Note: Descriptions are shown in the official language in which they were submitted.
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METHODS AND SYSTEMS FOR PACKAGING A
PRODUCT
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to packaging and, more
particularly, to a packaging carton and a method for making a packaging
assembly
with the carton.
[0003] At least some known cartons used for packaging a product
include markings, indicia, and/or a shape that communicates the product, a
manufacturer of the product, and/or a seller of the product to consumers. For
example, such cartons may include printed text that indicates a product's name
and
briefly describes the product, logos and trademarks that indicate a
manufacturer
and/or seller of the product, and/or designs that attract a consumer's
attention. Other
cartons, for example, may have a shape that corresponds to a product packaged
within
the carton and/or a shape that indicates a manufacture and/or seller of' the
product.
Still further, and for example, some known cartons may include a shape that
provides
functionality, such as a shape that promotes the display of the carton, a
shape that
facilitates stacking and/or arrangement of a plurality of cartons, and/or a
shape that
facilitates carrying the carton. However, cartons having shapes that are more
complex
than conventional rectangular cartons may be difficult and costly to
manufacture.
Additionally, such cartons may be less likely to maintain their shape during
transport
and/or display thereof.
[0004] Some known cartons that package a product are also sealed to
protect the product from tampering and to generally seal the joints of the
carton for
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containing the product within the carton as well as
protecting the product from contamination. For example,
some known cartons include a band around a joint between
portions of the carton, such as a lid and a base, to seal
the carton. Other known cartons may include a bag or a
liner that is sealed within the interior cavity of the
carton for storing the product in a sealed environment.
Moreover, there are at least some other known cartons, for
example, that completely wrap the carton in shrink-wrap that
is thereafter heated to shrink it tightly around the carton.
However, when a carton is completely sealed with shrink-wrap
portions of the carton may not be accessible without
breaking the seal, thereby possibly making display and/or
transport of the carton more difficult.
BRIEF SUMMARY OF THE INVENTION
According to one aspect of the present invention,
there is provided a method for applying a heat-shrink patch
to a carton for forming a shape of the carton, the carton
including a top panel, a bottom panel, at least one side
panel extending between the top panel and the bottom panel
and a movable section that is movable between a first
position and a second position, the method comprising:
providing a heat-shrink patch in a pre-shrunk configuration;
coupling the heat-shrink patch in the pre-shrunk
configuration to at least a portion of an interior surface
of a blank of sheet material including at least a portion of
the movable section; forming the carton from the blank of
sheet material wherein the heat-shrink patch in the pre-
shrunk configuration is coupled to an interior surface of
the formed carton; and moving the movable section from the
first position to the second position to form the shape of
the carton by heating the heat-shrink patch to shrink the
heat-shrink patch to a shrunk configuration.
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According to another aspect of the present invention, there is provided a
method for forming a packaging assembly including a carton having a shape, the
carton
including a top panel, a bottom panel, at least one side panel extending
between the top panel
and the bottom panel, the method comprising: providing a blank sheet of
material having a
first movable section coupled to a second movable section at a fold line, the
first movable
section and the second movable section being movable between a first position
and a second
position, wherein the first movable section and the second movable section
define a void
positioned on the fold line; applying an adhesive in a registered pattern to
an interior surface
of the blank and substantially surrounding the void; coupling a heat-shrink
patch in a pre-
shrunk configuration to each of the first movable section and the second
movable section
within the registered pattern to cover the void; forming the carton from the
blank wherein the
heat-shrink patch in the pre-shrunk configuration is coupled to an interior
surface of the
formed carton; and moving the first movable section towards the second movable
section to at
least partially close the void to form the shape of the carton by applying
heat to the heat-
shrink patch to shrink the heat-shrink patch to a shrunk configuration.
According to still another aspect of the present invention, there is provided
a
system for applying a heat-shrink patch to a carton for forming a shape of the
carton, the
system comprising: a blank of sheet material comprising a top panel, a bottom
panel, at least
one side panel extending between the top panel and the bottom panel and a
movable section
that is movable between a first position and a second position; a coupling
device configured to
couple the heat-shrink patch in the pre-shrunk configuration to an interior
surface of the blank
of sheet material; a forming device configured to form the carton from the
blank of sheet
material wherein the heat-shrink patch in the pre-shrunk configuration is
coupled to an interior
surface of the formed carton; and a heating device configured to heat at least
a portion of the
heat-shrink patch to shrink the heat-shrink patch to a shrunk configuration to
move the
movable section from the first position to the second position to form the
shape of the carton.
According to yet another aspect of the present invention, there is provided an
assembly for packaging a product, the assembly comprising: a carton having a
top, a bottom,
and a plurality of sides extending between the top and the bottom, wherein the
plurality of
sides each comprise a movable section that is movable between a first position
and a second
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position, the movable section being biased to the first position, wherein the
movable section
of each of the plurality of sides comprises an upper extension extending from
an upper portion
of the respective side along an upper fold line, and a lower extension
extending from a lower
portion of the respective side along a lower fold line and joined to the upper
extension of the
respective side along a central fold line, and each of the movable section
central fold lines are
located along a central longitudinal axis of the carton at a generally equal
distance from the
top of the carton, the central fold lines of the movable sections being spaced
a greater radial
distance from the central longitudinal axis of the carton in the first
position than in the second
position, wherein the movable sections are movable from the first position to
the second
position by bending the upper and lower extensions along the upper, lower, and
central fold
lines to move the central fold lines generally radially toward the central
longitudinal axis of
the carton to reduce a cross-sectional area of the carton defined between the
movable sections;
and a heat-shrinkable layer overlapping at least a portion of the carton,
wherein the heat-
shrinkable layer moves each movable section from the first position to the
second position
when the heat-shrinkable layer is heated to come into contact with the portion
of the carton.
According to a further aspect of the present invention, there is provided an
assembly for packaging a product, the assembly comprising: a carton having a
top, a bottom,
and a side extending between the top and the bottom, wherein at least one of
the top, the
bottom, and the side comprises a movable section that is movable between a
first position and
a second position, the movable section being biased to the first position,
wherein the side is a
first side, the carton further comprises a second side, a third side, and a
fourth side, each of the
first, second, third, and fourth sides extending from the bottom to the top of
the carton, and the
movable section comprises a first extension extending from the first side
along a first fold line
and a second extension extending from the second side along a second fold
line, wherein the
movable section is movable from the first position to the second position by
bending the first
and second extensions along the first and second fold lines to move the first
extension over
the second extension such that the first extension at least partially overlaps
the second
extension, and wherein in the first position an opening is defined between the
first and second
extensions and in the second position the first and second extensions form a
fifth side of the
carton defined between the first and second sides and obliquely angled with
respect to the first
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and second sides; and a heat-shrinkable layer overlapping at least a portion
of the carton for
forming the carton, the heat-shrinkable layer moves the movable section from
the first
position to the second position when the heat-shrinkable layer is heated to
come into contact
with the portion of the carton.
According to yet a further aspect of the present invention, there is provided
an
assembly for packaging a product, the assembly comprising: a carton having a
top, a bottom,
and a plurality of sides extending between the top and the bottom, wherein the
plurality of
sides includes a first side, a second side, a third side, and a fourth side,
wherein any two
opposite sides of the first, second, third, and fourth sides comprise a
movable section
including an upper extension extending from an upper portion of the respective
side along an
upper fold line, and a lower extension extending from a lower portion of the
respective side
along a lower fold line, wherein the movable sections are movable from the
first position to
the second position by bending the upper and lower extensions along the upper
and lower fold
lines to obliquely angle the upper and lower extensions with respect to the
respective side and
thereby vary a cross-sectional area of the carton along a height of the carton
measured
between the top and the bottom; and a heat-shrinkable layer overlapping at
least a portion of
the carton, wherein the heat-shrinkable layer moves the movable sections from
the first
position to the second position when the heat-shrinkable layer is heated to
come into contact
with the portion of the carton.
According to still a further aspect of the present invention, there is
provided an
assembly for packaging a product, the assembly comprising: a carton having a
top, a bottom,
and a plurality of sides extending between the top and the bottom, wherein the
plurality of
sides each comprise a movable section that is movable between a first position
and a second
position, the movable section being biased to the first position, wherein the
movable section
of each of the plurality of sides comprises an intermediate portion of the
respective side
extending from an upper portion of the respective side along an upper fold
line and extending
from a lower portion of the respective side along a lower fold line, wherein
the movable
sections are movable from the first position to the second position by bending
along the upper
and lower fold lines to obliquely angle the intermediate portions with respect
to the respective
sides and thereby vary a cross-sectional area of the carton along a height of
the carton
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measured between the top and the bottom; and a heat-shrinkable layer
overlapping at least a
portion of the carton, wherein the heat-shrinkable layer moves the movable
section from the
first position to the second position when the heat-shrinkable layer is heated
to come into
contact with the portion of the carton.
According to another aspect of the present invention, there is provided a
method for packaging a product, the method comprising: forming a carton having
a top, a
bottom, and a plurality of sides extending between the top and the bottom,
wherein the
plurality of sides each comprise a movable section that is moveable between a
first position
and a second position, the movable section being biased to the first position,
wherein the
movable section of each of the plurality of sides comprises an upper extension
extending from
an upper portion of the respective side along an upper fold line, and a lower
extension
extending from a lower portion of the respective side along a lower fold line
and joined to the
upper extension of the respective side along a central fold line, and each of
the movable
section central fold lines are located along a central longitudinal axis of
the carton at a
generally equal distance from the top of the carton, the central fold lines of
the movable
sections being spaced a greater radial distance from the central longitudinal
axis of the carton
in the first position than in the second position, wherein the movable
sections of the plurality
of sides are movable from the first position to the second position by bending
the upper and
lower extensions along the upper, lower, and central fold lines to move the
central fold lines
generally radially toward the central longitudinal axis of the carton to
reduce a cross-sectional
area of the carton defined between the movable sections, such that the movable
sections of the
plurality of sides collectively define a movable section of the carton;
wrapping a heat-
shrinkable layer around at least a portion of the carton including at least a
portion of the
movable section of the carton; and moving the movable section from the first
position to the
second position to form a shape of the carton by heating the heat-shrinkable
layer to shrink the
heat-shrinkable layer into contact with the movable section of the carton.
According to yet another aspect of the present invention, there is provided a
method for packaging a product, the method comprising: forming a carton having
a top, a
bottom, and a side extending between the top and the bottom, and a moveable
section that is
movable between a first position and a second position, the movable section
being biased to
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the first position, wherein the side is a first side, the carton further
comprises a second side, a
third side, and a fourth side, each of the first, second, third, and fourth
sides extending from
the bottom to the top of the carton, and the movable section comprises a first
extension
extending from the first side along a first fold line and a second extension
extending from the
second side along a second fold line, wherein the movable section is movable
from the first
position to the second position by bending the first and second extensions
along the first and
second fold lines to move the first extension over the second extension such
that the first
extension at least partially overlaps the second extension, and wherein in the
first position an
opening is defined between the first and second extensions, and in the second
position the first
and second extensions form a fifth side of the carton defined between the
first and second
sides and obliquely angled with respect to the first and second sides;
wrapping a heat-
shrinkable layer around at least a portion of the carton including at least a
portion of the
movable section of the carton; and moving the movable section from the first
position to the
second position to form a shape of the carton by heating the heat-shrinkable
layer to shrink the
heat-shrinkable layer into contact with the movable section.
According to yet a further aspect of the present invention, there is provided
a
method for packaging a product, the method comprising: forming a carton having
a top, a
bottom, and a plurality of sides extending between the top and the bottom,
wherein the
plurality of sides includes a first side, a second side, a third side, and a
fourth side, wherein
any two opposite sides of the first, second, third, and fourth sides comprise
a movable section
including an upper extension extending from an upper portion of the respective
side along an
upper fold line, and a lower extension extending from a lower portion of the
respective side
along a lower fold line, wherein the movable sections are movable from the
first position to
the second position by bending the upper and lower extensions along the upper
and lower fold
lines to obliquely angle the upper and lower extensions with respect to the
respective side and
thereby vary a cross-sectional area of the carton along a height of the carton
measured
between the top and the bottom, such that the movable sections of the sides
collectively define
a movable section of the carton; wrapping a heat-shrinkable layer around at
least a portion of
the carton including at least a portion of the movable section of the carton;
and moving the
movable section from the first position to the second position to form a shape
of the carton by
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heating the heat-shrinkable layer to shrink the heat-shrinkable layer into
contact with the
movable section of the carton.
According to still a further aspect of the present invention, there is
provided a
method for packaging a product, the method comprising: forming a carton having
a top, a
bottom, and a plurality of sides extending between the top and the bottom,
wherein the
plurality of sides each comprise a movable section that is movable between a
first position and
a second position, the movable section being biased to the first position,
wherein the movable
sections each comprise an intermediate portion of the respective side
extending from an upper
portion of the respective side along an upper fold line and extending from a
lower portion of
the respective side along a lower fold line, wherein the movable sections are
movable from
the first position to the second position by bending along the upper and lower
fold lines to
obliquely angle the intermediate portions with respect to the respective sides
and thereby vary
a cross-sectional area of the carton along a height of the carton measured
between the top and
the bottom, such that the movable sections of the sides collectively define a
movable section
of the carton; wrapping a heat-shrinkable layer around at least a portion of
the carton
including at least a portion of the movable section of the carton; and moving
the movable
section from the first position to the second position to form a shape of the
carton by heating
the heat-shrinkable layer to shrink the heat-shrinkable layer into contact
with the movable
section of the carton.
According to another aspect of the present invention, there is provided a
method for applying a heat shrinkable film to a carton for forming a shape of
the carton, the
carton including a top panel, a bottom panel, a plurality of side panels
extending between the
top panel and the bottom panel, and a movable section that is movable between
a first position
and a second position, the method comprising: providing a heat-shrinkable but
unshrunken
film; wrapping the film in an unheated condition around at least a portion of
the carton
including at least a portion of the movable section of the carton, wherein the
movable section
includes at least one opening having a size and at least one movable panel,
wherein the at least
one opening is a cut-out defined within at least one of the plurality of side
panels; and moving
the movable section from the first position to the second position to form a
shape of the carton
by heating the heat-shrinkable film to shrink the heat-shrinkable film into
contact with the
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movable section, wherein moving the movable section includes moving the at
least one
movable panel and reducing the size of the at least one opening of the movable
section.
According to yet another aspect of the present invention, there is provided a
system for applying a heat shrinkable film to a carton for forming a shape of
the carton, the
system comprising: a carton comprising a top panel, a bottom panel, a
plurality of side panels
extending between the top panel and the bottom panel, and a movable section
that is movable
between a first position and a second position; a wrapping device configured
to wrap a heat-
shrinkable but unshrunken film in an unheated condition around at least a
portion of the carton
including at least a portion of the movable section of the carton, wherein the
movable section
includes at least one opening having a size and at least one movable panel,
wherein the at least
one opening is a cut-out defined within at least one of the plurality of side
panels; and a
heating device configured to heat at least a portion of the heat-shrinkable
film into contact
with the movable section to move the movable section from the first position
to the second
position to form a shape of the carton, wherein moving the movable section
includes moving
the at least one movable panel and reducing the size of the at least one
opening of the movable
section.
According to another aspect of the invention, there is provided a method of
forming a shaped carton, the method comprising: providing a carton including a
plurality of
adjoined panels that define an interior space, the plurality of adjoined
panels including a
movable panel, the carton including a movable section comprising the movable
panel, and an
opening comprising a cutout defined at least partially in the movable panel;
wrapping a heat-
shrinkable but unshrunken film around at least a portion of the carton
including at least a
portion of the movable panel; and heating the heat-shrinkable film, thereby
shrinking the heat-
shrinkable film, moving the movable panel towards the interior space, thereby
reducing the
size of the opening from a first size to a second size less than the first
size, and forming the
shaped carton.
A further aspect of the invention provides a system for forming a shaped
carton, the system comprising: a carton including a plurality of adjoined
panels that define an
interior space, the plurality of adjoined panels comprising a movable panel,
the carton
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including a movable section including the movable panel, and an opening
comprising a cutout
defined at least partially in the movable panel; a wrapping device configured
to wrap a heat-
shrinkable but unshrunken film around at least a portion of the carton
including at least a
portion of the movable panel; and a heating device configured to heat the heat-
shrinkable film,
thereby shrinking the heat-shrinkable film, moving the movable panel towards
the interior
space, thereby reducing the size of the opening from a first size to a second
size less than the
first size, and forming the shaped carton.
There is also provided a method of forming a shaped carton, the method
comprising: providing a carton including a plurality of adjoined panels that
define an interior
space, the carton including a movable section comprising a movable panel, and
an opening
defined at least partially by a cutout disposed along an edge of the movable
panel; wrapping a
heat-shrinkable but unshrunken film around at least a portion of the carton
including at least a
portion of the movable panel; and heating the heat-shrinkable film, thereby
shrinking the heat-
shrinkable film, moving the movable panel towards the interior space, thereby
reducing the
size of the opening from a first size to a second size less than the first
size, and forming the
shaped carton.
In accordance with a still further aspect of the invention, there is provided
an
assembly for packaging a product, the assembly comprising: a blank of sheet
material having
an interior surface and an opposing exterior surface, the blank forming a
carton having a top, a
bottom, and a plurality of side panels, each side panel of the plurality of
side panels extending
between the top and the bottom, wherein a first movable side panel of the
plurality of side
panels is movable between a first position and a second position, the first
movable side panel
being initially biased to the first position; and a heat-shrink patch coupled
to the interior
surface and overlapping at least a portion of the first movable side panel,
wherein the heat-
shrink patch is shrinkable to urge the first movable side panel to the second
position and hold
the first movable side panel against the bias.
According to another aspect of the invention, there is provided an assembly
for
packaging a product, the assembly comprising: a blank of sheet material having
an interior
surface and an opposing exterior surface, the blank forming a carton having a
top, a bottom,
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and a side extending between the top and the bottom, at least one of the top,
the bottom, and
the side comprising a first movable section movable between a first position
and a second
position, the first movable section being initially biased in the first
position; a void at least
partially defined by the first movable section; and a first heat-shrink patch
coupled to the
interior surface, the first heat-shrink patch overlapping at least a portion
of the first movable
section and covering the void, wherein the first heat-shrink patch is
shrinkable to urge the first
movable section to the second position against the bias and at least partially
close the void.
A further aspect of the invention provides an assembly for packaging a
product, the assembly comprising: a blank of sheet material having an interior
surface and an
opposing exterior surface, the blank forming a carton having a top panel, a
bottom panel, a
side panel extending between the top panel and the bottom panel, and a
plurality of fold lines,
each fold line extending between at least two panels; a movable section formed
in at least one
of the top panel, the bottom panel and the side panel and positioned along a
fold line, the
movable section initially biased in a first position and movable to a second
position; a void
included within the movable section and positioned along a fold line; and a
heat-shrink patch
applied to the interior surface and covering the void, wherein the heat-shrink
patch is
shrinkable to urge the movable section from the first position to the second
position.
There is also provided an assembly for packaging a product, the assembly
comprising: a plurality of adjoined panels that define an interior space, the
plurality of
adjoined panels including a movable panel operative for being moved between a
first position
and a second position, the movable panel being initially in the first
position; and a heat-shrink
patch at least partially adhesively joined to the movable panel on a side of
the movable panel
facing the interior space, the heat-shrink patch being operative for shrinking
in response to
heat, so that shrinking the heat-shrink patch moves the movable panel from the
first position
to the second position.
In accordance with a still further aspect of the invention, there is provided
an
assembly for packaging a product, the assembly comprising: a plurality of
adjoined panels
that define an interior space, the plurality of adjoined panels including a
movable section
operative for being moved between a first position and a second position, the
movable section
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including an opening, the movable section being initially in the first
position; and a heat-
shrink patch joined to at least a portion of the movable section on a side on
the movable
section facing the interior space, the heat-shrink patch extending across at
least a portion of
the opening, wherein the heat-shrink patch is operative for shrinking in
response to heat, so
that shrinking the heat-shrink patch moves the movable section to the second
position and
reduces a size of the opening.
According to another aspect of the invention, there is provided an assembly
for
packaging a product, the assembly comprising: a plurality of adjoined panels
that define an
interior space, at least one of the adjoined panels defining a movable section
including an
opening positioned along a fold line, the movable section being initially in a
first position, the
movable section being configured to be moved to a second position; and a heat-
shrink patch
applied to the movable section on a side of the movable section facing the
interior space, the
heat-shrink patch extending across at least a portion of the opening, the heat-
shrink patch
being operative for shrinking in response to heat so that the heat-shrink
patch moves the
movable section to the second position.
A further aspect of the invention provides a method of forming a shaped
carton, the method comprising: providing a blank for forming a carton, the
carton including a
plurality of adjoined panels that define an interior space, at least one of
the adjoined panels
being a movable panel; joining a heat-shrink patch in an unshrunk
configuration to at least a
portion of the movable panel; forming the carton from the blank such that the
heat-shrink
patch faces the interior space; and heating the heat-shrink patch after
forming the carton,
thereby shrinking the heat-shrink patch, and moving the movable panel towards
the interior
space.
There is also provided a method of forming a shaped carton, the method
comprising: providing a blank for forming a carton, the blank including a
first movable panel
and a second movable panel joined to one another along a fold line, the first
movable panel
and the second movable panel defining a void disposed substantially along the
fold line;
applying an adhesive to the blank to substantially surround the void; joining
a heat-shrink
patch in a unshrunk configuration to the first movable panel and the second
movable panel to
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substantially cover the void; forming the carton from the blank such that the
heat-shrink patch
is at least partially disposed on an interior surface of the carton; and
applying heat to the heat-
shrink patch, thereby shrinking the heat-shrink patch, moving the first
movable panel towards
the second movable panel to at least partially close the void, and forming the
shaped carton.
In accordance with a still further aspect of the invention, there is provided
a
system for forming a shaped carton, the system comprising: a coupling device
configured to
couple a heat-shrink patch in an unshrunken configuration to a blank, the
blank being adapted
to form a carton including a plurality of adjoined panels that define an
interior space, at least
one of the adjoined panels being a movable panel, wherein the coupling device
is configured
to couple the heat-shrink patch to the blank so that the heat-shrink patch is
joined to the
movable panel of the carton; a forming device configured to form the carton
from the blank
such that the heat-shrink patch at least partially overlies an interior
surface of the formed
carton; and a heating device configured to heat at least a portion of the heat-
shrink patch on
the carton, thereby shrinking the heat-shrink patch, and moving the movable
panel towards the
interior space.
According to another aspect of the invention, there is provided a method of
forming a shaped carton, the method comprising: providing an unshaped carton,
the carton
including a plurality of adjoined panels that define an interior space, at
least one of the
adjoined panels being a movable panel, and a heat-shrink patch in an unshrunk
configuration
joined to a side of the movable panel facing the interior space; and heating
the heat-shrink
patch, thereby shrinking the heat-shrink patch, and moving the movable panel
from a first
position to a second position to form the shaped carton.
A further aspect of the invention provides a package assembly, comprising: a
carton including a plurality of adjoined panels that define an interior space,
the carton
including a movable section comprising a movable panel, and an opening
comprising a cutout
defined at least partially in the movable panel; and a heat-shrinkable but
unshrunken film
wrapped around at least a portion of the carton including at least a portion
of the movable
panel, wherein the heat-shrinkable film is operative for shrinking in response
to heat, wherein
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the shrinking of the film moves the movable panel towards the interior space
and reduces the
size of the opening.
There is also provided a package assembly, comprising: a carton including a
plurality of adjoined panels that define an interior space, the carton
including a movable
section comprising a movable panel, and an opening defined at least partially
by a cutout
disposed along an edge of the movable panel; and a heat-shrinkable but
unshrunken film
wrapped around at least a portion of the carton including at least a portion
of the movable
panel, the heat-shrinkable film being operative for shrinking in response to
heat, wherein the
shrinking of the heat-shrinkable film moves the movable panel towards the
interior space,
thereby reducing the size of the opening.
In accordance with a still further aspect of the invention, there is provided
a
package assembly, comprising: a carton including a plurality of adjoined
panels that define an
interior space, the carton including and a movable section that is movable
between a first
position and a second position, wherein the movable section includes an
opening and a
movable panel, wherein the opening comprises a cutout within at least one of
the plurality of
side panels; and a heat-shrinkable but unshrunken film wrapped around at least
a portion of
the carton including at least a portion of the movable section of the carton,
wherein the heat-
shrinkable film is operative for shrinking in response to heat, the shrinking
of the film being
for moving the movable section from the first position to the second position,
wherein moving
the movable section includes moving the movable panel and reducing the size of
the opening.
[0005] In another aspect, the present invention provides a method for applying
a heat-shrink patch to a carton for forming a shape of the carton. The carton
includes a top
panel, a bottom panel, at least one side panel extending between the top panel
and the bottom
panel and a movable section that is movable between a first position and a
second position.
The method includes providing a heat-shrink patch in a pre-shrunk
configuration. The heat-
shrink patch is coupled in the pre-shrunk configuration to at least a portion
of an interior
surface of a blank of sheet material including at least a portion of the
movable section. The
carton is formed from the blank of sheet material. The movable section is
moved from the
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first position to the second position to form the shape of the carton by
heating the heat-shrink
patch to shrink the heat-shrink patch to a shrunk configuration.
[0006] In another aspect, the present invention provides a method for forming
a
packaging assembly including a carton having a shape. The carton includes a
top panel, a
bottom panel, at least one side panel extending between the top panel and the
bottom panel
and a movable section that is movable between a first position and a second
position. The
method includes providing a blank sheet of material having a first movable
section coupled to
a second movable section at a fold line. The first movable section and the
second movable
section define a void positioned on the
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fold line. An adhesive is applied in a registered pattern to an interior
surface of the
blank and substantially surrounds the void. The heat-shrink patch is coupled
in a pre-
shrunk configuration to each of the first movable section and the second
movable
section within the registered pattern to cover the void. The first movable
section is
moved towards the second movable section to at least partially close the void
to form
the shape of the carton by applying heat to the heat-shrink patch to shrink
the heat-
shrink patch to a shrunk configuration.
[0007] In another aspect, the present invention provides a system for
applying a heat-shrink patch to a carton for forming a shape of the carton.
The system
includes a blank of sheet material comprising a top panel, a bottom panel, at
least one
side panel extending between the top panel and the bottom panel and a movable
section that is movable between a first position and a second position. A
coupling
device is configured to couple the heat-shrink patch in the pre-shrunk
configuration to
an interior surface of a blank of sheet material. The system further includes
a forming
device configured to form the carton from the blank of sheet material. A
heating
device is configured to heat at least a portion of the heat-shrink patch to
shrink the
heat-shrink patch to a shrunk configuration to move the movable section from
the first
position to the second position to form the shape of the carton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Figure 1 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0009] Figure 2 is a perspective view of the carton formed from the
blank shown in Figure 1.
[0010] Figure 3 is a perspective view of a packaging assembly
including the carton shown in Figure 2.
[0011] Figure 4 is a top plan view of a blank of sheet material for
fornling a carton, according to one embodiment of this invention.
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[0012] Figure 5 is a perspective view of the carton formed from the
blank shown in Figure 4.
[0013] Figure 6 is a perspective view of a packaging assembly
including the carton shown in Figure 5.
[0014] Figure 7 is a perspective view of an alternative embodiment
of the packaging assembly shown in Figure 6.
[0015] Figure 8 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0016] Figure 9 is a perspective view of the carton formed from the
blank shown in Figure 8.
[0017] Figure 10 is a perspective view of a packaging assembly
including the carton shown in Figure 9.
[0018] Figure 11 is a perspective view of an alternative embodiment
of the packaging assembly shown in Figure 10.
[0019] Figure 12 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0020] Figure 13 is a perspective view of the carton formed from the
blank shown in Figure 12.
[0021] Figure 14 is a perspective view of a packaging assembly
including the carton shown in Figure 13.
[0022] Figure 15 is a perspective view of an alternative embodiment
of the packaging assembly shown in Figure 14.
[0023] Figure 16 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
=
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[0024] Figure 17 is a perspective view of the carton formed from the
blank shown in Figure 16.
[0025] Figure 18 is a perspective view of a packaging assembly
including the carton shown in Figure 17.
[0026] Figure 19 is a perspective view of an alternative embodiment
of the packaging assembly shown in Figure 18.
[0027] Figure 20 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0028] Figure 21 is a perspective view of the carton formed from the
blank shown in Figure 20.
[0029] Figure 22 is a perspective view of a packaging assembly
including the carton shown in Figure 21.
[0030] Figure 23 is a perspective view of an alternative embodiment
of the packaging assembly shown in Figure 22.
[0031] Figure 24 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0032] Figure 25 is a perspective view of the carton formed from the
blank shown in Figure 24.
[0033] Figure 26 is a perspective view of a packaging assembly
including the carton shown in Figure 25.
[0034] Figure 27 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0035] Figure 28 is a perspective view of the carton formed from the
blank shown in Figure 27.
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[0036] Figure 29 is a perspective view of a packaging assembly
including the carton shown in Figure 28.
[0037] Figure 30 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0038] Figure 31 is a perspective view of the carton formed from the
blank shown in Figure 30.
[0039] Figure 32 is a perspective view of a packaging assembly
including the carton shown in Figure 31.
[0040] Figure 33 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0041] Figure 34 is a perspective view of the carton formed from the
blank shown in Figure 33.
[0042] Figure 35 is a perspective view of a packaging assembly
including the carton shown in Figure 34.
[0043] Figure 36 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0044] Figure 37 is a perspective view of the carton formed from the
blank shown in Figure 36.
[0045] Figure 38 is a perspective view of a packaging assembly
including the carton shown in Figure 37.
[0046] Figure 39 is a top plan view of a blank of sheet material for
forming a carton, according to one embodiment of this invention.
[0047] Figure 40 is a perspective view of the carton formed from the
blank shown in Figure 39.
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[0048] Figure 41 is a perspective view of a packaging assembly
including the carton shown in Figure 40.
[0049] Figure 42 is a flowchart illustrating a method for applying a
heat-shrink patch to a carton for forming a shape of the carton.
[0050] Corresponding reference characters indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0051] Generally, packaging assemblies are described herein that
may be formed from a carton having a heat-shrunk layer (sometimes referred to
as,
for example, "shrink-wrap") coupled to a portion thereof or from a carton
having a
heat-shrink layer in the form of a heat-shrink patch overlapping a portion of
the
carton. The heat-shrink patch may be attached to the carton on the inside of
the
carton or on the outside of the carton. In the exemplary embodiment, the
carton is
made from a paperboard material. The carton, however, could be made from other
materials, and therefore is not limited to a specific type of material. In
some
embodiments, a packaging assembly may include a movable section that is
movable
from a first position to a second position to form a shape of the packaging
assembly.
The movable section may be moved by, for example, wrapping a heat-shrinkable
layer around at least a portion of the movable section such that the layer
overlaps at
least a portion of the movable section, and heating the heat-shrinkable layer
to shrink
the heat-shrinkable layer into contact with at least a portion of the movable
section to
move the movable section from the first position to the second position as the
layer
shrinks under the heat.
[0052] Alternatively, the movable section may be moved by
attaching a heat-shrink patch to at least a portion of the movable section,
and heating
the heat-shrink patch such that shrinking of the patch causes the movable
section to
move from the first position to the second position. In one embodiment, a heat-
shrink
patch is coupled to an interior surface of the blank of sheet material. The
heat-shrink
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patch is connected to at least a portion of the movable section. The movable
section
is moved by heating the heat-shrink patch to shrink the heat-shrinkable patch
and urge
the movable section from the first position towards the second position. The
movable
section may be any portion of the carton and may be movable in any suitable
motion
and/or direction, whether such portion, motion, and/or direction is described
and/or
illustrated herein.
[0053] In some embodiments, a carton and/or a heat-
shrinkable/shrunk layer may include a marking thereon, such as, but not
limited to,
indicia that communicates the product, a manufacturer of the product, and/or a
seller
of the product. For example, printed text that indicates a product's name and
briefly
describes the product, logos and/or trademarks that indicate a manufacturer
and/or
seller of the product, and/or designs and/or ornamentation that attract
attention.
Moreover, =in some embodiments a packaging assembly may include a handle for
carrying the assembly.
[0054] The cartons, heat-shrinkable/shrunk layers, and packaging
assemblies generally may each have any suitable size, shape, and/or
configuration
(e.g., number of sides), whether such sizes, shapes, and/or configurations are
described and/or illustrated herein. For example, in one embodiment a
packaging
assembly includes a shape that corresponds to a product packaged within the
carton
and/or a shape that indicates a manufacture and/or seller of the product.
Moreover,
and for example, in one embodiment a packaging assembly includes a shape that
provides functionality, such as a shape that promotes the display of the
carton, a shape
that facilitates stacking and/or arrangement of a plurality of cartons, and/or
a shape
that facilitates carrying the carton. Similarly, the cartons, heat-
shrinkable/shrunk
layers, and packaging assemblies generally may be formed from any suitable
material,
whether such materials are described herein. For example, in one embodiment a
carton includes cardboard, corrugated board, and/or plastic. Additionally, in
one
embodiment, a heat-shrinkable/shrunk layer includes a sheet, a sleeve or a
patch of
shrinkable material that includes polyethylene, polypropylene, polyvinyl
chloride,
polyester, polyester glycol, nylon and/or oriented polystyrene. In an
alternative
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embodiment, any suitable shrinkable material known to those skilled in the art
and
guided by the teachings herein provided is used to fabricate heat-shrink
patch.
[0055] Referring now to the drawings, and more specifically to
Figures 1-3, although as described above a packaging assembly may have any
suitable
size, shape, and/or configuration (e.g., number of sides), Figures 1-3
illustrate the
formation of one embodiment of a packaging assembly. Specifically, Figure 1 is
a top
plan view of one embodiment of a blank of sheet material (designated in its
entirety
by reference numeral 20). Figure 2 is a perspective view of one embodiment of
a
carton (designated in its entirety by 100) formed from blank 20 shown in
Figure 1.
Figure 3 is a perspective view of one embodiment of a packaging assembly
(desipated in its entirety by 154) including carton 100 shown in Figure 2.
[0056] Referring to Figure 1, blank 20 includes a succession of six
side panels 22, 24, 26, 28, 30, and 32 that are connected together by a
plurality of
preformed, generally parallel, fold lines 36, 38, 40, 42, and 44,
respectively.
Specifically, each side panel 22, 24, 26, 28, 30, and 32 extends from an
adjacent side
panel along respective fold lines 36, 38, 40, 42, and 44. A side panel flap 46
extends
from an end portion (generally designated by 48) of side panel 32, or
alternatively
from an end portion (generally designated by 50) of side panel 22, along a
fold line 49
for facilitating securing end portions 48 and 50 together to form carton 100
(shown in
Figure 2). Each side panel 22, 24, 26, 28, 30, and 32 extends a height
measured
between a bottom end 52 and a top end 54. Side panel 22 or, alternatively,
side panel
24, 26, 28, 30 and/or 32, includes a top support panel 56 extending from top
end 54
thereof along a fold line 58 and a bottom support panel 60 extending from
bottom end
52 thereof along a fold line 62. Additionally, side panel 28 (or alternatively
any other
of side panels 22, 24, 26, 30, and/or 32) includes a top panel 64 extending
from top
end 54 thereof along a fold line 66 and a bottom panel 68 extending from
bottom end
52 thereof along a fold line 70. Top panel 64 and bottom panel 68 each include
two
securement tabs 72 and 74 extending therefrom along respective fold lines 76
and 78
for facilitating securing top panel 64 and bottom panel 68 to side panels 22,
24, 26,
28, 30, and 32 to form a top 114 (shown in Figure 2) and a bottom 116 (shown
in
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Figure 2) of carton 100. Moreover, top ends 54 and bottom ends 52 of each side
panel 26 and 30 include a securement flap 80 extending therefrom along a fold
line 82
for mating with securement tabs 72 and 74 to form carton 100. In alternative
embodiments, top panel 64 and bottom panel 68 may include any suitable
interconnection means in addition to, or alternatively to, the tab /flap
arrangement
described above. Accordingly, the top, bottom, and side panels 64, 68, 26, and
30,
respectively, are not limited to interconnection using a tab/flap arrangement.
For
example, in one embodiment, adhesive is applied to portions of the top,
bottom,
and/or side panels 64, 68, 26, and 30, respectively.
[0057] The side panels 22, 24, 26, 28, 30, and 32 each include an
upper panel portion 84 and a lower panel portion 86. Upper panel portions 84
each
include an upper panel extension SS extending therefrom along a fold line 90,
and
lower panel portions 86 each include a lower panel extension 92 extending
therefrom
along a fold line 94. Upper panel extensions 88 are each joined to a
corresponding
lower panel extension 92 along a central fold line 96. As can be seen in
Figure 1, an
opening 98 is defined between adjacent pairs of joined upper and lower panel
extensions 88 and 92 to accommodate changing a cross-sectional area of carton
100
as will be described below.
[0058] As shown in Figure 2, a carton 100 can be formed from blank
20 (shown in Figure 1) by folding blank 20 about fold lines 36, 38, 40, 42,
44, 49, 58,
62, 66, 70, 76, 78, and 82 (shown in Figure 1). In one embodiment, an adhesive
may
be applied to portions of blank 20 to secure carton 100 together. Generally,
side
panels 22, 24, 26, 28, 30, and 32 (shown in Figure 1) form six successive
sides
(generally designated by 102, 104, 106, 108, 110, and 112) of carton 100, top
panel
64 (shown in Figure 1) forms a top (generally designated by 114) of carton
100, and
bottom panel 68 (shown in Figure 1) fonns a bottom (generally designated by
116) of
carton 100. Carton 100 extends a height 118 measured between top 114 and
bottom
116 of carton 100 along a central longitudinal axis 120 extending through
carton 100.
As can be seen in Figure 2, in one embodiment, carton 100 includes a generally
hexagonal cross-sectional shape, for example, a cross section taken along the
plane 2-
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2 extending generally perpendicularly to central longitudinal axis 120. As can
also be
seen in Figure 2, each side 102, 104, 106, 108, 110, and 112 extends between
top 114
and bottom 116 of carton 100. More specifically, in one embodiment, each side
102,
104, 106, 108, 110, and 112 extends from top 114 to bottom 116. Any side 102,
104,
106, 108, 110, or 112 may be referred to herein as a first, a second, a third,
a fourth, a
fifth, and/or a sixth side.
[0059] Upper panel portions 84 and lower panel portions 86 (shown
in Figure 1) form upper portions 122 and lower portions 124, respectively, of
each
side 102, 104, 106, 108, 110, and 112. Upper panel extensions 88 and lower
panel
extensions 92 form upper extensions 126 and lower extensions 128,
respectively, of
each side 102, 104, 106, 108, 110, and 112. A corner 130 is defined at an
intersection
between top 114 and each side 102, 104, 106, 108, 110, and 112. Similarly, a
corner
132 is defined at an intersection between bottom 116 and each side 102, 104,
106,
108, 110, and 112. Moreover, a corner 134 is defined at an intersection
between each
adjacent side of sides 102, 104, 106, 108, 110, and 112.
[0060] The upper and lower extensions 126 and 128 each form a
movable section (generally designated by 136, 138, 140, 142, 144, and 146) of
carton
100. As can be seen in Figure 2, in one embodiment, each movable section 136,
138,
140, 142, 144, and 146 are located along central longitudinal axis 120 at a
generally
equal distance ftom top 114. More specifically, each central fold line 96 is
located
along central longitudinal axis 120 at a generally equal distance from top
114. Any
movable section 136, 138, 140, 142, 144, or 146 may be referred to herein as a
first, a
second, a third, a fourth, a fifth, and/or a sixth movable section.
[0061] The movable sections 136, 138, 140, 142, 144, and 146 are
each movable between a first position shown in Figure 2 (and generally
designated by
148) and a second position shown in Figure 3 (and generally designated by
150). In
one embodiment, movable sections 136, 138, 140, 142, 144, and 146 are movable
from first position 148 to second position 150 by bending upper and lower
extensions
126 and 128 along fold lines 90, fold lines 94, and central fold lines 96 to
generally
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radially move central fold lines 96 with respect to central longitudinal axis
120 of
carton 100. Accordingly, and as can be seen in Figures 2 and 3, movement
between
first and second positions 148 and 150, respectively, varies, or changes, a
cross-
sectional width of carton 100 defined between two opposite sides of sides 102,
104,
106, 108, 110, and 112 along the height of carton 100. In one embodiment, a
cross-
sectional width defined between two opposite sides of sides 102, 104, 106,
108, 110,
and 112 and taken through movable sections 136, 138, 140, 142, 144, and 146
(e.g., a
cross section taken along plane 3-3 in Figure 2) is generally greater in first
position
148 than in second position 150. More specifically, as can be seen in Figures
2 and 3,
each central fold line 96 is spaced a greater radial distance from central
longitudinal
axis 120 in first position 148 than in second position 150. In one embodiment,
at least
one of movable sections 136, 138, 140, 142, 144, and 146 is biased in first
position
148. Although movable sections 136, 138, 140, 142, 144, and/or 146 may be
biased
in first position 148 using any suitable mechanism, in one embodiment, a
structure of
carton 100 biases movable sections 136, 138, 140, 142, 144, and/or 146.
[0062] Once carton 100 has been formed, and either before,
simultaneously with, or after a product is placed within carton 100, a heat-
shrinkable
layer (generally designated by 152) can be wrapped around at least a portion
of carton
100 and heat-shrunk to form a packaging assembly, one embodiment of which is
shown in Figure 3 and generally designated by 154. Specifically, in the
embodiment
shown in Figure 3 heat-shrinkable layer 152 is wrapped around sides 102, 104,
106,
108, 110, and 112, a portion of which extends beyond top 114 and another
portion of
which extends beyond bottom 116. Layer 152 is then heated to shrink heat-
shrinkable
layer 152 into contact with carton 100. Layer 152 shrinks to fit snuggly
around carton
100. Although heat-shrinkable layer 152 can overlap any portion of carton 100,
in the
embodiment shown in Figure 3 heat-shrunk layer 152 substantially overlaps
sides
102, 104, 106, 108, 110, and 112 and corners 130, 132, and 134, and overlaps a
portion of top 114 and at least a portion of bottom 116. Although other types
of heat-
shrinkable layers may be used, in one embodiment heat-shrinkable layer 152 is
a sheet
of material or a sleeve of material. Additionally, although other materials
may be
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used for layer 152, in one embodiment layer 152 includes polyethylene,
polypropylene, and/or polyvinyl chloride.
[0063] The heat-shrunk layer 152 may facilitate sealing carton 100 to
protect a product contained within carton 100 from tampering and to generally
seal
the corners/joints of carton 100 for containing the product within carton 100
as well as
protecting the product from contamination. Heat-shrunk layer 152 can be used,
for
example, to replace bags or liners sometimes used within a container for
sealing a
product. The tight fit of heat-shrunk layer 152 may also facilitate
maintaining a shape
of carton 100 for example, to facilitate displaying, stacking and/or arranging
carton
100 or a plurality thereof of cartons, and/or maintaining a shape that
facilitates other
functionality such as carrying carton 100.
[0064] In one embodiment, top 114 (and/or one or more sides 102,
104, 106, 108, 110, and 112) includes a handle 156 extending outwardly
therefrom for
carrying the assembly. Heat-shrunk layer 152 includes an opening 158 therein
adjacent handle 156 such that handle 156 extends through opening 158 allowing
access to handle 156 when heat-shrunk layer 152 overlaps a portion of carton
100.
[0065] In one embodiment, carton 100 and/or layer 152 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[0066] Heat-shrinkable layer 152 may also facilitate forming of the
carton, and more specifically moving moveable sections 136, 138, 140, 142,
144, and
146 from first position 148 to second position 150 to form packaging assembly
154.
As described above, cartons having shapes that are more complex than
conventional
rectangular cartons may be difficult and therefore costly to manufacture.
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[0067] However, in one embodiment heat-shrinkable layer 152 is
wrapped around carton 100 such that heat-shrinkable layer 152 overlaps at
least a
portion of one or more of movable sections 136, 138, 140, 142, 144, and 146.
As
layer 152 is heated and shrinks into contact with movable sections 136, 138,
140, 142,
144, and 146, layer 152 moves movable sections 136, 138, 140, 142, 144, and
146
from first position 148 (shown in Figure 2) to second position 150 to form a
shape of
packaging assembly 154. Heat-shrunk layer 152 then holds movable sections 136,
138, 140, 142, 144, and 146 in second position 150 as long as layer 152
remains
substantially wrapped around carton 100. In one embodiment wherein movable
sections 136, 138, 140, 142, 144, and 146 are biased to first position 148,
layer 152
moves the movable sections to, and holds the movable section in, second
position 150
against the bias. By moving and holding movable sections 136, 138, 140, 142,
144,
and 146 into second position 150, layer 152 facilitates forming a shape of
packaging
assembly 154, and more specifically carton 100, that may be otherwise
difficult and
costly to form.
[006S] Although as described above a packaging assembly may have
any suitable size, shape, and/or configuration (e.g., number of sides),
Figures 4-7
illustrate the formation of one embodiment of a packaging assembly.
Specifically,
Figure 4 is a top plan view of one embodiment of a blank of sheet material
(designated in its entirety by reference numeral 200). Figure 5 is a
perspective view
of one embodiment of a carton (designated in its entirety by 266) formed from
blank
200 shown in Figure 4. Figure 6 is a perspective view of one embodiment of a
packaging assembly (designated in its entirety by 312) including carton 266
shown in
Figure 5, Figure 7 is a perspective view of an alternative embodiment of
packaging
assembly 312 shown in Figure 6.
[0069] Referring to Figure 4, blank 200 includes a succession of four
side panels 202, 204, 206, and 208 that are connected together by a plurality
of
preformed, generally parallel, fold lines 210, 212, and 214, respectively.
Specifically,
each side panel 202, 204, 206, and 208 extends from an adjacent side panel
along
respective fold lines 210, 212, and 214. A side panel flap 216 extends from an
end
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portion (generally designated by 218) of side panel 208, or alternatively from
an end
portion (generally designated by 220) of side panel 202, along a fold line 222
for
facilitating securing end portions 218 and 220 together to form carton 266
(shown in
Figure 5). Each side panel 202, 204, 206, and 208 extends a height measured
between
a bottom end 224 and a top end 226.
[0070] Side panel 202 and side panel 206 each include a top support
panel 228 extending from top end 226 thereof along a fold line 230 and a
bottom
support panel 232 extending from bottom end 224 thereof along a fold line 234.
Additionally, side panel 204 and side panel 208 each include a top panel 236
extending from top end 226 thereof along a fold line 23S and a bottom panel
240
extending from bottom end 224 thereof along a fold line 242. In one
embodiment, at
least one of top panels 236 includes an extension 244 extending therefrom for
interconnection with a slot 246 within the other top panel 236 for
facilitating securing
top panels 236 together to form a top 276 (shown in Figure 5) of carton 266
(shown in
Figure 5). Similarly, in one embodiment (not shown), at least one bottom panel
240
includes an extension extending therefrom for interconnection with a slot
within the
other bottom panel 240 for facilitating securing bottom panels 240 together to
form a
bottom 278 (shown in Figure 5) of carton 266 (shown in Figure 5). Of course,
top
panels 236 and bottom panels 240 may include any suitable interconnection
means in
addition to, or alternatively to, the extension/slot arrangement described
above.
Accordingly, top panels 236 and bottom panels 240 are not limited to
interconnection
using an extension/slot arrangement. For example, in one embodiment, adhesive
is
applied to portions of top panels 236 and/or bottom panels 240. In another
embodiment, top panels 236 and/or bottom panels 240 interconnect using hook-
and-
loop fasteners 248.
[0071] Side panels 202, 204, 206, and 208 each include an upper
panel portion 250 and a lower panel portion 252. Upper panel portions 250 each
include an upper panel extension 254 extending therefrom along a fold line
256, and
lower panel portions 252 each include a lower panel extension 258 extending
therefrom along a fold line 260. Upper panel extensions 254 are each joined to
a
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corresponding lower panel extension 258 along a central fold line 262. As can
be
seen in Figure 4, an opening 264 is defined between adjacent pairs of joined
upper
and lower panel extensions 254 and 258 to accommodate changing a cross-
sectional
area of carton 266 as will be described below.
[0072] As shown in Figure 5, a carton 266 can be formed from blank
200 (shown in Figure 4) by folding blank 200 about fold lines 210, 212, 214,
222,
230, 234, 238, and 242 (shown in Figure 4). In one embodiment, an adhesive may
be
applied to portions of blank 200 to secure carton 266 together. Generally,
side panels
202, 204, 206, and 208 (shown in Figure 4) form four successive sides
(generally
. designated by 268, 270, 272, and 274) of carton 266, top panels 236
(shown in Figure
4) form a top (generally designated by 276) of carton 266, and bottom panels
240
(shown in Figure 4) form a bottom (generally designated by 278) of carton 266.
Carton 266 extends a height 280 measured between top 276 and bottom 278 of
carton
266 along a central longitudinal axis 282 extending through carton 266. As can
be
seen in Figure 5, in one embodiment, carton 266 includes a generally
rectangular
cross-sectional shape, for example, a cross section taken along the plane 4-4
extending generally perpendicularly to central longitudinal axis 282. As can
also be
seen in Figure 5, each side 268, 270, 272, and 274 extends between top 276 and
bottom 278 of carton 266. More specifically, in one embodiment, each side 268,
270,
272, and 274 extends from top 276 to bottom 278. Any side 268, 270, 272, or
274
may be referred to herein as a first, a second, a third, and/or a fourth side.
[0073] Upper panel portions 250 and lower panel portions 252
(shown in Figure 4) form upper portions 284 and lower portions 286,
respectively, of
each side 268, 270, 272, and 274. Upper panel extensions 254 and lower panel
extensions 258 form upper extensions 288 and lower extensions 290,
respectively, of
each side 268, 270, 272, and 274. A corner 292 is defined at an intersection
between
top 276 and each side 268, 270, 272, and 274. Similarly, a corner 294 is
defined at an
intersection between bottom 278 and each side 268, 270, 272, and 274.
Moreover, a
corner 296 is defined at an intersection between each adjacent side of sides
268, 270,
272, and 274.
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[0074] Upper and lower extensions 288 and 290 each form a
movable section (generally designated by 298, 300, 302, and 304) of carton
266. As
can be seen in Figure 5, in one embodiment, each movable section 298, 300,
302, and
304 are located along central longitudinal axis 282 at a generally equal
distance from
top 276. More specifically, each central fold line 262 (shown in Figure 4) is
located
along central longitudinal axis 282 at a generally equal distance from top
276. Any
movable section 298, 300, 302, or 304 may be referred to herein as a first, a
second, a
third, and/or a fourth movable section.
[0075] Movable sections 298, 300, 302, and 304 are each movable
between a first position shown in Figure 5 (and generally designated by 306)
and a
second position shown in Figure 6 (and generally designated by 308). In one
embodiment, movable sections 298, 300, 302, and 304 are movable from first
position
306 to second position 308 by bending upper and lower extensions 288 and 290,
respectively, along fold lines 256, fold lines 260, and central fold lines 262
to
generally radially move central fold lines 262 with respect to central
longitudinal axis
282 of carton 266. Accordingly, and as can be seen in Figures 5 and 6,
movement
between first and second positions 306 and 308, respectively, varies, or
changes, a
cross-sectional width of carton 266 defined between two opposite sides of
sides 268,
270, 272, and 274 along the height of carton 266. In one embodiment, a cross-
sectional width defined between two opposite sides of sides 268, 270, 272, and
274
and taken through movable sections 298, 300, 302, and 304 (e.g., a cross
section taken
along plane 5-5 in Figure 5) is generally greater in first position 306 than
in second
position 308. More specifically, as can be seen in Figures 5 and 6, each
central fold
line 262 is spaced a greater radial distance from central longitudinal axis
282 in first
position 306 than in second position 308. In one embodiment, at least one of
movable
sections 298, 300, 302, and 304 is biased in first position 306. Although
movable
sections 298, 300, 302, and 304 may be biased in first position 306 using any
suitable
mechanism, in one embodiment, a structure of carton 266 biases movable
sections
298, 300, 302, and 304.
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[0076] Once carton 266 has been formed, and either before,
simultaneously with, or after a product is placed within carton 266, a heat-
shrinkable
layer (generally designated by 310) can be wrapped around at least a portion
of carton
266 and heat-shrunk to form a packaging assembly, one embodiment of which is
shown in Figure 6 and generally designated by 312. Specifically, in the
embodiment
shown in Figure 6 heat-shrinkable layer 310 is wrapped around sides 268, 270,
272,
and 274, a portion of which extends beyond top 276 and another portion of
which
extends beyond bottom 278. Layer 310 is then heated to shrink heat-shrinkable
layer
310 into contact with carton 266. Layer 310 shrinks to fit snuggly around
carton 266.
Although heat-shrinkable layer 310 can overlap any portion of carton 266, in
the
embodiment shown in Figure 6 heat-shrunk layer 310 substantially overlaps
sides
268, 270, 272, and 274 and corners 292, 294, and 296, and overlaps a portion
of top
276 and at least a portion of bottom 278. Figure 7 illustrates an alternative
embodiment of packaging assembly 312 wherein layer 310 does not overlap any
portion of top 276 or bottom 278 of carton 266. Although other types of heat-
shrinkable layers may be used, in one embodiment heat-shrinkable layer 310 is
a sheet
of material or a sleeve of material. Additionally, although other materials
may be
used for layer 310, in one embodiment layer 310 includes polyethylene,
polypropylene, and/or polyvinyl chloride.
[0077] Heat-shrunk layer 310 may facilitate sealing carton 266 to
protect a product contained within carton 266 from tampering and to generally
seal
the corners/joints of carton 266 for containing the product within carton 266
as well as
protecting the product from contamination. Heat-shrunk layer 310 can be used,
for
example, to replace bags or liners sometimes used within a container for
sealing a
product. The tight fit of heat-shrunk layer 310 may also facilitate
maintaining a shape
of carton 266 for example, to facilitate displaying, stacking and/or arranging
carton
266 or a plurality thereof of cartons, and/or maintaining a shape that
facilitates other
functionality such as carrying the carton 266.
[0078] In one embodiment, top 276 (and/or one or more of sides 268,
270, 272, and 274) includes a handle 314 extending outwardly therefrom for
carrying
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the assembly. Heat-shrunk layer 310 includes an opening 316 therein adjacent
handle
314 such that handle 314 extends through opening 316 allowing access to handle
314
when heat-shrunk layer 310 overlaps a portion of carton 266.
[0079] In one embodiment, carton 266 and/or layer 310 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[0080] Heat-shrinkable layer 310 may also facilitate forming of the
carton, and more specifically moving moveable sections 298, 300, 302, and 304
from
first position 306 to second position 308 to form packaging assembly 312. As
described above, cartons having shapes that are more complex than conventional
rectangular cartons may be difficult and therefore costly to manufacture.
[0081] However, in one embodiment heat-shrinkable layer 310 is
wrapped around carton 266 such that heat-shrinkable layer 310 overlaps at
least a
portion of one or more of movable sections 298, 300, 302, and 304. As layer
310 is
heated and shrinks into contact with movable sections 298, 300, 302, and 304,
layer
moves movable sections 298, 300, 302, and 304 from first position 306 (shown
in
Figure 5) to second position 308 to form a shape of packaging assembly 312.
Heat-
shrunk layer 310 then holds movable sections 298, 300, 302, and 304 in second
position 308 as long as layer 310 remains substantially wrapped around carton
266.
In one embodiment wherein movable sections 298, 300, 302, and 304 are biased
to
the first position, layer 310 moves the movable sections to, and holds the
movable
section in, second position 308 against the bias. By moving and holding
movable
sections 298, 300, 302, and 304 into second position 308, layer 310
facilitates forming
a shape of packaging assembly 312, and more specifically carton 266, that may
be
otherwise difficult and costly to form.
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[0082] Although as described above a packaging assembly may have
any suitable size, shape, and/or configuration (e.g., number of sides),
Figures 8-11
illustrate the formation of one embodiment of a packaging assembly.
Specifically,
Figure 8 is a top plan view of one embodiment of a blank of sheet material
(designated in its entirety by reference numeral 318). Figure 9 is a
perspective view
of one embodiment of a carton (designated in its entirety by 380) fon-ned from
blank
318 shown in Figure 8. Figure 10 is a perspective view of one embodiment of a
packaging assembly (designated in its entirety by 422) including carton 380
shown in
Figure 9. Figure 11 is a perspective view of an alternative embodiment of
packaging
assembly 422 shown in Figure 10.
[0083] Referring to Figure 8, blank 318 includes a succession of four
side panels 320, 322, 324, and 326 that are connected together by a plurality
of
preformed, generally parallel, fold lines 328, 330, and 332, respectively.
Specifically,
each side panel 320, 322, 324, and 326 extends from an adjacent one of the
side
panels along respective fold lines 328, 330, and 332. A side panel flap 334
extends
from an end portion (generally designated by 336) of side panel 320, or
alternatively
from an end portion (generally designated by 338) of side panel 326, along a
fold line
339 for facilitating securing end portions 336 and 338 together to fonn carton
380
(shown in Figure 9). Each side panel 320, 322, 324, and 326 extends a height
measured between a bottom end 340 and a top end 342.
[0084] Side panel 322 and side panel 326 each include a top support
panel 344 extending from top end 342 thereof along a fold line 346 and a
bottom
support panel 348 extending from bottom end 340 thereof along a fold line 350.
Additionally, side panel 320 and side panel 324 each include a top panel 352
extending from top end 342 thereof along a fold line 354 and a bottom panel
356
extending from bottom end 340 thereof along a fold line 358. In one
embodiment, at
least one of top panels 352 includes an extension 360 extending therefrom for
interconnection with a slot 362 within other top panel 352 for facilitating
securing top
panels 352 together to form a top 390 (shown in Figure 9) of carton 380 (shown
in
Figure 9). Similarly, in one embodiment (not shown), at least one of bottom
panels
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356 includes an extension extending therefrom for interconnection with a slot
within
the other bottom panel 356 for facilitating securing bottom panels 356
together to
form a bottom 392 (shown in Figure 9) of carton 380 (shown in Figure 9). Of
course,
top panels 352 and bottom panels 356 may include any suitable interconnection
means in addition to, or alternatively to, the extension/slot arrangement
described
above. Accordingly, top and bottom panels 352 and 356, respectively, are not
limited
to interconnection using an extension/slot arrangement. For example, in one
embodiment, adhesive is applied to portions of top and bottom panels 352 and
356,
respectively. In another embodiment, at least one of top panels 352 and bottom
panels 356 interconnect using hook-and-loop fasteners 364.
[0085] Side panels 322 and 326 each include an upper panel portion
366, a lower panel portion 368, and an intermediate panel portion 370. Upper
panel
portions 366 each include an upper panel extension 372 extending therefrom
along a
fold line 374, and lower panel portions 368 each include a lower panel
extension 376
extending therefrom along a fold line 378.
[0086] As shown in Figure 9, a carton 380 can be formed from blank
318 (shown in Figure 8) by folding blank 318 about fold lines 328, 330, 332,
339 350,
346, 350, 354, and 358 (shown in Figure 8). In one embodiment, an adhesive may
be
applied to portions of blank 318 to secure carton 380 together. Generally,
side panels
320, 322, 324, and 326 (shown in Figure 8) form four successive sides
(generally
designated by 382, 384, 386, and 388) of carton 380, top panels 352 (shown in
Figure
8) form a top (generally designated by 390) of carton 380, and bottom panels
356
(shown in Figure 8) form a bottom (generally designated by 392) of carton 380.
Carton 380 extends a height 394 measured between top 390 and bottom 392 of
carton
380 along a central longitudinal axis 396 extending through carton 380. As can
be
seen in Figure 9, in one embodiment, carton 380 includes a generally
rectangular
cross-sectional shape, for example, a cross section taken along the plane 6-6
extending generally perpendicularly to central longitudinal axis 396. As can
also be
seen in Figure 9, each side 382, 384, 386, and 388 extends between top 390 and
bottom 392 of carton 380. More specifically, in one embodiment, each side 382,
384,
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386, and 388 extends from top 390 to bottom 392. Any side 382, 384, 386, or
388
may be referred to herein as a first, a second, a third, and/or a fourth side.
[0087] Upper panel portions 366 and lower panel portions 368
(shown in Figure 8) form upper portions 398 and lower portions 400,
respectively, of
each side 388 and 384. Upper panel extensions 372 and lower panel extensions
376
form upper extensions 402 and lower extensions 404, respectively, of each side
388
and 384. A corner 406 is defined at an intersection between top 390 and each
side
382, 384, 386, and 388. Similarly, a corner 408 is defined at an intersection
between
bottom 392 and each side 382, 384, 386, and 388. Moreover, a corner 410 is
defined
at an intersection between each adjacent side of sides 382, 384, 3S6, and 388.
[0088] Upper and lower extensions 402 and 404 each form a
movable section (generally designated by 412 and 414) of carton 380. Any
movable
section 412 or 414 may be referred to herein as a first, a second, a third,
and/or a
fourth movable section. Movable sections 412 and 414 are each movable between
a
first position shown in Figure 9 (and generally designated by 416) and a
second
position shown in Figure 10 (and generally designated by 418). In one
embodiment,
movable sections 412 and 414 are movable from first position 416 to second
position
418 by bending upper and lower extensions 402 and 404, respectively, along
fold
lines 374 and fold lines 378 generally toward central longitudinal axis 396 of
carton
380 and such that extensions 402 and 404 are obliquely angled with respect to
corresponding side 384, 388. Accordingly, and as can be seen in Figures 9 and
10,
movement between first and second positions 416 and 418, respectively, varies,
or
changes, a cross-sectional width of carton 380 defined between two opposite
sides of
sides 384 and 388 along the height of carton 380. In one embodiment, a cross-
sectional width defined between two opposite sides 384 and 388 and generally
adjacent movable sections 412 and 414 (e.g., a cross section taken along plane
7-7 in
Figure 9) is generally greater in first position 416 than in second position
418. In one
embodiment, at least one of movable sections 412 and 414 is biased in first
position
416. Although movable sections 412 and 414 may be biased in first position 416
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using any suitable mechanism, in one embodiment, a structure of carton 380
biases
movable sections 412 and 414.
[0089] Once carton 380 has been fon-ned, and either before,
simultaneously with, or after a product is placed within carton 380, a heat-
shrinkable
layer (generally designated by 420) can be wrapped around at least a portion
of carton
380 and heat-shrunk to form a packaging assembly, one embodiment of which is
shown in Figure 10 and generally designated by 422. Specifically, in the
embodiment
shown in Figure 10 heat-shrinkable layer 420 is wrapped around sides 382, 384,
386,
and 388, a portion of which extends beyond top 390 and another portion of
which
extends beyond bottom 392. Layer 420 is then heated to shrink the heat-
shrinkable
layer into contact with carton 380. Layer 420 shrinks to fit snuggly around
carton
380. Although heat-shrinkable layer 420 can overlap any portion of carton 380,
in the
embodiment shown in Figure 10 heat-shrunk layer 420 substantially overlaps
sides
382, 384, 386, and 388 and corners 406, 408, and 410, and overlaps a portion
of top
390 and at least a portion of bottom 392. Figure 11 illustrates an alternative
embodiment of packaging assembly 422 wherein layer 420 does not overlap any
portion of top 390 or bottom 392 of carton 380. Although other types of heat-
shrinkable layers may be used, in one embodiment heat-shrinkable layer 420 is
a sheet
of material or a sleeve of material. Additionally, although other materials
may be
used for layer 420, in one embodiment layer 420 includes polyethylene,
polypropylene, and/or polyvinyl chloride.
[0090] Heat-shrunk layer 420 may facilitate sealing carton 380 to
protect a product contained within the carton from tampering and to generally
seal the
comers/joints of carton 380 for containing the product within carton 380 as
well as
protecting the product from contamination. Heat-shrunk layer 420 can be used,
for
example, to replace bags or liners sometimes used within a container for
sealing a
product. The tight fit of heat-shrunk layer 420 may also facilitate
maintaining a shape
of carton 380 for example, to facilitate displaying, stacking and/or arranging
carton
380 or a plurality thereof of cartons, and/or maintaining a shape that
facilitates other
functionality such as carrying the carton.
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[0091] In one embodiment, top 390 (and/or one or more of sides 382,
384, 386, and 388) includes a handle 424 extending outwardly therefrom for
carrying
assembly. Heat-shrunk layer 420 includes an opening 426 therein adjacent
handle
424 such that handle 424 extends through opening 426 allowing access to handle
424
when heat-shrunk layer 420 overlaps a portion of carton 380.
[0092] In one embodiment, carton 380 and/or layer 420 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[0093] Heat-shrinkable layer 420 may also facilitate forming of the
carton, and more specifically moving moveable sections 412 and 414 from first
position 416 to second position 418 to form packaging assembly 422. As
described
above, cartons having shapes that are more complex than conventional
rectangular
cartons may be difficult and therefore costly to manufacture.
[0094] However, in one embodiment heat-shrinkable layer 420 is
wrapped around carton 380 such that heat-shrinkable layer 420 overlaps at
least a
portion of one or more of movable sections 412 and 414. As layer 420 is heated
and
shrinks into contact with movable sections 412 and 414, layer moves movable
sections 412 and 414 from first position 416 (shown in Figure 9) to second
position
418 to form a shape of packaging assembly 422. Heat-shrunk layer 420 then
holds
movable sections 412 and 414 in second position 418 as long as layer 420
remains
substantially wrapped around carton 380. In one embodiment wherein movable
sections 412 and 414 are biased to the first position, layer 420 moves the
movable
sections to, and holds the movable section in, second position 418 against the
bias.
By moving and holding movable sections 412 and 414 into second position 418,
layer
420 facilitates forming a shape of packaging assembly 422, and more
specifically
carton 380, that may be otherwise difficult and costly to form.
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[0095] Although as described above a packaging assembly may have
any suitable size, shape, and/or configuration (e.g., number of sides),
Figures 12-15
illustrate the formation of one embodiment of a packaging assembly.
Specifically,
Figure 12 is a top plan view of one embodiment of a blank of sheet material
(designated in its entirety by reference numeral 428). Figure 13 is a
perspective view
of one embodiment of a carton (designated in its entirety by 490) formed from
blank
428 shown in Figure 12. Figure 14 is a perspective view of one embodiment of a
packaging assembly (designated in its entirety by 534) including carton 490
shown in
Figure 13. Figure 15 is a perspective view of an alternative embodiment of
packaging
assembly 534 shown in Figure 14.
[0096] Referring to Figure 12, blank 428 includes a succession of
four side panels 430, 432, 434, and 436 that are connected together by a
plurality of
preformed, generally parallel, fold lines 438, 440, and 442, respectively.
Specifically,
each side panel 430, 432, 434, and 436 extends from an adjacent one of side
panels
along respective fold lines 438, 440, and 442. A side panel flap 444 extends
from an
end portion (generally designated by 446) of side panel 430, or alternatively
from an
end portion (generally designated by 448) of side panel 436, along a fold line
450 for
facilitating securing end portions 446 and 448 together to form carton 490
(shown in
Figure 13). Each side panel 430, 432, 434, and 436 extends a height measured
between a bottom end 452 and a top end 454.
[0097] Side panel 432 and side panel 436 each include a top support
panel 456 extending from top end 454 thereof along a fold line 458 and a
bottom
support panel 460 extending from bottom end 452 thereof along a fold line 462.
Additionally, side panel 430 and side panel 434 each include a top panel 464
extending from top end 454 thereof along a fold line 466 and a bottom panel
468
extending from bottom end 452 thereof along a fold line 470. In one
embodiment, at
least one of top panels 464 includes an extension 472 extending therefrom for
interconnection with a slot 474 within the other top panel 464 for
facilitating securing
top panels 464 together to form a top 500 (shown in Figure 13) of carton 490
(shown
in Figure 13). Similarly, in one embodiment (not shown), at least one of
bottom
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panels 468 includes an extension extending therefrom for interconnection with
a slot
within the other bottom panel 468 for facilitating securing bottom panels 468
together
to form a bottom 502 (shown in Figure 13) of carton 490 (shown in Figure 13).
Of
course, top panels 464 and bottom panels 468 may include any suitable
interconnection means in addition to, or alternatively to, extension/slot
arrangement
described above. Accordingly, top and bottom panels 464 and 468, respectively,
are
not limited to interconnection using an extension/slot arrangement. For
example, in
one embodiment, adhesive is applied to portions of top and bottom panels 464
and
468, respectively. In another embodiment, at least one of top panels 464 and
bottom
panels 468 interconnect using hook-and-loop fasteners 476.
[0098] Side panels 432 and 436 each include an upper panel portion
478 and a lower panel portion 480. Upper panel portions 478 each include an
upper
panel extension 482 extending therefrom along a fold line 484, and lower panel
portions 480 each include a lower panel extension 486 extending therefrom
along a
fold line 488.
[0099] As shown in Figure 13, a carton 490 can be formed from
blank 428 (shown in Figure 12) by folding blank 428 about fold lines 438, 440,
442,
462, 458, 462, 466, and 470 (shown in Figure 12). In one embodiment, an
adhesive
may be applied to portions of blank 428 to secure carton 490 together.
Generally,
side panels 430, 432, 434, and 436 (shown in Figure 12) form four successive
sides
(generally designated by 492, 494, 496, and 498) of carton 490, top panels 464
(shown in Figure 12) form a top (generally designated by 500) of carton 490,
and
bottom panels 468 (shown in Figure 12) form a bottom (generally designated by
502)
of carton 490. Carton 490 extends a height 504 measured between top 500 and
bottom 502 of carton 490 along a central longitudinal axis 506 extending
through
carton 490. As can be seen in Figure 13, in one embodiment, carton 490
includes a
generally rectangular cross-sectional shape, for example, a cross section
taken along
the plane 8-8 extending generally perpendicularly to central longitudinal axis
506. As
can also be seen in Figure 13, each side 492, 494, 496, and 498 extends
between top
500 and bottom 502 of carton 490. More specifically, in one embodiment, each
side
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492, 494, 496, and 498 extends from top 500 to bottom 502. Any side 492, 494,
496,
or 498 may be referred to herein as a first, a second, a third, and/or a
fourth side.
[00100] Upper panel portions 478 and lower panel portions 480
(shown in Figure 12) form upper portions 508 and lower portions 510,
respectively, of
each side 498 and 494. Upper panel extensions 482 and lower panel extensions
486
form upper extensions 512 and lower extensions 514, respectively, of each side
498
and 494. A corner 516 is defined at an intersection between top 500 and each
side
492, 494, 496, and 498. Similarly, a corner 518 is defined at an intersection
between
bottom 502 and each side 492, 494, 496, and 498. Moreover, a corner 520 is
defined
at an intersection between each adjacent side of sides 492, 494, 496, and 498.
[00101] Upper and lower extensions 512 and 514 each form a
movable section (generally designated by 522 and 524) of carton 490. Any
movable
section 522 or 524 may be referred to herein as a first, a second, a third,
and/or a
fourth movable section. Movable sections 522 and 524 are each movable between
a
first position shown in Figure 13 (and generally designated by 526) and a
second
position shown in Figure 14 (and generally designated by 528). In one
embodiment,
movable sections 522 and 524 are movable from first position 526 to second
position
528 by bending upper and lower extensions 512 and 514, respectively, along
fold
lines 484 and fold lines 488 generally toward central longitudinal axis 506 of
carton
490 such that extensions 512 and 514 are obliquely angled with respect to
corresponding side 494, 498. Accordingly, and as can be seen in Figures 13 and
14,
movement between first and second positions 526 and 528, respectively, varies,
or
changes, a cross-sectional width of carton 490 defined between two opposite
sides of
sides 494 and 498 along the height of carton 490. In one embodiment, opposite
sides
494 and 498 each include a curved edge 530 to accommodate the changing cross-
sectional width. Curved edge 530 extends only a portion of height 504 of
carton 490,
although alternatively it may extend from top 500 to bottom 502. In one
embodiment,
a cross-sectional width defined between two opposite sides 494 and 498 and
generally
adjacent movable sections 522 and 524 (e.g., a cross section taken along plane
9-9 in
Figure 13) is generally greater in first position 526 than in second position
528. In
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one embodiment, at least one of movable sections 522 and 524 is biased in
first
position 526. Although movable sections 522 and 524 may be biased in first
position
526 using any suitable mechanism, in one embodiment, a structure of carton 490
biases movable sections 522 and 524.
[00102] Once carton 490 has been formed, and either before,
simultaneously with, or after a product is placed within carton 490, a heat-
shrinkable
layer (generally designated by 532) can be wrapped around at least a portion
of carton
490 and heat-shrunk to forrn a packaging assembly, one embodiment of which is
shown in Figure 14 and generally designated by 534. Specifically, in the
embodiment
shown in Figure 14 heat-shrinkable layer 532 is wrapped around sides 492, 494,
496,
and 498, a portion of which extends beyond top 500 and another portion of
which
extends beyond bottom 502. Layer 532 is then heated to shrink the heat-
shrinkable
layer into contact with carton 490. Layer 532 shrinks to fit snuggly around
carton
490. Although heat-shrinkable layer 532 can overlap any portion of carton 490,
in the
embodiment shown in Figure 14 heat-shrunk layer 532 substantially overlaps
sides
492, 494, 496, and 498 and corners 516, 518, and 520, and overlaps a portion
of top
500 and at least a portion of bottom 502. Figure 15 illustrates an alternative
embodiment of packaging assembly 534 wherein layer 532 does not overlap any
portion of top 500 or bottom 502 of carton 490. Although other types of heat-
shrinkable layers may be used, in one embodiment heat-shrinkable layer 532 is
a sheet
of material or a sleeve of material. Additionally, although other materials
may be
used for layer 532, in one embodiment layer 532 includes polyethylene,
polypropylene, and/or polyvinyl chloride.
[00103] Heat-shrunk layer 532 may facilitate sealing carton 490 to
protect a product contained within the carton from tampering and to generally
seal the
corners/joints of carton 490 for containing the product within carton 490 as
well as
protecting the product from contamination. Heat-shrunk layer 532 can be used,
for
example, to replace bags or liners sometimes used within a container for
sealing a
product. The tight fit of heat-shrunk layer 532 may also facilitate
maintaining a shape
of carton 490 for example, to facilitate displaying, stacking and/or arranging
carton
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490 or a plurality thereof of cartons, and/or maintaining a shape that
facilitates other
functionality such as carrying the carton.
[00104] In one embodiment, top 500 (and/or one or more of sides
492, 494, 496, and 49S) includes a handle 536 extending outwardly therefrom
for
carrying the assembly. Heat-shrunk layer 532 includes an opening 538 therein
adjacent handle 536 such that handle 536 extends through opening 538 allowing
access to the handle when heat-shrunk layer 532 overlaps a portion of carton
490.
[00105] In one embodiment, carton 490 and/or layer 532 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[00106] Heat-shrinkable layer 532 may also facilitate forming of the
carton, and more specifically moving moveable sections 522 and 524 from first
position 526 to second position 528 to form packaging assembly 534. As
described
above, cartons having shapes that are more complex than conventional
rectangular
cartons may be difficult and therefore costly to manufacture.
[00107] However, in one embodiment heat-shrinkable layer 532 is
wrapped around carton 490 such that heat-shrinkable layer 532 overlaps at
least a
portion of one or more of movable sections 522 and 524. As layer 532 is heated
and
shrinks into contact with movable sections 522 and 524, layer moves movable
sections 522 and 524 from first position 526 (shown in Figure 13) to second
position
528 to form a shape of packaging assembly 534. Heat-shrunk layer 532 then
holds
movable sections 522 and 524 in second position 528 as long as layer 532
remains
substantially wrapped around carton 490. In one embodiment wherein movable
sections 522 and 524 are biased to the first position, layer 532 moves the
movable
sections to, and holds the movable section in, second position 528 against the
bias.
By moving and holding movable sections 522 and 524 into second position 528,
layer
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532 facilitates forming a shape of packaging assembly 534, and more
specifically
carton 490, that may be otherwise difficult and costly to form.
[00108] Although as described above a packaging assembly may
have any suitable size, shape, and/or configuration (e.g., number of sides),
Figures 16-
19 illustrate the formation of one embodiment of a packaging assembly.
Specifically,
Figure 16 is a top plan view of one embodiment of a blank of sheet material
(designated in its entirety by reference numeral 540). Figure 17 is a
perspective view
of one embodiment of a carton (designated in its entirety by 600) formed from
blank
540 shown in Figure 16. Figure 18 is a perspective view of one embodiment of a
packaging assembly (designated in its entirety by 644) including carton 600
shown in
Figure 17. Figure 19 is a perspective view of an alternative embodiment of
packaging
assembly 644 shown in Figure 18.
[00109] Referring to Figure 16, blank 540 includes a succession of
four side panels 542, 544, 546, and 548 that are connected together by a
plurality of
preformed, generally parallel, fold lines 550, 552, and 554, respectively.
Specifically,
each side panel 542, 544, 546, and 548 extends from an adjacent one of the
side
panels along respective fold lines 550, 552, and 554. A side panel flap 556
extends
from an end portion (generally designated by 558) of side panel 542, or
alternatively
from an end portion (generally designated by 560) of side panel 548, along a
fold line
562 for facilitating securing end portions 558 and 560 together to form carton
600
(shown in Figure 17). Each side panel 542, 544, 546, and 548 extends a height
measured between a bottom end 564 and a top end 566.
[00110] Side panel 544 and side panel 548 each include a top support
panel 568 extending from top end 566 thereof along a fold line 570 and a
bottom
support panel 572 extending from bottom end 564 thereof along a fold line 574.
Additionally, side panel 542 and side panel 546 each include a top panel 576
extending from top end 566 thereof along a fold line 578 and a bottom panel
580
extending from bottom end 564 thereof along a fold line 582. In one
embodiment, at
least one of top panels 576 includes an extension 584 extending therefrom for
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interconnection with a slot 586 within other top panel 576 for facilitating
securing top
panels 576 together to form a top 610 (shown in Figure 17) of carton 600
(shown in
Figure 17). Similarly, in one embodiment (not shown), at least one of bottom
panels
580 includes an extension extending therefrom for interconnection with a slot
within
the other bottom panel 580 for facilitating securing bottom panels 580
together to
form a bottom 612 (shown in Figure 17) of carton 600 (shown in Figure 17). Of
course, top panels 576 and bottom panels 580 may include any suitable
interconnection means in addition to, or alternatively to, extension/slot
arrangement
described above. Accordingly, top and bottom panels 576 and 580, respectively,
are
not limited to interconnection using an extension/slot arrangement. For
example, in
one embodiment, adhesive is applied to portions of top and bottom panels 576
and
580, respectively. In another embodiment, at least one of top panels 576 and
bottom
panels 580 interconnect using hook-and-loop fasteners 588.
[00111] Side panels 542, 544, 546, and 548 each include an upper
panel portion 590, a lower panel portion 592, and an intermediate panel
portion 594.
Intermediate panel portions 594 each extend from upper panel portions 590
along a
fold line 596 to lower panel portions 592 along a fold line 598. Side panels
542, 544,
546, and 548 also each includes curved edges 597.
[00112] As shown in Figure 17, a carton 600 can be formed from
blank 540 (shown in Figure 16) by folding blank 540 about fold lines 550, 552,
554,
562, 570, 574, 578, and 582 (shown in Figure 16). In one embodiment, an
adhesive
may be applied to portions of blank 540 to secure carton 600 together.
Generally,
side panels 542, 544, 546, and 548 (shown in Figure 16) form four successive
sides
(generally designated by 602, 604, 606, and 608) of carton 600, top panels 576
(shown in Figure 16) form a top (generally designated by 610) of carton 600,
and
bottom panels 580 (shown in Figure 16) form a bottom (generally designated by
612)
of carton 600. Carton 600 extends a height 614 measured between top 610 and
bottom 612 of carton 600 along a central longitudinal axis 616 extending
through
carton 600. As can be seen in Figure 17, in one embodiment, carton 600
includes a
generally rectangular cross-sectional shape, for example, a cross section
taken along
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the plane 10-10 extending generally perpendicularly to central longitudinal
axis 616.
As can also be seen in Figure 17, each side 602, 604, 606, and 608 extends
between
top 610 and bottom 612 of carton 600. More specifically, in one embodiment,
each
side 602, 604, 606, and 608 extends from top 610 to bottom 612. Any side 602,
604,
606, or 608 may be referred to herein as a first, a second, a third, and/or a
fourth side.
[00113] Upper panel portions 590, lower panel portions 592, and
intermediate panel portions 594 (shown in Figure 12) form upper portions 618,
lower
portions 620, and intermediate portions 622, respectively, of each side 602,
604, 606,
and 608. A corner 624 is defined at an intersection between top 610 and each
side
602, 604, 606, and 608. Similarly, a corner 626 is defined at an intersection
between
bottom 612 and each side 602, 604, 606, and 608. Moreover, a corner 628 is
defined
at an intersection between each adjacent side of sides 602, 604, 606, and 608.
Additionally, as discussed above, sides 602, 604, 606, and 608 each include
curved
edges 597. In one embodiment, curved edges 597 extend only a portion of the
height
of carton 600, although alternatively curved edges 597 extend from top 610 to
bottom
612 of carton 600.
[00114] Sides 602, 604, 606, and 608 each form a movable section
(generally designated by 630, 632, 634, and 636, respectively) of carton 600.
Any
movable sections 630, 632, 634, or 636 may be referred to herein as a first, a
second,
a third, and/or a fourth movable section. Movable sections 630, 632, 634, and
636 are
each movable between a first position shown in Figure 17 (and generally
designated
by 638) and a second position shown in Figure 18 (and generally designated by
640).
In one embodiment, movable sections 630, 632, 634, and 636 are movable from
first
position 638 to second position 640 by bending them along fold lines 596 and
598
(shown in Figure 16). Accordingly, and as can be seen in Figures 17 and 18,
movement between first and second positions 638 and 640, respectively, varies,
or
changes, a cross-sectional width of carton 600 defined between two opposite
sides of
sides 604 and 608 along the height of carton 600. Additionally, because of
curved
edges 597, movement from first position 638 to second position 640 curves (or
increases a curvature of) sides 602, 604, 606, and/or 608 such that sides 602,
604,
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606, and 608 each include a curved surface. In one embodiment, only a portion
of
sides 602, 604, 606, and/or 608 are curved in second position 640 as shown in
Figure
18. Alternatively, in another embodiment, sides 602, 604, 606, and/or 608 are
curved
from top 610 to bottom 612 of carton 600.
[00115] In one embodiment, a cross-sectional width defined between
two opposite sides of sides 602, 604, 606, and 608 and generally adjacent
movable
sections 630, 632, 634, and 636 (e.g., a cross section taken along plane 11-11
in
Figure 17) is generally greater in first position 638 than in second position
640. In
one embodiment, at least one of movable sections 630, 632, 634, and 636 is
biased in
first position 638. Although movable sections 630, 632, 634, and 636 may be
biased
in first position 638 using any suitable mechanism, in one embodiment, a
structure of
carton 600 biases movable sections 630, 632, 634, and 636.
[00116] Once carton 600 has been formed, and either before,
simultaneously with, or after a product is placed within carton 600, a heat-
shrinkable
layer (generally designated by 642) can be wrapped around at least a portion
of carton
600 and heat-shrunk to form a packaging assembly, one embodiment of which is
shown in Figure 18 and generally designated by 644. Specifically, in the
embodiment
shown in Figure 1S heat-shrinkable layer 642 is wrapped around sides 602, 604,
606,
and 608, a portion of which extends beyond top 610 and another portion of
which
extends beyond bottom 612. Layer 642 is then heated to shrink the heat-
shrinkable
layer into contact with carton 600. Layer 642 shrinks to fit snuggly around
carton
600. Although heat-shrinkable layer 642 can overlap any portion of carton 600,
in the
embodiment shown in Figure 18 heat-shrunk layer 642 substantially overlaps
sides
602, 604, 606, and 608 and corners 624, 626, and 628, and overlaps a portion
of top
610 and at least a portion of bottom 612. Figure 19 illustrates an alternative
embodiment of packaging assembly 644 wherein layer 642 does not overlap any
portion of top 610 or bottom 612 of carton 600. Although other types of heat-
shrinkable layers may be used, in one embodiment heat-shrinkable layer 642 is
a sheet
of material or a sleeve of material. Additionally, although other materials
may be
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used for layer 642, in one embodiment layer 642 includes polyethylene,
polypropylene, and/or polyvinyl chloride.
[00117] Heat-shrunk layer 642 may facilitate sealing carton 600 to
protect a product contained within the carton from tampering and to generally
seal the
comers/joints of carton 600 for containing the product within carton 600 as
well as
protecting the product from contamination. Heat-shrunk layer 642 can be used,
for
example, to replace bags or liners sometimes used within a container for
sealing a
product. The tight fit of heat-shrunk layer 642 may also facilitate
maintaining a shape
of carton 600 for example, to facilitate displaying, stacking and/or arranging
carton
600 or a plurality thereof of cartons, and/or maintaining a shape that
facilitates other
functionality such as carrying the carton.
[00118] In one embodiment, top 610 (and/or one or more sides 602,
604, 606, and 608) includes a handle 646 extending outwardly therefrom for
carrying
the assembly. Heat-shrunk layer 642 includes an opening 648 therein adjacent
handle
646 such that handle 646 extends through opening 648 allowing access to handle
646
when heat-shrunk layer 642 overlaps a portion of carton 600.
[00119] In one embodiment, carton 600 and/or layer 642 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[00120] Heat-shrinkable layer 642 may also facilitate forming of the
carton, and more specifically moving moveable sections 630, 632, 634, and 636
from
first position 638 to second position 640 to form packaging assembly 644. As
described above, cartons having shapes that are more complex than conventional
rectangular cartons may be difficult and therefore costly to manufacture.
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[00121] However, in one embodiment heat-shrinkable layer 642 is
wrapped around carton 600 such that heat-shrinkable layer 642 overlaps at
least a
portion of one or more of movable sections 630, 632, 634, and 636. As layer
642 is
heated and shrinks into contact with movable sections 630, 632, 634, and 636,
layer
642 moves movable sections 630, 632, 634, and 636 from first position 638
(shown in
Figure 17) to second position 640 to form a shape of packaging assembly 644.
Heat-
shrunk layer 642 then holds movable sections 630, 632, 634, and 636 in second
position 640 as long as layer 642 remains substantially wrapped around carton
600.
In one embodiment wherein movable sections 630, 632, 634, and 636 are biased
to
the first position, layer 642 moves the movable sections to, and holds the
movable
section in, second position 640 against the bias. By moving and holding
movable
sections 630, 632, 634, and 636 into second position 640, layer 642
facilitates forming
a shape of packaging assembly 644, and more specifically carton 600, that may
be
otherwise difficult and costly to form.
[00122] Although as described above a packaging assembly may
have any suitable size, shape, and/or configuration (e.g., number of sides),
Figures 20-
23 illustrate the formation of one embodiment of a packaging assembly.
Specifically,
Figure 20 is a top plan view of one embodiment of a blank of sheet material
(designated in its entirety by reference numeral 670). Figure 21 is a
perspective view
of one embodiment of a carton (designated in its entirety by 740) formed from
blank
670 shown in Figure 20. Figure 22 is a perspective view of one embodiment of a
packaging assembly (designated in its entirety by 790) including carton 740
shown in
Figure 21. Figure 23 is a perspective view of an alternative embodiment of
packaging
assembly 790 shown in Figure 22.
[00123] Referring to Figure 20, blank 670 includes a succession of
four side panels 672, 674, 676, and 678 that are connected together by a
plurality of
preformed, generally parallel, fold lines 680, 682, and 684, respectively.
Specifically,
each side panel 672, 674, 676, and 678 extends from an adjacent one of the
side
panels along respective fold lines 680, 682, and 684. A side panel flap 686
extends
from an end portion (generally designated by 688) of side panel 672, or
alternatively
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from an end portion (generally designated by 690) of side panel 678, along a
fold line
692 for facilitating securing end portions 688 and 690 together to form carton
740
(shown in Figure 21). Each side panel 672, 674, 676, and 678 extends a height
measured between a bottom end 694 and a top end 696.
[00124] Side panel 674 and side panel 678 each include a top support
panel 698 extending from top end 696 thereof along a fold line 700 and a
bottom
support panel 702 extending from bottom end 694 thereof along a fold line 704.
Additionally, side panel 672 and side panel 676 each include a top panel 706
extending from top end 696 thereof along a fold line 708 and a bottom panel
710
extending from bottom end 694 thereof along a fold line 712. In one
embodiment, at
least one of top panels 706 includes an extension 714 extending therefrom for
interconnection with a slot 716 within the other top panel 706 for
facilitating securing
top panels 706 together to form a top 750 (shown in Figure 21) of carton 740
(shown
in Figure 21). Similarly, in one embodiment (not shown), at least one of
bottom
panels 710 includes an extension extending therefrom for interconnection with
a slot
within the other bottom panel 710 for facilitating securing bottom panels 710
together
to form a bottom 752 (shown in Figure 21) of carton 740 (shown in Figure 21).
Of
course, top panels 706 and bottom panels 710 may include any suitable
interconnection means in addition to, or alternatively to, extension/slot
arrangement
described above. Accordingly, top and bottom panels 706 and 710, respectively,
are
not limited to interconnection using an extension/slot arrangement. For
example, in
one embodiment, adhesive is applied to portions of top and bottom panels 706
and
710, respectively. In another embodiment, at least one of top panels 706 and
bottom
panels 710 interconnect using hook-and-loop fasteners 718.
[00125] Side panels 674 and 678 each include an extension panel
720 and 722, respectively, extending therefrom along a fold line 724, 726,
respectively. Side panel 676 also includes an extension panel 728 extending
therefrom along a fold line 730 and an opposite extension panel 732 extending
along a
fold line 734. In one embodiment, fold lines 724, 726, 730, and/or 734 are
curved.
Moreover, in one embodiment extension panel 720, 722, 728, and/or 732 includes
a
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curved edge 736. Any extension panel 720, 722, 728, or 732 may be referred to
herein as a first, second, third, and/or fourth extension. Additionally, as
can be seen
in Figure 20, a plurality of openings 738 are formed between adjacent panels
of
extension panels 720, 722, 728, and 732.
[00126] As shown in Figure 21, a carton 740 can be formed from
blank 670 (shown in Figure 20) by folding blank 670 about fold lines 680, 682,
684,
692, 700, 704, 708, and 712 (shown in Figure 20). In one embodiment, an
adhesive
may be applied to portions of blank 670 to secure carton 740 together.
Generally,
side panels 672, 674, 676, and 678 (shown in Figure 20) form four successive
sides
(generally designated by 742, 744, 746, and 748) of carton 740, top panels 706
(shown in Figure 20) form a top (generally designated by 750) of carton 740,
and
bottom panels 710 (shown in Figure 20) form a bottom (generally designated by
752)
of carton 740. Extension panels 720, 722, 728, and 732 each form a respective
extension 754, 756, 758, and 760. Carton 740 extends a height 762 measured
between top 750 and bottom 752 of carton 740 along a central longitudinal axis
764
extending through carton 740. As can also be seen in Figure 21, each side 742,
744,
746, and 748 extends between top 750 and bottom 752 of carton 740. More
specifically, in one embodiment, each side 742, 744, 746, and 748 extends from
top
750 to bottom 752. Any side 742, 744, 746, or 748 may be referred to herein as
a
first, a second, a third, and/or a fourth side.
[00127] A corner 766 is defined at an intersection between top 750
and each side 742, 744, 746, and 748. Similarly, a corner 768 is defined at an
intersection between bottom 752 and each side 742, 744, 746, and 748.
Moreover, a
corner 770 is defined at an intersection between each adjacent side of sides
742, 744,
746, and 748. Additionally, as discussed above, extensions 754, 756, 758, and
760
each include curved edges 736.
[00128] Extensions 754, 756, 758, and 760 each form a movable
section (generally designated by 772, 774, 776, and 778, respectively) of
carton 740.
Any movable section 772, 774, 776, or 778 may be referred to herein as a
first, a
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second, a third, and/or a fourth movable section. Movable sections 772, 774,
776, and
778 are each movable between a first position shown in Figure 21 (and
generally
designated by 780) and a second position shown in Figure 22 (and generally
designated by 782). In one embodiment, movable sections 772, 774, 776, and 778
are
movable from first position 780 to second position 782 by bending them along
the
fold lines corresponding fold lines 724, 726, 730, and 734 (shown in Figure
20).
Accordingly, and as can be seen in Figures 21 and 22, movement between first
and
second positions 780 and 782, respectively, creates a side (generally
designated by
784) defined between side 744 and side 746 and a side (generally designated by
786)
defined between side 746 and side 748. In one embodiment, side 784 is
obliquely
angled with respect to side 744 and side 786 is obliquely angled with respect
to side
746. Any side 742, 744, 746, 748, 784, or 786 may be referred to herein as a
first, a
second, a third, a fourth, a fifth, and/or a sixth side. In one embodiment,
sides 784
and/or 786 extend only partially between top 750 and bottom 752 of carton 740.
Alternatively, sides 784 and/or 786 extend from top 750 to bottom 752 of
carton 740.
[00129] Specifically, movable section 772 (extension 754) is bended
along fold line 724 towards an interior of carton 781 such that section 772 is
obliquely
angled with respect to side 744. Similarly, movable section 776 (extension
758) is
bended along fold line 730 towards an interior of carton 781 such that section
776 is
obliquely angled with respect to side 746 and such that section 776 at least
partially
overlaps section 772. Movable section 774 (extension 756) is also bended along
fold
line 726 towards an interior of carton 781 such that section 774 is obliquely
angted
with respect to side 748. Similarly, movable section 778 (extension 760) is
bended
along fold line 734 towards an interior of carton 781 such that section 778 is
obliquely
angled with respect to side 746 and such that section 778 at least partially
overlaps
section 774. As can be seen in Figure 22, in one embodiment movement from
first
position 780 to second position 782 at least partially closes openings 738
(shown in
Figure 20). Additionally, because of curved edges 736, movement from first
position
780 to second position 782 curves (or increases a curvature of) side 746 such
that side
746 includes a curved surface. In one embodiment, only a portion of side 746
is
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curved in second position 782 as shown in Figure 22. Alternatively, in another
embodiment side 746 is curved from top 750 to bottom 752 of carton 740. In one
embodiment, at least one of movable sections 772, 774, 776, and 778 is biased
in first
position 780. Although movable sections 772, 774, 776, and 778 may be biased
in
first position 780 using any suitable mechanism, in one embodiment, a
structure of
carton 740 biases movable sections 772, 774, 776, and 778.
[00130] Once carton 740 has been formed, and either before,
simultaneously with, or after a product is placed within carton 740, a heat-
shrinkable
layer (generally designated by 788) can be wrapped around at least a portion
of carton
740 and heat-shrunk to form a packaging assembly, one embodiment of which is
shown in Figure 22 and generally designated by 790. Specifically, in the
embodiment
shown in Figure 22 heat-shrinkable layer 788 is wrapped around sides 742, 744,
746,
748, 784, and 786, a portion of which extends beyond top 750 and another
portion of
which extends beyond bottom 752. Layer 788 is then heated to shrink the heat-
shrinkable layer into contact with carton 740. Layer 788 shrinks to fit
snuggly around
carton 740. Although heat-shrinkable layer 788 can overlap any portion of
carton
740, in the embodiment shown in Figure 22 heat-shrunk layer 788 substantially
overlaps sides 742, 744, 746, 748, 784, and 786 and corners 766, 768, and 770,
and
overlaps a portion of top 750 and at least a portion of bottom 752. Figure 23
illustrates an alternative embodiment of packaging assembly 790 wherein layer
788
does not overlap any portion of top 750 or bottom 752 of carton 740. Although
other
types of heat-shrinkable layers may be used, in one embodiment heat-shrinkable
layer
788 is a sheet of material or a sleeve of material. Additionally, although
other
materials may be used for layer 788, in one embodiment layer 788 includes
polyethylene, polypropylene, and/or polyvinyl chloride.
[00131] Heat-shrunk layer 788 may facilitate sealing carton 740 to
protect a product contained within the carton from tampering and to generally
seal the
corners/joints of carton 740 for containing the product within carton 740 as
well as
protecting the product from contamination. Heat-shrunk layer 788 can be used,
for
example, to replace bags or liners sometimes used within a container for
sealing a
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product. The tight fit of heat-shrunk layer 788 may also facilitate
maintaining a shape
of carton 740 for example, to facilitate displaying, stacking and/or arranging
carton
740 or a plurality thereof of cartons, and/or maintaining a shape that
facilitates other
functionality such as carrying the carton.
[00132] In one embodiment, top 750 (and/or one or more of sides
742, 744, 746, and 748) includes a handle 792 extending outwardly therefrom
for
carrying the assembly. Heat-shrunk layer 788 includes an opening 794 therein
adjacent handle 792 such that handle 792 extends through opening 794 allowing
access to handle 792 when heat-shrunk layer 788 overlaps a portion of carton
740.
[00133] In one embodiment, carton 740 and/or layer 788 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[00134] Heat-shrinkable layer 788 may also facilitate forming of the
carton, and more specifically moving moveable sections 772, 774, 776, and 778
from
first position 780 to second position 782 to form packaging assembly 790. As
described above, cartons having shapes that are more complex than conventional
rectangular cartons may be difficult and therefore costly to manufacture.
[00135] However, in one embodiment heat-shrinkable layer 788 is
wrapped around carton 740 such that heat-shrinkable layer 788 overlaps at
least a
portion of one or more of movable sections 772, 774, 776, and 778. As layer
788 is
heated and shrinks into contact with movable sections 772, 774, 776, and 778,
layer
moves movable sections 772, 774, 776, and 778 from first position 780 (shown
in
Figure 21) to second position 782 to form a shape of packaging assembly 790.
Heat-
shrunk layer 788 then holds movable sections 772, 774, 776, and 778 in second
position 782 as long as layer 788 remains substantially wrapped around carton
740.
In one embodiment wherein movable sections 772, 774, 776, and 778 are biased
to
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the first position, layer 788 moves the movable sections to, and holds the
movable
section in, second position 782 against the bias. By moving and holding
movable
sections 772, 774, 776, and 778 into second position 782, layer 788
facilitates forming
a shape of packaging assembly 790, and more specifically carton 740, that may
be
otherwise difficult and costly to forni..
[00136] In one embodiment, carton 854 and/or layer 880 includes a
marking thereon, such as, but not limited to, indicia that communicates the
product, a
manufacturer of the product, and/or a seller of the product. For example,
printed text
that indicates a product's name and briefly describes the product, logos and
trademarks that indicate a manufacturer and/or seller of the product, and/or
designs
and/or ornamentation that attracts attention.
[00137] Referring to Figures 24-41, a packaging assembly of the
present invention may have any suitable size, shape and/or configuration,
e.g., number
of sides. The present invention is described below in reference to its
application in
connection with several embodiments. However, it will be obvious to those
skilled in
the art and guided by the teachings herein provided that the invention is
likewise
applicable to any suitable packaging assembly having any suitable number of
top
panels, bottom panels and/or side panels, and forming any suitable packaging
assembly shape.
[00138] Figures 24-26 show a packaging assembly according to one
embodiment. Specifically, Figure 24 is a top plan view of a blank of sheet
material
1020. Figure 25 is a perspective view of a carton 1100 formed from blank 1020.
Figure 26 is a perspective view of a packaging assembly 1150 including carton
1100
formed from blank 1020.
[00139] Referring to Figure 24, in one embodiment, blank 1020 has
an interior surface 1021 and an opposing exterior surface. Blank 1020 includes
a
succession of side panels 1022, 1024, 1026 and 1028 that are connected
together by a
plurality of preformed, generally parallel, fold lines 1036, 1038 and 1040,
respectively. Side panels 1022, 1024, 1026 and 1028 extend from an adjacent
side
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panel along respective fold lines 1036, 1038 and 1040. A side panel flap 1046
extends from side panel 1022 along an end fold line 1048 to secure side panel
flap
1046 to side panel 1028 to form carton 1100. In an alternative embodiment, a
side
panel flap (not shown) extends from side panel 1028 along an end fold line
(not
shown) formed along an edge 1050 of side panel 1028 to secure the side panel
flap to
side panel 1022 to form carton 1100.
[00140] Each side panel 1022, 1024, 1026 and 1028 extends a height
measured between a bottom end 1052 and a top end 1054. As shown in Figure 24,
a
top support panel 1056 extends from side panel 1022 at top end 1054 along a
fold line
1058 and a bottom support panel 1060 extends from side panel 1022 at bottom
end
1052 along a fold line 1062. Additionally, a top support panel 1064 extends
from side
panel 1026 at top end 1054 along a fold line 1066 and a bottom support panel
1068
extends from side panel 1026 at bottom end 1052 along a fold line 1070. Top
support
panel 1064 is connected to top support panel 1056 to form a top 1114, shown in
Figure 25, of carton 1100. In one embodiment, top support panel 1064 includes
at
least one tab 1072 extending therefrom, which engages with a cooperating slit
1074
formed in top support panel 1056 to secure top support panel 1064 to top
support
panel 1056 to form top 1114. Bottom support panel 1068 is connected to bottom
support panel 1060 to from a bottom 1116, shown in Figure 25, of carton 1100.
As
shown in Figure 24, in one embodiment, bottom support panel 1068 includes at
least
one hook component 1075 of a hook-and-loop fastener, such as a VELCRO fastener
(VELCRO is a registered trademark of VELCRO Industries B.V., Curacao,
Netherlands), that cooperates with a loop component (not shown) of the hook-
and-
loop fastener positioned on bottom support panel 1060 to secure bottom support
panel
1068 to bottom support panel 1060. In one embodiment, a top flap 1080 is
connected
to side panel 1024 and/or side panel 1028 along fold line 1082 at top end 1054
for
cooperating with top support panels 1056, 1064 to form top 1114. Similarly, a
bottom
flap 1084 is connected to side panel 1024 and/or side panel 1026 along a fold
line
1086 at bottom end 1052 for cooperating with bottom support panels 1060, 1068
to
form bottom 1116. It is apparent to those skilled in the art and guided by the
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teachings herein provided that any suitable connecting mechanism can be used
to
connect top support panel 1056 to top support panel 1064 and/or bottom support
panel
1060 to bottom support panel 1068. For example, in one embodiment, adhesive is
applied to top support panels 1056, 1064, bottom support panels 1060, 1068,
top flaps
1080 and/or bottom flaps 1084 to connect the respective panels.
[00141] Referring to Figures 24-26, in one embodiment, at least one
of side panel 1022, 1024, 1026 and/or 1028 is movable between an initially
biased
first position and a second position having a curved or arcuate surface.
Referring
further to Figure 24, in a particular embodiment, blank 1020 includes two
movable
side panels, namely side panel 1024 and adjacent side panel 1026. Movable side
panel 1024 partially defines a void 1088 and movable side panel 1026,
connected to
movable side panel 1024 along fold line 1038, defines a remaining portion of
void
1088. It is apparent to those skilled in the art and guided by the teachings
herein
provided that any suitable number of voids 1088 may be formed in blank 1020 to
fomi. carton 1100 in a desired shape, as discussed below.
[00142] A heat-shrink patch 1090 is applied to interior surface 1021
of blank 1020 and connected to at least a portion of movable side panel 1024
and
movable side panel 1026 defining void 1088 to cover void 1088. In one
embodiment,
heat-shrink patch 1090 is a sheet or patch of shrinkable material that
includes
polyethylene, polypropylene, polyvinyl chloride, polyester, polyester glycol,
nylon
and/or oriented polystyrene. In an alternative embodiment, any suitable
shrinkable
material known to those skilled in the art and guided by the teachings herein
provided
is used to fabricate heat-shrink patch 1090. Further, in one embodiment, heat-
shrink
patch 1090 is transparent. Heat-shrink patch 1090 is movable from an initial,
first or
pre-shrunk configuration to a second or shrunk configuration having a shorter
width
and/or shorter length than in the pre-shrunk configuration. For example, heat-
shrink
patch 1090 is shrinkable to move from the pre-shrunk configuration to the
shrunk
configuration to move or urge movable side panel 1024 and/or 1026 to the
second
position. As heat-shrink patch 1090 shrinks, such as by applying suitable
heat, void
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1088 at least partially closes to move or urge movable side panels 1024 and
1026 with
respect to adjacent side panels 1022, 1024, 1026 and/or 1028.
[00143] In one embodiment, heat-shrink patch 1090 includes at least
one layer of a flexible, heat-shrinkable plastic film having an activated
shrink
temperature of at least about 140 F, and suitably about 150 F to about 195 F.
The
film has a gauge thickness of about 50 gauge to about 150 gauge. In one
embodiment, the film is formulated with a balanced shrink ratio, or balanced
orientation, such that the film shrinks an equal amount in a machine direction
or
orientation of the film and a cross-machine or transverse direction or
orientation of
the film. The balanced shrink ratio facilitates a uniform and consistent
shrink profile
and will not distort printed indicia and/or decorative patterns printed on the
film upon
the application of heat. Further, the fihn has a shrink factor of about 10% to
about
50% such that the film will shrink in the machine direction and the transverse
direction by about 10% to about 50%. In alternative embodiments, the film is
fornmlated with an unbalanced shrink ratio such that the film shrinks to a
greater
degree in one of the machine direction and the transverse direction. In a
particular
alternative embodiment, the film has a shrink factor in the machine direction
different
than a shrink factor in the transverse direction such that the film will
shrink in
opposite directions by a different percentage of an initial length. In another
alternative embodiment, heat-shrink patch 1090 includes a stretched film
coupled to
interior surface 1021 in a stretched configuration.
[00144] In a particular embodiment, heat-shrink patch 1090 is
coupled to movable side panel 1024 and movable side panel 1026 along a
boundary
line or area, generally shown by phantom line 1092 in Figure 24, which
substantially
surrounds and/or defines void 1088. Heat-shrink patch 1090 is coupled to
interior
surface 1021 of blank 1020 at movable side panel 1024 and movable side panel
1026
using any suitable coupling process, such as by applying an adhesive material
or an
adhesive layer to interior surface 1021 and/or a portion of heat-shrink patch
1090, and
applying a suitable pressure to couple heat-shrink patch 1090 to interior
surface 1021.
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[00145] As shown in Figure 25, carton 1100 is formed from blank
1020 by folding blank 1020 about fold lines 1036, 1038, 1040, 1048, 1058,
1062,
1066, 1070, 1082 and 1086. In one embodiment, an adhesive is applied to
portions of
blank 1020 to secure carton 1100 together. Top support panels 1056, 1064, and
top
flaps 1080 form top 1114. Bottom support panels 1060, 1068, and bottom flaps
1084
form bottom 1116. Carton 1100 extends a height 1118 measured between top 1114
and bottom 1116 of carton 1100 along a central longitudinal axis 1120
extending
through carton 1100. Once carton 1100 has been formed, and either before,
simultaneously with, or after a product is placed within carton 1100, heat-
shrink patch
1090 is heat-shrunk to form packaging assembly 1150, as shown in Figure 26.
[00146] Carton 1100 formed from blank 1020 is subjected to a
suitable heating process, as described above, to melt heat-shrink patch 1090
causing
heat-shrink patch 1090 to shrink without adversely affecting the coupling of
heat-
shrink patch 1090 to interior surface 1021 of blank 1020. As heat-shrink patch
1090
melts and shrinks, movable side panel 1024 and movable side panel 1026 are
moved
or urged together to at least partially close void 1088. After the heating
process, heat-
shrink patch 1090 cools and remains in the 'shrunk configuration to hold or
retain
carton 1100 in a substantially fixed second position. In this embodiment, with
heat-
shrink patch 1090 in the shrunk position, heat-shrink patch 1090 retains
movable side
panel 1024 and/or movable side panel 1026 in the second position. As shown in
Figure 26, movable side panel 1024 and/or movable side panel 1026 has an
arcuate or
curved surface in the second position.
[00147] In this embodiment, side panel 1024 and/or side panel 1026
is movable between a first position, as shown in Figure 25, and a second
position, as
shown in Figure 26. Accordingly, movement between the first position and the
second position varies or changes a cross-sectional area of carton 1100
defined
between side panels 1022, 1024, 1026 and 1028 along height 1118 of carton
1100. In
a particular embodiment, movable side panel 1024 and/Or movable side panel
1026 is
biased in the first position, as shown in Figure 25 using any suitable
mechanism, such
as a structure of carton 1100. In alternative embodiments, only a portion or
section of
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side panel 1022, 1024, 1026 and/or 1028 is movable between the first position
and the
second position.
[00148] In one embodiment, heat-shrink patch 1090 at least partially
seals carton 1100 to protect a product contained within the carton from
tampering, as
well as protecting the product from contamination. Heat-shrink patch 1090 can
be
used, for example, to replace bags or liners sometimes used within a container
for
sealing a product. Further, heat-shrink patch 1090 maintains a shape of carton
1100
for example, to facilitate displaying, stacking and/or arranging carton 1100
or a
plurality of cartons, and/or maintaining the carton shape.
[00149] Further, beat-shrink patch 1090 facilitates forming of carton
1100, and more specifically moving or urging moveable side panels 1024, 1026
from
the first position, as shown in Figure 25, to the second position to form
packaging
assembly 1150, as shown in Figure 26. As described above, cartons having
shapes
that are more complex than conventional rectangular cartons may be difficult
and
therefore costly to manufacture. As heat-shrink patch 1090 is heated and
shrinks,
heat-shrink patch 1090 moves, draws or urges movable side panels 1024, 1026 to
the
second position to form a shape of packaging assembly 1150. Heat-shrink patch
1090
holds side panels 1024, 1026 in the second position. In one embodiment wherein
movable side panels 1024, 1026 are biased to the first position, heat-shrink
patch
1090 moves the movable side panels to, and holds the movable side panels in,
the
second position against the bias. By moving and holding movable side panels
1024
and 1026 in the second position, heat-shrink patch 1090 forms a shape of
packaging
assembly 1150, and more specifically carton 1100, that may be otherwise
difficult and
costly to form.
[00150] Figures 27-29 show a packaging assembly according to an
alternative embodiment. Specifically, Figure 27 is a top plan view of blank of
sheet
material 1021. Figure 28 is a perspective view of carton 1101 formed from
blank
1021. Figure 29 is a perspective view of packaging assembly 1151 including
carton
1101 formed from blank 1021. Several element reference numbers shown in
Figures
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27-29 are used to indicate an element or a component that is identical to the
corresponding element or component described above and shown in Figures 24-26.
In this embodiment, an additional void is defined by blank 1021, as described
below.
[00151] Referring to Figure 27, in this embodiment, blank 1021 has
an interior surface 1022 and an opposing exterior surface. Blank 1021 includes
a
succession of side panels 1023, 1025, 1027 and 1029 that are connected
together by a
plurality of preformed, generally parallel, fold lines 1036, 1038 and 1040,
respectively. Side panels 1023, 1025, 1027 and 1029 extend from an adjacent
side
panel along respective fold lines 1036, 1038 and 1040. Side panel 1023, 1025,
1027
and/or 1029 is movable between a first position and a second position. Each
movable
side panel 1023, 1025, 1027 and/or 1029 defines at least a portion of a void
at a first
fold line and at least a portion of a void at a second fold line opposing the
first fold
line. As shown in Figures 27-29, blank 1021 includes three movable side
panels,
namely side panel 1025, side panel 1027 and side panel 1029. Movable side
panel
1025 defines a portion of void 1088 along fold line 1038. Movable side panel
1027
defines a remaining portion of void 1088 on a first side edge of movable side
panel
1027 along fold line 1038. Further, an opposing second side edge of movable
side
panel 1027 defines a portion of a second void 1094 along fold line 1040.
Movable
side panel 1029 defines a remaining portion of void 1094 along fold line 1040.
[00152] Heat-shrink patch 1091 covers void 1088 and void 1094.
Heat-shrink patch 1091 is coupled to movable side panel 1025 and movable side
panel 1027 along boundary line or area, generally shown by phantom line 1092
in
Figure 27, which substantially surrounds and/or defines void 1088. Further,
heat-
shrink patch 1091 is coupled to movable side panel 1027 and movable side panel
1029 along a boundary line or area, generally shown by phantom line 1096 in
Figure
27, which substantially sunounds and/or defines void 1094. In an alternative
embodiment, heat-shrink patch 1091 is coupled to movable side panel 1025 and
movable side panel 1027 along boundary area 1092 to cover first void 1088 and
a
second heat-shrink patch (not shown) is coupled to movable side panel 1027 and
movable side panel 1029 along boundary area 1096 to cover second void 1094.
Heat-
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shrink patch 1091 is coupled to interior surface 1022 of blank 1021 at movable
side
panel 1025, movable side panel 1027 and movable side panel 1029 using any
suitable
coupling process.
[00153] In this embodiment, carton 1101 formed from blank 1021, as
shown in Figure 28, is subjected to a suitable heating process to initiating
melting and
shrinkage of heat-shrink patch 1091 without adversely affecting the coupling
of heat-
shrink patch 1091 to interior surface 1022 of blank 1021. As heat-shrink patch
1091
melts and shrinks, movable side panel 1025 and movable side panel 1027 are
moved
or urged together to at least partially close void 1088, and movable side
panel 1027
and movable side panel 1029 are moved or urged together to at least partially
close
void 1094. After the heating process, heat-shrink patch 1091 cools and remains
in the
shrunk configuration to hold or retain carton 1101 in a substantially fixed
second
position. With heat-shrink patch 1091 in the shrunk position, heat-shrink
patch 1091
retains movable side panel 1025, movable side panel 1027 and/or movable side
panel
1029 in the second position. As shown in Figure 29, movable side panel 1025,
movable side panel 1027 and/or movable side panel 1029 has an arcuate or
curved
surface in the second position.
[00154] Figures 30-32 show a packaging assembly according to one
embodiment. Specifically, Figure 30 is a top plan view of a blank of sheet
material
1200. Figure 31 is a perspective view of a carton 1266 fomied from blank 1200
shown in Figure 30. Figure 32 is a perspective view of a packaging assembly
1299
including carton 1266 shown in Figure 31.
[00155] As shown in Figure 30, in one embodiment, blank 1200 has
an interior surface 1201 and an opposing exterior surface. Blank 1200 includes
a
succession of four side panels 1202, 1204, 1206 and 1208 that are connected
together
by a plurality of preformed, generally parallel, fold lines 1210, 1212 and
1214,
respectively. Each side panel 1202, 1204, 1206 and 1208 extends from an
adjacent
side panel along respective fold lines 1210, 1212 and 1214. A side panel flap
1216
extends from an end portion of side panel 1202 along fold line 1218 to secure
side
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panel flap 1216 to side panel 1208 to form carton 1266, as shown in Figure 31.
In an
alternative embodiment, a side panel flap (not shown) extends from an end
portion
1220 of side panel 1208 to secure the side panel flap to side panel 1202 to
form carton
1266. Each side panel 1202, 1204, 1206 and 1208 extends a height measured
between a bottom end 1224 and a top end 1226.
[00156] A top support panel 1228 extends from side panel 1202
and/or side panel 1206 at top end 1226 along a fold line 1230. Similarly, a
bottom
support panel 1232 extends from side panel 1202 and/or side panel 1206 at
bottom
end 1224 along a fold line 1234. In one embodiment, a top flap 1236 extends
from
side panel 1204 and/or side panel 1208 along a fold line 1238 and/or a bottom
flap
1240 extends from side panel 1204 and/or side panel 1208 at bottom end 1224
along a
fold line 1242. In one embodiment, adhesive is applied to top support panels
1228,
bottom support panels 1232, top flaps 1236 and/or bottom flaps 1240 to connect
the
respective panels. In an alternative embodiment, one top support panel 1228
includes
an extension or tab (not shown) that extends therefrom for engagement with a
slot
(not shown) formed within the other top support panel 1228 to secure top
support
panels 1228 together to form a top 1286 of carton 1266, as shown in Figure 31.
Similarly, one bottom support panels 1232 includes an extension or tab (not
shown)
that extends therefrom for engagement with a slot (not shown) within the other
bottom support panel 1232 to secure bottom support panels 1232 together to
form a
bottom 1288 of carton 1266, as shown in Figure 31. In another alternative
embodiment, top support panels 1228 and bottom support panels 1232 are
connected
together using hook-and-loop fasteners (not shown), as described above. It is
apparent to those skilled in the art and guided by the teachings herein
provided that
any suitable connecting mechanism can be used to connected top support panels
1228
together and/or bottom support panels 1232 together.
[00157] Referring to Figures 30-32, side panel 1202, 1204, 1206
and/or 1208, or at least a portion thereof, is movable between an initially
biased first
position and a second position having an arcuate or curved surface. As shown
in
Figure 30, in one embodiment, each side panel 1202, 1204, 1206 and 1208
includes
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an upper panel portion 1250, a lower panel portion 1252 and an intermediate
panel
portion 1254 extending between and connecting upper panel portion 1250 and
lower
panel portion 1252. Intermediate panel portion 1254 is connected to upper
panel
portion 1250 along a fold line 1256 and to lower panel portion 1252 along a
fold line
1260. In this embodiment, intermediate panel portion 1254 is movable from the
initially biased first position to the second position having an arcuate or
curved
surface. As shown in Figure 30, a void is defined between adjacent
intermediate
panel portions 1254 to accommodate changing a cross-sectional area of carton
1266,
as described below.
[00158] As shown in Figure 30, movable side panel 1202 partially
defines a first void 1264 along a first side edge corresponding to fold line
1218 and
partially defines a second void 1266 along a second side edge corresponding to
fold
line 1210. Side panel flap 1216, connected to movable side panel 1202 along
fold
line 1218, defines a remaining portion of first void 1264. Movable side panel
1204,
connected to movable side panel 1202 along fold line 1210, defines a remaining
portion of second void 1266 and partially defines a third void 1268 along a
second
side edge corresponding to fold line 1212. Movable side panel 1206, connected
to
movable side panel 1204 along fold line 1212, defines a remaining portion of
third
void 1268 and partially defines a fourth void 1270 along a second side edge
corresponding to fold line 1214. Movable side panel 1208, connected to movable
side
panel 1206 along fold line 1214, defines a remaining portion of fourth void
1270. In
one embodiment, moveable side panel 1208 further defines an arcuate portion
that
generally corresponds to the remaining portion of first void 1264 defined by
side
panel flap 1216 when carton 1266 is assembled.
[00159] A heat-shrink patch 1272 is coupled to interior surface 1201
of blank 1200 to cover each void 1264, 1266, 1268 and 1270. In a particular
embodiment, heat-shrink patch 1272 is coupled to side panel flap 1216, movable
side
panel 1202, movable side panel 1204, movable side panel 1206 and movable side
panel 1208 along a boundary line or area, generally shown by phantom line
1276,
which substantially surrounds and/or define voids 1264, 1266, 1268 and 1270.
Heat-
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shrink patch 1272 is coupled to interior surface 1201 of blank 1200 at side
panel flap
1216 and movable intermediate panel portions 1254 of side panels 1202, 1204,
1206
and 1208, using any suitable coupling process, such as by applying an adhesive
material or an adhesive layer to interior surface 1201 within boundary area
1276
and/or a portion of heat-shrink patch 1272, and applying a suitable pressure
to couple
heat-shrink patch 1272 to interior surface 1201. In an alternative embodiment,
a heat-
shrink layer, generally shown by phantom line 1277 in Figure 30, is applied to
the
exterior surface of blank 1200, opposing interior surface 1201.
[00160] As shown in Figure 31, carton 1266 is formed from blank
1200 by folding blank 1200 about fold lines 1210, 1212, 1214, 1218, 1230,
1234,
1238 and 1242. In one embodiment, an adhesive may be applied to portions of
blank
1200 to secure carton 1266 together. Top support panels 1228 and top flaps
1236
form top 1286 of carton 1266, and bottom support panels 1232 and bottom flaps
1240
form bottom 1288 of carton 1266. Carton 1266 extends a height 1290 measured
between top 1286 and bottom 1288 of carton 1266 along a central longitudinal
axis
1292 extending through carton 1266. As shown in Figure 31, in a first or pre-
shrunk
configuration, carton 1266 has a generally rectangular cross-sectional shape.
Once
carton 1266 has been formed, and either before, simultaneously with, or after
a
product is placed within carton 1266, heat-shrink patch 1272 is heat-shrunk to
form
packaging assembly 1299, as shown in Figure 32.
[00161] In one embodiment, carton 1266 formed from blank 1200 is
subjected to a suitable heating process, as described above, to melt heat-
shrink patch
1272 causing heat-shrink patch 1272 to shrink without adversely affecting the
coupling of heat-shrink patch 1272 to interior surface 1201. As heat-shrink
patch
1272 melts and shrinks, intermediate panel portion 1254 of side panel flap
1216 and
intermediate panel portion 1254 of movable side panels 1202, 1204, 1206 and
1208
are moved or urged to the second position to at least partially close
corresponding
voids 1264, 1266, 1268 and 1270. After the heating process, heat-shrink patch
1272
cools and remains in the shrunk configuration to hold or retain carton 1266 in
a
substantially fixed second position. In this embodiment, with heat-shrink
patch 1272
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in the shrunk position, heat-shrink patch 1272 retains intermediate panel
portion 1254
of movable side panel 1202, 1204, 1206 and/or 1208 in the second position. As
shown in Figure 32, intermediate panel portion 1254 has an arcuate or curved
surface
in the second position.
[00162] Accordingly, movement between the first position and the
second position varies or changes a cross-sectional area of carton 1266
defined
between side panels 1202, 1204, 1206 and 1208 along height 1290 of carton
1266. In
a particular embodiment, each movable side panel 1202, 1204, 1206 and 1208 is
biased in the first position, as shown in Figure 31. In this embodiment,
movable side
panel 1202, 1204, 1206 and/or 1208 may be biased in the first position using
any
suitable mechanism, such as a structure of carton 1266 biasing movable side
panels
1202, 1204, 1206 and/or 1208. In alternative embodiments, only a portion or
section
of side panel 1202, 1204, 1206 and/or 1208 is movable between the first
position and
the second position, such as intermediate panel portions 1254.
[00163] Figures 33-35 show a packaging assembly according to one
embodiment. Specifically, Figure 33 is a top plan view of a blank of sheet
material
1300. Figure 34 is a perspective view a carton 1400 formed from blank 1300
shown
in Figure 33. Figure 35 is a perspective view of a packaging assembly 1450
including
carton 1400 shown in Figure 34.
[00164] Referring to Figure 33, in one embodiment, blank 1300 has
an interior surface 1301 and an opposing exterior surface. Blank 1300 includes
a
succession of six side panels 1302, 1304, 1306, 1308, 1310 and 1312 that are
connected together by a plurality of preformed, generally parallel, fold lines
1314,
1316, 1318, 1320 and 1322, respectively. Each side panel 1302, 1304, 1306,
1308,
1310 and 1312 extends front an adjacent side panel along respective fold lines
1314,
1316, 1318, 1320 and 1322. A side panel flap 1324 extends from an end portion
of
side panel 1312 along fold line 1326 to secure side panel flap 1324 to side
panel 1302
to form carton 1400, as shown in Figure 34. In an alternative embodiment, a
side
panel flap (not shown) extends from edge 1328 of side panel 1302 to secure the
side
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panel flap to side panel 1312 to form carton 1400. Each side panel 1302, 1304,
1306,
1308, 1310 and 1312 extends a height measured between a bottom end 1330 and a
top
end 1332 of blank 1300.
[00165] A top support panel 1334 extends from side panel 1302 at
top end 1332 along a fold line 1336 and a bottom support panel 1338 extends
from
side panel 1302 at bottom end 1330 along a fold line 1340. Additionally, a top
support panel 1342 extends from side panel 1308 at top end 1332 along a fold
line
1344 and a bottom panel 1346 extends from side panel 1308 at bottom end 1330
along a fold line 1348. Top support panel 1342 and bottom support panel 1346
include two securement tabs 1350 and 1352 extending therefrom along respective
fold
lines 1354 and 1356 for facilitating securing top support panel 1342 and
bottom
support panel 1346 to side panels 1302, 1304, 1306, 1308, 1310 and 1312 to
form a
top 1414 and a bottom 1416 of carton 1400, respectively, as shown in Figure
34. In
one embodiment, a tab 1358 extends from side panel 1306 and/or side panel 1310
at
top end 1332 and/or bottom end 1330 along a fold line 1359 for mating with
securement tabs 1350 or 1352 to form carton 1400. In an alternative
embodiment,
any suitable connecting mechanism is used to secure top support panels 1334,
1342
and/or bottom support panels 1338 and/or 1346 to side panels 1302, 1304, 1306,
1308, 1310 and/or 1312 to form carton 1400.
[00166] Referring to Figures 33-35, side panel 1302, 1304, 1306,
1308, 1310 and/or 1312, or at least a portion thereof, is movable between an
initially
biased first position and a second position having an arcuate or curved
surface. As
shown in Figure 33, each side panel 1302, 1304, 1306, 1308, 1310 and 1312
includes
an upper panel portion 1360, a lower panel portion 1362 and an intermediate
panel
portion 1364 extending between and connecting upper panel portion 1360 and
lower
panel portion 1362. Intermediate panel portion 1364 is connected to upper
panel
portion 1360 along a fold line 1366 and to lower panel portion 1362 along a
fold line
1368. In this embodiment, intermediate panel portion 1364 is movable from the
initially biased first position to the second position having an arcuate or
curved
surface. As shown in Figure 33, a void is defined between adjacent
intermediate
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panel portions 1364 to accommodate changing a cross-sectional area of carton
1400,
as described below.
[00167] Referring further to Figure 33, in one embodiment,
intermediate panel portions 1364 of side panels 1302, 1304, 1306, 1308, 1310
and
1312 are movable between the initially biased first position and the second
position.
In this embodiment, movable side panel 1302 defines an arcuate portion along
edge
1328 that generally corresponds to a portion of void 1380 when carton 1400 is
assembled. Movable side panel 1302 partially defines a first void 1370 along a
second side edge corresponding to fold line 1314. Movable side panel 1304,
connected to movable side panel 1302 along fold line 1314, defines a remaining
portion of first void 1370 and partially defines a second void 1372 along a
second side
edge corresponding to fold line 1316. Movable side panel 1306, connected to
movable side panel 1304 along fold line 1316, defines a remaining portion of
second
void 1372 and partially defines a third void 1374 along a second side edge
corresponding to fold line 1318. Movable side panel 1308, connected to movable
side
panel 1306 along fold line 1318, defines a remaining portion of third void
1374 and
partially defines a fourth void 1376 along a second side edge corresponding to
fold
line 1320. Movable side panel 1310, connected to movable side panel 1308 along
fold line 1320, defines a remaining portion of fourth void 1376 and partially
defines a
fifth void 1378 along a second side edge corresponding to fold line 1322.
Movable
side panel 1312, connected to movable side panel 1310 along fold line 1322,
defines a
remaining portion of fifth void 1378 and partially defines a sixth void 1380
along a
second side edge corresponding to fold line 1326. Side panel flap 1324,
connected to
movable side panel 1312 along fold line 1326, defines a remaining portion of
sixth
void 1380.
[00168] A heat-shrink patch 1382 is coupled to interior surface 1301
of blank 1300 to cover each void 1370, 1372, 1374, 1376, 1378 and 1380. In a
particular embodiment, heat-shrink patch 1382 is coupled to each movable side
panel
1302, 1304, 1306, 1308, 1310 and 1312, and movable side panel flap 1324, along
a
boundary line or area, generally shown by phantom line 1384, which
substantially
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surrounds and/or defines voids 1370, 1372, 1374, 1376, 1378 and 1380. Heat-
shrink
patch 1382 is coupled to interior surface 1301 of blank 1300 at each movable
side
panel 1302, 1304, 1306, 1308, 1310 and 1312, and movable side panel flap 1324,
using any suitable coupling process, such as by applying an adhesive material
or an
adhesive layer to interior surface 1301 and/or a portion of heat-shrink patch
1382, and
applying a suitable pressure to couple heat-shrink patch 1382 to interior
surface 1301.
[00169] As shown in Figure 34, carton 1400 is formed from blank
1300 by folding blank 1300 about fold lines 1314, 1316, 1318, 1320, 1322,
1326,
1336, 1340, 1344, 1348, 1354, 1356 and 1359. In one embodiment, an adhesive is
applied to portions of blank 1300 to secure carton 1300 together. Top support
panels
1334, 1342 form a top 1414 of carton 1400, and bottom support panels 1338,
1346
form a bottom 1416 of carton 1400. Carton 1400 extends a height 1418 measured
between top 1414 and bottom 1416 of carton 1400 along a central longitudinal
axis
1420 extending through carton 1400. As shown in Figure 34, in a first or pre-
shrunk
configuration, carton 1400 includes a generally hexagonal cross-sectional
shape
extending generally perpendicularly to central longitudinal axis 1420. Once
carton
1400 has been formed, and either before, simultaneously with, or after a
product is
placed within carton 1400, heat-shrink patch 1382 is heat-shrunk to form
packaging
assembly 1450, as shown in Figure 35.
[00170] In one embodiment, carton 1400 is subjected to a suitable
heating process, as described above, to melt heat-shrink patch 1382 causing
heat-
shrink patch 1382 to shrink without adversely affecting the coupling of heat-
shrink
patch 1382 to interior surface 1301. As heat-shrink patch 1382 melts and
shrinks,
movable intermediate panel portion 1364 of side panel 1302, 1304, 1306, 1308,
1310
and/or 1312, and movable side panel flap 1324, are moved or urged to the
second
position to at least partially close corresponding void 1370, 1372, 1374,
1376, 1378,
and/or 1380. After the heating process, heat-shrink patch 1382 cools and
remains in
the shrunk configuration to hold or retain carton 1400 in a substantially
fixed second
position. In this embodiment, with heat-shrink patch 1382 in the shrunk
position,
heat-shrink patch 1382 retains movable intermediate panel portion 1364 of side
panel
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1302, 1304, 1306, 1308, 1310 and/or 1312 in the second position. As shown in
Figure 35, movable intermediate panel portion 1364 an arcuate or curved
surface in
the second position.
[00171] Referring further to Figures 34 and 35, at least a portion of
intermediate panel portion 1364 extends between fold line 1366 and fold line
1368
such that intermediate portion 1364 is movable between the first position and
the
second position. Accordingly, movement between the first position and the
second
position varies or changes a cross-sectional area of carton 1400 defined
between side
panels 1302, 1304, 1306, 1308, 1310 and 1312 along height 1418 of carton 1400.
In a
particular embodiment, each movable side panel 1302, 1304, 1306, 1308, 1310
and
1312 including movable intermediate panel portion 1364 is biased in the first
position,
as shown in Figure 34. Movable side panel 1302, 1304, 1306, 1308, 1310 and/or
1312 is biased in the first position using any suitable mechanism, such as a
structure
of carton 1400 biasing movable side panels 1302, 1304, 1306, 1308, 1310 and/or
1312. In this embodiment, a portion of upper panel portion 1360 and/or a
portion of
lower panel portion 1362 may also move with intermediate portion 1364,
depending
upon whether the corresponding void extends past fold line 1366 towards top
end
1332 and/or past fold line 1368 towards bottom end 1330.
[00172] Figures 36-38 show a packaging assembly according to one
embodiment. Specifically, Figure 36 is a top plan view of a blank of sheet
material
1500. Figure 37 is a perspective view a carton 1600 formed from blank 1500
shown
in Figure 36. Figure 38 is a perspective view of a packaging assembly 1650
including
carton 1600 shown in Figure 37.
[00173] Referring to Figure 36, in one embodiment, blank 1500 has
an interior surface 1501 and an opposing exterior surface. Blank 1500 include
a first
series 1502 of three successive side panels 1504, 1506, 1508, and a second
series
1510 of three successive side panels 1512, 1514 and 1516. Side panels 1504,
1506
and 1508 are connected together by preformed fold lines 1518 and 1520, and
side
panels 1512, 1514 and 1516 are similarly connected together by preformed fold
lines
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1522 and 1524, respectively. First series 1502 is coupled to second series
1510 by a
bottom support panel 1526. In this embodiment, side panel 1506 is connected to
bottom support panel 1526 along a fold line 1528 and side panel 1514 is
connected to
bottom support panel 1526 along a fold line 1529, generally opposing fold line
1528.
Further, a fold line 1530 and a generally opposing and parallel fold line 1531
are also
fornled in bottom panel 1526, as shown in Figure 36. Each side panel 1504,
1506 and
1508 extends a height measured between a bottom end 1552 and a top end 1554
and
each side panel 1512, 1514 and 1516 extends a height measured between a bottom
end 1556 and a top end 1558. Side panel 1504 is coupled to side panel 1512,
and side
panel 1508 is coupled to side panel 1516 to fon-n carton 1600, as shown in
Figure 37.
[00174] Blank 1500 also includes a first top support panel 1532
connected to side panel 1514 along fold line 1534 and extends outwardly
therefrom.
First top support panel 1532 includes a tab 1536. An opposing second top
support
panel 1538 is connected to side panel 1506 along fold line 1540 and extends
outwardly therefore. Second top support panel 1538 forms or defines a slot
1542.
With first top support panel 1532 folded with respect to side panel 1514 and
second
top support panel 1538 folded with respect to side panel 1506, tab 1536
engages with
slot 1542 to secure first top support panel 1532 to second top support panel
1538 to
form carton 1600, as shown in Figure 37. In an alternative embodiment, top
support
panel 1532 and top support panel 1538 are connected using any suitable
connecting
mechanism. For example, an adhesive is applied to portions of top support
panel
1532 and/or top support panel 1538. As shown in Figure 36, in one embodiment,
a
first top panel 1544 is connected to side panel 1504 along a fold line 1546
and a
second top panel 1548 is connected to side panel 1508 along a fold line 1550
to
provide additional support to the top of carton 1600.
[00175] As shown in Figure 36, in one embodiment, at least a
portion of each side panel 1504, 1506, 1508, 1512, 1514 and 1516 is movable
between an initially biased first position and a second position. As shown in
Figure
36, a void is at least partially defined between adjacent side panels to
accommodate
changing a cross-sectional area of carton 1600. In this embodiment, movable
side
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panel 1504 defines an arcuate portion along edge 1568 and partially defines a
first
void 1560 along a second side edge generally corresponding to fold line 1518.
Movable side panel 1506, connected to movable side panel 1504 along fold line
1518,
defines a remaining portion of first void 1560 and partially defines a second
void
1562 along a second side edge generally corresponding to fold line 1520.
Movable
side panel 1508, connected to movable side panel 1506 along fold line 1520,
defines a
remaining portion of second void 1562 and defines an arcuate portion along
edge
1570.
[00176] Similarly, movable side panel 1512 defines an arcuate
portion along edge 1572 that generally corresponds with the portion of first
void 1560
defined by movable side panel 1504 with carton 1600 in the assembly
configuration
and partially defines third void 1564 along a second side edge generally
corresponding to fold line 1522. Movable side panel 1514, connected to movable
side
panel 1512 along fold line 1522, defines a remaining portion of third void
1564 and
partially defines fourth void 1566 along a second side edge generally
corresponding to
fold line 1524. Movable side panel 1516, connected to movable side panel 1514
along fold line 1524, defines a remaining portion of fourth void 1566 and
defines an
arcuate portion along edge 1574 that generally corresponds with the portion of
second
void 1562 defined by movable side panel 1508 with carton 1600 in assembly
configuration.
[00177] A first heat-shrink patch 1576 is coupled to interior surface
1501 of blank 1500 to cover each void 1560 and 1562. In a particular
embodiment,
heat-shrink patch 1576 is coupled to each movable side panel 1504, 1506 and
1508 at
least along a boundary line or area, generally shown as phantom line 1578,
which
substantially surrounds and/or defines voids 1560 and 1562. Heat-shrink patch
1576
is coupled to interior surface 1501 at each movable side panel 1504, 1506 and
1508
using any suitable coupling process, such as by applying an adhesive material
or an
adhesive layer to interior surface 1501 and/or a portion of heat-shrink patch
1576, and
applying a suitable pressure to couple heat-shrink patch 1576 to interior
surface 1501.
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[00178] A second heat-shrink patch 1580 is coupled to interior
surface 1501 of blank 1500 to cover each void 1564 and 1566. In a particular
embodiment, heat-shrink patch 1580 is coupled to each movable side panel 1512,
1514 and 1516 at least along a boundary line or area, generally shown by
phantom
line 1582, which substantially surrounds and/or defines voids 1564 and 1566.
Heat-
shrink patch 1580 is coupled to interior surface 1501 at each movable side
panel
1512, 1514 and 1516 using any suitable coupling process, such as by applying
an
adhesive material or an adhesive layer to interior surface 1501 and/or a
portion of
heat-shrink patch 1580, and applying a suitable pressure to couple heat-shrink
patch
1580 to interior surface 1501.
[00179] As shown in Figure 37, carton 1600 can be formed from
blank 1500 by folding blank 1500 about fold lines 1518, 1520, 1522, 1524,
1528,
1529, 1530, 1531, 1534, 1540, 1546 and 1550. In one embodiment, an adhesive
may
be applied to portions of blank 1500 to secure carton 1600 together. Side
panel 1504
is connected to side panel 1512 to form side 1602, and side panel 1508 is
connected to
side panel 1516 to form side 1606. Side panel 1506 forms side 1604 and side
panel
1514 forms side 1608 of carton 1600, as shown in Figure 37. Bottom support
panel
1526 forms bottom 1614 of carton 1600. Top support panel 1532 connected to top
support panel 1538, and top panels 1544 and 1548, form top 1616 of carton
1600.
Carton 1600 extends a height 1618 measured between bottom 1614 and top 1616 of
carton 1600 along a central longitudinal axis 1620 extending through carton
1600. In
a first or pre-shrunk configuration, carton 1600 includes sides 1602, 1604,
1606 and
1608 in a pre-shrunk, first position. In one embodiment, the structure of
carton 1600
biases sides 1602, 1604, 1606 and 1608 in the first position. Once carton 1600
has
been fomied, and either before, simultaneously with, or after a product is
placed
within carton 1600, heat-shrink patches 1576 and 1580 are heat-shrunk to form
a
packaging assembly 1650, as shown in Figure 38.
[00180] In this embodiment, carton 1600 formed from blank 1500 is
subjected to a suitable heating process, as described above, to melt heat-
shrink
patches 1576 and 1580 causing heat-shrink patches 1576 and 1580 to shrink
without
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adversely affecting the coupling of heat-shrink patches 1576 and 1580 to
interior
surface 1501. As heat-shrink patches 1576 and 1580 melt and shrink, movable
side
panels 1504, 1506 and 1508, and movable side panels 1512, 1514 and 1516,
respectively, are moved or urged together to at least partially close
corresponding
void 1560, 1562, 1564 and 1566. After the heating process, heat-shrink patches
1576
and 1580 cool and remain in the shrunk configuration to hold or retain carton
1600 in
a substantially fixed second position. In this embodiment, with heat-shrink
patches
1576 and 1580 in the shrunk position, heat-shrink patches 1576 and 1580 retain
movable side panels 1504, 1506, 1508, 1512, 1514 and/or 1516 in the second
position.
[00181] Accordingly, movement between the first position and the
second position varies or changes a cross-sectional area of carton 1600
defined
between sides 1602, 1604, 1606 and 1608 along the height of carton 1600. In
alternative embodiments, only a portion or section of side 1602, 1604, 1606
and/or
1608 is movable between the first position and the second position.
[00182] Figures 39-41 show a packaging assembly according to one
embodiment. Specifically, Figure 39 is a top plan view of a blank of sheet
material
1700. Figure 40 is a perspective view a carton 1800 formed from blank 1700
shown
in Figure 39. Figure 41 is a perspective view of a packaging assembly 1850
including
carton 1800 shown in Figure 40.
[00183] Referring to Figure 39, in one embodiment, blank 1700 has
an interior surface 1701 and an opposing exterior surface. Blank 1700 includes
a
succession of four side panels 1702, 1704, 1706 and 1708 that are connected
together
by a plurality of preformed, generally parallel, fold lines 1710, 1712 and
1714,
respectively. Side panels 1702, 1704, 1706 and 1708 extend from an adjacent
side
panel along respective fold lines 1710, 1712 and 1714. A side panel flap 1716
extends from side panel 1702 along an end fold line 1718 to secure side panel
flap
1716 to side panel 1708 to form carton 1800. In an alternative embodiment, a
side
panel flap (not shown) extends from side panel 1708 along an end fold line
(not
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shown) formed along an edge 1720 to secure the side panel flap to side panel
1702 to
form carton 1800.
[00184] Each side panel 1702, 1704, 1706 and 1708 extends a height
measured between a bottom end 1722 and a top end 1724. As shown in Figure 39,
a
top support panel 1726 extends from side panel 1702 at top end 1724 along a
fold line
1728. A bottom support panel 1730 extends from side panel 1702 at bottom end
1722
along a fold line 1732. Additionally, a top support panel 1734 extends from
side
panel 1706 at top end 1724 along a fold line 1736 and a bottom support panel
1738
extends from side panel 1706 at bottom end 1722 along a fold line 1740. Top
support
panel 1726 is connected to top support panel 1734 to form a top 1814 of carton
1800.
Bottom support panel 1730 is connected to bottom support panel 1738 to form a
bottom 1816 of carton 1800. It is apparent to those skilled in the art and
guided by
the teachings herein provided that top support panels 1726, 1734 and/or bottom
support panels 1730, 1738 can be connected using any suitable connection
mechanism. For example, in one embodiment, adhesive is applied to top support
panels 1726, 1734 and/or bottom support panels 1730, 1738.
[00185] In one embodiment, a top panel 1742 is connected to side
panel 1704 along a fold line 1744 and a top panel 1746 is connected to side
panel
1708 along a fold line 1748 to provide additional support to top 1814 of
carton 1800.
Further, a bottom panel 1750 is connected to side panel 1704 along a fold line
1752
and a bottom panel 1754 is connected to side panel 1708 along a fold line 1756
to
provide additional support to the bottom of carton 1800.
[00186] As shown in Figure 39, at least a portion of side panel 1702,
1704, 1706 and/or 1708, at least a portion of top support panels 1726 and/or
1734,
and/or at least a portion of bottom support panels 1730 and/or 1738, is
movable
between an initially biased first position and a second position. In one
embodiment,
side panels 1702 and 1706, top support panels 1726 and 1734 and bottom support
panels 1730 and 1738 are movable. In this embodiment, movable side panel 1702
partially defines a first void 1760 along fold line 1728 and partially defines
a second
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void 1762 along fold line 1732. Movable top support panel 1726, connected to
movable side panel 1702 along fold line 1728, defines a remaining portion of
first
void 1760 and movable bottom support panel 1730, connected to movable side
panel
1702 along fold line 1732, defines a remaining portion of second void 1762.
Movable
side panel 1706 partially defines a third void 1764 along fold line 1736 and
partially
defines a fourth void 1766 along fold line 1740. Movable top support panel
1734,
connected to movable side panel 1706 along fold line 1736, defines a remaining
portion of third void 1764 and movable bottom support panel 1738, connected to
movable side panel 1704 along fold line 1740, defines a remaining portion of
fourth
void 1766.
[00187] A first heat-shrink patch 1770 is coupled to interior surface
1701 of blank 1700 to cover void 1760 and void 1762. In a particular
embodiment,
heat-shrink patch 1770 is coupled to movable side panel 1702, movable top
support
panel 1726 and movable bottom support panel 1730 at least along a boundary
line or
area, generally shown by phantom line 1772, which substantially surrounds
and/or
defines voids 1760 and 1762. Heat-shrink patch 1770 is coupled to interior
surface
1701 at movable top support panel 1726 and movable bottom support panel 1730
using any suitable coupling process, such as by applying an adhesive material
or an
adhesive layer to interior surface 1701 and/or a portion of heat-shrink patch
1770, and
applying a suitable pressure to couple heat-shrink patch 1770 to interior
surface 1701.
[00188] A second heat-shrink patch 1774 is coupled to interior
surface 1701 of blank 1700 to cover void 1764 and void 1766. In a particular
embodiment, heat-shrink patch 1774 is coupled to movable side panel 1706,
movable
top support panel 1734 and movable bottom support panel 1738 at least along a
boundary line or area, generally shown by phantom line 1776, which
substantially
surrounds and/or defines voids 1764 and 1766. Heat-shrink patch 1774 is
coupled to
interior surface 1701 at movable side panel 1706, movable top support panel
1734 and
movable bottom support panel 1738 using any suitable coupling process, such as
by
applying an adhesive material or an adhesive layer to interior surface 1701
and/or a
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portion of heat-shrink patch 1770, and applying a suitable pressure to couple
heat-
shrink patch 1770 to interior surface 1701.
[00189] As shown in Figure 40, carton 1800 is formed from blank
1700 by folding blank 1700 about fold lines 1710, 1712, 1714, 1718, 1728,
1732,
1736, 1740, 1744, 1748, 1752 and 1756. In one embodiment, an adhesive may be
applied to portions of blank 1700 to secure carton 1800 together. Top support
panel
1726 is connected to top support panel 1734 to form top 1814 of carton 1800.
Bottom
support panel 1730 is connected to bottom support panel 1738 to form bottom
1816 of
carton 1800. Carton 1800 extends a height 1818 measured between top 1814 and
bottom 1816 of carton 1800 along a central longitudinal axis 1820 extending
through
carton 1800. As shown in Figure 40, in a first or pre-shrunk configuration,
carton
1800 includes side panels 1702, 1704, 1706 and 1708 in a pre-shrunk, first
position.
In one embodiment, the structure of carton 1800 biases side panels 1702, 1704,
1706
and 1708 in first position. Once carton 1800 has been formed, and either
before,
simultaneously with, or after a product is placed within carton 1800, heat-
shrink
patches 1770 and 1774 are heat-shrunk to form packaging assembly 1850, as
shown
in Figure 41.
[00190] Carton 1800 formed from blank 1700 is subjected to a
suitable heating process, as described above, to melt heat-shrink patches 1770
and
1774 causing heat-shrink patches 1770 and 1774 to shrink without adversely
affecting
the coupling of heat-shrink patches 1770 and 1774 to interior surface 1701. As
heat-
shrink patch 1770 melts and shrinks, movable side panel 1702, movable top
support
panel 1726 and movable bottom support panel 1730 are moved or urged together
to at
least partially close corresponding voids 1760 and 1762. Similarly, as heat-
shrink
patch 1774 melts and shrinks, movable side panel 1706, movable top support
panel
1734 and movable bottom support panel 1738 are moved or urged together to at
least
partially close corresponding voids 1764 and 1766. After the heating process,
heat-
shrink patches 1770 and 1774 cool and remain in the shrunk configuration to
hold or
retain carton 1800 in a substantially fixed second position.
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[00191] In this embodiment, with heat-shrink patches 1770 and 1774
in the shrunk position, heat-shrink patch 1770 retains movable side panel
1702,
movable top support panel 1726 and movable bottom support panel 1730 in the
second position, and heat-shrink patch 1774 retains movable side panel 1706,
movable top support panel 1734 and movable bottom support panel 1738 in the
second position. As shown in Figure 41, at least a portion of movable side
panels
1702 and/or 1706, at least a portion of movable top support panel 1726 and/or
1734,
and/or at least a portion of movable bottom support panels 1730 and/or 1738
have an
arcuate or curved surface in the second position.
[00192] Referring further to Figures 40 and 41, at least a portion of
side panel 1702, 1704, 1706 and 1708 is movable between a first position, as
shown
in Figure 40, and a second position, as shown in Figure 41. Accordingly,
movement
between the first position and the second position varies or changes a cross-
sectional
area of carton 1800 defined between sides 1802, 1804, 1806 and 1808 along
height
1818 of carton 1800. In a particular embodiment, each movable side panel 1702,
1704, 1706 and/or 1708 is biased in the first position, as shown in Figure 40.
In this
embodiment, movable side panels 1702, 1704, 1706 and/or 1708 are biased in the
first
position using any suitable mechanism, such as a structure of carton 1800
biasing
movable side panels 1702, 1704, 1706 and/or 1708.
[00193] As shown in Figure 42, in one embodiment, a method 1900
for applying a heat-shrink patch to a carton for forming a shape of the carton
is
applied to any suitable carton including, without limitation, the cartons
described
above. It is apparent to those skilled in the art and guided by the teachings
herein
provided that method 1900 is suitable for applying a heat-shrink patch to any
suitable
carton that includes a top panel, a bottom panel, at least one side panel
extending
between the top panel and the bottom panel and at least one movable section
that is
movable between a first position and a second position for forming a shape of
the
carton. Method 1900 includes the steps of providing 1902 a heat-shrink patch
in a
pre-shrunk configuration, coupling 1904 the heat-shrink patch in the pre-
shrunk
configuration to at least a portion of an interior surface of a blank of sheet
material
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including at least a portion of the movable section, forming 1906 the carton
from the
blank of sheet material and moving 1908 the movable section from the first
position
to the second position to form the shape of the carton. The shape of the
carton is
fornied by heating the heat-shrink patch to shrink the heat-shrink patch to a
shrunk
configuration. In one embodiment, the method includes filling the carton with
contents before moving the movable section. In an alternative embodiment, the
carton is filled with contents after moving the movable section.
[00194] In an alternative embodiment, a preformed heat-shrink film
tube is coupled to at least a portion of the interior surface of the blank of
sheet
material, in addition to or as an alternative to the heat-shrink patch. In
this
embodiment, the heat-shrink film tube is coupled to the interior surface using
any
suitable coupling mechanism, such as an adhesive, heat and/or sonic welding.
In a
particular embodiment, moist or wet products and/or products requiring a high
barrier
protection are loaded into the heat-shrink film tube. The heat-shrink film
tube and/or
the carton are sealed to contain the products within the heat-shrink film
tube. The
carton is subjected to a suitable heating process, for example by directing or
focusing
heat at a portion of the heat-shrink film tube covering the voids formed in
the carton.
The movable sections of the carton move to at least partially close the voids
during
the controlled heating process to shape the carton, as desired. In this
embodiment, the
heat-shrink film tube provides a sealed, liquid-tight moisture barrier carton.
In
another alternative embodiment, a heat-shrink film laminate material is
coupled to at
least a portion of the interior surface of the blank of sheet material. The
heat-shrink
film laminate covers the voids formed in the blank of sheet material and is
exposed to
an exterior of the carton through the voids. The carton is subjected to a
suitable
heating process, for example by directing or focusing heat at the portion of
the heat-
shrink film laminate covering the voids formed in the carton, to shape the
carton, as
desired. The movable sections of the carton move to at least partially close
the voids
during the controlled heating process. In this embodiment, the heat-shrink
fihn
laminate provides an additional barrier protection to the carton.
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[00195] In one embodiment, the method includes filling the carton
with contents before moving the movable section. In an alternative embodiment,
the
carton is filled with contents after moving the movable section. Depending
upon the
product type and/or configuration, the carton is formed and shaped prior to
filling the
carton with product, e.g., while the carton is empty. Alternatively, the
carton is
formed, the product is loaded into the carton and the carton is sealed, prior
to shaping
the carton. In this embodiment, the loaded packaging assembly is subjected to
a
controlled heating process in which the heat-shrink patch is shrunk to shape
the
carton.
[00196] In one embodiment, providing step 1902 further includes
providing a heat-shrink patch in a pre-shrunk configuration having a marking
thereon
including graphics for the carton. The marking may include graphics for the
carton or
graphics to coordinate with additional graphics printed on the carton. In one
embodiment, the markings are applied using an opaque ink. Alternatively, the
markings may be applied using a translucent ink such that the markings
coordinate
with the additional graphics printed on the carton. The heat-shrink patch
includes
polyethylene, polypropylene, polyvinyl chloride, polyester, polyester glycol,
nylon
and/or oriented polystyrene. In alternative embodiments, the heat-shrink patch
includes any suitable material or combination of materials known to those
skilled in
the art and guided by the teachings herein provided.
[00197] In one embodiment, coupling step 1904 further includes
applying an adhesive in a registered pattern to at least a portion of the
interior surface
of the blank of sheet material including at least a portion of the movable
section. The
heat-shrink patch is cut to correspond to the registered pattern and adhered
to the
interior surface of the blank within the registered pattern. In one
embodiment, the
adhesive is applied such that the adhesive extends about a void at least
partially
defined by the movable section to substantially surround the void. With the
adhesive
substantially surrounding the void, the heat-shrink patch is adhered to the
interior
surface to cover the void and provide a seal preventing air and/or
contaminants from
entering the carton through the void. In alternative embodiments, coupling
step 1904
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includes employing any suitable coupling mechanism including, without
limitation, a
heating method and/or a sonic welding method, with or without the application
of an
adhesive.
[00198] In one embodiment, a first movable section and a second
movable section are coupled together along a fold line and define the void
along a
portion of the fold line. Adhesive is applied in a registered pattern to the
interior
surface of the blank of sheet material including at least a portion of the
first movable
section and at least a portion of the second movable section. For example, the
adhesive is applied within a boundary area that substantially surrounds and/or
defines
the void. The heat-shrink patch is cut to correspond to the registered
pattern. The
heat-shrink patch is adhered to the interior surface of the blank including at
least a
portion of the first movable section and at least a portion of the second
movable
section within the registered pattern to cover the void. In this embodiment,
during the
moving step the first movable section is moved or urged towards the second
movable
section to at least partially close the void defined along the fold line.
[00199] In an alternative embodiment, a second heat-shrink patch is =
coupled to the second movable section of the carton. The second movable
section is
moved from a first position to a second position to form a shape of the carton
by
heating the second heat-shrink patch to a shrunk configuration. In a
particular
alternative embodiment, the second heat-shrink patch is adhered to the
interior surface
of the blank to cover a second void at least partially defined by the second
movable
section. In addition to the use of different shrink film materials and/or
controlled
temperature applications, a controlled and/or specifically directed heat, time
and/or
temperature application to at least one area of the carton, such as to at
least one panel
or movable section, is utilized in particular embodiments to achieve a lesser
or greater
degree of shaping in the selected area or areas, as desired.
[00200] In one embodiment, moving step 1908 includes heating the
heat-shrink patch to shrink the heat-shrink patch to a shrunk configuration
and move
or urge the moveable section to the second position to form the shape of the
carton.
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The movable section may include at least one panel and/or at least one section
of at
least one panel. In this embodiment, the cross-sectional area of the carton is
changed
when the moveable section is moved from the first position to the second
position.
After the heating process, the heat-shrink patch is cooled to remain in the
shrunk
configuration to hold or retain the carton in a substantially fixed second
position. In
one embodiment, with the heat-shrink patch in the shrunk position, heat-shrink
patch
retains the movable panel or at least a movable section of the panel in the
second
position.
[00201] In one embodiment, heat is focused at the heat-shrink patch
to shrink the heat-shrink patch to a shrunk configuration and move the movable
section to the second position to form the shape of the carton. In a
particular
embodiment, heat is applied to selected portions of the heat-shrink patch at
different
intensities to differentially shrink the heat-shrink patch. Additionally, or
alternatively,
an intensity and/or temperature of the heat can be varied to create
differential
shrinkage of the heat-shrink patch. In one embodiment, a plurality of
different
heating temperatures can be applied to at least a portion of the heat-shrink
patch for
controlling a degree of shrinkage of the heat-shrink patch. For example, heat
is
applied to a first portion of the heat-shrink patch (or to a first heat-shrink
patch) at a
first temperature and heat is applied to a second portion of the heat-shrink
patch (or to
a second heat-shrink patch) at a second temperature different from the first
temperature.
[00202] In an alternative embodiment, moving step 1908 includes
providing a plurality of heat-shrink patches in a pre-shrunk configuration
having
different shrink orientations and percentages. The moveable section is moved
from
the first position to the second position by heating the heat-shrink patches
to shrink
the heat-shrink patches. Upon heating the different heat-shrink patches, each
heat-
shrink patch shrinks to a different degree allowing the heat-shrink patches to
form a
shape of the carton.
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[00203] In another embodiment, the movable section of the carton is
moved by applying at least one heat-shrink patch to the blank and heating the
at least
one heat-shrink patch at different temperatures to control the degree of
shrinkage. As
such, the heat-shrink patch forms the shape of the carton. It is further
possible to
control the degree of heat-shrink patch shrinkage by combining any of the
hereinabove described methods. As such, the degree of heat-shrink patch
shrinkage
can be controlled by any combination of using a specific heat-shrink patch
film type,
controlling the temperature of heating and/or targeting or focusing the heat
applied to
the heat-shrink patch. Any or a combination of these methods will facilitate
moving
the movable section of the carton from a first position to a second position
to form a
shape of the carton. This shape may further include a cut-out in the carton to
allow
visibility of the product within the carton. In one embodiment, the moveable
section
includes at least a portion of a cut-out fornied in the carton which allows
for the
movement of the carton. By heating the different heat-shrink patches, the
moveable
section can be moved such that the cut-out is closed by the panels of the
carton or the
cut-out is only partially closed to allow the product included within the
carton to be
visible to a consumer.
[00204] In one embodiment, a packaging assembly is formed that
includes a carton having a shape. The carton includes a top panel, a bottom
panel, at
. least one side panel extending between the top panel and the bottom panel
and a
movable section that is movable between a first position and a second
position. A
blank of sheet material is provided. The blank includes a first movable
section
coupled to a second movable section at a fold line. The first movable section
and the
second movable section define a void positioned on the fold line. An adhesive
is
applied in a registered pattern to an interior surface of the blank to
substantially
surround the void. The heat-shrink patch is coupled in a pre-shrunk
configuration to
the first movable section and the second movable section within the registered
pattern
to cover the void. The first movable section is moved or urged towards the
second
movable section to at least partially close the void to form the shape of the
carton.
Heat is applied to at least a portion of the heat-shrink patch to shrink the
heat-shrink
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patch to a shrunk configuration. In one embodiment, heat is applied at a
plurality of
temperatures across a dimension of the heat-shrink patch, e.g., along a length
and/or a
width of the heat-shrink patch.
[00205] The methods described hereinabove is performed by a
system or machine configured to carry out the steps shown in Figure 42. In one
embodiment, the system includes a carton having a top panel, a bottom panel,
at least
one side panel and at least one moveable section configured to move from a
first
position to a second position. The system further includes a coupling device
configured to couple the heat-shrink patch in the pre-shrunk configuration to
an
interior surface of a blank of sheet material. In one embodiment, the coupling
device
is configured to apply an adhesive in a registered pattern to at least a
portion of the
movable section and adhere the heat-shrink patch to the interior surface of
the carton
within the registered pattern. A forming device is configured to form the
carton from
the blank of sheet material.
[00206] A heating device is configured to heat at least a portion of
the heat-shrink patch to shrink the heat-shrink patch to a shrunk
configuration to
move the movable section from the first position to the second position to
form the
shape of the carton. The heat-shrinkable film is movable from an initial,
first or pre-
shrunk configuration to a second or shrunk configuration having a shorter
width
and/or shorter length than in the pre-shrunk configuration. In one embodiment,
the
heating device is configured to shrink the heat-shrink patch to the shrunk
configuration to move the movable section to at least partially close a void
at least
partially defined by the movable section. The heat-shrink film is shrinkable
to move
from the pre-shrunk configuration to the shrunk configuration to move or urge
the
moveable section of the carton to the second position. In a particular
embodiment, as
the heat-shrinkable film shrinks, such as by applying suitable heat, at least
one void
defined at least partially by or within the moveable section at least
partially closes to
move or urge adjacent movable sections together. After the heating process,
the heat-
shrink patch cools and remains in the shrunk configuration to hold or retain
the carton
in a substantially fixed second position. In one embodiment, with the heat-
shrink
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patch in the shrunk position, heat-shrink patch retains the movable panel or
at least a
movable section of the panel in the second position.
[00207] The packaging assembly of the present invention including
the heat-shrink patch at least partially seals the carton to protect a product
contained
within the carton from tampering and to generally seal the edges, corners
and/or joints
of the carton for containing the product within the carton, as well as
protecting the
product from contamination. The heat-shrink patch can be used, for example, to
replace bags or liners sometimes used within a container for sealing a
product.
Further, the heat-shrink patch maintains a shape of the carton for example, to
facilitate
displaying, stacking and/or arranging the carton or a plurality of cartons,
and/or
maintaining a shape that facilitates other functionality such as carrying the
carton.
[00208] The heat-shrink patch facilitates forming of the carton, and
more specifically moving the moveable sections of the carton from an initially
biased
first position to a second position having an arcuate or curved surface to
form the
packaging assembly. Cartons having shapes that are more complex than
conventional
rectangular cartons may be difficult and therefore costly to manufacture. As
the heat-
shrink patch is heated and shrinks the heat-shrink patch moves, draws or urges
the
movable sections to the second position to form a shape of the packaging
assembly.
The heat-shrink patch holds the moved sections in the second position. By
moving
and holding the movable sections in second position, the heat-shrink patch
forms a
shape of the packaging assembly, and more specifically the carton, that may be
otherwise difficult and costly to form.
[00209] While the invention has been described in terms of various
specific embodiments, those ,skilled in the art will recognize that the
invention can be
practiced with modification within the scope of the claims. The scope of the
claims should not be limited by the preferred embodiments set forth in the
examples, but should be given the broadest interpretation consistent with the
description as a whole.
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