer flap to the portion of the inner layer of material adjacent the inner flap.