CA2694491A1

CA2694491A1 - Carton with pour spout

Info

Publication number: CA2694491A1
Application number: CA2694491A
Authority: CA
Inventors: Steven A. Blase
Original assignee: Individual
Current assignee: Graphic Packaging International LLC
Priority date: 2007-07-31
Filing date: 2008-07-31
Publication date: 2009-02-05
Also published as: WO2009018400A2; WO2009018400A3

Abstract

A carton with a pour spout is disclosed. The carton includes rectangular side walls, top walls and end walls, and a spout formed in one of the end walls. The spout can be selectively moved between a closed position and an open position for pouring contents out of the carton. The carton is erected from a foldable paperboard blank having a pair of side wall panels which form the side walls of the carton, a pair of end wall panels which form the end walls of the carton, a plurality of top flaps and bottom flaps which form the top and bottom walls of the carton and a reinforcement wall panel which forms a reinforcement wall of the carton.

Description

CARTON WITH POUR SPOUT

PRIORITY
[0001] The present application claims benefit and priority of US Provisional Patent Application No. 60/935,198 and incorporates such by reference as if repeated in entirety herein.

BACKGROUND

[0002] This invention relates to cartons or sleeves used to store or carry products. The cartons or sleeves are formed from blanks and generally surround or hold at least a portion of the product or articles placed therein.

SUMMARY

[0003] In one aspect, the present invention provides a carton with a pour spout, including one formed from two layers of paperboard. The first layer of the paperboard forming a vertical hinged punch out with a generally angled top.
The second layer of paperboard folds directly in line with the first layer of paperboard to create the pour spout. In one embodiment, the pour spout opens on a horizontal creased line at the bottom with two flaps that fold inward. In order to create the spout, the two flaps are folded inside the punch out in the first layer of paperboard. A
re-closing features is created in this configuration, with the second layer spout able to be closed into the first layer punch out.

[0004] In a further aspect, the present invention includes a blank having a first end and a second end. The blank including a first side panel connected to a second side panel along a first fold line, the second side panel connected to a third side panel along a second fold line, the third side panel connected to a fourth side panel along a third fold line, and a reinforcement panel connected to the fourth side panel along a fourth fold line. A first end flap at the first end of the blank is attached along a first transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel. A second end flap at the second end of the blank is attached along a second transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel. A spout is formed in the first WCSR 3942886v1 I

side panel, with the spout including a spout flap and an aperture. A spout guide flap is formed in the reinforcement panel. Optionally, the spout has three sections, including a center section between a first side section and a second side section, with the first side section connected to the center section along a first spout fold line, and with the center section connected to the second side section along a second spout fold line. Optionally still, the spout can be partially separable from the first side panel along a spout tear line extending at least partially along a periphery of the spout. The spout can include a gripping protrusion at an upper portion, with the gripping protrusion adjacent the aperture. The gripping protrusion capable of being grasped to separate the spout along the spout tear line.

[0005] In another aspect, the present invention includes a carton having a first side panel connected to a second side panel along a first fold line, the second side panel connected to a third side panel along a second fold line, the third side panel connected to a fourth side panel along a third fold line, and a reinforcement panel connected to the fourth side panel along a fourth fold line. A first end flap at the first end of the blank is attached along a first transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel.
A second end flap at the second end of the blank is attached along a second transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel. The reinforcing panel is connected by adhesive to the first side panel. A
spout is formed in the first side panel, with the spout adjacent an aperture formed in the first side panel. A spout guide flap is formed in the reinforcement panel.
Optionally, the spout has three sections, including a center section between a first side section and a second side section, with the first side section connected to the center section along a first spout fold line, and with the center section connected to the second side section along a second spout fold line. The spout is partially separable from the first side panel along a spout tear line extending at least partially along a periphery of the spout. At least a portion of the spout is aligned with the spout guide flap, and adhesive is not applied to the spout or the spout guide flap. The spout optionally including a gripping protrusion at an upper portion, with the gripping protrusion adjacent the aperture. The gripping protrusion capable of being grasped to separate the spout along the spout tear line.

WCSR 3942886v1 2 [0006] In yet another aspect, the present application includes a method of forming a spout in a carton. The method including providing a blank including a first side panel connected to a second side panel along a first fold line, the second side panel connected to a third side panel along a second fold line, the third side panel connected to a fourth side panel along a third fold line, and a reinforcement panel connected to the fourth side panel along a fourth fold line. The blank also including a first end flap at the first end of the blank attached along a first transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel. The blank also including a second end flap at the second end of the blank attached along a second transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel. The blank further including a spout guide flap formed in the reinforcement panel and the spout formed in the first side panel, with the spout having three sections including a first spout side section, a spout central section, and a second spout side section. The first spout side section connected to the central spout section along a first spout fold line and the central spout section being connected to the second spout side section along a second spout fold line. The method further including separating the spout along a spout tear line formed at least partially along a periphery of the spout. The method further comprising folding the first spout section inward along the first spout fold line and folding the second spout section inward along the second spout fold line to form the spout. The method further including hinging the spout into the spout guide flap. The method optionally can include a grasping protrusion at an upper portion of the spout, and the step of separating the spout along a spout tear line can further include grasping the grasping protrusion at a portion adjacent the aperture to begin separating the spout from the first side panel. The method optionally can include, prior to hinging the spout into the spout guide flap, separating at least partially the spout guide flap along a spout guide flap tear line disposed at least partially along a periphery thereof. Optionally still, the spout guide flap can be generally rectangular and can be hinged into the inside of the carton. Further, the first side portion can include a first hook portion and the second side portion can include a second hook portion.
Further still, the first hook portion and the second hook portion can be disposed in the interior of the carton when the spout is hinged into the spout guide flap.

WCSR 3942886v1 3 [0007] The foregoing and other features, aspects, and advantages of the invention will become more apparent upon review of the detailed description of the embodiments set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.

[0009] FIG. 1 is a top plan schematic view showing a carton blank according to one embodiment of the invention.

[00010] FIGS. 2 and 3 are perspective views illustrating initial steps of forming a sleeve from the blank of FIG. 1 into a shipping or storage configuration.

[00011] FIG. 4 is a perspective view illustrating opening the sleeve from the shipping or storage configuration of FIG. 3 into a carton.

[00012] FIGS. 5-8 are perspective views of steps of closing the ends of the carton.

[00013] FIG. 9 is a perspective view showing the carton formed upon the completion of the steps of FIGS. 2-8.

[00014] FIG. 10 illustrates preliminary steps of forming a spout in the carton of FIG. 9.

[00015] FIG. 11 illustrates a subsequent step of forming the spout.

[00016] FIG. 12 shows the spout formed in the carton in a closed configuration.

[00017] FIG. 13 show the spout of FIG. 12 folded outward into an open configuration for pouring contents out of an interior of the carton.

DETAILED DESCRIPTION

[00018] Briefly described, the present invention is directed to cartons. In this specification, the terms "side," and "end" are used for ease of description are not intended to limit the scope of the invention or to imply relative sizes or orientations of panels or flaps.

WCSR 3942886v1 4 [00019] FIG. 1 is a top plan schematic view showing the outer side (e.g., printed surface) of a carton blank 1, according to one embodiment of the invention.
In the following description, the terms "side wall panel" and "end wall panel"
are used to refer to panels that are arranged to form the side walls and end walls of a carton formed from the blank. Furthermore, references to the right hand and left hand sides of the carton blank 1 are respective to a person's right and left sides when viewing the blank 1 in the orientation shown in FIG. 1.

[00020] As shown in FIG. 1, the carton blank 1 includes a first side wall panel and a second side wall panel 20. Although size and shape variations are within the scope of the invention, the side wall panels 10 and 20 are shown as both having the same height and width, and are rectangular in shape. In the orientation shown in FIG.
1, side wall panel 10 is located on the left-hand side of the blank 1 and side wall 20 is located on the right-hand side of the blank 1.

[00021] A first end wall panel 30 is pivotally attached to side wall panel 10 along a fold line 12, which forms a left side edge of the side wall panel 10 and a right side edge of the end wall panel 30. A second end wall panel 40 is disposed between side wall panels 10 and 20. End wall panel 40 is pivotally attached to side wall panel 10 along a fold line 14, which forms a right side edge of side wall panel 10 and a left side edge of end wall panel 40. End wall panel 40 is pivotally attached to side wall panel 20 along a fold line 22, which forms a left side edge of side wall panel 10 and a right side edge of end wall panel 40.

[00022] Still referring to FIG. 1, blank 1 includes rectangular top flaps 60, that are pivotally attached to upper edges of respective side wall panels 10, 20 along fold lines 16, 26, and rectangular bottom flaps 70, 90 that are pivotally attached to bottom edges of side wall panels 10, 20 along fold lines 18, 28. Blank 1 is additionally provided with top flaps 100, 120 that are pivotally attached to top edges of respective end wall panels 30, 40 along fold lines 36, 46, and bottom flaps 110, 130 that are pivotally attached to bottom edges of end wall panels 30, 40 along fold lines 38, 48. Top flaps 100, 120 are separated from adjacent side edges of top flap 60 by vertical cut lines 104, 124, and bottom flaps 110, 130 are separated from adjacent side edges of bottom flap 70 by cut lines 114, 134. Similarly, top flap 120 is separated from the adjacent side edge of top flap 80 by a cut line 126, and bottom flap 130 is WCSR 3942886v1 5 separated from the adjacent side edge of bottom flap 90 by a cut line 136.
Preferably, cut lines 104, 124, 114, 134, 126, 136 are continuous cut lines extending entirely or substantially entirely through blank 1, however they may be replaced with tear lines, such as tear lines formed with an alternating series of slits and nicks. The outer side edges of top flap 100 and bottom flap 110 may have cut-away portions 102, 112 to provide clearance gaps in the erected carton 2 (FIGS. 7 and 5). Similarly, the side edges of top flap 120 and bottom flap 130 that are adjacent the top pane180 and bottom panel 90, respectively, may include cut-away portions 122, 132 extending from cut lines 126, 136, respectively to provide clearance gaps in folded carton 2 (see FIGS. 5 and 7).

[00023] A reinforcement wall panel 50 for reinforcing end wall panel 30 is attached to side wall panel 20 along a fold line 24. Fold line 24 forms a right side edge of side wall panel 20 and a left side edge of reinforcement wall panel 50.
Reinforcement wall panel 50 includes a free outer edge 57 on the right side thereof, and top and bottom edges 56, 58. As shown in FIG. 1, in order to provide extra clearance for folding top flaps 100, 120 and bottom flaps 110, 130 (FIGS. 5 and 7), top and bottom edges 56, 58 may be slightly tapered such that the height of the reinforcement wall panel decreases from fold line 24 to free side edge 57.

[00024] Referring again to FIG. 1, end wall panel 30 includes a spout flap 31 formed by an arrangement of tear lines and fold lines. Specifically, spout flap 31 includes wing-shaped side portions 33, 34 disposed on opposite sides of a central lip portion 32.

[00025] As shown in FIG. 1, lip portion 32 is pentagonal in shape and includes a bottom edge formed by a horizontal fold line 32a, two lower side edges formed by vertical fold lines 32b, 32c extending from opposite ends of the fold line 32a, and two upper side edges formed by tear lines 32d, 32e which extend from fold lines 32b, 32c, respectively, at an incline and join each other at the top of lip portion 32.
Upper side edges 32d, 32e form an inverted V-shaped protrusion 32f which is designed to be gripped by a user's finger.

[00026] Side portions 33, 34 of spout flap 31 are mirror images of each other.
Side portion 33 is formed by a series of tear lines 33a, 33b, 33d that extend from the intersection point of fold lines 32a and 32b to the intersection point of fold line 32b WCSR 3942886v1 6 and tear line 32d. Tear line 33a extends laterally outward and then obliquely upward and outward from the intersection point of fold lines 32b and 32c, thereby forming a bottom edge of side portion 33. Tear line 33b extends in a hook-shaped path from tear line 33a and defines a catch member 33c. Tear line 33d extends obliquely inward and upward from tear line 33b to the intersection point of fold line 32c and tear line 32d, thereby forming a top edge of side portion 33.

[00027] Side portion 34 is formed by a series of tear lines 34a, 34b, 34d that extend from the intersection point of fold lines 32a and 32c to the intersection point of fold line 32c and tear line 32e. Tear line 34a extends laterally outward and then obliquely upward and outward from the intersection point of fold lines 32a and 32c, thereby forming a bottom edge of side portion 34. Tear line 34b extends in a hook-shaped path from tear line 34a and defines a catch member 34c. Tear line 34d extends obliquely inward and upward from tear line 34b to the intersection point of fold line 32c and tear line 32e, thereby forming a top edge of side portion 34.
Although tear lines 32d, 32e, 33a, 33b, 33d, 34a, 34b, 34d are described as being individual lines, these lines can be continuous so as to constitute segments of a single tear line. Additionally, fold lines 32a, 32b, 32c may be segments of a single fold line.

[00028] Spout flap 31 can be partially punched out of blank 1 to form a spout 300 for pouring contents out of carton 2, as shown in FIGS. 12 and 13. An aperture 35 is formed in end wall panel 30 directly above inverted V-shaped protrusion 32f, to allow a user to access protrusion 32f of spout flap 31/spout 300 with a finger.
Although aperture 35 is shown to have a partial diamond shape, other shapes are possible.

[00029] As shown in FIG. 1, reinforcement wall panel 50 includes a spout guide flap 51. Spout guide flap 51 is substantially rectangular in shape and is defined by tear lines 51a, 51b, 51c and a fold line 51e. Tear lines 51a and 51c form bottom and top edges of flap 51. Fold line 51e and tear line 51b form opposite side edges of flap 51. An inverted V-shaped segment is provided in tear line 51c, thereby forming a small protrusion 51d at the top of flap 51 for accommodating side portions 33, 34 of the spout flap, as will be described later. Spout guide flap 51 can be partially punched out of blank 1 to form a spout guide 51' for spout 31' (see FIG. 13).

WCSR 3942886v1 7 [00030] The particular shapes and sizes of spout flap 31 and spout guide flap 51 illustrated and described herein are merely examples. Other shapes and sizes are possible for spout flap 31 and spout guide flap 51. Additionally, the locations of fold line 51e and tear line 51b may be reversed. Alternatively, spout guide flap 51 may be replaced with an aperture.

[00031] FIGS. 2-13 illustrate an exemplary procedure for erecting a carton 2 from blank 1, according to one embodiment of the invention. As shown in FIG.
2, in a first step, reinforcement wall panel 50 is folded inward approximately 180 degrees along fold line 24 such that the interior side of reinforcement wall panel 50 and the interior side of side wall panel 20 are in contact with each other, or are nearly in contact with each other. Thereafter, as shown in FIG. 3, side wall panel 10 and end wall panel 20 are folded inward together approximately 180 degrees along fold line 14 such that the interior side of end wall panel 30 lies on top of reinforcement wall panel 50, and free edge 37 of end wall panel 30 is aligned with fold line 24.
In this configuration, lip portion 32 of spout flap 31 is positioned over spout guide flap 51.
The interior side of end wall pane130 may be secured to the outer side of the reinforcement wall panel with an adhesive material or any other suitable mechanism.
As shown in FIG. 1, adhesive material may be applied, for example, to the outer side of reinforcement wall panel 50 at adhesive locations 53, 55. Alternatively, adhesive material may be applied at other locations on the outer side of reinforcement wall pane150, or on the interior side of end wall panel 30. However, spout flap 31 and spout guide flap 51 should be free of adhesive material.

[00032] In the position shown in FIG. 3, blank 1 is prefolded in a substantially flat configuration. Blank 1 may be configured as shown in FIG. 3 prior to shipping from the manufacturer to a distributor or retailer in order to allow for quick and simple erecting of carton 2. Thus, as indicated in FIG. 1, fold lines 14 and 24 may each be referred to as a "prebreak", since blank 1 can be arranged in a substantially flat shipping or storage configuration, prior to final assembly of carton 2, by folding blank 1 flat along fold lines 14, 24.

[00033] As shown in FIG. 4, once blank 1 has been arranged in the shipping/storage configuration of FIG. 3, the process of erecting carton 2 can be continued by folding blank 1 along fold lines 12, 22 such that end wall panels 30, 50 WCSR 3942886v1 8 are parallel to each other and are perpendicular to side wall panels 10, 20.
At this stage, blank 1 is converted to a partially erected carton or sleeve 2'.
Thereafter, as illustrated in FIG. 5, bottom flaps 110, 130 are folded inward along their respective fold lines 38, 48 such that bottom flaps 110, 130 are positioned within side walls 10, 20 and end walls 30, 40 and are substantially perpendicular to side walls 10, 20 and end walls 30, 40. Referring to FIG. 6, bottom flaps 70, 90 are then folded inward along respective fold lines 18, 28 such that bottom flaps 70, 90 extend between side wall panels 10, 20 and such that one of bottom flaps 70, 90 overlaps the other.
Bottom flaps 70, 90 can then be secured together with adhesive material, which can be applied to the outer side of inner bottom panel 90 or 70, or to the interior side of outer top panel 70 or 90. Partially erected carton 2' is ready to be filled with food or other materials.

[00034] Next, as shown in FIG. 7, top flaps 100, 120 are folded inward along respective fold lines 36 and 46 such that top flaps 100, 120 extend within side walls 10, 20 and end walls 30, 40 and are substantially perpendicular to side walls 10, 20 and end walls 30, 40. Turning now to FIG. 8, top flaps 60, 80 are then folded inward along their respective fold lines 16, 26 such that top flaps 60, 80 extend between side wall panels 10, 20 and such that one of the top flaps 60, 80 overlaps the other. Top flaps 60, 80 can then be secured together with adhesive material, which can be applied to the outer side of inner top panel 80 or 60, or to the interior side of outer top panel 60 or 80.

[00035] In the above description, bottom flaps 110, 130, 70, 90 are folded before top flaps 100, 120, 60, 80 are folded. However, it is possible to first fold top flaps 100, 120, 60, 80 to form a partially erected carton, then fill the partially erected carton and subsequently fold bottom flaps 110, 130, 70, 90. This variation is not shown, but is evident based on FIGS. 5-8 and the related description.

[00036] The completion of the step shown in FIG. 8 yields a carton 2, as shown in FIG. 9. In the configuration shown in FIG. 9, carton 2 forms a rectangular prism having opposing rectangular end walls 30, 40, rectangular opposing side walls 10, 20, a rectangular top wal160/80 and a rectangular bottom wall 70/90. Spout flap 31 typically remains fully attached to end wall 30 and aligned with spout guide flap 51, WCSR 3942886v1 9 which is positioned behind spout flap 31. An example of a procedure for converting spout flap 31 to an operational spout 300 is described below.

[00037] As shown in FIG. 10, to form spout 300, spout flap 31 is first partially separated, or struck from end wall panel 30 along tear lines 33a, 33b, 33d, 32d, 32e, 34a, 34b, 34d and then folded outward away from end wall panel 30 along fold line 32a, thereby creating an opening 39 having the shape of spout flap 31, and exposing the underlying spout guide flap 51 on reinforcement wall panel 50. This step may be accomplished by a user inserting a finger into the aperture, or finger hole 35, then gripping protrusion 32f of lip portion 32 with finger and thumb, and then pulling spout flap 31 outward.

[00038] Still referring to FIG. 10, spout guide flap 51 is then partially separated or struck from reinforcement wall panel 50 along tear lines 51a, 51b, 51c, and typically folded inward into the interior volume of carton 2 along fold line 51e, thereby creating a spout guide opening 59 having the shape of spout guide flap 51.
The top side of spout guide opening 59 includes a small extension channe159a which corresponds to protrusion 51d of spout guide flap 51. Thereafter, as illustrated in FIG. 11, side portions 33, 34 of spout flap 31 are folded inward towards each other and into alignment with spout guide opening 59 such that catch members 33c, 34c are aligned with extension channel 59a.

[00039] As shown in FIG. 12, spout flap 31 is then pushed inward such that side portions 33, 34 are inserted through openings 39, 59 and into the interior volume of carton 2, and lip portion 32 of spout flap 31 is substantially flushly aligned with end wall pane130. Once side portions 33, 34 are inserted through openings 39, 59, side portions 33, 34 typically fold outward and away from each other along fold lines 32b, 32c such that catch members 33c, 34c extend vertically above openings 39, 59.
Upon the completion of this step, spout flap 31 and openings 39, 59 cooperate to form spout 300 configured in a closed position. Gripping protrusion 32f engages the outwardly facing surface of reinforcement wall panel 50 in a manner that seeks to prevent lip portion 32 from being pushed all the way through opening 59.

[00040] As shown in FIG. 13, spout 300 can be moved to an open position by pulling spout flap 31 outward, thereby exposing a portion of openings 39, 59 such that food or other materials can be poured out of spout 300. Spout 300 may be moved to WCSR 3942886v1 10 the open position by the user inserting a finger into the aperture, or finger hole 35, then gripping protrusion 32f of lip portion 32 with finger and thumb, and then pulling spout flap 31 outward. When spout flap 31 is pulled outward, there is a frictional interaction between side portions 33, 34 and spout guide opening 59, thereby supporting spout flap 31 and guiding the outward movement of spout flap 31.
Outward movement of spout flap 31 is limited by catch members 33c, 34c, which will engage the interior side of reinforcement wall pane150 to prevent spout flap 31 from being pulled completely out of openings 39, 59. Thus, spout 300 can be selectively opened and closed by a user.

[00041] For exemplary purposes only, the carton can be formed from a blank with dimensions including an overall example length of panels 10, 20, 30, 40, and 50 of at least approximately about 20 to 25 inches, such as for example at least approximately 21.375 inches with panel 50 having a length of at least approximately 2 to 3 inches, such as for example at least approximately 2.406-inch, panels 10 and 20 having lengths of at least approximately 5 to 10 inches, such as for example at least approximately 7 inches, panel 30 having a length of at least approximately 2 to 3 inches, such as for example at least approximately 2.469-inch, and pane140 having a length of at least approximately 2 to 3 inches, such as for example at least approximately 2.5-inch. The blank 5 can have an example width of at least approximately 10 to 20 inches, such as for example at least approximately 14.938-inch, with a width between longitudinal fold lines 16 and 28 at least approximately 5 to 15 inches, such as for example at least approximately 10-inch, and end flap widths at least approximately 2 to 3 inches, such as for example at least approximately 2.469-inches. The blank 1 can be formed of any caliper. All dimensional information presented herein is intended to be illustrative of typical embodiments of the disclosure and is not intended to be limiting. Further, the various features of the blanks 5 and 6 and the carton formed therefrom can have dimensions other than listed herein, without departing from the scope of this disclosure.

[00042] The blank 1 can be selectively reinforced at any specified locations by one or more reinforcing blanks. Cartons formed from the resulting multi-ply blanks can accordingly have enhanced strength and rigidity at selected sections of the carton.
WCSR 3942886v1 11 Selected reinforcement of specific areas of a blank can produce high strength cartons while using relatively small amounts of reinforcing blank.

[00043] In accordance with the exemplary embodiments, the cartons may be constructed of paperboard, for example. The blanks, and thus the cartons, can also be constructed of other materials, such as cardboard, solid unbleached sulfate (SUS) board, or any other material having properties suitable for enabling the carton to function at least generally as described above.

[00044] The blanks can also be laminated to or coated with one or more additional sheet-like materials at selected panels or panel sections. One or more panels of the blanks discussed above can be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product, advertising, and other information or images. The blanks may also be coated to protect information printed on the blanks. The blanks may be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.

[00045] For purposes of the description presented herein, the term "line of disruption" or "line of weakening" can be used to generally refer to cuts, tear lines, creases, scores, and fold lines (or overlapping and/or sequential combinations of at least one cut, crease, score, tear line, or fold line). A "breachable line of disruption"
is a line of disruption that is intended to be breached during ordinary use of the carton, such as when placing the carton in a dispensing configuration. An example of a breachable line of disruption is a tear line.

[00046] In accordance with the exemplary embodiments of the present invention, a fold line can be any substantially linear, although not necessarily straight, form of disruption or weakening in a blank that facilitates folding, pivoting or bending therealong.

[00047] In the present specification, a "panel" or "flap" need not be flat or otherwise planar. A "panel" or "flap" can, for example, comprise a plurality of interconnected generally flat or planar sections.

[00048] The above embodiments may be described as having one or more panels adhered together by glue. The term "glue" is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

WCSR 3942886v1 12 [00049] It will be understood by those skilled in the art that while the present invention has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention. For example, embodiments of the invention have been described as having several features included in combination, whereas each of these features may be included in a carton in isolation and in various combinations.

WCSR 3942886v1 13

Claims

1. A blank having a first end and a second end, the blank comprising:
a first side panel connected to a second side panel along a first fold line, the second side panel connected to a third side panel along a second fold line, the third side panel connected to a fourth side panel along a third fold line, and a reinforcement panel connected to the fourth side panel along a fourth fold line;
a first end flap at the first end of the blank attached along a first transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel;
a second end flap at the second end of the blank attached along a second transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel;
a spout formed in the first side panel; the spout comprising a spout flap and an aperture; and, a spout guide flap formed in the reinforcement panel.

2. The blank of claim 1 wherein the spout has three sections, including a center section disposed between a first side section and a second side section, the first side section being connected to the center section along a first spout fold line, and the center section being connected to the second side section along a second spout fold line.

3. The blank of claim 2 wherein the spout is partially separable from the first side panel along a spout tear line extending at least partially along a periphery of the spout.

4. The blank of claim 3 wherein the spout includes a gripping protrusion at an upper portion of the spout, the gripping protrusion being adjacent the aperture.

5. The blank of claim 4 wherein the gripping protrusion can be grasp to separate the spout along the spout tear line.

6. A carton comprising:
a first side panel connected to a second side panel along a first fold line, the second side panel connected to a third side panel along a second fold line, the third side panel connected to a fourth side panel along a third fold line, and a reinforcement panel connected to the fourth side panel along a fourth fold line;
a first end flap at the first end of the blank attached along a first transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel;
a second end flap at the second end of the blank attached along a second transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel;
the reinforcing panel being connected by adhesive to the first side panel;
a spout formed in the first side panel; the spout being adjacent an aperture formed in the first side panel; and, a spout guide flap formed in the reinforcement panel.

7. The carton of claim 6 wherein the spout has three sections, including a center section disposed between a first side section and a second side section, the first side section being connected to the center section along a first spout fold line, and the center section being connected to the second side section along a second spout fold line.

8. The carton of claim 7 wherein the spout is partially separable from the first side panel along a spout tear line extending at least partially along a periphery of the spout.

9. The carton of claim 8 wherein at least a portion of the spout is aligned with the spout guide flap and wherein adhesive is not applied to the spout or the spout guide flap.

10. The carton of claim 9 wherein the spout includes a gripping protrusion at an upper portion of the spout, the gripping protrusion being adjacent the aperture.

11. The carton of claim 10 wherein the gripping protrusion can be grasp to separate the spout along the spout tear line.

12. A method of forming a spout in a carton, the method comprising:
providing a blank, the blank including a first side panel connected to a second side panel along a first fold line, the second side panel connected to a third side panel along a second fold line, the third side panel connected to a fourth side panel along a third fold line, and a reinforcement panel connected to the fourth side panel along a fourth fold line; the blank also including a first end flap at the first end of the blank attached along a first transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel; the blank also including a second end flap at the second end of the blank attached along a second transverse fold line to either the first side panel, the second side panel, the third side panel, or the fourth side panel; the blank further including a spout guide flap formed in the reinforcement panel and the spout formed in the first side panel, the spout having three sections including a first spout side section, a spout central section, and a second spout side section, with the first spout side section connected to the central spout section along a first spout fold line and the central spout section being connected to the second spout side section along a second spout fold line;
separating the spout along a spout tear line, the spout tear line being formed at least partially along a periphery of the spout;
folding the first spout section inward along the first spout fold line and folding the second spout section inward along the second spout fold line to form the spout;
and, hinging the spout into the spout guide flap.

13. The method of claim 12 wherein the spout further includes a grasping protrusion at an upper portion and wherein the step of separating the spout along a spout tear line further includes:
grasping the grasping protrusion at a portion adjacent the aperture to begin separating the spout from the first side panel.

14. The method of claim 12 wherein prior to hinging the spout into the spout guide flap, the method further comprises:
separating at least partially the spout guide flap along a spout guide flap tear line disposed at least partially along a periphery thereof.

15. The method of claim 14 wherein the spout guide flap is generally rectangular and is hinged into the inside of the carton.

16. The method of claim 12 wherein the first side portion includes a first hook portion and the second side portion includes a second hook portion.

17. The method of claim 16 wherein the first hook portion and the second hook portion are disposed in the interior of the carton when the spout is hinged into the spout guide flap.