Patent Description:
Many products that consumers use on a weekly, or even daily, basis are often sold to consumers in packaging that provides for secure storage. For example water soluble unit dose products are often sold in plastic tubs that have a hinged closure having an opening and closing mechanism that the user manually manipulates to open and close the package. Flexible bags having a tongue in groove locking closure are also commonly used for such products.

Presently, manufacturers of products are intensely focused on sustainable packaging options. Pulp based packaging is garnering particular attention because the recycling stream for such materials is well developed and access thereto is convenient for consumers.

Packages that can be opened and securely closed multiple times can be difficult to fabricate from pulp based materials. Paperboard and corrugate are pulp based materials that show promise for packaging water soluble unit dose products. The rigidity and strength of paperboard and corrugate are a function of many variable, including the thickness of the material. To provide for a package that can be opened and securely closed multiple times, the locking mechanism must be robust. Locking mechanisms used paperboard and corrugate packages commonly employ tabs that fit into slots or panel edges that interfere with movement of flaps. Deformation of the panels, tabs, and flaps can operate to engage and disengage the locking mechanism. Robustness can be provided for by using thick paperboard or corrugate. Of course, increasing the thickness, and thereby weight, of the package per se can have a negative impact on the sustainability of the packaging.

To provide for a robust locking mechanism for packages formed from thin paperboard or corrugate, special attention must be given to the yield stress of the constituent material. The mechanical behavior of paperboard and corrugate below the yield stress is approximately elastic. Mechanisms that operate such the paperboard or corrugate behaves elastically can be robust. When paperboard or corrugate is stressed beyond the yield stress, plastic deformation occurs. For a locking mechanism constructed of paperboard or corrugate, plastic deformation can permanently degrade the function and security of the locking mechanism. As such, designs for locking mechanisms for paperboard and corrugate packages in which the constituent materials operate with elastic behavior are desirable.

With these limitations in mind, there is a continuing unaddressed need for a process for fabricating components of paperboard and corrugate packages that provide for maintaining functionality and security of a locking mechanism for paperboard and corrugate packages.

<CIT> relates to a consumer product comprising a container containing a detergent product preferably comprising water soluble unit dose articles. The container comprises a box and a lid, the lid comprises a top panel and flanks. The flanks comprise a first flank corresponding to a first side of the lid from a first flank corner to a second flank corner, the first flank comprises a first major flap comprising a first flank corrugated fiberboard layer. The first flank corrugated fiberboard layer is connected by a first flank fold line to the top panel, the first flank corrugated fiberboard layer comprises first flank flutes, each first flank flute running along a first flank flute length parallel to the first flank fold line, forming a channel in communication with an external environment outside of the lid at a first flank flute end and at a second first flank flute end. '<NUM> discloses a method for manufacturing said consumer product.

A process for packaging a product comprising the steps of: manufacturing the product, wherein said product is a substrate treatment composition ; providing a tray carriage system; providing a tray movable in or on said tray carriage system; moving said tray via said tray carriage system in a machine direction; providing a dispensing system above said tray carriage system; dispensing said product into said tray via said dispensing system; providing a hood engagement system above said tray carriage system and downstream of said dispensing system; providing a hood moveable in said hood engagement system, wherein said hood is erected by a process comprising the steps of: providing a flat blank comprising a leading panel, a trailing panel opposite said leading panel, a hood top extending between said leading panel and said trailing panel, a leading fold line between said leading panel and said hood top, a trailing fold line between said trailing panel and said hood top; providing a flat insert adhered to a panel selected from the group of said leading panel, said trailing panel, and combinations thereof, wherein said flat insert has a central portion between said leading fold line and said trailing fold line and wherein said central portion is unattached to said hood top; providing a die comprising a leading edge and trailing edge, a pair of side edges extending from said leading edge to said trailing edge, and a die recess, wherein said die recess is recessed relative to said leading edge, said trailing edge, and said side edges; providing hood mold having a cavity; orienting said flat insert towards said die recess; and positioning said die within said hood mold to fold said flat blank about said leading fold line and said trailing fold line and to fold said flat insert coincidentally with at least one of said leading fold line and said trailing fold line, whereby said central portion is spaced apart from said hood top; engaging said hood with said tray via said hood engagement system to fit said insert within said tray and close said tray to form a closed package; and shipping said closed package.

A process for erecting a hood for a tray is described herein. The process can be a part of an end to end process for packaging a product. The product can be any product of the type that can be shipped in a paperboard or corrugate package comprising a tray and a hood telescopically fitted to one another. The product can be a substrate treatment composition. The product can be a substrate treatment composition selected from a laundry treatment composition, a hard surface treatment composition, a laundry washing machine treatment composition, a hair treatment composition, a skin treatment composition, an oral care composition, a cosmetic composition, a nail treatment composition, an air treatment composition, a dish treatment composition, a disposable absorbent article, and a topical or ingested health care composition. The substrate treatment composition can comprise an ingredient selected from a surfactant, a bleach, a fabric softener, and combinations thereof.

A tray <NUM> employed in the process is shown in <FIG>. The tray <NUM> and hood can be formed of paperboard or corrugate. Paperboard and corrugate materials can comprise pulp. The paperboard or corrugate can have a thickness from <NUM> to about <NUM>. The paperboard or corrugate can be a laminate. The paperboard or corrugate can comprise pulp. The paperboard or corrugate can comprise colorants, preservatives, plasticizers, ultraviolet stabilizers, oxygen, perfume, recycled materials, moisture barriers, and combinations thereof. Corrugate can comprise a laminate of two sheets of paperboard having a fluted layer disposed between the two sheets of paperboard. Each of the tray <NUM> and hood can be a single piece of die cut paperboard or corrugate having a pattern of the faces of the tray <NUM> or hood and flaps extending from the faces or panels. The tray <NUM> or hood can be erected by joining a combination of the flaps or a combination of the flaps and faces or panels to erect the tray <NUM> or hood. The flaps and or faces or panels can be joined to one another by gluing, thermal bonding, fitting tabs to slots, and engaging interlocking structures.

The tray <NUM> can be conveyed in a machine direction MD. The tray <NUM> can comprise a leading face <NUM> and a trailing face <NUM> upstream of the leading face. The tray <NUM> can have a front face <NUM> and a back face <NUM> opposite the front face <NUM>. The front face <NUM> and the back face <NUM> extend from the leading face <NUM> to the trailing face <NUM> in the machine direction MD. The tray <NUM> can comprise a peripheral rim <NUM> defining a top opening of the tray <NUM>. The tray <NUM> can have a longitudinal axis L in line with the machine direction MD.

A hood <NUM> employed in the process is shown in <FIG>. The hood <NUM> can comprise a leading panel <NUM>, trailing panel <NUM> opposite to and upstream of the leading panel <NUM>, and a hood top <NUM> extending from the leading panel <NUM> to the trailing panel <NUM>. The hood <NUM> can comprise a pair of opposing hood side peripheral edges <NUM>. The hood <NUM> can be telescopically fitted to the tray <NUM> to form a closed package <NUM> (<FIG>).

The high speed process for dispensing a product <NUM> into a tray <NUM> described herein can be part of an end to end process for packaging a product <NUM>, as shown in <FIG>. The steps of the process can include manufacturing the product <NUM>. The product <NUM> can be a substrate treatment composition. A tray carriage system <NUM> can be provided. The tray <NUM> can be provided and be movable in or on the tray carriage system <NUM>. The tray <NUM> can be moved at the tray velocity TV via the tray carriage system <NUM> in the machine direction MD. The tray velocity TV can be constant or variable.

A dispensing system <NUM> can be provided and the product <NUM> can be dispensed into the tray <NUM> via the dispensing system <NUM>. The product <NUM> can be a water soluble unit dose laundry or dish cleaning product. The product <NUM> can be TIDE PODS, ARIEL <NUM> IN <NUM> PODS, FAIRY ALL IN ONE, CASCADE ACTION PACKS, CASCADE PLATINUM, and the like available from The Procter & Gamble Company.

A hood engagement system <NUM> can be provided above the tray carriage system <NUM> and downstream of the dispensing system <NUM>. The hood <NUM> is engaged with the tray <NUM> via the hood engagement system <NUM> to close the tray <NUM> to form the closed package <NUM>. The hood engagement system <NUM> can be a rotary hood engagement system <NUM> that fits a hood <NUM> to a tray <NUM> as the tray <NUM> passes beneath the hood engagement system <NUM>. The hood engagement system <NUM> can include a plurality of suction heads <NUM> that engage the hood top <NUM>. The hood <NUM> can be picked up by the suction head <NUM> as the suction head <NUM> passes a hood magazine <NUM>. The hood magazine <NUM> can serially feed a hood <NUM> to be engaged with the suction head <NUM> as the suction head <NUM> rotates past the hood magazine <NUM>. The suction heads <NUM> can be mounted on a rotating turret <NUM>. Suction applied to the suction head <NUM> holds the hood <NUM> against the section head <NUM>. Movement and control of the rotating turret <NUM> and the tray carriage system <NUM> can be coupled so that the hood <NUM> can be fitted to a tray <NUM> as the tray passes beneath the hood engagement system <NUM>. The angular velocity of the rotating turret <NUM> can be constant or variable. Rotation of the rotating turret <NUM> can be indexed so that the hood <NUM> can be fitted to a tray <NUM> passing beneath the rotating turret <NUM>. When the hood <NUM> is above the tray <NUM>, suction on the suction head <NUM> can be released to drop the hood <NUM> and fit the hood <NUM> onto the tray <NUM>. Optionally the suction head <NUM> can moved in the radial direction to push or slightly push the hood <NUM> onto the tray <NUM>.

The hood <NUM> and tray <NUM> can be engaged at a merging location <NUM> along the tray carriage system <NUM>. The hood engagement system <NUM> can further comprise a hood guide <NUM> above the tray carriage system <NUM> at or in or downstream of the merging location <NUM>. The hood guide <NUM> can be nearer to the tray carriage system <NUM> downstream of the merging location <NUM> than at the merging location <NUM>. The hood guide <NUM> can contact the hood top <NUM> to telescopically fit the hood <NUM> onto the tray <NUM>. The hood guide <NUM> can be a wedge that pushes the hood <NUM> to fit to the tray <NUM>. The hood guide <NUM> can be a belt that is positioned at a small angle relative to the machine direction MD to force the hood <NUM> to fit to the tray.

After the hood <NUM> is fitted to the tray <NUM>, the closed package <NUM> can be further processed and shipped. For example the closed package <NUM> can be shipped to a distributor or distribution facility and further along the supply chain until it reaches a location at which a user can open the package <NUM> by removing the hood <NUM>, retrieve the product <NUM> from the tray <NUM>, and use the product <NUM>.

The tray <NUM> can have a front face fold back <NUM> that is an integral extension of the front face <NUM> folded towards the interior of the tray <NUM> along a front face fold line <NUM> (<FIG>). Similarly, the tray <NUM> can have a back face fold back <NUM> that is an integral extension of the back face <NUM> folded towards the interior of the tray <NUM> along a back face fold line <NUM>. The front face fold back <NUM> and back face fold back <NUM> can provide for additional rigidity to the peripheral rim <NUM> of the tray <NUM>.

A front face flap <NUM> can extend from the peripheral rim <NUM> along the front face <NUM>. The front face flap <NUM> can extend from the front face <NUM> to a front face flap distal end <NUM>. A back face flap <NUM> can extend from the peripheral rim <NUM> along the back face <NUM>. The back face flap <NUM> can extend from the back face <NUM> to a back face flap distal end <NUM>. The front face flap <NUM> and back face flap <NUM> can be structured from a cutlines on in the front face <NUM> and back face <NUM>, respectively. The front face fold back <NUM> and back face fold back <NUM> can extend more deeply into the tray <NUM> than the cut lines that form the boundary of the front face flap <NUM> and back face flap <NUM>.

The front face fold line <NUM> and back face fold line <NUM> can be orthogonal to the flutes if the tray is constructed from corrugate. For corrugate, folding perpendicular to the flutes can provide for a hinge having springiness about the fold. For the tray <NUM> described herein, the springiness can be employed to form a closure system that engages the hood <NUM> with the tray <NUM> that can be opened and closed multiple times.

The blank from which the tray <NUM> is erected can include cut lines that define the shape and dimensions of the front face flap <NUM> and back face flap <NUM> and the cut lines can be positioned so that when the tray <NUM> is erected the front face flap <NUM> and the back face flap <NUM> are positioned as desired. As part of the process of erecting the tray <NUM> from the blank, the front face fold back <NUM> and back face fold back <NUM> can be folded towards the interior of the tray <NUM>. The parts of the front face fold back <NUM> and the back face fold back <NUM> from which the front face flap <NUM> and the back face flap <NUM> extend, respectively, can be unfolded and pointing upward after the tray <NUM> is erected. When the tray <NUM> is erected and the front face fold back <NUM> and the back face fold back <NUM> are folded towards the interior of the tray <NUM>, the front face flap <NUM> and the back face flap <NUM> can protrude upwardly from the peripheral rim <NUM> of the tray <NUM>.

As part of the process of packaging the product <NUM>, the front face flap <NUM> and the back face flap <NUM> can be folded outwardly away from the interior of the tray <NUM> before engaging the hood <NUM> with the tray <NUM>. The front face flap <NUM> and the back face flap <NUM> can be held down while engaging the hood <NUM> with the tray <NUM>. The front face flap <NUM> and the back face flap <NUM> can be outwardly folded by a pair of folding rails that are associated with the tray carriage system <NUM>. The folding rails can be provided upstream of the hood engagement system <NUM>. As the tray <NUM> is transported downstream, the folding rails can capture the distal ends of the flaps and movement of the tray <NUM> downstream and shaping of the folding rails can bend the front face flap <NUM> and the back face flap <NUM> outwardly away from the interior of the tray <NUM> so that the distal ends of the respect flaps are oriented towards the bottom of the tray <NUM>.

The hood <NUM> can be provided with an engagement mechanism the cooperates with the front face flap <NUM> and back face flap <NUM>, by way of nonlimiting example as shown in <FIG>. <FIG> is a cross section of a hood <NUM> looking in the upstream direction toward the hood trailing panel <NUM>. The hood <NUM> can further comprise a front panel inwardly folded flap <NUM> extending from the front panel <NUM> and a back panel inwardly folded flap <NUM> extending from the back panel <NUM>. Together the front panel <NUM> and back panel <NUM> can extend from the leading panel <NUM> to the trailing panel <NUM>. And the front panel inwardly folded flap <NUM> and the back panel inwardly folded flap <NUM> can be between the front panel <NUM> and the back panel <NUM>.

When the hood <NUM> is fitted to the tray <NUM>, the distal ends of the front face flap <NUM> and back face flap <NUM> can engage with the ends <NUM> of the front panel inwardly folded flap <NUM> and the back panel inwardly folded flap <NUM>, respectively (<FIG>). The user can unlock the hood <NUM> from the tray <NUM> by pushing on the front face flap <NUM> and the back face flap <NUM> to release the distal ends of front face flap <NUM> and the back face flap <NUM> from contact with the ends <NUM> of the front panel inwardly folded flap <NUM> and the back panel inwardly folded flap <NUM>, respectively. The front face flap <NUM> and the back face flap <NUM> rotate about a hinge formed by the front face fold line <NUM> and the back face fold line <NUM>. The front face flap <NUM> can be accessed through an aperture <NUM> in the front panel <NUM>. The back face flap <NUM> can be accessed through an aperture <NUM> in the back panel <NUM> (<FIG>).

The hood engagement system <NUM> is the mechanism for positioning a hood <NUM> so that the hood <NUM> can be fitted to a tray <NUM> as the tray <NUM> moves downstream in the machine direction MD.

Precise control of movement of the tray <NUM> can be provided a carriage system <NUM> comprising a plurality of linear motor vehicles <NUM> (<FIG>). The carriage system <NUM> can be a horizontally oriented track system in which movement of individual linear motor vehicles <NUM> is controlled. A suitable linear motor track system can be an ITRAK system from Rockwell Automation. A tray <NUM> can be conveyed by adjacent linear motor vehicles <NUM>. Each linear motor vehicle <NUM> can have a restraint plate <NUM> attached thereto. The restraint plate <NUM> can be oriented orthogonal to the machine direction MD. Each tray <NUM> can be held by restraint plates <NUM> of adjacent linear motor vehicles <NUM>. In operation, adjacent pairs of linear motor vehicles <NUM> can be individually controlled or controlled in pairs to hold a tray <NUM> between the restraint plates <NUM> of adjacent linear motor vehicles <NUM>.

The pitch P amongst trays <NUM> can be nonconstant and individually controlled. The position of individual trays <NUM> can be controlled to match up with the position of the hood <NUM> being fitted thereto. Vision systems or sensors can detect the position and speed of the hood <NUM> and a computer system can adjust the velocity of the tray <NUM> so that the hood <NUM> is fitted to a tray <NUM> as the tray <NUM> passes through the location at which the hood <NUM> merges with the tray <NUM>.

The carriage system <NUM> can be configured to convey the trays <NUM> in a condition in which the tray <NUM> is squeezed in the longitudinal direction so that the front face <NUM> and back face <NUM> are outwardly bowed away from the longitudinal axis L. The outward bowing of the front face <NUM> and the back face <NUM> can arise during manufacture of the flat paperboard or corrugate. The amount of force applied in the machine direction MD and counter to the machine direction MD by the carriage system <NUM> can increase the amount of bowing as compared to the amount of bowing that might arise due to manufacture of the flat paperboard or corrugate and that which might arise as a result of transforming the flat paperboard or corrugate into a three-dimensional tray <NUM>. Outwardly bowing the front face <NUM> and the back face <NUM> can help provide for a tight fit between the hood <NUM> and the tray <NUM> and a secure engagement of the locking mechanism. The tray <NUM> can be bowed, by way of non-limiting example, in a carriage system <NUM> that employs linear motor vehicles <NUM> by controlling or setting the spacing between adjacent linear motor vehicles <NUM>. The spacing between adjacent linear motor vehicles <NUM> can be set to be less than the distance between the leading face <NUM> and trailing face <NUM>, as measured between the outer surfaces, of the tray <NUM> in an unloaded condition. The software operating the adjacent linear motor vehicles <NUM> can be programmed to control the amount of bowing desired at different positions along the carriage system <NUM>, which may vary as a function of position.

As described previously and shown in <FIG>, the hood <NUM> can comprise a front panel inwardly folded flap <NUM> and a back panel inwardly folded flap <NUM>. The hood <NUM> can be sized and dimensioned to fit tightly with the tray <NUM> so that the tray <NUM> may be securely closed.

After the tray <NUM> has a hood partially fitted thereto, the hood <NUM> can be further fitted to the tray <NUM> by providing a bumper <NUM> that pushes the hood <NUM> onto the tray <NUM> as the tray <NUM> moves further downstream in the machine direction MD (<FIG>). The bumper <NUM> can be configured to provide a reaction surface against which at least part of the hood <NUM> contacts. The distance between portions of the bumper <NUM> and the carriage system <NUM> can decrease as a function of distance in the machine direction. The bumper <NUM> can function as a wedge that pushes the hood <NUM> down onto the tray <NUM> as the tray <NUM> and hood <NUM> are conveyed in the machine direction downstream. The further fitting of the hood <NUM> to the tray <NUM> downstream of location at which the hood <NUM> is first fitted to the tray <NUM> can occur while the tray <NUM> is held and under the control of the carriage system <NUM>. As the tray <NUM> and hood <NUM> move in the machine direction, the hood <NUM> can be further telescopically fit to the tray <NUM>. The bumper <NUM> can have a smooth surface that engages with the hood <NUM> so that the hood <NUM> slides easily along the bumper <NUM>. The smooth surface of the bumper <NUM> can be a polished steel or aluminum surface or a plastic material such as an acetal plastic or other plastic material having a low coefficient of friction and a smooth finish. The bumper <NUM> can be a static bumper, a movable belt, a moveable rope, or the similar mechanism for applying force to fit the hood <NUM> more closely to the tray <NUM>.

After the trailing panel <NUM> is fitted to the tray <NUM>, the tray <NUM> and hood <NUM> engaged therewith can be handed off from the carriage system <NUM> to a downstream conveyor <NUM>. A second bumper <NUM> can be positioned above the downstream conveyor <NUM> to further telescopically fit the hood <NUM> to the tray <NUM>. The second bumper <NUM> can be wedge shaped or positioned to present a wedging surface to the hood <NUM> as the tray <NUM> and hood <NUM> are conveyed further downstream in the machine direction.

After the hood <NUM> is fitted to the tray <NUM> to form a closed package <NUM>, the closed package <NUM> can be further processed and or finished and shipped from the location at which the closed package <NUM> is assembled. The closed package <NUM> can be shipped to a distribution center, customers, or consumers to finally reach the location at which the user opens the package <NUM> to use or consume the contents of the package <NUM>.

A dispensing system <NUM> can be provided and the product <NUM> can be dispensed into the tray <NUM> via the dispensing system <NUM>. A hood engagement system <NUM> can be provided above the tray carriage system <NUM> and downstream of the dispensing system <NUM>.

The hood <NUM> is engaged with the tray <NUM> via the hood engagement system <NUM> to close the tray <NUM> to form the closed package <NUM>. The hood <NUM> can be engaged with the tray <NUM> while the tray <NUM> is moving in the machine direction MD.

After the hood <NUM> is fitted to the tray <NUM>, the closed package <NUM> can be shipped. For example the closed package <NUM> can be shipped to a distributor or distribution facility and further along the supply chain until it reaches a location at which a user can open the package <NUM> by removing the hood <NUM>, retrieve the product <NUM> from the tray <NUM>, and use the product <NUM>.

The hood <NUM> may tightly conform to the tray <NUM> to provide for a robust connection between the hood <NUM> and tray <NUM> for the closed package <NUM>. If the conformance between the hood <NUM> and the tray <NUM> is tight, processes that operate at a fixed rate with little or no control over movement of one or both of the hood <NUM> and tray <NUM> may be inadequate to enable the tray <NUM> to catch a hood <NUM> as the hood merges with the tray <NUM>.

The dispensing system <NUM> can be a hopper, for example a clamshell hopper, that opens when a tray <NUM> is beneath the dispensing system <NUM> to drop products <NUM> into the tray. With the hopper in the closed position, a certain count or weight of products <NUM> can be fed into the hopper. When a tray is passing beneath the hopper, the hopper can open and drop the products <NUM> into the tray <NUM>. Optionally, the dispensing system <NUM> can be chute into which a certain count or weight of products <NUM> are fed and directed into a tray <NUM> passing beneath the dispensing system. Optionally, the dispensing system <NUM> can be a gated chute. When the gate is closed products <NUM> can be fed into the chute. When the tray <NUM> is passing beneath the chute, the gate can open to release the products <NUM> and drop them into the tray <NUM> passing underneath. The dispensing system <NUM> can be horizontal or vertically oriented carousel for dispensing a certain count or weight of products <NUM>. The dispensing system <NUM> can include a shuttle and dispense products <NUM> as the dispensing system <NUM> moves downstream in the machine direction MD and then shuttles back upstream to dispense products <NUM> into the next arriving tray <NUM>.

The hood <NUM> can be erected from a flat blank <NUM> (<FIG>). The flat blank <NUM> can comprise a leading panel <NUM>, a trailing panel <NUM> opposite the leading panel <NUM>, and hood top <NUM> extending between the leading panel <NUM> and the trailing panel <NUM>. The flat blank <NUM> can further comprise a front panel <NUM> and the back panel <NUM>. The flat blank <NUM> can be provided with a plurality of fold lines. When the hood <NUM> is erected, the flat blank <NUM> can be folded about the fold lines to transform the flat blank <NUM> from an essentially two-dimensional structure into a three-dimensional structure. The fold lines can be continuous or intermittent. The fold lines can be a preferentially weakened portion of the flat blank <NUM>. The fold lines can be formed by indenting the paperboard or corrugate from which the flat blank <NUM> is constructed. Optionally, the fold lines can be formed by scoring the paperboard or corrugate from which the flat blank <NUM> is constructed.

The flat blank <NUM> can comprise a leading fold line <NUM> between the leading panel <NUM> and the hood top <NUM>. The flat blank <NUM> can comprise a trailing fold line <NUM> between trailing panel <NUM> and the hood top <NUM>. The flat blank <NUM> can further comprise side fold lines <NUM>. The side fold lines <NUM> form the boundary between the hood top <NUM> and each of the front panel <NUM> and back panel <NUM>. Optionally, the flat blank <NUM> can further comprise a central fold line <NUM> parallel to the leading folding line <NUM> and the trailing fold line <NUM>. The central fold line <NUM> can provide a line about which the central portion <NUM> can bend to become spaced apart from the hood top <NUM> at a desired location.

To provide a mechanism for reducing the potential for excessively deforming the tray <NUM> at and nearby the front face flap <NUM> and back face flap <NUM>, a flat insert <NUM> can be adhered to a panel selected from the group of the leading panel <NUM>, the trailing panel <NUM>, and combinations thereof. The flat insert <NUM> can be adhered to a surface selected from the group of the leading panel <NUM>, the trailing panel <NUM>, the hood top <NUM>, and combinations thereof. The flat insert <NUM> has a central portion <NUM> between the leading fold line <NUM> and the trailing fold line <NUM>. The central portion <NUM> can be unattached to the hood top <NUM>.

When erected, the flat insert <NUM> is transformed into a three-dimensional shape that provides structural support behind the front face flap <NUM> and the back face flap <NUM>. Recall, that the locking mechanism between the hood <NUM> and the tray <NUM> relies on the end <NUM> of the of the front panel inwardly folded flap <NUM> abutting the front face distal end <NUM> of the front face flap <NUM> and the end <NUM> of the back panel inwardly folded flap <NUM> abutting the back face distal end <NUM> of the back face flap <NUM>. The user can push the front face flap <NUM> and back face flap <NUM> to disengage the front face flap <NUM> and the back face flap <NUM> from the end <NUM> of the front panel inwardly folded flap <NUM> and the end <NUM> of the back panel inwardly folded flap <NUM>, respectively. If the user pushes too hard on the front face flap <NUM> and the back face flap <NUM>, there could be regional deformation of the tray <NUM> near the front face flap <NUM> and back face flap <NUM> which could weaken the engagement of the front face flap <NUM> and the back face flap <NUM> from an end <NUM>. If the tray <NUM> is plastically deformed near the front face flap <NUM> and the back face flap <NUM>, the front face flap <NUM> and the back face flap <NUM> may fail to engage at all with an end <NUM>.

The front panel <NUM> and the back panel <NUM> can comprise a predetermined removable portion <NUM>. The predetermined removable portion <NUM> can be a partial die cut or perforation that defines the shape of the predetermined removeable portion <NUM>. When the user obtains the package <NUM>, the user can punch out the predetermined removable portions <NUM> to form the apertures <NUM>. The user can then access the front face flap <NUM> and the back face flap <NUM> to disengage the hood <NUM> from the tray <NUM>.

The flat insert <NUM> can be corrugate having flutes and the flutes extending in a direction between the front panel <NUM> and the back panel <NUM>. The flat insert <NUM> can be paperboard.

The hood <NUM> can be erected using a die <NUM> and a hood mold <NUM> (<FIG>). The die <NUM> can be positioned in facing relationship with the flat blank <NUM> and punched into a mold to transform the flat blank <NUM> into the hood <NUM>. When the flat blank <NUM> is transformed into a hood <NUM>, the central portion <NUM> of the flat insert <NUM> can become spaced apart from the hood top <NUM>.

The die <NUM> can be metal, plastic, or an assembly of components of metal and plastic.

Conventionally, dies that are employed to construct simple hoods, like those found in a common bankers box, shoe box, or the like, present a flat surface to contact the hood top. In the present application, the die <NUM> comprises a die recess <NUM>. The die recess <NUM> can accommodate separation of the central portion <NUM> from the hood top <NUM>. The central portion <NUM>, when spaced apart from the hood top <NUM>, can provide for structural support behind the front face flap <NUM> and the back face flap <NUM> to limit undesirable deformation of the front face <NUM> and back face <NUM> near the front face flap <NUM> and the back face flap <NUM>.

The die <NUM> can comprise a leading edge <NUM> and trailing edge <NUM> and a pair of side edges <NUM> extending from the leading edge <NUM> to the trailing edge <NUM>. The die <NUM> can comprise a die recess <NUM> that is recessed relative to the leading edge <NUM>, the trailing edge <NUM> and the side edges <NUM>.

The hood mold <NUM>, which comprises a cavity <NUM>, can be provided. The cavity <NUM> provides the three-dimensional space to accommodate the erected hood <NUM>. To erect the hood <NUM>, the flat insert <NUM> is oriented towards the die recess <NUM>. The leading fold line <NUM> can be positioned in line with the leading edge <NUM> of the die <NUM>. The trailing fold line <NUM> can be positioned in line with the trailing edge <NUM>.

The die <NUM> can be positioned within the hood mold <NUM> to fold the flat blank <NUM> about the leading fold line <NUM> and the trailing fold line <NUM> and to fold the flat insert <NUM> coincidentally with the leading fold line <NUM> and the trailing fold line <NUM>. By way of this folding, the central portion <NUM> is spaced apart from the hood top <NUM>.

The die <NUM> can be pressed into the hood mold <NUM>. Optionally, the hood mold <NUM> can be pressed to fit over the die <NUM>. Optionally both the die <NUM> and the hood mold <NUM> can be pressed so that the die <NUM> is within the hood mold <NUM>.

As the leading panel <NUM> and trailing panel <NUM> are bent about the leading fold line <NUM> and trailing fold line <NUM>, the portions of the flat insert <NUM> adhered thereto are also bent about the relevant fold line. Since the flat insert <NUM> is adhered to a panel selected form the leading panel <NUM>, the trailing panel <NUM>, and combinations thereof, there is no shear displacement between the flat insert <NUM> and the panel or panels to which the flat insert <NUM> is attached. The radius of the bend of the flat insert <NUM> is smaller than the radius of the bend between the leading panel <NUM> and the hood top <NUM> and the radius of the bend between the trailing panel <NUM> and the hood top <NUM>. Since there is no change in the length of the central portion <NUM> between leading fold line <NUM> and the trailing fold line <NUM>, the central portion <NUM> is forced out of plane relative to the hood top <NUM>. The die recess <NUM> can provide for space to accommodate the out of plane deformation of the central portion <NUM>.

The central fold line <NUM> can provide for controlled deformation of the central portion <NUM>. The central fold line <NUM> can be midway between the leading fold line <NUM> and the trailing fold line <NUM>. Providing a central fold line <NUM> can help to center the location where the maximum separation between the central portion <NUM> the hood top <NUM> occurs. By centering such location, the central fold line <NUM> can proximal or even behind the location of the front face flap <NUM> and the back face flap <NUM> when the hood <NUM> is engaged with the tray <NUM>. At least part of the central portion <NUM> can form an angle about the central fold line <NUM>.

The die <NUM> can further comprise a pair of flat insert seating areas <NUM>. One of the flat insert seating areas <NUM> can be between the leading edge <NUM> and the die recess <NUM> and another of the flat seating areas <NUM> can be between the trailing edge <NUM> and the die recess <NUM>. The flat insert seating areas <NUM> can be sized and dimensioned to accommodate portions of the flat insert <NUM> that are adjacent the leading fold line <NUM> and the trailing fold line <NUM>. That is, the flat insert seating areas <NUM> can be sized and dimensioned to accommodate portions of the flat insert <NUM> that extend beyond die recess <NUM>.

The flat insert seating areas <NUM> provide space within which the flat insert <NUM> can be seated so that when the die <NUM> is fitted with in the hood mold <NUM>, portions of the flat insert <NUM> near the leading edge <NUM> and the trailing edge <NUM> do interfere with forming precise fold lines between the hood top <NUM> and the leading panel <NUM> and the hood top <NUM> and the trailing panel <NUM>. Sizing and dimensioning the flat insert seating areas <NUM> to have a shape that is the same as or closely similar to the shapes of the flat insert <NUM> that extend beyond the die recess <NUM> can provide for crisper folding at the boundary between the hood top <NUM> and the leading panel <NUM> and trailing panel <NUM> since the die <NUM> can contact more of the surface of the flat blank <NUM>.

The flat insert seating areas <NUM> can be recessed relative to the side edges <NUM> and be sized and dimensioned to accommodate portions of the flat insert <NUM> that extend beyond the die recess <NUM>. In such an arrangement, the flat insert <NUM> may not interfere with formation of crisp folds between the hood top <NUM> and the front panel <NUM> and back panel <NUM> as well as between the hood top <NUM> and the leading panel <NUM> and trailing panel <NUM>.

Optionally, between at least part of each flat insert seating area <NUM> and the die recess <NUM>, a tab <NUM> can project above the flat insert seating areas <NUM>. Each tab <NUM> can be located at or near, or substantially at or near, the boundary between each flat insert seating area <NUM> and the die recess <NUM>. When the hood <NUM> is being erected, these tabs <NUM> can induce a fold line to form in the flat insert <NUM> at or near the boundary between the flat insert seating areas <NUM> and the die recess <NUM>. This can be beneficial in that it can provide for a shaped transition between the central portion <NUM> that is spaced apart from the hood top <NUM> and the locations where the flat insert <NUM> is bent about the leading edge <NUM> and the trailing edge <NUM>. Moreover, when the hood <NUM> is erected, the central portion <NUM> may be under residual stress and the shaped transition may help to direct these residual stresses to be predominantly orthogonal to the leading panel <NUM> and the trailing panel <NUM>.

The tabs <NUM> can project <NUM> to about <NUM>, optionally <NUM>, above the side edges <NUM>. The thicker the paperboard or corrugate constituting the flat insert <NUM>, the greater amount of projection that might be possible. The side edges <NUM> can define a forming plane <NUM> and the tabs <NUM> can project above the forming plane <NUM> (i.e. in a direction away from the die recess <NUM>).

The die <NUM> can further comprise vent holes <NUM> within the die recess <NUM>. The vent holes <NUM> can be beneath the side edges <NUM>. The vent holes <NUM> can be elevationally lower than both the side edges <NUM> and the flat insert seating areas <NUM>. The vent holes <NUM> can permit air to escape from the die recess <NUM> as the central portion <NUM> deforms inwardly into the die recess <NUM> and is spaced apart from the hood top <NUM>.

The die recess <NUM> can have an adjustable volume. The adjustable volume can be provided for by a die <NUM> that is extendable and contractable in that the distance between the leading edge <NUM> and the trailing edge <NUM> is adjustable (<FIG>). Such a die <NUM> can be practical to use for erecting hoods <NUM> of different sizes as define by the distance between the leading fold line <NUM> and the trailing fold line <NUM>. An extendable and contractable die <NUM> can be provide by the die sidewalls <NUM> comprising a plurality sidewall segments <NUM>. The sidewall segments can define or partially define the die recess <NUM>. The sidewall segments <NUM> can be positioned to abut one another to provide for a small hood <NUM>. The sidewall segments <NUM> can be positioned spaced apart from one another to form a large hood <NUM>. The sidewall segments <NUM> permit the distance between the leading edge <NUM> and the trailing edge <NUM> to be fixed at different distances.

A cross section of a hood <NUM> is shown in <FIG>. The hood <NUM> can comprise a pair of opposing predetermined removable portions <NUM> or apertures. As shown in <FIG>, when the central portion <NUM> is spaced apart from the hood top <NUM>, at least part of the central portion <NUM> can be positioned between the opposing predetermined removable portions <NUM> or apertures. Insert bend lines <NUM> are illustrated in <FIG>, which can occur when the die <NUM> is provided with tabs <NUM> as described herein. The pair of insert bend lines <NUM> can be on opposite sides of the central fold line <NUM>. One insert bend line <NUM> can be between the central fold line <NUM> and the leading panel <NUM>. One insert bend line <NUM> can be between the central fold line <NUM> and the trailing panel <NUM>. The flat insert <NUM> can be adhered to a panel selected from the leading panel <NUM>, the trailing panel <NUM>, and combinations thereof, by adhesive <NUM>. The central bend lines <NUM> can be positioned so that when the central portion <NUM> is fitted to the die <NUM>, they are near or at, or substantially near or at, the boundary between the flat insert seating areas <NUM> and the die recess <NUM>. The central bend lines <NUM> can be positioned so that when the central portion <NUM> is fitted to the die <NUM>, they are near or at, or substantially near or at, the locations of the tabs <NUM> that are optionally present at the boundary between the flat insert seating areas <NUM> and the die recess <NUM>.

A partial cross section of another hood is shown in <FIG>. As shown in Fig. <NUM>, the central portion <NUM> can be positioned to provide structural support behind the front face flap <NUM> and the back face flap <NUM>. When the user pushes inwardly the front face flap <NUM> and the back face flap <NUM> to disengage these flaps from the ends <NUM> of the front panel inwardly folded flap <NUM> and the back panel inwardly folded flap <NUM>, the central portion can <NUM> can limit deformation of the tray near the front face flap <NUM> and the back face flap <NUM>.

Claim 1:
A process for packaging a product (<NUM>) comprising the steps of:
manufacturing the product, wherein said product is a substrate treatment composition (<NUM>) ;
providing a tray carriage system (<NUM>);
providing a tray (<NUM>) movable in or on said tray carriage system;
moving said tray via said tray carriage system in a machine direction (MD);
providing a dispensing system (<NUM>) above said tray carriage system;
dispensing said product into said tray via said dispensing system;
providing a hood engagement system (<NUM>) above said tray carriage system and
downstream of said dispensing system;
providing a hood (<NUM>) moveable in said hood engagement system, characterized in that said hood is erected by a process comprising the steps of:
providing a flat blank (<NUM>) comprising a leading panel (<NUM>), a trailing panel (<NUM>) opposite said leading panel, a hood top (<NUM>) extending between said leading panel and
said trailing panel, a leading fold line (<NUM>) between said leading panel and said hood top, a trailing fold line (<NUM>) between said trailing panel and said hood top;
providing a flat insert (<NUM>) adhered to a panel selected from the group of said leading panel, said trailing panel, and combinations thereof, wherein said flat insert has a central portion (<NUM>) between said leading fold line and said trailing fold line and
wherein said central portion is unattached to said hood top;
providing a die (<NUM>) comprising a leading edge (<NUM>) and trailing edge (<NUM>), a pair of side edges (<NUM>) extending from said leading edge to said trailing edge, and a die recess (<NUM>), wherein said die recess is recessed relative to said leading edge, said trailing edge, and said side edges;
providing hood mold (<NUM>) having a cavity (<NUM>);
orienting said flat insert towards said die recess; and
positioning said die within said hood mold to fold said flat blank about said leading fold line and said trailing fold line and to fold said flat insert coincidentally with at least one of said leading fold line and said trailing fold line, whereby said central
portion is spaced apart from said hood top;
engaging said hood with said tray via said hood engagement system to fit said insert within said tray and close said tray to form a closed package (<NUM>); and
shipping said closed package.