FIELD OF THE INVENTION
The present invention is in the general field of flexible products in sheet or planar form, including paper and other thin form materials which can be wound around a mandrel, tube or other form.
BACKGROUND OF THE INVENTION
Flexible sheet material, such as paper webs, textiles and polymer films are typically wound around cylindrical forms as a way of dense packaging for shipping and storage. Cylindrical forms such as tubes are easily handled in automated winding processes and can be placed on end for storage of rolls of material. Thin sheet paper is rolled in this manner in production and printing processes.
Cylindrical forms or mandrels for winding material can be made of steel, wood or wood pulp such as heavy or light gauge cardboard or polymeric or plastic material and sized appropriately for the intended application. Cylindrical forms have a diameter which represents bulk space or a void in shipping and storage. Also, the appearance of product and particularly graphical product available in rolled form can be difficult to visualize in its flat, planar state due to the minimal surface area displayed.
SUMMARY OF THE INVENTION
The present invention provides a flat roll gift wrap product that includes sheet material, such as, for example, gift wrapping paper, and a form that has at least two planar sides joined by arcuate transitions about which sheet material is wound as a gift wrap unit. In an exemplary embodiment, a flat roll form has first and second opposed planar sides and arcuate transitions which form arcuate transitions between the first and second planar sides, and a flexible, sheet material is continuously wrapped about the flat roll form over the first and second planar sides and the arcuate transitions without any creases formed in the sheet material. A radius of the arcuate transitions can be as small as possible without resulting in formation of a crease in the sheet material along the portion of the area of the arcuate transitions. The sheet material can have graphic or other printed indicia on an exterior surface thereof which is oriented outward with respect to the flat roll form so that a substantial portion of the graphic on the sheet material is visible.
In another embodiment, the flat roll gift wrap product includes a flat roll unit of sheet material wound about a flat roll form, and an envelope for containing the gift wrap unit. In yet another embodiment, the flat roll gift wrap product includes a container that supports a gift wrap unit, or a plurality of gift wrap units. The container can further include at least one envelope each containing one or more flat roll units.
DESCRIPTION OF THE DRAWINGS
The various embodiments of the present invention can be understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Also, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a perspective view of an embodiment of a flat roll gift wrap product which includes a flat roll gift wrap product which includes sheet material wound about a flat roll form having arcuate transitions, according to an embodiment of the invention;
FIG. 2A is a perspective view of a flat roll gift wrap product which includes sheet material wound about a flat roll form having arcuate transitions that include planar segments, according to an embodiment of the invention;
FIG. 2B is a cross-sectional view of a flat roll gift wrap product which includes sheet material wound about a flat roll form having arcuate transitions that include planar segments, according to an embodiment of the invention;
FIG. 3A is a perspective view of rolled gift wrap of the prior art;
FIG. 3B is a perspective view of a flat roll gift wrap product illustrating the design pattern of the sheet material proximate the planar surface of the flat roll form, according to an embodiment of the invention;
FIGS. 4-7 are cross-sectional views illustrating the core regions of the flat roll forms of various flat roll gift wrap products, according to embodiments of the invention;
FIG. 8 is a perspective view of a flat roll gift wrap product which includes an envelope and a flat roll gift wrap unit disposed therein, according to an embodiment of the invention;
FIG. 9 is a perspective view of a flat roll gift wrap product which includes a multiple compartment container and at least one flat roll gift wrap unit disposed therein, according to an embodiment of the invention;
FIGS. 10-11 are perspective views of a flat roll gift wrap products that include at least two flat roll gift wrap units packaged in an envelope, according to an embodiment of the invention; and
FIG. 12 is a perspective view of a flat roll gift wrap product that includes a container for supporting a plurality of flat roll gift wrap units according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED AND ALTERNATE EMBODIMENTS
As illustrated in the FIGS. 1 and 2, a flat roll gift wrap product, indicated generally at 100, is a compact assembly of sheet material 102 wound about a flat roll form 104. As used herein a “flat roll” of the flat roll form 104 refers to or means a generally elongate form which has at least one substantially planar or flat surface and about which a sheet material 102, such as, for example, paper or plastic, is wound one or more times.
In one embodiment FIG. 1 shows form 104 which includes a first planar surface 106 that is generally rectangular, the first planar surface having a first side edge 122 opposed to a second side edge 124 and a first end 130 opposed to a second end 131. The second planar surface 108, which is shown substantially parallel to and spacially aligned with the first planar surface 106, is generally rectangular and has a first side edge 126 opposed to a second side edge 128 and a first end 132 opposed to a second end 133. A first arcuate transition 140 is disposed between the first side edge 122 of the first planar surface 106 and the first side edge 126 of the second planar surface 108, a second arcuate transition 142 disposed between the second side edge 124 of the first planar surface 106 and the second side edge 128 of the second planar surface 108. A sheet material 102 has a width Ws that extends along the length Lf of the flat roll form between, for example, the first end 130 and the second end 131 of the form. The sheet material has a length wound about the form such that portions of the sheet material located proximate to the first and second arcuate transitions of the form are curved.
By “arcuate” it is meant that the arcuate transitions 140, 142, have a profile or cross-sectional shape that is generally convex between the first planar surface 106 and the second planar surface 108. As shown in FIG. 1, the arcuate transitions 140, 142, have a radius, RI, that can be substantially equal to one-half the distance, d, between the planar surfaces 106, 108. Stated differently, the diameter of the arcuate transitions is substantially equal to the distance, d, between the planar surfaces 106, 108. It should be understood, however, that various portions of the arcuate transitions 140, 142, can have varying radii. For example, the arcuate transitions can have a shape that is oval or oblong. Furthermore, first arcuate transition 140 can have a different profile shape than second arcuate transition 142.
Thus in the example embodiment of FIG. 1, the flat roll form 104 has two planar, parallel and opposed sides 106, 108, which are generally rectangular in shape, with parallel and aligned edges defining an overall length, Lf, of the flat roll form 104. 21, 22 are arcuate transitions 30. The arcuate transitions adjoin the elongate edges of each of the opposed sides and are located laterally outboard of the elongate edges of planar surfaces have a exterior convex form which projects outwardly from core of the flat roll form.
In alternative embodiments, as illustrated in FIGS. 2A and 2B, the arcuate transitions can include at least one planar segment, for example, planar segments 250, 252, 254, 256, which are angled relative to the first and second planar surfaces 240, 242, such that the profile is generally convex and adjoins the substantially parallel and aligned planar surfaces 240, 242. The example embodiment shown in FIG. 2A has arcuate transitions 240, 242, portions of which include a combination of substantially planar segments 250, 252, 254, 256, and curved or radius surfaces 257, 258, having a radius R1 and R2 which may be the equal or different. The planar surface segments are angled relative to the first and second planar surfaces 206, 208 by an angle, alpha, for example, α1, α2, α3, α4, that can range from between about 90 degrees and about 180 degrees, and also, for example, from between about 120 degrees and about 150 degrees. The angles al, α2, α3, α4, can be the same or different. In the example embodiment shown in FIG. 2B, the arcuate transitions 240, 242, of flat roll form have a plurality of substantially planar segments 244, 246, each of which is oriented at an angle, beta, for example, β1 to β16, relative to its adjacent planar segments. The angles β1 to β16 can vary between each of the planar segments and can range from between about 90 degrees and about 180 degrees, and also for example, from between about 120 degrees and about 150 degrees.
Therefore, the arcuate transitions 140, 142, 240, 242, of FIGS. 1, 2A, and 2B above can include a combination of radiused surfaces and planar surface segments, and in alternative embodiments, can include a plurality of planar surface segments adjoined to form a generally convex profile between the first and second planar surfaces 106, 108, 206, 208, respectively. The flat roll gift wrap products 100, 200, of FIGS. 1, 2A and 2B have arcuate transitions that ensure that the sheet material proximate to the arcuate transitions of the flat roll form has no crease, for example a crease along the length of the form, Lf.
As apparent from FIG. 1, the distance between the ends 130, 131132, 133 of the planar surfaces 106, 108, can be greater than the between the side edges 122, 124 and 126, 128. Also, a comparison of FIGS. 1 and 2A show that the overall width Wf1 of the form 104, and the overall width Wf2 of the form 204, as well as the width of the first and second planar surfaces 140, 142, 240, and 242, can be varied as desired to accommodate the width, Ws, of sheet material. The width Ws of the sheet 102 is shown as a dimension that is slightly less than the length of the form 104, 204, however, the width of the sheet material 102 can be substantially equal to the length Lf of the form 104, 204, and in some cases may be greater than the length of the form. In one embodiment the sheet material has a width Ws that has a length such that the sheet material is wound about the form 104, 204, at least once, and in alternative embodiments at least about five times, and alternatively, at least ten times or more. The flat roll gift wrap product can include at least about 25 sq. ft. of sheet material, in another embodiment, at least about 50 sq. ft. sheet material, in yet another embodiment, at least about 100 sq. ft. or more of sheet material.
Referring to FIG. 1, the combined surface area of the planar surfaces 106, 108 is greater than the combined surface area of the arcuate transitions 140, 142. In another embodiment, the combined area of sheet material 102 supported the planar surfaces 106, 108 generally along 362 is greater than the combined surface area of sheet material 102 supported by the arcuate transitions 140, 142 generally along 364. In yet another embodiment, the combined area of the sheet material supported by one of the planar surfaces, for example planar surface 106, is greater than the combined area of sheet material supported by the arcuate transitions. The combined area of sheet material proximate the planar surfaces of the form can be substantially greater than the combined area of sheet material proximate the arcuate transitions, and the ratio can range, for example, from about 2:1 to about 50:1, or for example from about 4:1 to about 20:1.
As apparent from FIGS. 1 and 2A, the width of the first and second planar surfaces 106, 108 and 206, 208, respectively, can be varied as desired, and affords the advantage of making visible a substantial portion of the sheet material 102, and therefore, the overall appearance of any graphic indicia drawn over the planar surfaces. As also apparent by comparison to a prior art gift wrap roll 10 as shown in FIG. 3A of the prior art, the amount of print pattern or design example print pattern 360 on the sheet material 302 of gift wrap product 300 of FIG. 3B on the sheet material 20 that is easily discernable, is much greater on the flat roll gift wrap product 300 of FIG. 3B compared to the conventional roll 10 of the prior art (FIG. 3A). Also, where the applied print is in the form of a repeating pattern as is common on gift wrap paper, the pattern is preferably visible in its entirety, or repeated, at least once, on at least one of the planar sides 306, 308, of the flat roll form 20 so that a shopper can clearly see the entire graphic design or print pattern, 360 of the gift wrap. Where the graphic design is a repeating pattern, and depending upon the size and scale of the design, the design may be repeated at least once and often many times over on one of the planar sides 306, 308 of the flat roll form 304. Because gift wrap is selected for purchase primarily on the basis of the graphic design applied to the sheet material, the form 304 of the flat roll gift wrap product 300 provides for a greatly improved retail presentation of the product to the consumer.
The flat roll forms of the embodiments described above can be made of any suitable material, including but not limited to, for example, polymer, paper, cardboard, corrugated board or other organic or synthetic materials which are formable into the described shapes. In many cases the minimization of the total weight of the flat roll gift wrap product is desirable. For example, the flat roll form 104, 204, 304 can be made of a polymer, such as a thermoplastic or a thermoset material that is a foam polymer, to provide for a flat roll form that has a lower weight compared to one made of solid polymer. In alternative embodiments, the flat roll form may include hollow portions, as will be further described.
The sheet material of the flat roll gift wrap products described above can be any flexible material in sheet form material in sheet form, such as, for example, paper or plastic. In another embodiment the sheet material is a non-textile material. The sheet material of the flat roll gift wrap products according to the various embodiments described herein may be used as sheet material that is not a wrapping material, for example, and can be used for purposes other than wrapping gifts.
FIGS. 4 through 7 are cross-section illustrations of various embodiments of the flat roll gift wrap product which illustrate the various form cores defined by the planar surfaces and the arcuate transitions of the form. FIG. 4 illustrates a homogeneous flat roll form 404 with opposed planar surfaces 406 and 408 and arcuate transitions 440, 442 that is formed by molding or extrusion or an alternative manufacturing process that can produce, for example, a solid, a porous, or at least a partially hollow core 460, such that the relative positions of the exterior surfaces and the shape of the sheet material 402 disposed thereabout is substantially maintained. The resistance of the form 404 against collapse or distortion due to the weight of the sheet material 402 can depend upon, among other variables, the strength of the material used in the forms, the design of the core 460, and as described above with respect to FIG. 1, the radius, R, of the arcuate transitions 440, 442. For example, depending on other factors the radius, R, can be large enough to avoid creasing or buckling of the form 404, or formation of any creases or folds in the sheet material 402, for example, in the region of or proximate to any of the arcuate transitions 440, 442 of the form 404. FIG. 4 shows that the planar surfaces 406, 408, are spaced apart a distance, d, substantially equal to the diameter of the arcuate transitions 440, 442, however, distance, d, can be greater to or less than the diameter of the arcuate transitions 440, 442.
The embodiment of flat roll gift wrap product 500 of FIG. 5 includes a form 504 that is formed by a material having a planar surface, such as for example, a cardboard or paperboard or other formable material which has adequate rigidity so that the core 560 of the flat roll form 504 may include a minimal void 562, yet the planar surfaces 506, 508 and the arcuate transitions 540, 542 remain in the respective locations. For example, the planar surfaces 506, 508 do not collapse inwardly into the core 560 under the weight of the sheet material 502, nor do the arcuate transitions 540, 542 buckle inward toward the core 560 or bulge the planar surfaces 506, 508 under pressure from the sheet material 502 wound tightly against the arcuate transitions 540, 542.
To achieve the requisite rigidity of the material having a planar surface used to make the form 504, such as cardboard, fiberboard, plastic board or corrugated variations thereof, can be arranged with double thickness, i.e. at least two layers. The double or multiple thickness of the planar material can be thick enough to fill or substantially fill the core 560 so that there is very limited possibility, or no possibility, of collapse of the flat roll form 504. Additional folds can be made in the material used to make the form 504 so that multiple layers of the material reside within the core 560 of the flat roll form 504. Material such as cardboard or foam board with skin covering can be scored on one side and folded along score lines to create the arcuate transitions 540,542.
FIG. 6 illustrates a flat roll gift wrap product 600, wherein the form 604 includes a corrugated medium 670 within core 660, and the corrugated medium can have segments 672, 674, which are diagonally disposed relative to one another and form an angle, theta, which is less than about 90 degrees. In another embodiment, flat roll form 604 includes corrugations 676, 679, which abut within core 660, and which create spaced-apart regions or hollow portions of the core.
FIG. 7 illustrates another type of form 704 of a flat roll gift wrap product 700, wherein the core 760 is in the form of a continuous piece which is pinched together to form the planar surfaces 706, 708, with unpinched or expanded areas forming the arcuate transitions 740, 742, at each lateral side of the form 704. The core 760 in can be made of any suitable material which can be so shaped, including but not limited to, for example, plastic, paper or fiber board or other moldable materials. As shown, portions of the core defined by the arcuate transitions 740, 742 at least include openings 780, 782, and the core 760 is partially hollow. The sheet material 702 may generally follow the contour of the form 704 over the arcuate transitions 740, 742, and the slightly recessed planar surfaces 706, 708, and therefore can present a substantial surface area of the sheet material 702 for retail display while also ensuring that no creases are formed in the sheet material, for example, along the arcuate transitions 740, 742.
FIG. 8 illustrates a flat roll form product 800 includes a retail display container such as an envelope 803, which contains at least one gift wrap unit 801, where the gift wrap unit includes sheet material wound about the flat roll form. The gift wrap unit can includes any combination of the sheet materials and the flat roll forms described above with respect to the various embodiments of a flat roll gift wrap product. The envelope 803 can be made of cellophane, transparent cellophane, or any other suitable material. In one embodiment at least a portion of the sheet material 802 is visible to display a pattern 805 on the sheet material, and in another embodiment, at least one complete pattern of the sheet material is visible. In another embodiment the envelope 803 is sealed with a header 807 which can optionally include an opening 809 for suspension of the product 800 on a display hook. The header 807 can be made from the same material as and integral with the envelope, or as a separate piece such as cardboard which is encapsulated by the envelope 803. The flat planar form of the product 800 enables stacking of multiple products packaged in this way on one or more display hooks for a high-density display.
FIG. 9 illustrates a flat roll form product 900 in a retail display container 901, for example, in the form of a box which holds one or more flat roll gift wrap units 905, 906 in a first compartment 902, and a second compartment 904, respectively. The one or more gift wrap units 905, 906, can be different sizes and can reside in different size compartments 902, 904, however, the gift wrap units 905, 906, can be the same size, and the compartments 902, 904, can be the same size. The container 901 can also include additional compartments, for example, a third compartment 903 which can contain, for example, complimentary gift wrap items, such as, for example, bows and ribbons.
FIGS. 10 and 11 illustrate other forms of retail packaging and display of the flat roll gift wrap product 1000 having multiples gift wrap units 1020 and 1120, packaged side-by-side as shown in FIG. 10 within envelope 1010, and stacked as shown in FIG. 11 within envelope 1110 which has sufficient depth. Both type envelopes are sealed with a header 1030, 1130 and each can include an opening 1032, 1132 for suspended display on a hook. In packages of these types, the multiple flat roll units 1020, 1120 can be of an assortment of designs, complimentary or not, and packaged in different numbers of multiples. The flat form gift wrap products 1000, 1100 allow for densely arranged displays and bulk shipping with minimal air space. The flat roll form products 1000, 1100 in the illustrated type retail display envelopes 1010 and 1110 maximize visibility to a shopper of the print patterns on the sheet material 102 (FIG. 1).
In another embodiment, FIG. 12 illustrates a flat roll gift wrap product 1200 which includes a container 1210 that supports one or more gift wrap units 1222. The gift wrap units 1222 include a flat roll form and sheet material of the several embodiments described above. The flat roll gift wrap product 1200 can optionally include a plurality of envelopes 1230 each of which contains one or more gift wrap units 1222. The gift wrap units 1222 may be arranged in a side-by-side arrangement, for example where the planar surfaces of the flat roll form are co-planar, or in a stacked arrangement, for example where the planar surfaces of the flat roll form reside in different planes from unit to unit, inside the container 1210 within the container 1210, or within the envelopes 1230, or both. The gift wrap units of sheet material wound about the forms are compactly arranged in the container such that the sheet material proximate the arcuate transitions of the form has substantially no creases.
The container 1210 can be various shapes and sizes, such as, for example, one of several polygon shapes. As illustrated, the container is a shipping carton or container that has at least four sides 1212, 1214, 1216, 1218, and a bottom 1220, and a lid 1222. The container 1210 can be made or various materials, including but not limited to, for example, cardboard, fiberboard, plastic, foam polymer, paper, corrugated board or metal, and can be a bulk shipping container for large quantities of the packaged product for shipment by truck, rail or ship. The sheet density of the flat roll gift wrap product 1200 can be measured and defined as the sheet material volume divided by the container volume (i.e. sheet material volume/container volume), and can be substantially greater than the sheet density of conventional products, for example, a container, for example container 1210 that contains round gift wrap rolls of the prior art (FIG. 3A). The sheet density according to the example embodiments herein can be, for example, at least about 0.1, at least about 0.5, at least about 0.7, and in alternative embodiments, at least about 0.9. The unit density of the flat roll gift wrap product 1200 can be measured and defined as the flat roll unit volume divided by the container volume (i.e. flat roll unit volume/container volume), and can be substantially greater than the gift wrap unit volume of conventional products, for example, a container that contains round gift wrap rolls of the prior art (FIG. 3A) in which the round cylindrical forms consume a substantial amount of air space. The gift wrap unit density according to the example embodiments herein can be, for example, at least about 0.5, at least about 0.7, at least about 0.9, and in alternative embodiments, at least about 0.95. Thus, the flat roll gift wrap product 1200 can provide for a more efficient and cost-effective method of shipment, with less air space within the container 1210 as compared to conventional gift wrap products.
Although the invention is shown and described with respect to certain embodiments, it is obvious that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The present invention includes all such equivalents and modifications, and is limited only by the scope of the claims.
Patent Application
20070151875
