Slide Opening Box with Integral Liner

Abstract

A box with a sliding opening has an integral liner to keep pourable contents fresh and dry. The box has a slide that is moveable by a user's thumb across the opening to open and close the box and the liner during the same operation. The user in one motion can either open the box and the liner to pour out the contents or close the box and the liner so the contents do not spill out. Advantageously, the box is formed from a single blank piece of paper or cardboard stock, and a single planar sheet of moisture impervious material liner is placed onto the blank and folded in a particular sequence such that the slide ends up inside the box for easy assembly with a resulting sealed liner bag inside.

Description

BACKGROUND

The present disclosure relates to packaging for pourable materials, and in particular, to a box with a slide opening and an integral liner for containing and dispensing pourable items such as cereal or other foodstuffs.

A wide range of pourable products such as dry cereals, powdered laundry soap and many others are dispensed in cardboard boxes. To access the contents, a user must generally open the top of the box. Sometimes the contents are held in a wax paper or other plastic-type bag inside the box and that bag must be torn open after opening the box. To store contents and maintain their freshness or dryness and limit exposure to humid ambient air, a user folds over the bag to close the bag and closes the box when possible which typically has an awkward, difficult to manipulate closure, particularly in the case of traditional breakfast cereal boxes.

Standard cereal boxes are typically delivered in a tube-shaped standard folding carton, partially assembled and collapsed condition. When manufacturing boxes in large quantities, e.g. for mass distributed breakfast cereals, it is preferable to have the box delivered to the end-manufacturer as a folded flat. Automated machinery at the food processor opens up the flat carton, folds and secures top or bottom flaps to form a box with an open end. Next the machinery fills the box with product, and the box is closed to complete packaging.

Applicant has developed packages of new and differing functionality which offer significant improvements in dispensing product yet maintaining the processing same as standard folding cartons with conventional high speed machinery, over the prior art. Applicant is the named inventor on numerous U.S. patents directed to specialty packaging including U.S. Pat. Nos. 6,116,499, 6,273,332, 6,360,942, 6,435,402, 6,945,449, 7,040,528, 7,156,286 and 7,743,973, and application Ser. No. 12/686,252 filed Jan. 12, 2010. These patents and the pending application show the progression of Applicant's innovative packaging designs, and how they have evolved to become friendlier to the high-speed form, fill, and seal machines used by major food processing companies in producing hundreds of packages per minute.

While Applicant's packages described in existing patents offer many advantages over the prior art, there remains a need for a mass producible box with a sealed bag inside, for storing and maintaining the required liner by cereal MFG companies, while providing dispensing portions of the contents and re-closing the box with ease. The need exists for a box for containing pourable items where the liner bag is conveniently constructed along with the box, and a liner bag inside which can be opened and closed as the box is opened and closed by a convenient slide opener.

SUMMARY

A box having an integral liner containing pourable items, and a method of packaging and dispensing pourable products, such as cereal, is disclosed. A box having an integral liner is formed from a foldable box blank. The foldable box blank has a plurality of sides coupled together, each of the sides corresponding to a side of the box when folded. In one embodiment, the foldable box blank is preferably made of cardboard material.

A first side of the box blank has a side opening, which serves as the opening through which pourable product will be dispensed. Coupled to the first side opening, a slide allows the box to be opened and closed when the package is used. It is anticipated that the slide may be coupled to the first side prior to assembly, and in this manner, the package may be constructed specifically from a single flat piece of box blank stock. Alternatively, the side opening can be located virtually anywhere on the box convenient for pouring.

As freshness is a desired characteristic of goods contemplated to be dispensed from the box, a bag substantially sealed inside the box is contemplated as part of the package. In one exemplary embodiment, the bag may be made from a moisture impervious material, including a heat-sealable plastic-type material known to skilled persons for maintaining the freshness and dryness of contained items, or any material which satisfies these purposes. Typically the moisture impervious material substantially covers the box blank prior to assembly of the package. The moisture impervious material has a perforated portion, defining an opening, overlaying the side opening of the box, which may be sealed together. By sealing the openings of the box and bag, a substantially air-tight re-sealable package is produced. The union of the openings also prevents product or other material from lodging between the bag and box.

Once the box blank and moisture impervious material have been folded into the box and bag, respectively, forming the package, product may be introduced into the package. It is anticipated that product may be introduced during the folding process by leaving one side, in one embodiment a top or bottom side, open for the introduction of product. Once product is introduced into the package, the remaining side may be closed, sealing the package until opened by a user. Glue or a similar adhesive may also be used to attach selected portions of the bag, notably around the opening, to the box blank. Using the integral liner also eliminates the empty corners found in conventional cereal boxes with bags, and thus makes it possible for manufacturers to use smaller boxes saving on paper and the environment.

Completing the method, to use the package, a user moves the slide opening to expose the bag inside the box. In one embodiment, it is anticipated the slide will have a first portion adapted to slide along the first side of the box, and a second portion adapted to extend away from the box top. It is also anticipated that the slide may comprise a tab allowing a user to actuate the slide more easily. In an alternative embodiment, a removable patch (not shown) may also be sealed over the perforated portion.

Upon first use of the slide, the box opening is exposed along with the section of the bag to be opened. A user may remove the section of the bag, which is typically surrounded by perforations, to access the product. In addition to the perforated opening being located overlaying the box opening, in one embodiment, a tab may be present adjacent the perforated portion of the bag to facilitate removal. Once the portion of the bag surrounded by perforations is removed, with the slide in an open configuration, product may be poured through the side opening.

Once a desired amount of pourable product is dispensed from the box, a user may move the slide to a position covering the side opening and the opening in the bag, which will close the box and bag with one movement. Without further actions by the user such as folding over the bag or clipping it closed, freshness of the pourable product in the package will be preserved. Due to the position of the opening on the side of the box and tabbed slide, the slide may be engaged with a user's thumb in one embodiment. In order to prevent the portion of the slide covering the opening from dislocating from the box, the slide may be equipped with one or more stops adapted to limit sliding movement of the slide.

In one alternative embodiment, it is anticipated that the sheet of moisture impervious material may be in a folded condition prior to the steps of sealing opposing edges of the moisture impervious material to form a bag and attaching the bag to the box blank. In this embodiment, the folded sheet of moisture impervious material also has an opening defined by perforations adapted to overlay the side opening. It is anticipated that the method of use of the assembled package in this embodiment will be substantially the same as in other embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flat pattern view of the blank from which an embodiment of the box is made.

FIG. 2 is a perspective view of the blank and the liner material adapted to cover the blank, also showing an initial assembly step.

FIG. 3 is a perspective view of the blank and liner material, also showing subsequent assembly steps.

FIG. 4 is a plan view of the partially assembled box showing the lifting flap in one embodiment of the invention and a portion of the liner material cut away for clarity of illustration.

FIG. 5 is a front perspective view of the box showing assembly of the lifting flap and hidden components of the lifting flap in dashed line.

FIG. 6 is a front perspective view of the box showing the lifting flap in a closed configuration.

FIG. 7 is an inverted front perspective view of the box being filled from the bottom with pourable product.

FIG. 8 is a front perspective view of the box showing operation of the slider and lifting flap.

FIG. 9 is a perspective view of an alternative embodiment of the invention showing a liner separate from a blank having adhesive areas.

FIG. 10 is a perspective view of a liner folded and adhered to a blank by compression, and hot rollers sealing edges of the liner forming a bag.

FIG. 11 is a front perspective view of the box showing the sealed bag inside the box prior to closing the box bottom.

FIG. 12 is a front perspective view of the box prior to filling and closing the box.

FIG. 13 is an inverted front perspective view of the box being filled from the bottom with pourable product.

FIG. 14 is an inverted front perspective view of the bottom of the bag being hot sealed prior to closing.

DESCRIPTION

FIG. 1 illustrates one embodiment of a die cut paper or cardboard blank 10 that may be used to form the box 12. The blank 10 has a top end 14 and a bottom end 16 and is scored for folding between a first minor side 18, a first major side 20, a second minor side 22 and a second major side 24, all generally rectangular in shape. The first minor side 18 includes flap 26 and aperture 28 and is attached to the first major side 20 by fold line 30. The first major side 20 includes major flaps 32 and 34 and is connected to second minor side 22 by fold line 36. The second minor side 22 includes flaps 38 and 40 and is connected to second major side 24 by fold line 42. The second major side 24 includes flaps 44 and 46 and is connected to the overlapping flap or manufacturer's joint 48 (which includes aperture 49) by fold line 50.

Still referring to FIG. 1, the slider retention portion 52 is attached to the first minor side 18 along fold lines 54 and 56 with a slotted opening 58. The slider retention portion 52 is formed with aperture 60 and includes the stopper tabs 62 and 64 and a minor flap 65. The slider retention portion 52 is attached to the slider 66 along perforated lines 68 and 70. The slider 66 includes the slide 72 which is connected along fold lines 76 and 78 to the lifting flap 74 and includes the tab 80 configured for engagement by a user's thumb when folded, and small cutouts 81 in the minor sides 18, 22, and 48 to provide easy access to the tab 80. The lifting flap 74 is attached to the attachment portion 82 along fold line 84. The slider 66 is formed with aperture 90 and includes tabs 86 and 88. The minor flaps 26, 38, 40 rather than being entirely separated from the major flaps 32, 34, 44, and 46 have instead a line of weakness or are perforated. Additionally, the minor flaps 26, 38, 40, and 65 have a fold line 67 the function of which is explained below.

FIG. 2 illustrates an embodiment with the liner 100 shown prior to being affixed to the blank 10. The liner 100 includes an opening 112 and a liner flap 102. The liner flap 102 is attached to a connector portion 106 connecting it with the liner 100 and removable liner portion 104. The liner 100 is connected to the removable liner portion 104 with a perforation line 104a. As can be appreciated from FIG. 2, pulling flap 102 away from the liner 100 removes the removable liner portion 104 along perforation line 104a. The liner 100 is preferably made of a plastic, waxed paper, or other materials known to persons skilled in the art for containing pourable items in a box in a fresh or dry state. The apertures, 28, 49, 60, and 90, and liner opening 112 are all compatible in shape, although not necessarily the same shape, such that when the four openings are aligned as discussed herein, a path is provided from the interior of the box to the exterior.

Still referring to FIG. 2, construction of the box 12 begins with folding the slider 66 over onto the slider retention portion 52 along perforated lines 68, 70. Referring to FIG. 3, the overlapping slider 66 and slider retention portion 52 are then folded over onto minor side 18 along fold line 56. The liner 100 is then affixed to the blank 10 and glued or otherwise adhered to the blank 10 to secure the liner 100 thereto such that the liner opening 112 is placed substantially in alignment with aperture 28 of the first minor side 18. As shown in FIG. 4, in one embodiment, the liner 100 extends about a half inch (0.5 in.) beyond the top end 14, the bottom end 16, and about that same distance into the overlapping flap 48 and extending over onto portions of slider retention portion 52 and the slider 66. In one embodiment a series of small glue dots, not shown, are deposited on the blank 10, particularly near the aperture 28 to ensure proper alignment is maintained, as well as across the remainder of the blank 10.

To continue box assembly, the slide 72 is situated between the slider retention portion 52 and the liner 100 with the slide 72 in communication with the liner flap 102. Further, the overlapping flap 48 is folded along fold line 50 so that it is approximately perpendicular to second major side 24 and then similarly folding between second major side 24 and second minor side 22 along fold line 42, folding between second minor side 22 and first major side 20 along fold line 36 and then folding between first major side 20 and first minor side 18 along fold line 30. The overlapping flap 48 is then glued or otherwise adhered to the first minor side 18 to form a generally rectangular box 12 as shown in FIG. 5.

FIG. 6 shows the box 12 further assembled with flaps 32, 44 and 38 folded over and glued or otherwise adhered together to close the top of the box 12. The lifting flap 74 is also folded over onto the folded flaps 32 and 44 with the attachment portion 82 glued or otherwise adhered thereto. FIG. 6 also shows the tab 80 on the lifting flap 74.

FIG. 7 shows the box 12 being filled from the bottom with pourable product prior to final assembly, which is one method of filling the assembled box 12. Final assembly of the box 12 is accomplished by folding over flaps 26 and 40, and then flaps 46 and 34, which are then glued or otherwise adhered together to close the bottom of the box 12 to hold the pourable product. As mentioned above, flaps 26 and 40 may be scored with fold lines 67, which helps retain all the cereal or other product and prevents dust or small particles of product from being released from the box as it is closed. Assembling the package in this manner creates a box with a sealed, air-tight liner bag inside to keep the cereal or other pourable product dry and fresh.

FIG. 8 shows a manner of dispensing pourable product from the box 12 following removal of the liner cover 104 from the liner 100. The tab 80 is lifted by a user's thumb in the direction of the arrow 120 to move the slide 72 upward to align the aperture 90 with the aperture 28 on the first minor side 18. The stopper members 62, 64 prevent advance of the slide 72 beyond the first minor side 18 by engaging the tabs 86, 88 on the slide 72. The liner opening 112 is created by pulling the liner flap 102. The pourable product within the box 12 is then dispensed from the box 12 through the liner opening 112 and out through apertures 90 and 28. Pushing down on the tab 80 in the opposite direction of the arrow 120 moves the slide 72 back down to close the aperture 28 and also to close the liner opening 112.

In some embodiments, it may be preferable to prepare the liner 100 and blank 10 for assembly by passing the blank 10 and liner 100 through hot rollers or other sealing apparatus under pressure. Referring to FIGS. 9-14, an alternative method of forming and attaching the liner 100 and assembling the box 12 is shown. In FIG. 9, the liner 100 is folded along fold line 36 as the overlapping slider 66 and slider retention portion 52 are folded over onto minor side 18 along fold line 56 (See, FIG. 3).

Adhesive strips 114 incorporated onto the surface of the unassembled blank 10 are designed to hold the liner 100 in position as the blank 10 is folded into a three-dimensional box 12. Although adhesive strips are contemplated, alternative embodiments may employ adhesive in spots, not shown, across predetermined portions of the box blank, or in another configuration to support the bag in position.

Referring to FIG. 10, with the liner 100 folded over the blank 10, hot pressure is applied to seal the liner 100. In one embodiment, the liner 100 may be passed through a hot rolling mechanism.

As shown in FIG. 11, the liner 100 is glued and closed proximal the top of the box prior to assembly of the flaps 32, 44, and 38, which are folded over and glued or otherwise adhered together to close the top of the box 12, along with the lifting flap 74 which is folded over onto the folded flaps 32 and 44 with the attachment portion 82 glued or otherwise adhered thereto (See FIGS. 5-6). In this manner of assembly, in one alternative embodiment, the side of the liner 100 adjacent the bottom of the blank 10 is left unsealed. In one embodiment, due to adhesion with the blank 10, as the blank 10 is folded into a three dimensional box, the liner 100 at the bottom of the box 12 opens to accommodate pourable product as shown in FIG. 12.

Referring to FIGS. 13 and 14, pourable product is introduced into the box 12 in the same manner as the embodiment shown in FIG. 7. In this embodiment, the liner 100 is not adhered to flaps 26, 40, 34, and 46 prior to introduction of the pourable product. Rather, the product is introduced into the box 12, and thereafter a hot roller or other mechanism is brought to bear against the liner 100, to seal it. Once the liner 100 is sealed, flaps 26, 40, 34 and 46 are closed to create an assembled box 12 having a pourable product contained by a sealed liner 100 therein.

While particular forms of the invention have been illustrated and described, it will also be apparent to those skilled in the art that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited except by the full breadth and scope of the appended claims.

Claims

1. A method of packaging and dispensing pourable product comprising the steps of: forming a box blank having a plurality of sides coupled together, a first side having a side opening and coupled to a slide covering the side opening;attaching moisture impervious material to substantially cover the box blank, the moisture impervious material having an opening overlying the side opening;forming the box blank into a box with the attached moisture impervious material forming a bag inside the box;introducing the product into the bag;selectively moving the slide uncovering the side opening and the opening in the moisture impervious material, thereby opening the box and the bag with one movement; anddispensing the pourable product through the side opening and the opening in the moisture impervious material.

2. The method of claim 1 further comprising the step of selectively moving the slide covering the side opening and the opening in the bag, thereby closing the box and the bag with one movement.

3. The method of claim 1 further comprising the step of removing a removable portion of the moisture impervious material to form the opening in the bag.

4. The method of claim 1 further comprising the step of engaging a tab on the slide with a user's thumb.

5. The method of claim 1 further comprising the step of moving the slide against at least one stop member limiting sliding movement of the slide.

6. The method of claim 3 further comprising the step of perforating the bag to create the removable portion.

7. A method of packaging and dispensing pourable product comprising the steps of: forming a box blank having a plurality of sides coupled together, a first side having a side opening and coupled to a slide covering the side opening;folding a sheet of moisture impervious material;sealing opposing edges of the sheet together forming a bag;attaching the bag to the box blank, the bag having an opening overlying the side opening;forming the box blank into a box;introducing the product into the bag;selectively moving the slide uncovering the side opening and the opening in the bag, thereby opening the box and the bag in one movement; anddispensing the pourable product through the side opening arid the opening in the bag.

8. The method of claim 7 further comprising the step of removing a removable portion of the moisture impervious material to form an opening in the bag.

9. The method of claim 7 further comprising the step of engaging a tab on the slide with a user's thumb.

10. The method of claim 7 further comprising the step of moving the slide against at least one stop member limiting sliding movement of the slide.

11. The method of claim 7 further comprising the step of perforating the bag to create a removable portion.

12. The method of claim 7 further comprising the step of applying an adhesive to predetermined portions of the box blank for attaching the bag.

13. A package for dispensing pourable product comprising: a box blank having a plurality of sides foldably coupled together, and a first side having a side opening coupled to a slide for covering the side opening;a sheet of moisture impervious material adapted to cover a substantial portion of the box blank, the moisture impervious material having a perforated portion of the moisture impervious material overlying the side opening;an adhesive for securing a portion of the moisture impervious material to the box blank;wherein the moisture impervious material is adhered to the box blank, and forms a bag when the blank is folded into the package.

14. The package of claim 13 wherein the slide is foldably coupled to a tab configured to be engaged by a user's thumb for ease in selectively moving the slide.

15. The package of claim 13 wherein the slide has at least one stop member to limit movement of the slide so the slide remains proximate the side opening.