NESTED PAIR OF BLANKS

Abstract

The invention relates to a nested pair of blanks on a unitary sheet which minimizes the amount of scrap sheet material (i.e., sheet scrap) upon separation of the blanks and construction of containers formed from the blanks. The nested pair of blanks provides a first blank for forming a container, a second blank for forming an identical container, and a non-linear separation interface that connects the first and second blanks to one another in a rotationally inverted relationship. The nested configuration reduces the amount of sheet scrap in the sheet. The invention further relates to a container formed from the first or second blank having features that reduce sheet scrap and offset the potential weakening of the container bottom resulting from reduced overlapping sheet material.

Description

BACKGROUND OF THE INVENTION

This invention relates to a nested blank arrangement on a unitary sheet with features which minimize scrap sheet material (i.e., sheet scrap) while strengthening the bottom of a container formed from one of the blanks. More specifically, the invention is a nested pair of blanks on a unitary sheet which minimizes the amount of sheet scrap upon separation of the blanks and construction of containers formed from the blanks. The nested pair of blanks further minimizes the amount of sheet material required to form container bottoms. Stated differently, the increased nesting between the panels and flaps of the blanks on the sheet reduces the amount of overlapping sheet material on the bottom flaps forming the container bottom. The invention further relates to a container formed from one of the blanks and having an automatic bottom, wherein notched edges of the bottom panels correspondingly engage one another to form a container bottom and offset the potential weakening of the container bottom resulting from reduced overlapping sheet material.

The positioning of blanks on a sheet such that portions of the blanks are connected to one another is referred to as nesting or a nested arrangement. Known nested arrangements of blanks are formed by a die-cutting machine that cuts and scores a web of board (e.g., paperboard) into one or more sheets defining one or more blanks. In practice, the die-cutting machine cuts and scores a single sheet of board into one or more adjacent blanks. The unused board material of the sheet located between the adjacent blanks is scrap material which may be discarded or recycled. In an effort to reduce the cost of producing containers from the blanks, manufacturers attempt to minimize the amount of board in the blanks.

As known in the industry, the cost of the board material contributes significantly to the total cost of producing containers. Furthermore, when die-cutting the sheet of board into multiple adjacent blanks, it is desirable to form the blanks as close to one another as possible. The positioning of the blanks close to one another reduces the amount of sheet scrap and increases the number of blanks simultaneously formed from the board by the die-cutting machine. Specifically, the die-cutting machine may accommodate more blanks at the same time if the blanks occupy a smaller area.

Known nested arrangements of blanks often fail to sufficiently reduce the amount of sheet scrap, thereby increasing the cost of manufacturing blanks. Some nesting arrangements incorporate linear interfaces that connect, for example, a first and second blank. These types of arrangements fail to achieve the reduction in sheet scrap attained by the present invention as described herein.

Further, known nested arrangements attempting to minimize sheet scrap result in containers having weakened bottoms due to the decrease in the amount of overlap of the bottom panels secured to each other. The present invention provides a pair of nested blanks on a unitary sheet having a nested arrangement, a non-linear separation interface, and engagement notches which address these problems.

SUMMARY OF THE INVENTION

The invention is a nested pair of blanks on a unitary sheet having a first blank for forming a container, a second blank for forming an identical container, and a non-linear separation interface that connects the first and second blanks to one another in a rotationally inverted relationship (i.e., half-turn rotationally inverted with respect to one another). Advantageously, the non-linear separation interface reduces the amount of sheet scrap in the sheet.

Although efficient for manufacturing purposes, the non-linear separation interface also reduces the amount of sheet material available to form a container bottom in a container formed from one of the blanks. The reduction in area of the bottom panels forming the container bottom potentially weakens the container bottom. The invention addresses the potentially weakened container bottom by providing bottom panels having notched edges that correspondingly engage one another upon construction to counter the reduced bottom panel area (i.e., overlapping material) and strengthen the container bottom.

In one embodiment, the invention is a nested pair of blanks on a unitary sheet having a first blank for forming a container, a second blank for forming an identical container, and a non-linear separation interface that connects the blanks to one another in a rotationally inverted relationship that reduces sheet scrap. As set forth above, the invention incorporates blanks having notched edges that correspondingly engage one another upon construction to form a container bottom upon separation of the blank and construction of the container. The engagement notches strengthen the container bottom and counter the effect of reduced overlapping material in the container bottom (i.e., potentially weakened bottom).

More specifically, the invention provides first and second blanks having one or more body panels that are connected to one another along vertical fold lines. In further detail, each of the body panels of the first and second blanks include a front panel having opposing first and second side panels, and a rear panel that is connected to the front panel by the second side panel.

The first and second blanks also include bottom panels connected to edges of the body panels. The bottom panels of each of the first and second blanks include a first bottom closure panel connected to an edge of the front panel, and a second bottom closure panel connected to an edge of the rear panel. At least one of the bottom panels of the first blank is connected to and nested vertically with at least one of the bottom panels of the second blank.

The first and second blanks may also include bottom flaps connected to edges of the respective body panels. In one embodiment, each of the first and second blanks include a first bottom closure flap connected to respective edges of the first side panels, and a second bottom closure flap connected to respective edges of the second side panels.

The adjacent bottom panels and flaps of the blanks define the non-linear separation interface. Thus, one or more of the adjacent bottom closure panels and one or more of the adjacent bottom closure flaps of the first and second blanks may define the non-linear separation interface.

Each of the nested blanks includes notched edges that correspondingly engage one another to form container bottoms upon separation of the blanks from the sheet and construction of the containers. The notched edges define engagement notches that permit the reduction in sheet scrap, while maintaining sufficient strength in the container bottom.

First and second locking closure flaps connected to respective edges of the first and second side panels of the first and second blanks secure the tops of the containers formed from the blanks. In the unitary sheet, the first and second locking closure flaps of the blanks are positioned opposite the non-linear separation interface. This particular embodiment also provides first and second top closure panels connected to respective edges of the front and rear panels of the blanks. The first and second top closure panels are positioned on the sheet opposite the non-linear separation interface and further secure the tops of the containers formed from the blanks.

The invention further provides first and second tuck flaps connected to respective edges of the first and second top closure panels of the blanks. The tuck flaps secure the first and second top closure panels to one another. The tuck flaps are positioned on the sheet opposite the front and rear panels of the blanks. Glue flaps are connected to respective edges of the rear panels of the blanks and form a part of the manufacturer's joint upon construction of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a partial top plan view of known nesting arrangements of blanks on a unitary sheet illustrating sheet scrap in parallel cross-hatched lines between the blanks;

FIG. 2 is a perspective view of a known container having an automatic bottom illustrating overlapping sheet material in a container bottom in hidden double cross-hatched lines;

FIG. 3A is a partial perspective view of one bottom panel of a known container illustrating the area of overlap between the bottom panels in double cross-hatched lines;

FIG. 3B is a partial perspective view of another bottom panel of a known container illustrating the area of overlap between the bottom panels in double cross-hatched lines;

FIG. 4 is a top plan view of one embodiment of a nested pair of blanks on a unitary sheet of the invention illustrating sheet scrap in parallel cross-hatched lines;

FIG. 5 is an enlarged top plan view of a portion of one embodiment of a nested pair of blanks of the invention depicting notched edges in bottom panels of the blanks;

FIG. 6 is a partial perspective view of a container having an automatic bottom formed from one embodiment of a nested pair of blanks of the invention illustrating overlapping sheet material in a container bottom in hidden double cross-hatched lines;

FIG. 7 is an enlarged perspective view of a portion of a container formed from one embodiment of the nested pair of blanks of the invention illustrating overlapping sheet material in a container bottom in hidden double cross-hatched lines;

FIG. 8A is a partial perspective view of one bottom panel of a container formed from one embodiment of the nested pair of blanks of the invention illustrating the area of overlap between the bottom panels in double cross-hatched lines;

FIG. 8B is a partial perspective view of another bottom panel of a container formed from one embodiment of the nested pair of blanks of the invention illustrating the area of overlap between the bottom panels in double cross-hatched lines;

FIG. 9A is a partial perspective view of the bottom of a container formed from one embodiment of the nested pair of blanks of the invention illustrating the initial stages of the formation of a container bottom;

FIG. 9B is a partial perspective view of the bottom of a container formed from one embodiment of the nested pair of blanks of the invention illustrating latter stages of the formation of a container bottom; and

FIG. 9C is a partial perspective view of the bottom of a container formed from one embodiment of the nested pair of blanks of the invention illustrating the completed formation of a container bottom.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which multiple embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. Further, like numbers with the prime notation refer to like or similar elements of the structure.

Packaging is typically formed from packaging blanks, or blanks for short. It will be understood that as used herein the term “blank” may include cardboard, rigid paper, flexible plastic, or similar products made of paperboard or plastic. In particular, the packaging industry favors the use of one-piece flexible blanks, which are readily incorporated into automated processes for forming containers. The term “unitary sheet” refers to material having a broad, continuous surface so connected that it is possible to pass from any one point of the surface to any other point without leaving the surface. Sheet may also refer to separate pieces of, for example, paperboard used to form blanks.

It will be understood by those skilled in the art that the term “container” as used herein refers to various embodiments of the present structure for retaining a variety articles as formed from the various embodiments of the blank described below.

The term “panel” used in conjunction with the nested pair of blanks of the present invention refers to the major component part of a blank or container, and defines the major partition elements of the blank or container. Those skilled in the art will also appreciate that panels include edges defined as the line of intersection of two surfaces or a border. A “free edge” of a panel refers to an edge that does not intersect with another surface or panel.

The term “flap” refers to a secondary blank or container element that is typically hinge-connected along a free edge of a panel or another flap. It will be understood that the term “tab” refers to a tertiary element of the blank or container that is generally hinged to a portion of a free edge of a panel or flap, or struck from within the plane of a panel or flap.

It will be understood by those skilled in the art that the terms “top panel” and “lower panel” may also refer to “lower panel” and “upper panel” dependent upon the perspective of the individual viewing the apparatus. It will also be appreciated that the term “top” implies the opposite of “bottom.”

With reference to the orientation of the sheet in FIG. 4, it will be understood that the terms “internal surface” and “external surface” may be referred to as “inside surface” and “outside surface.” Stated differently, the term internal surface implies the surface of the container closest to the interior of the container. Thus, it will be understood that the term external surface implies the side of the container opposite the internal surface (i.e., the side farthest from the interior of the container).

The dimensions or measurements for containers will typically be expressed in the order of length (L), width (W), and depth (D), wherein L is typically the larger dimension at the open end of the container, W is usually the smaller dimension at the open end of the container, and D is the distance between the open ends of the container (e.g., L×W×D). With reference to the orientation of the sheet in FIG. 4, it will be understood that the term “width” refers to a distance measured from the leftmost portion of the sheet to the rightmost portion of the sheet.

Further, as used herein the concept of a panel being “between” two other panels does not necessarily imply that the three panels or flaps are contiguous (i.e., in intimate contact). Rather, as used herein, the concept of one panel being between two other panels is meant to describe the relative positions of the panels within the blank or container structure, respectively.

Similarly, the concept of a first panel being connected to a second panel by a third panel, “opposite” the second panel, merely describes the relative positions of the first and second panels within the blank structure. It will further be understood that the term “finished” means coated with a material to produce an attractive glossy finish. The term “finished” will also be understood to mean the inclusion of printed material or other identifying indicia (e.g., a company's logo).

It will be understood by those skilled in the art that the term “score” refers to a crease along which the adjacent components or portions of a component of the blank are folded without cracking or breaking to form a container. It will be understood that the term “cut-score” refers to an impression formed by a cutting tool (e.g., a punch, die, or blade) that extends partially through a sheet of paperboard or the like. The term “perforations” refers to a series of holes or impressions formed by a cutting tool (e.g., a punch or die) that permits easy separation of, for example, panels.

It will be further understood that the term “fold line” or “score line” refers to a crease along which the adjacent components of a blank are folded without cracking or breaking to form a container. The term “secured” may refer to adhered with adhesive (e.g., glue) or bonded with heat.

The term “substantially rectangular” is meant to succinctly describe a simple geometric shape approximating a rectangle. Similarly, the term “substantially parallel” is meant to describe the spatial relationship between, for example, one panel to another panel, wherein the relationship is approximately parallel.

Those skilled in the art will also appreciate that the term “adjacent” refers to two or more, for example, panels that have a common border or are in close proximity to one another. Nevertheless, it will be understood that adjacent may or may not imply contact, but always implies the absence of anything of the same kind in between. Furthermore, as used herein, it will be understood that the term “article” will refer primarily to consumer products that are packaged for shipment (e.g., pharmaceuticals, consumables, etc.). It will be understood, however, that “article” may also refer to any number of goods such as individually packaged consumables for humans and animals, as well as individually packaged non-consumables.

As used herein, the term “separation interface” refers to an area of the sheet defining a common border between the pair of nested blanks. Stated differently, the term “separation interface” refers an area of the sheet connecting the pair of nested blanks that is capable of coming apart and dividing the sheet into separate components (i.e., blanks).

An overall view of an embodiment of a nested pair of blanks on a unitary sheet of the invention is set forth at 10 in the top plan view of FIG. 4. In general terms, the invention provides a first blank 11 for forming a container 60, a second blank 12 for forming an identical container, and a non-linear separation interface 13 that connects the first and second blanks 11, 12 to one another in a rotationally inverted relationship (i.e., half-turned and inverted with respect to one another). As a novel feature of the invention, the non-linear separation interface 13 reduces the amount of sheet scrap S in the sheet 10 and improves manufacturing efficiencies. In one embodiment, the sheet 10 is formed from paperboard.

Referring to FIG. 4, the first and second blanks 11, 12 include one or more body panels 14, 15, 16, 17, 20, 21, 22, 23 connected along substantially vertical fold lines 18 and oriented horizontally. In further detail, the body panels 14, 15, 16, 17 of the first blank 11 include a substantially rectangular front panel 14 having opposing first and second side panels 15, 16, and a substantially rectangular rear panel 17 connected to the front panel 14 by the second side panel 16. In like fashion, the body panels 20, 21, 22, 23 of the second blank 12 include a substantially rectangular front panel 20 having opposing first and second side panels 21, 22, and a substantially rectangular rear panel 23 connected to the front panel 20 by the second side panel 22. The body panels of the first and second blanks 11, 12 form the major component parts of the respective blanks.

The first blank 11 may include one or more bottom panels 25, 26 connected to edges of the body panels 14, 15, 16, 17. The second blank 12 also includes one or more bottom panels 30, 31 connected to edges of the body panels 20, 21, 22, 23. Each of the first and second blanks 11, 12 may also provide one or more bottom flaps 27, 28, 32, 33 connected to edges of the body panels 15, 16, 21, 22 of the respective blanks. The bottom panels 25, 26, 30, 31 and bottom flaps 27, 28, 32, 33 of the blanks 11, 12 form a part of the respective container bottoms.

Still referring to FIG. 4, the bottom panels 25, 26 of the first blank 11 include a first bottom closure panel 25 connected to an edge of the front panel 14, and a second bottom closure panel 26 connected to an edge of the rear panel 17. Further, the bottom panels 30, 31 of the second blank 12 include a first bottom closure panel 30 connected to an edge of the front panel 20, and a second bottom closure panel 31 connected to an edge of the rear panel 23. As discussed herein, the first and second bottom panels 25, 26, 30, 31 of the blanks engage one another respectively, during construction of the containers formed from the blanks.

With respect to the bottom flaps 27, 28, 32, 33, the first blank 11 includes a first bottom closure flap 27 connected to an edge of the first side panel 15, and a second bottom closure flap 28 connected to an edge of the second side panel 16. The second blank 12 may likewise include a first bottom closure flap 32 connected to an edge of the first side panel 21, and a second bottom closure flap 33 connected to an edge of the second side panel 22.

Each of the first and second bottom closure panels 25, 26, 30, 31 of the first and second blanks 11, 12 include first and second bottom glue flaps 35, 36, 37, 38 defined by a cut-score line 39 in the respective bottom closure panels (see FIG. 4). During construction of a container 60 from either of the blanks as illustrated in FIGS. 9B and 9C, a portion of the first bottom glue flap 35 is adhered to a portion of the first bottom closure panel 25. Further, a portion of the second bottom glue flap 36 is adhered to a portion of the second bottom closure panel 26.

In combination with the corresponding engagement of the notched edges 24 of the first and second bottom closure panels 25, 26 of the first blank, the glue flaps 35, 36 as adhered to portions of both closure panels facilitates the automatic formation of the container bottom 29 upon construction (see FIG. 9C). Specifically, upon the formation of the manufacturer's glue joint with a glue flap 56, the substantially flat, partially formed container 60 is expanded, thereby permitting the engagement notches 40 to secure the container bottom 29.

As configured on the unitary sheet 10 depicted in FIG. 4, at least one of the bottom panels 25, 26 of the first blank 11 is connected to and nested vertically with at least one of the bottom panels 30, 31 of the second blank 12. In one embodiment, the first bottom closure panel 25 of the first blank 11 is connected to the second bottom closure panel 31 of the second blank 12, and the second bottom closure panel 26 of the first blank 11 is connected to the first bottom closure panel 30 of the second blank 12.

Still referring to FIG. 4, the adjacent bottom panels 25, 26, 30, 31 of the first and second blanks 11, 12 define the non-linear separation interface 13. The non-linear separation interface 13 is further defined by one or more of the bottom closure flaps 27, 28, 32, 33 connected to edges of the body panels 15, 16, 21, 22 of the first and second blanks 11, 12. Accordingly, one or more of the adjacent bottom closure panels 25, 26, 30, 31 and one or more of the adjacent bottom closure flaps 27, 28, 32, 33 of the first and second blanks 11, 12 may define the non-linear separation interface 13 on the unitary sheet 10.

In one embodiment of the invention, the non-linear separation interface 13 is defined by the first and second bottom closure panels 25, 26 of the first blank 11, and the first and second bottom closure panels 30, 31 of the second blank 12. In this embodiment, the first bottom closure panel 25 of the first blank 11 is connected to and nested vertically with the second bottom closure panel 31 of the second blank 12. Furthermore, the second bottom closure panel 26 of the first blank 11 is connected to and nested vertically with the first bottom closure panel 30 of the second blank 12.

With reference to FIG. 4, one or more of the bottom closure panels 25, 26 of the first blank 11 are connected to and nested vertically with one or more of the bottom closure flaps 32, 33 of the second blank. Further, one or more of the bottom closure panels 30, 31 of the second blank 12 may be connected to and nested vertically with one or more of the bottom closure flaps 27, 28 of said first blank 11. In particular, the first bottom closure panel 25 of the first blank 11 is connected to and nested vertically with the second bottom closure flap 33 of the second blank 12. Furthermore, the second bottom closure panel 26 of the first blank 11 is connected to and nested vertically with the first bottom closure flap 32 of the second blank 12.

In further description, at least one of the bottom panels 25, 26 of the first blank 11 is connected to and vertically nested with at least one of the bottom panels 30, 31 of the second blank 12 and at least one of the bottom flaps 32, 33 of the second blank 12. Specifically, the first bottom closure panel 25 of the first blank 11 is connected to and nested vertically with the second bottom closure panel 31 of the second blank 12 and second bottom closure flap 33 of the second blank 12. Further, the second bottom closure panel 26 of the first blank 11 is connected to the first bottom closure panel 30 of the second blank 12 and the first bottom closure flap 32 of the second blank 12.

In continuing detail, at least one of the bottom panels 30, 31 of the second blank 12 is connected to and vertically nested with at least one of the bottom panels 25, 26 of the first blank 11 and at least one of the bottom flaps 27, 28 of the first blank 11. In particular, the first bottom closure panel 30 of the second blank 12 is connected to the second bottom closure panel 26 of the first blank 11 and the second bottom closure flap 28 of the first blank 11. Further, the second bottom closure panel 31 of the second blank 12 is connected to the first bottom closure panel 25 of the first blank 11 and the first bottom closure flap 27 of the first blank 11.

Still referring to FIG. 4, one embodiment provides at least one of the bottom flaps 27, 28 of the first blank 11 connected to and nested vertically with at least one of the bottom panels 30, 31 of the second blank 12. In more detail, the first bottom closure flap 27 of the first blank 11 is connected to and vertically nested with the second bottom closure panel 31 of the second blank. In another embodiment, the second bottom closure flap 28 of the first blank 11 is connected to and vertically nested with the first bottom closure panel 30 of the second blank 12.

Still further, at least one of the bottom flaps 32, 33 of the second blank 12 may be connected to and nested vertically with at least one of the bottom panels 25, 26 of the first blank 11. Specifically, the second bottom closure flap 33 of the second blank 12 is connected to and vertically nested with the first bottom closure panel 25 of the first blank 11. Further, the first bottom closure flap 32 of the second blank 12 is connected to and vertically nested with the second bottom closure panel 26 of the first blank 11.

With reference to FIG. 5, each of the nested blanks 11, 12 includes one or more notched edges 24 that correspondingly engage one another to form container bottoms upon separation of the blanks from the sheet 11 and construction of the container 60. In particular, edges 24 of the bottom panels 25, 26 of the first blank 11 have engagement notches 40 that correspondingly engage one another to form the container bottom upon separation of the blank from the sheet and construction of the container. In similar fashion, edges 24 of the bottom panels 30, 31 of the second blank 12 include engagement notches 40 that correspondingly engage one another to form the container bottom upon separation of the blank from the sheet and construction of the identical container. As illustrated in FIG. 5, one or more of the notched edges 24 define angles A that are oriented on the sheet 10 at approximately 45 degrees relative to the substantially vertical fold lines 18 in the blanks 11, 12. The angle A may vary depending upon the size and shape of the notches 40.

As described in greater detail, the first and second bottom closure panels 25, 26 of the first blank 11 include one or more notched edges 24 that correspondingly engage one another to form the container bottom. Similarly, the first and second bottom closure panels 30, 31 of the second blank 12 include one or more notched edges 24 that correspondingly engage one another to form a container bottom 29.

The notched edges 24 strengthen the container bottom and counter the reduced surface area of the bottom panels 25, 26, 30, 31 resulting from the efficient nesting of the blanks 11, 12 on the unitary sheet 10. In comparing known containers depicted in FIGS. 2-3B to the present invention depicted in FIGS. 6-8B, the reduction in available surface area of the bottom panels 25, 26 is evident. The overlapping sheet material of the inventive bottom panels 25, 26 indicated by hidden double cross-hatched lines in FIGS. 6 and 7 is less than the overlapping material of known bottom panels 25′, 26′ indicated by hidden double cross-hatched lines in FIG. 2. In further detail, the area of overlap of the inventive bottom panels 25, 26 indicated by double cross-hatched lines in FIGS. 8A and 8B is less than the area of overlap of known bottom panels 25′, 26′ indicated by double cross-hatched lines in FIGS. 3A and 3B.

The reduction in the overlapping sheet material in a container bottom and the area of overlap in the bottom panels 25, 26, 30, 31 results from the efficient nesting of the pair of blanks 11, 12 in the present invention. Specifically, the inventive sheet 10 illustrated in FIG. 4 includes less sheet scrap S (represented by parallel double cross-hatched lines) than the known sheet illustrated in FIG. 1. Accordingly, the present invention increases manufacturing efficiencies by reducing sheet scrap S in a sheet, yet addresses the potentially weakened bottom by providing bottom panels having engagement notches that secure the bottom panels to one another and strengthen the container bottom 29.

In terms of relative percent, the sheet scrap S illustrated in the inventive sheet of FIG. 4 is approximately 27% of the sheet scrap S′ illustrated in the known sheet of FIG. 1. Further, the overlapping sheet material illustrated in the inventive container bottom 29 of FIG. 6 is approximately 26% of the overlapping sheet material illustrated in the known container bottom 29′ of FIG. 2.

Directing attention to the first blank 11 of FIG. 4, one embodiment of the present invention may also provide first and second locking closure flaps 41, 42 connected to edges of the first and second side panels 15, 16, respectively. The first and second locking closure flaps 41, 42 of the first blank 11 are positioned on the unitary sheet 11 opposite the non-linear separation interface 13 and secures the top of the container 60 formed from the blank 11. This particular embodiment also provides first and second top closure panels 47, 48 connected to edges of the front and rear panels 14, 17 of the first blank 11. The top closure panels 47, 48 form a part of the top of the container 60 and are positioned on the sheet 11 opposite the non-linear separation interface 13. The first blank 11 may also include first and second tuck flaps 52, 53 connected to edges of the first and second top closure panels 47, 48, respectively, opposite the front and rear panels 14, 17. The tuck flaps 52, 53 secure the top closure panels 47, 48 to each other. A glue flap 56 is provided in the first blank 11 to assist in construction of the container 60 formed from the blank 11. The glue flap 56 is connected to an edge of the rear panel 17 of the first blank 11, opposite the second side panel 16, and is eventually secured to the first side panel 15 upon construction of the container 60.

Referring now to the second blank 12 of FIG. 4, the invention provides first and second locking closure flaps 45, 46 connected to edges of the first and second side panels 21, 22 of the second blank 12, respectively. The first and second locking closure flaps 45, 46 of the second blank 12 are positioned on the unitary sheet 11 opposite the non-linear separation interface 13 and secures the top of the container 60 formed from the blank. The second blank 12 may further include first and second top closure panels 50, 51 connected to edges of the front and rear panels 20, 23, respectively. The first and second top closure panels 50, 51 are positioned on the sheet 10 opposite the non-linear separation interface 13 and form a part of the top of the container. First and second tuck flaps 54, 55 are provided on the second blank 12 and are connected to edges of the first and second top closure panels 50, 51, respectively, opposite the front and rear panels 20, 23. To assist in construction of the identical container, the second blank 12 may include a glue flap 57 connected to an edge of the rear panel 23 of the second blank, opposite the second side panel 22.

As depicted in FIG. 4, the first and second blanks 11, 12 are oriented on the sheet asymmetrically about a vertical axis of symmetry. Stated differently, the body panels 14, 15, 16, 17, 20, 21, 22, 23 of the first and second blanks 11, 12 are oriented on the sheet in a non-linear arrangement. In a novel aspect of the invention, the non-linear arrangement in connection with the separation interface 13 reduces sheet scrap S and promotes manufacturing efficiencies.

The invention also provides a container 60 formed from the first or second blank 11, 12 as described above. As shown in FIGS. 6-8B, the container 60 includes an interlocking container bottom 29 that is automatically formed upon construction. The container 60 includes first and second bottom closure panels 25, 26 that are secured to one another, first and second bottom closure flaps 27, 28 secured to the first and second bottom closure flaps, a substantially rectangular front panel 14 connected to the first bottom closure panel 25, and a substantially rectangular rear panel 17 connected to the second bottom closure panel 26. The container 60 further includes a substantially rectangular first side panel 15 connected to the first bottom closure flap 27 and to respective edges of the front and rear panels 14, 17, and a substantially rectangular second side panel 16 secured to the second bottom closure flap 28 and to respective edges of the front and rear panels 14, 17. As constructed, the front and rear panels 14, 17 and the first and second side panels 15, 16 define substantially parallel planes, respectively.

In another novel aspect of the invention, the first and second bottom closure panels 25, 26 include notched edges 24 that correspondingly engage one another to form the container bottom 29. Upon construction, portions of the first and second bottom closure flaps 27, 28 are positioned between overlapping portions of the first and second bottom closure panels 25, 26.

Construction of the container bottom 29 is illustrated in FIGS. 9A-9C. In further detail, the glue flap 56 is adhered to the first side panel 15 to form the basic container structure. Thereafter, a portion of the first bottom closure flap 27 is secured to the first bottom glue flap 35 of the first bottom closure panel 25. Further, a portion of the second bottom closure flap 28 is secured to the second bottom glue flap 36 of the second bottom closure panel 26. At this stage, the partially formed container may be folded substantially flat such that the cut-score lines 39 defining the first and second bottom glue flaps 35, 36 permit the folding of the first side panel 15 and rear panel 17 against the second side panel 16 and front panel 14, respectively. In this substantially flat configuration, the first bottom closure panel 25 is substantially adjacent to the front panel 14, the second bottom closure panel 26 is substantially adjacent to the rear panel 17, the first bottom closure flap 27 is substantially adjacent to the first side panel 15, and the second bottom closure flap 28 is substantially adjacent to the second side panel 16.

Further, portions of the first and second bottom closure panels 25, 26 are substantially adjacent to one another, and are substantially adjacent to the first and second bottom closure flaps 27, 28, respectively. Subsequently, the container 60 may be expanded by pulling the first side panel 15 and rear panel 17 away from the front panel 14 and second side panel 16. In forming the container bottom 29, a user may manipulate the panels to advance the notched edges 24 of the first and second bottom closure panels 25, 26 towards one another until the engagement notches 40 correspondingly engage one another to thereby form the container bottom 29.

In the drawings and specification, there have been disclosed typical embodiments on the invention and, although specific terms have been employed, they have been used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.

Claims

1. A nested pair of blanks on a unitary sheet, comprising:

a first blank for forming a container, said first blank having one or more body panels connected to one another and oriented horizontally, said first blank having one or more bottom panels connected to edges of said one or more body panels of said first blank;

a second blank for forming an identical container, said second blank having one or more body panels connected to one another and oriented horizontally, said second blank having one or more bottom panels connected to edges of said one or more body panels of said second blank; and

a non-linear separation interface connecting said first and second blanks to one another in a rotationally inverted relationship that reduces sheet scrap;

wherein said one or more bottom panels of said first and second blanks define said non-linear separation interface.

2. A nested pair of blanks according to claim 1, wherein said sheet comprises paperboard.

3. A nested pair of blanks according to claim 1, wherein:

said first blank having one or more notched edges that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the container; and

said second blank having one or more notched edges that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the identical container.

4. A nested pair of blanks according to claim 1, wherein:

edges of said one or more bottom panels of said first blank having engagement notches that correspondingly engage one another to form the container bottom upon separation of said blank from said sheet and construction of the container; and

edges of said one or more bottom panels of said second blank having engagement notches that correspondingly engage one another to form the container bottom upon separation of said blank from said sheet and construction of the identical container.

5. A nested pair of blanks according to claim 1, wherein at least one of said one or more bottom panels of said first blank is connected to and nested vertically with at least one of said one or more bottom panels of said second blank.

6. A nested pair of blanks according to claim 1, wherein said non-linear separation interface is further defined by:

one or more bottom flaps connected to edges of said one or more body panels of said first blank; and

at least one of said one or more bottom flaps of said first blank is connected to and nested vertically with at least one of said one or more bottom panels of said second blank.

7. A nested pair of blanks according to claim 1, wherein said non-linear separation interface is further defined by:

one or more bottom flaps connected to edges of said one or more body panels of said second blank; and

at least one of said one or more bottom flaps of said second blank is connected to and nested vertically with at least one of said one or more bottom panels of said first blank.

8. A nested pair of blanks according to claim 1, wherein said non-linear separation interface is further defined by:

one or more bottom flaps connected to edges of said one or more body panels of said first blank; and

one or more bottom flaps connected to edges of said one or more body panels of said second blank;

at least one of said bottom panels of said first blank is connected to and vertically nested with at least one of said one or more bottom panels of said second blank and at least one of said bottom flaps of said second blank.

9. A nested pair of blanks according to claim 8, wherein at least one of said bottom panels of said second blank is connected to and vertically nested with at least one of said one or more bottom panels of said first blank and at least one of said one or more bottom flaps of said first blank.

10. A nested pair of blanks according to claim 1, wherein each said first and second blanks is asymmetrical about a vertical axis of symmetry.

11. A nested pair of blanks according to claim 1, wherein said body panels of said first and second blanks are oriented on said sheet in a non-linear arrangement.

12. A nested pair of blanks according to claim 1, wherein said one or more body panels of said first blank include:

a substantially rectangular front panel, said front panel having opposing first and second side panels; and

a substantially rectangular rear panel connected to said front panel by said second side panel.

13. A nested pair of blanks according to claim 12, wherein said one or more bottom panels of said first blank include:

at least one bottom panel connected to an edge of said front panel; and

at least one bottom panel connected to an edge of said rear panel.

14. A nested pair of blanks according to claim 1, wherein said one or more body panels of said second blank include:

a substantially rectangular front panel, said front panel having opposing first and second side panels; and

a substantially rectangular rear panel connected to said front panel by said second side panel.

15. A nested pair of blanks according to claim 14, wherein said one or more bottom panels of said second blank include:

at least one bottom panel connected to an edge of said front panel; and

at least one bottom panel connected to an edge of said rear panel.

16. A nested pair of blanks according to claim 1, wherein:

said first blank having one or more bottom flaps connected to edges of said one or more body panels of said first blank; and

said second blank having one or more bottom flaps connected to edges of said one or more body panels of said second blank.

17. A nested pair of blanks on a unitary sheet, comprising:

a first blank for forming a container, said first blank having a substantially rectangular front panel, said front panel having opposing first and second side panels, a substantially rectangular rear panel connected to said front panel by said second side panel, and a bottom panel connected to an edge of said front panel;

a second blank for forming an identical container, said second blank having: a substantially rectangular front panel, said front panel having opposing first and second side panels, a substantially rectangular rear panel connected to said front panel by said second side panel; and a bottom panel connected to an edge of said rear panel; and

a non-linear separation interface connecting said first and second blanks to one another in a rotationally inverted relationship that reduces sheet scrap;

wherein said one or more bottom panels of said first and second blanks define said non-linear separation interface.

18. A nested pair of blanks according to claim 17, wherein said sheet comprises paperboard.

19. A nested pair of blanks according to claim 17, wherein:

said first blank having one or more notched edges that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the container; and

said second blank having one or more notched edges that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the identical container.

20. A nested pair of blanks according to claim 17, wherein said bottom panel of said first blank is connected to and nested vertically with said bottom panel of said second blank.

21. A nested pair of blanks according to claim 17, said non-linear separation interface is further defined by:

a bottom flap connected to an edge of said first side panel of said first blank; and

said bottom flap of said first blank is connected to and vertically nested with said bottom panel of said second blank.

22. A nested pair of blanks according to claim 17, said non-linear separation interface is further defined by:

a bottom flap connected to an edge of said second side panel of said second blank; and

said bottom flap of said second blank is connected to and vertically nested with said bottom panel of said first blank.

23. A nested pair of blanks according to claim 17, said non-linear separation interface is further defined by:

a bottom panel connected to an edge of said rear panel of first blank; and

a bottom panel connected to an edge of said front panel of said second blank;

wherein said bottom panel connected to said rear panel of said first blank is connected to and nested vertically with said bottom panel connected to said front panel of said second blank.

24. A nested pair of blanks according to claim 23, wherein:

edges of said bottom panels of said first blank having engagement notches that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the container; and

edges of said bottom panels of said second blank having engagement notches that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the identical container.

25. A nested pair of blanks according to claim 23, said non-linear separation interface is further defined by:

a bottom flap connected to an edge of said second side panel of said first blank; and

said bottom flap connected to said second side panel of said first blank is connected to and vertically nested with said bottom panel connected to said front panel of said second blank.

26. A nested pair of blanks according to claim 23, said non-linear separation interface is further defined by:

a bottom flap connected to an edge of said first side panel of said second blank; and

said bottom flap connected to said first side panel of said second blank is connected to and vertically nested with said bottom panel connected to said rear panel of said first blank.

27. A nested pair of blanks according to claim 17, further comprising first and second locking closure flaps connected to edges of said first and second side panels of said first blank, respectively, opposite said non-linear separation interface.

28. A nested pair of blanks according to claim 17, further comprising first and second top closure panels connected to edges of said front and rear panels of said first blank, respectively, opposite said non-linear separation interface.

29. A nested pair of blanks according to claim 28, further comprising first and second tuck flaps connected to edges of said first and second top closure panels of said first blank, respectively, opposite said front and rear panels of said first blank.

30. A nested pair of blanks according to claim 17, further comprising a glue flap connected to an edge of said rear panel of said first blank, opposite said second side panel of said first blank.

31. A nested pair of blanks according to claim 17, further comprising first and second locking closure flaps connected to edges of said first and second side panels of said second blank, respectively, opposite said non-linear separation interface.

32. A nested pair of blanks according to claim 17, further comprising first and second top closure panels connected to edges of said front and rear panels of said second blank, respectively, opposite said non-linear separation interface.

33. A nested pair of blanks according to claim 32, further comprising first and second tuck flaps connected to edges of said first and second top closure panels of said second blank, respectively, opposite said front and rear panels of said second blank.

34. A nested pair of blanks according to claim 17, further comprising a glue flap connected to an edge of said rear panel of said second blank, opposite said second side panel of said second blank.

35. A nested pair of blanks on a unitary sheet, comprising:

a first blank for forming a container, said first blank having a substantially rectangular front panel, said front panel having opposing first and second side panels, a substantially rectangular rear panel connected to said front panel by said second side panel, a first bottom closure panel connected to an edge of said front panel, a second bottom closure panel connected to an edge of said rear panel, a first bottom closure flap connected to an edge of said first side panel, and a second bottom closure flap connected to an edge of said second side panel; and

a second blank for forming an identical container, said second blank having: a substantially rectangular front panel, said front panel having opposing first and second side panels, a substantially rectangular rear panel connected to said front panel by said second side panel, a first bottom closure panel connected to an edge of said front panel, a second bottom closure panel connected to an edge of said rear panel, a first bottom closure flap connected to an edge of said first side panel, and a second bottom closure flap connected to an edge of said second side panel; and

a non-linear separation interface connecting said first and second blanks to one another in a rotationally inverted relationship that reduces sheet scrap.

36. A nested pair of blanks according to claim 35, wherein said one or more bottom closure panels and said one or more bottom closure flaps of said first and second blanks define said non-linear separation interface.

37. A nested pair of blanks according to claim 35, wherein one or more of said bottom closure panels of said first blank is connected to and nested vertically with one or more of said bottom closure flaps of said second blank.

38. A nested pair of blanks according to claim 35, wherein one or more of said bottom closure panels of said second blank is connected to and nested vertically with one or more of said bottom closure flaps of said first blank.

39. A nested pair of blanks according to claim 35, wherein said first bottom closure panel of said first blank is connected to and vertically nested with said second bottom closure panel and second bottom closure flap of said second blank.

40. A nested pair of blanks according to claim 35, wherein said second bottom closure panel of said first blank is connected to and vertically nested with said first bottom closure panel and said first bottom closure flap of said second blank.

41. A nested pair of blanks according to claim 35, wherein said first bottom closure flap of said first blank is connected to and vertically nested with said second bottom closure panel of said second blank.

42. A nested pair of blanks according to claim 35, wherein said second bottom closure flap of said first blank is connected to and vertically nested with said first bottom closure panel of said second blank.

43. A nested pair of blanks according to claim 35, wherein said first bottom closure flap of said second blank is connected to and vertically nested with said second bottom closure panel of said first blank.

44. A nested pair of blanks according to claim 35, wherein said second bottom closure flap of said second blank is connected to and vertically nested with said first bottom closure panel of said first blank.

45. A nested pair of blanks according to claim 35, wherein:

said first and second bottom closure panels of said first blank having one or more notched edges that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the container; and

said first and second bottom closure panels of said second blank having one or more notched edges that correspondingly engage one another to form a container bottom upon separation of said blank from said sheet and construction of the identical container.

46. A container having an interlocking container bottom, comprising:

first and second bottom closure panels secured to one another, said first and second bottom closure panels having notched edges that correspondingly engage one another to form a container bottom;

first and second bottom closure flaps secured to said first and second bottom closure flaps, portions of said first and second bottom closure flaps positioned between overlapping portions of said first and second bottom closure panels;

a substantially rectangular front panel connected to said first bottom closure panel;

a substantially rectangular rear panel connected to said second bottom closure panel, said front panel and said rear panel defining substantially parallel planes;

a substantially rectangular first side panel connected to said first bottom closure flap and to respective edges of said front and rear panels; and

a substantially rectangular second side panel secured to said second bottom closure flap and to respective edges of said front and rear panels, said first side panel and said second side panel defining substantially parallel planes.