FIELD OF THE INVENTION

This invention relates to making three-dimensional structures by folding flat sheet materials to form an article useful for decoration or, on a larger scale, an article used as a general purpose support structure. A specific provides both a package and container for forming a decorative polygonal container.

BACKGROUND OF THE INVENTION

A variety of containers that are presently in use are formed from one or more paperboard blanks that are divided by fold lines into a plurality of panels. This type of container has attained great popularity because it is inexpensive to produce and takes little storage space before it is folded and formed into a container suitable for containing articles of manufacture. In addition, it can be made attractive and provides adequate protection for many types of articles that may be disposed therein.

Most containers of this type include a top formed by a single rectangular top panel that is joined to a side panel along a fold line. If it is desired to have a more elaborate top or bottom portion, either for added structural protection or for aesthetic reasons, it has usually been necessary to depart from folded container construction, thus sacrificing any inherent advantages.

SUMMARY OF THE INVENTION

A first embodiment of the present disclosure provides for a blank of foldable material. The blank comprises a flat, substantially rectangular, blank of foldable material having top, bottom, left and right side edges, and a plurality of interconnected body panels disposed between the left and right side edges. Each of the panels extends from the top edge and the bottom edge. The top edge and the bottom edge have a plurality of peaks and valleys. A first portion of the plurality of peaks and valleys are joined by curvilinear lines and a second portion of the peaks and valleys are joined by straight lines. The curvilinear lines joining the peaks and valleys of the top portion are adjacent at least one of the straight lines joining the peaks and valleys of the top portion. The blank also comprises a first plurality of fold lines adjacent both the top edge and the bottom edge. The first plurality of fold lines comprises a plurality of identical arch-shaped lines and a plurality of straight vertical lines. The arch-shaped fold lines are arranged side by side with the sides meeting and terminating at points on the valleys of both the top and bottom edges. The straight vertical fold lines connect the apexes of the arched shapes and the peaks along the top and bottom edges between the sides of the arches. The blank also comprises a second plurality of arch-shaped fold lines disposed between and connecting the apexes of the arched shapes. Each of the arch-shaped fold lines separates each of the panels into a first body region and a second region containing the plurality of fold lines adjacent both the top edge and the bottom edge. The right and left side edges are joinable to first form a cylinder having a circumference defined by a plurality of the first body regions. The top edge is folded inward along the fold lines and the bottom edge is folded inward along the fold lines to form a substantially flat panel at the top and a substantially flat panel at the bottom.

A second embodiment of the present disclosure provides for a polygonal container. The container comprises a flat, substantially rectangular, blank of foldable material having top, bottom, left and right side edges, and a plurality of interconnected body panels disposed between the left and right side edges. Each of the panels extends from the top edge and the bottom edge. The top edge and the bottom edge have a plurality of peaks and valleys. A first portion of the plurality of peaks and valleys are joined by curvilinear lines and a second portion of the peaks and valleys are joined by straight lines. The curvilinear lines joining the peaks and valleys of the top portion are adjacent at least one of the straight lines joining the peaks and valleys of the top portion. The blank also comprises a first plurality of fold lines adjacent both the top edge and the bottom edge. The first plurality of fold lines comprises a plurality of identical arch-shaped lines and a plurality of straight vertical lines. The arch-shaped fold lines are arranged side by side with the sides meeting and terminating at points on the valleys of both the top and bottom edges. The straight vertical fold lines connect the apexes of the arched shapes and the peaks along the top and bottom edges between the sides of the arches. The blank also comprises a second plurality of arch-shaped fold lines disposed between and connecting the apexes of the arched shapes. Each of the arch-shaped fold lines separates each of the panels into a first body region and a second region containing the plurality of fold lines adjacent both the top edge and the bottom edge. The right and left side edges are joinable to first form a cylinder having a circumference defined by a plurality of the first body regions. The top edge is folded inward along the fold lines and the bottom edge is folded inward along the fold lines to form a substantially flat panel at the top and a substantially flat panel at the bottom. Sealing means is disposed within a region of each flat panel circumscribed and formed by the top and bottom edges respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary blank for a paper package;

FIG. 2 is a perspective view of an exemplary container formed from the blank similar to that shown in FIG. 1; and,

FIG. 3 is a plan view of the top of the exemplary container of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The term machine direction (MD) is known to those of skill in the art as the direction of travel of a web material through any processing equipment. The cross-machine direction (CD) is orthogonal and coplanar to the MD. The Z-direction is orthogonal to both the machine and cross-machine directions.

FIG. 1 shows an unfolded carton blank 10 of one embodiment of the present invention. The body portion and the end walls forming a proper and complete container may be assembled from a single carton blank 10. The carton blank 10 is preferably formed from a paperboard material which has been suitably cut and scored as shown. It should be understood that a container having at least three side walls can be formed in accordance with the present disclosure. However, one of skill in the art would readily appreciate that a container having at least five side walls can be formed in a similar manner in accordance with the present disclosure.

As shown, the unfolded carton blank 10 is provided with a plurality of parallel extending score lines d defining a plurality of body panel portions. As shown, each of the plurality of parallel extending score lines d are parallel to the CD. However, the plurality of parallel extending score lines d can be oriented in any direction necessary to form each of the body panel portions shown. In the exemplary embodiment shown, carton blank 10 is provided with five parallel extending score lines d. Each body panel is bounded by an adjacent pair of the parallel extending score lines d. Thus, a first pair of parallel extending score lines d form first body panel 14. A second pair of parallel extending score lines d form second body panel 16. Likewise a third 18, fourth 20, a and fifth body panel 22 are formed by succeeding adjacent parallel extending score lines d with fifth body panel 22 having left side edge e forming the outer edge of the panel. However, one of skill in the art will realize that any number of parallel extending score lines d can be provided so as to obtain a resulting container having a cross-section of any desired arcuate or polygonal contour. The parallel extending score lines d are preferably disposed generally parallel to the CD. In the embodiment shown, each of the body panels 14, 16, 18, 20, 22 are disposed collectively elongate in the MD.

Disposed adjacent to each body panel 14, 16, 18, 20, 22 of carton blank 10 are a pair of side panels. In the embodiment shown, a first side panel of a particular body panel is disposed at a first end of the body panel on the longitudinal axis (e.g., in the embodiment shown along the CD) of the body panel. A second side panel is disposed on the longitudinal axis of the body panel and distal from the first side panel. Each side panel could be defined as an extension of the respective body panel and defining the CD edge of the respective body panel.

In other words, each side panel is bounded by extensions of the parallel extending score lines d, the top and bottom MD edges forming the boundaries of carton blank 10, and arcuate score lines a, aâ€² that are disposed generally parallel to the MD and extend archingly across each body panel forming carton blank 10. By way of non limiting example, first side panel 26 and sixth side panel 38 are disposed upon distal CD ends of first body panel 14. Naturally, second side panel 28 and seventh side panel 40 are disposed upon distal ends of second body panel 16, third side panel 30 and eighth side panel 42 are disposed upon distal ends of third body panel 18, fourth side panel 32 and ninth side panel 44 are disposed upon distal ends of fourth body panel 20, and fifth side panel 34 and tenth side panel 46 are disposed upon distal ends of fifth body panel 22. Each side panel is bounded and separated from the corresponding body panel by an arcuate score line a, aâ€².

It was surprisingly found that each arcuate score line a, aâ€² facilitates a Z-direction rotation (i.e., a rotation out of the MD/CD plane of the carton blank 10) of each side panel 26, 28, 30, 32, 34/38, 40, 42, 44, 46 about an axis formed by the arcuate score line a, aâ€² from the corresponding body panel 14, 16, 18, 20, 22. As can be seen in FIG. 2, rotation provides the two ends of the resulting container 54 formed by adjacent side panels 26, 28, 30, 32, 34/38, 40, 42, 44, 46 to fold nearly flat (i.e. substantially planar or even planar). Having two ends of the resulting container 54 formed by adjacent side panels 26, 28, 30, 32, 34/38, 40, 42, 44, 46 that can fold essentially flat facilitates the packaging of multiple resulting containers 54 as well as facilitating the ability to provide adjacent resulting containers 54 in a closest-packing orientation that maximizes the number of resulting containers 54 in a given amount of shelf space.

Returning again to FIG. 1, top and bottom edges of the carton blank 10 include outwardly rounded edges (or segments) with quasi-alternating linear edges (or segments). Left side edge e and right side edge f are vertical and straight and parallel with the CD. Edge f is interrupted by shapes that form three closure tabs: first closure tab f1, second closure tab f2, and third closure tab f3. When forming the resulting container 54, first closure tab f1, second closure tab f2, and third closure tab f3 can be adhered to body panel 22 proximate to edge e by any means known to those of skill in the art. When first closure tab f1, second closure tab f2, and third closure tab f3 are adhered to body panel 22, it was found suitable to provide an additional score line g that facilitates folding of the edge-adhered carton blank 10 into a flattened condition for shipping due to the odd number of body panels used to form resulting container 54.

A plurality of arch-shaped fold lines (b/c and bâ€²/câ€²) are arranged along both edges with the arch-shaped fold lines along the bottom (bâ€²/câ€²) of carton blank 10 being symmetrical with the arch-shaped fold lines disposed along the top (b/c) of carton blank 10. Preferably, the arch-shaped fold lines along the bottom (bâ€²/câ€²) of carton blank 10 are aligned with the arch-shaped fold lines along the top (b/c) of carton blank 10. The arches are arranged side-by-side and the arch-shaped fold lines (b/c and bâ€²/câ€²) which represent the sides of the arches terminate along each edge at a valley disposed between adjacent arches formed by the outwardly rounded edges and quasi-alternating linear edges. Each arch shaped fold line (b/c and bâ€²/câ€²) terminates at a vertex formed by the intersection of the extensions of the parallel extending score lines d and arcuate score lines a, aâ€². All dotted lines which represent the extensions of the parallel extending score lines d in FIG. 1 are creased in order to aid in the folding of carton blank 10 and the formation of resulting container 54, so that the extensions of the parallel extending score lines d are encouraged to fold in the opposite direction from the arch-shaped fold lines (b/c and bâ€²/câ€²).

The extensions of the parallel extending score lines d may be described more specifically regarding the arch shapes that appear along the top and bottom edges of the carton blank 10 shown in FIG. 1. Extensions of the parallel extending score lines d are each disposed between an apex of an arch shape forming the top and bottom edges of carton blank 10 and the intersection formed by arch shaped fold lines (b/c and bâ€²/câ€²) of adjacent body panels and adjacent arcuate score lines a, aâ€² disposed upon adjacent body panels. While other fold lines may be pre-creased, the extensions of the parallel extending score lines d are preferably perforated to provide an inward bias to the folding of each recess formed by adjacent arcuate score lines a, aâ€² and adjacent arch shaped fold lines b/c, bâ€²/câ€². Further clarity will be given to the invention with regard to the arch shapes of carton blank 10 infra.

As shown in FIG. 2 and FIG. 3, the folded resulting container 54 is shown with body panels and side panels disposed in their intended final configuration. As can be seen, one side panel is rotated about an arcuate score line a that separates each side panel 26, 28, 30, 32, 34 from the corresponding body panel 14, 16, 18, 20, 22. Concurrently with such rotation, each side panel 26, 28, 30, 32, 34 is folded about corresponding arch-shaped fold lines b, c and forms an apex between adjacent side panels 26, 28, 30, 32, 34 consistent with the extensions of the parallel extending score lines d that separates adjacent body panels 14, 16, 18, 20, 22. As shown, the resulting folds produce an end of resulting container 54 that resembles a plurality of pie-shaped triangular sections that are bounded by arch-shaped fold lines b, c, arcuate score line a, and a portion of the top edge of carton blank 10. Naturally, the bottom portion of carton blank 10 can form an end similar to that described supra to resemble a plurality of pie-shaped triangular sections that are bounded by arch-shaped fold lines bâ€², câ€², arcuate score line aâ€², and a portion of the bottom edge of carton blank 10.

The finally resulting container 54 can then be closed and held in a closed manner with sealing means 56. The sealing means 56 may comprise any sealing means known to those of skill in the art for retaining relevant portions of the finally formed resulting container 54 in fixed relation to each other. By way of non-limiting example, sealing means 56 may comprise glue disposed at the intersection of all folded side panels, a tape strip disposed upon the surface forming the side of resulting container 54 and contacting each side panel forming the end of resulting container 54, a locking tab that engages at least two portions of the sides forming resulting container 54, and the like. Similarly, tabs can be included upon portions of the top and bottom edges forming carton blank 10. These tabs can then be resultingly disposed in a face-to-face relationship upon the folding described supra that results in the formation of an end of resulting container 54. Depositing an adhesive or other substance upon opposed portions of the tabs can then fixably position each pie-shaped portion of the end of resulting container 54.

As shown in FIGS. 1 and 2, a preferred embodiment of the carton blank 10 forms a resulting container 54 suitable for storing articles therein. Exemplary, but non-liming, articles include consumer products. Such consumer products can be edible or non-edible. Edible consumer products can include candy, snack products, such as snack chips, pretzels, and the like. Non-edible products can include, but are not limited to, tissue products, facial tissues, paper toweling, bath tissue, hardware, combinations thereof, and the like. In order to facilitate removal of products disposed within resulting container 54, access panel 50 may be disposed upon at least one body panel of the carton blank 10. The access panel 50 may be formed by perforations in order to facilitate its removal from the finally formed resulting container 54. One or more finger grip region 52 may be formed in concert with access panel 50 in order to facilitate gripping of the access panel 50 and removal of access panel 50 from resulting container 54.

A plurality of resulting containers 54 can be co-packaged or co-wrapped with other resulting containers 54 to provide for a package containing several resulting containers. This has been found to provide a convenient means for a consumer to obtain several resulting containers 54 containing similar products therein without the inconvenience of having to handle several individual resulting containers 54. Such a co-packaging or co-wrapping execution can use a polymeric film or other suitable bundling means any machinery known to those of skill in the art to bulk wrap several resulting container 54 together.

It should also be realized by one of skill in the art that the resulting container 54 can be creatively decorated with indicium or indicia that coordinate the outer surface of the resulting container defined by body panels 14, 16, 18, 20, 22 with the pie-shaped triangular sections forming the ends of resulting container 54 and being substantially bounded by two of the plurality of straight vertical lines d, dâ€² and one of the second plurality of arch-shaped fold lines a, aâ€². By way of non-limiting example the container portion defined by body panels 14, 16, 18, 20, 22 could be provided as a representative fruit, cookie, berry, nut, and the like. Accordingly, the pie-shaped triangular sections forming the ends of resulting container 54 could be coordinatingly decorated to represent a portion, or slice, of a pie containing the fruit, cookie, berry, or nut, or can represent a cross-sectional view of the fruit, cookie, berry, or nut. Clearly, there are an innumerable number of suitable coordinated designs for use with the instantly disclosed container. For example, if the resulting container 54 is envisioned to hold candy therein, body panels 14, 16, 18, 20, 22 could be decorated with a design representing a perspective view of a jar containing the candy. The pie-shaped triangular sections forming the ends of resulting container 54 could be designed to represent a cross-sectional view of such a container.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact dimensions and values recited. Instead, unless otherwise specified, each such dimension and/or value is intended to mean both the recited dimension and/or value and a functionally equivalent range surrounding that dimension and/or value. For example, a dimension disclosed as â€œ40 mmâ€ is intended to mean â€œabout 40 mmâ€ .

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.