EFFICIENTLY MANUFACTURED POLYHEDRON CONTAINER ADAPTED FOR DISPLAY OF CONTENTS THROUGH PLURALITY OF ADJACENT OUTER PANELS

A container including an assembled combination of opaque paperboard and substantially transparent polymer sheet is disclosed. The containing may have a convex polyhedron shape and include at least a first group of three substantially flat mutually adjacent outer panels, wherein the first group of mutually adjacent outer panels share at least a first substantially transparent window that is present on and extends continuously and wraps from a first of the first group of panels, to a second of the first group of panels, to a third of the first group of panels, the first window being defined by a first window cutout through the paperboard, and the first window being occupied by a continuous section of the polymer sheet present and at least partially forming each of the first group of panels. The container may be a retail package.

BACKGROUND

Manufacturers and sellers of retail products typically sold as packages containing grouped quantities of individually consumable products continuously strive to design retail packaging containers with features that end-purchasers will find eye-catching, attractive and, at the same time and to the extent feasible, functionally advantageous. Given the myriad combinations of design options and component materials available for configuring retail containers, there is always room for improvement in designs for containers toward the objectives of providing the manufacturer/seller a competitive advantage in (1) attracting end-purchasers to view and consider their products when displayed in a retail setting; (2) providing functional advantages for storage and dispensation of the individually consumable products following purchase, and (3) providing for efficient and cost-effective manufacture.

DESCRIPTION OF EXAMPLES

Referring toFIG. 1, a container100within contemplation of the present disclosure may have a combination of substantially flat outer surfaces that together form any convex polyhedral shape, but in the depicted non-limiting example the shape may be a rectangular cuboid, or “box”. Containers having a rectangular cuboid shape are used for transporting, packaging and displaying many types of products, and are relatively efficiently manufactured. The container100may have a variety of construction/assembly configurations and a variety of configurations to provide for opening of the container and access to its contents. A container having a rectangular cuboid shape will having the following 12 outwardly-protruding corners and six panels forming outward-facing surfaces, identified inFIG. 1herein for reference:

top-front corner 100a;bottom-rear corner 100j;right-front corner 100b;top-right corner 100k;bottom-front corner 100c;bottom-right corner 100l;left-front corner 100d;front panel 101;top-left corner 100e;rear panel 102;rear-left corner 100f;top panel 103;bottom-left corner 100g;bottom panel 104;top-rear corner 100h;right side panel 105; andright-rear corner 100i;left side panel 106.
For purposes herein, front panel101will be deemed the facing panel of a container to be used as a retail package, i.e., the panel that is configured to be displayed facing forward in a typical physical retail setting, e.g., when the container is sitting on a retail store shelf.

Referring toFIGS. 1 and 2, in some examples, container100may be assembled from a unitary, suitably configured flat300, which may be cut from a sheet of paperboard or cardboard, or any other suitable sheet material having sufficient rigidity to form a structurally stable container suited to it intended purposes. In some examples, it may be preferred that the assembled container100be assembled so that it may not be opened non-destructively, so as to discourage premature opening or tampering prior to purchase of the container (with contained product) by a consumer. Accordingly, in some examples container100may be assembled from a flat300that includes a configuration of assembly flaps301that are folded about corners along assembly fold lines302and underlap sections forming one or more of adjacent panels101-106, wherein a respective overlying panel and underlying flap301are bonded to each other, e.g., via adhesive, and form a corner of the container at the assembly fold line302, as well as impart structural integrity to the container. Folding about fold lines302may be facilitated by embossing or impressing grooves in the material of the flat along the fold lines, during its manufacture, thereby reducing bending stiffness/bending resistance at the fold lines. In some examples, at least two opposing panels of the container100may have an assembly flap301underlying and bonded thereto. In some examples, at least two opposing panels of the container100, and one panel adjacent to each of the opposing panels, the one panel meeting each of the opposing panels at respective corners, may have an assembly flap301, or a plurality of assembly flaps301, underlying the one adjacent panel. It will be appreciated that, in the example depicted inFIGS. 2 and 3, following assembly of a container100from the depicted container flat300, each of opposing panels105,106will have assembly flaps301underlying them, those assembly flaps extending upward and downward (relative the orientation shown inFIG. 1) from top-left and top-right corners of top and bottom panels103,104. Additionally, following assembly of the container rear panel102will be adjacent panels105,106, and will also have at least one assembly flap301underlying it, that assembly flap extending downward from top panel103at the top-rear corner100hof the container100.

Referring toFIGS. 2A, 2B, 3 and 4, in some examples, container100may be imparted with one or more translucent or transparent windows107,108. Such windows may be formed by cutting associated holes of the desired window shape(s) through the material (e.g., paperboard) forming the main portion of the container flat300, along window cutouts107d,108d, and then overlaying over each such hole on the inside surface (relative the finished container) of the flat, a suitably shaped and sized section of a translucent or transparent window sheet material120, with sufficient margins109of window sheet material about the window cutout edges to provide suitable regions of interface between these materials to facilitate affixing the window sheet material120to the main portion material via, for example, adhesive disposed between the window sheet and main portion material in the margins109. A single integral section of the window sheet material120may extend across several panels of the flat300as shown, and be folded into 90-degree bends along with the main material of the flat along fold lines302, to form corners of the container. The window sheet material120may be suitably sized and shaped as a single continuous section so as to extend across and cover all of the window cutouts in the flat300(as suggested inFIG. 2B), or alternatively, window sheet material120may be suitably sized and shaped in a plurality of individual sections, so to only cover each window cutout individually (as suggested inFIG. 2A). Where a plurality of windows are present on a single panel as in the depicted examples, it may be preferred that the window sheet material120be a single continuous section as suggested inFIG. 2B, such that it imparts added rigidity and structural robustness to the portion(s) of the panel between the window cutouts. On the other hand, if the material (e.g., paperboard) from which the main portion of the flat300is made is sufficiently rigid to provide a suitable structurally robust container even after being cut to create the desired configuration of windows, it may be desired to include individual sheets more closely sized and shaped only for each window, for purposes of saving material costs of window sheet material.

The selected window sheet material may be any translucent or transparent film or sheet material, and may be sheet material extruded or cast from a thermoplastic polymeric resin. In some examples, the selected resin may be polyethylene terephthalate (PET) or modified PET; in other examples, the selected resin may be polypropylene. In order to retain structural integrity in the assembled container100despite removal of material within the window cutout(s) from the main portion of the flat, to form the windows, in some examples, it may be desired that the window sheet material selected have a rigidity, reflected as Bending Resistance, that is at least 30 percent, more preferably at least 40 percent, and even more preferably at least 50 percent, of that of the material forming the main portion of the container flat, measured according the Bending Resistance Measurement Method set forth below. PET may be particularly suited to this purpose, in that sheets extruded or cast from PET tend to be relatively stiffer, per unit caliper, than sheets extruded or cast from other translucent/transparent thermoplastic resins, while being relatively inexpensive and easily processed and worked. Additionally, although relatively stiff, sheets cast or extruded from PET tend to be flexible and tough, not brittle, and plasticly deformable in folding processes, making them amenable to easy creation of folds therein, to form robust corner structures. Further, PET-based material may be selected such that sheets cast or extruded from it tend to have optical properties that are desirable for windows, i.e, near or substantial colorlessness and high clarity/transparency.

In the examples depicted inFIGS. 2A, 2B, and 3-9, (and using the references to panels and corners identified inFIG. 1) it can be seen that flat300forming container100may be configured such that a window such as windows107,108occupies three mutually adjacent panels. In the example shown in the figures, and referring particularly toFIG. 3, a first window107may occupy front panel101(window portion107a), and wrap around to mutually adjacent top panel103(window portion107c) and mutually adjacent right side panel105(window portion107b). A second window108may occupy front panel101(window portion108a), and wrap around to mutually adjacent bottom panel104(window portion108c) and mutually adjacent left side panel106(window portion108b). At the same time, it can be seen that the window107does not extend to the tri-corner intersection of top-front corner100a, right-front corner100band top-right corner100k; and window108does not extend to the tri-corner intersection of bottom-front corner100c, left-front corner100d, and bottom-left corner100g. Further, it will be observed that the edges of the main/largest portions of the windows107a,108amay be angled or slanted, relative the corners outlining the panel101on which they are situated. The configuration illustrated provides several advantages: (1) It provides a view of product(s) contained within the container from three sides of the container; (2) it avoids a construction wherein edges of the window sheet material are exposed, in ordinary handling and opening of the container; (3) despite providing windows that are cut through the main sheet material forming the container flat300, the assembled container100has inherent structural integrity, particularly when selected window sheet material has suitable rigidity; (4) the configuration is relatively easily manufactured and assembled into a container.

With regard to item (2), when relatively rigid window sheet materials such as those made of PET are cut, the cut edges can be sharp enough to be uncomfortable, or even cause skin cuts, to a consumer who runs their hands along them. Accordingly, it is advantageous to configure a container with windows that incorporate such materials such that no cut edges of the window sheet material project or extend away from the paperboard material, upon opening of the container100in the designed manner.

With regard to item (3), when the window sheet material is plasticly deformable in the manner of sheet material formed of PET, structurally well-defined and rigid corners in the material may be formed at, e.g., corners100a,100b,100cand100dthat substantially retain the structural integrity of the container as if no windows were present.

With regard to item (4), it may be noted that no portion of the window sheet material is present in any of the assembly flaps, and thus, does not complicate the folding thereof or assembly of the container100from the flat300.

Referring now toFIG. 5, the container100in the examples depicted may be particularly well-suited to contain, and visibly display, one or more orderly stacks of individually consumable products200, along at least three surfaces of the container. This may be deemed useful when the individually consumable products are themselves deemed attractive and/or attractively individually packaged and the manufacturer therefore wishes to display them in a retail setting, and/or, such visibility is useful to the consumer, following purchase and during storage/dispensation, to enable the consumer to monitor the quantity of individually consumable products remaining in the supply within the container100, as the products are consumed, while at the same time, the remaining unconsumed individually consumable products remain neatly contained within the container100.

Referring toFIG. 10, the manufacturer may provide individually consumable products200in one or more orderly stacks, wherein each product in a stack bears an individual configuration of decorative graphics201a, and wherein when the products are stacked their individual configurations of decorative graphics201acollectively form a coherent design recognizable across a plurality of the products' viewable surfaces in the stack, the coherent design being visible through at least one window107,108. One example of such a coherent design may be seen inFIG. 10.

Referring toFIGS. 6-9(and using the references provided byFIG. 1), in some examples a panel that does not include a window, such as rear panel102, may include an access opening configuration. The access opening configuration in some examples may include a path of weakness110configured to facilitate tearing of the material of the panel therealong, providing an opening in the container and providing access to its contents. The path of weakness may be created by a path of perforations or scoring in the material of the panel. The path of weakness may be configured such that an opening flap111is formed, following tearing therealong. In some examples the path of weakness may include opposing straight portions113and a transverse portion112joining the straight portions113. The access opening configuration may also include a flap hinge line114, along which the material of the panel has been embossed or grooved, to promote bending of the material along the hinge line114such that the flap may be neatly opened and hinge about line114in manner similar to the way in which a door opens about its hinges.

An opening flap may be configured to include a reclosing feature. Referring toFIG. 13, in the example shown, the reclosing feature may include a closure tab111t. The container100may include another feature configured to interact with a closure tab, such as a slot (not specifically shown) cut through the panel on which the opening flap111is located, positioned and sized to enable the closure tab111to be inserted therein, in a position in which it will hold flap111in a reclosed position. In another example specifically shown inFIG. 13, the flap111with included closure tab111tmay be positioned and arranged, and the tab may be precut from the panel102as shown, such that the tab may be inserted behind an assembly flap301underlying panel102, thereby holding flap111in a reclosed position following opening/tearing of the package along path of weakness110and resulting creation of the opening flap111.

Referring now toFIGS. 7, 8, 11, 12 and 14A-14G, individually consumable products200may by individually packaged (e.g., wrapped), in individual packages201(FIGS. 11, 12). Individual packages201may also include opening flaps. In some examples, packages201may have the form of an envelope with an opening/closing flap202. It has been learned that configuring a container opening flap edge111ewith a container opening flap edge profile111ep, and an individual package flap edge202ewith a package flap edge profile202ep(non-limiting examples shown inFIGS. 14A-14G), such that the two profiles111epand202epare visually similar, has associative effects believed to be appreciated by consumers, in some cases being perceived as suggesting that the container and the individual packages therein are opened in a similar manner. Herein, “visually similar” means that the respective profiles111epand202eptrace respective paths that:(a) have the same number of straight line segments such as line segments204; and/or(b) have the same number of continuous curves such as curves203, wherein the curves have the same number of inflection points such as inflection point206.
Herein, a “continuous curve” is a portion of a profile that is not a straight line segment, and does not have a break, i.e., an abrupt change of direction. Examples of visually similar pairs of respective profiles111epand202epare illustrated inFIGS. 14A-14G. The illustrated pairs meet the definition of “visually similar” set forth above, as follows:

FIGS. 14A, 14B: Profiles111epand202epeach have the same number (one) of continuous curves203, with the same number of inflection points (zero).

FIG. 14C: Profiles111epand202epeach have the same number (one) of straight line segments204. This alone is sufficient to cause the profiles to meet the above definition of “visually similar.” However, further, profiles111epand202epeach have the same number (two) of continuous curves203, with the same number of inflection points (zero). This alone is also sufficient to cause the profiles to meet the above definition of “visually similar.”

FIG. 14D: Profiles111epand202epeach have the same number (four) of straight line segments204.

FIG. 14E: Profiles111epand202epeach have the same number (two) of straight line segments204.

FIG. 14F: Profiles111epand202epeach have the same number (two) of straight line segments204. This alone is sufficient to cause the profiles to meet the above definition of “visually similar.” However, further, profiles111epand202epeach have the same number (one) of continuous curves203, with the same number of inflection points (zero). This alone is also sufficient to cause the profiles to meet the above definition of “visually similar.”

FIG. 14G: Profiles111epand202epeach have the same number (one) of continuous curves203, with the same number of inflection points206(two).

Referring toFIGS. 12 and 13, for purposes herein, a closure tab such as closure tab111t, or closure tape such as closure tape202t, that outlines an extension from the flap profile111ep,202epthat creates an opposing pair of abrupt discontinuities (abrupt changes of direction) from remainder of the flap profile, is disregarded when determining visual similarity of the respective remainders of the flap profiles. Thus, the flap edges202eand111erespectively shown inFIGS. 12 and 13are “visually similar” as defined herein (because they have the same number of continuous curves), disregarding tab111tand tape202t.

The container configuration herein may be particularly well-suited to containing, displaying and visibly storing stacks of individually consumable products each having a relatively flat configuration. In some examples such products may be disposable absorbent articles, in more particular examples, feminine hygiene pads. A supply including a plurality of individual feminine hygiene pads will often be packaged by the manufacturer in a single container. When in an opened configuration ready for use, a feminine hygiene pad is typically generally flat, and accordingly, a pad may be folded into a relatively flat folded configuration of reduced surface area, then packaged in an individual wrapper. Manufacturers often seek to make the individual wrappers visually appealing to consumers. Consequently, a supply of individually folded and wrapped feminine hygiene pads can accommodate orderly stacking thereof, in one or more stacks which may be neatly contained within a container100having a suitably selected size, shape and interior volume therewithin. One or more windows on the container having features described herein allow consumers to view attractively packaged individual products and orderly stacks thereof, enhancing the appearance of the container when on display at retail. Following purchase, the one or more windows can serve to enable the purchaser to monitor the quantity of unconsumed individual products (e.g., pads) remaining in the container during storage, as the products are individually removed from the container for use.

Bending Resistance Measurement Method

The Bending Resistance of a sample of container material is measured using a three-point bend test on a constant rate of extension tensile tester (a suitable instrument is the MTS Alliance using Testworks 4.0 Software or TestSuite Software, as available from MTS Systems Corp., Eden Prairie, Minn.) using a load cell for which the forces measured are within 1% to 99% of the limit of the cell. All testing is performed in a room controlled at 23° C.±3° C. and 50%±2% relative humidity.

The three-point bend fixture components are described as follows, referring toFIGS. 15A and 15B.

The bottom, stationary fixture51consists of two cylindrical bars52. Each is 3.15 mm in diameter by 114 mm in length, made of polished stainless steel and is mounted on a support structure53. These two bars are mounted horizontally, parallel, at the same height and with ends aligned. The fixture is configured such that the distance between the two bars52(center to center, measured perpendicular to their longitudinal axes) is set at, or adjustable to, a spacing s of 25 mm±0.5 mm.

The top fixture54consists of a third cylindrical bar55, also 3.15 mm in diameter by 114 mm in length, made of polished stainless steel and mounted on a support structure56. When in place the bar55of the top fixture54is parallel, and with ends aligned, with the bars52of the bottom fixture51.

The respective bottom and top fixtures are configured such that bar55is, or through adjustment may be, centered over bars52.

Each of the top and bottom fixtures includes an integral adapter57t,57b, configured to be mounted on the upper and lower portions of tensile tester such that the longitudinal axes of the bars52,55are orthogonal to the (vertical) motion of the crossbeam of the tensile tester.

Obtain samples of sizes sufficient to provide the specimens described below, of the materials from which the subject container is made. Condition the samples at 23° C.±3° C. and 50%±2% relative humidity two hours prior to testing.

Specimens are cut from areas of the sample that are free of folds, wrinkles or adhesive.

For a sample that is known to be isotropic in bending resistance, rectangular specimens are cut therefrom to a dimension of 25.0 mm by 50.0 mm, noting the side of the material that faces (or is intended to face) outwardly on a container.

For a sample that is identified as or suspected of being anisotropic in bending resistance, the objective is to determine the direction along which bending resistance of the sample is lowest. Begin by cutting a supply of circular starting specimens all of the same diameter, at least 38.0 mm but not more than 50.0 mm (a circular cutting die of the selected size may be used), from the sample, noting their rotational orientations relative the sample prior to removing them from the sample. Using the testing procedure described below and with the midpoint of each circular starting specimen centered over the lower bars52, test successive circular starting specimens (applying only one bend per specimen) by iteratively bending successive specimens along differing axes to identify the direction along which bending resistance of the sample is lowest, and identify the circular starting specimen which exhibited such lowest bending resistance with a line identifying such direction (the identifying line will be coincident with the line of contact made on the specimen by upper bar55, at the outset of bending). Cut final rectangular test specimens from remaining portions of the sample(s), with dimensions of 25.0 mm by 50.0 mm, with the shorter (25.0 mm) sides parallel to the identifying line marked on the identified circular starting specimen (when the identified circular starting specimen is placed in the same position and rotational orientation that it occupied prior to being cut from the sample). Again, note the side of the material that faces (or is intended to face) outwardly on a container.

Program the tensile tester for a flexural bend test, to move the crosshead such that the top fixture moves down with respect to the lower fixture at a rate of 1.0 mm/sec until the upper bar55touches the top surface of the specimen, then continue for an additional 12 mm collecting force (N) and displacement (mm) data at 50 Hz, and return the crosshead to its original gage. Ensure that the gap between the bars52of the lower fixture is 25 mm±0.5 mm (center of bar to center of bar) with the upper bar55centered over the lower bars.

For each test, load the specimen such that it spans the two lower bars55, and is centered under the upper bar55with its longer (50.0 mm) sides perpendicular to the bars and the side identified as the outwardly-facing side (when the material forms a container) facing up. Zero the crosshead and load cell. Start the run and collect data.

Construct a graph of force (N) versus displacement (mm). From the graph, record the maximum peak force to the nearest 0.01 N. In like fashion, repeat the entire test sequence for a total of 6 test specimens.

Calculate the arithmetic mean of the peak force recorded for each set of replicates and report as Bending Resistance to the nearest 0.01 N.

Non-limiting examples of structures and combinations of features contemplated herein include those set forth in the following claims.