Reinforced Carton with Reclosable Lid

Abstract

A carton is formed from two or more laminated webs that can be cut, scored, or otherwise provided with lines of weakening. The carton includes a reclosable pivotable lid that can be secured in a closed position by a latch.

1 . A carton formed at least from an outer blank and an inner blank adhered to the outer blank, comprising: 
 a multi-ply front panel formed at least from the inner blank and the outer blank;    a multi-ply first end panel formed at least from the inner blank and the outer blank;    a multi-ply back panel formed at least from the inner blank and the outer blank;    a multi-ply second end panel formed at least from the inner blank and the outer blank;    a top panel; and    a bottom panel, wherein 
 a lid pattern is formed at least in the front panel, the first end panel and the second end panel, the lid pattern at least partially defining a latch and a pivotable lid,  
 a base portion of the latch is formed in the outer blank and is adhered to the inner blank, and  
 the lid pattern defines at least part of a lower edge of the pivotable lid.  
   
   
   
       2 . The carton of  claim 1 , wherein the latch is defined at least partially by a perimeter line of disruption in the outer blank.  
   
   
       3 . The carton of  claim 2 , wherein the latch further comprises a latch tab connected to the base portion, wherein the latch tab is not adhered to the inner blank.  
   
   
       4 . The carton of  claim 1 , wherein the bottom panel comprises a plurality of overlapped single-ply flaps.  
   
   
       5 . The carton of  claim 4 , wherein the top panel comprises a plurality of overlapped single-ply flaps.  
   
   
       6 . The carton of  claim 5 , wherein the carton is substantially parallelepipedal.  
   
   
       7 . A method of forming multi-ply carton blanks, comprising: 
 providing a first web of material;    providing a second web of material;    continuously moving the first web of material through a production line;    continuously moving the second web of material through the production line;    adhering the first web of material to the second web of material to form a combined web of material; and    repeatedly and simultaneously providing the combined web of material with a first pattern of lines of disruption and a second pattern of lines of disruption at a disrupting station, wherein, 
 the first patterns of lines of disruption are formed in the second web of material, and  
 the second patterns of lines of disruption are formed in the first and second webs of material.  
   
   
   
       8 . The method of  claim 7 , wherein repeatedly providing the combined web of material with the second patterns of lines of disruption comprises cutting the combined first and second webs into individual carton blanks.  
   
   
       9 . The method of  claim 8 , wherein each blank comprises an outer blank formed from the second web of material and having one of the first patterns of lines of disruption formed therein, and an inner blank formed from the first web of material.  
   
   
       10 . The method of  claim 9 , wherein each first pattern of lines of disruption at least partially defines a lid pattern in an outer blank.  
   
   
       11 . The method of  claim 10 , wherein each second pattern of lines of disruption at least partially defines a back panel, a first end panel, a front panel, and a second end panel in an outer blank.  
   
   
       12 . The method of  claim 10 , wherein each second pattern of lines of disruption at least partially defines a back panel, a first end panel, a front panel, and a second end panel in an inner blank.  
   
   
       13 . The method of  claim 10 , wherein each lid pattern defines a latch feature in an outer blank.  
   
   
       14 . The method of  claim 9 , further comprising repeatedly providing the first web of material with a pattern of edge lines of disruption before adhering the first web of material to the second web of material.  
   
   
       15 . The method of  claim 9 , wherein each second pattern of lines of disruption at least partially defines a plurality of top flaps and a plurality of bottom flaps in the second web of material.  
   
   
       16 . A method of forming multi-ply carton blanks, comprising: 
 providing a first web of material;    providing a second web of material;    moving the first web of material through a production line;    moving the second web of material through the production line;    forming a combined web of material from the first and second webs of material; and    after combining the first and second webs of material, repeatedly and simultaneously providing the combined web of material with a first pattern of lines of disruption and a second pattern of lines of disruption at a disrupting station, wherein, 
 the first patterns of lines of disruption are formed in the second web of material, each repeated first pattern of lines of disruption comprising at least one breachable line of disruption, and  
 the second patterns of lines of disruption are formed in the first and in the second web of material, each repeated second pattern of lines of disruption comprising at least two transverse fold lines.  
   
   
   
       17 . The method of  claim 16 , wherein providing the combined web of material with the second patterns of lines of disruption comprises cutting the combined first and second webs into individual carton blanks.  
   
   
       18 . The method of  claim 17  wherein each blank comprises an outer blank formed from the second web of material and having one of the first patterns of lines of disruption formed therein, and an inner blank formed from the first web of material.  
   
   
       19 . The method of  claim 18 , wherein each second pattern of lines of disruption at least partially defines an outer back panel, an outer first end panel, an outer front panel, and an outer second end panel in an outer blank, and further defines an inner back panel, an inner first end panel, an inner front panel, and an inner second end panel in an inner blank.  
   
   
       20 . The method of  claim 18 , wherein each first pattern of lines of disruption at least partially defines a lid pattern and a latch feature in an outer blank.  
   
   
       21 . The method of  claim 18 , further comprising repeatedly providing the first web of material with a pattern of edge lines of disruption before combining the first and second webs of material.