Carton with plastic reclosable header

Abstract

The disclosure relates to a method and apparatus for manufacturing a package with a rigid or semi-rigid container and a polymeric or plastic header with a reclosure, such as a zipper. The rigid or semi-rigid container is typically provided in a stack of flat containers. The header is sealed, glued or otherwise secured to the containers. The container, typically inverted, is filled, and the bottom is formed by folding and sealing the bottom portion of the container.

What is claimed is: 
     
         1 . A package including:
 a container portion formed from a rigid or semi-rigid material, the container portion including first and second gusseted sides, a front panel, a rear panel, a folded bottom and an open top;   a header fastened to an upper portion of the container portion, thereby covering the open top of the container portion and providing a closed package for contents therewithin, wherein a lower portion of the container portion is free of fastening to the header, the header being formed of polymeric material and including a zipper for access therethrough, the header having a length greater than one half of a circumference of the container portion, the circumference formed by the front and rear panels and the first and second gusseted sides;   the zipper being chosen from the group consisting of a flanged zipper free of sliders, a flanged zipper with a slider, a flanged zipper with opening lips, a flanged tamper-resistant zipper, a tamper-evident zipper, a string zipper, a double zipper, a multiple track zipper, a zipper with a tear line, a zipper with flanges connected above the locking elements, a zipper with flanges connected below the locking elements, a leak-resistant zipper, a zipper with a peel seal, a hinged zipper, a zipper with spot seals, a zipper with eyemarks, a partly sealed zipper, a zipper with shape-retaining characteristics, a pinch grip pull zipper, zipper tape, a perforated cap zipper tape, a zipper with a weakened line of resistance, a zipper with a wedge, a zipper with a stabilizing post, a zipper with guide ribs, a zipper with a compression post, and a laminated zipper tape with a tear bead.   
     
     
         2 . The package of  claim 1  wherein the first and second sides include respective first and second gussets formed by respective first and second folds in the respective first and second gusseted sides. 
     
     
         3 . The package of  claim 1  wherein the header is formed from first and second walls of polymeric material. 
     
     
         4 . The package of  claim 3  wherein the first and second walls of polymeric material are formed from a single folded sheet of polymeric material. 
     
     
         5 . The package of  claim 3  wherein the two walls of polymeric material are joined at ends thereof by first and second cross seals which are joined to respective central areas of the first and second gusseted sides. 
     
     
         6 . The package of  claim 5  wherein portions of the header above the zipper are releasably joined to the first and second gusseted sides. 
     
     
         7 . The package of  claim 5  wherein the header is folded whereby portions of the header above the zipper are glued to the first and second gusseted sides. 
     
     
         8 . The package of  claim 1  wherein the folded bottom includes first front and rear horizontal folds and a second horizontal fold, wherein the first front and rear horizontal folds provide a transition from the respective front and rear panels to the folded bottom and wherein the second horizontal fold provide a fin seal. 
     
     
         9 . The package of  claim 8  wherein the fin seal is sealed against the folded bottom. 
     
     
         10 . The package of  claim 9  wherein forming of the fin seal causes triangular ears to be formed, the triangular ears being sealed to the bottom of the package. 
     
     
         11 . The package of  claim 9  wherein forming the fin seal causes triangular ears to be formed, the triangular ears being sealed to the first and second gusseted sides of the package. 
     
     
         12 . The package of  claim 1  wherein the zipper opens across a first portion of the header and wherein the zipper does not open across a second portion of the header. 
     
     
         13 . The package of  claim 1  further including a cap which fits over the header and an upper portion of the container portion. 
     
     
         14 . The package of  claim 1  further including a band which extends around the periphery of an upper portion of the container portion. 
     
     
         15 . The package of  claim 14  wherein the header is folded against the box and held in position by the band. 
     
     
         16 . The package of  claim 1  further including a reinforcing structure on at least one of the first and second gusseted sides. 
     
     
         17 . The package of  claim 1  wherein the zipper extends only partially across the header. 
     
     
         18 . The package of  claim 1  wherein the header includes a structure for opening the header thereby providing access to the zipper. 
     
     
         19 . The package of  claim 18  wherein the structure for opening the header is chosen from the group consisting of a line of perforations, a laser scored line, a tear bead, a tear notch, a peel seal, and a linear tear line. 
     
     
         20 . The package of  claim 18  wherein the structure for opening the header further provides tamper evidence. 
     
     
         21 . The package of  claim 3  wherein the first wall of polymeric material includes a line of weakness with a shroud thereover, the shroud including the zipper. 
     
     
         22 . The package of  claim 21  further including a seal between the first and second walls of polymeric material. 
     
     
         23 . The package of  claim 3  wherein the zipper is located on an off-center position on the header. 
     
     
         24 . The package of  claim 3  wherein the zipper is located between the first and second walls of polymeric material. 
     
     
         25 . The package of  claim 3  wherein the zipper includes first and second flanges, and wherein the first flange is sealed to the first wall of polymeric material and the second flange is sealed to the second wall of polymeric material and wherein the zipper is on the exterior of the header. 
     
     
         26 . The package of  claim 25  wherein the zipper includes a slider. 
     
     
         27 . The package of  claim 3  wherein the header further includes a pour spout formed by the zipper extending over only a portion of the width of the header. 
     
     
         28 . The package of  claim 3  wherein the header includes a compartment for printed material, wherein the compartment is attached to the header by a line of weakness whereby the user can tear away the compartment. 
     
     
         29 . The package of  claim 3  wherein the first and second walls of polymeric material have printed material thereon. 
     
     
         30 . A package including:
 a container portion formed from a rigid or semi-rigid material, the container portion including first and second gusseted sides, a front panel, a rear panel, a folded bottom and an open top;   a header fastened to an upper portion of the container portion, thereby covering the open top of the container portion and providing a closed package for contents therewithin, wherein a lower portion of the container portion is free of fastening to the header, the header being formed of polymeric material and including a structure for access through the header, the header having a length greater than one half of a circumference of the container portion, the circumference formed by the front and rear panels and the first and second gusseted sides;   the structure for access through the header being chosen from the group consisting of a line of perforations, a laser scored line, a tear bead, a tear notch, a peel seal, a tamper-evident zipper, and a linear tear line.   
     
     
         31 . The package of  claim 30  wherein the first and second gusseted sides include respective first and second gussets formed by respective first and second folds in the respective first and second gusseted sides. 
     
     
         32 . The package of  claim 30  wherein the header is formed from first and second walls of polymeric material. 
     
     
         33 . The package of  claim 32  wherein the first and second walls of polymeric material are formed from a single folded sheet of polymeric material. 
     
     
         34 . The package of  claim 32  wherein the two walls of polymeric material are joined at ends thereof by first and second cross seals which are joined to respective central areas of the first and second gusseted sides. 
     
     
         35 . The package of  claim 34  wherein upper portions of the header are releasably joined to the first and second gusseted sides. 
     
     
         36 . The package of  claim 34  wherein the header is folded whereby upper portions of the are glued to the first and second gusseted sides. 
     
     
         37 . The package of  claim 30  wherein the folded bottom includes first front and rear horizontal folds and a second horizontal fold, wherein the first front and rear horizontal folds provide a transition from the respective front and rear panels to the folded bottom and wherein the second horizontal fold provide a fin seal. 
     
     
         38 . The package of  claim 37  wherein the fin seal is sealed against the folded bottom. 
     
     
         39 . The package of  claim 38  wherein forming of the fin seal causes triangular ears to be formed, the triangular ears being sealed to the bottom of the package. 
     
     
         40 . The package of  claim 38  wherein forming the fin seal causes triangular ears to be formed, the triangular ears being sealed to the first and second gusseted sides of the package. 
     
     
         41 . The package of  claim 30  further including a cap which fits over the header and an upper portion of the container portion. 
     
     
         42 . The package of  claim 30  further including a band which extends around the periphery of an upper portion of the container portion. 
     
     
         43 . The package of  claim 42  wherein the header is folded against the box and held in position by the band. 
     
     
         44 . The package of  claim 30  further including a reinforcing structure on at least one of the first and second gusseted sides. 
     
     
         45 . The package of  claim 30  wherein the zipper includes first and second flanges, and wherein the first flange is sealed to the first wall of polymeric material and the second flange is sealed to the second wall of polymeric material and wherein the zipper is on the exterior of the header. 
     
     
         46 . The package of  claim 30  wherein the zipper is located on an off-center position on the header.