Direct Contact Carton Pour Spout Device

The present application claims priority to, and the benefit of, U.S. Provisional Application No. 63/661,307, which was filed on Jun. 18, 2024, and is incorporated herein by reference in its entirety.

The present invention relates generally to the field of cartons. More specifically, the present invention relates to a new and improved direct contact carton with an integrated pour spout. More specifically, the invention relates to a paper-based container that is comprised of a carton and a perforated portion created during the manufacturing process and configured to partially detach forming a spout. Accordingly, the present disclosure makes specific reference thereto. Nonetheless, it is to be appreciated that aspects of the present invention are also equally applicable to other like applications, devices, and methods of manufacture.

Single-use containers are commonly used to store and hold semi-liquid or liquids items including juices, milks, drinks, beverages, sauces, shampoo, liquid soap, cleaning agents, and the like. Many of these single-use containers are plastic containers that are typically disposed of after a single use, and unfortunately find their way into oceans, rivers, and other environments as pollutants. As such, materials and practices have been developed regarding the use of bio-degradable materials in place of plastics that are typically used in single-use solid, semi-solid and liquid food/product containers.

Food and drink cartons can be made from many materials including paperboard, duplex, white kraft, recycled packaging, or a composite multi-layered material. Some of these cartons are considered “food grade” or “direct contact” cartons that allow for direct contact with food or liquids. Many of these cartons are made out of a single piece of paperboard. Depending on the need, the paperboard template can be waxed, coated, or otherwise lined to form a moisture barrier and contain a liquid or semi-liquid product.

Gable top cartons are frequently used for liquid products, such as milk and juice cartons. These containers use polyethylene-coated paperboard or other liquid packaging board and sometimes a foil laminate. These cartons are typically opened by pushing the gables at the top back and pulling the top or “spout” out to open the container. Some of these containers have fitments or attachments to assist in opening and consuming the contents. Cuboid waxed paperboard containers are a formed paperboard with a low-density polyethylene (ldpe) layer container crimped and sealed with a flat top and may similarly be used to contain liquids.

Existing fold apart direct contact container “spouts” are problematic for many reasons. These types of containers can be extremely difficult to open, close, and often leak. One solution is the addition of a plastic cap or pour spout that can be directly integrated into the container. The plastic pour spout is added to the container as part of the manufacturing process. The user unscrews the cap to access the plastic spout. Unfortunately, this adds additional materials and steps during manufacturing that increases assembly time and cost. This further complicates the disposal and recycling processes for these materials as plastic and paper components must be separated before recycling.

Therefore, there exists a long felt need in the art for a direct contact pour spout carton that is constructed only out of a single material. There is also a long felt need in the art for an improved direct contact pour spout carton that is constructed as a flat top or gable top container. Further, there is a long felt need in the art for an improved direct contact pour spout carton with a punch out opening that does not leak prior to opening. Finally, there is a long felt need in the art for an improved direct contact pour spout carton that is relatively inexpensive to manufacture and that does not use plastic components.

The subject matter disclosed and claimed herein, in one embodiment thereof, comprises a direct contact pour spout carton device. The device is comprised of a direct contact pour spout carton device that comprises a carton body configured in various shapes and sizes, such as gable tops, trapezoidal forms, or custom geometries, designed for liquid or semi-liquid contents. The carton body includes multiple sidewalls, a bottom, and a top, made from materials such as LDPE-coated paperboard or multilayer composites for enhanced barrier properties. Features like grease-resistant coatings or foil-lined boards with double skive seals improve durability under wet or refrigerated conditions. The pour spout, integrated into the carton body, includes perforated portions, a cap with a living hinge, and optional resealing mechanisms, enabling controlled dispensing and reclosure. The manufacturing process involves precision die-cutting, scoring, or perforating to incorporate the spout features, followed by folding and sealing to form a durable and functional container.

In this manner, the improved direct contact pour spout carton of the present invention accomplishes all of the forgoing objectives, thereby providing a paperboard only based container that does not require additional plastic parts. The direct contact pour spout carton of the present invention also provides a leak-proof punch out opening for dispensing liquids and semi-liquids. The direct contact pour spout carton may be constructed with a flat top or a gable top. Finally, a pour spout of the direct contact pour spout carton is perforated into the carton during manufacture prior to assembly.

The following presents a simplified summary to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some general concepts in a simplified form as a prelude to the more detailed description that is presented later.

The subject matter disclosed and claimed herein, in one embodiment thereof, comprises a direct contact pour spout carton device. The direct contact pour spout carton device is comprised of a carton body with a gable top configuration but is adaptable to various shapes and closure mechanisms to meet diverse dispensing needs. Potential configurations include rectangular, trapezoidal, or cylindrical forms, and closures such as flip-top lids or screw caps. These designs ensure versatility for applications ranging from liquid storage to specialized dispensing solutions.

The carton body is comprised of multiple sidewalls, a bottom, and a top, which, when folded and assembled, form the structural surfaces of the device. The sidewalls may include embossed, textured, or printed features to enhance grip, provide branding opportunities, or add functional elements. These structural components contribute to both the practicality and aesthetic appeal of the carton.

The material of the carton body is predominantly a paper-based or paperboard substrate coated with low-density polyethylene (LDPE) to provide barrier properties for containing liquid or semi-liquid contents. Alternative materials in addition to LDPE-coated paperboard include SBS paperboard, non-laminated paperboard and multi-layer composite paperboard that incorporates aluminum or plant-derived polymers for enhanced performance. Some embodiments integrate grease-resistant coatings or foil-lined substrates for added durability, particularly in wet or refrigerated conditions. A skive seal may be incorporated to enhance edge integrity and prevent liquid leakage.

The gable top configuration of the carton includes a pair of opposing side panels and end panels that converge at a ridge. The gable top may also feature scored or pre-folded lines to facilitate easy opening and maintain structural integrity during handling and storage. Alternative top designs, such as flat tops with integrated spouts or tapered tops for precise pouring, provide additional flexibility for different applications.

The integrated pour spout enables convenient dispensing of the carton's contents. It is comprised of a perforated sidewall portion, a top perforation portion, a living hinge, and a detachable cap. The cap is secured along perforation lines and can pivot via the living hinge, which is formed by scoring or thinning the material. The hinge ensures the cap remains attached while allowing repeated opening and closing. The perforations are designed to balance ease of use with resistance to accidental damage, and a reclosure fastener, such as an adhesive strip or tab, enables resealing after initial use.

Accordingly, the direct contact pour spout carton device of the present invention is particularly advantageous as it provides a paperboard only based container that does not require additional plastic parts. The direct contact pour spout carton of the present invention also provides an acceptable-for-use in wet environments punch out opening for dispensing liquids and semi-liquids. The direct contact pour spout carton may be constructed with a flat top or a gable top. Finally, a pour spout of the direct contact pour spout carton is perforated into the carton during manufacture prior to assembly.

To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and are intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.

As noted above, there exists a long felt need in the art for a direct contact pour spout carton that is constructed only out of a single material. There is also a long felt need in the art for an improved direct contact pour spout carton that is constructed as a flat top or gable top container. Further, there is a long felt need in the art for an improved direct contact pour spout carton with a punch out opening that does not leak prior to opening. Finally, there is a long felt need in the art for an improved direct contact pour spout carton that is relatively inexpensive to manufacture and that does not use plastic components.

The present invention, in one exemplary embodiment, is comprised of a direct contact pour spout carton device. The direct contact pour spout carton device comprises a carton body with a gable top configuration but can adapt to various shapes and closure mechanisms to accommodate diverse dispensing requirements. Potential configurations include rectangular, trapezoidal, or cylindrical forms, as well as closures like flip-top lids or screw caps, providing versatility for applications ranging from liquid storage to specialized dispensing.

The carton body includes multiple sidewalls, a bottom, and a top that, when folded and assembled, create the structural surfaces of the device. The sidewalls may incorporate embossed, textured, or printed features to enhance grip, offer branding opportunities, or serve functional purposes. These structural features enhance both the practicality and appearance of the carton.

The material of the carton body is primarily a paper-based or paperboard substrate coated with low-density polyethylene (LDPE) for barrier properties suitable for liquid or semi-liquid contents. Alternative materials include LDPE-coated paperboard, SBS paperboard, or multilayer composites with aluminum or plant-derived polymers for improved performance. Certain embodiments incorporate grease-resistant coatings or foil-lined substrates for greater durability, particularly in wet or refrigerated conditions, with a skive seal included to improve edge integrity and prevent leaks.

The gable top configuration features opposing side and end panels that converge at a ridge. It may also include scored or pre-folded lines to ensure easy opening and maintain structural integrity during use. Alternative designs, such as flat tops with integrated spouts or tapered tops for precise pouring, offer additional versatility for different applications.

The integrated pour spout facilitates the convenient dispensing of the carton's contents. It includes a perforated sidewall portion, a top perforation portion, a living hinge, and a detachable cap. The cap is secured along perforation lines and pivots using the living hinge, created by scoring or thinning the material. This hinge keeps the cap attached while allowing repeated opening and closing. The perforations are engineered to balance ease of use with resistance to accidental damage, and a reclosure fastener, such as an adhesive strip or tab, enables resealing after initial use.

The direct contact pour spout carton device is advantageous as it provides a paperboard-based container that eliminates the need for additional plastic components. It features a leak-proof punch-out opening for dispensing liquids and semi-liquids. The carton can be constructed with a flat top or a gable top, and the pour spout is perforated into the carton during manufacturing before assembly.

Referring initially to the drawings,illustrates a perspective view of one potential embodiment of a direct contact pour spout carton deviceof the present invention in accordance with the disclosed architecture. The direct contact pour spout carton deviceis comprised of a carton bodythat is folded to assemble a carton with a gable top configuration. However, different embodiments of the direct contact pour spout carton devicemay comprise a variety of container shapes, types, and sizes, such as but not limited to rectangular prisms, trapezoidal forms, cylindrical forms, or custom geometries designed for specific dispensing applications. It should be noted that the present invention is not limited to gable top containers but may include other closure mechanisms, such as but not limited to flip-top lids or integrated screw caps.

The carton bodyis comprised of at least one (but preferably a plurality of) sidewalls, a bottom, and a top, which collectively create the structural surfaces of the devicewhen folded and assembled. The plurality of sidewallsmay comprise a first sidewall, a second sidewall, a third sidewall (not shown), and a fourth sidewall (not shown). Each sidewallis generally planar but may include embossed, raised and/or recessed textured, or printed elements for branding or functional enhancements such as improved grip.

The outer surfaceand inner surfaceof the carton bodyare comprised of a paper-based or paperboard material of relatively low-density polyethylene (LDPE) on one or both surfaces,. This material, referred to as “milk stock,” provides barrier properties suitable for liquid or semi-liquid contents. Said material may include a multi-layered milk stock material or any paper-based material. Alternative materials for the carton bodymay include but are not limited to LDPE-coated paperboard, solid bleached sulfate (SBS) paperboard, polymer-coated substrates, or multilayer composites that may incorporate aluminum or plant-derived polymers for enhanced barrier properties.

It is noted that, in some embodiments, the carton bodymay be made from a foil-lined board and is comprised of at least one skive seal, as seen in, to enhance durability in wet environments. The foil-lined board introduces an additional barrier layer against moisture ingress, making the deviceparticularly suited for applications where prolonged exposure to humid conditions or refrigeration is anticipated. The skive sealreinforces the integrity of the edges and joins, ensuring resistance to liquid leakage. In different embodiments, the sealmay be a single, double, or multi-skive seal.

The topof the body, in the embodiment shown, is configured as a gable top. The gable topcomprises a pair of opposing side panelsand a pair of opposing end panels. The side panelsextend upward from a pair of opposing sidewallsand converge at a ridge. The end panelsextend upward from the remaining sidewallsand terminate below the ridge. Alternative top configurations may include but are not limited to flat tops with integrated spouts, re-closable tops with zip closures, or tapered tops designed for precise pouring control. The gable topmay include scored or pre-folded linesto facilitate user manipulation and ensure structural integrity during transport and storage.

The pour spoutis integrated into the carton bodyand is configured for convenient dispensing of the carton's contents. The pour spoutcomprises a sidewall perforated portion, a top perforation portion, a living hinge, and a cap portion. The cap portionis a detachable flap formed as part of the carton bodyand is secured along the perforation lines,of the sidewall perforated portionand the top perforation portion. The living hingemovably connects the cap portionto the carton body, allowing the cap portionto pivot while remaining permanently attached. The living hingemay be constructed by scoring or thinning the bodymaterial at the hingelocation during manufacturing to provide flexibility without compromising durability.

When the perforation lines of the sidewall perforated portionand the top perforation portionare broken, an openingis formed for dispensing the device'scontents. The perforation lines,may vary in their density, pattern, or depth to balance ease of opening with resistance to unintentional damage during handling. The pour spoutmay also include a reclosure fastener, such as a tab or adhesive strip, to allow the deviceto be resealed after initial use.

The present invention also includes a method of manufacturingthe direct contact pour spout carton device. The methodbegins with generating a carton bodytemplate comprising a plurality of side panels, a bottom panel, and a top panel[Step]. The template may be formed using precision die-cutting techniques to ensure uniformity and minimize material waste. Next, the pour spoutis integrated into the template by forming the perforated portionsand, the living hinge, and the cap portion[Step]. These features may be created through a combination of mechanical scoring, laser cutting, or perforation processes. The carton bodyis then assembled by folding the template along predefined fold lines and joining the edges of the bodyusing adhesive, heat sealing, or ultrasonic welding methods, depending on the material [Step]. The resulting devicecomprises the plurality of sidewalls, the bottom, and the top, forming a sealed enclosure. Finally, the pour spoutis activated by breaking the perforations,along the sidewall perforated portionand the top perforation portionto create the openingfor dispensing the device'scontents [Step].

Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. As used herein “direct contact pour spout carton device” and “device” are interchangeable and refer to the direct contact pour spout carton deviceof the present invention.

Notwithstanding the forgoing, the direct contact pour spout carton deviceof the present invention and its various components can be of any suitable size and configuration as is known in the art without affecting the overall concept of the invention, provided that they accomplish the above-stated objectives. One of ordinary skill in the art will appreciate that the size, configuration, and material of the direct contact pour spout carton deviceas shown in the FIGS. are for illustrative purposes only, and that many other sizes and shapes of the direct contact pour spout carton deviceare well within the scope of the present disclosure. Although the dimensions of the direct contact pour spout carton deviceare important design parameters for user convenience, the direct contact pour spout carton devicemay be of any size, shape, and/or configuration that ensures optimal performance during use and/or that suits the user's needs and/or preferences.

Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.