Carton with Pour Spout

Abstract

Cartons with pour spouts for dispensing materials such as granular or pelletal materials are disclosed. A carton according to the disclosure is easily converted from a closed configuration for storing materials to an open configuration in which a spout is formed for pouring materials from the carton. The carton can also be easily and securely reclosed after being used in the open configuration. When the carton is in a closed configuration, a top panel can be formed from overlapping side top flaps. A front top end flap or panel can be folded under the side top flaps. The front top end flap or panel and portions of the side top flaps can be unfolded to form a spout and thereby place the carton in an open configuration. The spout and the side top flaps can be folded into closed positions after opening the carton in order to place the carton in a reclosed configuration.

1 . A carton comprising:
 a front panel;   a rear panel;   a first side panel;   a second side panel opposite the first side panel;   a bottom panel;   a top panel comprising a first side top flap and a second side top flap; and   a front top end panel foldably connected to the front panel, the first side top flap and the second side top flap;   wherein, when the carton is in a closed configuration
 the front top end panel extends inwardly from the front panel towards an interior of the carton, 
 the second side top flap partially overlaps the first side top flap or the first side top flap partially overlaps the second side top flap, and 
 the first side top side flap and the second side top side flap lie over the front top end panel; and 
   wherein the carton is configured to be placed in an open configuration in which a spout is formed in a top of the carton and defines an opening for pouring contents from the carton; and   wherein, when the carton is in the open configuration, the front top end panel is folded outwardly away from the interior of the carton and forms a front lip of the spout, and portions of the first and second top side flaps form side walls of the spout.   
     
     
         2 . The carton of  claim 1 , wherein the front top end panel comprises a center section foldably connected to the front panel, a first side section foldably connected to center section and the first side top flap, and a second side section foldably connected to the center section and the second side top flap. 
     
     
         3 . The carton of  claim 2 , wherein, when the carton is in the closed configuration, the first side section and the second side section are folded over the center section. 
     
     
         4 . The carton of  claim 3 , wherein the center section, the first side section and the second side section are triangular sections. 
     
     
         5 . The carton of  claim 1 , wherein:
 the first side top flap comprises a first flap section, a second flap section and a first break line between the first flap section and the second flap section, the first flap section being foldably connected to the front top end panel; and   the second side top side flap comprises third flap section, a fourth flap section and a second break line between the third flap section and the fourth flap section, the third flap section being foldably connected to the front top end panel;   wherein, when the carton is in the closed configuration
 the first flap section and the second flap section are detachably connected to each other along the first break line, 
 the third flap section and the fourth flap sections are detachably connected to each other along the second break line, and 
 the second and fourth flap sections are attached to each other. 
   
     
     
         6 . The carton of  claim 5 , wherein:
 the first flap section and the second flap section are foldably connected to each other along a first fold line extending from the first break line; and   the third flap section and the fourth flap section are foldably connected to each other along a second fold line extending from the second break line.   
     
     
         7 . The carton of  claim 6 , wherein the first and second fold lines are oblique fold lines. 
     
     
         8 . The carton of  claim 6 , wherein, when the carton is in the open configuration:
 the first flap section and the second flap section are detached from each other along the first break line,   the third flap section and the fourth flap section are detached from each other along the second break line,   the second flap section and the fourth flap section are attached to each other, and   the first flap section and the third flap section are folded along the first fold line and the second fold line, respectively, and extend transversely to the second flap section and the fourth flap section, thereby forming the side walls of the spout.   
     
     
         9 . The carton of  claim 5 , wherein, when the carton is in the open configuration:
 the first flap section and the second flap section are detached from each other along the first break line;   the third flap section and the fourth flap section are detached from each other along the second break line;   the second flap section and the fourth flap section are attached to each other; and   the first flap section and the third flap section extend transversely to the second flap section and the fourth flap section, thereby forming the side walls of the spout.   
     
     
         10 . The carton of  claim 1 , wherein the front panel comprises a female locking member configured to receive and retain a tip of the spout lip for reclosing the carton after the carton has been placed in the open configuration. 
     
     
         11 . The carton of  claim 1 , wherein:
 the carton is configured to be placed in a reclosed configuration after being placed in the open configuration; and   when the carton is in the reclosed configuration, the first side top flap and the second side top flap are folded in an overlapping relationship, the front lip of the spout extends downwardly, substantially parallel to the front panel, and a tip of the front lip is received in a female locking member in the front panel.   
     
     
         12 . The carton of  claim 1 , wherein:
 the carton is configured to be placed in a reclosed configuration after being placed in the open configuration; and   when the carton is in the reclosed configuration, the first side top flap and the second side top flap are folded in an overlapping relationship, and the front lip of the spout extends substantially parallel to and lies below the first side top flap and the second side top flap.   
     
     
         13 . A carton comprising:
 a front panel;   a rear panel;   a first side panel;   a second side panel opposite the first side panel;   a bottom panel;   a top panel comprising
 a first side top flap comprising a first flap section, a second flap section, and a first break line between the first flap section and the second flap section; and 
 a second side top flap comprising a third flap section, a fourth flap section, and a second break line between the third flap section and the fourth flap section; and 
   a front top end flap or front top end panel foldably connected to the front panel;   wherein, when the carton is in a closed configuration
 the front top end flap or front top end panel extends inwardly from the front panel towards an interior of the carton beneath the first side top flap and the second side top flap, and 
 the second side top flap partially overlaps the first side top flap, or the first side top flap partially overlaps the second side top flap; 
   wherein the carton is configured to be placed in an open configuration in which a spout is formed in a top of the carton and defines an opening for pouring contents from the carton; and   wherein, when the carton is in the open configuration
 the front top end flap or front top end panel is folded outwardly away from the interior of the carton and forms a front lip of the spout, 
 the first flap section and the second flap section are detached from each other along the first break line, 
 the third flap section and the fourth flap section are detached from each other along the second break line, and 
 the first flap section and the third flap section extend transversely to the second flap section and the fourth flap section, thereby forming side walls of the spout. 
   
     
     
         14 . The carton of  claim 13 , wherein the second flap section and the fourth flap section are attached to each other when the carton is in the closed configuration and when the carton is in the open configuration. 
     
     
         15 . The carton of  claim 13 , wherein the front top end flap or front top end panel comprises a center section, a first side section foldably connected the center section, and a second side section foldably connected to the center section. 
     
     
         16 . The carton of  claim 13 , wherein:
 the first flap section and the second flap section are foldably connected to each other along a first fold line extending from the first break line; and   the third flap section and the fourth flap section are foldably connected to each other along a second fold line extending from the second break line.   
     
     
         17 . The carton of  claim 16 , wherein the first and second fold lines are oblique fold lines or arcuate fold lines. 
     
     
         18 . The carton of  claim 16 , wherein, when the carton is in the open configuration, the first flap section and the third flap section are folded along the first fold line and the second fold line, respectively. 
     
     
         19 . The carton of  claim 1 , wherein:
 the carton is configured to be placed in a reclosed configuration after being placed in the open configuration; and   when the carton is in the reclosed configuration, the first flap section and the third flap section are folded in an overlapping relationship, the front lip of the spout extends inwardly from the front panel towards an interior of the carton, and the first flap section and the second flap section lie over the front lip.   
     
     
         20 . The carton of  claim 19 , wherein the first flap section includes a first notch and the third flap section includes a second notch, and wherein the first notch and the second notch interlockingly engage each other when the carton is in the reclosed configuration. 
     
     
         21 . The carton of  claim 13 , wherein the rear panel comprises gripping regions disposed adjacent to the first side panel and the second side panel, the gripping regions extending transversely to a remainder of the rear panel. 
     
     
         22 . A carton blank for forming a carton, comprising:
 a front panel;   a rear panel;   a first side panel foldably connected to the front panel;   a second side panel foldably connected to the front panel;   a first side top flap foldably connected to the first side panel;   a second side top flap foldably connected to the second side panel;   a plurality of flaps configured to form a bottom panel of the carton; and   a front top end panel foldably connected to the front panel, the first side top flap and the second side top flap;   wherein the blank is configured to form the carton in a closed configuration in which
 the front top end panel extends inwardly from the front panel towards an interior of the carton, 
 the second side top flap partially overlaps the first side top flap, or the first side top flap partially overlaps the second side top flap, and 
 the first side top side flap and the second side top side flap lie over the front top end panel; and 
   wherein the blank is configured to form the carton in an open configuration in which
 a spout is formed in a top of the carton and defines an opening for pouring contents from the carton, 
 the front top end panel is folded outwardly away from the interior of the carton and forms a front lip of the spout, and 
 portions of the first and second top side flaps form side walls of the spout. 
   
     
     
         23 . The carton blank of  claim 22 , wherein the front top end panel comprises a center section foldably connected to the front panel, a first side section foldably connected to center section and the first side panel, and a second side section foldably connected to the center section and the second side panel. 
     
     
         24 . The carton blank of  claim 23 , wherein the first side section and the second side section are configured to be folded over the center section when the carton is in the closed configuration. 
     
     
         25 . The carton blank of  claim 24 , wherein the center section, the first side section and the second side section are triangular sections. 
     
     
         26 . The carton blank of  claim 22 , wherein:
 the first side top flap comprises a first flap section and a second flap section detachably connected to each other along a first break line, the first flap section being foldably connected to the front top end panel; and   the second side top side flap comprises third flap section and a fourth flap section detachably connected to each other along a second break line, the third flap section being foldably connected to the front top end panel;   wherein, the blank is configured to form the carton in the closed configuration such that
 the first flap section and the second flap section are detachably connected to each other along the first break line, 
 the third flap section and the fourth flap sections are detachably connected to each other along the second break line, and 
 the second and fourth flap sections are attached to each other. 
   
     
     
         27 . The carton blank of  claim 26 , wherein:
 the first flap section and the second flap section are foldably connected to each other along a first fold line extending from the first break line; and   the third flap section and the fourth flap section are foldably connected to each other along a second fold line extending from the second break line.   
     
     
         28 . The carton blank of  claim 27 , wherein the first and second fold lines are oblique fold lines. 
     
     
         29 . The carton blank of  claim 27 , wherein the blank is configured to form the carton in the open configuration such that:
 the first flap section and the second flap section are detached from each other along the first break line,   the third flap section and the fourth flap section are detached from each other along the second break line,   the second flap section and the fourth flap section are attached to each other, and   the first flap section and the third flap section are folded along the first fold line and the second fold line, respectively, and extend transversely to the second flap section and the fourth flap section, thereby forming the side walls of the spout.   
     
     
         30 . The carton blank of  claim 26 , wherein the blank is configured to form the carton in the open configuration such that:
 the first flap section and the second flap section are detached from each other along the first break line;   the third flap section and the fourth flap section are detached from each other along the second break line;   the second flap section and the fourth flap section are attached to each other; and   the first flap section and the third flap section extend transversely to the second flap section and the fourth flap section, thereby forming the side walls of the spout.   
     
     
         31 . The carton blank of  claim 22 , wherein the front panel comprises a female locking member configured to receive and retain a tip of the spout lip for reclosing the carton after the carton has been placed in the open configuration. 
     
     
         32 . The carton blank of  claim 22 , wherein:
 the blank is configured to form the carton in a reclosed configuration after the carton is placed in the open configuration; and   the front lip of the spout is configured to extend downwardly, substantially parallel to the front panel when the carton is in the reclosed configuration, with a tip of the front lip received in an opening in the front panel.   
     
     
         33 . The carton blank of  claim 22 , wherein:
 the blank is configured to form the carton in a reclosed configuration after the carton is placed in the open configuration;   the first side top flap and the second side top flap are configured to be folded in an overlapping relationship when the carton is in the reclosed configuration; and   the front lip of the spout is configured to extend substantially parallel to and lie below the first side top flap and the second side top flap when the carton is in the reclosed configuration.   
     
     
         34 . A carton blank for forming a carton, comprising:
 a rear panel;   a first side panel foldably connected to the rear panel;   a second side panel foldably connected to the rear panel;   a first side top flap foldably connected to the first side panel, the first side top flap comprising a first flap section, a second flap section and a first break line between the first flap section and the second flap section;   a second side top flap foldably connected to the second side panel, the second side top flap comprising a third flap section, a fourth flap section and a second break line between the third flap section and the fourth flap section;   a plurality of flaps configured to form a bottom panel of the carton;   a front flap foldably connected to the second side panel; and   a front top end flap or front top end panel foldably connected to the front flap;   wherein the blank is configured to form the carton in a closed configuration in which
 the first side top flap and the second side top flap form a top panel of the carton, 
 the front top end flap or front top end panel extends inwardly from the front flap towards an interior of the carton beneath the first side top flap and the second side top flap, 
 the second side top flap partially overlaps the first side top flap, or the first side top flap partially overlaps the second side top flap; and 
   wherein the carton is configured to be placed in an open configuration in which
 a spout is formed in a top of the carton and defines an opening for pouring contents from the carton, 
 the front top end flap or front top end panel is folded outwardly away from the interior of the carton and forms a front lip of the spout, 
 the first flap section and the second flap section are detached from each other along the first break line, 
 the third flap section and the fourth flap section are detached from each other along the second break line, and 
 the first flap section and the third flap section extend transversely to the second flap section and the fourth flap section, thereby forming side walls of the spout. 
   
     
     
         35 . The carton blank of  claim 34 , wherein the front top end flap has a center section, a first side section foldably connected the center section, and a second side section foldably connected to the center section. 
     
     
         36 . The carton blank of  claim 34 , wherein the second flap section and the fourth flap section are configured to be attached to each other when the carton is in the closed configuration and when the carton is in the open configuration. 
     
     
         37 . The carton blank of  claim 34 , wherein:
 the first flap section and the second flap section are foldably connected to each other along a first fold line extending from the first break line; and   the third flap section and the fourth flap section are foldably connected to each other along a second fold line extending from the second break line.   
     
     
         38 . The carton blank of  claim 37 , wherein the first and second fold lines are arcuate fold lines. 
     
     
         39 . The carton blank of  claim 37 , wherein the blank is configured to form the carton in the open configuration such that the first flap section and the third flap section are folded along the first fold line and the second fold line, respectively. 
     
     
         40 . The carton blank of  claim 34 , wherein:
 the blank is configured to form the carton in a reclosed configuration after the carton is formed in the open configuration; and   the front lip of the spout is configured to extend the inwardly from the front panel towards an interior of the carton when the carton is in the reclosed configuration; and   the first flap section and the second flap section are configured to lie over the front lip when the carton is in the reclosed configuration.   
     
     
         41 . The carton blank of  claim 40 , wherein the first flap section includes a first notch and the third flap section includes a second notch, and wherein the first notch and the second notch are configured to interlockingly engage each other when the carton is in the reclosed configuration. 
     
     
         42 . The carton blank of  claim 34 , wherein the rear panel comprises gripping regions disposed adjacent the first side panel and the second side panel, and wherein the gripping regions are defined by a pair of fold lines in the rear panel and are configured to be folded to extend transversely to a remainder of the rear panel.