U.S. patent application number 11/739863 was filed with the patent office on 2008-10-30 for nested pair of blanks.
Invention is credited to David Eric Stier.
Application Number | 20080269034 11/739863 |
Document ID | / |
Family ID | 39887685 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080269034 |
Kind Code |
A1 |
Stier; David Eric |
October 30, 2008 |
NESTED PAIR OF BLANKS
Abstract
The invention relates to a nested pair of blanks on a unitary
sheet which minimizes the amount of scrap sheet material (i.e.,
sheet scrap) upon separation of the blanks and construction of
containers formed from the blanks. The nested pair of blanks
provides 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. The nested configuration
reduces the amount of sheet scrap in the sheet. The invention
further relates to a container formed from the first or second
blank having features that reduce sheet scrap and offset the
potential weakening of the container bottom resulting from reduced
overlapping sheet material.
Inventors: |
Stier; David Eric; (Avon
Lake, OH) |
Correspondence
Address: |
SUMMA, ALLAN & ADDITON, P.A.
11610 NORTH COMMUNITY HOUSE ROAD, SUITE 200
CHARLOTTE
NC
28277
US
|
Family ID: |
39887685 |
Appl. No.: |
11/739863 |
Filed: |
April 25, 2007 |
Current U.S.
Class: |
493/52 ;
229/100 |
Current CPC
Class: |
B65D 5/10 20130101; B65D
2301/10 20130101 |
Class at
Publication: |
493/52 ;
229/100 |
International
Class: |
B65D 5/02 20060101
B65D005/02 |
Claims
1. A nested pair of blanks on a unitary sheet, comprising: a first
blank for forming a container, said first blank having one or more
body panels connected to one another and oriented horizontally,
said first blank having one or more bottom panels connected to
edges of said one or more body panels of said first blank; a second
blank for forming an identical container, said second blank having
one or more body panels connected to one another and oriented
horizontally, said second blank having one or more bottom panels
connected to edges of said one or more body panels of said second
blank; and a non-linear separation interface connecting said first
and second blanks to one another in a rotationally inverted
relationship that reduces sheet scrap; wherein said one or more
bottom panels of said first and second blanks define said
non-linear separation interface.
2. A nested pair of blanks according to claim 1, wherein said sheet
comprises paperboard.
3. A nested pair of blanks according to claim 1, wherein: said
first blank having one or more notched edges that correspondingly
engage one another to form a container bottom upon separation of
said blank from said sheet and construction of the container; and
said second blank having one or more notched edges that
correspondingly engage one another to form a container bottom upon
separation of said blank from said sheet and construction of the
identical container.
4. A nested pair of blanks according to claim 1, wherein: edges of
said one or more bottom panels of said first blank having
engagement notches that correspondingly engage one another to form
the container bottom upon separation of said blank from said sheet
and construction of the container; and edges of said one or more
bottom panels of said second blank having engagement notches that
correspondingly engage one another to form the container bottom
upon separation of said blank from said sheet and construction of
the identical container.
5. A nested pair of blanks according to claim 1, wherein at least
one of said one or more bottom panels of said first blank is
connected to and nested vertically with at least one of said one or
more bottom panels of said second blank.
6. A nested pair of blanks according to claim 1, wherein said
non-linear separation interface is further defined by: one or more
bottom flaps connected to edges of said one or more body panels of
said first blank; and at least one of said one or more bottom flaps
of said first blank is connected to and nested vertically with at
least one of said one or more bottom panels of said second
blank.
7. A nested pair of blanks according to claim 1, wherein said
non-linear separation interface is further defined by: one or more
bottom flaps connected to edges of said one or more body panels of
said second blank; and at least one of said one or more bottom
flaps of said second blank is connected to and nested vertically
with at least one of said one or more bottom panels of said first
blank.
8. A nested pair of blanks according to claim 1, wherein said
non-linear separation interface is further defined by: one or more
bottom flaps connected to edges of said one or more body panels of
said first blank; and one or more bottom flaps connected to edges
of said one or more body panels of said second blank; at least one
of said bottom panels of said first blank is connected to and
vertically nested with at least one of said one or more bottom
panels of said second blank and at least one of said bottom flaps
of said second blank.
9. A nested pair of blanks according to claim 8, wherein at least
one of said bottom panels of said second blank is connected to and
vertically nested with at least one of said one or more bottom
panels of said first blank and at least one of said one or more
bottom flaps of said first blank.
10. A nested pair of blanks according to claim 1, wherein each said
first and second blanks is asymmetrical about a vertical axis of
symmetry.
11. A nested pair of blanks according to claim 1, wherein said body
panels of said first and second blanks are oriented on said sheet
in a non-linear arrangement.
12. A nested pair of blanks according to claim 1, wherein said one
or more body panels of said first blank include: a substantially
rectangular front panel, said front panel having opposing first and
second side panels; and a substantially rectangular rear panel
connected to said front panel by said second side panel.
13. A nested pair of blanks according to claim 12, wherein said one
or more bottom panels of said first blank include: at least one
bottom panel connected to an edge of said front panel; and at least
one bottom panel connected to an edge of said rear panel.
14. A nested pair of blanks according to claim 1, wherein said one
or more body panels of said second blank include: a substantially
rectangular front panel, said front panel having opposing first and
second side panels; and a substantially rectangular rear panel
connected to said front panel by said second side panel.
15. A nested pair of blanks according to claim 14, wherein said one
or more bottom panels of said second blank include: at least one
bottom panel connected to an edge of said front panel; and at least
one bottom panel connected to an edge of said rear panel.
16. A nested pair of blanks according to claim 1, wherein: said
first blank having one or more bottom flaps connected to edges of
said one or more body panels of said first blank; and said second
blank having one or more bottom flaps connected to edges of said
one or more body panels of said second blank.
17. A nested pair of blanks on a unitary sheet, comprising: a first
blank for forming a container, said first blank having a
substantially rectangular front panel, said front panel having
opposing first and second side panels, a substantially rectangular
rear panel connected to said front panel by said second side panel,
and a bottom panel connected to an edge of said front panel; a
second blank for forming an identical container, said second blank
having: a substantially rectangular front panel, said front panel
having opposing first and second side panels, a substantially
rectangular rear panel connected to said front panel by said second
side panel; and a bottom panel connected to an edge of said rear
panel; and a non-linear separation interface connecting said first
and second blanks to one another in a rotationally inverted
relationship that reduces sheet scrap; wherein said one or more
bottom panels of said first and second blanks define said
non-linear separation interface.
18. A nested pair of blanks according to claim 17, wherein said
sheet comprises paperboard.
19. A nested pair of blanks according to claim 17, wherein: said
first blank having one or more notched edges that correspondingly
engage one another to form a container bottom upon separation of
said blank from said sheet and construction of the container; and
said second blank having one or more notched edges that
correspondingly engage one another to form a container bottom upon
separation of said blank from said sheet and construction of the
identical container.
20. A nested pair of blanks according to claim 17, wherein said
bottom panel of said first blank is connected to and nested
vertically with said bottom panel of said second blank.
21. A nested pair of blanks according to claim 17, said non-linear
separation interface is further defined by: a bottom flap connected
to an edge of said first side panel of said first blank; and said
bottom flap of said first blank is connected to and vertically
nested with said bottom panel of said second blank.
22. A nested pair of blanks according to claim 17, said non-linear
separation interface is further defined by: a bottom flap connected
to an edge of said second side panel of said second blank; and said
bottom flap of said second blank is connected to and vertically
nested with said bottom panel of said first blank.
23. A nested pair of blanks according to claim 17, said non-linear
separation interface is further defined by: a bottom panel
connected to an edge of said rear panel of first blank; and a
bottom panel connected to an edge of said front panel of said
second blank; wherein said bottom panel connected to said rear
panel of said first blank is connected to and nested vertically
with said bottom panel connected to said front panel of said second
blank.
24. A nested pair of blanks according to claim 23, wherein: edges
of said bottom panels of said first blank having engagement notches
that correspondingly engage one another to form a container bottom
upon separation of said blank from said sheet and construction of
the container; and edges of said bottom panels of said second blank
having engagement notches that correspondingly engage one another
to form a container bottom upon separation of said blank from said
sheet and construction of the identical container.
25. A nested pair of blanks according to claim 23, said non-linear
separation interface is further defined by: a bottom flap connected
to an edge of said second side panel of said first blank; and said
bottom flap connected to said second side panel of said first blank
is connected to and vertically nested with said bottom panel
connected to said front panel of said second blank.
26. A nested pair of blanks according to claim 23, said non-linear
separation interface is further defined by: a bottom flap connected
to an edge of said first side panel of said second blank; and said
bottom flap connected to said first side panel of said second blank
is connected to and vertically nested with said bottom panel
connected to said rear panel of said first blank.
27. A nested pair of blanks according to claim 17, further
comprising first and second locking closure flaps connected to
edges of said first and second side panels of said first blank,
respectively, opposite said non-linear separation interface.
28. A nested pair of blanks according to claim 17, further
comprising first and second top closure panels connected to edges
of said front and rear panels of said first blank, respectively,
opposite said non-linear separation interface.
29. A nested pair of blanks according to claim 28, further
comprising first and second tuck flaps connected to edges of said
first and second top closure panels of said first blank,
respectively, opposite said front and rear panels of said first
blank.
30. A nested pair of blanks according to claim 17, further
comprising a glue flap connected to an edge of said rear panel of
said first blank, opposite said second side panel of said first
blank.
31. A nested pair of blanks according to claim 17, further
comprising first and second locking closure flaps connected to
edges of said first and second side panels of said second blank,
respectively, opposite said non-linear separation interface.
32. A nested pair of blanks according to claim 17, further
comprising first and second top closure panels connected to edges
of said front and rear panels of said second blank, respectively,
opposite said non-linear separation interface.
33. A nested pair of blanks according to claim 32, further
comprising first and second tuck flaps connected to edges of said
first and second top closure panels of said second blank,
respectively, opposite said front and rear panels of said second
blank.
34. A nested pair of blanks according to claim 17, further
comprising a glue flap connected to an edge of said rear panel of
said second blank, opposite said second side panel of said second
blank.
35. A nested pair of blanks on a unitary sheet, comprising: a first
blank for forming a container, said first blank having a
substantially rectangular front panel, said front panel having
opposing first and second side panels, a substantially rectangular
rear panel connected to said front panel by said second side panel,
a first bottom closure panel connected to an edge of said front
panel, a second bottom closure panel connected to an edge of said
rear panel, a first bottom closure flap connected to an edge of
said first side panel, and a second bottom closure flap connected
to an edge of said second side panel; and a second blank for
forming an identical container, said second blank having: a
substantially rectangular front panel, said front panel having
opposing first and second side panels, a substantially rectangular
rear panel connected to said front panel by said second side panel,
a first bottom closure panel connected to an edge of said front
panel, a second bottom closure panel connected to an edge of said
rear panel, a first bottom closure flap connected to an edge of
said first side panel, and a second bottom closure flap connected
to an edge of said second side panel; and a non-linear separation
interface connecting said first and second blanks to one another in
a rotationally inverted relationship that reduces sheet scrap.
36. A nested pair of blanks according to claim 35, wherein said one
or more bottom closure panels and said one or more bottom closure
flaps of said first and second blanks define said non-linear
separation interface.
37. A nested pair of blanks according to claim 35, wherein one or
more of said bottom closure panels of said first blank is connected
to and nested vertically with one or more of said bottom closure
flaps of said second blank.
38. A nested pair of blanks according to claim 35, wherein one or
more of said bottom closure panels of said second blank is
connected to and nested vertically with one or more of said bottom
closure flaps of said first blank.
39. A nested pair of blanks according to claim 35, wherein said
first bottom closure panel of said first blank is connected to and
vertically nested with said second bottom closure panel and second
bottom closure flap of said second blank.
40. A nested pair of blanks according to claim 35, wherein said
second bottom closure panel of said first blank is connected to and
vertically nested with said first bottom closure panel and said
first bottom closure flap of said second blank.
41. A nested pair of blanks according to claim 35, wherein said
first bottom closure flap of said first blank is connected to and
vertically nested with said second bottom closure panel of said
second blank.
42. A nested pair of blanks according to claim 35, wherein said
second bottom closure flap of said first blank is connected to and
vertically nested with said first bottom closure panel of said
second blank.
43. A nested pair of blanks according to claim 35, wherein said
first bottom closure flap of said second blank is connected to and
vertically nested with said second bottom closure panel of said
first blank.
44. A nested pair of blanks according to claim 35, wherein said
second bottom closure flap of said second blank is connected to and
vertically nested with said first bottom closure panel of said
first blank.
45. A nested pair of blanks according to claim 35, wherein: said
first and second bottom closure panels of said first blank having
one or more notched edges that correspondingly engage one another
to form a container bottom upon separation of said blank from said
sheet and construction of the container; and said first and second
bottom closure panels of said second blank having one or more
notched edges that correspondingly engage one another to form a
container bottom upon separation of said blank from said sheet and
construction of the identical container.
46. A container having an interlocking container bottom,
comprising: first and second bottom closure panels secured to one
another, said first and second bottom closure panels having notched
edges that correspondingly engage one another to form a container
bottom; first and second bottom closure flaps secured to said first
and second bottom closure flaps, portions of said first and second
bottom closure flaps positioned between overlapping portions of
said first and second bottom closure panels; a substantially
rectangular front panel connected to said first bottom closure
panel; a substantially rectangular rear panel connected to said
second bottom closure panel, said front panel and said rear panel
defining substantially parallel planes; a substantially rectangular
first side panel connected to said first bottom closure flap and to
respective edges of said front and rear panels; and a substantially
rectangular second side panel secured to said second bottom closure
flap and to respective edges of said front and rear panels, said
first side panel and said second side panel defining substantially
parallel planes.
Description
BACKGROUND OF THE INVENTION
[0001] 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.
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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.
SUMMARY OF THE INVENTION
[0006] 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.
[0007] 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.
[0008] 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).
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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:
[0017] FIG. 1 is a partial top plan view of known nesting
arrangements of blanks on a unitary sheet illustrating sheet scrap
in parallel cross-hatched lines between the blanks;
[0018] FIG. 2 is a perspective view of a known container having an
automatic bottom illustrating overlapping sheet material in a
container bottom in hidden double cross-hatched lines;
[0019] FIG. 3A is a partial perspective view of one bottom panel of
a known container illustrating the area of overlap between the
bottom panels in double cross-hatched lines;
[0020] FIG. 3B is a partial perspective view of another bottom
panel of a known container illustrating the area of overlap between
the bottom panels in double cross-hatched lines;
[0021] FIG. 4 is a top plan view of one embodiment of a nested pair
of blanks on a unitary sheet of the invention illustrating sheet
scrap in parallel cross-hatched lines;
[0022] FIG. 5 is an enlarged top plan view of a portion of one
embodiment of a nested pair of blanks of the invention depicting
notched edges in bottom panels of the blanks;
[0023] FIG. 6 is a partial perspective view of a container having
an automatic bottom formed from one embodiment of a nested pair of
blanks of the invention illustrating overlapping sheet material in
a container bottom in hidden double cross-hatched lines;
[0024] FIG. 7 is an enlarged perspective view of a portion of a
container formed from one embodiment of the nested pair of blanks
of the invention illustrating overlapping sheet material in a
container bottom in hidden double cross-hatched lines;
[0025] FIG. 8A is a partial perspective view of one bottom panel of
a container formed from one embodiment of the nested pair of blanks
of the invention illustrating the area of overlap between the
bottom panels in double cross-hatched lines;
[0026] FIG. 8B is a partial perspective view of another bottom
panel of a container formed from one embodiment of the nested pair
of blanks of the invention illustrating the area of overlap between
the bottom panels in double cross-hatched lines;
[0027] FIG. 9A is a partial perspective view of the bottom of a
container formed from one embodiment of the nested pair of blanks
of the invention illustrating the initial stages of the formation
of a container bottom;
[0028] FIG. 9B is a partial perspective view of the bottom of a
container formed from one embodiment of the nested pair of blanks
of the invention illustrating latter stages of the formation of a
container bottom; and
[0029] FIG. 9C is a partial perspective view of the bottom of a
container formed from one embodiment of the nested pair of blanks
of the invention illustrating the completed formation of a
container bottom.
DETAILED DESCRIPTION OF THE INVENTION
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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."
[0036] With reference to the orientation of the sheet in FIG. 4, it
will be understood that the terms "internal surface" and "external
surface" may be referred to as "inside surface" and "outside
surface." Stated differently, the term internal surface implies the
surface of the container closest to the interior of the container.
Thus, it will be understood that the term external surface implies
the side of the container opposite the internal surface (i.e., the
side farthest from the interior of the container).
[0037] 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.times.W.times.D). With reference to the
orientation of the sheet in FIG. 4, it will be understood that the
term "width" refers to a distance measured from the leftmost
portion of the sheet to the rightmost portion of the sheet.
[0038] 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.
[0039] 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).
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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).
[0045] 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 FIG. 4. In general terms, the invention provides a
first blank 11 for forming a container 60, a second blank 12 for
forming an identical container, and a non-linear separation
interface 13 that connects the first and second blanks 11, 12 to
one another in a rotationally inverted relationship (i.e.,
half-turned and inverted with respect to one another). As a novel
feature of the invention, the non-linear separation interface 13
reduces the amount of sheet scrap S in the sheet 10 and improves
manufacturing efficiencies. In one embodiment, the sheet 10 is
formed from paperboard.
[0046] Referring to FIG. 4, the first and second blanks 11, 12
include one or more body panels 14, 15, 16, 17, 20, 21, 22, 23
connected along substantially vertical fold lines 18 and oriented
horizontally. In further detail, the body panels 14, 15, 16, 17 of
the first blank 11 include a substantially rectangular front panel
14 having opposing first and second side panels 15, 16, and a
substantially rectangular rear panel 17 connected to the front
panel 14 by the second side panel 16. In like fashion, the body
panels 20, 21, 22, 23 of the second blank 12 include a
substantially rectangular front panel 20 having opposing first and
second side panels 21, 22, and a substantially rectangular rear
panel 23 connected to the front panel 20 by the second side panel
22. The body panels of the first and second blanks 11, 12 form the
major component parts of the respective blanks.
[0047] 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.
[0048] Still referring to FIG. 4, the bottom panels 25, 26 of the
first blank 11 include a first bottom closure panel 25 connected to
an edge of the front panel 14, and a second bottom closure panel 26
connected to an edge of the rear panel 17. Further, the bottom
panels 30, 31 of the second blank 12 include a first bottom closure
panel 30 connected to an edge of the front panel 20, and a second
bottom closure panel 31 connected to an edge of the rear panel 23.
As discussed herein, the first and second bottom panels 25, 26, 30,
31 of the blanks engage one another respectively, during
construction of the containers formed from the blanks.
[0049] 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.
[0050] 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 FIG. 4). During
construction of a container 60 from either of the blanks as
illustrated in FIGS. 9B and 9C, a portion of the first bottom glue
flap 35 is adhered to a portion of the first bottom closure panel
25. Further, a portion of the second bottom glue flap 36 is adhered
to a portion of the second bottom closure panel 26.
[0051] 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 FIG. 9C). Specifically,
upon the formation of the manufacturer's glue joint with a glue
flap 56, the substantially flat, partially formed container 60 is
expanded, thereby permitting the engagement notches 40 to secure
the container bottom 29.
[0052] As configured on the unitary sheet 10 depicted in FIG. 4, at
least one of the bottom panels 25, 26 of the first blank 11 is
connected to and nested vertically with at least one of the bottom
panels 30, 31 of the second blank 12. In one embodiment, the first
bottom closure panel 25 of the first blank 11 is connected to the
second bottom closure panel 31 of the second blank 12, and 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.
[0053] Still referring to FIG. 4, the adjacent bottom panels 25,
26, 30, 31 of the first and second blanks 11, 12 define the
non-linear separation interface 13. The non-linear separation
interface 13 is further defined by one or more of the bottom
closure flaps 27, 28, 32, 33 connected to edges of the body panels
15, 16, 21, 22 of the first and second blanks 11, 12. Accordingly,
one or more of the adjacent bottom closure panels 25, 26, 30, 31
and one or more of the adjacent bottom closure flaps 27, 28, 32, 33
of the first and second blanks 11, 12 may define the non-linear
separation interface 13 on the unitary sheet 10.
[0054] 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.
[0055] With reference to FIG. 4, one or more of the bottom closure
panels 25, 26 of the first blank 11 are connected to and nested
vertically with one or more of the bottom closure flaps 32, 33 of
the second blank. Further, one or more of the bottom closure panels
30, 31 of the second blank 12 may be connected to and nested
vertically with one or more of the bottom closure flaps 27, 28 of
said first blank 11. In particular, the first bottom closure panel
25 of the first blank 11 is connected to and nested vertically with
the second bottom closure flap 33 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 flap 32 of the second blank 12.
[0056] 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.
[0057] 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.
[0058] Still referring to FIG. 4, one embodiment provides at least
one of the bottom flaps 27, 28 of the first blank 11 connected to
and nested vertically with at least one of the bottom panels 30, 31
of the second blank 12. In more detail, the first bottom closure
flap 27 of the first blank 11 is connected to and vertically nested
with the second bottom closure panel 31 of the second blank. In
another embodiment, the second bottom closure flap 28 of the first
blank 11 is connected to and vertically nested with the first
bottom closure panel 30 of the second blank 12.
[0059] 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.
[0060] With reference to FIG. 5, each of the nested blanks 11, 12
includes one or more notched edges 24 that correspondingly engage
one another to form container bottoms upon separation of the blanks
from the sheet 11 and construction of the container 60. In
particular, edges 24 of the bottom panels 25, 26 of the first blank
11 have engagement notches 40 that correspondingly engage one
another to form the container bottom upon separation of the blank
from the sheet and construction of the container. In similar
fashion, edges 24 of the bottom panels 30, 31 of the second blank
12 include engagement notches 40 that correspondingly engage one
another to form the container bottom upon separation of the blank
from the sheet and construction of the identical container. As
illustrated in FIG. 5, one or more of the notched edges 24 define
angles A that are oriented on the sheet 10 at approximately 45
degrees relative to the substantially vertical fold lines 18 in the
blanks 11, 12. The angle A may vary depending upon the size and
shape of the notches 40.
[0061] 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.
[0062] 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 FIGS.
2-3B to the present invention depicted in FIGS. 6-8B, the reduction
in available surface area of the bottom panels 25, 26 is evident.
The overlapping sheet material of the inventive bottom panels 25,
26 indicated by hidden double cross-hatched lines in FIGS. 6 and 7
is less than the overlapping material of known bottom panels 25',
26' indicated by hidden double cross-hatched lines in FIG. 2. In
further detail, the area of overlap of the inventive bottom panels
25, 26 indicated by double cross-hatched lines in FIGS. 8A and 8B
is less than the area of overlap of known bottom panels 25', 26'
indicated by double cross-hatched lines in FIGS. 3A and 3B.
[0063] 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 FIG. 4 includes less sheet scrap S (represented
by parallel double cross-hatched lines) than the known sheet
illustrated in FIG. 1. Accordingly, the present invention increases
manufacturing efficiencies by reducing sheet scrap S in a sheet,
yet addresses the potentially weakened bottom by providing bottom
panels having engagement notches that secure the bottom panels to
one another and strengthen the container bottom 29.
[0064] In terms of relative percent, the sheet scrap S illustrated
in the inventive sheet of FIG. 4 is approximately 27% of the sheet
scrap S' illustrated in the known sheet of FIG. 1. Further, the
overlapping sheet material illustrated in the inventive container
bottom 29 of FIG. 6 is approximately 26% of the overlapping sheet
material illustrated in the known container bottom 29' of FIG.
2.
[0065] Directing attention to the first blank 11 of FIG. 4, one
embodiment of the present invention may also provide first and
second locking closure flaps 41, 42 connected to edges of the first
and second side panels 15, 16, respectively. The first and second
locking closure flaps 41, 42 of the first blank 11 are positioned
on the unitary sheet 11 opposite the non-linear separation
interface 13 and secures the top of the container 60 formed from
the blank 11. This particular embodiment also provides first and
second top closure panels 47, 48 connected to edges of the front
and rear panels 14, 17 of the first blank 11. The top closure
panels 47, 48 form a part of the top of the container 60 and are
positioned on the sheet 11 opposite the non-linear separation
interface 13. The first blank 11 may also include first and second
tuck flaps 52, 53 connected to edges of the first and second top
closure panels 47, 48, respectively, opposite the front and rear
panels 14, 17. The tuck flaps 52, 53 secure the top closure panels
47, 48 to each other. A glue flap 56 is provided in the first blank
11 to assist in construction of the container 60 formed from the
blank 11. The glue flap 56 is connected to an edge of the rear
panel 17 of the first blank 11, opposite the second side panel 16,
and is eventually secured to the first side panel 15 upon
construction of the container 60.
[0066] Referring now to the second blank 12 of FIG. 4, the
invention provides first and second locking closure flaps 45, 46
connected to edges of the first and second side panels 21, 22 of
the second blank 12, respectively. The first and second locking
closure flaps 45, 46 of the second blank 12 are positioned on the
unitary sheet 11 opposite the non-linear separation interface 13
and secures the top of the container 60 formed from the blank. The
second blank 12 may further include first and second top closure
panels 50, 51 connected to edges of the front and rear panels 20,
23, respectively. The first and second top closure panels 50, 51
are positioned on the sheet 10 opposite the non-linear separation
interface 13 and form a part of the top of the container. First and
second tuck flaps 54, 55 are provided on the second blank 12 and
are connected to edges of the first and second top closure panels
50, 51, respectively, opposite the front and rear panels 20, 23. To
assist in construction of the identical container, the second blank
12 may include a glue flap 57 connected to an edge of the rear
panel 23 of the second blank, opposite the second side panel
22.
[0067] As depicted in FIG. 4, the first and second blanks 11, 12
are oriented on the sheet asymmetrically about a vertical axis of
symmetry. Stated differently, the body panels 14, 15, 16, 17, 20,
21, 22, 23 of the first and second blanks 11, 12 are oriented on
the sheet in a non-linear arrangement. In a novel aspect of the
invention, the non-linear arrangement in connection with the
separation interface 13 reduces sheet scrap S and promotes
manufacturing efficiencies.
[0068] The invention also provides a container 60 formed from the
first or second blank 11, 12 as described above. As shown in FIGS.
6-8B, the container 60 includes an interlocking container bottom 29
that is automatically formed upon construction. The container 60
includes first and second bottom closure panels 25, 26 that are
secured to one another, first and second bottom closure flaps 27,
28 secured to the first and second bottom closure flaps, a
substantially rectangular front panel 14 connected to the first
bottom closure panel 25, and a substantially rectangular rear panel
17 connected to the second bottom closure panel 26. The container
60 further includes a substantially rectangular first side panel 15
connected to the first bottom closure flap 27 and to respective
edges of the front and rear panels 14, 17, and a substantially
rectangular second side panel 16 secured to the second bottom
closure flap 28 and to respective edges of the front and rear
panels 14, 17. As constructed, the front and rear panels 14, 17 and
the first and second side panels 15, 16 define substantially
parallel planes, respectively.
[0069] 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.
[0070] Construction of the container bottom 29 is illustrated in
FIGS. 9A-9C. In further detail, the glue flap 56 is adhered to the
first side panel 15 to form the basic container structure.
Thereafter, a portion of the first bottom closure flap 27 is
secured to the first bottom glue flap 35 of the first bottom
closure panel 25. Further, a portion of the second bottom closure
flap 28 is secured to the second bottom glue flap 36 of the second
bottom closure panel 26. At this stage, the partially formed
container may be folded substantially flat such that the cut-score
lines 39 defining the first and second bottom glue flaps 35, 36
permit the folding of the first side panel 15 and rear panel 17
against the second side panel 16 and front panel 14, respectively.
In this substantially flat configuration, the first bottom closure
panel 25 is substantially adjacent to the front panel 14, the
second bottom closure panel 26 is substantially adjacent to the
rear panel 17, the first bottom closure flap 27 is substantially
adjacent to the first side panel 15, and the second bottom closure
flap 28 is substantially adjacent to the second side panel 16.
[0071] 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.
[0072] 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.
* * * * *