Abstract
A folded sleeve, more particularly, a folded sleeve and methods for forming and assembling a folded sleeve are provided.
Claims
1. A folded sleeve for containing a plurality of shaving razor cartridge containers, the folded sleeve comprising: a. a first wall; b. a second wall opposite the first wall; c. a pair of side walls that are opposite each other and connect the first and second walls to define a sleeve cavity configured to receive the plurality of shaving razor cartridge containers; and d. one or more notches, wherein at least one notch of the one or more notches is formed by at least one of a part of the first wall and a part of the second wall and at least one of a part of one side wall and a part of the other side wall, and wherein at least a portion of the at least one notch extends into the sleeve cavity of the folded sleeve.
2. The folded sleeve according to claim 1, wherein the at least one notch comprises a first notch formed by the part of the second wall and the part of the one side wall.
3. The folded sleeve according to claim 2, wherein the part of the second wall and the part of the one side wall are connected at an angle of from about 60 to about 120.
4. The folded sleeve according to claim 2, wherein the at least one notch further comprises a second notch formed by the part of the second wall and the part of the other side wall.
5. The folded sleeve according to claim 4, wherein the part of the second wall and the part of the other side wall are connected at an angle of from about 60 to about 120.
6. The folded sleeve according to claim 1, wherein the at least one notch comprises a first notch formed by the part of the first wall and the part of the one side wall.
7. The folded sleeve according to claim 6, wherein the part of the first wall and the part of the one side wall are connected at an angle of from about 60 to about 120.
8. The folded sleeve according to claim 6, wherein the at least one notch comprises a second notch formed by the part of the first wall and the part of the other side wall.
9. The folded sleeve according to claim 8, wherein the part of the first wall and the part of the other side wall are connected at an angle of from about 60 to about 120.
10. The folded sleeve according to claim 1, wherein the first wall, the second wall, and the pair of side walls further define a first end opening configured for at least one of receiving into and dispensing from the sleeve cavity at least one of the plurality of shaving razor cartridge containers.
11. The folded sleeve according to claim 10, wherein the first wall, the second wall, and the pair of side walls further define a second end opening opposite the first end opening.
12. The folded sleeve according to claim 11, wherein at least one of the first or the second end opening comprises at least one of the one or more notches.
13. The folded sleeve according to claim 12, wherein the one or more notches comprise at least two notches, and wherein at least one of the first or the second end opening comprises the at least two notches.
14. The folded sleeve according to claim 1, wherein the folded sleeve comprises a first shaving razor cartridge container compartment comprising at least one of the one or more notches.
15. The folded sleeve according to claim 14, wherein the folded sleeve comprises a second shaving razor cartridge container compartment comprising at least one other of the one or more notches.
16. The folded sleeve according to claim 1, wherein at least one of the one or more notches is configured to engage one or more of the plurality of shaving razor cartridge containers.
17. A method for forming a sleeve blank, the method comprising: providing a precursor sleeve blank; creating a plurality of fold lines within the precursor sleeve blank to define a first wall portion, a second wall portion, and a pair of side wall portions, wherein at least one of the side wall portions is connected to both the first wall portion and the second wall portion; and forming one or more notch portions in the precursor sleeve blank by (i) cutting at least one notch cut line in the precursor sleeve blank that extends from a part of at least one of the first wall and the second wall to a part of at least one of the pair of side walls, and (ii) creating a notch fold line between the part of at least one of the first wall and the second wall and the part of at least one of the pair of side walls to form the sleeve blank.
18. The method according to claim 17, wherein forming the one or more notch portions comprises forming two or more notch portions in the precursor sleeve blank by cutting a first notch cut line in the precursor sleeve blank that extends from the part of the second wall to the part of one side wall and cutting a second notch cut line in the precursor sleeve blank that extends from the part of the second wall to the part of the other side wall.
19. The method according to claim 17, wherein forming the one or more notch portions comprises forming two or more notch portions in the precursor sleeve blank by cutting a first notch cut line in the precursor sleeve blank that extends from the part of the first wall to the part of one side wall and cutting a second notch cut line in the precursor sleeve blank that extends from the part of the first wall to the part of the other side wall.
20. A method for assembling a folded sleeve for containing a plurality of shaving razor cartridge containers, the method comprising: providing a sleeve blank comprising a plurality of fold lines that define at least a first wall portion, a second wall portion, and a pair of side wall portions, wherein at least one of the side wall portions is positioned between the first wall portion and the second wall portion; forming one or more notch portions including a notch fold line and a notch cut line in the sleeve blank; folding the sleeve blank along the plurality of the fold lines to form a folded sleeve comprising a sleeve cavity defined by a first wall corresponding to the first wall portion, a second wall corresponding to the second wall portion, and a pair of side walls corresponding to the pair of side wall portions; forming at least one notch by folding at least one of the one or more notch portions along a corresponding notch fold line, wherein the at least one notch protrudes into the sleeve cavity of the folded sleeve; and inserting a plurality of shaving razor cartridge containers into the sleeve cavity of the folded sleeve, wherein the at least one notch engages at least one of the plurality of shaving razor cartridge containers.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1A is a perspective view of one possible example of a folded sleeve according to the present disclosure;
[0009] FIG. 1B is another perspective view of the folded sleeve of FIG. 1A;
[0010] FIG. 1C is a cross section view of the sleeve of FIG. 1A taken along line 1C-1C;
[0011] FIG. 1D is a cross section view of the sleeve of FIG. 1A taken along line 1D-1D;
[0012] FIG. 2A is a top plan view of one possible example of a precursor sleeve blank according to the present disclosure;
[0013] FIG. 2B is a top plan view of one possible example of a sleeve blank formed from the precursor sleeve blank of FIG. 2A according to the present disclosure;
[0014] FIG. 2C is a flow chart illustrating the steps for forming the sleeve blank of FIG. 2B from the precursor sleeve blank of FIG. 2A;
[0015] FIG. 2D are perspective views illustrating the steps for folding one possible example of a sleeve blank to form one example of a folded sleeve;
[0016] FIG. 2E is a top plan view of another possible example of a sleeve blank formed from the precursor sleeve blank of FIG. 2A according to the present disclosure;
[0017] FIG. 2F is a flow chart illustrating the steps for forming the sleeve blank of FIG. 2E from the precursor sleeve blank of FIG. 2A; and
[0018] FIG. 2G are perspective views illustrating the steps for folding one possible example of a sleeve blank to form one example of a folded sleeve.
[0019] FIG. 3 is a perspective view of the folded sleeve of FIG. 2G containing a plurality of consumer product cartridge containers.
[0020] FIG. 4 is a flow chart illustrating the steps for folding the sleeve blank of FIGS. 2B and 2E to form a folded sleeve.
DETAILED DESCRIPTION OF THE INVENTION
Folded Sleeve
[0021] Referring to FIGS. 1A-1D, perspective and cross section views of examples of a folded sleeve 12, which may be hollow, in accordance with the present disclosure is illustrated. The folded sleeve 12 may comprise a first wall 14, a second wall 16 opposite the first wall 14, and a pair of side walls 18, 20, in which the side walls 18, 20 are opposite each other and connect the first wall 14 and the second wall 16 to define a sleeve cavity 22 of the sleeve 12. Although the sleeve 12 is depicted in FIGS. 1A-1D as having a substantially rectangular cross-section, it may be understood that other cross-sectional geometries are possible, including circular, semi-circular, square, etc. In addition, while the first and second walls 14, 16 are depicted as having a larger surface area than the side walls 18, 20, it may be understood that other configurations are possible. The sleeve 12 may further comprise one or more pliable tabs, in this case, a first pliable tab 24A and a second pliable tab 24B (referred to herein collectively with reference numeral 24), that protrude or extend, for example, at least partially into the sleeve cavity 22. Pliable as used herein with reference to the tabs 24 means that the tabs 24 are easily bent, flexible, foldable, and/or movable between positions under normal consumer use conditions for consumer products, as opposed to being rigid and not designed to be bent and/or movable without sustaining damage, for example without buckling and/or compressing.
[0022] The folded sleeve 12 may comprise one or more notches 48A, 48B (collectively referred to herein with reference numeral 48), also referred to as stop folds. At least one of the one or more notches 48 is formed by at least one of a part of the first wall 14 and a part of the second wall 16 and at least one of a part of one side wall, e.g., side wall 18, and a part of the other side wall, e.g., side wall 20. For example, the one or more notches 48 may be formed by a part 18 of the side wall 18 and a part 16 of the second wall 16 and/or a part 20 of the side wall 20 and a part 16 of the second wall 16. In the example shown in FIGS. 1A-1D, the folded sleeve 12 comprises two or more notches 48A and 48B, in which a first notch 48A is formed by the part 16 of the second wall 16 and the part 18 of the side wall 18 and a second notch 48B is formed by the part 16 of the second wall 16 and the part 20 of the side wall 20.
[0023] As shown in FIGS. 1A-1D, at least a portion of one of the one or more notches 48 protrudes and/or extends at least partially into the sleeve cavity 22 of the folded sleeve 12. In one example, the part 16 of the second wall 16 and the part 18 of the side wall 18 are connected along a notch fold line 49A at an angle of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other. In one example, the part 16 of the second wall 16 and the part 20 of the side wall 20 are connected along a notch fold line 49B at an angle of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other. At least one of the notches 48A, 48B may comprise a notch opening 51A, 51B. In one example, as shown in FIG. 1B, the part 16 of the second wall 16 of the first notch 48A extends into the sleeve cavity 22 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance D1 from the second wall 16 to the first wall 14. In one example, the part 18 of the side wall 18 of the first notch 48A extends into the sleeve cavity 22 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance D2 from the side wall 18 to the side wall 20. In one example, the part 16 of the second wall 16 of notch 48B extends into the sleeve cavity 22 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance D1 from the second wall 16 to the first wall 14. In one example, the part 20 of the side wall 20 of notch 48B extends into the sleeve cavity 22 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance D2 from the side wall 18 to the side wall 20.
[0024] With reference to step V of FIG. 2D, another example of a folded sleeve, for example a folded sleeve 112, is illustrated. The folded sleeve 112 of FIG. 2D may comprise structures similar to the folded sleeve 12 of FIGS. 1A-1D as described herein. The description of these structures applies equally to the example shown in FIG. 2D, where applicable. The folded sleeve 112 may comprise a first wall 114, a second wall 116 opposite the first wall 114, and a pair of side walls 118, 120 that connect the first wall 114 and the second wall 116 to define a sleeve cavity 122 of the folded sleeve 112. Although the sleeve 112 is depicted in FIG. 2D as having a substantially rectangular cross-section, it may be understood that other cross-sectional geometries are possible, including circular, semi-circular, square, etc. In addition, while the first and second walls 114, 116 are depicted as having a larger surface area than the side walls 118, 120, it may be understood that other configurations are possible. The sleeve 112 may further comprise one or more pliable tabs, in this case, a first pliable tab 124A and a second pliable tab 124B (referred to herein collectively with reference numeral 124), that protrude or extend, for example, at least partially into the sleeve cavity 122.
[0025] The folded sleeve 112 comprises one or more notches 148A, 148B (collectively referred to herein with reference numeral 148), also referred to as stop folds. At least one of the one or more notches 148 is formed by at least one of a part of the first wall 114 and a part of the second wall 116 and at least one of a part of one side wall, e.g., side wall 118, and a part of the other side wall, e.g., side wall 120. For example, the one or more notches 148 may be formed by a part 118 of the side wall 118 and a part 114 of the first wall 114 and/or a part 120 of the side wall 120 and a part 114 of the first wall 114. In the example shown in FIG. 2D, the folded sleeve 112 comprises two or more notches 148A and 148B, wherein a first notch 148A is formed by the part 114 of the first wall 114 and the part 118 of the side wall 118 and a second notch 148B is formed by the part 114 of the first wall 114 and the part 120 of the side wall 120. At least one of the notches 148A, 148B may comprise a notch opening 151A, 151B. With continued reference to step V of FIG. 2D, at least a portion of one of the one or more notches 148 protrudes and/or extends at least partially into the sleeve cavity 122 of the folded sleeve 112. In one example, the part 114 of the first wall 114 and the part 118 of the side wall 118 are connected along a notch fold line 149A at an angle of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other. In one example, the part 114 of the first wall 114 and the part 120 of the side wall 120 are connected along a notch fold line 149B at an angle of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other.
[0026] In one example, the part 114 of the first wall 114 of notch 148A extends into the sleeve cavity 122 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance (not labeled in FIG. 2D; see D1 in FIG. 1B) from the second wall 116 to the first wall 114. In one example, the part 118 of the side wall 118 of notch 148A extends into the sleeve cavity 122 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance D2 from the side wall 118 to the side wall 120. In one example, the part 114 of the first wall 114 of notch 148B extends into the sleeve cavity 122 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance from the first wall 114 to the second wall 116. In one example, the part 120 of the side wall 120 of notch 148B extends into the sleeve cavity 122 greater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance D2 from the side wall 120 to the side wall 118.
[0027] With reference to FIGS. 1A-1D and step V of FIG. 2D, in one example, the first wall 14, 114, the second wall 16, 116, and pair of side walls 18, 20 and 118, 120 of the respective folded sleeve 12, 112 may define a first end opening 30A, 130A and a second end opening 30B, 130B opposite the first end opening 30A, 130A (referred to herein collectively with reference numeral 30 or 130), in which the first end opening 30A, 130A and/or the second end opening 30B, 130B may be configured for at least one of receiving into or dispensing from the sleeve cavity 22, 122 at least one of a plurality of consumer product containers, such as shaving razor cartridge containers (not shown; see FIG. 3). In one example, the first end opening 30A, 130A defined in the folded sleeve 12, 112 may be dimensioned to receive into and dispense from the sleeve cavity 22, 122 of the folded sleeve 12, 112 at least one consumer product container, e.g., a shaving razor cartridge container.
[0028] In one example, at least one of the first and second end openings 30A, 30B and 130A, 130B may comprise at least one of the one or more notches 48, 148. In another example, at least one of the first and second end openings 30A, 30B and 130A, 130B may comprise at least two notches 48, 148. In one example, one or more notches 48, 148 may be more proximate to one end opening, 30A, 30B and 130A, 130B, as compared to the other end opening 30A, 30B and 130A, 130B. In the example shown in FIGS. 1A-1D, the second end opening 30B of the sleeve 12 may comprise the first notch 48A formed by the part 16 of the second wall 16 and the part 18 of the side wall 18 and the second notch 48B formed by the part 16 of the second wall 16 and the part 20 of the side wall 20. In the example shown in step V of FIG. 2D, the second end opening 130B of the sleeve 112 may comprise the first notch 148A formed by the part 114 of the first wall 114 and the part 118 of the side wall 118 and the second notch 148B formed by the part 114 of the first wall 114 and the part 120 of the side wall 120.
[0029] To aid in the receiving and/or dispensing of the consumer product containers (not shown; see FIG. 3), the folded sleeve 12, 112 may further comprise one or more cutouts 32, 132. The one or more cutouts 32, 132 may be configured to permit access to at least one consumer product container during dispensing by a user. For example, the first and/or second wall 14, 16 and 114, 116 may comprise the cutout 32, 132 at one or more of the end openings 30, 130. The one or more cutouts 32, 132 when present, may form at least a part of at least one of the end openings 30, 130, for example, the first end opening 30A, 130A. In the example shown in FIGS. 1A-1D, the first wall 14 comprises two cutouts 32A, 32B at the first opening 30A. In the example shown in step V of FIG. 2D, the first wall 114 comprises a cutout, e.g., one cutout 132, at the first end opening 130A.
[0030] With reference to the example shown in FIG. 3, a consumer product dispensing system is illustrated, which comprises the folded sleeve 12 and a plurality of consumer product containers, e.g., shaving razor cartridge containers 28A-28F (referred to herein collectively with reference numeral 28), which may contain one or more consumer products, e.g., one or more shaving razor cartridges (not shown). The first end opening 30A and/or the second end opening 30B of the sleeve 12 may be configured to receive into and/or dispense from the sleeve cavity 22 the plurality of shaving razor cartridge containers 28. At least one of the notches 48 may be configured to engage one or more of the plurality of consumer product containers present within the sleeve cavity 22 of the folded sleeve 12. In one example, as described herein, at least one of the notches 48 may be configured to retain the shaving razor cartridge container 28 within the sleeve cavity 22 of the folded sleeve 12. The one or more cutouts 32, when present, may be configured to permit access to at least one of the one or more shaving razor cartridge containers 28 during dispensing by a user. In particular, the one or more cutouts 32 may facilitate grasping of a shaving razor cartridge container 28 containing a shaving razor cartridge by a user, for example, by grasping a shaving razor cartridge container wall (not labeled). By grasping the shaving razor cartridge container 28, the user avoids inadvertently contacting a blade (not visible) of the shaving razor cartridge. The shaving razor cartridge container 28 thus provides safety for the user when dispensing, as the shaving razor cartridge container 28 functions as an overcap by covering the blades of the shaving razor cartridge contained therein and preventing a user from contacting the blade.
[0031] With reference to the example shown in FIGS. 1A-1D, the folded sleeve 12 may further comprise one or more inner walls 42 that define two or more consumer product container compartments 44A, 44B within the sleeve cavity 22 of the folded sleeve 12 that are configured to receive, retain, and/or dispense one or more of the plurality of consumer product containers, e.g., shaving razor cartridge containers 28 (see FIG. 3), present within the consumer product container compartments 44A, 44B (also referred to herein as shaving razor cartridge container compartments 44A, 44B). At least one of the inner walls 42 may be attached to at least one of the first and second walls 14, 16 of the sleeve 12. At least one of the inner walls 42 may comprise an inner wall flap 46 that, when present, may assist in the attaching of the inner wall 42 to the first and/or second walls 14, 16 (see also FIG. 2G). For example, the inner wall flap 46 may facilitate easier forming of the sleeve 12 by providing a bonding or affixing portion that helps to hold the sleeve 12 together after the first, second, and pair of side walls 14, 16, 18, 20 have been folded to form the folded sleeve 12. The bonding and/or affixing portion may be adhesively attached to one or more of the first, second, and pair of side walls 14, 16, 18, 20, as described herein.
[0032] At least one of the inner walls 42 may extend at least partially between the first end opening 30A and the second end opening 30B of the sleeve cavity 22 of the sleeve 12, as shown in FIGS. 1A-1D and 3. At least one of the inner walls 42 may extend at least partially between the first wall 14 and the second wall 16 of the sleeve 12 to define the two or more shaving razor cartridge container compartments 44A, 44B. The two or more shaving razor cartridge container compartments 44A, 44B may be completely separated from one another by the one or more inner walls 42. Alternatively, in other examples (not shown), the two or more shaving razor cartridge container compartments 44A, 44B may be functionally separated from one another, even though at least one of the inner walls 42 is not fully attached to one or both of the first wall 14 and the second wall 16 (in other words, there may be a gap or space between an end of the inner wall 42 and the first wall 14 and/or the second wall 16, so long as the inner wall 42 physically keeps the consumer product containers, e.g., shaving razor cartridge containers 28, in the shaving razor cartridge container compartment 44A from moving into the shaving razor cartridge container compartment 44B and vice versa).
[0033] In the example shown in FIGS. 1A-1D and 3, the shaving razor cartridge container compartments 44A, 44B comprise substantially similar dimensions, such that the sleeve 12 is substantially symmetrical. In other examples (not shown), one of the shaving razor cartridge container compartments 44A, 44B may comprise a dimension that is different from the other of the shaving razor cartridge container compartments 44A, 44B, e.g., one of the shaving razor cartridge container compartments 44A, 44B may be wider than the other, to, for example, accommodate consumer product containers of differing sizes or types (not shown).
[0034] At least one of the shaving razor cartridge container compartments 44A, 44B may comprise the one or more notches 48A, 48B. In one example, the first shaving razor cartridge container compartment 44A comprises the first notch 48A. In one example, the shaving razor cartridge container compartment 44B comprises the second notch 48B. As shown in FIG. 3, the notches 48, when present, may be configured to prevent the consumer product containers, e.g., the shaving razor cartridge containers 28, from inadvertently moving, slipping, or falling out of the sleeve cavity 22 of the sleeve 12. The notches 48 may be configured to contact at least a part of the shaving razor cartridge containers 28 present within the sleeve cavity 22 of the sleeve 12. In the example shown in FIG. 3, the first notch 48A engages at least a part of an adjacent one of the shaving razor cartridge containers, i.e., shaving razor cartridge container 28A, present in the first shaving razor cartridge container compartment 44A, and the second notch 48B engages at least a part of an adjacent one of the shaving razor cartridge containers, i.e., shaving razor cartridge container 28D, present in the second shaving razor cartridge container compartment 44B. Although not shown, the notches 148A, 148B of the sleeve 112 shown in step V of FIG. 2D may similarly contact at least a part of one or more consumer product containers present within the sleeve cavity 122.
[0035] In one example, the sleeve 12 may comprise at least one of the first wall 14, second wall 16, and/or side walls 18, 20 that comprises two or more layers of material. For example, as shown in FIGS. 1A-1C, the first wall 14 comprises two or more layers of material 14A, 14B. The two or more layers of material 14A, 14B may comprise identical features, for example, one or more cutouts 32 and/or windows 36 as described herein, when the two or more layers of material 14A, 14B are commensurate in surface area and share a common interface between one or more surfaces of the two or more layers of material 14A, 14B (such as in a laminate configuration). Alternatively, the two or more layers of material 14A, 14B do not have to fully align and/or share the same features as each other, such as when the surface area of the layer of material 14B is less than the surface area of the layer of material 14A, as best seen in FIGS. 1A and 1C. In one example (not shown), the layer of material 14B may be a strip of material that only contacts a portion, i.e., less than all, of the layer of material 14A.
[0036] In the example shown in FIG. 2D, in addition to the first wall 114, the second wall 116, and the pair of side walls 118, 120, the sleeve 112 may further comprise an overlap flap 140 that facilitates easier forming of the sleeve 112 by providing a bonding or affixing portion that helps to hold the sleeve 112 together after the first, second, and pair of side walls 114, 116, 118, 120 have been folded to form the folded sleeve 112. The bonding and/or affixing portion may be adhesively attached to one or more of the first, second, and pair of side walls 114, 116, 118, 120, as described herein.
[0037] The folded sleeve 12, 112 of the present disclosure is configured to receive, retain, and/or dispense a plurality of consumer product containers, e.g., shaving razor cartridge containers 28, for example, from four to ten, for example, from six to eight, shaving razor cartridge containers 28 within the sleeve cavity 22, 122 of the folded sleeve 12, 112. In the case of the folded sleeve 12 shown in FIGS. 1A-1D and 3, each of the one or more shaving razor cartridge container compartments 44A, 44B may be configured to receive three consumer product containers, e.g., shaving razor cartridge containers 28A-28C and 28D-28F. Although not shown, the exemplary folded sleeve 112 illustrated in step V of FIG. 2G may be configured to receive, for example, four consumer product containers.
[0038] With reference to the folded sleeve 12 shown in FIGS. 1A-1D, at least one of the one or more pliable tabs 24 may be in a first position, e.g., see pliable tab portions 56A, 56B (referred to herein collectively with reference numeral 56) shown in FIGS. 2E and 2G, during formation of the sleeve 12 from a precursor sleeve blank 52, where the pliable tab 24, prior to bending and/or folding, is substantially coplanar with a respective wall, e.g., the first wall 14 and/or the second wall 16 (see first and second wall portions 68, 70 as shown in FIGS. 2E and 2G), which permits a consumer product container, e.g., a shaving razor cartridge container 28 (see FIG. 3), to slide by the pliable tab 24 without the pliable tab 24 engaging the consumer product container. In other words, when the pliable tab 24 is in the first position, the pliable tab 24 does not engage the consumer product container as the consumer product container slides past the pliable tab 24 within the sleeve cavity 22. At least one of the one or more pliable tabs 24 may be in a second position, where the pliable tab 24 protrudes into the sleeve cavity 22 of the sleeve 12. In one example, when the pliable tab 24 is in the second position, the pliable tab 24 forms a maximum angle with the respective wall, for example, the first wall 14 or the second wall 16, of from about 90 to about 170, for example, or from about 90 to about 105. For example, as shown in FIG. 1C with respect to the first pliable tab 24A, the first pliable tab 24A forms a maximum angle with the first wall 14 of from about 90 to about 170, for example, or from about 90 to about 105. The second pliable tab 24B may similarly form a maximum angle (not shown) with the first wall 14 of from about 90 to about 170, for example, or from about 90 to about 105.
[0039] In one example, with reference to FIG. 3, upon introducing one or more consumer product containers, e.g., shaving razor cartridge containers 28, into the sleeve cavity 22 of the folded sleeve 12 through at least one end opening 30, for example, the first end opening 30A and/or the second end opening 30B, of the folded sleeve 12, at least one of the one or more pliable tabs 24 may engage at least one of the shaving razor cartridge containers 28 if the pliable tab is in the second position when the shaving razor cartridge container 28 is present within the folded sleeve 12. In the example shown in FIG. 3, the first pliable tab 24A may engage at least part of one of the consumer product containers, i.e., shaving razor cartridge container 28C, if the first pliable tab 24A is in the second position when the shaving razor cartridge container 28C is present within the shaving razor cartridge container compartment 44A. In another example, the pliable tab 24B may engage at least part of one of the consumer product containers, e.g., shaving razor cartridge container 28F, if the second pliable tab 24B is in the second position when the shaving razor cartridge container 28F is present within the shaving razor cartridge container compartment 44B. In the example shown in FIG. 3, the first and second notches 48A, 48B and the first and second pliable tabs 24A, 24B engage one or more of the shaving razor cartridge containers 28 to inhibit the shaving razor cartridge containers 28 present within the sleeve cavity 22 of the folded sleeve 12 from unintentionally and/or inadvertently moving, slipping, dislodging, and/or falling out of the sleeve cavity 22 during shipping and/or when handled by a user.
[0040] Although not illustrated, it is understood that the pliable tabs 124 of the folded sleeve 112 shown in FIG. 2D may similarly comprise a first position (as illustrated with respect to corresponding pliable tab portions 156A, 156B), in which the one or more pliable tabs 124 do not engage the consumer product container, and a second position, in which the one or more pliable tabs 124 each form a maximum angle (not shown) with the first wall 114 or the second wall 116 of from about 90 to about 170, for example, or from about 90 to about 105. The pliable tabs 124 of the folded sleeve 112 may similarly engage at least one of the consumer product containers.
[0041] In one example, the folded sleeve 12, 112 may further comprise one or more windows formed in one or more of the first wall 14, 114 and the second wall 16, 116. With reference to FIGS. 1A-1D, the folded sleeve may comprise, for example, a first window 36A and a second window 36B (referred to herein collectively with reference numeral 36), both of which are formed in the first wall 14. In the example shown in FIG. 2D, the sleeve 112 comprises a first window 136A and a second window 136B (referred to herein collectively with reference numeral 136), in which the first window 136A is formed in the first wall 114 and the second window 136B is formed in the second wall 116. In other examples (not shown), the first wall 14, 114 may be devoid of windows, and the second wall 16, 116 may comprise two or more windows.
[0042] In one example, at least one of the one or more pliable tabs 24, 124 may be associated with one of the windows 36, 136, and the pliable tab 24, 124, when associated with the window 36, 136, may extend at least partially into the sleeve cavity 22, 122 of the sleeve 12, 112 from the window 36, 136, specifically from a perimeter of the window 36, 136, for example, at least one perimeter edge 38, 138 of the window 36, 136. In the example shown in FIGS. 1A-1D, the first wall 14 comprises the first window 36A having a perimeter edge 38A from which a pliable tab 24, e.g., the first pliable tab 24A, extends at least partially into the sleeve cavity 22 of the sleeve 12, and the first wall 14 comprises the second window 36B having a perimeter edge 38B from which a pliable tab 24, e.g., the second pliable tab 24B, extends at least partially into the sleeve cavity 22 of the sleeve 12. In the example shown in FIGS. 1A-1D, the second wall 16 is devoid of any windows. In the example shown in FIG. 2D, the first wall 114 comprises the first window 136A having a perimeter edge 138A from which a pliable tab 124, e.g., the first pliable tab 124A, extends at least partially into the sleeve cavity 122 of the sleeve 112, and the second wall 116 comprises a second window 136B having a perimeter edge 138B from which a pliable tab 124, e.g., the second pliable tab 124B, extends at least partially into the sleeve cavity 122 of the sleeve 112.
[0043] With reference to the exemplary folded sleeve 12 shown in FIGS. 1A-1D in which the first and second windows 36A, 36B are formed in the first wall 14, the perimeter of the first window 36A may be substantially the same as the perimeter of the second window 36B, i.e., dimensions of the first and second windows 36A, 36B may be substantially the same. In other examples (not shown), the first wall 14 may comprise the first and second windows 36A, 36B, and one of the first window 36A or the second window 36B may have a greater perimeter than the other of the first window 36A or the second window 36B, i.e., the first window 36A comprises at least one dimension that is less than or greater than at least one corresponding dimension of the second window 36B. With reference to the exemplary folded sleeve 112 shown in FIG. 2D, the first window 136A may have a different perimeter than the second window 136B. In the illustrated example, the first window 136A is present in the first wall 114, and the second window 136B is present in the second wall 116, in which the first window 136A has a greater perimeter than the second window 136B, i.e., the first window 136A comprises at least one dimension that is greater than at least one corresponding dimension of the second window 136B. In other examples (not shown), the first and second windows 136A, 136B may comprise substantially similar perimeters.
[0044] When the folded sleeve 12, 112 comprises one or more windows 36, 136, at least a portion of the sleeve cavity 22, 122 of the folded sleeve 12, 112 may be visible through at least one of the one or more windows 36, 136. At least a portion of the sleeve cavity 22, 122 of the folded sleeve 12, 112 may also be accessible through at least one of the one or more windows 36, 136 by a user. As shown in FIG. 3, when one or more consumer product containers, e.g., one or more shaving razor cartridge containers 28 are present within the sleeve cavity 22 of the sleeve 12, at least a portion of at least one of the one or more consumer product containers may be visible through at least one window 36.
[0045] The folded sleeve 12, 112 of FIGS. 1A-1D and 2D may comprise a recyclable material or a biodegradable material or a compostable material or a natural material, such as pulp, for example, wood pulp, or paper or paperboard. The sleeve 12, 112 may comprise a folded sleeve that comprises one or more fold lines, as described herein. In some examples, the folded sleeve 12, 112 may comprise a contiguous material and may be, for example, formed from a single piece or sheet of material, such as paperboard. In some particular examples, the sleeve 12, 112 may be formed from a single sleeve blank (see FIG. 2A). The consumer product containers, e.g., the shaving razor cartridge containers 28A-28F, may also comprise a recyclable material or a biodegradable material or a compostable material or a natural material, such as pulp, for example, wood pulp, or paper or paperboard. In some examples, the sleeve 12, 112 and the consumer product containers may comprise the same material(s).
Method for Forming a Sleeve Blank
[0046] Referring to FIGS. 2A-2C and 2E, perspective views and a flow chart of possible methods for forming a sleeve blank 50, 150, as shown in FIGS. 2B and 2E, from a precursor sleeve blank 52, as shown in FIG. 2A, suitable for assembling into a folded sleeve 12, 112 of the present disclosure is illustrated.
[0047] As shown in FIG. 2A, a precursor sleeve blank 52 comprises a sleeve blank material 54. As shown in FIGS. 2B and 2E, the sleeve blank material 54 may be cut, for example, to form any windows 36, 136 as described herein; any pliable tab portions 56, 156 (see FIGS. 2B and 2E) associated with the window(s) 36, 136 to permit the pliable tab portions 56, 156 to be folded away from their respective windows 36, 136 to ultimately form the pliable tabs 24, 124 in the resulting sleeve 12, 112 as described herein; any cutouts 32, 132 as described herein; any overlap flap portions 78, 178 that may form one or more inner wall flaps 46 or overlap flaps 140 as described herein; any notch portions 58, 158 that can be folded to create notches 48, 148 in the resulting sleeve 12, 112 as described herein; and/or any inner wall portions 60 that can be folded to create inner walls 42 in the resulting sleeve 12 as described herein.
[0048] Referring to FIGS. 2A-2C, one possible method 1000 for forming an example of a sleeve blank 150 suitable, for example, for use as a folded sleeve 112 (see FIG. 2D) includes step 1001 of providing a precursor sleeve blank 52. In step 1002, the precursor sleeve blank 52 may optionally be cut, if necessary, to a size suitable for the folded sleeve 112. Once the precursor sleeve blank 52 is of a size suitable for the folded sleeve 112, one or more notch portions 158 may be formed in step 1003 by cutting one or more notch cut lines 180 in the precursor sleeve blank 52. The notch portions 158, when folded, form the notches 148 in the folded sleeve 112, as described herein. Step 1004 may include optionally forming, e.g., cutting, one or more windows 136, in this case, windows 136A and 136B. Step 1005 may include optionally cutting, for example, along a perimeter edge 138 of the one or more windows 136 to form any pliable tab portions 156, for example, a first pliable tab portion 156A and a second pliable tab portion 156B, such that each of the one or more pliable tab portions 156 is associated with one of the one or more windows 136. Step 1006 may include optionally forming, e.g., cutting, any cutouts 132 in the precursor sleeve blank 52. The method 1000 may further comprise optionally cutting any overlap flap portions 178 in step 1007. In step 1008, an adhesive 162 may be applied to the sleeve blank 150 and/or the precursor sleeve blank 52, for example, the adhesive 162 may be applied in the form of a landing strip 164 suitable for receiving a portion of the sleeve blank 150 to assist in forming and holding the folded sleeve 112 together.
[0049] Referring to FIGS. 2A, 2E, and 2F, one possible method 2000 for forming another example of a sleeve blank 50 suitable, for example, for use as a folded sleeve 12 (see FIGS. 1A-1D) includes step 2001 of providing a precursor sleeve blank 52. In step 2002, the precursor sleeve blank 52 may optionally be cut, if necessary, to a size suitable for the sleeve 12. Once the precursor sleeve blank 52 is of a size suitable for the folded sleeve 12, one or more notch portions 58 may be formed in step 2003 by cutting one or more notch cut lines 80 in the precursor sleeve blank 52. The notch portions 58, when folded, form the notches 48 in the folded sleeve 12, as described herein. Step 2004 may include optionally forming, e.g., cutting, one or more windows 36, in this case, windows 36A-36C. Step 2005 may include optionally cutting, for example, along a perimeter edge 38 of the one or more windows 36 to form any pliable tab portions 56, for example, a first pliable tab portion 56A and a second pliable tab portion 56B, such that each of the one or more pliable tab portions 56 is associated with one of the one or more windows 36. Step 2006 may include optionally forming, e.g., cutting, any cutouts 32 in the precursor sleeve blank 52. The method 2000 may further comprise optionally forming, i.e., cutting, any overlap flap portions 78 in step 2007, and optionally forming, i.e., cutting any inner wall portions 60 in step 2008. In step 2009, an adhesive 62 may be applied to the sleeve blank 50 and/or the precursor sleeve blank 52, for example, the adhesive 62 may be applied in the form of a landing strip 64 suitable for receiving a portion of the sleeve blank 50 to assist in forming and holding the folded sleeve 12 together.
[0050] The sleeve blank material 54 may comprise a recyclable material or a biodegradable material or a compostable material or a natural material such as pulp, for example, wood pulp, or paper or paperboard. In one example, as shown in FIG. 2A, the precursor sleeve blank 52 and the sleeve blank material 54 may comprise a contiguous material, for example, a single piece of material, that can be cut and/or imparted with fold lines to achieve a sleeve blank 50 suitable for folding into a sleeve 12, 112 of the present disclosure.
Method for Assembling a Folded Sleeve
[0051] Referring to FIG. 4, one method 3000 for forming or assembling a folded sleeve, e.g., the folded sleeve 12, 112 (see FIGS. 1A-1D, 2D, and 2G), is illustrated, in which the folded sleeve 12, 112 may be for containing a plurality of consumer product containers, e.g., shaving razor cartridge containers 28 (see FIG. 3). In step 3001, a precursor sleeve blank 52 is provided, which may include the precursor sleeve blank 52 shown in FIG. 2A. In step 3002, a plurality of fold lines may be created in the precursor sleeve blank 52, in which the fold lines may comprise crease lines, perforations, and the like and may assist with making a predetermined fold. The plurality of fold lines define a first wall portion, a second wall portion, and a pair of side wall portions, in which at least one of the side wall portions is connected to both the first wall portion and the second wall portion, as described herein. One or more notch portions are formed in step 3003 by (i) cutting at least one notch cut line in the precursor sleeve blank that extends from a part of at least one of the first wall and the second wall to a part of at least one of the pair of side walls, and (ii) creating a notch fold line between the part of at least one of the first wall and the second wall and the part of at least one of the pair of side walls to form a sleeve blank, e.g., the sleeve blank 50, 150 (see FIGS. 2B and 2E), as described herein. In step 3004, the sleeve blank is folded along a plurality of the fold lines to form a folded sleeve 12, 112 as described herein, in which the folded sleeve 12, 112 includes a sleeve cavity defined by a first wall corresponding to the first wall portion, a second wall corresponding to the second wall portion, and a pair of side walls corresponding to the pair of side wall portions, as described herein. In step 3005, at least one notch is formed by folding at least one of the notch portions along a corresponding notch fold line to form the at least one notch, in which the at least one notch protrudes into the sleeve cavity of the folded sleeve, as described herein. In step 3006, a plurality of consumer product containers, e.g., a plurality of shaving razor cartridge containers 28A-28F (see FIG. 3) into the sleeve cavity of the folded sleeve 12, 112, in which the at least one notch engages at least one of the plurality of consumer product containers, e.g., at least one of the shaving razor cartridge containers 28A-28F, as described herein.
[0052] Referring to FIG. 2D, perspective views of one possible method for folding a sleeve blank 150 to form a folded sleeve 112 suitable for use in a consumer product dispensing system, for example, a shaving razor cartridge dispensing system (see FIG. 3), is illustrated.
[0053] In this example, the method for folding a sleeve blank 150 into a folded sleeve 112 comprises providing a sleeve blank 150 in step I of FIG. 2D. The sleeve blank 150 may be formed, as described herein. The sleeve blank 150 comprises a plurality of fold lines 166a-h (referred to herein collectively with reference numeral 166). As described herein, the fold lines 166 may include crease lines, perforations, and the like and may assist with making a predetermined fold. The fold lines 166 may define at least a first wall portion 168 (between fold lines 166b and 166e), a second wall portion 170 (between fold line 166g and one outer edge (not labeled) of the sleeve blank 150), and a pair of side wall portions 172, 174 (between fold lines 166a and 166b and fold lines 166e and 166g, respectively). One of the pair of side wall portions 172, 174, for example, side wall portion 174, may be positioned between the first wall portion 168 and the second wall portion 170.
[0054] The sleeve blank 150 comprises one or more notch portions 158 (stop fold portions), e.g., a first notch portion 158A and a second notch portion 158B (referred to herein collectively with reference numeral 158) formed by cutting a respective notch cut line 180a, 180b, for example, by cutting the sleeve blank 150 between one or more of the side wall portions 172, 174 and adjacent portions of one or more of the first wall portion 168 and/or the second wall portion 170. As shown in FIG. 2D, one notch portion 158, i.e., the first notch portion 158A, is formed by creating a first notch cut line 180a between a part of the side wall portion 172 and a part of the first wall portion 168, and another notch portion 158, i.e., the second notch portion 158B, is formed by creating a second notch cut line 180b between a part of the side wall portion 174 and a part of the first wall portion 168. The notch portions 158A, 158B each further comprise two additional sets of fold lines 166c and 166f, respectively.
[0055] In one example, if at least one window 136 is not present in the sleeve blank 150, then one or more windows 136 may be formed, i.e., cut, into the sleeve blank 150, and if at least one pliable tab portion 156 is not present in the sleeve blank 150, then one or more pliable tab portions 156 may be formed in the sleeve blank 150, as described above. At least one fold line 166 may be associated with at least one of the windows 136 to define one or more pliable tab portions 156, such that each of the one or more pliable tab portions 156 is associated with one of the one or more windows 136. As shown in FIGS. 2B and 2D, a first window 136A is formed in the first wall portion 168, and a first pliable tab portion 156A is associated with the first window 136A, with fold line 166d defining the first pliable tab portion 156A. In one example, in addition to a first pliable tab portion 156A, the sleeve blank 150 may further comprise another fold line 166h associated with a second window 136B to define a second pliable tab portion 156B. As shown in FIGS. 2B and 2D, the second window 136B is formed in the second wall portion 170, and the second pliable tab portion 156B is associated with the second window 136B. The first pliable tab portion 156A and/or second pliable tab portion 156B may be associated with their respective windows 136A, 136B along at least one perimeter edge 138A, 138B of the windows 136A, 136B, along which the pliable tab portions 156A, 156B may be folded along their respective fold lines 166d, 166h. To aid in folding of the pliable tab portions 156A, 156B, sides 176 of the pliable tab portions 156A, 156B may be cut from adjacent portions of the respective first and second wall portions 168, 170 during formation of the pliable tab portions 156A, 156B.
[0056] In one example, the sleeve blank 150 further comprises an overlap flap portion 178. The overlap flap portion 178 may further comprise an adhesive 162 on one or more surfaces of the overlap flap portion 178. The overlap flap portion 178 may be connected to one of the first wall, second wall, or pair of side wall portions 168, 170, 172, 174, along at least one fold line 166. In the example shown in FIG. 2D, the overlap flap portion 178 is connected to the side wall portion 172 along fold line 166a. An edge of the overlap flap portion 178 may define the other outer edge (not labeled) of the sleeve blank 150.
[0057] As shown in step II of FIG. 2D, the overlap flap portion 178 is folded over toward the side wall portion 172 along the fold line 166a between the overlap flap portion 178 and the side wall portion 172. The exposed surface of the overlap flap portion 178 may comprise the adhesive 162, e.g., in the form of a landing strip 164 as described herein. It is understood that the sleeve blank 150 may vary with respect to the relative locations of the first wall, second wall, and side wall portions 168, 170, 172, 174, overlap flap portion 178, fold lines 166, notch portions 158 and associated notch cut lines 180, pliable tab portions 156, and/or windows 136.
[0058] Steps III and IV of FIG. 2D include folding the sleeve blank 150 along the fold line 166b between the first wall portion 168 and the side wall portion 172 and along the fold lines 166e, 166g between the side wall portion 174 and the first and second wall portions 168, 170, such that the landing strip 164 of adhesive 162 contacts an inner surface (not labeled) of the second wall portion 170 and attaches, for example, by bonding such as with the adhesive 162, the overlap flap portion 178 to at least the second wall portion 170. In step IV of FIG. 2D, the overlap flap portion 178 corresponds to the overlap flap 140, and folding of the sleeve blank 150 along the plurality of fold lines 166 and the attachment of the overlap flap portion 178 to the second wall portion 170 forms the folded sleeve 112 having a sleeve cavity 122 defined by the first wall 114 corresponding to the first wall portion 168, the second wall 116 corresponding to the second wall portion 170, and the pair of side walls 118, 120, corresponding to the pair of side wall portions 172, 174. At least one end opening 130, for example, end openings 130A and 130B, is formed in the sleeve 112, as shown in step IV of FIG. 2D. The sleeve blank 150 may comprise a cutout 132 in at least one of the first and second wall portions 168, 170 and/or resulting first and second walls 114, 116 that is located at at least one end opening 130, for example, end opening 130A. The cutout 132 may exhibit a radius (R; see FIG. 2B) of from about 5 mm to about 40 mm and/or from about 10 mm to about 30 mm and/or from about 10 mm to about 20 mm.
[0059] With continued reference to step IV of FIG. 2D, the notch portions 158 may be formed into notches 148, for example, a first notch 148A and a second notch 148B. The first notch 148A may be formed by folding a part 114 of the first wall 114 and a part 118 of the side wall 118 inward along fold lines 166c, e.g., into the sleeve cavity 122 and toward the second wall 116 and the side wall 120. The second notch 148B may similarly be formed by folding a part 114 of the first wall 114 and a part 120 of the side wall 120 inward along fold lines 166f, e.g., into the sleeve cavity 122 and toward the second wall 116 and the side wall 118.
[0060] In one example, the part 114 of the first wall 114 and the part 118 of the side wall 118 that define the first notch 148A are connected along a notch fold line 149A and define an angle (not labeled) of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other. In one example, the part 114 of the first wall 114 and the part 120 of the side wall 120 that define the second notch 48B are connected along a notch fold line 149B and define an angle (not labeled) of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other. In the example shown in step IV of FIG. 2D, the angle may be about 90.
[0061] In step V of FIG. 2D, the pliable tab portion 156A is folded along the associated fold line 166d to form a pliable tab 124A that protrudes at least partially into the sleeve cavity 122 of the sleeve 112. Further, the pliable tab portion 156B is folded along the associated fold line 166h to form a pliable tab 124B that protrudes at least partially into the sleeve cavity 122 of the sleeve 112. Although the folding of the pliable tab portions 156A, 156B is depicted as occurring in step V of FIG. 2D, it may be understood that the pliable tab portions 156A, 156B may also be folded in step III prior to formation of the first and second notches 148A, 148B.
[0062] Prior to formation of the first and second notches 148A, 148B (prior to or after folding of the pliable tab portions 156A, 156B to form the pliable tabs 124A, 124B), a plurality of consumer product containers, for example, shaving razor cartridge containers 28A-28F (see FIG. 3) containing one or more consumer products, for example, shaving razor cartridges (not shown), may be inserted into the sleeve cavity 122 of the sleeve 112. At least one of the one or more pliable tabs 124A, 124B engages at least one of the plurality of consumer product containers, for example, the shaving razor cartridge containers 28, as described herein. The first and second notches 148A, 148B may then be formed to further secure the consumer product containers within the sleeve cavity 122.
[0063] Even though FIGS. 2B and 2D illustrate a method for forming one example of a folded sleeve 112, for example, a folded sleeve 112 suitable for use with a four-count consumer product dispensing system, the disclosure is not limited to such a folded sleeve 112.
[0064] Referring to FIG. 2G, perspective views of one possible method for folding a sleeve blank 50 to form a folded sleeve 12 suitable for use in a consumer product dispensing system, for example, a shaving razor cartridge dispensing system (see FIG. 3), is illustrated.
[0065] In this example, the method for folding a sleeve blank 50 into a sleeve 12 comprises providing a sleeve blank 50 in step I of FIG. 2G. The sleeve blank 50 may be formed, as described with respect to FIGS. 2A, 2E, and 2F. The sleeve blank 50 comprises a plurality of fold lines 66a-66j (referred to herein collectively with reference numeral 66). The fold lines 66 may comprise crease lines, perforations, and the like and may assist with making a predetermined fold. The fold lines 66 may define at least two first wall portions 68, for example, a first first wall portion 68A (between fold line 66h and one outer edge (not labeled) of the sleeve blank 50) and a second first wall portion 68B (between fold lines 66b and 66c); a second wall portion 70 (between fold lines 66c and 66f); and a pair of side wall portions 72, 74 (between fold lines 66c and 66e and fold lines 66f and 66h, respectively). One of the pair of side wall portions 72, 74, for example, the side wall portion 74, is positioned between the first first wall portion 68A and the second wall portion 70, and the other of the side wall portions, for example the side wall portion 72, is positioned between the second first wall portion 68B and the second wall portion 70.
[0066] The sleeve blank 50 further comprises one or more notch portions 58 (stop fold portions), e.g., a first notch portion 58A and a second notch portion 58B (referred to herein collectively with reference numeral 58), formed by making a cut along a respective notch cut line 80a, 80b, for example, by cutting the sleeve blank 50 between one or more side wall portions 72, 74, and the second wall portion 70. As shown in FIG. 2G, the first notch portion 58A is formed by creating a first notch cut line 80a between a part of the side wall portion 72 and a part of the second wall portion 70, and the second notch portion 58B is formed by creating a second notch cut line 80b between a part of the side wall portion 74 and a part of the second wall portion 70. The notch portions 58A, 58B each further comprise two additional sets of fold lines 66d and 66g, respectively.
[0067] In one example, if at least one window 36 is not present in the sleeve blank 50, then one or more windows 36 may be formed, i.e., cut, into the sleeve blank 50, and if at least one pliable tab portion 56 is not present in the sleeve blank 50, then one or more pliable tab portions 56 may be formed in the sleeve blank 50, as described above. At least one fold line 66 may be associated with at least one of the windows 36 to define one or more pliable tab portions 56, such that each of the one or more pliable tab portions 56 is associated with one of the one or more windows 36. In the example shown in FIGS. 2E and 2G, first and second windows 36A, 36B may be formed in the first wall portion 68A, and first and second pliable tab portions 56A, 56B may be associated with the first window 36A and the second window 36B, respectively, with fold line 66j defining the first pliable tab portion 56A and fold line 66i defining the second pliable tab portion 56B (labeled in step II). In this example, the sleeve blank 50 comprises a third window 36C that is devoid of a pliable tab portion and is formed in the second first wall portion 68B. The second wall portion 70 is devoid of any windows or pliable tab portions. Each of the pliable tab portions 56A, 56B may be associated with their respective windows 36A, 36B along at least one perimeter edge 38A, 38B of the windows 36A, 36B, along which the pliable tab portions 56A, 56B may be folded along their respective fold lines 66i and 66j. To aid in folding the pliable tab portions 56A, 56B, sides 76 of the pliable tab portions 56A, 56B may be cut from adjacent portions of the first wall portion 68A during formation of the pliable tab portions 56A, 56B.
[0068] In one example, the sleeve blank 50 may further comprise an overlap flap portion 78. The overlap flap portion 78 may further comprise an adhesive 62a on one or more surfaces of the overlap flap portion 78. In the example shown in FIG. 2G, the overlap flap portion 78 is connected to an inner wall portion 60 along a fold line 66a (not labeled in FIG. 2G; see FIG. 2E). An edge of the overlap flap portion 78 may define the other outer edge (not labeled) of the sleeve blank 50.
[0069] As shown in step I of FIG. 2G, the overlap flap portion 78 may be folded over toward the inner wall portion 60 along the fold line 66a (see FIG. 2E) between the overlap flap portion 78 and the inner wall portion 60. The exposed surface of the overlap flap portion 78 may comprise the adhesive 62a, for example, in the form of a landing strip 64a as described herein. It is understood that the sleeve blank 50 may vary with respect to locations of the first first wall, second first wall, second wall, and side wall portions 68A, 68B, 70, 72, 74, overlap flap portion 78, fold lines 66a-66j, notch portions 58, and associated notch cut lines 80, pliable tab portions 56, and windows 36.
[0070] In step II of FIG. 2G, the inner wall portion 60, the second first wall portion 68B, and the side wall portion 72 may be folded over onto the second wall portion 70 along the fold line 66b between the inner wall portion 60 and the second first wall portion 68B and along the fold lines 66c and 66e between the side wall portion 72 and the second first wall and second wall portions 68B, 70, resulting in one portion of the second wall portion 70 being covered by the second first wall portion 68B. The landing strip 64a of adhesive 62a contacts an inner surface (not labeled) of the second wall portion 70 and attaches, for example, by bonding such as with the adhesive 62a, the overlap flap portion 78 to an adjacent portion of the second wall portion 70. A portion of the second wall portion 70 is visible through the window 36C, and a cutout 32C is present in the second first wall portion 68B. In addition, adhesive 62b, e.g., in the form of one or more landing strips 64b, may be present on or may be applied to an outer surface (not labeled) of the second first wall portion 68B in step II.
[0071] Step III of FIG. 2G includes folding the sleeve blank 50 along the fold lines 66f and 66h between the side wall portion 74 and the first first wall portion 68A and second wall portion 70, such that a remaining, uncovered portion of the second wall portion 70 is covered with the first first wall portion 68A and the first window 36A in the first first wall portion 68A may overlap and may be aligned, for example, registered with, the window 36C present in the second first wall portion 68B. The one or more landing strips 64b of adhesive 62b on the outer surface of the second first wall portion 68B contact an inner surface (not labeled) of the first first wall portion 68A and attach, for example, by bonding, via the landing strip 64b of adhesive 62b, the first first wall portion 68A to the second first wall portion 68B. Attachment of the overlap flap portion 78 (which corresponds to the inner wall flap 46; see also FIGS. 1A-1C) to the second wall portion 70 and attachment of the first first wall portion 68A to the second first wall portion 68B forms the folded sleeve 12 having a sleeve cavity 22 defined by the first wall 14 corresponding to the first wall portions 68A, 68B, the second wall 16 corresponding to the second wall portion 70, and the pair of side walls 18, 20, corresponding to the pair of side wall portions 72, 74, respectively (see also FIGS. 1A-1D).
[0072] At least one end opening 30, for example, end openings 30A and 30B, is formed in the sleeve 12, as shown in step IV of FIG. 2G. Further, at least one end opening 30, for example, end opening 30A may comprise a cutout 32, in this case a plurality of cutouts 32A-32C. The sleeve blank 50 may comprise two cutouts 32A, 32B formed in the first first wall portion 68A and another single cutout 32C formed in the second first wall portion 68B, in which the cutout 32C may overlap and/or align, for example, register, with one of the two cutouts 32A, 32B in the first first wall portion 68A. In the example shown in FIG. 2G, the cutout 32A registers with the cutout 32C. One or more of the cutouts 32 may each independently exhibit a radius (R; see FIG. 2E) of from about 5 mm to about 40 mm and/or from about 10 mm to about 30 mm and/or from about 10 mm to about 20 mm. The inner wall 42 may be formed by the inner wall portion 60, which may be bonded via the overlap flap portion 78 to the second wall portion 70 as described in step III above. The sleeve blank 50 may also comprise one or more inner wall portions 60, which form one or more corresponding inner walls 42 upon folding of the sleeve blank 150 to form the sleeve 12 and result in formation of two or more shaving razor cartridge container compartments 44. In the example shown, the sleeve 12 comprises first and second shaving razor cartridge container compartments 44A, 44B, with registered cutouts 32A and 32C being associated with first shaving razor cartridge container compartment 44A and cutout 32B being associated with second shaving razor cartridge container compartment 44B.
[0073] As shown in step IV of FIG. 2G, the notch portions 58 may be formed into notches 48, for example, a first notch 48A and a second notch 48B. The first notch 48A may be formed by folding a part 16 of the second wall 16 and a part 18 of the side wall 18 inward along fold lines 66d, e.g., into the sleeve cavity 22 and toward the second wall 16 and the side wall 20. The second notch 48B may similarly be formed by folding a part 16 of the second wall 16 and a part 20 of the side wall 20 inward along fold lines 66g, e.g., into the sleeve cavity 22 and toward the first wall 14 and the side wall 18. In one example, the part 16 of the second wall 16 and the part 18 of the side wall 18 that define the first notch 48A are connected along a notch fold line 49A and define the angle (see FIGS. 1A and 1B) of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other. In one example, the part 16 of the second wall 16 and the part 20 of the side wall 20 that define the second notch 48B are connected along a notch fold line 49B and define the angle (see FIG. 1B) of from about 60 to about 120 and/or from about 75 to about 110 and/or from about 85 to about 100 with respect to each other.
[0074] In step V of FIG. 2G, the pliable tab portions 56A, 56B may be folded along their associated fold lines 66i and 66j to form pliable tabs 24A, 24B, respectively, that protrude at least partially into the sleeve cavity 22 of the sleeve 12 as described herein. Although the folding of the pliable tab portions 56A, 56B is depicted as occurring in step V of FIG. 2G, it may be understood that the pliable tab portions 56A, 56B may also be folded in step III prior to formation of the first and second notches 48A, 48B.
[0075] Prior to formation of the first and second notches 48A, 48B (prior to or after folding of the pliable tab portions 56A, 56B to form the pliable tabs 24A, 24B), a plurality of consumer product containers, for example, shaving razor cartridge containers 28A-28F (see FIG. 3) containing one or more consumer products, for example, shaving razor cartridges (not shown), may be inserted into the sleeve cavity 22 of the sleeve 12. For example, two or more shaving razor cartridge containers 28 may be added to each of the two or more shaving razor cartridge container compartments 44A, 44B. At least one of the one or more pliable tabs 24A, 24B engages at least one of the plurality of consumer product containers, for example, the shaving razor cartridge containers 28, as described herein. The first and second notches 48A, 48B may then be formed to further secure the consumer product containers within the sleeve cavity 22.
[0076] Even though FIGS. 2D and 2G illustrate a method for forming one example of a sleeve 12, for example, a sleeve 12 suitable for use with a six-count consumer product dispensing system similar to the system as shown in FIG. 3, the disclosure is not limited to such a sleeve 12.
[0077] The sleeve blank 50, 150 as shown in FIGS. 2B, 2D, 2E, and 2G may comprise a recyclable material or a biodegradable material or a compostable material or a natural material such as pulp, for example, wood pulp, or paper or paperboard. The sleeve blank 50, 150 may comprise a contiguous material, for example, a single piece or sheet of material, such as paperboard. In some examples, the sleeve 12, 112 in accordance with the present disclosure, may be reusable.
[0078] Even though the above description has been directed primarily to a folded sleeve 12, 112 for use with a shaving razor cartridge dispensing system, the folded sleeve 12, 112 may be used with other consumer product dispensing systems comprising a plurality of consumer products other than, or in addition to, shaving razor cartridges. For example, the folded sleeve 12, 112 may be used with a consumer product dispensing system, for example, for manual and/or electric toothbrush heads contained within a consumer product container; for soluble fibrous structure consumer products, such as a laundry detergent, a dishwashing detergent, a body wash, a shampoo, a conditioner, a hand wash, a toilet cleaner, a hard surface cleaner, a shaving cream, a mouthwash, or a medicine contained within a soluble fibrous structure consumer product container; and/or for pods or pouches, such as a laundry detergent, a dishwashing detergent, a body wash, a shampoo, a conditioner, a hand wash, a toilet cleaner, a hard surface cleaner, a shaving cream, a mouthwash, or a medicine contained within a consumer product container.
[0079] As described herein, the sleeve 12, 112 may be formed from a single sheet of material, for example, paperboard, using folds and/or cuts, and may be folded flat for storage and shipping. In particular, the one or more pliable tabs 24, 124 are foldable and can be folded out of the way, i.e., in the first position. With reference to FIGS. 2D and 2G, in some examples, the sleeve 12, 112 may be shipped as the sleeve blank 50, 150 shown in step I. In other examples, the sleeve 12, 112 may be shipped in a partially folded form, as shown in step III in FIGS. 2D and 2G. Upon receipt at an end destination, the sleeve 12, 112 may be unfolded and if needed, further assembled as described herein, after which the sleeve 12, 112 may be loaded with consumer product containers, as described herein. Shipping in this manner may allow for improved packing efficiency and may decrease the chances of damage to the sleeve 12, 112, e.g., crushing and/or deformation.
[0080] The notches 48, 148 and the pliable tabs 24, 124 help to retain the consumer product containers within the sleeve cavity 22, 122 of the sleeve 12, 112 and also create a positive stop when loading the consumer product containers into the sleeve 12, 112. The one or more cutouts 32, 132 facilitate access to the consumer product containers, and when the consumer product comprises shaving razor cartridges, the shaving razor cartridge containers 28 may help to protect the user from inadvertently contacting the blade of the shaving razor cartridge during dispensing.
[0081] Because the sleeve 12, 112 is formed from a single sheet of material, there is no need to assemble, e.g., glue or otherwise attach, additional components to the sleeve 12, 112 to create the desired features, such as the pliable tabs 24 and 124, the separate shaving razor cartridge container compartments 44A, 44B, etc. In addition, unlike plastic injection molded dispensing systems, use of a foldable paperboard material eliminates the need to design and/or purchase additional equipment, such as a mold. Paperboard may be more easily recyclable by the consumer, such that once the consumer products have been used, consumers may be more likely to recycle, rather than discard, the sleeve 12, 112 and/or the consumer product containers.
[0082] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. Dimensions should not be held to an impossibly high standard of metaphysical identity that does not allow for discrepancies due to typical manufacturing and measuring tolerances. Therefore, the term about should be interpreted as being within typical manufacturing and measuring tolerances (for example, 2%).
[0083] Every document cited herein, including any cross referenced or related patent or application is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such disclosure. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0084] While particular examples of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the disclosure. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure.
