Method of forming a container having an integral pour spout

Abstract

A packaging blank capable of forming a reclosable container comprises in one embodiment a front panel having opposing side panels, a rear panel connected to the front panel by the second side panel, a top panel connected to a top edge of the front panel, a bottom panel connected to a bottom edge of the front panel, and a pour spout flap connected to a top edge of the second side panel. Upon construction the packaging blank provides a reclosable container having an integral pour spout that is releasably securable to a portion of the top panel. Still further, the invention relates to a method of forming the container and a method of packaging articles in the container.

1 . A method of packaging articles in a container having a reclosable pour spout, said method comprising the steps of: 
 providing a one-piece flexible blank having a front panel, first and second side panels connected to opposing edges of the front panel, a rear panel connected to the front panel by the second side panel, a first bottom panel connected to a bottom edge of the front panel, a second bottom panel connected to a bottom edge of the rear panel, a glue flap connected to an edge of the rear panel opposite the edge to which the second side panel is connected, and a pour spout flap connected to a top edge of the second side panel;    folding the blank to form a container having an internal packaging compartment; and    positioning articles to be packaged in the packaging compartment;    wherein the container is substantially flat, yet capable of being constructed into a substantially rectangular container.    
   
   
       2 . A method according to  claim 1 , wherein the step of folding the blank comprises: 
 folding the rear panel over the front panel; and    securing the glue flap to an edge of the first side panel such that the rear panel and front panel, and the first side panel and second side panel, define substantially parallel planes, respectively.    
   
   
       3 . A method according to  claim 2 , wherein the blank provided includes: 
 a first bottom flap connected to a bottom edge of the first side panel;    a second bottom flap connected to a bottom edge of the second side panel; and    wherein the step of folding further comprises:    folding the second bottom panel towards the front panel;    folding the first and second bottom flaps against the second bottom panel; and    securing the first and second bottom flaps to the second bottom panel;    the steps performed after the step of securing the glue flap.    
   
   
       4 . A method according to  claim 3 , wherein the step of folding further comprises: 
 folding the first bottom panel against the second bottom panel, first bottom flap, and second bottom flap; and    securing the first bottom panel to the second bottom panel such that the first bottom flap and second bottom flap are secured between the first and second bottom panels;    the steps performed after the step of securing the first and second bottom flaps.    
   
   
       5 . A method according to  claim 1 , further comprising the step of forming a reclosable pour spout after the step of positioning the articles.  
   
   
       6 . A method according to  claim 5 , wherein the blank provided includes: 
 a first top panel connected to a top edge of the front panel, the first top panel having an opening adjacent to the pour spout flap; and    a second top panel connected to a top edge of the rear panel, the second top panel having an opening adjacent to the pour spout flap; and    a first top flap connected to a top edge of the first side panel; and    the step of forming the reclosable pour spout comprises:    folding the second top panel towards the front panel such that the second top panel and the first and second bottom panels define substantially parallel planes;    folding the first top flap against the second top panel; and    securing the first top flap to the second top panel.    
   
   
       7 . A method according to  claim 6 , wherein the step of forming further comprises: 
 folding the first top panel against the second top panel and the first top flap such that the openings in the first and second top panels are in communication; and    securing the first top panel to the second top panel such that the first top flap is secured between the first and second top panels;    the steps performed after the step of securing the first top flap.    
   
   
       8 . A method according to  claim 7 , wherein the step of folding further comprises: 
 folding the pour spout flap against the first top panel; and    securing the pour spout flap against the first top panel such that removal of the pour spout flap from the first top panel permits the articles in the container to flow through the openings in the first and second top panels;    the steps performed after the step of securing the first top panel.    
   
   
       9 . A method of forming a container having a reclosable pour spout, said method comprising the steps of: 
 providing a one-piece flexible blank having a front panel, first and second side panels connected to opposing edges of the front panel, a rear panel connected to the front panel by the second side panel, a first top panel connected to a top edge of the front panel, a second top panel connected to a top edge of the rear panel, a first bottom panel connected to a bottom edge of the front panel, a second bottom panel connected to a bottom edge of the rear panel, a glue flap connected to an edge of the rear panel opposite the edge to which the second side panel is connected, and a pour spout flap connected to a top edge of the second side panel; and    folding the blank to form a container having a reclosable pour spout;    wherein the container is substantially flat, yet capable of being constructed into a substantially rectangular container.    
   
   
       10 . A method according to  claim 9 , wherein the step of folding the blank comprises: 
 folding the rear panel over the front panel; and    securing the glue flap to an edge of the first side panel such that the rear panel and front panel, and the first side panel and second side panel, define substantially parallel planes, respectively.    
   
   
       11 . A method according to  claim 10 , wherein the step of folding further comprises: 
 folding the second bottom panel towards the front panel; and    folding the second top panel towards the front panel such that the second top panel and the second bottom panel define substantially parallel planes;    the steps performed after the step of securing the glue flap.    
   
   
       12 . A method according to  claim 11 , wherein the blank provided includes: 
 a first top flap connected to a top edge of the first side panel; and    the step of folding further comprises:    folding the first top flap against the second top panel; and    securing the first top flap to the second top panel;    the steps performed after the step of folding the second top panel.    
   
   
       13 . A method according to  claim 12 , wherein the blank provided includes: 
 a first bottom flap connected to a bottom edge of the first side panel; and    a second bottom flap connected to a bottom edge of the first side panel; and    the step of folding further comprises:    folding the first and second bottom flaps against the second bottom panel; and    securing the first and second bottom flaps to the second bottom panel;    the steps performed after the step of securing the first top flap.    
   
   
       14 . A method according to  claim 13 , wherein the step of folding further comprises: 
 folding the first bottom panel against the second bottom panel, first bottom flap, and second bottom flap; and    securing the first bottom panel to the second bottom panel such that the first and second bottom flaps are secured between the first and second bottom panels;    the steps performed after the step of securing the first and second bottom flaps.    
   
   
       15 . A method according to  claim 14 , wherein the blank provided includes: 
 an opening defined by the first top panel; and    an opening defined by the second top panel;    wherein the step of folding further comprises:    folding the first top panel against the second top panel and first top flap such that the openings in the first and second top panels are in communication; and    securing the first top panel to the second top panel such that the first top flap is secured between the first and second top panels;    the steps performed after the step of securing the first bottom panel.    
   
   
       16 . A method according to  claim 15 , wherein the step of folding further comprises: 
 folding the pour spout flap against the first top panel; and    securing the pour spout flap to the first top panel to thereby releasably seal the openings in the first and second top panels;    the steps performed after the step of securing the first top panel.