Gable top container with perforated opening arrangement

Abstract

A gable top container for storing an item is provided. The gable top container has a bottom made from at least one bottom forming panel. A side is formed from at least one side forming panel that extends from the bottom. A pair of gusset panels and a pair of gable panels extend from the side. The gable panels are arranged with respect to the gusset panels to form a gable top. Each of the gable panels has a fin that defines perforations that allow for the removal of at least a portion of the fin in order to effect opening of the container from one end of the gable panels to an opposite end of the gable panels. The container may be opened in order for a fork or spoon to be used in order to remove contents therefrom.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figs. in which:

FIG. 1 is a plan view of a unitary blank that is used to form a gable top container in accordance with one exemplary embodiment of the present invention.

FIG. 2 is a perspective view of the gable top container formed by the blank of FIG. 1 in the closed position.

FIG. 3 is a perspective view of the gable top container formed by the blank of FIG. 1 in an open position in which the entire end of the gable top container is opened.

FIG. 4 is a perspective view of the gable top container formed by the blank of FIG. 1 in an open position in which a spout is formed.

FIG. 5 is a perspective view of a gable top container in the closed position in accordance with one exemplary embodiment of the present invention.

FIG. 6 is a plan view of a unitary blank that is used to form a gable top container in accordance with an alternative exemplary embodiment of the present invention.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.

It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

The present invention provides for a gable top container 10 with a pair of fins 32 and 38 at the top of the container 10 that include perforations 44 and 46. A user of the container 10 may tear the fins 32 and 38 along the perforations 44 and 46 in order to remove upper portions 34 and 40 of the fins 32 and 38. The perforated opening arrangement allows access through the entire end of the container 10. The interior of the container 10 can be accessed to allow a user to remove contents with the use of a fork or spoon. The perforated opening arrangement is configured in such a manner that the end of the container 10 may be opened relatively quickly with little effort and tearing of the paperboard that makes up the container 10.

FIG. 1 shows a paperboard blank 12 that can be used to form the container 10 in accordance with one exemplary embodiment of the present invention. The paperboard making up the blank 12 is generally rendered liquid impervious through application of a thermoplastic material such as polyethylene. The thermoplastic material is typically applied to both the front and back of the blank 12. The use of a thermoplastic coating may also achieve other benefits by preventing the entry or exit of odors or oxygen. Additionally, the thermoplastic coating may serve as a mechanism with which to seal the container 10 through heat and pressure during formation. The blank 12 is provided with a number of score lines such as the one represented by score line 64. The blank 12 can be folded along the score lines into the shape of a container 10 as shown in FIG. 2 and held into the desired shape through the geometry of the folds along with the sealing of various portions of the container 10 through the application of heat and pressure.

Referring to FIGS. 1 and 2, the blank 12 includes a plurality of side forming panels 14, 16, 18 and 20 that make up the side 84 of the container 10 when formed. A plurality of bottom forming panels 56, 58, 60 and 62 are present to likewise form the bottom 82 of container 10. The formation of the side 84 and bottom 82 of the container 10 from the various panels mentioned is commonly known in the art. Briefly, a side seam 22 is provided and is located adjacent the side forming panel 20 and bottom forming panel 62. The side seam 22 may be adhered to the side forming panel 14 and the bottom forming panel 56 during formation of the container 10. The blank 12 can be bent along various score lines so that the bottom forming panels 56, 58, 60 and 62 are folded into the bottom 82 of the container 10. The panels 56, 58, 60 and 62 lock into one another and form a bottom 82 that is multi-layered at certain locations. Heat and pressure may be applied to the panels 56, 58, 60 and 62 and side seam 22 to securely form the bottom 82 and sides 84 of the container 10. In one embodiment, heat is applied to the thermoplastic coating of the paperboard at various strategic locations that are designated as adhesion points. Next, the blank 12 is bent into the shape of container 10 and a sealing pressure is applied to the heated points in order to fuse the thermoplastic material to form a liquid impervious seal and effect closure of the bottom 82 and side 84 of the container 10. It is to be understood that the disclosed arrangement of forming the bottom 82 and side 84 of the container 10 is exemplary and that other designs are possible in accordance with other embodiments of the present invention.

The first side forming panel 14 is attached to a gusset panel 24. The gusset panel 24 includes a plurality of score lines that allow the gusset panel 24 to be folded in a desired configuration during formation of the container 10. The gusset panel 24 forms an end of the top of the container 10 and is inwardly disposed into an inverted V shape. Another gusset panel 28 is also included and is attached to the third side forming panel 18. Gusset panel 28 likewise has a plurality of score lines formed thereon that allow the gusset panel 28 to be bent in a desired manner to form an end of the top of the container 10 that is both inverted and V-shaped. The gusset panels 24 and 28 may be designed in any manner commonly known in the construction of gable top containers 10. For example, the gusset panels 24 and 28 may be provided as those shown in U.S. Pat. No. 4,813,546, the entire contents of which are incorporated by reference herein in their entirety for all purposes.

A gable panel 26 is located between gusset panels 24 and 28. The top of the gable panel 26 has a fin 32. The fin 32 defines perforations 44 that in turn demarcate an upper portion 34 of the fin 32 and a lower portion 36 of fin 32. Fin 32 has a height 52 that is measured from a score line 48 to an edge 86 of fin 32. The perforations 44 extend substantially in a linear direction parallel to score line 48. The perforations 44 may be located any distance from the score line 48. In one embodiment, the perforations 44 are located at the midpoint of the height 52 of fin 32. Alternatively, the perforations 44 may be located on fin 32 so as to be disposed at one third of the height 52 of fin 32 so that the upper portion 34 has twice the height of the lower portion 36. In a further embodiment, the perforations 44 are located at the same height of the fin 32 as an upper edge 66 of the gusset panel 24 and an upper edge 68 of the gusset panel 28. In this regard, the upper edges 66 and 68 contact opposite sides of the fin 32, and the perforations 44 are located in the height 52 direction of the fin 32 at the same point as the contact points of the upper edges 66 and 68 to fin 32. In still other embodiments, the perforations 44 may be located from one fourth to three fourths the distance of height 52 from the score line 48. In yet other embodiments, the perforations 44 may be located anywhere up to seven eighths the height 52 of fin 32 from score line 48.

Gable panel 30 also includes a fin 38 that defines perforations 46. Perforations 46 separate an upper portion 40 of fin 38 from a lower portion 42 of fin 38. Perforations 46 extend in a substantially linear orientation parallel to a score line 50 that designates the bottom of fin 38. Fin 38 has a height 54 that extends from score line 50 to an edge 88 of the fin 38. Perforations 46 may be located at any point in the height 54 direction of fin 38. For example, perforations 46 may be located one half or one third of height 54 from score line 50. Further, perforations 46 may be located with respect to the upper edge 68 of the gusset panel 28 and to an upper edge 70 of side seam 22. In this regard, perforations 46 may be located at the same point in the height 54 direction as the contact points of upper edges 68 and 70 to fin 38. In other embodiments, the perforations 46 may be located from one fourth to three fourths the distance of height 54 from the score line 50. In yet other embodiments, the perforations 46 may be located anywhere up to seven eighths the height 54 of fin 38 from score line 50. Gusset panel 24, gusset panel 28, gable panel 26 and gable panel 30 along with a portion of the side seam 22 remain as part of the side 84 of container 10 until after filling the container 10 with product. At such time, these components are then formed into the top of container 10.

In order to construct the container 10, the upper portions of the side seam 22 can be adhered to the gusset panel 24. The side seam 22 may be adhered, for instance, through the use of heat and pressure. The bottom 82 and side 84 of the container 10 may then be formed. Various top score lines may then be pre-bent. The side 84 and the top of the container 10 may be in a square or rectangular shape and the container 10 may be filled with product. Once the container 10 is filled with product, the gable top of the container 10 may be constructed by folding the gusset panels 24 and 28 in addition to the gable panels 26 and 30 along the various score lines into the structure shown in FIG. 2. The perforations 44 and 46 may be located at the apex of the inverted V shaped portion of the gable top formed by gable panels 26 and 30 in some embodiments or above the apex in other embodiments.

The fins 32 and 38 can be adhered to one another in order to seal and close the top of container 10. In this regard, heat and pressure may be applied to the upper portions 34 and 40 of fins 32 and 38 so that the upper portions 34 and 40 are adhered to one another while the lower portions 36 and 42 are not adhered. The bond strength between upper portions 34 and 40 is selected in order to create a strong enough seal to keep the top of the container 10 closed and to prevent product within the container 10 from escaping. The container 10 may be constructed in order to be of any volumetric capacity. For example, the container 10 may be an eight ounce carton in accordance with one embodiment. In accordance with other exemplary embodiments, the container 10 may be from a four to a sixteen ounce container 10, a thirty two ounce container 10, a sixty four ounce container 10, a four ounce to a one hundred twenty eight ounce container 10, or a gallon container 10.

A user of the container 10 may grasp the upper portions 34 and 40 and pull in order to tear the fins 32 and 38 at the perforations 44 and 46. Removal of upper portions 34 and 40 results in opening of the container 10 as shown in FIG. 3. Here, the lower portions 36 and 42 of fins 32 and 38 are not adhered to one another and therefore separate after tearing of perforations 44 and 46. Likewise, the gusset panels 24 and 28 are not adhered to one another or to the gable panels 26 and 30 and separate upon removal of the upper portions 34 and 40. In this regard, the gable panels 26 and 30 may separate completely from one another along their length. The gable panels 26 and 30 may therefore open along their length. The top of the container 10 may then be further unfolded, if necessary, to completely open the top of the container 10 as shown in FIG. 3. In such a configuration, the entire end of the container 10 is opened to allow access therein. The upper edges 66 and 68 of the gusset panels 24 and 28 are generally aligned with the top of the lower portions 36 and 42 of fins 32 and 38 so as to form a container 10 with a substantially even top rim. However, it is to be understood that in other embodiments that the top of the lower portions 36 and 42 may be above or below the upper edges 66 and 68. The container 10 may be opened so that the perimeter formed by the upper edges 66 and 68 and the tops of lower portions 36 and 42 define a perimeter that is the same size as the perimeter defined by the bottom 82.

Opening of the entire end of the container 10 allows the user to have sufficient space to remove contents of the container 10 with a fork or spoon. Such a configuration may be advantageous when the container 10 is used for holding food items such as soup that require a utensil for removal. Alternatively, the container 10 may be used for holding dehydrated potatoes or other food items. Here, the user may tear off the upper portions 34 and 40 in order to open the container 10. Water may be added and the contents may be heated in a microwave. Subsequently, the opening of the container 10 is sufficiently large to allow a user to remove contents with the use of a fork or spoon. The container 10 could be used for holding a variety of dry, granular or palletized products.

The perforations 44 may include apertures 90 that extend completely through the paperboard making up the container 10 along with any thermoplastic coating that may be present on either side of the paperboard. Perforations 46 can also include apertures 94 that are provided in a similar manner to apertures 90. Alternatively, apertures 90 and 94 of the perforations 44 and 46 may extend through only a portion of the paperboard or through only the thermoplastic coating in other embodiments. The perforations 44 and 46 can be designed in a variety of manners in order to achieve fins 32 and 38 that require various amounts of force to be applied thereon in order to separate the upper portions 34 and 40 from the lower portions 36 and 42. In certain embodiments, the apertures 90 and 94 may be as deep as 75% to 80% of the thickness of the paperboard. Here, the thermoplastic coating may remain in tact in order to provide barrier properties and prevent contamination.

In accordance with one embodiment, tabs 92 of perforations 44 and tabs 96 of perforations 46 may have a length that is twice that of the apertures 90 and 94 intermediate the tabs 92 and 96. For instance, the apertures 90 and 94 of perforations 44 and 46 may have a length of ⅛^th inch and the tabs 92 and 96 of perforations 44 and 46 may have a length of 1/16^th inch in one embodiment. In other embodiments, apertures 90 and 94 may have a length of ⅛^th inch and tabs 92 and 96 may have a length of 1/32^nd. In other embodiments the lengths of both the tabs 92 and 96 and the lengths of apertures 90 and 94 of perforations 44 and 46 may be the same. For example, both the apertures 90 and 94 and tabs 92 and 96 of perforations 44 and 46 may have a length of 1/32^nd inch. The perforations 44 and 46 may be arranged with respect to one another so that upon formation of container 10 the apertures 90 of perforations 44 align with the apertures 94 of perforations 46. Alternatively, the perforations 44 and 46 can be arranged so that their apertures 90 and 94 do not align but instead overlap with the tabs 92 and 96. Although described as being elongated and substantially parallel to score lines 48 and 50, the perforations 44 and 46 can be variously configured in other embodiments. For example, the perforations 44 and 46 may be elongated and disposed at an angle to score lines 48 and 50. Instead of having apertures 90 and 94 that are generally elongated in form, the perforations 44 and 46 may have circular shaped apertures 90 and 94 in other embodiments. Again, it is to be understood that the perforations 44 and 46 may be of any size or shape and that the apertures 90 and 94 may be of any depth in accordance with various exemplary embodiments.

The gable top container 10 may also be configured to open so as to form a conventional spout 72 as shown in FIG. 4. A user may first pull apart the connection of fins 32 and 38 so they separate from one another from their ends to a location proximate to their midpoints. The remaining length of fins 32 and 38 stay connected. Next, a user can pull outward an inverted V portion of gusset panel 28 to form a pair of wings made up of gusset panel 28 and gable panels 26 and 30. In this instance, the wings bend outward along score line 74 of gable panel 26 and along score line 76 of gable panel 30. The wings can be pushed inward in order to form a spout 72 from which product in the container 10 may be dispensed or accessed. In the formation of spout 72, the perforations 44 and 46 need not be torn or otherwise broken so that the upper portion 34 of fin 32 remains connected to lower portion 36 and so that upper portion 40 of fin 38 remains connected to lower portion 42.

FIG. 5 shows an alternative exemplary embodiment of the gable top container 10 in which additional score lines 78 and 80 have been added to gable panels 26 and 30. The additional score lines 78 and 80 allow for an additional spout to be formed opposite spout 72 as shown in FIG. 4. It may be the case that a user seeks to form a spout by opening the gable top of container 10 on a side opposite the one configured for forming the spout. In such an instance the user may tear the paperboard forming the container 10 and either damage the container 10 or create an improperly formed spout. The presence of additional score lines 78 and 80 allows the user to open container 10 to form a spout on either side of the gable top without improperly tearing the paperboard forming the container 10.

FIG. 6 is an alternative exemplary embodiment of the gable top container 10. Here, the perforations 44 and 46 of gable panels 26 and 30 have been relocated from their position in the embodiment of FIG. 1. In FIG. 6, perforations 44 are provided at the same location as score line 48 in FIG. 1. Likewise, perforations 46 are present at the location of score line 50 in FIG. 1. Fin 32 extends from perforations 44 to edge 86, and fin 38 extends from perforations 46 to edge 88. Additionally, score lines present on gusset panels 24 and 28 and on side seam 22 have been replaced with perforations. Specifically, perforations 98 are present on gusset panel 24, and perforations 100 are present on gusset panel 28. Perforations 102 are present on side seam 22. Perforations 98, 44, 100, 46 and 102 are arranged essentially in line with one another. Apertures of the perforations 98, 44, 100, 46 and 102 may be cut completely through the paperboard or may be cut through 75% of the paperboard of blank 12. As with the embodiment shown in FIG. 6 and as with all other embodiments, the perforations and apertures may be of any length and be of any ratio. The specific lengths and ratios shown and described herein are for sake of example. Further, the apertures may extend through 100% of the blank 12 or may extend through some lesser amount.

While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.

Claims

1. A gable top container, comprising: a bottom made from at least one bottom forming panel;a side made from at least one side forming panel that extends from said bottom;a pair of gusset panels extending from said side; anda pair of gable panels extending from said side and arranged with respect to said gusset panels to form a gable top, wherein each of said gable panels has a fin that defines perforations that allow for the removal of at least a portion of said fin in order to effect opening of the container from one end of said gable panels to an opposite end of said gable panels.

2. The gable top container as in claim 1, wherein said perforations of said fins are located between an upper portion of said fins and a lower portion of said fins, and wherein said upper portion of said fins is configured to be removed in order to effect opening of the container.

3. The gable top container as in claim 2, wherein said lower portions of said fins are defined by said perforations of said fins and score lines of said gable panels, and wherein said perforations are arranged in a parallel configuration to said score lines of said gable panels.

4. The gable top container as in claim 2, wherein said upper portions of said fins are adhered to one another, and wherein said lower portions of said fins are not adhered to one another.

5. The gable top container as in claim 1, wherein said perforations have a plurality of tabs and apertures that are of the same length.

6. The gable top container as in claim 1, wherein said perforations have a plurality of tabs and apertures in which the length of said apertures is twice the length of said tabs.

7. The gable top container as in claim 1, wherein said perforations have a plurality of tabs and apertures in which the length of said tabs is twice the length of said apertures.

8. The gable top container as in claim 1, wherein said gable panels have a score line from which said fins extend, and wherein said perforations are located less than the midpoint of the distance from said score lines to the edge of said fins.

9. The gable top container as in claim 1, wherein said gable panels and one of said gusset panel is configured for being opened to form a spout.

10. The gable top container as in claim 9, wherein said gable panels and the other one of said gusset panel are configured for being opened to form a spout.

11. The gable top container as in claim 1, wherein said perforations of said fins are located at the lower edge of said fins.

12. A gable top container, comprising: a bottom formed by first, second, third and fourth bottom forming panels;a side formed by first, second, third and fourth side forming panels extending from said bottom;a side seam extending from said fourth bottom forming panel and said fourth side forming panel, wherein said side seam is attached to said first side forming panel and said first bottom forming panel;a pair of gusset panels extending from said side; anda pair of gable panels extending from said side and arranged with respect to said gusset panels to form a gable top, wherein each of said gable panels define perforations that allow for the removal of at least a portion of said gable panels in order to effect opening of the container such that said gable panels separate from one another along the length of said gable panels in order to cause an end of the container to be opened.

13. The gable top container as in claim 12, wherein each of said gable panels has a fin that extends from a score line of said gable panel to an edge of said gable panel, and wherein said perforations are defined by said fins of said gable panels.

14. The gable top container as in claim 13, wherein said perforations are located less than the midpoint of the distance from said score lines to said edges of said gable panels.

15. The gable top container as in claim 13, wherein upper portions of said fins are configured to be removed in order to effect opening of the container such that said gable panels separate from one another along their length.

16. The gable top container as in claim 13, wherein said perforations are arranged in a parallel configuration to said score lines of said gable panels.

17. The gable top container as in claim 12, wherein said bottom defines a perimeter, and wherein said gusset panels and said gable panels are configured to open such that the edges of said gusset panels and the tops of said gable panels define a perimeter of the same size as said perimeter of said bottom.

18. The gable top container as in claim 12, wherein said perforations have a plurality of tabs and apertures that are of the same length.

19. The gable top container as in claim 12, wherein said perforations have a plurality of tabs and apertures in which the length of said apertures is twice the length of said tabs.

20. The gable top container as in claim 12, wherein said gable panels and one of said gusset panel is configured for being opened to form a spout.

21. The gable top container as in claim 20, wherein said gable panels and the other one of said gusset panel are configured for being opened to form a spout.

22. The gable top container as in claim 12, wherein each of said gable panels has a fin that extends from said perforations of said gable panels to an edge of said gable panels.

23. A gable top container, comprising: a bottom formed by first, second, third and fourth bottom forming panels;a side formed by first, second, third and fourth side forming panels extending from said bottom;a side seam extending from said fourth side forming panel, wherein said side seam is attached to said first side forming panel;a pair of gusset panels extending from said side; anda pair of gable panels extending from said side and arranged with respect to said gusset panels to form a gable top, wherein said gable, panels have fins that extend from score lines of said gable panels to edges of said gable panels, wherein upper portions of said fins are adhered to one another, and wherein said fins define perforations parallel to said score lines that allow for the removal of said upper portions of said fins in order to effect opening of the container such that said gable panels separate from one another along the length of said gable panels in order to cause an end of the container to be opened.