Patent Publication Number: US-8991685-B2

Title: Partition

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/557,454 filed on Nov. 9, 2011, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     Embodiments generally relate to partitions. 
     BACKGROUND 
     Partitions are sometimes used to separate the interior of a container or box into a plurality of cells to prevent items such as bottles from breaking or becoming damaged during shipping and handling. Many partitions are formed by assembling together a plurality of individual pieces. While capable of being shipped to a user in a relatively flat position, partitions formed using a plurality of pieces require the user to either manually assemble and erect the partition for use or to utilize specialized machinery to assemble and erect the partition for use. 
     Some partitions require intricate folding and/or tabbing and/or gluing to erect the partition, which requires either manual assembly or assembly by specialized machines, both of which are expensive and time consuming. 
     SUMMARY 
     The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim. 
     Generally, according to one aspect, disclosed is a partition formed from a single piece of foldable material comprising a first panel, a second panel, and a third panel, wherein the first panel is adhered at least partially to the third panel so that the first panel forms a first flap and a second flap, wherein the second panel is adhered at least partially to the third panel so that the second panel forms a third flap and a fourth flap, and wherein a first portion of the third panel corresponds to a first center panel and a second portion of the third panel corresponds to a second center panel. Moreover, the first flap and the first center panel define a first cell configured to receive a first item, the first flap and the second flap define a second cell configured to receive a second item, the second flap and the second center panel define a third cell configured to receive a third item, the second center panel and the fourth flap together form a fourth cell configured to receive a fourth item, the fourth flap and the third flap define a fifth cell configured to receive a fifth item, and the third flap and the first center panel define a sixth cell configured to receive a sixth item. 
     According to another aspect, the foldable material is comprised of a flexible material so that the first, second, third, and fourth flaps are configured to generally conform to product housed in any of the first, second, third, fourth, fifth, or sixth cells. 
     According to another aspect, the foldable material has a thickness of between approximately 15 thousandths of an inch and approximately 40 thousandths of an inch. 
     According to another aspect, the first panel is adhered to the third panel along a middle portion of the first panel and along a middle portion of the third panel. 
     According to another aspect, the second panel is adhered to the third panel along a middle portion of the second panel and along a middle portion of the third panel. 
     According to another aspect, the partition has a leading edge that is generally wedge-shaped. 
     According to another aspect, disclosed is a unitary blank comprising a first panel, a second panel and a third panel each comprising a top and a bottom edge, wherein the second panel is positioned between the first and third panels. The unitary blank also comprises a first cut line that separates an upper portion of the first panel from an upper portion of the second panel and a second cut line that separates a lower portion of the first panel from a lower portion of the second panel, wherein the first panel is foldably connected to the second panel at a first center portion located between the first cut line and the second cut line. The unitary blank further comprises a third cut line that separates an upper portion of the second panel from an upper portion of the third panel and a fourth cut line that separates a lower portion of the second panel from a lower portion of the third panel, wherein the second panel is foldably connected to the third panel at a second center portion located between the third cut line and the fourth cut line. 
     According to another aspect, the top edge of the third panel extends beyond the top edges of the first and second panels, and wherein the bottom edge of the third panel extends beyond the bottom edges of the first and second panels. 
     According to another aspect, the blank is formed of a flexible material having a thickness of between approximately 15 thousandths of an inch and approximately 40 thousandths of an inch. 
     According to another aspect, dimensions of the first and second panels are substantially equal. 
     According to another aspect, the blank comprises at least one glue area. 
     According to another aspect, disclosed is a single blank comprising a first panel that is adjacent a second panel that is adjacent a third panel, a first cut line that extends from an edge of the first panel to an edge of the second panel, and a second cut line that extends from the edge of the first panel to the edge of the second panel, wherein the first and second cut lines divide the first panel into a first flap, a second flap, and a third flap and divide the second panel into a fourth flap, a fifth flap, and a sixth flap. 
     According to another aspect, the first, second, and third panels each comprise top and bottom edges and wherein the top edge of the third panel extends beyond the top edges of the first and second panels and wherein the bottom edge of the third panel extends beyond the bottom edges of the first and second panels. 
     According to another aspect, the blank has a thickness ranging from approximately 15 thousandths of an inch and approximately 40 thousandths of an inch. 
     According to another aspect, the blank comprises at least one glue area. 
     According to another aspect, the fourth flap of the second panel is separated from an upper portion of the third panel by a first cut line. 
     According to another aspect, the sixth flap of the second panel is separated from a lower portion of the third panel by a second cut line. 
     According to another aspect, the first flap of the first panel is separated from the fourth flap of the second panel by a third cut line. 
     According to another aspect, the second flap of the first panel is separated from the fifth flap of the second panel by a fold line. 
     According to another aspect, the third flap of the first panel is separated from the sixth flap of the second panel by a fourth cut line. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a unitary blank of foldable material which may be folded and glued into a partition according to one embodiment; 
         FIG. 2  is plan view of a unitary blank of foldable material which may be folded and glued into a partition according to another embodiment; 
         FIG. 3  is a perspective view of a partially assembled and knocked-down flat partition formed from the blank of  FIG. 1 ; 
         FIG. 4  is a perspective view of an erected partition formed from the blank of  FIG. 1 ; and 
         FIG. 5  is a perspective view of an erected partition formed from the blank of  FIG. 1 , inserted within a package and between a plurality of bottles. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. 
     Referring now to the drawings for a better understanding of the invention,  FIG. 1  illustrates a single blank of foldable material  1  such as, but not limited to, paperboard, chip board, or corrugated board. In some embodiments, the blank may have a thickness of between approximately 15 thousandths of an inch and approximately 40 thousandths of an inch, although the blank may have any suitable thickness and such thickness may vary depending on the product the partition is intended to protect and/or the density of the blank. As illustrated, blank  1  includes three adjacent panels  2 ,  3 , and  4 . In some embodiments, panels  2 ,  3 , and  4  are generally rectangular in shape, although the panels may have any suitable shape. Panels  2 ,  3 , and/or  4  may be substantially equal in the dimension Q, but the dimension Q of each or all of the panels  2 ,  3 , and  4  may vary from one another. Specifically, panel  3  may be larger than the other panels to keep panel  4  from binding when the blank is folded. Also in some embodiments, two of the panels (panels  2  and  3  as illustrated) are substantially equal in the dimension P, while the top edge  15  of one of the panels (panel  4  as illustrated) extends slightly beyond the top edges  13 ,  14  of panels  2  and  3 , respectively, and the bottom edge  18  of panel  4  extends slightly beyond the bottom edges  16 ,  17  of panels  2  and  3 , respectively. In other embodiments, all three panels  2 ,  3 , and  4  have substantially the same dimensions. 
     In the configuration where one of the panels (panel  4  as shown) includes top  15  and bottom  18  edges that extend beyond the top  13 ,  14  and bottom edges  16 ,  17  of panels  2  and  3 , this configuration helps ensure even and consistent folding of the blank  1  into an assembled partition. Moreover, having one panel with greater dimensions than the dimensions of the other two panels aids in the insertion of the partition into a container and aids in the separation of the flaps on panels  2  and  3  from panel  4 , as described with respect to  FIG. 4  below. 
     As shown in  FIG. 1 , blank  1  includes cut lines  5   a  and  5   b  that separate panels  2  and  3 . Fold line  7  is positioned between cut lines  5   a  and  5   b  so that panels  2  and  3  are foldably connected to one another along fold line  7 . Blank  1  also includes cut lines  6   a  and  6   b  that separate panels  3  and  4 . Fold line  8  is positioned between cut lines  6   a  and  6   b  so that panels  3  and  4  are foldably connected to one another along fold line  8 . Blank  1  also includes at least one glue area, such as glue area  11  located on the rear side of panel  4 , although more or less glue areas could be used. The glue area(s) may also be positioned differently than illustrated. 
     Blank  1  may be folded into a knock-down flat (KDF) configuration using standard machinery, such as a standard flexo/folder/gluer machine The machine folds panel  4  over onto panel  3 , and then adhesive is applied on the rear side of panel  4  at glue area  11  and panel  2  is folded onto panel  3  to assemble the partition into its KDF configuration. The adhesive applied at glue area  11  on the backside of panel  4  binds panels  2  and  4  together. In some embodiments, the now partially assembled blank is then passed through a roller which applies pressure to the folded partition and further binds panel  2  to panel  4  at glue area  11 .  FIG. 3  illustrates an embodiment of the partially assembled blank in its KDF configuration that is ready for shipment. 
       FIG. 2  illustrates another embodiment of a single blank from which a partition is formed. Blank  20  may be formed of a foldable material such as paperboard, chip board, or corrugated board. In some embodiments, the blank may have a thickness of between approximately 15 thousandths of an inch and approximately 40 thousandths of an inch, although the blank may have any suitable thickness and such thickness may vary depending on the product the partition is intended to protect and/or the density of the blank. As illustrated, blank  20  includes three adjacent panels  21 ,  22  and  23 . Panels  21 ,  22  and  23  are all generally rectangular in shape and are substantially the same in dimension Q, although the panels may have any suitable shape and may not be substantially the same in dimension Q. Panels  21  and  22  as shown have substantially equal dimensions, although they need not. In some embodiments, two of the panels (panels  21  and  22  as illustrated) are substantially equal in dimension P, while the top edge  44  of one of the panels (panel  23  as illustrated) extends slightly beyond the top edges  42 ,  43  of panels  21  and  22 , respectively, and the bottom edge  47  of panel  23  extends slightly beyond the bottom edges  45 ,  46  of panels  21  and  22 , respectively. In other embodiments, all three panels  21 ,  22 , and  23  have substantially the same dimensions. 
     In embodiments where the dimension P of one of the panels (panel  23  as illustrated) is greater than the dimension P of the other panels, such a configuration aids in even and consistent folding of the panels into a partially assembled partition. In addition, the extension of the top  44  and bottom  47  edges of panel  23  beyond the top  42 ,  43  and bottom edges  45 ,  46  of panels  21  and  22 , respectively, aids in the insertion of the partition into a container and aids in the separation of flaps  24 ,  26 ,  27 , and  29  on panels  21  and  22  away from panel  23  for insertion into the container. 
     As shown in  FIG. 2 , blank  20  includes score lines  72  and  74  that generally extend from an outer edge  48  of panel  21  to an inner edge  49  of panel  23 . These score lines divide panel  21  into three portions  24 ,  25 ,  26  and divide panel  22  into three portions  27 ,  28 , and  29 . Score lines  72  and  74  may be perforation lines, fold lines, or other suitable lines of weakness. Portion  24  is separated from portion  27  via cut line  64 , while portion  25  is separated from portion  28  by fold line  66 , and portion  26  is separated from portion  29  via cut line  68 . Panels  21  and  22  are foldably connected to one another via fold line  66  located between portions  25  and  28 . Portions  24 ,  26 ,  27 , and  29  define flaps in the assembled partition. Panels  22  and  23  are separated from one another via cut lines  39  and  40  but are foldably connected via fold line  41 . Blank  20  also includes glue areas  35 ,  36 ,  37 , and  38 , although more or less glue areas may be used and glue areas may be located at other suitable locations along blank  20 . For instance, glue area  11  of blank  1  may be used instead of glue areas  35 - 38 . The use of glue is optional, and the folded partition may be held in place using other means, for example but not limited to, staples or by the interaction of features on one panel engaging with features on another panel. 
     The partition shown in  FIG. 2  also includes optional notches  50 ,  51 , and  52  separating panels  24 ,  27  and  25 ,  28  and  26 ,  29 , respectively. Optional notches  53 ,  54 ,  55  may be generally diamond shaped as shown in  FIG. 2 , although the notches may have any suitable shape. Notches  53 ,  54 ,  55  align with notches,  50 ,  51 ,  52  when the partition is folded into the partially assembled knock-down flat (KDF) configuration. The notches help prevent any packaging present on the objects to be separated by the partition (for example, labels on a wine bottle) from becoming damaged during insertion of the partition and/or positioning of the objects within the partition. In other embodiments, notches  50 - 55  are not used at all. 
     As with blank  1 , blank  20  may be folded into a knock-down flat (KDF) configuration using standard machinery, such as a standard flexo/folder/gluer machine In some embodiments, the standard flexo/folder/gluer applies glue or other suitable adhesive at glue areas  35 ,  36 ,  37 , and  38 . After applying the adhesive, the machine folds panel  23  over onto panel  22 . The machine then folds panel  21  on top of panel  23  in its position on top of panel  22  to assemble the partition into the KDF configuration. The adhesive applied at glue areas  37 ,  38  bonds panels  22  and  23  together. The adhesive applied at glue areas  35  and  36  bonds panels  21  and  23  together. In some embodiments, the now partially assembled blank is then passed through a roller which applies pressure to the folded partition and further binds panel  22  to panel  23  and panel  21  to panel  23  at glue areas  35 ,  36 ,  37 , and  38 . 
     Turning to the embodiment shown in FIGS.  1  and  3 - 5 , as shown in  FIG. 4 , panel  4 ′ of erected partition  60  corresponds to panel  4  of blank  1  and acts as a center divider, with the center divider having a first portion  76  with an edge  15 ′ corresponding to edge  15  of blank  1  of  FIG. 1  and a second portion  78  with an edge  18 ′ corresponding to edge  18  of blank  1  of  FIG. 1 . Erected partition  60  includes a plurality of flaps  31 ,  32 ,  33 , and  34 , which are used to separate objects, such as bottles or other product, within a container. Flap  31  of erected partition  60  includes edge  13 ′, which corresponds to top edge  13  of panel  2  of blank  1  shown in  FIG. 1  after it has been folded away from panel  4 ′. Flap  32  of erected partition  60  includes edge  16 ′, which corresponds to bottom edge  16  of panel  2  of blank  1  in  FIG. 1  after it has been folded away from panel  4 ′. Flap  33  of erected partition  60  includes edge  14 ′, which corresponds to top edge  14  of panel  3  of blank  1  in  FIG. 1  after it has been folded away from panel  4 ′. Flap  34  of erected partition  60  includes edge  17 ′, which corresponds to bottom edge  17  of panel  3  of blank  1  in  FIG. 1  after it has been folded away from panel  4 ′. 
     The partition  60  depicted in  FIG. 4  may be erected and inserted into a container using standard or custom machinery. The machine receives the partition in its partially assembled knock-down flat position (as shown in  FIG. 3 ) and, in one embodiment, positions the partition within the container so that fold line  7 ′, which corresponds to fold line  7  of blank  1  in  FIG. 1 , is oriented upwards as shown in  FIG. 4 . The machine then creates flaps  31 ,  32 ,  33 ,  34  shown in  FIG. 4  by manipulating edges  13 ′,  14 ′,  16 ′, and  17 ′ away from the center panel  4 ′. As shown in  FIG. 4 , the center panel  4 ′ (which corresponds to panel  4  of blank  1  in  FIG. 1 ) extends beyond edges  13 ′,  14 ′,  16 ′, and  17 ′, thus making it easier for the machine to separate the edges  13 ′,  14 ′,  16 ′,  17 ′ from the center panel  4 ′ when forming flaps  31 ,  32 ,  33 , and  34 . The container may then be subsequently loaded with bottles or other objects to be separated by the partition. 
     Because the material of blank  1  is relatively thin, flaps  31 ,  32 ,  33 ,  34  are flexible and curvilinear in nature. The curvilinear nature of the flaps allows the flaps to conform to the size and shape of bottles or other product positioned within the partition (as shown in  FIG. 5 ). Because the flaps conform to the contour of the bottle or other product positioned within the partition, partition  60  is capable of being used with various sized and shaped bottles or other product contained within partition. In this way, partition  60  may be used with wine or beer bottles or other product having different diameters, allowing the partition to be more universal. 
     Also provided is a method of erecting the partition  60  and positioning it within a container filled with bottles or other objects to be separated by the partition. According to one embodiment, as described above, a standard partition inserting machine erects (opens) the partition  60  by separating edges  13 ′,  14 ′,  16 ′,  17 ′ from center divider  4 ′, fanning them out to form flaps  31 ,  32 ,  33 ,  34  and to create enough space to receive the neck of each bottle or other object to be separated by the partition. According to one embodiment, partition  60  is inserted into a container loaded with bottles or other objects to be separated by the partition. Specifically, the machine positions the partition  60  within the container so that the necks of the bottles (or other objects) within the container are each received within the space/cells created between flaps  31 ,  32 ,  33 , and  34  and the center panel  4 ′. The machine then urges the partition downwards into the container, allowing the necks of the bottles to guide the flaps  31 ,  32 ,  33 ,  34  into their final resting position, as shown in  FIG. 5 . As described above, the final resting position of the flaps is determined by the shape of the bottles within the package as shown in  FIG. 5 . In this way, as described above, the curvilinear nature of the flaps allows for the partition to be universally used to separate bottles or other product of various sizes within a container. In other embodiments, the partition is manually erected and positioned within a container that is pre-loaded with bottles or other objects, or is manually erected and positioned within an empty container for subsequent loading of bottles or other objects to be separated by the partition. 
       FIG. 5  depicts erected partition  60  after it has been inserted within a container to separate a plurality of bottles. Specifically, partition  60  separates bottles  62  and helps prevent them from contacting one another. As shown in  FIG. 5 , partition  60  creates six cells for receiving bottles  62  where the size of each cell is determined by the diameter of each of the bottles or other product due to the curvilinear nature of the flaps  31 ,  32 ,  33 , and  34 . Specifically flap  34  and second portion  78  of center panel  4 ′ form a first cell, flap  34  and flap  33  form a second cell, flap  33  and the first portion  76  of center panel  4 ′ form a third cell, the first portion  76  of center panel  4 ′ and flap  31  form a fourth cell, flap  31  and flap  32  form a fifth cell, and flap  32  and second portion  78  of center panel  4 ′ form a sixth cell. 
     As mentioned above, the partition described above is capable of being formed, folded, erected, and loaded on standard equipment, thus reducing capital investment and labor costs. Reduced cost and assembly time is also achieved because erecting the partition does not involve gluing or complicated folding or other intricate steps. Moreover, the partition described is universal in nature and can accommodate objects having different dimensions, thus eliminating the need to stock different partitions for different products, which reduces inventory costs. The partition design also reduces paperboard waste, as the partition is configured so it does not lie flush against the sides of the container. In addition, in certain embodiments, the positioning of the glue area uses substantially less adhesive. In addition, in some embodiments, the leading edge of the erected and assembled partition (i.e., the partition edge that first enters the container when the partition is inserted) is generally wedge-shaped instead of generally straight, which provides an easier entry with less opportunity to damage product housed within the container and/or any labeling on product housed within the container due to reduced forces at the point of contact between the leading edge and the product housed in the container. For example, the third panel  4  or  23  that forms the center panels  76  or  78  is shown at one end of the blank so that the second panel  3  or  28  wraps round to meet one face of the third panel and the first panel  2  or  21  wraps in the same direction round to meet the other face of the third panel. In an alternative arrangement, the third panel  4  or  23  that forms the center panels  76  or  78  may be positioned in the center of the blank, with the second panel wrapping one way to meet one face of the third panel, and the first panel wrapping the other way to meet the other face of the third panel. 
     Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below.