Packages, blanks for making packages and associated methods and apparatus

• US 20030144121A1
• Filed: 12/13/2002
• Published: 07/31/2003
• Est. Priority Date: 12/14/2001
• Status: Active Grant

• Current Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Kastanek, Raymond S., Walsh, Joseph C., Conatser, Robert L.
• Granted Patent: US 8,025,618 B2
• Time in Patent Office: Days
• US Class Current: 493/51
• CPC Class Codes: B31B 2105/001 made from laminated webs, e.g. including laminating the webs
• CPC Class Codes: B65D 2301/10 Blanks mutually positioned to minimise waste material upon cutting out the individual blank from a continuous or large sheet
• CPC Class Codes: B65D 2571/00141 glued
• CPC Class Codes: B65D 2571/00388 Two rows of more than two cells
• CPC Class Codes: B65D 2571/00487 and formed integrally with a partition
• CPC Class Codes: B65D 2571/00524 integral
• CPC Class Codes: B65D 2571/0066 formed from one single sheet
• CPC Class Codes: B65D 2571/00802 Other shapes
• CPC Class Codes: B65D 2571/00839 Integral reinforcements
• CPC Class Codes: B65D 2571/00919 Informative or decorative surfaces
• CPC Class Codes: B65D 2571/00956 engaging the bottom wall
• CPC Class Codes: B65D 5/0281 the tubular body presenting double or multiple walls for thermal insulating purposes B65D81/3853
• CPC Class Codes: B65D 5/4212 Information or decoration elements, e.g. content indicators, or for mailing B65D5/522 takes precedence
• CPC Class Codes: B65D 5/4266 Folding lines, score lines, crease lines
• CPC Class Codes: B65D 5/441 Reinforcements linings B65D5/56
• CPC Class Codes: B65D 5/5425 and defining after rupture a lid hinged to the upper edge of the container body
• CPC Class Codes: B65D 5/544 and defining after rupture a lid hinged about a line located in the top surface of the container
• CPC Class Codes: B65D 5/563 Laminated linings; Coatings
• CPC Class Codes: B65D 5/703 the score-lines or incisions extending in the body of the tubular container
• CPC Class Codes: B65D 5/705 Tearable flaps defined by score-lines or incisions provided in the body of a tubular container made of a single blank
• CPC Class Codes: B65D 5/744 : combined with swivelling devices having a bottom-wall and two side-walls
• CPC Class Codes: B65D 71/0022 : formed by folding or erecting one blank, and provided with vertical partitions

Abstract

Disclosed herein, for example, are methods and apparatus for forming carton blanks. In one such method, a first web of material and a second web of material may be provided. At least one line of disruption may be formed in one of the webs of material. A combined section may be formed that includes a section of the first web of material and a section of the second web of material. Thereafter, a carton blank may be formed by separating the combined section from the first web of material and the second web of material. Also disclosed herein, for example, are various carton blanks and cartons.

Claims

1. A method of forming a carton blank, said method comprising:

providing at least a first web of paperboard material and a second web of paperboard material;

providing at least a first section of paperboard material within said first web of paperboard material and a second section of paperboard material within said second web of paperboard material;

forming at least one first line of disruption in said first section;

forming at least one combined section comprising said first section and said second section by adhering at least a portion of said first section to at least a portion of said second section; and

thereafter, forming a carton blank by separating said at least one combined section from said first web of paperboard material and from said second web of paperboard material.

2. The method of claim 1 wherein said forming at least one first line of disruption in said first section comprises forming at least one fold line in said first section.

3. The method of claim 1 wherein said forming at least one first line of disruption in said first section comprises forming at least one cut line in said first section.

4. The method of claim 3 wherein said forming at least one cut line in said first section comprises forming said at least one cut line extending completely through said web of first material.

5. The method of claim 1 and further comprising:

forming at least one second line of disruption in said second section.

6. The method of claim 5 wherein said forming at least one second line of disruption in said second section occurs before said forming at least one combined section.

7. The method of claim 1 and further comprising:

forming at least one second line of disruption in said combined section after said adhering has occurred and before said separating has occurred.

8. The method of claim 1 wherein said forming at least one combined section occurs after said forming at least one first line of disruption.

9. The method of claim 1 and further comprising:

providing a third web of material and;

providing at least one third section of material within said third web of material;

wherein said forming said at least one combined section further comprises adhering at least a portion of said third section to at least a portion of said second section;

wherein said at least one combined section further comprises said third section; and

wherein said forming a carton blank further comprises separating said combined section from said third web of material.

10. A method of forming a carton blank, said method comprising:

providing at least a first web of material and a second web of material;

forming at least one first line of disruption in a first section located within said first web of material;

forming at least one second line of disruption in a second section located within said second web of material;

placing at least a portion of said first section in superposed relationship with at least a portion of said second section, wherein at least a portion of said at least one first line of disruption is misaligned with at least a portion of said at least one second line of disruption;

forming at least one combined section comprising said first section and said second section by adhering at least a portion of said first section to at least a portion of said second section; and

forming a carton blank by separating said combined section from said first web of material and said second web of material.

11. The method of claim 10 wherein said first web of material comprises a web of paperboard material.

12. The method of claim 10 wherein:

said first web of material comprises web of paperboard material; and

said second web of material comprises a web of paperboard material.

13. The method of claim 10 wherein said forming at least one first line of disruption in said first section comprises forming at least one fold line in said first section.

14. The method of claim 10 wherein said forming at least one first line of disruption in said first section comprises forming at least one cut line in said first section.

15. The method of claim 14 wherein said forming at least one cut line in said first section comprises forming said at least one cut line extending completely through said web of first material.

16. The method of claim 10 wherein said forming at least one first line of disruption in said first section occurs before said forming at least one combined section.

17. The method of claim 10 and further comprising:

forming at least one second line of disruption in said combined section after said adhering has occurred and before said separating has occurred.

18. The method of claim 10 and further comprising:

providing at least one third web of material;

providing at least one third section of material within said third web of material;

wherein said at least one combined section further comprises said third section; and

wherein said forming a carton blank further comprises separating said combined section from said third web of material.

19. A method of forming a carton blank, said method comprising:

providing at least a first web of substantially rigid material and a second web of substantially rigid material;

providing at least a first section of material within said first web of substantially rigid material and a second section of material within said second web of substantially rigid material;

forming at least one first line of disruption in said first section;

forming at least one combined section comprising said first section and said second section by adhering at least a portion of said first section to at least a portion of said second section; and

thereafter, forming a carton blank by separating said combined section from said first web of substantially rigid material and from said second web of substantially rigid material.

20. The method of claim 19 wherein said forming at least one first line of disruption in said first section comprises forming at least one fold line in said first section.

21. The method of claim 19 wherein said forming at least one first line of disruption in said first section comprises forming at least one cut line in said first section.

22. The method of claim 21 wherein said forming at least one cut line in said first section comprises forming said at least one cut line extending completely through said first web of substantially rigid material.

23. The method of claim 19 and further comprising:

forming at least one second line of disruption in said second section.

24. The method of claim 23 wherein said forming at least one second line of disruption in said second section occurs before said forming at least one combined section.

25. The method of claim 19 and further comprising:

forming at least one second line of disruption in said combined section after said adhering has occurred and before said separating has occurred.

26. The method of claim 19 wherein said forming at least one combined section occurs after said forming at least one first line of disruption.

27. The method of claim 19 wherein said first web of substantially rigid material comprises a paperboard material.

28. The method of claim 27 wherein said second web of substantially rigid material comprises a paperboard material.

29. The method of claim 19 and further comprising:

providing at least one third web of material;

providing at least one third section of material within said third web of material;

wherein said forming at least one combined section further comprises adhering at least a portion of said third section to at least a portion of said second section;

wherein said at least one combined section further comprises said third section; and

wherein said forming a carton blank further comprises separating said combined section from said third web of material.

30. Apparatus for forming carton blanks, said apparatus capable of processing a plurality of webs of material moving through said apparatus in a downstream direction, said apparatus comprising:

at least a first web of material and a second web of material;

at least a first disrupting station and a second disrupting station;

at least one combining station in which at least a portion of said first web is adhered to at least a portion of said second web;

wherein said combining station is located downstream from both said first disrupting station and said second disrupting station;

wherein, said first web of material extends through said first disrupting station and said at least one combining station;

wherein, said second web of material extends through said second disrupting station and said at least one combining station.

31. The apparatus of claim 30 and further comprising:

a third web of material;

wherein, said third web of material extends through said at least one combining station.

32. The apparatus of claim 30 wherein said first web of material does not extend through said second disrupting station.

33. The apparatus of claim 32 wherein said second web of material does not extend through said first disrupting station.

34. The apparatus of claim 30 wherein said first web of material comprises a web of paperboard material.

35. The apparatus of claim 30 wherein said first disrupting station is capable of forming at least one cut line.

36. The apparatus of claim 30 wherein said first disrupting station is capable of forming at least one fold line.

37. The apparatus of claim 30 and further comprising:

a third disrupting station located downstream from said at least one combining station;

wherein, said first web of material and said second web of material both extend through said third disrupting station.

38. The apparatus of claim 30 and further comprising:

a third web of material;

wherein, said third web of material extends through said at least one combining station.

39. Apparatus for use in forming carton blanks comprising:

first rotary cutting apparatus mounted at a fixed location;

first moving apparatus for moving a first continuous strip of material into said first rotary cutting apparatus so that said first rotary cutting apparatus forms at least one perforated line in said first continuous strip of material;

second rotary cutting apparatus mounted at a fixed location;

second moving apparatus for moving a second continuous strip of material into said second rotary cutting apparatus so that said second rotary cutting apparatus forms at least one perforate line in said second continuous strip of material;

a first laminating roll mounted at a fixed location;

a second laminating roll mounted adjacent to and urged toward said first laminating roll so as to form a nip therebetween;

at least a first guide apparatus for guiding said first continuous strip of material into said nip;

at least a second guide apparatus for guiding said second continuous strip of material into said nip so that said first and second continuous strips of material have facing surfaces;

at least portions of one of said facing surfaces having an adhesive coating thereon;

said first and second laminating rolls applying sufficient force on said first and second continuous strips of material at said nip to pull said first and second continuous strips of material through said first and second laminating rolls and to laminate said first and second continuous strips of material together to form a laminated product;

said first and second rotary cutting apparatus being located before said first and second laminating rolls;

said at least one perforated line in said first continuous strip having a configuration that differs from the configuration of said at least one perforated line in said second continuous strip of material;

at least a portion of said configuration in said first continuous strip of material being in a superposed relationship in said laminated product with at least a portion of said configuration in said second continuous strip of material;

cutting and creasing apparatus for forming cut and fold lines in at least one of said first and second layers so that a carton may be formed from said laminated product;

cutting apparatus for forming individual carton blanks from said laminated product; and

collection apparatus for collecting said individual carton blanks.

40. Apparatus as in claim 39 and further comprising:

said first and second rotary cutting apparatus having additional structure for forming substantially all of the cut lines and fold lines for a carton blank in said first and second continuous strips of material;

each of said carton blanks in said first continuous strip of material being substantially identical to each of said carton blanks in said second continuous strip of material;

each of said carton blanks in said first continuous strip of material being substantially superposed over each of said carton blanks in said second continuous strip of material in said laminated product; and

said cutting apparatus cutting at least one additional cut line for forming said individual carton blanks.

41. Apparatus as in claim 39 wherein:

said cutting and creasing apparatus being located after said first and second layers have been laminated together.

42. Apparatus as in claim 39 and further comprising:

printing apparatus for said first continuous strip of material and printing apparatus for said second continuous strip of material located before said first and second rotary cutting apparatus; and

primary moving apparatus for moving each of said first and second continuous strips of material into said printing apparatus.

43. Apparatus for use in forming carton blanks comprising:

first rotary cutting apparatus mounted at a fixed location;

first moving apparatus for moving a first continuous strip of material into said first rotary cutting apparatus so that said first rotary cutting apparatus forms at least one perforated line in said first continuous strip of material;

second printing apparatus mounted at a fixed location;

second moving apparatus for moving a second continuous strip of material into said second rotary cutting apparatus so that said printing apparatus forms at least one area of indicia in said second continuous strip of material;

a first laminating roll mounted at a fixed location;

a second laminating roll mounted adjacent to and urged toward said first laminating roll so as to form a nip therebetween;

at least a first guide apparatus for guiding said first continuous strip of material into said nip;

at least a second guide apparatus for guiding said second continuous strip of material into said nip so that said first and second continuous strips of material have facing surfaces;

at least portions of one of said facing surfaces having an adhesive coating thereon;

said first and second laminating rolls applying sufficient force on said first and second continuous strips of material at said nip to pull said first and second continuous strips of material through said first and second laminating rolls and to laminate said first and second continuous strips of material together to form a laminated product;

said first rotary cutting apparatus and said printing apparatus being located before said first and second laminating rolls;

said at least one perforated line in said first continuous strip having a configuration that differs from the configuration of said at least one area of indicia in said second continuous strip of material;

at least a portion of said configuration in said first continuous strip of material being in a superposed relationship in said laminated product with at least a portion of said configuration in said second continuous strip of material;

cutting and creasing apparatus for forming cut and fold lines in said first and second layers so that a carton may be formed from said laminated product;

cutting apparatus for forming individual carton blanks from said laminated product; and

collection apparatus for collecting said individual carton blanks.

44. A method for forming carton blanks comprising:

mounting a first rotary cutting apparatus at a fixed location;

moving a first continuous strip of material into and through said first rotary cutting apparatus;

forming at least one perforated line at spaced apart intervals in said first continuous strip of material to form a first configuration;

mounting a second rotary cutting apparatus at another fixed location;

moving a second continuous strip of material into and through said second rotary cutting apparatus;

forming at least one perforated line at spaced apart intervals in said second continuous strip of material to form a second configuration that differs from said first configuration;

mounting two laminating rolls to form a nip therebetween;

driving at least one of said two laminating rolls to apply a force on each of said first and second continuous strips of material to move said first and second continuous strips of material between said laminating rolls;

locating said first and second rotary cutting apparatus before said two laminating rolls;

moving said first and second continuous strips of material into said nip so that said first and second continuous strips of material have facing surfaces;

applying an adhesive material to at least one of said facing surfaces;

moving said first and second continuous strips of material through said laminating two rolls to form a laminated product; and

locating at least a portion of said first configuration and at least a portion of said second configuration in a superposed relationship in said laminated product;

forming cut lines and fold lines in said laminated product; and

cutting said laminated product into individual carton blanks.

45. A method as in claim 44 and further comprising:

forming substantially all of the cut and fold lines for a carton blank at spaced apart intervals in said first continuous strip of material as it passes through said first rotary cutting apparatus;

forming substantially all of the cut and fold lines for a carton blank at spaced apart intervals in said second continuous strip of material as it passes through said second rotary cutting apparatus;

making said carton blanks formed by said first and second rotary cutting apparatus substantially identical; and

laminating said first and second continuous strips of material together so that said carton blanks in said first and second continuous strips of material are in a superposed relationship.