Method and article for packaging paper and the like

A generally rectangular transparent and clear container for packing pressure-sensitive adhesive sheet stock which has a base and a cover that engage with each other with a snap action to establish a generally continuous closure around the perimeter of the container. The base has a raised bottom portion which has formed therein a series of spaced apart channels which are parallel to the end walls of the base, and a series of spaced apart channels which are parallel to the side walls of the base. A plurality of raised pads are formed between the channels which support the pressure sensitive adhesive sheet stock above a border channel which defines the perimeter of the base.

BACKGROUND OF THE INVENTION 
The invention relates to containers and methods for packaging and 
distributing paper, and more particularly to containers and methods for 
packaging and distributing pressure-sensitive adhesive (psa) paper sheet 
stock which is commonly used in printing of psa labels and the like in 
short low-volume runs by the offset process, as distinguished from 
printing by the flexographic process which usually employs psa paper roll 
stock and is associated with long high-volume runs. 
PRIOR ART 
Sheet stock coated with pressure-sensitive adhesive and provided with 
release liner to protect the adhesive, is commonly used by relatively 
small printers who utilize off-set printing techniques. Off-set printing 
techniques are of a nature where typically small runs are made achieving 
high quality results thereby satisfying the demands of specialty orders. 
For example, psa sheet stock is commonly used by small businesses for 
mailing labels, product identification, and bumper stickers. 
The off-set printing industry is such that manufacturers of psa sheet stock 
package it in bundles containing, for example, a count of 100 or 200 
sheets. The size of the sheet stock is typically 81/2 by 11 inches. 
Typically a standard number of bundles, say ten, are then packed in a 
carton and shipped to a paper merchant. The paper merchant warehouses the 
paper stock, and sells it to printers on demand, breaking the cartons 
which are in inventory, and supplying what paper is required by a 
printer's order. 
In the past, paper merchants typically delivered from the warehouse to 
printers. However, with increasing numbers of small print shops with 
relatively small paper requirements, it has been less and less practical 
for merchants to truck orders to all their printer customers. Therefore, 
there has been a trend for paper merchants to open up "cash and carry 
stores" centered in areas where there are quite a few small printers. The 
printers send their own personnel to such a store to pick up a carton or 
two. In this manner, the small printer market is becoming more and more 
like a retail market, where visibility, packaging and display become more 
important. 
The psa sheet stock reaches the end user after being subjected by the 
printer to off-set printing, and often also to guillotining into several 
labels per sheet. Smaller printers are prone to use psa sheet stock 
because their orders are typically small and require high quality results. 
It is common for smaller printers to print specialty labels and signs on 
psa sheet stock and display them in their stores without the labels having 
been previously ordered by a particular customer. In this respect, 
consumers visit the printer's store to shop, i.e., to see what types of 
labels and other various signs are available before purchasing. This is 
even more clearly like a retail market, where visibility, packaging and 
display are important. 
It is a practice in the industry to package the customary 100 count or 200 
count bundles of psa sheet stock by either a polywrap or a cardboard box 
such as that used to package typing paper. 
The polywrap is generally transparent, allowing the user to see the 
contents. However, once the polywrap is either wholely or partially 
removed from the bundle of psa sheet stock, it cannot be practically 
re-sealed nor can it be practically used for any subsequent re-packaging. 
Also, once the seal is broken on the polywrap, there is a continuous 
threat that the psa sheet stock will be exposed to moisture or other 
damage. These disadvantages may occur frequently because often printers 
only need part of a bundle to fulfill a particular job. The remainder of 
the bundle then sits open on the shelf. 
Packaging the psa sheet stock in a cardboard box prevents the purchaser 
from seeing the contents without removing the lid. Also, cardboard tends 
to attract moisture and transfer it onto the psa sheet stock, thereby 
tending to cause the psa sheet stock to curl. Curling makes it difficult 
for the printer to use the psa sheet stock properly during printing. 
Curling also inhibits the proper application of the psa sheet stock after 
printing. 
When cardboard boxes of psa sheet stock change hands during the course of 
reaching the end user, various labels and graphics are placed on the 
outside of the box. The contents of a box cannot be seen without removing 
the lid, and the labels or graphics placed thereon may not be consistent 
with the box's contents. Thus, when an end user wants to determine what is 
in a box, he or she will have to remove the box's lid to assure its 
contents are consistent with the labels and graphics placed thereon. Also, 
removal and replacement of labels and graphics on the container is often 
desired by subsequent users. Cardboard does not allow labels and graphics 
to be removed without undue effort and possible damage to the cardboard 
box. 
In order to allow the contents of cardboard boxes to be seen, recently it 
has sometimes been a practice to cut a small window, say 1/2 inch by one 
inch, in the boxes, thus giving limited visibility of the contents. 
However, this then generally requires polywrapping of the contents to 
protect them against dust and moisture, both of which have readier access 
through the window than through the paper itself. 
In general, neither the polywrap nor the cardboard box provides continuous 
protection of the psa sheet stock against exposure to moisture, nor do 
they combine reusability with the ability to see through the package. They 
do not give printers a reusable pack, and they do not give the end user a 
package he or she can use. 
SUMMARY OF THE INVENTION 
The invention provides a method and container for packaging printable 
pressure-sensitive adhesive sheet stock. The preferred embodiment of the 
present invention provides a method and container for packaging the psa 
sheet stock so that it is protected against moisture, and so that the 
paper merchant can display such stock, and so that the printer can also 
use the same container to display such stock, after printing, and also if 
desired after guillotining. 
The container is generally rectangular and has a depth such that the closed 
container has zero ullage (the amount the container lacks of being full) 
when filled with a standard count (usually 200 or 100) of psa sheet stock 
of average caliper. That is, the container is substantially full so that, 
with the bottom piece of the psa sheet stock resting on the bottom of the 
container, the top piece abuts the inside of the container's cover when 
the cover is closed. 
This allows a substantially full container to support one or more 
containers stacked thereon. Also, the cover of the container is hubbed, in 
a manner to be described, both to provide interlocking stability when a 
number of containers are stacked on each other, and to provide a snap 
closure around the entire perimeter of the cover, including the hinged 
edge of the cover. 
The container lid, walls and bottom are slightly flexible, so the 
supported, stabilized relationship of stacked containers holds even if the 
paper caliper is greater or less than average caliper by several percent, 
thus in a sense causing one or more containers to be slightly "overfilled" 
or "underfilled." That is, the caliper of the psa sheet stock may vary by 
several percent without serious adverse effect on the support of one 
container by another, or the interlocking stability of the stack. 
Thus, several containers can be stacked upon one another in a stable manner 
during shipping, storage, or while on display. The snap closure is 
provided by the interaction of the cover's hubbed portion with the base of 
the container. 
The container is transparent and clear to allow visual inspection of its 
contents without the necessity of opening the cover. This feature allows 
paper merchants or printers to display printed psa sheet stock within the 
container, thereby allowing purchasers to see the contents without opening 
the cover. It also allows for a quick visual inspection of the remaining 
quantity of psa sheet stock to determine whether it is time to re-stock or 
print more of a particular item. 
The transparent and clear material is moisture resistant to protect the psa 
sheet stock during shipping and storage. Furthermore, the material 
provides a relatively rigid molded container capable of withstanding the 
rigors of handling and shipping the psa sheet stock through the chain of 
distribution. The durability of the container allows it to be reused 
throughout the course of its usable life. 
The container is also provided with a hinged recloseable cover which allows 
easy access to the container's contents but is capable of snap closure 
around the entire cover perimeter including the hinged edge, thus 
maintaining good protection against moisture (and dust) in the closed 
position. 
The transparency of the present container allows inserts to be used for 
identifying the contents of the container and identifying the supplier of 
the contents. Such inserts can be readily removed and replaced with other 
inserts, or with labels, down the line of distribution, as desired. Also, 
contents may be seen regardless of what inserts or labels represent 
provided the inserts or labels do not cover the entire package. 
The features of the container are also advantageous because, in those lines 
of distribution mentioned above in which small printers go to paper 
merchants to purchase bundles of psa sheet stock, the paper merchants have 
in their inventory psa sheet stock from various manufacturers. A printer 
visiting the paper merchant can readily see and compare stocks packaged 
according to the invention, while he cannot as readily examine and compare 
stocks that are conventionally packaged. Furthermore, the printer can 
observe the display, recloseability, and reusability features of the 
container, and the fact that he will be able to use his own identifying 
inserts, if desired. The container is therefore a purchase "premium" to 
the printer. In these respects, the use of the container gives both the 
manufacturer of the stock and the paper merchant a competitive advantage 
in moving goods. 
The recloseability of the container allows printers to open the container, 
remove as much psa sheet stock as they need, print something thereon, and 
then place the psa sheet stock back in the container. The printer can then 
either display the printed psa sheet stock in the transparent and clear 
container, or ship the printed psa sheet stock to customers. When printed 
psa sheet stock is displayed within the transparent container, customers 
can open the container, remove as much printed sheet stock as they desire, 
and reclose the container. The recloseability provides convenient access 
to the contents of the container while simultaneously providing continuous 
protection of the psa sheet stock from humidity or other damage. 
Additionally, customers purchasing printed psa sheet stock from a printer 
can reuse the transparent and clear container to transport the psa sheet 
stock. The container may also be re-used by the customer to display the 
psa sheet stock if necessary. 
These advantages to the printer's customers give printers who use the 
containers a competitive advantage in selling printed psa sheet stock. The 
durability of the container allows it to be reused as required or desired 
for shipping, handling, storage or display by the paper merchant, the 
printer, the printer's customer, and anyone else in the chain of 
distribution, as may be desired. 
The construction and arrangement of the transparent and clear container is 
such that a recloseable cover is mounted on a hinge at one short side of 
the container's base. The cover and base each has its own flange around 
its perimeter, and the outer edge of each of these flanges preferably 
consists of a planar portion. The cover flange also has a hubbed portion 
including a positive-draft guiding section defining a guiding hub and a 
negative-draft locking section defining a locking hub. The base flange has 
an offset section which acts as a stop when contacted by the offset 
section of the cover flange. 
The base flange also has a negative-draft section which receives the 
negative-draft locking section of the cover flange. The joinder between 
the negative-draft section of the base flange and the planar portion of 
the base flange defines a detent edge extending around the perimeter of 
the base. When the cover is closed and snapped shut around its perimeter, 
a generally continuous closure is created by the interaction of the base 
flange and the cover flange. 
The container may be economically formed by the vacuum molding process. 
Consistently with that process, the walls of the base of the container 
have a slight draft angle, and the bottom corners tend to be rounded. In 
order to prevent the edges and corners of the psa sheet stock from curling 
by laying against the bottom corners of the container, platform means is 
provided at the base's bottom so the psa sheet stock lays flat. The 
platform means is defined by a plurality of channels which provide 
additional strength to the container. 
When the containers of the invention are stored on shelves they are 
generally stored lengthwise running from the front of the shelf to the 
back. With the hinge on the back of the container rather than one of the 
sides the containers can be more densely packed per unit length of shelf 
when stored, thereby taking up the least amount of shelf space.

DETAILED DESCRIPTION OF AN EXAMPLE OF THE INVENTION 
Referring now to the drawings, and in particular to FIG. 1, there is shown 
the container which is generally referred to by reference numeral 1. The 
container 1 is substantially rectangular, having a base 3 and a cover 5 
which are engageable and closable with each other by snap action around 
their entire perimeters. The container 1 is preferably formed of 40-gage 
non-pigmented virgin polyvinyl chloride sheet stock to the following 
nominal dimensions: length--11 inches, height--23/4 inches, and width--9 
9/16 inches. Various molding techniques are known which could be used to 
form the container 1. The preferred vacuum molding process is economical 
and typically results in rounding of the outside bottom corners or edges 8 
along the length and width of the base 3, as best seen in FIG. 6. Also, a 
border channel 7, best seen in FIG. 6, is formed during molding. The 
border channel 7 extends around the perimeter of the bottom 9 of the base 
3. 
Referring to FIG. 2, the bottom 9 includes a rectangular array of 
intersecting channels 19 and raised pads 25. This array is bounded by 
border channel 7. The array has a generally waffled configuration and 
includes a series of channels 13 which are parallel to the end walls 15 
and 17. Another series of channels 19 is provided which are parallel to 
side walls 21 and 23. 
Between the series of channels 13 and 19 are a multiplicity of raised pads 
25. The raised pads 25 provide a substantially flat surface upon which the 
psa sheet stock 26 rests, as best shown in FIG. 6. The stock 26 overhangs 
the raised pads 25 which are contiguous to the border channel 7. This 
occurs on all four sides of the psa sheet stock 26, so the stock is held 
slightly above the curved outside bottom corners or edges 8, and the edges 
and corners of the lowermost sheets of stock 26 cannot be curled or bent 
by contact with the curved edges 8. 
Referring now to FIGS. 1 and 3, the base 3 has two end walls 15 and 17, and 
two side walls 21 and 23, all extending upwardly from the border channel 7 
and forming slightly rounded corners at their intersections. The end walls 
15 and 17, and the side walls 21 and 23 are preferably disposed with a 
draft angle of 4 degrees, for example, to achieve economical and proper 
molding without an unnecessary increase in the size of the container. 
A base flange 27 (FIGS. 3, 5) extends around the perimeter of the base at 
the upper edges of the end walls 15 and 17, and the side walls 21 and 23. 
Referring to FIG. 5, there is shown a cross-section of the base flange 27 
with its thickness exaggerated for clarity. The base flange 27 includes a 
planar portion 29 having two widths, as best shown in FIGS. 1 and 2. The 
two widths of the planar portion 29 assist in opening the cover 5 as more 
fully described below. A base offset section 31 runs laterally from the 
side and end walls 15, 17, 21, and 23 to a negative-draft section 33 of 
the base flange 27. The base offset section 31 essentially forms a ledge 
on the inside of the base flange 27. The negative-draft section 33 joins 
the planar portion 29 at a detent edge 34, as best shown in FIG. 5. 
A cover flange 35 (FIG. 4) extends around the perimeter of the cover 6. The 
cover flange 36 includes a planar portion 37. At the front end of the 
cover, the planar portion 37 has a notch 39 formed therein, as best shown 
in FIGS. 1 and 2. The notch 39 and the planar portion 37 of the cover 
flange 36 cooperate with the planar portion 29 of the base flange 27 to 
facilitate opening the cover 6, as more fully described below. The cover 
flange 35 includes a hub portion 41 which includes a negative-draft 
locking section 43 defining a locking hub and an positive-draft section 46 
defining a guiding hub. The section 45 extends from the cover proper 47 to 
an offset section 49. The offset section 49 runs laterally from section 45 
to the negative-draft locking section 43 to which it is joined at a detent 
edge 48. 
The cover flange 36 and the base flange 27 are constructed and arranged so 
that a generally continuous nesting or closure is created between the 
cover 5 and the base 3 when the cover 5 is closed. The nesting 
relationship is such as to substantially inhibit the ingress of moisture, 
but need not establish a hermetic seal, and usually does not. The negative 
draft of the section 43 may be, for example, 5 degrees. As the lid is 
closed, the detent edge 48 of the lid snaps past the detent edge 34 of the 
base and the locking hub 43 and offset section 48 snap into a nesting 
relationship, more or less, with the sections 33 and 31 of the base. 
Since the walls are most strongly supported against sideward spreading at 
the corners of the container, the snap action may be most pronounced at 
the corners as the lid is closed. This detenting and snap action also 
tends to extend at least a limited distance from each corner along the 
base and cover flanges 27 and 35, to thereby nest the sections 43 and 40 
into the sections 33 and 31 at least at those regions. 
The nesting of flange elements of the lid and base as shown in an idealized 
manner in FIG. 5; in practice the angularity of adjacent elements such as 
33 and 42 or 31 and 49 may differ somewhat so that there is not continuous 
contact throughout their vertical extents as shown. Nevertheless, the 
nesting relation is sufficient to establish continuous contact between the 
flanges along the lengths of the regions of nesting. 
The material of the container is stiff enough that such nesting at the 
corner regions is sufficient to establish acceptable closure even midway 
between corners along the lengths of the end walls 15, 17 and side walls 
21, 23, even though nesting at such midpoints may be relatively loose and 
the cover and base flanges at these locations may be only closely 
positioned adjacent each other rather than in actual contact. 
It is to be noted that the cover and base flanges 35 and 27 extend around 
all four sides, including the hinge end of the container. Thus, at the 
hinge end, the planar portion 29 of the base flange 27 extends along the 
entire length of the end wall 17 inboard of the hinge 53, as most clearly 
seen in FIGS. 2 and 3. As seen in the same figures, the same is true of 
the planar portion 37 of the lid flange 35. The other elements of the base 
and cover flanges are still further inboard, and so they also extend along 
the entire length of the wall inboard of the hinge in the closed condition 
of the container. Thus, the seal can indeed extend in this manner along 
the hinge side of the container much as it extends along the other sides. 
After the cover is lowered, closing of the container can conveniently be 
completed by using the thumb and forefinger to grasp the planar portions 
29 and 37 and press them together to snap the container fully closed. For 
example, this can be done at the two front corners of the container using 
the thumb and forefinger of each hand, and the process can then be 
repeated at the two rear corners. If points midway between the corners 
require further closing, the planar portions 29 and 37 at those locations 
can be squeezed together also. 
As previously mentioned, the planar portion 29 of the base flange 27 
includes two widths, the outside edges of which are joined by a transverse 
edge 51, as best shown in FIGS. 1 and 2. When the cover 6 is closed the 
planar portion 37 of the cover flange 35 overlies the planar portion 29 of 
the base flange 27. The transverse edge 51 is aligned within the notch 39 
each other so that when the planar portions 29 and 37 are overlying, the 
canted section 51 and part of the planar portion 29 are exposed within the 
notch 39. Furthermore, the planar portion 37 is wider than the narrower 
width of planar portion 29 so that opposing forces can be exerted on those 
portions, respectively, by thumb and index finger of one hand, thereby 
breaking the seal or seals around the rim and opening the lid. 
Other arrangements can be provided, but the important relationship from the 
standpoint of opening convenience is that the flange portions 29 and 37 of 
the base and flange are arranged so that when the container is closed, 
there is at least one region where the upper flange portion has its lower 
face exposed, as at region 38 of upper flange portion 37 (FIG. 2), and at 
least one region where the lower flange portion has its upper face 
exposed, as at region 30 of lower flange portion 29 (FIG. 3), and these 
respective regions of exposure occur adjacent each other along the length 
of the front or end wall 15, These can be conveniently grasped with the 
thumb and forefinger and squeezed to prize the cover and base flanges 
apart and release them from each other at the front of the container. 
Lifting of the cover then readily causes release of the flanges at the 
remaining portions of the container. 
The hinge 53 is preferably given some width, as best seen in FIG. 3, so 
that it can flex somewhat to accommodate relative snap action motion 
between the cover and base flanges 35 and 27 as the container is closed. 
The hinge 53 connects the cover 5 and the base 3, at the base wall 
opposite to notch 39, that is, to end wall 17 in the illustrated 
container. As shown, the hinge 53 and notch 39 are preferably associated 
with the opposed end walls of the base, rather than with its opposed side 
walls. In this manner, when a multiplicity of containers are placed along 
a shelf with their lid fronts facing forward for most convenient opening, 
the containers can be more densely packed per unit length of shelf, 
thereby maximizing shelf space. 
The cover 5 is constructed so that the cover proper 6 forms a plane which 
is spaced from and parallel to the plane formed by the planar portion 37, 
as best shown in FIG. 3. When the container 1 is situated in a horizontal 
upright position and the cover 5 is closed, the plane formed by the cover 
proper 6 lies beneath the plane formed by the planar portion 37. Thus, the 
cover flange 35 defines a shallow rectangular recess that receives border 
channel 7 of the rectangular bottom 9 of an identical container stacked 
thereon in a manner that stabilizes the stacked containers against 
horizontal forces. If a multiplicity of containers are stacked upon each 
other, channels 7, 9 and 13 of the bottom of one container rest upon the 
cover proper 6 of the container below it. Preferably, the cover proper 6 
and the cover flange 35 are proportioned to snugly receive border channel 
7 of the bottom 9 of an identical container, thus providing a tight 
interlocking effect preventing and lateral sliding of one container 
relative to the other. 
The container 1 may be vacuum form molded by well-known techniques from, 
preferably, non-pigmented virgin polyvinyl chloride sheet stock. The 
material is moisture resistant and transparent, so that the contents of 
formed and filled containers may be seen without opening the cover 5. The 
material as molded is relatively rigid, but is capable of yielding for 
snap-action closing and is capable of readily flexing along a hinging 
joint such as the hinge 53, and is adapted to endure the rigors of 
shipping and handling. 
The method of packaging the psa sheet stock of a given nominal thickness 
includes the steps of providing the manufacturer of the psa sheet stock 
with the container 1 matched to a given standard sheet count, for example 
a count of 100 or 200 sheets of psa sheet stock, each sheet comprising the 
printable facestock itself, the coating of psa, and the release liner for 
protecting the psa. The container 1 is proportioned for stock of average 
caliper so that the top sheet of psa sheet stock abuts the lower surface 
of the cover proper 6, and the bottom sheet rests upon the raised pads 25. 
This allows stacked containers to be supported by the fill of the psa 
sheet stock in the container located thereunder. If the psa sheet stock in 
a container is, say, two or three percent thinner or thicker than average 
caliper, the cover 5 and waffled bottom are resilient enough so they will 
conform to the fill of psa sheet stock in the container 1, and the 
supporting relationship between containers in a stack is maintained. 
The paper manufacturer may put removable inserts in the container to 
designate or describe the stock. These, as well as the stock itself, are 
visible from the exterior of the container. The inserts may be color-coded 
or printed in any manner. 
Sometimes the filled containers are shipped directly to a printer, but it 
is more customary in the industry to ship them to a paper merchant first 
who may deliver them to a printer from stock or hold them and display them 
in stock for pick-up by a printer. Once the container reaches the 
printer's shelf, the printer can remove as much psa sheet stock as needed, 
print it, then return it to the container for storage, display, and 
subsequent distribution. The printer may guillotine the stock into 
separate labels which may then be shrink-wrapped in individual packs and 
replaced in the container. The printer may simply remove any previously 
provided color-coded or printed inserts and may provide his own labels or 
inserts on or in the container. 
While the invention has been shown and described with respect a to 
particular embodiment, this is for the purpose of illustration rather than 
limitation, and other variations and modifications of the disclosed 
embodiment will be apparent to those skilled in the art all within the 
intended spirit and scope of the invention. Accordingly, the patent is not 
to be limited in scope and effect to the specific embodiment herein shown 
and described nor in any other way that is inconsistent with the extent to 
which the art has been advanced by the invention.