DIRECT CONTACT CARTON POUR SPOUT DEVICE

Abstract

A direct contact pour spout carton device is provided. 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 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.

Claims

1. A direct contact pour spout carton device comprising: a carton body comprising a plurality sidewall, a bottom, and a top, wherein the carton body is foldable into an assembled configuration; a pour spout integrated into the carton body, the pour spout comprising: a sidewall perforated portion, a top perforation portion, a living hinge connecting the carton body to a cap portion, wherein the cap portion is configured to pivot via the living hinge; and a first perforation line defining the sidewall perforated portion and a second perforation line defining the top perforation portion, wherein the first perforation line and the second perforation line are configured to be broken to form an opening for dispensing from the carton body.

2. The direct contact pour spout carton device of claim 1, wherein the living hinge is scored on the carton body.

3. The direct contact pour spout carton device of claim 1 further comprised of a reclosure fastener configured to release the pour spout after an initial use.

4. The direct contact pour spout carton device of claim 1, wherein the carton body is comprised of an embossed material to improve grip.

5. The direct contact pour spout carton device of claim 1, wherein the carton body is comprised of a textured material to improve grip.

6. The direct contact pour spout carton device of claim 1, wherein the carton body is comprised of a foil-lined board.

7. The direct contact pour spout carton device of claim 1, wherein the carton body is comprised of a paper-based material and an aluminum.

8. The direct contact pour spout carton device of claim 1, wherein the carton body is comprised of a milk stock material and an aluminum.

9. The direct contact pour spout carton device of claim 1, wherein the carton body is comprised of a multilayer composite.

10. The direct contact pour spout carton device of claim 9, wherein the carton body is further comprised of a plant-derived polymer.

11. A direct contact pour spout carton device comprising: a carton body formed from a paper-based material, the carton body comprising: a sidewall, a bottom, and a top; and a pour spout integrated into the carton body, the pour spout comprising: a perforated portion located along the sidewall and the top, a cap portion detachable along the perforated portion, and a living hinge configured to allow pivoting of the cap portion while remaining attached to the carton body.

12. The direct contact pour spout carton device of claim 11, wherein the carton body is comprised of a milk stock or a paper-based material.

13. The direct contact pour spout carton device of claim 11, wherein the carton body is comprised of a skive seal.

14. The direct contact pour spout carton device of claim 11, wherein the top is comprised of a gable top.

15. The direct contact pour spout carton device of claim 11, wherein the gable top is comprised of a first side panel and a second side panel converging at a ridge.

16. The direct contact pour spout carton device of claim 15, wherein the gable top is comprised of a first end panel and a second end panel terminating below the ridge.

17. The direct contact pour spout carton device of claim 11, wherein the top is comprised of a flat top.

18. The direct contact pour spout carton device of claim 11, wherein the top is comprised of a tapered top.

19. The direct contact pour spout carton device of claim 11 further comprised of a reclosure fastener.

20. A method of manufacturing a direct contact pour spout carton device, the method comprising the following steps: generating a carton body template comprising a side panel, a bottom panel, and a top panel; forming a pour spout in the carton body template by creating a first perforated portion on at the side panel and a second perforation portion on the top panel, a cap portion defined by the perforated portions, and a living hinge adjacent to the cap portion; assembling a carton body by folding the carton body template along a predefined fold line and joining a first edge and a second edge of the template to form a sealed enclosure; and activating the pour spout by breaking the first perforated portion and the second perforated portion to create an opening for dispensing a content from the carton body.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which:

[0019] FIG. 1 illustrates a perspective view of one potential embodiment of a direct contact pour spout carton device of the present invention in accordance with the disclosed architecture;

[0020] FIG. 2 illustrates a perspective view of one potential embodiment of a direct contact pour spout carton device of the present invention in accordance with the disclosed architecture; and

[0021] FIG. 3 illustrates a flowchart of a method of manufacturing one potential embodiment of a direct contact pour spout carton device of the present invention in accordance with the disclosed architecture.

DETAILED DESCRIPTION

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] Referring initially to the drawings, FIG. 1 illustrates a perspective view of one potential embodiment of a direct contact pour spout carton device 100 of the present invention in accordance with the disclosed architecture. The direct contact pour spout carton device 100 is comprised of a carton body 110 that is folded to assemble a carton with a gable top configuration. However, different embodiments of the direct contact pour spout carton device 100 may 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.

[0031] The carton body 110 is comprised of at least one (but preferably a plurality of) sidewalls 120, a bottom 130, and a top 140, which collectively create the structural surfaces of the device 100 when folded and assembled. The plurality of sidewalls 120 may comprise a first sidewall 122, a second sidewall 124, a third sidewall (not shown), and a fourth sidewall (not shown). Each sidewall 120 is generally planar but may include embossed, raised and/or recessed textured, or printed elements for branding or functional enhancements such as improved grip.

[0032] The outer surface 112 and inner surface 114 of the carton body 110 are comprised of a paper-based or paperboard material of relatively low-density polyethylene (LDPE) on one or both surfaces 112,114. 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 body 110 may 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.

[0033] It is noted that, in some embodiments, the carton body 110 may be made from a foil-lined board and is comprised of at least one skive seal 190, as seen in FIG. 2, to enhance durability in wet environments. The foil-lined board introduces an additional barrier layer against moisture ingress, making the device 100 particularly suited for applications where prolonged exposure to humid conditions or refrigeration is anticipated. The skive seal 190 reinforces the integrity of the edges and joins, ensuring resistance to liquid leakage. In different embodiments, the seal 190 may be a single, double, or multi-skive seal 190.

[0034] The top 140 of the body 110, in the embodiment shown, is configured as a gable top. The gable top 140 comprises a pair of opposing side panels 144 and a pair of opposing end panels 148. The side panels 144 extend upward from a pair of opposing sidewalls 120 and converge at a ridge 146. The end panels 148 extend upward from the remaining sidewalls 120 and terminate below the ridge 146. 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 top 140 may include scored or pre-folded lines 192 to facilitate user manipulation and ensure structural integrity during transport and storage.

[0035] The pour spout 150 is integrated into the carton body 110 and is configured for convenient dispensing of the carton's contents. The pour spout 150 comprises a sidewall perforated portion 152, a top perforation portion 154, a living hinge 156, and a cap portion 160. The cap portion 160 is a detachable flap formed as part of the carton body 110 and is secured along the perforation lines 152,154 of the sidewall perforated portion 152 and the top perforation portion 154. The living hinge 156 movably connects the cap portion 160 to the carton body 110, allowing the cap portion 160 to pivot while remaining permanently attached. The living hinge 156 may be constructed by scoring or thinning the body 110 material at the hinge 156 location during manufacturing to provide flexibility without compromising durability.

[0036] When the perforation lines of the sidewall perforated portion 152 and the top perforation portion 154 are broken, an opening 158 is formed for dispensing the device's 100 contents. The perforation lines 152,154 may vary in their density, pattern, or depth to balance ease of opening with resistance to unintentional damage during handling. The pour spout 150 may also include a reclosure fastener 196, such as a tab or adhesive strip, to allow the device 100 to be resealed after initial use.

[0037] The present invention also includes a method of manufacturing 200 the direct contact pour spout carton device 100. The method 200 begins with generating a carton body 110 template comprising a plurality of side panels 120, a bottom panel 130, and a top panel 140 [Step 202]. The template may be formed using precision die-cutting techniques to ensure uniformity and minimize material waste. Next, the pour spout 150 is integrated into the template by forming the perforated portions 152 and 154, the living hinge 156, and the cap portion 160 [Step 204]. These features may be created through a combination of mechanical scoring, laser cutting, or perforation processes. The carton body 110 is then assembled by folding the template along predefined fold lines and joining the edges of the body 110 using adhesive, heat sealing, or ultrasonic welding methods, depending on the material [Step 206]. The resulting device 100 comprises the plurality of sidewalls 120, the bottom 130, and the top 140, forming a sealed enclosure. Finally, the pour spout 150 is activated by breaking the perforations 152,154 along the sidewall perforated portion 152 and the top perforation portion 154 to create the opening 158 for dispensing the device's 100 contents [Step 208].

[0038] 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 device 100 of the present invention.

[0039] Notwithstanding the forgoing, the direct contact pour spout carton device 100 of 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 device 100 as shown in the FIGS. are for illustrative purposes only, and that many other sizes and shapes of the direct contact pour spout carton device 100 are well within the scope of the present disclosure. Although the dimensions of the direct contact pour spout carton device 100 are important design parameters for user convenience, the direct contact pour spout carton device 100 may 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.

[0040] 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.

[0041] 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.