Patent Application
20080269034
This invention relates to a nested blank arrangement on a unitary sheet with features which minimize scrap sheet material (i.e., sheet scrap) while strengthening the bottom of a container formed from one of the blanks. More specifically, the invention is a nested pair of blanks on a unitary sheet which minimizes the amount of sheet scrap upon separation of the blanks and construction of containers formed from the blanks. The nested pair of blanks further minimizes the amount of sheet material required to form container bottoms. Stated differently, the increased nesting between the panels and flaps of the blanks on the sheet reduces the amount of overlapping sheet material on the bottom flaps forming the container bottom. The invention further relates to a container formed from one of the blanks and having an automatic bottom, wherein notched edges of the bottom panels correspondingly engage one another to form a container bottom and offset the potential weakening of the container bottom resulting from reduced overlapping sheet material.
The positioning of blanks on a sheet such that portions of the blanks are connected to one another is referred to as nesting or a nested arrangement. Known nested arrangements of blanks are formed by a die-cutting machine that cuts and scores a web of board (e.g., paperboard) into one or more sheets defining one or more blanks. In practice, the die-cutting machine cuts and scores a single sheet of board into one or more adjacent blanks. The unused board material of the sheet located between the adjacent blanks is scrap material which may be discarded or recycled. In an effort to reduce the cost of producing containers from the blanks, manufacturers attempt to minimize the amount of board in the blanks.
As known in the industry, the cost of the board material contributes significantly to the total cost of producing containers. Furthermore, when die-cutting the sheet of board into multiple adjacent blanks, it is desirable to form the blanks as close to one another as possible. The positioning of the blanks close to one another reduces the amount of sheet scrap and increases the number of blanks simultaneously formed from the board by the die-cutting machine. Specifically, the die-cutting machine may accommodate more blanks at the same time if the blanks occupy a smaller area.
Known nested arrangements of blanks often fail to sufficiently reduce the amount of sheet scrap, thereby increasing the cost of manufacturing blanks. Some nesting arrangements incorporate linear interfaces that connect, for example, a first and second blank. These types of arrangements fail to achieve the reduction in sheet scrap attained by the present invention as described herein.
Further, known nested arrangements attempting to minimize sheet scrap result in containers having weakened bottoms due to the decrease in the amount of overlap of the bottom panels secured to each other. The present invention provides a pair of nested blanks on a unitary sheet having a nested arrangement, a non-linear separation interface, and engagement notches which address these problems.
The invention is a nested pair of blanks on a unitary sheet having a first blank for forming a container, a second blank for forming an identical container, and a non-linear separation interface that connects the first and second blanks to one another in a rotationally inverted relationship (i.e., half-turn rotationally inverted with respect to one another). Advantageously, the non-linear separation interface reduces the amount of sheet scrap in the sheet.
Although efficient for manufacturing purposes, the non-linear separation interface also reduces the amount of sheet material available to form a container bottom in a container formed from one of the blanks. The reduction in area of the bottom panels forming the container bottom potentially weakens the container bottom. The invention addresses the potentially weakened container bottom by providing bottom panels having notched edges that correspondingly engage one another upon construction to counter the reduced bottom panel area (i.e., overlapping material) and strengthen the container bottom.
In one embodiment, the invention is a nested pair of blanks on a unitary sheet having a first blank for forming a container, a second blank for forming an identical container, and a non-linear separation interface that connects the blanks to one another in a rotationally inverted relationship that reduces sheet scrap. As set forth above, the invention incorporates blanks having notched edges that correspondingly engage one another upon construction to form a container bottom upon separation of the blank and construction of the container. The engagement notches strengthen the container bottom and counter the effect of reduced overlapping material in the container bottom (i.e., potentially weakened bottom).
More specifically, the invention provides first and second blanks having one or more body panels that are connected to one another along vertical fold lines. In further detail, each of the body panels of the first and second blanks include a front panel having opposing first and second side panels, and a rear panel that is connected to the front panel by the second side panel.
The first and second blanks also include bottom panels connected to edges of the body panels. The bottom panels of each of the first and second blanks include a first bottom closure panel connected to an edge of the front panel, and a second bottom closure panel connected to an edge of the rear panel. At least one of the bottom panels of the first blank is connected to and nested vertically with at least one of the bottom panels of the second blank.
The first and second blanks may also include bottom flaps connected to edges of the respective body panels. In one embodiment, each of the first and second blanks include a first bottom closure flap connected to respective edges of the first side panels, and a second bottom closure flap connected to respective edges of the second side panels.
The adjacent bottom panels and flaps of the blanks define the non-linear separation interface. Thus, one or more of the adjacent bottom closure panels and one or more of the adjacent bottom closure flaps of the first and second blanks may define the non-linear separation interface.
Each of the nested blanks includes notched edges that correspondingly engage one another to form container bottoms upon separation of the blanks from the sheet and construction of the containers. The notched edges define engagement notches that permit the reduction in sheet scrap, while maintaining sufficient strength in the container bottom.
First and second locking closure flaps connected to respective edges of the first and second side panels of the first and second blanks secure the tops of the containers formed from the blanks. In the unitary sheet, the first and second locking closure flaps of the blanks are positioned opposite the non-linear separation interface. This particular embodiment also provides first and second top closure panels connected to respective edges of the front and rear panels of the blanks. The first and second top closure panels are positioned on the sheet opposite the non-linear separation interface and further secure the tops of the containers formed from the blanks.
The invention further provides first and second tuck flaps connected to respective edges of the first and second top closure panels of the blanks. The tuck flaps secure the first and second top closure panels to one another. The tuck flaps are positioned on the sheet opposite the front and rear panels of the blanks. Glue flaps are connected to respective edges of the rear panels of the blanks and form a part of the manufacturer's joint upon construction of the container.
The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the following detailed description taken in conjunction with the accompanying drawings in which:
The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which multiple embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. Further, like numbers with the prime notation refer to like or similar elements of the structure.
Packaging is typically formed from packaging blanks, or blanks for short. It will be understood that as used herein the term “blank” may include cardboard, rigid paper, flexible plastic, or similar products made of paperboard or plastic. In particular, the packaging industry favors the use of one-piece flexible blanks, which are readily incorporated into automated processes for forming containers. The term “unitary sheet” refers to material having a broad, continuous surface so connected that it is possible to pass from any one point of the surface to any other point without leaving the surface. Sheet may also refer to separate pieces of, for example, paperboard used to form blanks.
It will be understood by those skilled in the art that the term “container” as used herein refers to various embodiments of the present structure for retaining a variety articles as formed from the various embodiments of the blank described below.
The term “panel” used in conjunction with the nested pair of blanks of the present invention refers to the major component part of a blank or container, and defines the major partition elements of the blank or container. Those skilled in the art will also appreciate that panels include edges defined as the line of intersection of two surfaces or a border. A “free edge” of a panel refers to an edge that does not intersect with another surface or panel.
The term “flap” refers to a secondary blank or container element that is typically hinge-connected along a free edge of a panel or another flap. It will be understood that the term “tab” refers to a tertiary element of the blank or container that is generally hinged to a portion of a free edge of a panel or flap, or struck from within the plane of a panel or flap.
It will be understood by those skilled in the art that the terms “top panel” and “lower panel” may also refer to “lower panel” and “upper panel” dependent upon the perspective of the individual viewing the apparatus. It will also be appreciated that the term “top” implies the opposite of “bottom.”
With reference to the orientation of the sheet in
The dimensions or measurements for containers will typically be expressed in the order of length (L), width (W), and depth (D), wherein L is typically the larger dimension at the open end of the container, W is usually the smaller dimension at the open end of the container, and D is the distance between the open ends of the container (e.g., L×W×D). With reference to the orientation of the sheet in
Further, as used herein the concept of a panel being “between” two other panels does not necessarily imply that the three panels or flaps are contiguous (i.e., in intimate contact). Rather, as used herein, the concept of one panel being between two other panels is meant to describe the relative positions of the panels within the blank or container structure, respectively.
Similarly, the concept of a first panel being connected to a second panel by a third panel, “opposite” the second panel, merely describes the relative positions of the first and second panels within the blank structure. It will further be understood that the term “finished” means coated with a material to produce an attractive glossy finish. The term “finished” will also be understood to mean the inclusion of printed material or other identifying indicia (e.g., a company's logo).
It will be understood by those skilled in the art that the term “score” refers to a crease along which the adjacent components or portions of a component of the blank are folded without cracking or breaking to form a container. It will be understood that the term “cut-score” refers to an impression formed by a cutting tool (e.g., a punch, die, or blade) that extends partially through a sheet of paperboard or the like. The term “perforations” refers to a series of holes or impressions formed by a cutting tool (e.g., a punch or die) that permits easy separation of, for example, panels.
It will be further understood that the term “fold line” or “score line” refers to a crease along which the adjacent components of a blank are folded without cracking or breaking to form a container. The term “secured” may refer to adhered with adhesive (e.g., glue) or bonded with heat.
The term “substantially rectangular” is meant to succinctly describe a simple geometric shape approximating a rectangle. Similarly, the term “substantially parallel” is meant to describe the spatial relationship between, for example, one panel to another panel, wherein the relationship is approximately parallel.
Those skilled in the art will also appreciate that the term “adjacent” refers to two or more, for example, panels that have a common border or are in close proximity to one another. Nevertheless, it will be understood that adjacent may or may not imply contact, but always implies the absence of anything of the same kind in between. Furthermore, as used herein, it will be understood that the term “article” will refer primarily to consumer products that are packaged for shipment (e.g., pharmaceuticals, consumables, etc.). It will be understood, however, that “article” may also refer to any number of goods such as individually packaged consumables for humans and animals, as well as individually packaged non-consumables.
As used herein, the term “separation interface” refers to an area of the sheet defining a common border between the pair of nested blanks. Stated differently, the term “separation interface” refers an area of the sheet connecting the pair of nested blanks that is capable of coming apart and dividing the sheet into separate components (i.e., blanks).
An overall view of an embodiment of a nested pair of blanks on a unitary sheet of the invention is set forth at 10 in the top plan view of
Referring to
The first blank 11 may include one or more bottom panels 25, 26 connected to edges of the body panels 14, 15, 16, 17. The second blank 12 also includes one or more bottom panels 30, 31 connected to edges of the body panels 20, 21, 22, 23. Each of the first and second blanks 11, 12 may also provide one or more bottom flaps 27, 28, 32, 33 connected to edges of the body panels 15, 16, 21, 22 of the respective blanks. The bottom panels 25, 26, 30, 31 and bottom flaps 27, 28, 32, 33 of the blanks 11, 12 form a part of the respective container bottoms.
Still referring to
With respect to the bottom flaps 27, 28, 32, 33, the first blank 11 includes a first bottom closure flap 27 connected to an edge of the first side panel 15, and a second bottom closure flap 28 connected to an edge of the second side panel 16. The second blank 12 may likewise include a first bottom closure flap 32 connected to an edge of the first side panel 21, and a second bottom closure flap 33 connected to an edge of the second side panel 22.
Each of the first and second bottom closure panels 25, 26, 30, 31 of the first and second blanks 11, 12 include first and second bottom glue flaps 35, 36, 37, 38 defined by a cut-score line 39 in the respective bottom closure panels (see
In combination with the corresponding engagement of the notched edges 24 of the first and second bottom closure panels 25, 26 of the first blank, the glue flaps 35, 36 as adhered to portions of both closure panels facilitates the automatic formation of the container bottom 29 upon construction (see
As configured on the unitary sheet 10 depicted in
Still referring to
In one embodiment of the invention, the non-linear separation interface 13 is defined by the first and second bottom closure panels 25, 26 of the first blank 11, and the first and second bottom closure panels 30, 31 of the second blank 12. In this embodiment, the first bottom closure panel 25 of the first blank 11 is connected to and nested vertically with the second bottom closure panel 31 of the second blank 12. Furthermore, the second bottom closure panel 26 of the first blank 11 is connected to and nested vertically with the first bottom closure panel 30 of the second blank 12.
With reference to
In further description, at least one of the bottom panels 25, 26 of the first blank 11 is connected to and vertically nested with at least one of the bottom panels 30, 31 of the second blank 12 and at least one of the bottom flaps 32, 33 of the second blank 12. Specifically, the first bottom closure panel 25 of the first blank 11 is connected to and nested vertically with the second bottom closure panel 31 of the second blank 12 and second bottom closure flap 33 of the second blank 12. Further, the second bottom closure panel 26 of the first blank 11 is connected to the first bottom closure panel 30 of the second blank 12 and the first bottom closure flap 32 of the second blank 12.
In continuing detail, at least one of the bottom panels 30, 31 of the second blank 12 is connected to and vertically nested with at least one of the bottom panels 25, 26 of the first blank 11 and at least one of the bottom flaps 27, 28 of the first blank 11. In particular, the first bottom closure panel 30 of the second blank 12 is connected to the second bottom closure panel 26 of the first blank 11 and the second bottom closure flap 28 of the first blank 11. Further, the second bottom closure panel 31 of the second blank 12 is connected to the first bottom closure panel 25 of the first blank 11 and the first bottom closure flap 27 of the first blank 11.
Still referring to
Still further, at least one of the bottom flaps 32, 33 of the second blank 12 may be connected to and nested vertically with at least one of the bottom panels 25, 26 of the first blank 11. Specifically, the second bottom closure flap 33 of the second blank 12 is connected to and vertically nested with the first bottom closure panel 25 of the first blank 11. Further, the first bottom closure flap 32 of the second blank 12 is connected to and vertically nested with the second bottom closure panel 26 of the first blank 11.
With reference to
As described in greater detail, the first and second bottom closure panels 25, 26 of the first blank 11 include one or more notched edges 24 that correspondingly engage one another to form the container bottom. Similarly, the first and second bottom closure panels 30, 31 of the second blank 12 include one or more notched edges 24 that correspondingly engage one another to form a container bottom 29.
The notched edges 24 strengthen the container bottom and counter the reduced surface area of the bottom panels 25, 26, 30, 31 resulting from the efficient nesting of the blanks 11, 12 on the unitary sheet 10. In comparing known containers depicted in
The reduction in the overlapping sheet material in a container bottom and the area of overlap in the bottom panels 25, 26, 30, 31 results from the efficient nesting of the pair of blanks 11, 12 in the present invention. Specifically, the inventive sheet 10 illustrated in
In terms of relative percent, the sheet scrap S illustrated in the inventive sheet of
Directing attention to the first blank 11 of
Referring now to the second blank 12 of
As depicted in
The invention also provides a container 60 formed from the first or second blank 11, 12 as described above. As shown in
In another novel aspect of the invention, the first and second bottom closure panels 25, 26 include notched edges 24 that correspondingly engage one another to form the container bottom 29. Upon construction, portions of the first and second bottom closure flaps 27, 28 are positioned between overlapping portions of the first and second bottom closure panels 25, 26.
Construction of the container bottom 29 is illustrated in
Further, portions of the first and second bottom closure panels 25, 26 are substantially adjacent to one another, and are substantially adjacent to the first and second bottom closure flaps 27, 28, respectively. Subsequently, the container 60 may be expanded by pulling the first side panel 15 and rear panel 17 away from the front panel 14 and second side panel 16. In forming the container bottom 29, a user may manipulate the panels to advance the notched edges 24 of the first and second bottom closure panels 25, 26 towards one another until the engagement notches 40 correspondingly engage one another to thereby form the container bottom 29.
In the drawings and specification, there have been disclosed typical embodiments on the invention and, although specific terms have been employed, they have been used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.
