Patent Publication Number: US-2019185203-A1

Title: Assembly and method for creating custom three-dimensional structures from printable blank sheets

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation of U.S. application Ser. No. 14/831,420, filed on Aug. 20, 2015, and entitled “Assembly and Method for Creating Custom Three-Dimensional Structures from Printable Blank Sheets,” the disclosure of which is incorporated by reference in its entirety. 
     U.S. application Ser. No. 14/831,420 is a continuation of U.S. application Ser. No. 13/612,198, filed on Sep. 12, 2012, and entitled “Assembly and Method for Creating Custom Three-Dimensional Structures from Printable Blank Sheets,” now issued as U.S. Pat. No. 9,132,935, the disclosure of which is incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The present invention relates to printable blank sheets for running through a printer, and in particular, to printable blank sheets that are capable of being formed into custom three-dimensional structures. 
     Custom print materials have become a common way for businesses to market themselves. Custom print materials that are typically used in advertising include two-dimensional products like postcards, flyers and door hangers, as well as three-dimensional products like golf ball boxes, candy boxes and pop-up calendars. Typically, custom print materials are sent to print shops that specialize in preparing custom print materials, as the materials have had to be printed and assembled by specialized machines. As a result, having custom print materials made can be costly and time-consuming. 
     Some printable blank templates are currently available for creating custom print three-dimensional materials without having to send them to print shops. These templates are die-cut with perforations and scored lines. The perforations surround the desired shape of the object and the scored lines indicate where the object should be folded to create a three-dimensional structure. The drawback to the currently available die-cut templates is that it is hard to detach the desired object from the excess sheet. It is difficult to fold the templates along the perforations due to the irregular placement of the perforations, thus the perforations are not weakened before they are torn apart. Trying to separate the perforated lines before weakening them often causes tearing of the object, which affects the strength and image of the resulting three-dimensional structure. 
     SUMMARY 
     According to the present invention, a printable blank comprises a sheet with outline perforation lines defining a periphery of an object. The sheet is capable of being passed through a printer to have an image printed on it. The sheet also comprises run-out perforation lines extending from the periphery to edges of the sheet, wherein the sheet can be folded along the run-out perforations to detach the object from the sheet. 
     A method for creating custom print structures includes running a printable blank sheet through a printer and then bending the sheet along run-out perforation lines to detach an object from the sheet. The object can then be folded along scored fold lines to assemble it into a three-dimensional structure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective side view of a golf ball box. 
         FIG. 2A  is a top view of a printable blank sheet having perforations, scored lines and die-cut lines. 
         FIG. 2B  is a top view of the printable blank sheet seen in  FIG. 2A , having two box flats placed upon the sheet. 
         FIG. 3  is a flow chart that shows how a custom print three-dimensional object can be formed from a printable blank sheet. 
         FIG. 4  is a side view of a printable blank sheet that is folded along run-out perforations. 
         FIG. 5A  is a top view of a die-cut box flat after it has been removed from a sheet utilizing the current invention. 
         FIG. 5B  is a top view of a die-cut box flat after it has been removed from a sheet utilizing the traditional die-cut template without run-out perforations. 
     
    
    
     DETAILED DESCRIPTION 
     In general, the present invention relates to printable blank sheets for creating custom three-dimensional structures. An outline of an object on the sheet is surrounded by perforations to help remove the object from the sheet. The sheet is capable of being run through a printer or a copier to have a custom image printed on it. The sheet is then capable of being folded back and forth along run-out perforations to help remove the excess sheet areas from the object. The object can be detached from the sheet and folded along scored lines to be formed into a three-dimensional structure. 
       FIG. 1  is a perspective side view of golf ball box  12 . Box  12  includes side faces  20 ,  22 ,  24 , and  26 , and end faces  30  and  32 . Side face  20  is connected to side face  22 . Side face  22  is connected to side face  20 , side face  24 , end face  30  and end face  32 . Side face  24  is connected to side face  22  and side face  26 . Side face  26  is connected to side face  24 . 
     Golf ball box  12  is formed by bending a flat box into a three-dimensional structure that is capable of holding golf balls. Side face  26  and side face  20  are attached with tabs and die-cut lines. End face  30  and end face  32  can be opened and closed so that golf balls can be placed in and taken out of golf ball box  12 . Forming box  12  from a flat allows for individual customization of box  12 , by providing a way to print a custom image on box  12  before it is assembled. This allows businesses to create their own custom print marketing materials at a lower cost. 
       FIGS. 2A-2B  are top views of sheet  10 , which contains two box flats  12  for printing.  FIG. 2A  shows the perforated, scored and die-cut lines on sheet  10 .  FIG. 2B  shows the areas that define two box flats  12  and the areas that define the excess sheet.  FIG. 2A  includes run-out perforations R (R 10 , R 12 , R 14 , R 16 , R 18 , R 20 , R 22 , R 24 , R 26 , R 28 , R 30 , R 32  and R 34 ), perforations P (P 10 , P 12 , P 16 , P 18 , P 20 , P 22 , P 24 , P 26 , P 28 , P 30 , P 32 , P 34 , P 36 , P 38 , P 40 , P 42  and P 44 ), scored lines S (S 10 A, S 10 B, S 12 , S 14 , S 16 , S 18 , S 20 , S 22 , S 24 , S 26 , S 28 , S 30 , S 32  and S 34 ) and die-cut lines D (D 10  and D 12 ).  FIG. 2A  also shows print areas PA. Sheet  10  can be made of paper, plastic, or any other suitable material that is capable of being printed on. Run-out perforations R run longitudinally across sheet  10  from one side to the other side. Run-out perforations R can be of any suitable weight, including micro-perforations. Perforations P surround the outline of two box flats  12  on sheet  10 . Perforations P can be of any suitable weight, including micro-perforations. Scored lines S are located on box flats  12  and define where box flats  12  should be folded. Scored lines S can be of any suitable weight. Die-cut lines D are located on box flats  12  and define areas where tabs can be inserted to hold boxes  12  together once they are formed into three-dimensional structures. Print areas PA are the areas on box flats  12  that are capable of being printed on without printing on the run-out perforations R, perforations P, scored lines S or die-cut lines D. 
     Each run-out perforation R is aligned with a perforation P, a scored line S, or both. Connecting each run-out perforation R with perforations P or scored lines S allows a user to bend sheet  10  along run-out perforations R without creating unwanted fold lines across sheet  10 . The only fold lines that will be made when bending run-out perforations R are folds along perforations P or scored lines S, which will be folded regardless. Folding run-out perforations R will weaken them and allow for easier detachment of box flats  12  from sheet  10 . 
     As shown in  FIG. 2B , each box flat  12  has side panels  20 ,  22 ,  24  and  26 ; end panels  30  and  32 ; side tabs  40 ,  42 ,  44 ,  46 ,  54 ,  56  and  58 ; and end tabs  50  and  52 .  FIG. 2B  further includes sheet  10  with excess sheet areas  100 ,  101 ,  102 A,  102 B,  103 ,  104 A,  104 B,  106 A,  106 B,  108 A,  108 B,  110 A,  110 B,  112 A,  112 B,  114 A,  114 B,  116 A,  116 B,  118 A,  118 B,  120 A,  120 B,  122 A,  122 B,  124 A,  124 B and  126  (collectively referred to as “excess sheet areas  100 - 126 ”). Excess sheet areas  100 - 126  surround box flats  12 . Excess sheet areas  100 - 126  are outlined by run-out perforations R and perforations P. Excess sheet areas  100 - 126  are expendable parts of sheet  10  that can be discarded when box flats  12  are removed from sheet  10 . 
     As seen in  FIGS. 2A-2B , side panel  20  has sides P 14 , S 22 , S 12  and S 20 . On side P 14 , side panel  20  is connected to side tab  56  along scored line S 10 A and to side tab  54  along scored line SLOB. The outline of side tab  56  is defined by perforated line P 10  and the outline of side tab  54  is defined by perforated line P 12 . Side panel  20  is connected to side tab  44  along scored line S 20 . The outline of side tab  44  is defined by perforated line P 16 . Side panel  20  is connected to side tab  40  along scored line S 22 . The outline of side tab  40  is defined by perforated line P 18 . 
     Side panel  22  has sides S 12 , S 26 , S 28  and S 14 . Side panel  22  is connected to side panel  20  along scored line S 12  and to side panel  24  along scored line S 14 . Side panel  22  is connected to end panel  32  along scored line S 26  and to end panel  30  along scored line S 28 . End panel  32  has sides S 26 , P 20 , S 24  and P 24 . End panel  32  is connected to end tab  52  along scored line S 24 . The outline of end tab  52  is defined by perforated line P 22 . End panel  30  has sides S 28 , P 26 , S 30 , and P 30 . End panel  30  is connected to end tab  50  along scored line S 30 . The outline of end tab  50  is defined by perforated line P 28 . 
     Side panel  24  has sides S 14 , S 32 , S 34  and S 16 . Side panel  24  is connected to side panel  22  along scored line S 14  and to side panel  26  along scored line S 16 . Side panel  24  is connected to side tab  46  along scored line S 32  and to side tab  42  along scored line S 34 . The outline of side tab  46  is defined by perforated line P 32  and the outline of side tab  42  is defined by perforated line P 34 . 
     Side panel  26  has sides S 16 , P 36 , S 18  and P 38 . The outline of side panel  26  is defined on opposite sides by perforated lines P 36  and P 38 . Side panel  26  is connected to side panel  24  by scored line S 16 . Side panel  26  is connected to end tab  58  along scored line S 18 . The outline of end tab  58  is defined by perforated lines P 40 , P 42  and P 44 . 
     Sheet  10  can be run through a printer or copier to have an image printed on it. After printing, sheet  10  can be folded along run-out perforations R. When folded, run-out perforations R will weaken and separate more easily. This allows excess sheets areas  100 - 126  to disconnect from one another. Further, folding sheet  10  along perforations P will allow excess sheet areas  100 - 126  to disconnect from box flats  12 . Box flats  12  will then be free-standing. The outline of box flats  12  are defined by perforations P. 
     Box flats  12  can be folded along scored lines S to form three-dimensional structures. Scored lines S 12 , S 14 , S 16  and S 18  can be folded into approximately 90 degree angles so that side panels  20 ,  22 ,  24  and  26  are at approximately 90 degree angles to the side panels they are attached to. Side tabs  54  and  56  can be folded along scored lines S 10 B and S 10 A, respectively. Side tab  54  can be inserted into die-cut line D 12  and side tab  56  can be inserted into die-cut line D 10 . This holds boxes  12  in three-dimensional rectangular shapes. Side tabs  40 ,  42 ,  44  and  46  can be folded along scored lines S 22 , S 34 , S 20  and S 32 , respectively, to fold side tabs  40 ,  42 ,  44  and  46  inward. End panels  30  and  32  can then be folded inward along scored lines S 28  and S 26 , respectively, and end tabs  50  and  52  can be folded inward along scored lines S 30  and S 24 , respectively. End tab  50  can be inserted into the gap that is formed between side panel  26  along perforated line P 38  and the rest of the box. End tab  52  can be inserted into the gap that is formed between side panel  26  along perforated line P 36  and the rest of the box. 
     Folding sheet  10  along run-out perforations R allows box flats  12  to be easily disconnected from sheet  10 . Run-out perforations R prevent tearing in box flats  12  when trying to disconnect them from sheet  10 . By creating an easier and more effective way to disconnect box flats  12  from sheet  10 , businesses can more easily create custom print materials to use in their marketing campaigns. Being able to create their own custom printed materials provides businesses with easy and cheap ways to market their businesses, versus the costly alternative of having to send any custom print orders to print shops, which can be time consuming and expensive. 
       FIG. 3  is a flow-chart showing the steps required to form a three-dimensional structure from a printable blank sheet. Steps  200 ,  202 ,  204 ,  206  and  208  show how businesses can create their own custom print marketing materials from printable blank sheets. 
     Step  200  includes running a blank sheet through a color printer or copier. The blank sheet can be made of paper, plastic, or any other suitable material that is capable of being printed on. The sheet will include the outline of an object defined by perforated lines and will have run-out perforations running from one side of the sheet to the other side. Both the perforations surrounding the object and the run-out perforations can be of any suitable weight. The blank sheet will be supplied to the user with scored lines and perforations from a manufacturer. The blank sheet will also have areas that are capable of being printed on so that the object can be custom printed. Prior to printing on the sheet, a template on a computer can be used to create the custom image that is to be printed on the sheet. The sheet will also have scored lines that define where the object can be folded to create a three-dimensional structure. The scored lines can be any suitable weight. 
     Step  202  includes bending the sheet along run-out perforations that run from one side of the sheet to the other side of the sheet. The sheet should be folded along the run-out perforations in an alternating manner, so that the resulting folded structure resembles a fan. The sheet should then be flattened out and folded along the run-out perforations in the opposite direction, again resembling a fan structure when completely folded. The sheet should then once again be flattened out, allowing the run-out perforations to break apart. 
     Step  204  includes detaching an object from the sheet. As stated above, the outline of the object will be defined by a set of perforated lines. To detach the object from the sheet, the excess sheet areas should be folded along the perforated lines surrounding the object, so that the excess sheet areas can be detached from the object. The excess sheet areas will already be partially detached after the sheet was folded along the run-out perforations. 
     Step  206  includes folding the object along scored lines. As stated above, the object will have scored lines that define where the object should be folded in order to form a three-dimensional structure. To form the three-dimensional structure, the object needs to be folded along each scored line. The scored lines should all be folded into approximately 90 degree angles. Each scored line should be folded inward, so that the blank sides of the object are folded towards each other. This allows the custom printed areas of the object to remain visible. 
     Step  208  includes assembling the object into a three-dimensional structure. To do this, side tabs and end tabs attached to the object need to be inserted into die-cut slots that will hold them in place. The only parts of the object that should remain visible after tucking the side tabs and end tabs into their designated slots should be four side panels and two end panels. 
     This method provides an efficient and effective way to form custom print three-dimensional structures from printable blank sheets. Using this method, businesses will be able to create custom marketing materials at a lower cost and in a time-efficient manner. Compared to the traditional die-cut objects, the new method allows for great accuracy and less chance that the object will be torn when trying to detach it from the excess sheet areas. This method increases the incentive for businesses to create their own custom print marketing materials by providing presentable and strong final products. 
       FIG. 4  is a side view of sheet  10  when it is partially folded along run-out perforations R (R 10 , R 12 , R 14 , R 16 , R 18 , R 20 , R 22 , R 24 , R 26 , R 28 , R 30 , R 32  and R 34 ). Each run-out perforation R runs from one side of sheet  10  to the other side and is interrupted by a portion of box flats  12 . Run-out perforations R partially define excess sheet areas  100 - 126  that are to be detached from box flats  12 . 
     As seen in  FIG. 4 , sheet  10  can be folded along each run-out perforation R in an alternating manner. When sheet  10  is completely folded along run-out perforations R it should resemble a fan. Folding sheet  10  weakens run-out perforations R so that they can be easily separated. Separating sheet  10  along run-out perforations R allows box flats  12  to easily separate from sheet  10  without tearing. This creates a stronger and more presentable final structure. 
       FIG. 5A  shows die-cut box flat  12  after it has been removed from sheet  10  using the current invention.  FIG. 5B  shows identically shaped die-cut box flat  12  after it was removed from a sheet using the traditional die-cut template without run-out perforations R. As seen in  FIG. 5A , when box flat  12  is separated from excess sheet areas  100 - 126  using the invention, there is minimal tearing of box flat  12 . As seen in Table 1, the average number of tears per box flat  12  when using the new invention is 0.3 tears per object. 
                     TABLE 1                  Number of tears per product with new invention.                         Sample Number   Errant Tears   Usable Product?                                 1   0   Yes       2   1   Yes       3   2   No       4   0   Yes       5   1   Yes       6   0   Yes       7   0   Yes       8   0   Yes       9   0   Yes       10   0   Yes       11   0   Yes       12   0   Yes       13   0   Yes       14   0   Yes       15   0   Yes       16   0   Yes       17   0   Yes       18   1   Yes       19   1   Yes       20   0   Yes                    
As seen in  FIG. 5B , when the traditional die-cut template without run-out perforations is used, there is significant tearing of box flat  12 , as evident by tears a, b, c, d, e, f, g and h.  FIG. 5B  is an actual representation of the tears in box flat  12  that were seen in one round testing. As seen in Table 2, the average number of tears per box flat  12  when using the traditional die-cut template equals 6.4 tears per box flat.
 
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Number of tears per product with traditional die-cut product. 
               
            
           
           
               
               
               
            
               
                 Sample Number 
                 Errant Tears 
                 Usable Product? 
               
               
                   
               
            
           
           
               
               
               
            
               
                 1 
                 7 
                 No 
               
               
                 2 
                 5 
                 No 
               
               
                 3 
                 4 
                 No 
               
               
                 4 
                 4 
                 Yes 
               
               
                 5 
                 7 
                 No 
               
               
                 6 
                 6 
                 No 
               
               
                 7 
                 8 
                 No 
               
               
                 8 
                 4 
                 No 
               
               
                 9 
                 7 
                 No 
               
               
                 10 
                 7 
                 No 
               
               
                 11 
                 6 
                 Yes 
               
               
                 12 
                 4 
                 Yes 
               
               
                 13 
                 6 
                 No 
               
               
                 14 
                 7 
                 No 
               
               
                 15 
                 8 
                 No 
               
               
                 16 
                 7 
                 No 
               
               
                 17 
                 8 
                 No 
               
               
                 18 
                 8 
                 No 
               
               
                 19 
                 3 
                 Yes 
               
               
                 20 
                 12 
                 No 
               
               
                   
               
            
           
         
       
     
     As evident from the test data above, the invention is a great improvement over the prior die-cut template without run-out perforations. To detach the prior die-cut template, one had to be careful to tear box flat  12  out of sheet  10  only around perforations P. This is difficult to do since perforations P are irregularly placed on the sheet and there is no way to easily fold the sheet along perforations P to weaken perforations P. The invention allows a user to split excess sheet areas  100 - 126  into different pieces by first folding them along run-out perforations R. This allows a user to fold excess sheet areas  100 - 126  along perforations P that surround the object so that perforations P can weaken before they are torn. This provides a lesser chance of tearing box flat  12  and a more presentable and usable product in the end, while still allowing a user to custom print their own image on sheet  10 . 
     While the invention has been described with reference to golf ball sleeve box  12  with a specific shape and size, any die-cut object that is capable of being formed from a flat sheet into a two-dimensional or three-dimensional structure can be placed on the printable blank sheet. Examples can include business cards, postcards, candy boxes, door hangers or pop-up calendars. The sheet was described with reference to a particular material, shape and size, but the sheet can be made of any material that is capable of being printed on and can be any size and shape that is capable of being run through a printer or copier. 
     While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.