LAMINATED BLANK, PACKAGING FORMED THEREFROM, AND METHOD

Abstract

In one aspect, a blank is formed of a substrate laminated with a thin polymer film layer. The blank includes fold lines and cutouts such that it is formable into a pack with a base that is fully sealed by the film layer, thereby solving the technical problem of packs formed from blanks where the bases include unsealed gaps or holes. In further aspects, a folded blank, packaging articles formed therefrom, and methods of manufacture are provided.

Claims

1. A blank which can be folded to form a pack, the blank being formed of a laminate comprising a cellulosic substrate layer laminated to a film layer, the blank comprising: a laminated front face connected to a laminated base via a first transverse fold line at a first transverse edge of the base; a laminated rear face connected to the base via a second transverse fold line at a second transverse edge of the base opposite the first transverse edge of the base; the base having opposing first and second longitudinal edges extending between the first transverse edge and the second transverse edge, a third transverse fold line disposed intermediate the first and second transverse fold lines about which the base is foldable in an opposite sense to the first and second transverse fold lines; first and second front side panel segments extending transversely from first and second opposing, generally longitudinal edges of the front face; first and second rear side panel segments extending transversely from first and second opposing, generally longitudinal edges of the rear face; the first front side panel segment and the first rear side panel segment cooperating to form a first side panel when the blank is folded to form an assembled pack; the second front side panel segment and the second rear side panel segment cooperating to form a second side panel when the blank is folded to form the assembled pack; each of the front face, rear face, the first front and rear side panels, and the second front and rear side panels having an upper edge such that in the assembled pack, the upper edges of the front face, rear face, first front and rear side panels, and second front and rear side panels form an opening into the pack; a first base support panel extending between the first front side panel and the first rear side panel on the first longitudinal edge of the base, the first base support panel having a first cutout region adjacent the first longitudinal edge of the base comprising unsupported film; a second base support panel extending between the second front side panel and the second rear side panel on the second longitudinal edge of the base, the second base support panel having a second cutout region adjacent the second longitudinal edge of the base comprising unsupported film; the first cutout region bounded by the first longitudinal edge of the base, a first front support arm extending from a transverse edge of the first front side panel segment, and a first rear support arm extending from a transverse edge of the first rear side panel segment; the second cutout region bounded by the second longitudinal edge of the base, a second front support arm extending from a transverse edge of the second front side panel segment, and a second rear support arm extending from a transverse edge of the second rear side panel segment; wherein the first and second front support arms are each foldable along the first transverse fold line and the first and second rear support arms are each foldable along the second transverse fold line; and wherein the first front support arm, first rear support arm, second front support arm, and second rear support arm are configured to fold to a position overlying and substantially parallel to the base when the blank is folded to form the assembled pack.

2. The blank as claimed in claim 1, further comprising a laminated lid connected to the rear face via a fourth transverse fold line along the upper edge of the rear face, wherein the lid covers the opening into the pack when the blank is folded to form the assembled pack and the lid is folded along the fourth transverse fold line.

3. The blank as claimed in claim 2, further comprising a window formed in the laminated lid, the window defined by a cutout in the cellulosic substrate layer wherein the window comprises an unsupported portion of the film layer.

4. The blank as claimed in claim 2, further comprising: a laminated front face connected to a laminated base via a first transverse fold line at a first transverse edge of the base; a first upper front flap connected to the first front side panel segment via a first flap fold line at the upper edge of the first front side panel segment; a second upper front flap connected to the second front side panel segment via a second flap fold line at the upper edge of the second front side panel segment; a first upper rear flap connected to the first rear side panel segment via a third flap fold line at the upper edge of the first rear side panel segment; a second upper rear flap connected to the second rear side panel segment via a fourth flap fold line at the upper edge of the second rear side panel segment; and a front face flap connected to the front face via a fifth transverse fold line along the upper edge of the front face.

5. The blank as claimed in claim 1, wherein: the upper edge of each of the first and second rear side panel segments intersecting with the upper edge of the rear face to form an angle in the range of about 160 to about 175 degrees; and the upper edge of each of the first and second front side panel segments intersecting with the upper edge of the front face to form an angle in the range of about 160 to about 175 degrees.

6. The blank as claimed in claim 1, wherein: each of the first and second opposing, generally longitudinal edges of the front face intersecting with the upper edge of the front face to form an angle in the range of about 80 to about 85 degrees; and each of the first and second opposing, generally longitudinal edges of the rear face intersecting with the upper edge of the rear face to form an angle in the range of about 80 to about 85 degrees.

7. The blank as claimed in claim 1, further comprising: the first generally longitudinal edge of the front face connected to the first front side panel via a first generally longitudinal fold line along the first generally longitudinal edge of the front face; the second generally longitudinal edge of the front face connected to the second front side panel via a first generally longitudinal fold line along the second generally longitudinal edge of the front face; the first generally longitudinal edge of the rear face connected to the first rear side panel via a third generally longitudinal fold line along the first generally longitudinal edge of the rear face; and the second generally longitudinal edge of the rear face connected to the second rear side panel via a fourth generally longitudinal fold line along the second generally longitudinal edge of the rear face.

8. The blank as claimed in claim 1, wherein each of the first, second, and third transverse fold lines comprise a line of preferential folding.

9. The blank as claimed in claim 8, wherein the line of preferential folding comprises a series of perforations in the cellulosic substrate layer.

10. The blank as claimed in claim 1, further comprising: the first cutout region having a generally trapezoidal shape defined by a first long generally parallel side, a first short generally parallel side, a first pair of angled sides connecting the first long and first short generally parallel sides, and a first height defined by a perpendicular distance between the first long and first short generally parallel sides; the second cutout region having a generally trapezoidal shape comprising a second long generally parallel side, a second short generally parallel side, a second pair of angled sides connecting the second long and second short generally parallel sides, and a second height defined by a perpendicular distance between the second long and second short generally parallel sides; and the first base support panel further comprising: a first seal section side opposite and generally parallel to the first longitudinal edge of the base; a first cutout connector with a generally triangular shape comprising a first triangle base defined by the first short generally parallel side of the first cutout and first pair of legs extending between the first triangle base and intersecting at the first seal section side; a first connector rear fold line disposed between the first cutout connector and the first rear support arm; a first connector front fold line disposed between the first cutout connector and the first front support arm; and a first connector fold line extending between the first short generally parallel side of the first cutout and the first intersection; the second base support panel further comprising: a second seal section side opposite and generally parallel to the first longitudinal edge of the base; a second cutout connector with an isosceles triangle shape comprising a second triangle base that is the second short generally parallel side of the second cutout and second triangle legs extending between the second triangle base and intersecting at the second seal section side at a second intersection that bisects the second seal section side; a second connector rear fold line disposed between the second cutout connector and the second rear support arm; a second connector front fold line disposed between the second cutout connector and the second front support arm; and a second connector fold line extending between the second short generally parallel side of the second cutout and the second intersection.

11. A method for forming the blank of claim 1, the method comprising the steps of: providing a cellulosic web; in a first cutting stage, making a plurality of through cuts in the cellulosic web to form a number of features of the pack, wherein the plurality of through cuts define at least first and second cutout regions that are mirror images of one another in the cellulosic substrate; laminating at least one surface of the cellulosic substrate with a polymer film to form a laminate web, wherein said at least first and second cutout regions comprise said polymer film and are devoid of the cellulosic web; in a second cutting stage, making an external cut to define a peripheral outline of an unfolded blank to cut the unfolded blank from the laminate web; in a first folding stage, folding the laminate web in a first direction about the second transverse fold line; in a second folding stage, folding the laminate web in a second direction opposite the first direction about the third transverse fold line; applying adhesive to at least one of the first front side panel and the first rear side panel and to at least one of the second front side panel and the second rear side panel; and in a third folding stage, after said step of applying adhesive, folding the laminate web in the first direction about the first transverse fold line to adhere the first front side panel and the first rear side panel and to adhere the second front side panel and the second rear side panel.

12. The method as claimed in claim 11, wherein the first cutting stage further comprises: creating a fourth transverse series of perforations defining a lid fold line bounding an edge of a lid portion, wherein the plurality of through cuts further defines a window in the lid portion.

13. The method as claimed in claim 11, wherein the first cutting stage further comprises: creating a first series of generally longitudinal perforations defining a first rear face fold line; creating a second series of generally longitudinal perforations defining a second rear face fold line; creating a third series of generally longitudinal perforations defining a first front face fold line; and creating a fourth series of generally longitudinal perforations defining a second front face fold line.

14. The method as claimed in claim 11, further comprising: each of the first and second rear face fold lines intersecting with the upper edge of the rear face panel an angle in the range of about 80 to about 85 degrees; and each of the first and second front face fold lines intersecting with the upper edge of the front face panel at an angle in the range of about 80 to about 85 degrees.

15. The method as claimed in claim 11, wherein the first cutting stage further comprises: creating a first transverse series of perforations defining the first transverse fold line; creating a second transverse series of perforations defining the second transverse fold line; and creating a third transverse series of perforations defining the third transverse fold line.

16. The method as claimed in claim 15, wherein the first cutting stage further comprises: creating a fourth transverse series of perforations defining a lid fold line; creating a fifth transverse series of perforations defining a lid flap fold line; creating a sixth series of perforations defining a first upper rear flap fold line; creating a seventh series of perforations defining a first upper front flap fold line; creating an eighth series of perforations defining a second upper rear flap fold line; and creating a ninth series of perforations defining a second upper front flap fold line.

17. The method as claimed in claim 11, further comprising: the first upper rear flap fold line and the second upper rear flap fold line each intersecting with the upper edge of the rear face panel at an angle in the range of about 160 to about 175 degrees; and the first upper front flap fold line and the second upper front flap fold line each intersecting with the upper edge of the front face panel at an angle in the range of about 160 to about 175 degrees.

18. The method as claimed in claim 11, wherein the step of laminating is selected from then group consisting of adhesive lamination, extrusion coating, and extrusion lamination.

19. The method as claimed in claim 11, wherein said step of laminating comprises applying a polymer film to both surfaces of the card layer.

20. The method as claimed in claim 11, wherein the second cutting stage comprises: cutting a first line generally parallel to the second transverse fold line opposite from the base, such that the rear face is disposed between the first cut line and the second transverse fold line; cutting a second line generally parallel to the first transverse fold line opposite from the base, such that the front face is disposed between the second cut line and the first transverse fold line; and cutting third and fourth lines connecting the first and second cut lines such that all cuts and folds made in the step of making first cuts and fold lines in the card layer are within the bounds of the first through fourth cut lines.

21. The method as claimed in claim 11, wherein the adhesive is a hot melt adhesive.

22. A method for forming a pack, comprising: providing a blank, the blank being formed of a laminate comprising a cellulosic substrate layer laminated to a film layer, the blank comprising: a laminated front face connected to a laminated base via a first transverse fold line at a first transverse edge of the base; a laminated rear face connected to the base via a second transverse fold line at a second transverse edge of the base opposite the first transverse edge of the base; the base having opposing first and second longitudinal edges extending between the first transverse edge and the second transverse edge, and a third transverse fold line disposed intermediate the first and second transverse fold lines about which the base is foldable in an opposite sense to the first and second transverse fold lines; first and second front side panel segments extending transversely from first and second opposing, generally longitudinal edges of the front face; first and second rear side panel segments extending transversely from first and second opposing, generally longitudinal edges of the rear face; the first front side panel segment and the first rear side panel segment cooperating to form a first side panel when the blank is folded to form an assembled pack; the second front side panel segment and the second rear side panel segment cooperating to form a second side panel when the blank is folded to form the assembled pack; each of the front face, rear face, the first front and rear side panels, and the second front and rear side panels having an upper edge such that in the assembled pack, the upper edges of the front face, rear face, first front and rear side panels, and second front and rear side panels form an opening into the pack; a first base support panel extending between the first front side panel and the first rear side panel on the first longitudinal edge of the base, the first base support panel having a first cutout region adjacent the first longitudinal edge of the base comprising unsupported film; a second base support panel extending between the second front side panel and the second rear side panel on the second longitudinal edge of the base, the second base support panel having a second cutout region adjacent the second longitudinal edge of the base comprising unsupported film; the first cutout region bounded by the first longitudinal edge of the base, a first front support arm extending from a transverse edge of the first front side panel segment, and a first rear support arm extending from a transverse edge of the first rear side panel segment; the second cutout region bounded by the second longitudinal edge of the base, a second front support arm extending from a transverse edge of the second front side panel segment, and a second rear support arm extending from a transverse edge of the second rear side panel segment; wherein the first and second front support arms are each folded along the first transverse fold line and the first and second rear support arms are each folded along the second transverse fold line; and the first front support arm, first rear support arm, second front support arm, and second rear support arm are structured and operable to fold to a position overlying and substantially parallel to the base when the blank is folded to form the assembled pack; and pushing the first and second side panels inward toward the base, causing the first and second base support panels to fold inward and downward to be substantially parallel to the base.

23. The method of claim 22, wherein the upper edge of the front face has a front face flap attached thereto along a front face fold line, the upper edge of the rear face has a lid attached thereto along a fourth transverse fold line, the upper edge of the first front side panel has a first upper front flap attached thereto along a first upper front flap fold line, the upper edge of the second front side panel has a second upper front flap attached thereto along a second upper front flap fold line, the upper edge of the first rear side panel has a first upper rear flap attached thereto along a first upper rear flap fold line, and the second rear side panel has a second upper rear flap attached thereto along a second upper rear flap fold line, the method further comprising: folding the front face flap along the front face fold line, such that the front face flap is approximately perpendicular to the front face; folding the lid along the fourth transverse fold line such that a portion of the lid overlaps and is flush with the first and second upper front flaps, the first and second upper rear flaps, and the front face flap; and adhering the overlapping portion of the lid to the first and second top front and rear flaps and the front face flap.

24. The method as claimed in claim 23, wherein the step of adhering the overlapping portion of the lid to the first and second top front and rear flaps and the front face flap is performed by heat sealing a portion of the film layer covering the overlapping portion of the lid to an aligned and facing portion of the film layer covering the first and second upper front flaps, the first and second upper rear flaps, and the front face flap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for the purpose of illustrating preferred embodiments and are not to be construed as limiting the invention.

[0009] FIG. 1 is a diagram of a blank according to an exemplary embodiment of the present disclosure.

[0010] FIG. 2A is a diagram of fold lines and first cuts of the exemplary blank formed on a web of material according to the present disclosure and an illustration of the first cuts and fold lines step of the method according to the present disclosure.

[0011] FIG. 2B is an illustration of the blank after the laminating step of the method according to the present disclosure.

[0012] FIG. 2C is a diagram of final cuts of the exemplary blank according to the present disclosure and an illustration of the perimeter and final cuts formed during the final cutting step of the method according to the present disclosure.

[0013] FIG. 2D is an illustration of the blank after first folding substep of the method according to the present disclosure.

[0014] FIG. 2E is an illustration of the after the second folding and adhesive application substeps of the method according to the present disclosure.

[0015] FIG. 2F is an illustration of the blank after the final folding substep of the method according to the present disclosure.

[0016] FIGS. 3A and 3B are detailed diagrams of the first and second base support panels of the blank according to the present disclosure.

[0017] FIG. 4 is a diagram of the blank according to the present disclosure, including exemplary dimensions.

[0018] FIG. 5A is a flow chart describing the steps of an exemplary method for forming the blank in accordance with the present disclosure.

[0019] FIG. 5B is a flow chart describing the steps of an exemplary method forming the pack in accordance with the present disclosure from the blank in accordance with the present disclosure.

[0020] FIG. 6A is a front view of the assembled pack according to the present disclosure.

[0021] FIG. 6B is a rear view of the assembled pack according to the present disclosure.

[0022] FIG. 6C is a top view of the assembled pack according to the present disclosure, with certain features omitted for illustrative purposes.

[0023] FIG. 6D is a side view of the assembled pack according to the present disclosure.

[0024] FIG. 6E is a fragmentary side cross-sectional view showing the bottom panel.

[0025] FIG. 6F is a bottom view of the assembled pack according to the present disclosure.

[0026] FIG. 7A is a perspective image taken generally from above and the left side of an exemplary embodiment of the assembled pack according to the present disclosure.

[0027] FIG. 7B is a perspective image of the assembled pack appearing in FIG. 7A taken generally from the rear.

[0028] FIG. 7C is a perspective image of the assembled pack appearing in FIG. 7A taken generally from the left side.

[0029] FIG. 7D is a perspective image of the assembled pack appearing in FIG. 7A taken generally from the right side.

[0030] FIG. 7E is a perspective image of the assembled pack appearing in FIG. 7A taken generally from the front.

[0031] FIG. 8A is a perspective image taken generally from above and the front of an exemplary embodiment of an assembled, filled, and sealed pack according to the present disclosure.

[0032] FIG. 8B is a perspective image of the pack appearing in FIG. 8A taken generally from above, the front, and right side.

[0033] FIG. 8C is an image of the pack appearing in FIG. 8A taken generally from the left side.

[0034] FIG. 8D is an image of the pack appearing in FIG. 8A taken generally from the front.

[0035] FIG. 8E is an image of the pack appearing in FIG. 8A taken generally from the top.

[0036] FIG. 8F is a perspective image of the pack appearing in FIG. 8A taken generally from above, the rear, and right side.

[0037] FIG. 8G is an image of the pack appearing in FIG. 8A taken generally from the bottom.

[0038] FIG. 8H is a perspective image of the pack appearing in FIG. 8A taken generally from above, the front, and left side.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] The terms a or an, as used herein, are defined as one or more than one. The term another, as used herein, is defined as at least a second or more. The terms including and/or having as used herein, are defined as comprising (i.e., open transition). The term coupled or operatively coupled, as used herein, is defined as indirectly or directly connected.

[0040] As used in this application, the terms front, rear, upper, lower, upwardly, downwardly, left, right, vertical, horizontal, and other orientation descriptors are intended to facilitate the description of the exemplary embodiment(s) of the present invention, and are not intended to limit the structure thereof to any particular position or orientation.

[0041] All numbers herein are assumed to be modified by the term about, unless stated otherwise. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes, inter alia, 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

[0042] Referring first to FIGS. 1 and 2A, there appears a diagram of an exemplary blank 100. This blank 100 may be formed during execution of the method 200, as discussed below, and may be assembled into a packaging article such as a container or pack 300, as discussed below. As will be discussed in more detail below, the blank 100 consists of a card or cellulosic substrate layer 138 laminated with a film layer 10. The fibrous substrate 138 is formed of paper or paperboard sheet material, such as Kraft paper, Kraft board, card stock, carton paperboard (e.g., milk or beverage carton paperboard), cup stock, Manila paper, Manila board, or the like. In certain embodiments, the substrate 138 is formed of folding box board (FBB), solid bleached board (SBB), high density SBB, or solid bleached sulfate (SBS) board. SBB and SBS are typically used in the carton industry. In embodiments, the substrate 138 has a thickness in the range of 100 m to 500 m, e.g., 100 m, 125 m, 150 m, 175 m, 200 m, 225 m, 250 m, 275 m, 300 m, 325 m, 350 m, 375 m, 400 m, 425 m, 450 m, 475 m, or 500 m. Dashed lines represent fold lines, as discussed in detail below, with reference to FIG. 2A. Solid lines represent cuts through the substrate 138 or the substrate 138 and the film layer 10, as discussed in detail below, with respect to FIGS. 2A and 2C. The exceptions to this rule are the indications of first and second lid overlap portions 134, 136, which are indicated with cross hatching and include neither cuts nor fold lines, but are rather a specific section of a lid portion 12, as discussed in more detail below.

[0043] In embodiments, the film layer 10 is a thin layer of polymer film, such as polypropylene, applied to one or both surfaces of the substrate 138. The polymer film layer 10 may be applied such that the ratio of polymer to fibrous substrate 138 in the lamination is sufficiently low to render the blanks 100 and assembled packs 300 recyclable. In embodiments, the polymer film layer 10 may have a multilayer laminate structure. Such structures may include one or more sublayers designed to provide specific characteristics, such as barrier properties, toughness, or abuse resistance, in accordance with the desired packaging attributes and the needs of the contents packaged in the pack 300 that is formable from the blank 100. Such barrier properties may include oxygen, moisture, or light barrier characteristics, among others. Additionally, the film layer 10 may incorporate one or more layers designed for abuse resistance to protect against physical damage. Tie layers, i.e., specialized resins to bond or improve adhesion between dissimilar materials, may also be used as needed to enhance the adhesion between different layers of the film layer 10.

[0044] The illustrated pack 300, formed from the blank 100, has six sides, as do typical boxes. These six sides are present in the blank 100, including the lid 12, a rear face 14, a front face, 16, a base 18, a first side panel 20, and a second side panel 22. The front face 16 is connected to the base 18 via a first transverse away fold line 88 along a first transverse edge 410 of the base 18. The rear face 14 is connected to the base 18 via a second transverse away fold line 86 along a second transverse edge 412 of the base 18. The base 18 is bound by the first transverse edge 410 disposed between the base 18 and the front face 16; the second transverse edge 412 disposed between the base 18 and the rear face 14; and first and second longitudinal edges 406, 408 extending perpendicularly between the first and second transverse edges 410, 412. The lid 12 is connected to the rear face 14 via a fourth transverse away fold line 68 along an upper edge 416 of the rear face 14. The front face 16 has opposing longitudinal edges 433 extending between the first transverse edge 410 of the base 18 and the upper edge 414 of the front face 16. The rear face 14 has opposing longitudinal edges 431 extending between the first transverse edge 412 of the base 18 and the upper edge 416 of the rear face 14.

[0045] The first and second side panels 20, 22 are mirror images of one another, and, as such, their first and second designations are arbitrary. For consistency herein and with the figures, from the perspective of the viewer, the first side panel and any first features associated therewith are depicted on the left side of the blank 100/pack 300 and the figure. The second side panel and any second features associated therewith are depicted on the right side of the blank 100/pack 300 and the figure. The exceptions to this are FIGS. 6B and 6F, which are rear and bottom views of the assembled pack 300, respectively, so that the second side panel is on the left and the first side panel is on the right. Also, for consistency, in at least FIGS. 1 and FIGS. 2A-2C, rear features of the blank 100/pack 300 are toward the top of the respective figures and front features are toward the bottom.

[0046] In this blank 100 form, the first side panel 20 is divided into a first rear side panel segment 34 and a first front side panel segment 36 and the second side panel 22 is divided into a second rear side panel segment 38 and a second front side panel segment 40. As will be apparent, when the blank 100 is assembled into the pack 300, the first rear and front side panel segments 34, 36 and the second rear and front side panel segments 38, 40 will come together to form the united first and second side panels 20, 22, respectively. The first rear side panel segment 34 has an upper edge 418. The first front side panel segment 36 has an upper edge 419. The second rear side panel segment 38 has an upper edge 420. The second front side panel segment 40 has an upper edge 421. The rear face 14 has an upper edge 416. The front face 16 has an upper edge 414. When the blank 100 is formed into the pack 300, the upper edges 414, 416, 418, 419, 420, 421 form an opening 422 into the pack 300, as shown in FIG. 6C. The first front side panel segment 36 has a transverse edge 427, collinear with the first transverse edge 410 of the base 18. The second front side panel segment 40 has a transverse edge 429, collinear with the first transverse edge 410 of the base 18. The first rear side panel segment 34 has a transverse edge 423, collinear with the second transverse edge 412 of the base 18. The second rear side panel segment 38 has a transverse edge 425, collinear with the second transverse edge 412 of the base 18.

[0047] In addition to the six sides described above, the blank 100 includes various flaps and features integral to the assembly of the blank 100 into the pack 300. As discussed in more detail below with respect to FIG. 2B, the entirety of the viewable surface of the substrate 138 includes the film layer 10, including the cutout regions, as illustrated by diagonal surface lines in a window region 24, a first cutout region 50, and a second cutout region 52. Excluding the window 24 and the first and second cutout regions 50, 52, the blank 100 consists of the substrate 138 laminated with the film layer 10. At the window 24 and the first and second cutout regions 50, 52, the blank 100 consists of only the film layer 10, unsupported by the substrate 138. The surface of the substrate 138 that faces away from the viewer, i.e., the surface that will form the outside surface of the assembled pack 300, may also be laminated with a film layer, but this is not required. Although the film layer in the window region 24 and the cutout regions 50, 52 is depicted as shaded for illustration purposes, it will be recognized that a transparent film layer 20 is also contemplated.

[0048] The blank 100 also includes first and second tabs 30, 32, disposed adjacent to the first and second front side panel segments 36, 40, respectively. The first and second tabs 30, 32 will be adhered to the respective adhesive regions 29, 31 of the first and second rear side panel segments 34, 38, respectively, to form the united first and second side panels 20, 22 in pack 300. As will be discussed below with respect to the method 200, the adhesion of the first and second tabs 30, 32 to the respective adhesive regions 29, 31 of first and second rear side panel segments 34, 38 is advantageously achieved with a hot melt adhesive, although other types of adhesives are contemplated.

[0049] The blank 100 also includes first and second upper rear flaps 42, 46, extending transversely from the upper edges 418, 420 of the first and second rear side panel segments 34, 38, respectively; first and second upper front flaps 44, 48, extending transversely from the upper edges 419, 421 of the first and second front side panel segments 36, 40, respectively; and a front face flap 28, extending transversely from the upper edge 414 of the front face 16. The blank 100 may also include a lid flap 26, extending transversely from the lid 12. The lid flap 26 will be adhered to the front face flap 28, when the blank 100 is formed into the pack 300. The lid 12 includes the first and second lid overlap portions 134, 136 on either side of the lid 12. The first upper rear and front flaps 42, 44 will be adhered to the first lid overlap portion 134. The second upper rear and front flaps 46, 48 will be adhered to the second lid overlap portion 136. As will be discussed below with respect to the method 200, in certain embodiments, the adhesion of the lip flap 26 to the front face flap 28; the first upper rear and front flaps 42, 44 to the first lid overlap portion 134; and the second upper rear and front flaps 46, 48 to the second lid overlap portion 136, is achieved through heat sealing of the film layer 10. It is understood that upper as used with reference to the first and second upper rear and front flaps 42, 44, 46, 48, is referring to the upper portion of the pack 300 that may be assembled out of the blank 100.

[0050] First and second base support panels 140, 142 are disposed on either side of the base 18 and include the first and second cutout regions 50, 52; first and second front support arms 54, 58; first and second rear support arms 56, 60, and first and second cutout connectors 62, 64, as detailed below with reference to FIGS. 3A and 3B.

[0051] Now referring to FIG. 2A, there appears a diagram of fold lines and first cuts of the blank 100. In the illustrated embodiment of FIGS. 1, 2A-2F, 3A, and 3B, the fold lines consist of perforated fold lines comprising a series of slits or thru cuts which alternate with uncut portions or lands along a desired folding path. It will be recognized that alternative methods of making fold lines may be used as would be understood by persons skilled in the art. For example, mechanical score lines may be formed, e.g., using scoring rules, to create a groove, partial cut, or crease. In embodiments, each fold line feature will be folded to some extent to form the pack 300.

[0052] For ease of exposition, each fold line is designated herein as away or toward. Away fold line indicates that the eventual fold along that fold line will be such that the angle created will point away from the viewer of the figure. Toward fold line indicates that the eventual fold along that fold line will be such that the angle created will point toward from the viewer of the figure. As would be understood by persons skilled in the art, the fold lines may be uniform regardless of the eventual folding along the various fold lines, in which case, these away and toward designations represent no distinction. Forming the fold lines may be performed, however, such that folding along a particular fold line is particularly facilitated to be either away or toward the viewer. The away and toward designations are distinctive only when this type of fold line formation is performed.

[0053] Unlike fold lines, which are perforated lines in embodiments as described above, as used herein, cuts are continuous cuts that extend completely along the length of the cut and entirely through the substrate 138 (in the case of cuts made prior to the lamination step) or through the substrate 138 and the film layer 10 (for cuts made after the lamination step). The fold lines and first cuts illustrated in FIG. 2A represent the fold lines and cuts, respectively, made during the first cutting step 204 of the method 200, as discussed below with reference to FIG. 5A.

[0054] In certain embodiments, the blank 100 includes a lid flap away fold line 66 disposed between the lid 12 and the lid flap 26, although this fold line 66 is eliminated in embodiments that do not include the lid flap 26. The blank 100 also includes the fourth transverse away fold line 68, along the rear face upper edge 416 and disposed between the lid 12 and the rear face 14; a second transverse away fold line 86 along the second transverse edge 412 of the base 18, and disposed between the rear face 14 and the base 18; a first transverse away fold line 88 along the first transverse edge 410 of the base 18, disposed between the front face 16 and the base 18; and a front face toward fold line 114, along the upper edge 414 of the front face 16, disposed between the front face 16 and the front face flap 28. A third transverse toward fold line 98 is formed in the base 18 intermediate the first transverse and second away fold lines 88, 86. The lip flap away fold line 66 (when included), the fourth transverse away fold line 68, the second transverse away fold line 86, the third transverse toward fold line 98, the first transverse away fold line 88, and the front face toward fold line 114 are all generally parallel to one another.

[0055] The blank 100 also includes first and second rear face away fold lines 82, 84, disposed between the rear face 14 and the first and second rear side panel segments 34, 38, respectively. First and second front face away fold lines 83, 85 are disposed between the front face 16 and the first and second front side panel segments 36, 40, respectively. The rear face 14 is delineated by the fourth transverse away fold line 68, the second rear face away fold line 84, the second transverse away fold line 86, and the first rear face away fold line 82. The front face 16 is delineated by the first transverse away fold line 88, the second front face away fold line 85, the front face toward fold line 114, and the first front face away fold line 83. The blank 100 also includes a first flap toward fold line 120 between the first front side panel segment 36 and the first flap 30. A second flap toward fold line 122 is disposed between the second front side panel segment 40 and the second flap 32.

[0056] The blank 100 includes a first upper rear flap toward fold line 70 along the upper edge 418 of the first rear side panel segment 34, disposed between the first rear side panel segment 34 and the first upper rear flap 42. A first upper front toward fold line 72 along the upper edge 419 of the first front side panel segment 36 is disposed between the first front side panel segment 36 and the first upper front flap 44. A second upper rear flap toward fold line 74 is disposed along the upper edge 420 of the second rear side panel segment 38, disposed between the second rear side panel segment 38 and the second upper rear flap 46. A second upper front flap toward fold line 76 along the upper edge 421 of the second front side panel segment 40, is disposed between the second front side panel segment 40 and the second upper front flap 48. Again, in the context of the first and second upper rear and front flap toward fold lines 70, 72, 74, 76, the term upper refers to the upper edge of the pack 300 that may be assembled out of the blank 100.

[0057] As shown, the fold lines 70, 72, 74, 76 are slightly angled toward the base 18, as compared with the fourth transverse away fold line 68 and the front face toward fold line 114. In the illustrated embodiment, the angling shown is approximately 170 degrees. In certain embodiments, the angling is in the range of about 160 to about 175 degrees. The purpose of this angling is to offset any upward tendencies caused by the inward folding of the first and second base support panels 140, 142, as described in detail below with respect to FIGS. 3A and 3B. This offset ensures that the upper edges 414, 416, 418, 419, 420, 421 will present an even, flush surface when the blank 100 is formed into the pack 300. The even, flush upper edges 414, 416, 418, 419, 420, 421 allow for a secure seal when the lid 12 is closed and sealed. Thicker substrates 138 may require greater angled offsets, i.e., more acute angles between the fold lines 70, 72, 74, 76 and the fourth transverse away fold line 68 and the front face toward fold line 114. In certain embodiments, no offset is provided, such that there is no such angling and the first and second upper rear flap toward fold lines 70, 74 are essentially linear extensions of the fourth transverse away fold line 68 and the first and second upper front flap toward fold lines 72, 76 are essentially linear extensions of the front face toward fold line 114.

[0058] The first and second cutout regions 50, 52, described in more detail with respect to FIGS. 3A and 3B below, are cut out of the substrate 138 with first and second cutout cuts 126, 128 (see FIG. 2A).

[0059] The window 24 is cut out of the lid 12 with a window cut 124 around the perimeter of the window 24. For ease of removal of the entire area that is cut out to form the window 24, an additional bisecting cut 125 may be made, as shown. Although the illustrated pack 300 includes the window 24, it is understood that some embodiments of pack 300 do not include a window 24 in the lid 12. In such embodiments, the blank 100 does not include the window 24 or the window cut 124. In certain embodiments, the lid 12 may be omitted.

[0060] Now referring to FIGS. 3A and 3B, along with FIGS. 1 and 2A, there appear detailed diagrams of the first and second base support panel 140, 142, respectively.

[0061] In the illustrated exemplary embodiment, the first cutout region 50 has a generally isosceles trapezoidal shape having a first long parallel side 152 (which is the first longitudinal edge 406 of the base 18), a first short parallel side 154, a first pair of opposing angled sides 156 connecting the first long and short parallel sides 152, 154, and a first trapezoid height 148 that is the perpendicular distance between the first long and short parallel sides 152, 154. The second cutout region 52 has a generally isosceles trapezoidal shape having a second long parallel side 158 (which is the second longitudinal edge 408 of the base 18), a second short parallel side 160, a second pair of opposing angled sides 162 connecting the second long and short parallel sides 158, 160, and a second trapezoid height 150 that is the perpendicular distance between the second long and short parallel sides 158, 160.

[0062] The first and second cutout regions 50, 52 are formed by the first and second cutout cuts 126, 128, respectively, as shown in FIG. 2A. The blank 100 also includes a first rear support away fold line 90 along the transverse edge 423 of the first rear side panel segment 34, disposed between the first rear side panel segment 34 and the first rear support arm 54. A first front support away fold line 92, along the transverse edge 427 of the first front side panel segment 36, is disposed between the first front side panel segment 36 and the first front support arm 56. A second rear support away fold line 94, along the transverse edge 425 of the second rear side panel segment 38, is disposed between the second rear side panel segment 38 and the second rear support arm 58. A second front support away fold line 96, along the transverse edge 429 of the second front side panel segment 40, is disposed between the second front side panel segment 40 and the second front support arm 60. The first and second rear support away fold lines 90, 94 are essentially extensions of the second transverse away fold line 86. The first and second front support away fold lines 92, 96 are essentially extensions of the first transverse away fold line 88.

[0063] The first base support panel 140 is bound by the first rear support away fold line 90, the first long parallel side 152 of the first cutout region 50, the first front support away fold line 92, and a first base support panel side 164, which is a segment of the perimeter of the blank 100, parallel to the first long parallel side 152 and perpendicular to the first rear and front support away fold lines 90, 92. The second base support panel 142 is bound by the second rear support away fold line 94, the second long parallel side 158 of the second cutout region 52, the second front support away fold line 96, and a second base support panel side 166, which is a segment of the perimeter of the blank 100, parallel to the second long parallel side 158 and perpendicular to the second rear and front support away fold lines 94. 96. The first base support panel 140 has a first support panel width 144, which is the shortest, i.e., perpendicular, distance between the first base support panel side 164 and the first long parallel side 152 of the first cutout region 50. The first support panel width 144 is greater than the first trapezoid height 148. The second base support panel 142 has a second support panel width 146, which is the shortest, i.e., perpendicular, distance between the second base support panel side 166 and the second long parallel side 158 of the second cutout region 52. The second support panel width 146 is greater than the second trapezoid height 150.

[0064] The difference between the first support panel width 144 and the first trapezoid height 148 and between the second support panel width 146 and the second trapezoid height 150 allows for the disposition of the first and second cutout connectors 62, 64. The first cutout connector 62 is bound between the first rear and front support arms 54, 56 and the first short parallel side 154 of the first cutout region 50. In certain embodiments, the second cutout connector 64 is bound between the second rear and front support arms 58, 60 and the second short parallel side 160 of the second cutout region 52. In the illustrated exemplary embodiment, the first and second cutout connectors 62, 64 are generally isosceles triangle-shaped, having first and second triangle bases 172, 176 and first and second triangle legs 174, 178 that connect the first and second triangle bases 172, 176 to the first and second intersections 168, 170 bisecting the first and second base support panel sides 164, 166. As such, the first short parallel side 154 of the trapezoidal shape of the first cutout region 50 is also the first triangle base 172 of the first cutout connector 62. Similarly, the second short parallel side 160 of the trapezoidal shape of the second cutout region 52 is also the second triangle base 176 of the second cutout connector 64.

[0065] Between the first front and rear support arms 54, 56, the first cutout connector 62 includes a first connector rear away fold line 102, a first connector center toward fold line 104, and a first connector front away fold line 106. Between the second front and rear support arms 58, 60, the second cutout connector 64 includes a second connector rear away fold line 108, a second connector center toward fold line 110, and a second connector front away fold line 112. The first connector rear and front away fold lines 102, 106 follow the first triangle legs 174 to the first intersection 168. Fold lines 102, 106 follow the same angled trajectory as the first angled sides 156 of the trapezoidal shape of the first cutout region 50. The second connector rear and front away fold lines 108, 112 follow the second triangle legs 178 to the second intersection 170. Fold lines 108, 112 follow the same angled trajectory as the second angled sides 162 of the trapezoidal shape of the second cutout region 52. The first connector center toward fold line 104 extends the shortest, i.e., perpendicular, distance between the first short parallel side 154/the first triangle base 172 and the first intersection 168. The second connector center toward fold line 110 extends the shortest distance between the second short parallel side 160/second triangle base 176 and the second intersection 170.

[0066] In embodiments, the first and second cutout connectors 62, 64 are omitted and the first and second cutout regions 50, 52 are generally isosceles triangle-shaped, rather than isosceles trapezoid-shaped, with the first and second angled sides 156, 162 extending all the way to the first and second intersections 168, 170.

[0067] The film layer 10 covers the first and second cutout regions 50, 52, so that at the first and second cutout regions 50, 52, the blank 100 consists of only the film layer 10 and not substrate 138, i.e., unsupported film. The first and second cutout cuts 126, 128 are therefore through the substrate 138 only and occur before the substrate 138 is laminated with film layer 10.

[0068] When pack 300 is assembled from blank 100, the combination of the first cutout region 50, the first rear and front support arms 54, 56, and the first cutout connector 62 with the first connector rear away fold line 102, the first connector center toward fold line 104, and the first connector front away fold line 106, will fold inward toward the base 18. Similarly, the combination of the second cutout region 52, the second rear and front support arms 58, 60, and the second cutout connector 64 with the second connector rear away fold line 108, the second connector center toward fold line 110, and the second connector front away fold line 112 will fold inward toward the base 18. These inward folds result in the first and second rear and front support arms 54, 56, 58, 60 being substantially parallel to the base 18. It is understood that, as the arms 54, 56, 58, 60 are folded and part of the same blank 100 as the base 18, they are not perfectly parallel to the base 18, but rather folded at a very acute angle. This distinction from being truly parallel is what is meant by substantially parallel in this context.

[0069] The film layer 10 provides a completely sealed base 18. The film layer 10, lacking the paper substrate layer in the first and second cutout regions 50, 52, makes those sections less thick than other sections of the blank 100 that include both the substrate 138 and the film layer 10. The use of the first and second cutout regions 50, 52 therefore ensures that the inward-folding combinations are not too thick with too many layers of paper board/substrate. The first and second cutout connectors 62, 64 are relatively small so as to maximize the area of the first and second cutout regions 50, 52, thereby minimizing the thickness of the first and second base support panels 140, 142 as they fold inward.

[0070] Now referring to FIG. 2B, there appears an illustration of the laminating step 206 of method 200, as discussed below with reference to FIG. 5A. The fold line formation and cutting illustrated in FIG. 2A was performed on the unlaminated substrate 138. In this step, the entire surface of the blank 100 that faces the viewer of FIGS. 1-2F is laminated with film layer 10. As discussed above, this film layer 10 is the only substance of the window 24 (when included) and the first and second cutout regions 50, 52. In some embodiments, the surface of the blank 100 that faces away from the viewer may also be laminated, but this is not required. Laminating after making the fold lines and first cuts ensures that any small perforations of substrate 138 made while making the fold lines are sealed.

[0071] In embodiments, the film layer 10 is a polymer laminate, such as polypropylene. In embodiments, the polymer laminate is relatively thin while maintaining an effective barrier between the food or other packaged product and the paper board substrate 138 of the blank 100. In embodiments, the ratio of polymer to fibrous substrate in the film layer 10 used to form the blank 100 is sufficiently low to render the assembled packs 300 recyclable. As used herein, the term recyclable may refer to a paper-based product that is eligible for acceptance into paper recycling programs, including curbside collection programs and recycling programs that use drop-off locations, including products that comply with one or more promulgated standards or guidelines for recyclability, and including materials that are sufficiently free of plastic materials, such as polyethylene, nylon, polypropylene, polyester, and others which would impede recyclability.

[0072] Now referring to FIG. 2C, there appears a diagram of final cuts of the blank 100 and an illustration of the perimeter and final cuts step 208 of method 200, as discussed below with reference to FIG. 5A. After the film layer 10 has been applied, the perimeter cut 130 is made, which forms the entire outer shape of the blank 100, as shown in FIG. 1. First and second lid flap cuts 78 and 80 are also made between the lid 12 and the first and second upper rear flaps 42, 46, respectively. First and second face cuts 116, 118 are also made between the front face flap 28 and the first and second upper front flaps 44, 48, respectively.

[0073] Now referring to FIGS. 2D-2F, there appear diagrams illustrating the first folding step 210 of the present method 200, as discussed below with reference to FIG. 5A. In FIG. 2D, the blank 100 is folded along the second transverse away fold line 86 so that the laminated surface of the blank 100 is folded flush against itself. Specifically, the blank 100 is folded so that the base 18 and the front face 16 are folded flush against the rear face 14 and the lid 12. In FIG. 2E, the blank 100 is folded down along the third transverse toward fold line 98 and the first and second connector center toward fold lines 104, 110. In embodiments, this fold bisects the base 18 and the first and second base support panels 140, 142, including the first and second cutout regions 50, 52. Adhesive 132 is applied to the first and second rear side panel segments 34, 38, near the perimeter cut 130. In certain embodiments, the adhesive is a hot melt adhesive. Alternately, the adhesive 132 may be any suitable adhesive including single component adhesives, two component adhesives, solvent-based adhesives, solventless adhesives, water-based adhesives, and others as would be understood by persons skilled in the art. In FIG. 2F, the blank 100 is folded along the first transverse away fold line 88. This places the adhesive regions 29, 31 of the first and second rear side panel segments 34, 38 flush against the respective first and second tabs 30, 32 so that the first adhesive region 29 is adhered to the first tab 30 and the second adhesive region 31 is adhered to the second tab 32. The blank 100 is now in a convenient form to be stacked and shipped to an end user.

[0074] Now referring to FIG. 4, a diagram indicating exemplary dimensions of an exemplary blank 100 of the present disclosure is provided. The dimensions indicated are merely exemplary and should not be considered to be limiting on the various dimensions of the various features of the blank 100. One skilled in the art will recognize that the blank 100 and its features may have a range of dimensions. All dimensions shown are in mm. In this exemplary embodiment, the lid 12 has a width of 151.93 mm, including 34 mm on either side of the window 24, which has dimensions of 5583.93 mm. There is 14 mm between the window 24 and the fourth transverse away fold line 68. The length of the fourth transverse away fold line 68 between the first and second rear face away fold lines 82, 84 is 120 mm. The base 18 has dimensions of 65110 mm, where the 65 mm height is bisected by the third transverse toward fold line 98. The first and second base support panels 140, 142 each have a height of 65 mm. The front face 16 has a height of 60 mm, as measured along the shortest, i.e., perpendicular, distance between the first transverse away fold line 88 and the front face toward fold line 114. The front face flap 28 has a width, meaning the shortest, i.e., perpendicular, distance between the front face toward fold line 114 and the perimeter of the blank 100, of 12 mm. The overall dimensions of the blank 100 are 288234.15 mm.

[0075] Now referring to FIG. 5A, a flow chart illustrating the steps of a method 200 for the production of a blank in accordance with this disclosure is provided. In its most basic form, method 200 includes the step 202 of providing a substrate sheet 138; the step 204 of making first cuts and fold lines in the substrate 138; the step 206 of laminating at least one surface of the substrate sheet 138 with film layer 10; and the step 208 of making perimeter and final cuts through the substrate sheet 138.

[0076] The substrate sheet 138 provided in step 202 is formed of paper or paperboard sheet material, such as Kraft paper, Kraft board, carton paperboard (e.g., milk or beverage carton paperboard), cup stock, Manila paper, Manila board, or the like. In certain embodiments, the substrate 138 is formed of folding box board, (FBB), solid bleached board (SBB), high density SBB, or solid bleached sulfate (SBS) board. SBB and SBS are typically used in the carton industry. In embodiments, the substrate 138 has a thickness in the range of 100 m to 500 m, e.g., 100 m, 125 m, 150 m, 175 m, 200 m, 225 m, 250 m, 275 m, 300 m, 325 m, 350 m, 375 m, 400 m, 425 m, 450 m, 475 m, or 500 m.

[0077] The first cuts and fold lines made in step 204 are detailed above with respect to FIG. 2A. The first cuts include the window cut 124 (when the window 24 is included) and the first and second cutout region cuts 126, 128. Once these cuts 124, 126, 128 are made, the substrate material for those cutouts is removed. Step 204 is performed through a cutting process, e.g., die cutting process. The substeps of step 204, of making first cuts in the substrate 138 and fold lines in the substrate 138, are performed substantially simultaneously, which is why they are listed as a single combined step.

[0078] The step of making fold lines in the substrate 138 includes at least the substeps of making the second transverse away fold line 86; making a first transverse away fold line 88, thereby delineating a base 18 bound by the two longest sides 152, 158 of the first and second trapezoid cutout regions 50, 52/first and second longitudinal edges 406, 408 of the base 18, the second transverse away fold line 86, and the first transverse away fold line 88; making the third transverse toward fold line 98 parallel to the second transverse away fold line 86 that connects the first and second trapezoid cutout regions 50, 52 and divides the base 18; making the first and second rear face away fold lines 82, 84 extending longitudinally from the second transverse away fold line 86, thereby delineating the rear face 14 bound by the second transverse away fold line 86 and the first and second rear face away fold lines 82, 84; making the first and second front face away fold lines 83, 85 extending longitudinally from the first transverse away fold line 88, thereby delineating the front face 16 bound by the first transverse away fold line 88 and the first and second front face away fold lines 83, 85; making the first flap toward fold line 120 extending longitudinally from the first transverse away fold line 88, thereby delineating the first front side panel segment 36 bound by the first transverse away fold line 88, the first front face away fold line 83, and the first flap toward fold line 120; and making the second flap toward fold line 122 extending longitudinally from the first transverse away fold line 88, thereby delineating the second front side panel segment 40 bound by the first transverse away fold line 88, the second front face away fold line 85, and the second flap toward fold line 122.

[0079] The step of making fold lines in the substrate 138, as shown in FIG. 2A, includes at least the substeps of making the fourth transverse away fold line 68; making the second transverse away fold line 86 parallel to the fourth transverse away fold line 68; making the first transverse away fold line 88, thereby delineating a base 18 bound by the two longest sides 152, 158 of the first and second trapezoid cutout regions 50, 52, the second transverse away fold line 86, and the first transverse away fold line 88; making the third transverse toward fold line 98 parallel to the second transverse toward fold line 86 that connects the first and second cutout regions 50, 52 and divides the base 18; making the front face toward fold line 114 parallel to the first transverse away fold line 88; making the first and second rear face away score lines 82, 84 between the fourth transverse away fold line 68 and the second transverse away fold line 86, thereby delineating a rear wall 14 bound by the fourth transverse away fold line 68, the second transverse away fold line 86, and the first and second rear face away fold lines 82, 84; making the first and second front face away fold lines 83, 85 between the first transverse away fold line 88 and the front face toward fold line 114, thereby delineating a front face 16 bound by the first transverse away fold line 88, the front wall toward fold line 114, and the first and second front face away fold lines 83, 85; making the first connector back and front away fold lines 102, 106 following the trajectory of the angled sides 156 of the first cutout region 50 and ending at the first intersection 168 one with the other; making the second connector rear and front away fold lines 108, 112 following the trajectory of the angled sides 162 of the second cutout region 52 and ending at the second intersection 170 one with the other; making the first connector center toward fold line 104 bisecting an angle created by the first connector rear and front away fold lines 102, 106 and ending at the first intersection 168; making the second connector center toward fold line 110 bisecting an angle created by the second connector rear and front away fold lines 108, 112 and ending at the second intersection 170; making the first flap toward fold line 120 between the first transverse away fold line 88 and the front face toward fold line 114, thereby delineating the first front side panel segment 36 bound by the first transverse away fold line 88, the first front face away fold line 83, the front face toward fold line 114, and the first flap toward fold line 120; and making the second flap toward fold line 122 between the first transverse away fold line 88 and the front wall toward fold line 114, thereby delineating the second front side panel segment 40 bound by the first transverse away fold line 88, the second front wall away fold line 85, the front face toward fold line 114, and the second flap toward fold line 122.

[0080] In embodiments, the step 204 of making first cuts also includes the substeps of cutting out the window 24 from the lid 12 and removing the sheet material that previously occupied the window cutout region. In embodiments, the substep of making fold lines in the substrate 138 also includes the substep of making the lid flap away fold line 66 which is parallel to the fourth transverse away fold line 68 and on another side of the fourth transverse away fold line 68 as the second transverse away fold line 86.

[0081] In embodiments, the substep of making the fourth transverse away fold line 68 comprises making the fourth transverse away fold line 68 between the first and second rear face away fold lines 82, 84; making the first upper rear flap toward fold line 70 intersecting with the fourth transverse away fold line 68 at about a 160-175 degree angle and intersecting with the first rear face away fold line 82 at about an 80-85 degree angle; and making the second upper rear flap toward fold line 74 intersecting with the fourth transverse away fold line 68 at about a 160-175 degree angle and intersecting with the second rear face away fold line 84 at about an 80-85 degree angle. In embodiments, the substep of making a front face toward fold line 114 comprises making the front face toward fold line 114 between the first and second front face away fold lines 83, 85; making the first upper front flap toward fold line 72 intersecting with the front face toward fold line 114 at about a 160-175 degree angle and intersecting with the first front face away fold line 83 at about an 80-85 degree angle, such that the first front side panel segment 36 is bound by the first transverse away fold line 88, the first front face away fold line 83, the first upper front flap toward fold line 72, and the first flap toward fold line 120; and making the second upper front flap toward fold line 76 intersecting with the front face toward fold line 114 at a about 160-175 degree angle and intersecting with the second front face away fold line 85 at about an 80-85 degree angle, such that the second front side panel segment 40 is bound by the first transverse away fold line 88, the second front face away fold line 85, the second upper front flap toward fold line 76, and the second flap toward fold line 122.

[0082] The film layer 10 that is laminated onto substrate 138 in step 206 is a thin layer of polymer laminate, such as polypropylene, applied to one or both surfaces of the substrate 138. As shown in FIG. 2B, the laminating step 206 occurs after the first and second cutout regions 50, 52 and the window 24 have been cut out of the substrate 138 so that the blank 100 consists of the film layer 10 only over these features. In addition, performing the laminating step 206 after making the fold lines ensures that any small slits or perforations made through substrate 138 while making the fold lines are sealed with the film layer 10.

[0083] In embodiments, the polymer film layer 10 is applied such that the ratio of polymer to fibrous substrate in the laminate used to form the blank is sufficiently low to render the blanks and assembled packs recyclable. In embodiments, the polymer film layer 10 has a multilayer laminate structure. Such structures may include one or more layers designed to provide specific characteristics, such as barrier properties, toughness, or abuse resistance, in accordance with the desired packaging attributes and the needs of the contents packaged in the pack that is formable from the blank. In embodiments, the film layer 10 comprises one or more layers with barrier properties, which may include oxygen, moisture, or light barrier characteristics, among others. Additionally, the film layer may incorporate one or more layers designed for abuse resistance to protect against physical damage. Tie layers, i.e., specialized resins to bond or improve adhesion between dissimilar materials, may also be used as needed to enhance the adhesion between different layers of the film layer.

[0084] The step 208 of making perimeter and final cuts through the substrate 138 are performed substantially simultaneously, which is why they are listed as a single combined step 208. The step of making a perimeter cut 130 entails a single cut through the substrate sheet 138 and the film layer 10, the perimeter cut 130 surrounding all of the first cuts and fold lines made in the first cuts and fold lines step 204. The perimeter and final cuts made step 208 are illustrated and discussed above with reference to FIG. 2C.

[0085] In embodiments, the perimeter cut 130 is made by cutting a first line parallel to the second transverse away fold line 86, where the first cut line is along what is shown as the fourth transverse away fold line 68 in FIG. 2A; cutting a second line parallel to the first transverse away fold line 88, where the second cut line is along what is shown as the front face toward fold line 114 in FIG. 2A; and cutting third and fourth lines connecting the first and second cut lines such that all cuts and folds made in the step 204 of making first cuts and fold lines in the card layer are within the bounds of the first through fourth cut lines.

[0086] The perimeter cut 130, as shown in FIG. 2C, is made such that a substantially rectangular lid 12 is formed, the lid 12 being bound on three sides by the perimeter cut 120 and on a fourth side by the fourth transverse away fold line 68, such that the center of the three sides bound by the perimeter cut 120 is parallel to the fourth transverse away fold line 68; the first and second upper rear flaps 42, 46 are formed on either side of the lid 12; the first and second rear side panel segments 34, 38 are formed adjacent to the first and second upper rear flaps 42, 46, respectively; the first and second base support panels 140, 142 are formed adjacent to the first and second rear side panel segments 34, 38, respectively; the first and second tabs 30, 32 are formed extending from the first and second front side panel segments 36, 40, respectively, the first and second front side panel segments 36, 40 being adjacent to the first and second base support panels 140, 142, respectively; the first and second upper front flaps 44, 48 are formed extending from the first and second front side panel segments 36, 40; and a front face flap 28 is formed between the first and second upper front flaps 44, 48, extending from the front face 16. The step of making final cuts also entails making the first and second lip flap cuts 78, 80 between the lid 12 and the first and second upper rear flaps 42, 46, respectively, wherein the first and second lip flap cuts 78, 80 extend no further than the fourth transverse away fold line 68; and making the first front face cut 116 between the first upper front flap 44 and the front face flap 28; and making the second front face cut 118 between the second upper front flap 48 and the front face flap 28.

[0087] Now referring to FIG. 5B, a flow chart illustrating the steps of a method 200 for the production of a pack in accordance with this disclosure is provided. In some embodiments, after step 208, the blanks 100 are stacked and shipped to end users in their flattest form. Alternatively, the blanks 100 are shipped after the folding step 210, which also includes applying adhesive 212, as described below and above, with respect to FIGS. 2D-2F. In certain embodiments, the folding step 210, including the adhesive application substep 212, is performed using a folding and gluing machine. At the end of the folding step 210, the rear face 14, base 18, and front face 16 are folded in such a way that they form something of a W shape.

[0088] The folding step 210 includes the substeps of folding the blank 100 along the second transverse away fold line 86 such that the at least one laminated surface of the blank 100 is flush against itself; folding the blank 100 along the third transverse toward fold line 98, the first connector toward fold line 104, and the second connector toward fold line 110, such that the first and second trapezoid cutout regions 50, 52 are folded in half; applying adhesive 132 to at least portions of the first and second rear side panel segments 34, 38 that are proximate to the perimeter cut 130; and folding the blank 100 along the first transverse away fold line 88 such that the first and second flaps 30, 38 are made flush against the portions of the first and second rear side panel segments 34, 38 to which the adhesive 132 was applied in the adhesive application step 212, such that the adhesive regions 29, 31 of the first and second rear side panel segments 34, 38 to which the adhesive 132 was applied such that the first and second tabs 30, 32 are adhered to the adhesive regions 29, 31 of the first and second rear side panel segments 34, 38, respectively. With this adhesion, the first rear and front side panel segments 34, 36 are unified into the first side panel 20 and the second rear and front side panel segments 38, 40 are unified into the second side panel 22, even if the first and second side panels 20, 22 are still folded in this form of the blank 100.

[0089] In certain embodiments, the adhesive application substep 212 is performed by applying a hot melt adhesive to at least portions of the first and second rear side panel segments 34, 38 that are proximate to the perimeter cut 130. In certain embodiments, the adhesive is a hot melt adhesive. Alternatively, the adhesive 132 may be any suitable adhesive including single component adhesives, two component adhesives, solvent-based adhesives, solventless adhesives, water-based adhesives, and others as would be understood by persons skilled in the art.

[0090] After the folding step 210, the blanks 100 are provided to an end user for final assembly of the pack 300. The step 214 of assembling the pack 300 from the folded blank 100 includes the substeps of pushing the first and second side panels 20, 22 inward toward the base 18, such that the first and second base support panels 140, 142 fold inward and downward to be approximately flush and substantially parallel with the base 18; adding contents to the pack 300; folding the first upper rear flap 42 and the first upper front flap 44 outward along the first upper rear and front toward fold line 70, 72, respectively, such that the first upper rear flap 42 and the first upper front flap 44 are approximately perpendicular to the first side panel 20; folding the second upper rear flap 46 and the second upper front flap 48 outward along the second upper rear and front toward fold line 74, 76, respectively, such that the second upper rear flap 46 and the second upper front flap 48 are approximately perpendicular to the second side panel 22; folding the front face flap 28 outward along the front face toward fold line 114, such that the front face flap 28 is approximately perpendicular to the front face 16; folding the lid 12 down along the fourth transverse away fold line 68 such that a portion of the lid 12 overlaps and is flush with the first and second upper front and rear flaps 42, 44, 46, 48 and the front face flap 28; and adhering the overlapping portion of the lid 12 to the first and second upper front and rear flaps 42, 44, 46, 48 and the front face flap 28. In embodiments, the adhesion substep 216 is performed by heat sealing the film layer 10 covering the overlapping portion of the lid 12 to the film layer covering the first and second upper front and rear flaps 42, 44, 46, 48 and the front face flap 28. In embodiments, the assembly step 214, including adding the contents and heat sealing 216 is performed by the end user.

[0091] Now referring to FIGS. 6A-6F, various diagrams of the assembled pack 300 according to the present disclosure are provided. The pack 300 depicted will have been formed by completing all steps of method 200 and 200, as described above. FIG. 6A is a front view of the assembled pack 300 according to the present disclosure. The first rear side panel segment 34 has been adhered to the first flap 30 to form the first side panel 20. Although not visible in this view, it is understood that the first flap 30 has been folded toward the viewer and toward the first front side panel segment 36. The second rear side panel segment 38 has been adhered to the second flap 32 to form the second side panel 22. Although not visible in this view, it is understood that the second flap 32 has been folded toward the viewer and toward the second front side panel segment 40. The lid flap 26 is shown overlapping the front face 16. It is understood that in embodiments that do not include the lid flap 26 or the lid flap away fold line 66, this view would show the thin width of the lid 12 atop the thin width of the front face flap 28.

[0092] FIG. 6B is a rear view of the assembled pack 300 according to the present disclosure. The lid 12 is shown adjacent to and extending out from either side of the rear face 14. On the far side of pack 300 from the viewer, the lid flap 26 is shown extending downward over the front face flap 28, to which it is heat sealed.

[0093] FIG. 6C is a top view of the assembled pack 300 according to the present disclosure, with the lid 12, the first and second front and rear flaps 42, 44, 46, 48, and the front face flap 28 omitted for illustrative purposes. The first and second tabs 30, 32 are folded back toward the first and second front side panel segments 36, 40, respectively. The adhesive region portions 29, 31 of the respective first and second rear side panel segments 34, 38 have been adhered to the first and second tabs 30, 32, to form the first and second side panels 20, 22, respectively. In the illustrated embodiment, the adhesive regions 29, 31 define adhesive tabs which are similar to the respective tabs 30, 32, except that the regions 29, 31 are not demarcated by a fold line as are the tabs 30, 32. In this manner each of the adhesive joints 33 (see FIGS. 6D and 7B) between the adhesive region 29 and the first tab 30, and between the adhesive region 31 and the second tab 32, define tab-to-tab fin joints creating a linear flange like structure when joined together. In the illustrated embodiment, wherein the adhesive regions 29, 31 are not bounded by a line of preferential folding as are the tabs 30, 32, the tab joints 33 lie closer to the sidewalls 20, 22 and do protrude excessively.

[0094] When the first and second side panels 20, 22 are pushed inward toward the base 18, the first and second base support panels 140, 142 fold inward and downward toward the base 18 along the first connector fold lines 102, 104, 106 and along the second connector fold lines 108, 110, 112, respectively. It is understood that the first cutout region 50 now faces the base 18 and is disposed between the first rear and front support arms 54, 56 and the base 18. It is understood that the second cutout region 52 now faces the base 18 and is disposed between the second rear and front support arms 58, 60 and the base 18.

[0095] FIG. 6D is a side view of the assembled pack 300 according to the present disclosure. In particular, the second side of pack 300 is shown in FIG. 6D. The second side is shown on the right in most Figures herein. The film layer 10 on the inside of the lid 12 is heat sealed to the film layer 10 on the second upper rear and front flaps 46, 48 at the upper edge 420 of the second side panel 22. The film layer 10 on the inside of the lid flap 26 is heat sealed to the film layer 10 on the front face flap 28. The second rear and front side panel segments 38, 40 have been unified into the second side panel 22. The second flap toward fold line 122 is indicated in dashed lines but is understood to be behind the second rear side panel segment 38. The base 18 may tend to fold slightly upward along the third transverse toward fold line 98 when pack 300 is not filled. As best seen in FIG. 6E, the second cutout region 52 is disposed between the base 18 and second rear and front support arms 58, 60.

[0096] FIG. 6F is a bottom view of the assembled pack 300 according to the present disclosure. The base 18 is divided by the third transverse toward fold line 98, shown in dashed lines. In this embodiment, the lid 12 does not include the lid flap 26 or the lid flap away fold line 66. As such, the lid 12 is shown on three sides slightly overlapping the first and second upper front and rear flaps 42, 44, 46, 48 and the front face flap 28. In some embodiments, the lid 12 is sized and dimensioned to overlap the first and second upper front and rear flaps 42, 44, 46, 48 and the front face flap 28 without extending beyond them. In such embodiments, the lid 12 would not be visible from this view. On the left, the overlap and adhesion of the second rear side panel segment 38 and the second flap 32 to form the second side panel 22 is visible. On the right, the overlap and adhesion of the first rear side panel segment 34 and the first flap 30 to form the first side panel 20 is visible.

[0097] Now referring to FIGS. 7A-7E and 8A-8H, there appear several views of an exemplary assembled pack 300 according to the present disclosure. As best seen in FIGS. 8A, 8B, 8E, 8F, and 8H, the pack 300 has been filled with a freshly packaged sandwich, which may be viewed through the window 24. As the base 18 of the pack 300 is completely sealed with film layer 10, any moisture would remain sealed within the pack 300 and would not affect the structural integrity of the pack 300 or leak out. As the pack 300 has also been heat sealed, gas and liquid are prevented from entering the space within the pack 300, thereby maintaining the freshness of the sandwich much longer than if it were exposed to outside elements through gaps or holes in the pack 300.

[0098] The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.