Methods and Apparatus for Manufacture of a Reclosable Plastic Carton

Abstract

A carton formed from a unitary blank for storing food within and methods of manufacture of the carton therefrom, are disclosed herein. The carton comprises a generally rectangular bottom having a pair of major bottom flaps and a pair of minor bottom flaps that are folded to form a substantially closed bottom, and a pair of major side panels, a pair of minor side panels, and a secondary side panel that are folded perpendicular to the bottom. An opening is defined by the upper ends of the major side panels and the minor side panels opposite the bottom and is generally non-rectangular.

1 . A carton formed from a unitary blank, the carton comprising:
 a generally rectangular bottom with a pair of major bottom flaps and a pair of minor bottom flaps where the bottom flaps are folded to form a substantially closed bottom;   a plurality of upstanding side panels, including a pair of major side panels, a pair of minor side panels, and a secondary side panel, where the side panels are each folded generally perpendicular to the bottom, the major and minor side panels are attached to the bottom at a lower end thereof and the secondary side panel is attached to one of the major side panels or one of the minor side panels; and   an opening defined by upper ends of the major side panels and the minor side panels opposite the bottom that is generally non-rectangular and having a rim around a peripheral edge thereof, the rim having a width greater than the thickness of the side panels.   
   
   
       2 . The carton formed from a unitary blank in accordance with  claim 1 , wherein the carton further comprises a reclosable lid, the lid having a channel about a periphery of an underside thereof for receiving the rim of the opening. 
   
   
       3 . The carton formed from a unitary blank in accordance with  claim 1 , wherein the carton further comprises a film attached to the rim of the carton to seal the opening. 
   
   
       4 . The carton formed from a unitary blank in accordance with  claim 1 , wherein the secondary side panel is sealed to one of the other side panels. 
   
   
       5 . The carton formed from a unitary blank in accordance with  claim 4 , wherein the bottom flaps are sealed to adjacent bottom flaps to form an enclosed interior for containing a food product. 
   
   
       6 . The carton formed from a unitary blank in accordance with  claim 1 , wherein the rim has a rolled lip about the peripheral edge. 
   
   
       7 . The carton formed from a unitary blank in accordance with  claim 1 , wherein the carton is made of one or more materials selected from the group consisting of polypropylene, high density polyethylene, and polyethylene terephthalate. 
   
   
       8 . The carton formed from a unitary blank in accordance with  claim 7 , wherein the carton further has a barrier layer. 
   
   
       9 . The carton formed from a unitary blank in accordance with  claim 8 , wherein the barrier layer comprises ethylene vinyl alcohol. 
   
   
       10 . The carton formed from a unitary blank in accordance with  claim 1 , wherein an outer surface of the carton is suitable for printing indicia or other markings. 
   
   
       11 . The carton formed from a unitary blank in accordance with  claim 1 , wherein the carton is used for storing food products selected from the group consisting of rice, stuffing, cereal, cookies, crackers, cake mixes, dry desserts, coffee and instant beverages. 
   
   
       12 . A carton formed from a unitary blank in accordance with  claim 1 , wherein the opening is oval and the side panels are substantially rectangular in shape. 
   
   
       13 . A carton formed from a unitary blank in accordance with  claim 1 , wherein the secondary side panel has a width that is less than a width of either the major and minor panels. 
   
   
       14 . A carton formed from a unitary blank in accordance with  claim 13 , wherein the secondary side panel has a length that is equal to a length of the major and minor panels. 
   
   
       15 . A reclosable food carton comprising:
 a generally rectangular bottom with a pair of major bottom flaps and a pair of minor bottom flaps where the bottom flaps are folded and sealed to adjacent bottom flaps to form a substantially closed bottom;   a plurality of upstanding side panels, including a pair of major side panels, a pair of minor side panels, and a secondary side panel, where the side panels are each folded generally perpendicular to the bottom, the major and minor side panels are attached to the bottom at a lower end thereof and the secondary side panel is attached to one of the major side panels or one of the minor side panels and is sealed to the other of the major side panels or the minor side panels forming an enclosed interior having side panels generally rectangular in shape;   a generally oval opening defined by upper ends of the major side panels and the minor side panels opposite the bottom and having a rim around a peripheral edge thereof; and   a reclosable lid having a channel about a periphery of an underside thereof for receiving the rim of the opening.   
   
   
       16 . The reclosable food carton in accordance with  claim 15 , wherein the rim has a width greater than the thickness of the side panels. 
   
   
       17 . The reclosable food carton in accordance with  claim 15 , wherein the carton is made of a material having barrier properties. 
   
   
       18 . The reclosable food carton in accordance with  claim 17 , wherein the material having barrier properties is one or more materials selected from the group consisting of polypropylene, high density polyethylene, and polyethylene terephthalate. 
   
   
       19 . The reclosable food carton in accordance with  claim 15 , wherein the secondary side panel is attached to one of the minor side panels and is sealed to an interior of one of the major side panels.