Direct contact carton pour spout device

Abstract

A direct contact pour spout carton device is provided. The device is comprised of a direct contact pour spout carton device that comprises a carton body configured in various shapes and sizes, such as gable tops, trapezoidal forms, or custom geometries, designed for liquid or semi-liquid contents. The carton body includes multiple sidewalls, a bottom, and a top, made from materials such as LDPE-coated paperboard or multilayer composites for enhanced barrier properties. Features like grease-resistant coatings or foil-lined boards with skive seals improve durability under wet or refrigerated conditions. The pour spout, integrated into the carton body, includes perforated portions, a cap with a living hinge, and optional resealing mechanisms, enabling controlled dispensing and reclosure. The manufacturing process involves precision die-cutting, scoring, or perforating to incorporate the spout features, followed by folding and sealing to form a durable and functional container.

What is claimed is: 
     
         1 . A direct contact pour spout carton device comprising:
 a carton body comprising a plurality sidewall, a bottom, and a top, wherein the carton body is foldable into an assembled configuration;   a pour spout integrated into the carton body, the pour spout comprising:
 a sidewall perforated portion, 
 a top perforation portion, 
 a living hinge connecting the carton body to a cap portion, wherein the cap portion is configured to pivot via the living hinge; and 
   a first perforation line defining the sidewall perforated portion and a second perforation line defining the top perforation portion, wherein the first perforation line and the second perforation line are configured to be broken to form an opening for dispensing from the carton body.   
     
     
         2 . The direct contact pour spout carton device of  claim 1 , wherein the living hinge is scored on the carton body. 
     
     
         3 . The direct contact pour spout carton device of  claim 1  further comprised of a reclosure fastener configured to release the pour spout after an initial use. 
     
     
         4 . The direct contact pour spout carton device of  claim 1 , wherein the carton body is comprised of an embossed material to improve grip. 
     
     
         5 . The direct contact pour spout carton device of  claim 1 , wherein the carton body is comprised of a textured material to improve grip. 
     
     
         6 . The direct contact pour spout carton device of  claim 1 , wherein the carton body is comprised of a foil-lined board. 
     
     
         7 . The direct contact pour spout carton device of  claim 1 , wherein the carton body is comprised of a paper-based material and an aluminum. 
     
     
         8 . The direct contact pour spout carton device of  claim 1 , wherein the carton body is comprised of a milk stock material and an aluminum. 
     
     
         9 . The direct contact pour spout carton device of  claim 1 , wherein the carton body is comprised of a multilayer composite. 
     
     
         10 . The direct contact pour spout carton device of  claim 9 , wherein the carton body is further comprised of a plant-derived polymer. 
     
     
         11 . A direct contact pour spout carton device comprising:
 a carton body formed from a paper-based material, the carton body comprising:
 a sidewall, 
 a bottom, and 
 a top; and 
   a pour spout integrated into the carton body, the pour spout comprising:
 a perforated portion located along the sidewall and the top, 
 a cap portion detachable along the perforated portion, and 
 a living hinge configured to allow pivoting of the cap portion while remaining attached to the carton body. 
   
     
     
         12 . The direct contact pour spout carton device of  claim 11 , wherein the carton body is comprised of a milk stock or a paper-based material. 
     
     
         13 . The direct contact pour spout carton device of  claim 11 , wherein the carton body is comprised of a skive seal. 
     
     
         14 . The direct contact pour spout carton device of  claim 11 , wherein the top is comprised of a gable top. 
     
     
         15 . The direct contact pour spout carton device of  claim 11 , wherein the gable top is comprised of a first side panel and a second side panel converging at a ridge. 
     
     
         16 . The direct contact pour spout carton device of  claim 15 , wherein the gable top is comprised of a first end panel and a second end panel terminating below the ridge. 
     
     
         17 . The direct contact pour spout carton device of  claim 11 , wherein the top is comprised of a flat top. 
     
     
         18 . The direct contact pour spout carton device of  claim 11 , wherein the top is comprised of a tapered top. 
     
     
         19 . The direct contact pour spout carton device of  claim 11  further comprised of a reclosure fastener. 
     
     
         20 . A method of manufacturing a direct contact pour spout carton device, the method comprising the following steps:
 generating a carton body template comprising a side panel, a bottom panel, and a top panel;   forming a pour spout in the carton body template by creating a first perforated portion on at the side panel and a second perforation portion on the top panel, a cap portion defined by the perforated portions, and a living hinge adjacent to the cap portion;   assembling a carton body by folding the carton body template along a predefined fold line and joining a first edge and a second edge of the template to form a sealed enclosure; and   activating the pour spout by breaking the first perforated portion and the second perforated portion to create an opening for dispensing a content from the carton body.