U.S. patent application number 09/996565 was filed with the patent office on 2002-08-22 for box covered with a non-woven material.
Invention is credited to Vayrette, Sophie Helene.
Application Number | 20020113116 09/996565 |
Document ID | / |
Family ID | 8857087 |
Filed Date | 2002-08-22 |
United States Patent
Application |
20020113116 |
Kind Code |
A1 |
Vayrette, Sophie Helene |
August 22, 2002 |
Box covered with a non-woven material
Abstract
A box comprising a body formed from a blank, wherein the blank
comprises a support having a first surface and a second surface and
at least the first surface has printing thereon. The blank further
comprises at least one sheet of non-woven material, the at least
one sheet of non-woven material being arranged on the first surface
of the support. The at least one sheet of non-woven material may be
at least partially transparent so that the printing on the first
surface of the support is visible through the sheet of non-woven
material.
Inventors: |
Vayrette, Sophie Helene;
(Courbevoie, FR) |
Correspondence
Address: |
Thomas L. Irving
FINNEGAN, HENDERSON, FARABOW,
GARRETT & DUNNER, L.L.P.
1300 I Street, N.W.
Washington
DC
20005-3315
US
|
Family ID: |
8857087 |
Appl. No.: |
09/996565 |
Filed: |
November 30, 2001 |
Current U.S.
Class: |
229/5.84 ;
206/459.5 |
Current CPC
Class: |
B65D 5/563 20130101;
B65D 5/62 20130101 |
Class at
Publication: |
229/5.84 ;
206/459.5 |
International
Class: |
B65D 005/56; B65D
005/62 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 30, 2000 |
FR |
00 15518 |
Claims
What is claimed is:
1. A box comprising: a body formed from a blank, wherein the blank
comprises a support having a first surface and a second surface,
wherein at least the first surface has printing thereon, and at
least one sheet of non-woven material, the at least one sheet of
non-woven material being arranged on the first surface of the
support, and the at least one sheet of non-woven material being at
least partially transparent so that the printing on the first
surface of the support is visible through the at least one sheet of
non-woven material.
2. A box according to claim 1, wherein the blank is precut and
folded to form the body.
3. A box according to claim 1, wherein the first surface forms an
outer surface of the box.
4. A box according to claim 1, wherein the at least one sheet of
non-woven material comprises a first sheet of non-woven material on
the first surface, and wherein the box further comprises a second
sheet of non-woven material on the second surface.
5. A box according to claim 4, wherein the second surface has
printing thereon, and the second sheet of non-woven material is at
least partially transparent so that the printing on the second
surface of the support is visible through the second sheet of
non-woven material.
6. A box according to claim 1, wherein the at least one sheet of
non-woven material is secured to the support by bonding.
7. A box according to claim 1, wherein the bonding is chosen from
adhesive bonding and adhesive-varnish bonding.
8. A box according to claim 1, wherein the support is made of a
cardboard material.
9. A box according to claim 8, wherein the cardboard material has a
grammage ranging from about 150 g/m.sup.2 to about 500
g/m.sup.2.
10. A box according to claim 9, wherein the cardboard material has
a grammage ranging from about 250 g/m.sup.2 to about 400
g/m.sup.2.
11. A box according to claim 1, wherein the support is made of a
thermoplastic material.
12. A box according to claim 11, wherein the thermoplastic material
is chosen from high-density polyethylenes, polypropylenes,
polyvinyl chlorides, and polyethylene terephthalates.
13. A box according to claim 11, wherein the support has a
thickness ranging from about 150 .mu.m to about 800 .mu.m.
14. A box according to claim 13, wherein the support has a
thickness ranging from about 300 .mu.m to about 600 .mu.m.
15. A box according to claim 1, wherein the at least one sheet of
non-woven material is formed from thermoplastic fibers.
16. A box according to claim 15, wherein the thermoplastic fibers
comprise polyolefin fibers.
17. A box according to claim 16, wherein the polyolefin fibers are
chosen from polypropylene fibers and polyethylene fibers.
18. A box according to claim 15, wherein the thermoplastic fibers
comprise polyester fibers.
19. A box according to claim 1, wherein the at least one sheet of
non-woven material has a thickness ranging from about 50 .mu.m to
about 800 .mu.m.
20. A box according to claim 1, wherein the at least one sheet of
non-woven material has a thickness ranging from about 100 .mu.m to
about 400 .mu.m.
21. A box according to claim 1, wherein the at least one sheet of
non-woven material has a thickness ranging from about 100 .mu.m to
about 200 .mu.m.
22. A box according to claim 1, wherein the blank comprises score
lines and wherein the blank is folded at the score lines.
23. A box comprising: a body formed by folding a blank, wherein the
blank comprises a support having a first surface and a second
surface, wherein at least the first surface has printing thereon
and forms an outer surface of the box, and at least one sheet of
non-woven material comprising thermoplastic fibers, the at least
one sheet of non-woven material being arranged on the first surface
of the support, and the at least one sheet of non-woven material
being at least partially transparent so that the printing on the
first surface of the support is visible through the at least one
sheet of non-woven material.
24. A box according to claim 23, wherein the at least one sheet of
non-woven material comprises a first sheet of non-woven material on
the first surface, and wherein the box further comprises a second
sheet of non-woven material on the second surface.
25. A box according to claim 24, wherein the second surface has
printing thereon, and the second sheet of non-woven material is at
least partially transparent so that the printing on the second
surface of the support is visible through the second sheet of
non-woven material.
26. A box according to claim 23, wherein the support is made of a
cardboard material.
27. A box according to claim 23, wherein the support is made of a
thermoplastic material.
28. A box according to claim 23, wherein the thermoplastic fibers
are chosen from polyolefin fibers or polyester fibers.
29. A method of manufacturing a box, comprising: providing a
support having a first surface and a second surface; applying
printing to the first surface of the support; coating the printed
first surface of the support with an adhesive; applying a sheet of
non-woven material to the printed first surface of the support; and
folding the printed support to form the box.
30. A method according to claim 29, further comprising scoring the
support to form score lines, and wherein folding the support
comprises folding the support at the score lines.
31. A method according to claim 29, further comprising cutting the
support to form a blank, and wherein folding the support comprises
folding the blank to form the box.
32. A method according to claim 29 further comprising scoring the
support to form score lines and cutting the support to form a
blank, and wherein folding the support includes folding the blank
to form the box.
33. A method according to claim 32, further comprising, prior to
the scoring and the cutting, coating the second surface of the
support with an adhesive and applying a second sheet of non-woven
material to the second surface.
34. A method according to claim 33, further comprising applying
printing to the second surface of the support.
35. A method according to claim 29, further comprising applying
printing to the second surface of the support.
36. A method according to claim 33, wherein the sheet of non-woven
material is at least partially transparent so that the printing on
the first surface of the support is visible through the sheet of
non-woven material.
37. A method according to claim 29, wherein the first surface forms
an outer surface of the box.
38. A method of manufacturing the box of claim 1, comprising:
providing the blank; and folding the blank so that the first
surface forms the outside of the box.
39. A blank for forming a body of a box, the blank comprising: a
support having a first surface and a second surface, wherein at
least the first surface has printing thereon, and at least one
sheet of non-woven material, the at least one sheet of non-woven
material being arranged on the first surface of the support, and
the at least one sheet of non-woven material being at least
partially transparent so that the printing on the first surface of
the support is visible through the at least one sheet of non-woven
material.
40. A blank according to claim 39, wherein the blank comprises
score lines, the blank being configured to be folded along the
score lines to form the body of the box.
Description
[0001] The present invention relates in general to a box used for
packaging certain objects, and in particular to a box having a body
formed from a blank. Such a box may be formed from cardboard
material, plastic, or some other similar material. The box may be
used to hold tubes or pots containing cosmetic products or care
products, for example.
[0002] Traditionally, boxes used in the field of cosmetics are
formed by folding a precut blank. The precut blank may include a
support made of cardboard or synthetic materials, for example.
These materials may or may not be transparent. It may be possible
for the support to be printed on one or both sides, using known
techniques, such as, for example, screen printing, offset printing,
or intaglio printing. A varnish or a synthetic film may be
deposited on the printed side. Such boxes may be characterized by a
relatively smooth feel.
[0003] However, the blanks covered with a varnish or with a thin
synthetic film, which are traditionally used for manufacturing
boxes, may be difficult to handle. In particular, after the blanks
have been cut, they are stacked on top of each other before each is
folded to form a box. Because the surface of the blanks is smooth,
as described above, they may slide against each other. It thus may
be difficult to keep the blanks superposed and aligned so as to
form a stack without having to place the blanks in a tray.
Furthermore, to form the boxes, each of the blanks may be taken
from the stack one after the other before being folded to form a
box. Because of the surface finish of the blanks, static may occur
and may prevent easy removal of the blanks from the stack. This may
result in several blanks remaining stuck together.
[0004] In the field of the packaging of cosmetic and care products,
there is an unending search for new designs, in terms of the visual
appearance, functional characteristics, and sensory perception, for
example, touch or feel, of packaging boxes. Thus, a need has arisen
for replacing the feel of conventional boxes, such as those formed
of thermoplastic or cardboard material, for example, with warmer,
gentler feels such as those afforded by fabrics. Further, a need
exists to provide boxes that facilitate handling, especially during
the formation of the box from the blank.
[0005] Patent Application JP 08 050452 describes a printed material
for manufacturing, in particular, a label, comprising a printed
support covered with a layer of porous material that transmits
light. The porous material may be a non-woven material impregnated
with a transparent ink in certain regions corresponding to regions
of the support on which patterns are printed so as to disclose
these patterns in sharp contrast with the other regions. This layer
of porous material also may be bonded onto boxes or tins of food
which in other respects are manufactured in a conventional way.
[0006] By bonding a non-woven material onto the boxes, an
additional stage is generated in the method of manufacture of the
boxes. In addition, bonding a non-woven material onto the boxes may
be relatively difficult when the boxes are already assembled. For
example, the stage of bonding the non-woven material onto
three-dimensional objects may be relatively tricky, especially when
there are several faces and various corners to be covered. In
addition, already-assembled boxes carry the risk of deforming when
the non-woven material is applied, particularly when there is
nothing inside the boxes to stabilize their structure. Such a box
may therefore be relatively difficult to produce and thus may have
a relatively high cost of manufacture.
[0007] Further, printing onto non-woven materials has been found to
present problems, particularly in terms of printing resolution.
These problems may be a result of the coarse characteristics often
associated with these non-woven materials.
[0008] Hence, it may be desirable to produce a box designed for
packaging products that has a feel and a visual appearance that
differs from those of conventional boxes.
[0009] Also, it may be desirable to provide a box at low cost that
allows for good printing resolution, and that has a feel similar to
that of fabrics.
[0010] Further, it may be desirable to facilitate the manufacture
of a packaging box, in particular, by making the blanks that form
the boxes easier to handle, for example.
[0011] It should be understood that the invention could be
practiced without performing one or more of the aspects described
above. Other aspects will become apparent from the detailed
description which follows.
[0012] As embodied and broadly described herein, the invention
includes a box comprising a body obtained by folding a precut
blank. The blank may comprise a support printed on at least one
surface and at least one sheet of non-woven material. The sheet of
non-woven material may be arranged on the printed surface of the
support and may be at least somewhat transparent such that the
printing of the support is visible through the sheet.
[0013] A box may be provided that may have the feel of a fabric
while maintaining good printability characteristics, particularly
in terms of resolution. Apart from the sensation it affords, this
feel may provide functional advantages in that it may improve the
grip on the box. For example, in the field of cosmetics and care
products, such as when the box is intended to house a pot or tube
of liquid or creamy product that is to be applied using the
fingers, it may be advantageous to improve the grip on the box.
[0014] Furthermore, when manufacturing the box, applying the
non-woven material directly to the blank prior to folding may be
relatively simple to achieve. For example, it may be applied from a
reel and be paid out directly onto the support, which has already
been printed on, as it travels past the reel.
[0015] Furthermore, the use of a non-woven material to cover at
least one surface of the support of the blank may prevent the
blanks from sliding against each other and also may keep a stack of
blanks intact without having to place the blanks in a tray. In
addition, extraction of each blank from the stack prior to folding
the blank to form the box may be easier.
[0016] In accordance with another aspect, the box may comprise a
body formed from a blank. The blank may comprise a support having a
first surface and a second surface, with at least the first surface
have printing thereon. The blank also may comprise at least one
sheet of non-woven material. The at least one sheet of non-woven
material may be arranged on the first surface of the support. The
at least one sheet of non-woven material also may be at least
partially transparent so that the printing on the first surface of
the support is visible through the sheet of non-woven material.
[0017] In an exemplary embodiment, a sheet of non-woven material
may be provided on both surfaces of the support. As the non-woven
material may not be as abrasive as the raw cardboard used to make
conventional boxes, the objects packaged in the box, for example,
objects with hot stampings, have a minimized risk of becoming
damaged by rubbing against the inside of the box.
[0018] According to another embodiment, the sheet of non-woven
material may be secured to the support by bonding, for example, via
an adhesive bonding or an adhesive-varnish bonding.
[0019] The support may be made of a cardboard material having a
grammage ranging from about 150 g/m.sup.2 to about 500 g/m.sup.2.
For example, the grammage may range from about 250 g/m.sup.2 to
about 400 g/m.sup.2. The support could be made rigid enough to
protect the object it packages, but not too rigid so that it
hampers folding of the support to form the box.
[0020] Alternatively, the support may be made of a material chosen
from a thermoplastic material, such as, for example, high-density
polyethylenes, polypropylenes, polyvinyl chlorides and polyethylene
terephthalates. Its thickness may range from about 150 .mu.m to
about 800 .mu.m. For example, the thickness may range from about
300 .mu.m to about 600 .mu.m.
[0021] The non-woven material may be formed of thermoplastic
fibers, for example polyolefin fibers, such as polypropylene fibers
or polyethylene fibers, or of polyester fibers. Its color may be
white or slightly tinted. The feel obtained from the non-woven
material may vary according to the nature and thickness of the
non-woven material. It may be possible to obtain highly varied
visual effects and feels ranging from silky to rough and passing
through a multitude of grades, depending on the desired
characteristics.
[0022] The sheet of non-woven material may have a thickness ranging
from about 50 .mu.m to about 800 .mu.m. For example, the thickness
may range from about 100 .mu.m to about 400 .mu.m. Optionally, the
thickness may range from about 100 m to about 200 .mu.m. The
thickness could be selected to allow the sheet to have sufficient
transparency for the printed decoration to be visible and also
provide the desired feel.
[0023] In yet another aspect, the box may comprise a body formed by
folding a blank, wherein the blank comprises a support having a
first surface and a second surface. At least the first surface may
have printing thereon and may form an outer surface of the box. The
blank also may comprise at least one sheet of non-woven material
comprising thermoplastic fibers. The at least one sheet of
non-woven material may be arranged on the first surface of the
support and may be at least partially transparent so that the
printing on the first surface of the support is visible through the
at least one sheet of non-woven material.
[0024] The at least one sheet of non-woven material may comprise a
first sheet of non-woven material on the first surface and the box
may further comprise a second sheet of non-woven material on the
second surface. The second surface may have printing thereon and
the second sheet may be at least partially transparent so that the
printing on the second surface is visible through the second sheet
of non-woven material.
[0025] The blank may comprise score lines and the blank may be
folded at the score lines.
[0026] According to another aspect of the invention, the method of
manufacture of the box comprises the following steps: printing a
support on at least one side; coating the printed surface of the
support with an adhesive; applying a sheet of non-woven material to
the printed surface of the support; scoring and cutting the support
so as to obtain a blank which is folded along the scored lines to
form the box.
[0027] Alternatively, prior to scoring and cutting, the second
surface of the support is coated with an adhesive and a second
sheet of non-woven material is applied to the second side.
[0028] According to yet another aspect, a method of manufacturing a
box may comprise providing a support having a first surface and a
second surface, applying printing to the first surface of the
support, coating the printed first surface of the support with an
adhesive, applying a sheet of non-woven material to the printed
first surface of the support, and folding the printed support to
form the box.
[0029] The term "providing" is used herein in a broad sense, and
may refer to, but is not limited to, making available for use,
enabling useage, giving, supplying, obtaining, getting a hold of,
acquiring, purchasing, selling, distributing, possessing, making
ready for use, and/or placing in a position ready for use.
[0030] The method may further comprise scoring the support to form
score lines. The folding of the support may comprise folding the
support at the score lines.
[0031] The method also may comprise cutting the support to form a
blank. The folding may comprise folding the blank to form a box.
Prior to scoring and cutting, the second surface may be coated with
an adhesive and a second sheet of non-woven material may be applied
to the second surface. Printing also may be applied to the second
surface. The first surface may form an outer surface of the
box.
[0032] According to another aspect, a blank may comprise a support
having a first surface and a second surface, wherein at least the
first surface has printing thereon, and at least one sheet of
non-woven material. The sheet of non-woven material may be arranged
on the first surface of the support, and the sheet of non-woven
material may be at least partially transparent so that the printing
on the first surface of the support is visible through the sheet of
non-woven material.
[0033] Besides the structural and procedural arrangements set forth
above, the invention could include a number of other arrangements,
such as those explained hereinafter. It is to be understood that
both the foregoing description and the following description are
exemplary. The accompanying drawings are included to provide a
further understanding of the invention and are incorporated in and
constitute a part of this specification. The drawings illustrate
exemplary embodiments of the invention and, together with the
description, serve to explain certain principles. In the
drawings,
[0034] FIG. 1 is a sectional view of an embodiment of a blank;
[0035] FIG. 2 is a sectional view of another embodiment of a
blank;
[0036] FIG. 3 is a perspective view of a cut blank for forming a
box;
[0037] FIG. 4 is a perspective view of an embodiment of a box
formed from the blank of FIG. 3; and
[0038] FIG. 5 is an embodiment of a method for forming the box of
FIG. 4.
[0039] Reference will now be made in detail to the exemplary
embodiments of the invention, examples of which are illustrated in
the accompanying drawings. Wherever possible, the same reference
numbers will be used throughout the drawings to refer to the same
or like parts.
[0040] An exemplary embodiment of a blank 10, as seen in FIG. 1 may
have a transparent or non-transparent printable support 20. The
printable support 20 may be made of a cardboard material, or of a
thermoplastic material, such as, for example, high-density
polyethylene, polypropylene, polyvinylchloride, or polyethylene
terephthalate. For example, in the case of a cardboard support, the
cardboard may have a grammage below about 400 g/m.sup.2, although
other grammages may work as well. Alternatively, in the case of a
high-density polyethylene or a polypropylene, its thickness may
range from about 300 .mu.m to about 400 .mu.m, although other
thickness may work as well. Other materials may also be used.
[0041] A first surface 21 of the support 20 may be printed so as to
convey information relating to the identity, make of, brand name
of, or other information relating to the product, or any other
printed matter, including for purely decorative purposes. The
surface 21 may form the outside surface of the box when the support
20 is folded. Printing may be by any known technique, such as, for
example, numerically controlled printing, screen printing, intaglio
printing, flexographic printing, or offset printing.
[0042] A layer of adhesive 40, for example, an adhesive, an
adhesive-varnish, or other similar adhesive material, may be
deposited on the printed surface 21 of the support 20. Drying may
be performed in a conventional oven when a conventional adhesive is
used. For example, when the support 20 is made of a cardboard
material, the adhesive layer 40 may be a UV-drying varnish. This
will allow drying without using hot air, which may cause the
cardboard to cockle.
[0043] A sheet 30 of non-woven material, which may have been carded
to raise at least some of the fibers to provide a fabric feel, for
example, covers the printed surface of the support 20. The sheet 30
may be bonded to the support 20 via the layer of adhesive 40. Such
a sheet of non-woven material 30 may be formed of an intermingling
of fibers, the tightness of which may vary. The fibers may be
synthetic fibers and welded together in a conventional way, for
example, by hot rolling. Hot rolling includes passing the fibers
between two rolls, one of which is heated and has bosses facing the
other roll, to form spot welds. For example, the non-woven material
may be made of polyolefin fibers, for example, polypropylene fibers
or polyethylene fibers. Alternatively, the non-woven material may
be made of polyester. The thickness of the sheet 30 may range from
about 100 .mu.m to about 200 .mu.m, although other thickness may
also work.
[0044] In an exemplary embodiment, the printed information on the
surface 21 of the support 20 is visible through the sheet 30 of
non-woven material because of the contact transparency of the sheet
30 of non-woven material.
[0045] In an exemplary embodiment, the second surface 22 of the
support 20 also may be printed. For example, this would make it
possible to provide additional information on the inside of the
box.
[0046] Another exemplary embodiment of the blank 10 is shown in
FIG. 2. In this embodiment, the second surface 22 of the support
20, which is the surface that is intended to constitute the inside
surface of the box, may be covered with an adhesive layer 50, for
example, an adhesive or an adhesive-varnish with good adhesive
properties.
[0047] A sheet 60 of non-woven material as previously described,
which may have been carded to raise at least some of the fibers to
provide a fabric feel, for example, may cover the surface 22 of the
support 20, to which it is bonded by means of the adhesive layer
50. This sheet 60 of non-woven material may be identical to the
sheet 30 provided on the outside of the box or may be made of a
different material. In this embodiment, the surface 22 may be
printed before being coated with the adhesive layer 50.
[0048] FIG. 3 shows an embodiment of a blank prior to folding and
FIG. 4 shows an embodiment of a box 100 comprising a body obtained
by folding the blank shown in FIG. 3. Such a box may have a front
panel, a rear panel connected by two side panels, two openings, one
at each end of the body.
[0049] FIG. 5 shows an exemplary method of manufacturing the box
100. The method includes providing the support 20 having a first
surface 21 and a second surface 22 (step 510). For example, the
support 20 may be paid out from a reel. A printing may be applied
to the surface 21 (step 520), such as, for example, by numerically
controlled printing. The printed surface 21 may then be coated with
an adhesive 40 (step 530), such as, for example, UV-drying varnish.
The adhesive 40 may be applied either in a second pass or on-line.
A sheet of non-woven material 30, such as, for example, a
polyolefin, may be applied to the surface 21 (step 540). The
assembly may then be dried using a UV system. The support 20 may
then be scored to provide score lines (step 550) and then cut to
obtain a blank 10 (step 560). Because of its intrinsic
stretchability properties, the sheet of polyolefin non-woven
material deforms during scoring without the risk of tearing or of
scoring inappropriately. Other materials may provide similar
properties and are understood to be within the scope of invention.
The blank 10 may then be folded along the scored lines and bonded
or simply assembled according to the conventional techniques for
forming the box 100 (step 570).
[0050] According to an alternative form of this method, the second
surface 22 of the support 20 may be printed thereon prior to the
scoring and cutting of the support 20.
[0051] According to yet another alternative, the second surface 22
of the support 20, which may or may not be printed, may be coated
with an adhesive 50, such as, for example, a UV-drying varnish,
prior to the scoring and cutting stage. A second sheet of non-woven
material 60 may then be applied to the support 20 prior to the
scoring and cutting of the support 20.
[0052] In the foregoing detailed description, reference has been
made to certain preferred embodiments of the invention. It will be
apparent to those skilled in the art that variants can be made to
the structure and methodology. Thus, it should be understood that
the invention is not limited to the examples and embodiments
discussed in the specification. Rather, the present invention is
intended to cover variations and modifications.
* * * * *