Laminated blank, packaging formed therefrom, and method

Abstract

In one aspect, a blank is formed of a substrate laminated with a thin polymer film layer. The blank includes fold lines and cutouts such that it is formable into a pack with a base that is fully sealed by the film layer, thereby solving the technical problem of packs formed from blanks where the bases include unsealed gaps or holes. In further aspects, a folded blank, packaging articles formed therefrom, and methods of manufacture are provided.

What is claimed is: 
     
         1 . A blank which can be folded to form a pack, the blank being formed of a laminate comprising a cellulosic substrate layer laminated to a film layer, the blank comprising:
 a laminated front face connected to a laminated base via a first transverse fold line at a first transverse edge of the base;   a laminated rear face connected to the base via a second transverse fold line at a second transverse edge of the base opposite the first transverse edge of the base;   the base having opposing first and second longitudinal edges extending between the first transverse edge and the second transverse edge,   a third transverse fold line disposed intermediate the first and second transverse fold lines about which the base is foldable in an opposite sense to the first and second transverse fold lines;   first and second front side panel segments extending transversely from first and second opposing, generally longitudinal edges of the front face;   first and second rear side panel segments extending transversely from first and second opposing, generally longitudinal edges of the rear face;   the first front side panel segment and the first rear side panel segment cooperating to form a first side panel when the blank is folded to form an assembled pack;   the second front side panel segment and the second rear side panel segment cooperating to form a second side panel when the blank is folded to form the assembled pack;   each of the front face, rear face, the first front and rear side panels, and the second front and rear side panels having an upper edge such that in the assembled pack, the upper edges of the front face, rear face, first front and rear side panels, and second front and rear side panels form an opening into the pack;   a first base support panel extending between the first front side panel and the first rear side panel on the first longitudinal edge of the base, the first base support panel having a first cutout region adjacent the first longitudinal edge of the base comprising unsupported film;   a second base support panel extending between the second front side panel and the second rear side panel on the second longitudinal edge of the base, the second base support panel having a second cutout region adjacent the second longitudinal edge of the base comprising unsupported film;   the first cutout region bounded by the first longitudinal edge of the base, a first front support arm extending from a transverse edge of the first front side panel segment, and a first rear support arm extending from a transverse edge of the first rear side panel segment;   the second cutout region bounded by the second longitudinal edge of the base, a second front support arm extending from a transverse edge of the second front side panel segment, and a second rear support arm extending from a transverse edge of the second rear side panel segment;   wherein the first and second front support arms are each foldable along the first transverse fold line and the first and second rear support arms are each foldable along the second transverse fold line; and   wherein the first front support arm, first rear support arm, second front support arm, and second rear support arm are configured to fold to a position overlying and substantially parallel to the base when the blank is folded to form the assembled pack.   
     
     
         2 . The blank as claimed in  claim 1 , further comprising a laminated lid connected to the rear face via a fourth transverse fold line along the upper edge of the rear face, wherein the lid covers the opening into the pack when the blank is folded to form the assembled pack and the lid is folded along the fourth transverse fold line. 
     
     
         3 . The blank as claimed in  claim 2 , further comprising a window formed in the laminated lid, the window defined by a cutout in the cellulosic substrate layer wherein the window comprises an unsupported portion of the film layer. 
     
     
         4 . The blank as claimed in  claim 2 , further comprising:
 a laminated front face connected to a laminated base via a first transverse fold line at a first transverse edge of the base;   a first upper front flap connected to the first front side panel segment via a first flap fold line at the upper edge of the first front side panel segment;   a second upper front flap connected to the second front side panel segment via a second flap fold line at the upper edge of the second front side panel segment;   a first upper rear flap connected to the first rear side panel segment via a third flap fold line at the upper edge of the first rear side panel segment;   a second upper rear flap connected to the second rear side panel segment via a fourth flap fold line at the upper edge of the second rear side panel segment; and   
       a front face flap connected to the front face via a fifth transverse fold line along the upper edge of the front face. 
     
     
         5 . The blank as claimed in  claim 1 , wherein:
 the upper edge of each of the first and second rear side panel segments intersecting with the upper edge of the rear face to form an angle in the range of about 160 to about 175 degrees; and   the upper edge of each of the first and second front side panel segments intersecting with the upper edge of the front face to form an angle in the range of about 160 to about 175 degrees.   
     
     
         6 . The blank as claimed in  claim 1 , wherein:
 each of the first and second opposing, generally longitudinal edges of the front face intersecting with the upper edge of the front face to form an angle in the range of about 80 to about 85 degrees; and   each of the first and second opposing, generally longitudinal edges of the rear face intersecting with the upper edge of the rear face to form an angle in the range of about 80 to about 85 degrees.   
     
     
         7 . The blank as claimed in  claim 1 , further comprising:
 the first generally longitudinal edge of the front face connected to the first front side panel via a first generally longitudinal fold line along the first generally longitudinal edge of the front face;   the second generally longitudinal edge of the front face connected to the second front side panel via a first generally longitudinal fold line along the second generally longitudinal edge of the front face;   the first generally longitudinal edge of the rear face connected to the first rear side panel via a third generally longitudinal fold line along the first generally longitudinal edge of the rear face; and   the second generally longitudinal edge of the rear face connected to the second rear side panel via a fourth generally longitudinal fold line along the second generally longitudinal edge of the rear face.   
     
     
         8 . The blank as claimed in  claim 1 , wherein each of the first, second, and third transverse fold lines comprise a line of preferential folding. 
     
     
         9 . The blank as claimed in  claim 8 , wherein the line of preferential folding comprises a series of perforations in the cellulosic substrate layer. 
     
     
         10 . The blank as claimed in  claim 1 , further comprising:
 the first cutout region having a generally trapezoidal shape defined by a first long generally parallel side, a first short generally parallel side, a first pair of angled sides connecting the first long and first short generally parallel sides, and a first height defined by a perpendicular distance between the first long and first short generally parallel sides;   the second cutout region having a generally trapezoidal shape comprising a second long generally parallel side, a second short generally parallel side, a second pair of angled sides connecting the second long and second short generally parallel sides, and a second height defined by a perpendicular distance between the second long and second short generally parallel sides; and   the first base support panel further comprising:
 a first seal section side opposite and generally parallel to the first longitudinal edge of the base; 
 a first cutout connector with a generally triangular shape comprising a first triangle base defined by the first short generally parallel side of the first cutout and first pair of legs extending between the first triangle base and intersecting at the first seal section side; 
 a first connector rear fold line disposed between the first cutout connector and the first rear support arm; 
 a first connector front fold line disposed between the first cutout connector and the first front support arm; and 
 a first connector fold line extending between the first short generally parallel side of the first cutout and the first intersection; 
   the second base support panel further comprising:
 a second seal section side opposite and generally parallel to the first longitudinal edge of the base; 
 a second cutout connector with an isosceles triangle shape comprising a second triangle base that is the second short generally parallel side of the second cutout and second triangle legs extending between the second triangle base and intersecting at the second seal section side at a second intersection that bisects the second seal section side; 
 a second connector rear fold line disposed between the second cutout connector and the second rear support arm; 
 a second connector front fold line disposed between the second cutout connector and the second front support arm; and 
 a second connector fold line extending between the second short generally parallel side of the second cutout and the second intersection. 
   
     
     
         11 . A method for forming the blank of  claim 1 , the method comprising the steps of:
 providing a cellulosic web;   in a first cutting stage, making a plurality of through cuts in the cellulosic web to form a number of features of the pack, wherein the plurality of through cuts define at least first and second cutout regions that are mirror images of one another in the cellulosic substrate;   laminating at least one surface of the cellulosic substrate with a polymer film to form a laminate web, wherein said at least first and second cutout regions comprise said polymer film and are devoid of the cellulosic web;   in a second cutting stage, making an external cut to define a peripheral outline of an unfolded blank to cut the unfolded blank from the laminate web;   in a first folding stage, folding the laminate web in a first direction about the second transverse fold line;   in a second folding stage, folding the laminate web in a second direction opposite the first direction about the third transverse fold line;   applying adhesive to at least one of the first front side panel and the first rear side panel and to at least one of the second front side panel and the second rear side panel; and   in a third folding stage, after said step of applying adhesive, folding the laminate web in the first direction about the first transverse fold line to adhere the first front side panel and the first rear side panel and to adhere the second front side panel and the second rear side panel.   
     
     
         12 . The method as claimed in  claim 11 , wherein the first cutting stage further comprises:
 creating a fourth transverse series of perforations defining a lid fold line bounding an edge of a lid portion, wherein the plurality of through cuts further defines a window in the lid portion.   
     
     
         13 . The method as claimed in  claim 11 , wherein the first cutting stage further comprises:
 creating a first series of generally longitudinal perforations defining a first rear face fold line;   creating a second series of generally longitudinal perforations defining a second rear face fold line;   creating a third series of generally longitudinal perforations defining a first front face fold line; and   creating a fourth series of generally longitudinal perforations defining a second front face fold line.   
     
     
         14 . The method as claimed in  claim 11 , further comprising:
 each of the first and second rear face fold lines intersecting with the upper edge of the rear face panel an angle in the range of about 80 to about 85 degrees; and   each of the first and second front face fold lines intersecting with the upper edge of the front face panel at an angle in the range of about 80 to about 85 degrees.   
     
     
         15 . The method as claimed in  claim 11 , wherein the first cutting stage further comprises:
 creating a first transverse series of perforations defining the first transverse fold line;   creating a second transverse series of perforations defining the second transverse fold line; and   creating a third transverse series of perforations defining the third transverse fold line.   
     
     
         16 . The method as claimed in  claim 15 , wherein the first cutting stage further comprises:
 creating a fourth transverse series of perforations defining a lid fold line;   creating a fifth transverse series of perforations defining a lid flap fold line;   creating a sixth series of perforations defining a first upper rear flap fold line;   creating a seventh series of perforations defining a first upper front flap fold line;   creating an eighth series of perforations defining a second upper rear flap fold line; and   creating a ninth series of perforations defining a second upper front flap fold line.   
     
     
         17 . The method as claimed in  claim 11 , further comprising:
 the first upper rear flap fold line and the second upper rear flap fold line each intersecting with the upper edge of the rear face panel at an angle in the range of about 160 to about 175 degrees; and   the first upper front flap fold line and the second upper front flap fold line each intersecting with the upper edge of the front face panel at an angle in the range of about 160 to about 175 degrees.   
     
     
         18 . The method as claimed in  claim 11 , wherein the step of laminating is selected from then group consisting of adhesive lamination, extrusion coating, and extrusion lamination. 
     
     
         19 . The method as claimed in  claim 11 , wherein said step of laminating comprises applying a polymer film to both surfaces of the card layer. 
     
     
         20 . The method as claimed in  claim 11 , wherein the second cutting stage comprises:
 cutting a first line generally parallel to the second transverse fold line opposite from the base, such that the rear face is disposed between the first cut line and the second transverse fold line;   cutting a second line generally parallel to the first transverse fold line opposite from the base, such that the front face is disposed between the second cut line and the first transverse fold line; and   cutting third and fourth lines connecting the first and second cut lines such that all cuts and folds made in the step of making first cuts and fold lines in the card layer are within the bounds of the first through fourth cut lines.   
     
     
         21 . The method as claimed in  claim 11 , wherein the adhesive is a hot melt adhesive. 
     
     
         22 . A method for forming a pack, comprising:
 providing a blank, the blank being formed of a laminate comprising a cellulosic substrate layer laminated to a film layer, the blank comprising:
 a laminated front face connected to a laminated base via a first transverse fold line at a first transverse edge of the base; 
   a laminated rear face connected to the base via a second transverse fold line at a second transverse edge of the base opposite the first transverse edge of the base;
 the base having opposing first and second longitudinal edges extending between the first transverse edge and the second transverse edge, and a third transverse fold line disposed intermediate the first and second transverse fold lines about which the base is foldable in an opposite sense to the first and second transverse fold lines; 
 first and second front side panel segments extending transversely from first and second opposing, generally longitudinal edges of the front face; 
 first and second rear side panel segments extending transversely from first and second opposing, generally longitudinal edges of the rear face; 
 the first front side panel segment and the first rear side panel segment cooperating to form a first side panel when the blank is folded to form an assembled pack; 
 the second front side panel segment and the second rear side panel segment cooperating to form a second side panel when the blank is folded to form the assembled pack; 
 each of the front face, rear face, the first front and rear side panels, and the second front and rear side panels having an upper edge such that in the assembled pack, the upper edges of the front face, rear face, first front and rear side panels, and second front and rear side panels form an opening into the pack; 
 a first base support panel extending between the first front side panel and the first rear side panel on the first longitudinal edge of the base, the first base support panel having a first cutout region adjacent the first longitudinal edge of the base comprising unsupported film; 
 a second base support panel extending between the second front side panel and the second rear side panel on the second longitudinal edge of the base, the second base support panel having a second cutout region adjacent the second longitudinal edge of the base comprising unsupported film; 
 the first cutout region bounded by the first longitudinal edge of the base, a first front support arm extending from a transverse edge of the first front side panel segment, and a first rear support arm extending from a transverse edge of the first rear side panel segment; 
 the second cutout region bounded by the second longitudinal edge of the base, a second front support arm extending from a transverse edge of the second front side panel segment, and a second rear support arm extending from a transverse edge of the second rear side panel segment; 
 wherein the first and second front support arms are each folded along the first transverse fold line and the first and second rear support arms are each folded along the second transverse fold line; and 
 the first front support arm, first rear support arm, second front support arm, and second rear support arm are structured and operable to fold to a position overlying and substantially parallel to the base when the blank is folded to form the assembled pack; and 
   pushing the first and second side panels inward toward the base, causing the first and second base support panels to fold inward and downward to be substantially parallel to the base.   
     
     
         23 . The method of  claim 22 , wherein the upper edge of the front face has a front face flap attached thereto along a front face fold line, the upper edge of the rear face has a lid attached thereto along a fourth transverse fold line, the upper edge of the first front side panel has a first upper front flap attached thereto along a first upper front flap fold line, the upper edge of the second front side panel has a second upper front flap attached thereto along a second upper front flap fold line, the upper edge of the first rear side panel has a first upper rear flap attached thereto along a first upper rear flap fold line, and the second rear side panel has a second upper rear flap attached thereto along a second upper rear flap fold line, the method further comprising:
 folding the front face flap along the front face fold line, such that the front face flap is approximately perpendicular to the front face;   folding the lid along the fourth transverse fold line such that a portion of the lid overlaps and is flush with the first and second upper front flaps, the first and second upper rear flaps, and the front face flap; and   adhering the overlapping portion of the lid to the first and second top front and rear flaps and the front face flap.   
     
     
         24 . The method as claimed in  claim 23 , wherein the step of adhering the overlapping portion of the lid to the first and second top front and rear flaps and the front face flap is performed by heat sealing a portion of the film layer covering the overlapping portion of the lid to an aligned and facing portion of the film layer covering the first and second upper front flaps, the first and second upper rear flaps, and the front face flap.