OPPOSING-FOIL PANEL HAVING ONE OR MORE ZONES WITH A DISTRIBUTED INTERCONNECTING STRUCTURE

Abstract

An opposing-foil panel includes spaced apart planar foils, a first zone between the foils and defining a first zone length in a machine direction and a first zone width extending in a cross-machine direction, normal to the machine direction, across a first portion of the foil width, a plurality of elongated support members affixed to the foils in the first zone and extending along the first zone length and spaced apart along the first zone width, a second zone between the foils adjacent to the first zone and defining a second zone length and a second zone width extending across a second portion of the foil width, and a distributed interconnecting structure affixed to the foils in the second zone and distributed across the second zone width with greater density than the first plurality of elongated support members is distributed across the first zone width.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of, and priority to, U.S. Provisional Patent Application Ser. No. 62/219,133, filed Sep. 16, 2015, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to rigid or semi-rigid opposing-foil panels and methods of forming such panels, and more specifically to such panels having one or more zones with a distributed interconnecting structure.

BACKGROUND

Conventional opposing-foil panels are used to construct various panel products including, for example, collapsible container sleeves for shipping and/or storage of one or more items. Such sleeves typically have formed therein a number of vertically extending and spaced apart living hinges, and some panels used to make such sleeves typically have complicated designs for supporting the structures and repeated operation of such living hinges, for ensuring adequate bonding of such panels along their edges, and/or for providing high compressive load bearing capacity. Such panels can therefore be expensive to manufacture and to purchase. It is therefore desirable to design and manufacture opposing-foil panels for use in constructing such collapsible sleeves and/or for other uses that will support the structures and repeated operation of living hinges, ensure adequate bonding of such panels along their edges and/or provide one or more zones of high compressive load bearing capacity, yet be more cost efficiently manufactured than conventional opposing-foil panels having one or more such features.

SUMMARY

The present invention may comprise one or more of the features recited in the attached claims, and/or one or more of the following features and combinations thereof. In a first example aspect, an opposing-foil panel may comprise first and second planar foils each defining a foil height extending linearly along a machine direction between first and second foil ends, a foil width extending linearly along a cross-machine direction, normal to the machine direction, between first and second foil sides and an interior surface between the first and second foil ends and the first and second foil sides, the interior surface the first planar foil spaced apart from the interior surface of the second planar foil, a first zone between the first and second planar foils, the first zone defining a first zone length extending along the machine direction and coextensive with the foil height and a first zone width parallel to and extending in the cross-machine direction across a first portion of the foil width, a first plurality of elongated support members affixed to the interior surfaces of the first and second planar foils in the first zone, the first plurality of elongated support members extending along the first zone length in the machine direction and spaced apart along the first zone width in the cross-machine direction, a second zone between the first and second planar foils adjacent to the first zone, the second zone defining a second zone length extending along the machine direction and coextensive with the foil height and a second zone width parallel to and extending in the cross-machine direction across a second portion of the foil width, and a distributed interconnecting structure affixed to the interior surfaces of the first and second planar foils in the second zone and extending along the second zone length in the machine direction, the distributed interconnecting structure including a plurality of support members distributed across the second zone width with greater density than the first plurality of elongated support members is distributed across the first zone width.

A second example aspect includes the subject matter of the first example aspect, and wherein the plurality of support members may comprise a second plurality of elongated support members each affixed to the interior surface of at least one of the first and second planar foils in the second zone, the second plurality of elongated support members extending along the second zone length in the machine direction and spaced apart along the second zone width in the cross-machine direction.

A third example aspect includes the subject matter of the second example aspect, and wherein the first plurality of elongated support members defines a first distance along the first width of the first zone between each adjacent one of the first plurality of elongated support members, and wherein the second plurality of elongated support members defines a second distance along the second width of the second zone between each adjacent one of the second plurality of elongated support members, and wherein the first distance is greater than the second distance.

A fourth example aspect includes the subject matter of the second example aspect, and wherein the distributed interconnecting structure further comprises a first plurality of lateral support members affixed to and between adjacent ones of the second plurality of elongated support members and spaced apart from the interior surfaces of the first and second foils, each of the first plurality of lateral support members extending between adjacent ones of the first plurality of lateral support members in the cross-machine direction and extending along the second zone length in the machine direction.

A fifth example aspect includes the subject matter of the fourth example aspect, and wherein the distributed interconnecting structure may further comprise a second plurality of lateral support members affixed to and between the adjacent ones of the second plurality of elongated support members and spaced apart from the interior surfaces of the first and second foils and from the first plurality of lateral support members, each of the second plurality of lateral support members extending between the adjacent ones of the first plurality of lateral support members in the cross-machine direction and extending along the second zone length in the machine direction.

A sixth example aspect includes the subject matter of the second example aspect, and wherein the second plurality of elongated support members comprises at least one of a plurality of linear or arcuate-shaped ribs.

A seventh example aspect includes the subject matter of the second example aspect, and wherein at least one of the second plurality of elongated support members extends diagonally from the interior surface of at least one of the first and second planar foils along the cross-machine direction.

An eighth example aspect includes the subject matter of the second example aspect, and wherein at least one of the second plurality of elongated support members defines a cylindrical or oval cross-section in the cross-machine direction.

A ninth example aspect includes the subject matter of the second example aspect, and may further comprise an intermediate planar foil disposed between the first and second planar foils, the intermediate planar foil defining a height extending linearly along the machine direction between the first and second foil ends of the first and second planar foils, a width extending linearly along the cross-machine direction between the first and second foil sides of the first and second planar foils, a first planar surface facing the interior surface of the first planar foil and a second planar surface, opposite the first planar surface, facing the interior surface of the second planar foil, wherein a first subset of the second plurality of elongated support members is affixed to and between the interior surface of the first planar foil and the first planar surface of the intermediate planar foil in the second zone, and a second subset of the second plurality of elongated support members is affixed to at least one of the interior surface of the second planar foil and the second planar surface of the intermediate planar foil in the second zone.

A tenth example aspect includes the subject matter of the first example aspect, and wherein the second zone comprises a living hinge zone, and wherein the opposing-foil panel further comprises a living hinge formed along the length of the living hinge zone with the first and second planar foils and at least a portion of the distributed interconnecting structure.

An eleventh example aspect includes the subject matter of the first example aspect, and wherein the second zone comprises an end zone positioned between the first zone and the first or second sides of the first and second planar foils.

A twelfth example aspect includes the subject matter of the first example aspect, and wherein the second zone defines a zone of the panel in which the distributed interconnecting structure provides enhanced deformation resistance, as compared with the first zone, to compressive forces applied to an external surface of at least one of the first and second planar foils.

A thirteenth example aspect includes the subject matter of the first example aspect, and wherein the first zone defines a first volume between the interior surfaces of the first and second planar foils, the first zone length and a portion of first zone width adjacent to the second zone, and the second zone defines a second volume between the interior surfaces of the first and second planar foils, the second zone length and the second zone width, and wherein the first plurality of elongated support members disposed within the first volume defines a first mass of material, and the distributed interconnecting structure disposed within the second volume defines a second mass of material, and wherein the first volume is approximately equal to the second volume and the first mass of material is approximately equal to the second mass of material.

A fourteenth example aspect includes the subject matter of the thirteenth example aspect, and may further comprise a third zone defined between the first and second planar foils, the third zone defining a third zone length extending along the machine direction and coextensive with the foil height and a third zone width parallel to and extending in the cross-machine direction across a third portion of the foil width, the third zone adjacent to the second zone with the second zone disposed between and contiguous with each of the first and third zones, and a third plurality of elongated support members affixed to and between the interior surfaces of the first and second planar foils in the third zone, the third plurality of elongated support members extending along the third zone length in the machine direction and spaced apart along the third zone width in the cross-machine direction, wherein the third zone defines a third volume between the interior surfaces of the first and second planar foils, the third zone length and a portion of the third zone width adjacent to the second zone, and wherein the third plurality of elongated support members disposed within the third volume defines a third mass of material, and wherein the third volume is approximately equal to each of the first and second volumes and the third mass of material is approximately equal to each of the first and second masses of material.

A fifteenth example aspect includes the subject matter of the first example aspect, and wherein the first planar foil, the second planar foil, the first plurality of elongated support members and the distributed interconnecting structure are all of unitary construction.

A sixteenth example aspect includes the subject matter of the first example aspect, and may further comprise a lateral hinge extending in the cross-machine direction between the first and second foil ends along at least a portion of the first zone, the lateral hinge having a first end extending from the at least a portion of the first zone into the second zone and a second end opposite the first end, wherein the opposing-foil panel is separated along a first path extending in the machine direction through the second zone from the first foil end to the first end of the lateral hinge, and wherein the opposing-foil panel is separated along a second path extending in the machine direction from the first foil end to the second end of the lateral hinge to define a pivoting panel between the lateral hinge and the first and second paths.

A seventeenth example aspect includes the subject matter of the sixteenth example aspect, and may further comprise a third zone between the first and second planar foils adjacent to a second side of the at least a portion of the first zone opposite the first side, the third zone defining a third zone length extending along the machine direction and coextensive with the foil height and a third zone width parallel to and extending in the cross-machine direction across a third portion of the foil width, and a second distributed interconnecting structure affixed to the interior surfaces of the first and second planar foils in the third zone and extending along the third zone length in the machine direction, the second distributed interconnecting structure including a plurality of support members distributed across the third zone width with greater density than the first plurality of elongated support members is distributed across the first zone width, wherein the second path extends in the machine direction through the third zone from the first foil end to the second end of the lateral hinge.

In an eighteenth example aspect, an opposing-foil panel may comprise first and second planar foils each defining a foil height extending linearly along a machine direction between first and second foil ends, a foil width extending linearly along a cross-machine direction, normal to the machine direction, between first and second foil sides and an interior surface between the first and second foil ends and the first and second foil sides, the interior surface the first planar foil spaced apart from the interior surface of the second planar foil, a plurality of panel zones between the first and second planar foils each defining a panel zone length extending along the machine direction and coextensive with the foil height and a panel zone width parallel to and extending in the cross-machine direction across a different portion of the foil width, each of the plurality of panel zones including therein multiple elongated support members affixed to the interior surfaces of the first and second planar foils with each of the multiple elongated support members extending along the panel zone length of the corresponding panel zone in the machine direction and spaced apart along the panel zone width of the corresponding panel zone in the cross-machine direction, a plurality of living hinge zones defined between the first and second planar foils and spaced apart along the foil width, each of the plurality of living hinge zones defining a living hinge zone length extending along the machine direction and coextensive with the foil height and a living hinge zone width parallel to and extending in the cross-machine direction across a different portion of the foil width between and adjacent to different ones of the plurality of panel zones, each of the plurality of living hinge zones including therein a distributed interconnecting structure affixed to the interior surfaces of the first and second planar foils and extending along the corresponding living hinge zone length in the machine direction and distributed across the corresponding zone width with greater density than the multiple elongated support members are distributed across the panel widths of each of the plurality of panel zones, and a plurality of living hinges each formed along the length of a different one of the plurality of living hinge zones with the first and second planar foils and at least a portion of the corresponding distributed interconnecting structure.

In a nineteenth example aspect, an opposing-foil panel for a collapsible container sleeve may comprise a first planar foil having a foil height extending and a foil width, a second planar foil also having the foil height and the foil width and spaced apart from the first planar foil, the foil height defining a machine direction parallel therewith and the foil width defining a cross-machine direction parallel therewith, the cross-machine direction normal to the machine direction, the foil width terminating at each of first and second opposite sides of the first and second planar foils to define respective first and second panel sides, a first panel zone defined between the first and second planar foils and having a length extending across the foil height and a width extending along a first portion of the foil width, a first plurality of elongated support members affixed to the opposed interior surfaces of the first and second planar panel members in the first panel zone, each of the first plurality of elongated support members extending across the length of the first panel zone and spaced apart along the width of the first panel zone, a panel end zone defined between the first and second planar foils and having a length extending across the foil length and a width extending along a second portion of the foil width with one side thereof adjacent to the first panel zone and an opposite side thereof terminating at the first panel side, and a distributed interconnecting structure affixed to the opposed interior surfaces of the first and second planar foils along the length of the panel end zone and distributed across the width of the panel end zone with greater density than the first plurality of elongated support members is distributed across the width of the first panel zone, the first panel side being joinable with one of the second panel side and a panel side of another panel to form the collapsible container sleeve.

A twentieth example aspect includes the subject matter of the nineteenth example aspect, and may further comprise a plurality of spaced apart living hinges each extending along the panel in the machine direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified diagram of a side elevational view of one embodiment of a panel stock formed to include a number of zones with distributed interconnecting structures.

FIG. 2 is a top plan view of a collapsible shipping container sleeve made using two of the panels cut from the panel stock illustrated in FIG. 1.

FIG. 3 is a top plan view of the collapsible shipping container sleeve of FIG. 2 shown in a partially collapsed state.

FIG. 4 is a top plan view of the collapsible shipping container sleeve of FIGS. 2 and 3 shown in a fully collapsed state.

FIG. 5A is a side elevation, magnified and partial cutaway view of one embodiment of a portion 5A of one of the panels cut from the panel stock illustrated in FIG. 1.

FIG. 5B is a cross-sectional view of the panel of FIG. 5A along the section lines 5B-5B thereof.

FIG. 6 is a simplified diagram of a zone of the panel illustrated in FIG. 5B at which a living hinge is to be formed.

FIG. 7 is a simplified diagram of the portion of the panel illustrated in FIG. 6 showing formation of the living hinge.

FIG. 8 is a simplified diagram of the portion of the panel illustrated in FIGS. 6 and 7 showing the formed living hinge in a folded configuration.

FIG. 9 is a cross-sectional view similar to the cross-sectional view of FIG. 5B and illustrating other embodiments of the panel stock of FIG. 1 in the areas of the panel joining and living hinge zones.

FIG. 10A is a side elevation and magnified view similar to the side-elevation view of FIG. 5A but illustrating still other embodiments of the panel stock of FIG. 1 in the areas of the panel joining and living hinge zones.

FIG. 10B is a cross-sectional view of the panel stock of FIG. 10A along the section lines 10B-10B thereof.

FIG. 11A is a cross-sectional view of a portion of a panel illustrating an alternate embodiment of an interconnecting structure between the opposing panel foils within one of the panel zones.

FIG. 11B is a cross-sectional view of a portion of a panel illustrating another alternate embodiment of an interconnecting structure between the opposing panel foils within one of the panel zones.

FIG. 11C is a cross-sectional view of a portion of a panel illustrating yet another alternate embodiment of an interconnecting structure between the opposing panel foils within one of the panel zones.

FIG. 11D is a cross-sectional view of a portion of a panel illustrating still another alternate embodiment of an interconnecting structure between the opposing panel foils within one of the panel zones.

FIG. 12A is a cross-sectional view of a portion of a panel illustrating another alternate embodiment of a distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 12B is a cross-sectional view of the embodiment illustrated in FIG. 12A, shown with the living hinge zone partially compressed during formation of the living hinge.

FIG. 12C is a cross-sectional view of the embodiments illustrated in FIGS. 12A and 12B, shown with the living hinge zone further compressed during formation of the living hinge.

FIG. 12D is a cross-sectional view of the embodiments illustrated in FIGS. 12A-12C, shown with the living hinge zone still further compressed during formation of the living hinge.

FIG. 13A is a cross-sectional view of a portion of a panel illustrating yet another alternate embodiment of a distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 13B is a cross-sectional view of the embodiment illustrated in FIG. 13A, shown with the living hinge zone partially compressed during formation of the living hinge.

FIG. 14A is a cross-sectional view of a portion of a panel illustrating still another alternate embodiment of a distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 14B is a cross-sectional view of the embodiment illustrated in FIG. 14A, shown with the living hinge zone partially compressed during formation of the living hinge.

FIG. 15A is a cross-sectional view of a portion of a panel illustrating a further alternate embodiment of a distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 15B is a cross-sectional view of the embodiment illustrated in FIG. 15A, shown with the living hinge zone partially compressed during formation of the living hinge.

FIG. 16A is a cross-sectional view of a portion of a panel illustrating yet a further alternate embodiment of a distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 16B is a cross-sectional view of the embodiment illustrated in FIG. 16A, shown with the living hinge zone partially compressed during formation of the living hinge.

FIG. 17 is a cross-sectional view of a portion of a panel illustrating an embodiment of a multi-tiered distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 18 is a cross-sectional view of a portion of a panel illustrating an alternate embodiment of a multi-tiered distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 19 is a cross-sectional view of a portion of a panel illustrating another alternate embodiment of a multi-tiered distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 20 is a cross-sectional view of a portion of a panel illustrating yet another alternate embodiment of a multi-tiered distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 21 is a cross-sectional view of a portion of a panel illustrating still another alternate embodiment of a multi-tiered distributed interconnecting structure between the opposing panel foils within one of the living hinge zones.

FIG. 22A is a simplified diagram of a side elevational view of an embodiment of a panel cut from a panel stock having end zones and living hinge zones sized and located along the panel to provide for the formation of hinged container sleeves of at least two different dimensions, and in which the illustrated panel has been sized and the living hinges have been formed in the living hinge zones to produce a hinged container sleeve having a first dimensional configuration.

FIG. 22B is a simplified diagram of a side elevational view of another panel cut from the same panel stock illustrated in FIG. 22A but in which the panel has been sized and the living hinges have been formed in the living hinge zones to produce a hinged container sleeve having a second dimensional configuration.

FIG. 23 is a simplified diagram of a side elevational view of an embodiment of a panel from which a panel product is to be cut and in which a number of zones having distributed interconnecting structures have been selectively formed to provide enhanced structural support in a corresponding number of selected areas of the panel product.

FIG. 24 is a cross-sectional view of a portion of a panel illustrating an alternate embodiment in which a secondary foil is formed on or affixed to either of the top and/or bottom foils of the opposed-foil panel.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to a number of illustrative embodiments shown in the attached drawings and specific language will be used to describe the same. For purposes of this disclosure, the term “living hinge” is defined as a thin flexible hinge or flexure bearing made by thinning an area, or adjacent areas, of a relatively rigid material so the material will bend along a line defined by the hinge.

Referring to the attached figures, an embodiment is shown in FIG. 1 of a panel stock 10 formed to include a number of zones with distributed interconnecting structures. In some embodiments, one or more such zones may be provided to accommodate formation of living hinges. Alternatively or additionally, such zones may be provided at and along one or more of the panel edges to facilitate joinder and bonding of two such panels along such edges. Alternatively or additionally still, one or more such zones may be selectively located along the panel stock 10 to provide enhanced structural integrity in and at one or more corresponding selected areas thereof.

Details of the panel stock 10 and of panels 12 cut or otherwise separated from the panel stock 10 shown in FIG. 1 are illustratively shown in FIGS. 5A-5B in the context of one example configuration of such panels 12 from which collapsible container sleeves 17 with multiple living hinges may be subsequently formed. The general structure and operation of one such subsequently formed collapsible container sleeve 17 is illustrated in FIGS. 2-4. In the embodiment illustrated in FIGS. 1-5B, the panel stock 10 is illustratively formed such that each panel 12 includes end areas or zones 16A, 16B at, adjacent to and along opposing sides 10A′, 10B′ thereof which are configured to facilitate subsequent joinder of two such panels along their edges together, e.g., to form a closed-sided container 17 as illustrated in FIGS. 2-4. The panel stock 10 is further illustratively formed such that each panel 12 includes multiple, spaced apart living hinge areas or zones 18A-18C configured to be subsequently processed, e.g., in a conventional manner, to form multiple corresponding living hinges along the panel 12. The end zones 16A, 16B and the living hinge areas or zones 18A-18C are separated by one of a plurality of different panel areas or zones 19A-19D as generally illustrated in FIGS. 1-4. A simplified example of a structure and process for forming a living hinge in one such area or zone 18A is illustrated in FIGS. 6-8. In alternate embodiments, living hinges in one or more of the multiple areas or zones 18A-18C may be formed as part of the formation of the panel stock 10, e.g., either prior to or following separation thereof into individual panels 12. FIGS. 9-10B illustrate various alternate embodiments of the end areas or zones 16A, 16B and/or of one or more of the multiple living hinge areas or zones 18A-18C. FIGS. 11A-11D illustrate various alternate embodiments of one or more of the panel areas or zones 19A-19D, and FIGS. 12-21 illustrate further various alternate embodiments of the end areas or zones 16A, 16B and/or one or more of the multiple living hinge areas or zones 18A-18C (and/or in either or both of the end zones 16A, 16B). FIGS. 22A and 22B illustrate one example embodiment of the panel stock 10 having end zones and living hinge zones sized and located along the panel to provide for the formation of hinged container sleeves of at least two different dimensions. FIG. 23 illustrates an example embodiment of a panel from which a panel product is to be cut and in which a number of zones having distributed interconnecting structures have been selectively formed to provide enhanced structural support in a corresponding number of selected areas of the panel product. FIG. 24 illustrates an example embodiment of a panel in which a secondary foil is formed on or affixed to either of the top and/or bottom foils of the panel.

In one embodiment, the panel stock 10 is of unitary construction and is illustratively provided in the form of a polymer structure fabricated in accordance with a conventional extrusion process. In some such embodiments, the polymer panel stock 10 is a thermoplastic polyolefin, examples of which may be or include, but are not limited to, polypropylene, polyethylene, polymethylpentene, and/or polybutene-1. In alternate embodiments, the panel stock 10 may be formed, in whole or in part, from one or more non-polymer materials, and/or may be formed using one or more processes other than, or in addition to, a conventional extrusion process, and it will be understood that any such alternate panel stock material(s) and/or formation process(es) is/are intended to fall within the scope of this disclosure.

Referring now to FIG. 1, a simplified diagram is shown of a side elevation view of one embodiment of the panel stock 10 formed to include a number of zones with distributed interconnecting structures. In the illustrated embodiment, the panel stock 10 is fabricated in the form of a continuous stock, e.g., using a conventional extrusion process, from which individual panels 12 of any desired height, H, may be subsequently cut, or otherwise separated, in a conventional manner. In some alternate embodiments, the panels 12 may be formed separately and individually, e.g., via a conventional extrusion process or other conventional process. In embodiments in which the panels 12 are initially provided in the form of a panel stock 10, as illustrated in FIG. 1, the panel stock 10 is illustratively extruded in the direction E, e.g., the so-called “machine direction,” to produce a continuous and substantially planar stock 10 having width W₁ which extends between two opposing sides 10A and 10B thereof. In some example embodiments, the width W₁ is in the range of approximately 2.2-2.6 meters, although other stock widths are contemplated by this disclosure. In any case, portions of the panel stock 10 along each side edge are trimmed, e.g., cut, from the stock 10 along the cut lines 14A, 14B such that the resulting finished panel width W₂ extends between two opposing sides 10A′, 10B′ that are both inboard of the opposing sides 10A, 10B. In one example embodiment, the finished panel width, W₂, is approximately 93 inches, although other finished panel widths are contemplated by this disclosure. The height, H, of each of the panels 12 cut or otherwise separated from the panel stock 10 extends along the machine direction E between a top edge 12A of the panel 12 and a bottom edge 12B of the panel between panel cut lines 15. It will be understood that while the panels 12 illustrated in FIG. 1 all have the same height, H, individual panels 12 cut or otherwise separated from the panel stock 10 may have differing heights. In any case, the transverse direction to the machine direction E is the direction in which the widths W₁ and W₂ extend between the sides 10A, 10B and 10A′, 10B′ respectively of the panel stock 10, and this transverse direction will be referred to herein as the “cross-machine direction” or “CMD,” and/or as the trans-machine direction or “TMD.”

In any case, the panel stock 10 illustrated in FIG. 1, and therefore also each panel 12 cut or otherwise separated therefrom, includes panel end areas or zones 16A, 16B at and adjacent to respective ones of the two opposing ends 10A′, 10B′ thereof, wherein each panel end zone 16A, 16B extends along the panel stock 10 in the machine direction E. The two opposing panel end areas or zones 16A, 16B are separated by a number of living hinge areas or zones spaced apart along the width, W₂, of the panel 12 in the cross-machine direction, and each living hinge area or zone extends along the panel stock 10 in the machine direction E. Each adjacent pair of living hinge areas or zones, and also each adjacent set of living hinge areas or zones and end zones 16A, 16B, is separated in the cross-machine direction by a different one of a number of panel zones. Each of the living hinge areas or zones and each of the panel zones extend along the panel stock 10 in the machine direction E.

The panel stock 10, and therefore each panel 12, may include any number of living hinge areas or zones positioned at any corresponding number of locations along the panel stock 10 (and panels 12) to establish corresponding hinge locations thereat. In the example embodiment shown in FIG. 1, the illustrated panel stock 10 includes three such living hinge areas 18A-18C, each defining a longitudinal axis therethrough which extends along the machine direction E, and four panel zones 19A-19D each of which also extend along the machine direction E. The panel zone 19A is defined between the end zone 16A and the living hinge zone 18A, the panel zone 19B is defined between the living hinge zones 18A and 18B, the panel zone 19C is defined between the living hinge zones 18B and 18C, and the panel zone 19D is defined between the living hinge zone 18C and the end zone 16B. In the illustrated example, the width W₂ of the is the sum of the distances A-D, where A is the distance between the edge 10A′ of the panel stock 10 and the center of the living hinge area 18A, B is the distance between the centers of the living hinge zones 18A, 18B, C is the distance between the centers of the living hinge zones 18B, 18C and D is the distance between the center of the living hinge zone 18C and the edge 10B′ of the panel stock 10. The

In some embodiments, the panel 12 is cut or otherwise separated from the panel stock 10 illustrated in FIG. 1 and the living hinge areas or zones 18A-18C are subsequently each further processed to form and establish a corresponding living hinge along the length thereof. In some alternate embodiments, the living hinges may be formed and established along the lengths of the living hinge areas or zones 18A-18C during, i.e., as part of, formation of the panel stock 10, e.g., prior to or after separation of the panel stock 10 into individual panels 12.

When the panel 12 is cut or otherwise separated from the panel stock 10 illustrated in FIG. 1 and the living hinges formed and established along each of the living hinge areas or zones 18A-18C, the opposing ends 10A′, 10B′ of two of the panels 12₁ and 12₂ may be joined together along their lengths in a conventional manner, e.g., via thermal bonding, adhesive bonding, one or more conventional fixation members or the like, to form a closed-sided container sleeve 17 as illustrated in the top plan view of FIG. 2. In the illustrated example, the living hinges 18B, 18C of each panel 12₁ and 12₂ form the corners of the closed-sided container sleeve 17, the living hinges 18A of the two panels 12₁, 12₂ form oppositely-oriented living hinges and the end zones 16A, 16B of the panel 12₁ are joined to and with the end zones 16B, 16A of the panel 12₂. When the closed-sided container sleeve 17 is used as, or as part of, a shipping or storage container, the living hinges 18A are generally unused, i.e., the panel zones 19B and 19D lie along a common plane as illustrated in FIG. 2. When not in use as, or as part of, a storage or shipping container, the living hinges 18A may be actuated, along with the living hinges 18B and 18C to collapse the closed-sided container sleeve 17 into a compact, generally linear form for storage thereof as illustrated by example in FIGS. 3 and 4. In some alternate embodiments, the panels 12₁, 12₂ may illustratively formed, e.g., extruded or otherwise formed, as a single panel including six living hinges, e.g., two sets of living hinges 18A-18C, and end zones 16A, 16B along opposing sides thereof. In such alternate embodiments, the closed-sided container sleeve 17 thus includes only a single joint formed by joining the end zones 16A, 16B along the opposite sides of the single panel.

A container sleeve 17 of the type and configuration illustrated in FIGS. 2-4 is sometimes referred to as a “pallet box” or “pallet box sleeve,” and may be used in conjunction with a conventional pallet or pallet assembly to store and/or transport one or more items. Alternatively, the container sleeve 17 may include an attachable or integral bottom and/or a removable or articulated top to form a complete storage and/or shipping container.

Referring now to FIGS. 5A and 5B, a side elevation, magnified and partial cutaway view and a cross-sectional view respectively are shown of one embodiment of the portion 5A of the panel 12 illustrated in FIG. 1. In the illustrated embodiment, the panel 12 includes a planar panel member 20A on one side thereof and a planar panel member 20B on an opposite side thereof. The phrases “planar panel member” and “panel member” used to describe the members 20A and 20B will be understood to be synonymous with the terms “foil,” “panel foil,” “liner” and “panel liner,” and either of the planar panel members 20A, 20B may be referred to herein as a “foil,” “panel foil,” “liner” or “panel liner,” and the planar panel members 20A, 20B may be collectively referred to herein as “foils,” “panel foils,” “liners” or “panel liners. Between the panel end area or zone 16A at/adjacent to the panel edge 10A′ and the living hinge area or zone 18A, a plurality of spaced apart support walls, ribs or flutes 22 extend and are connected between the foils 20A, 20B along the panel zone 19A in the cross-machine direction to form an interconnecting structure 31 within the panel zone 19A. In the illustrated embodiment, this same interconnecting structure 31 in the form of an arrangement of support walls 22 also extends between the panel foils 20A, 20B within each of the remaining panel zones 19B-19D. Illustratively, the panel foils 20A, 20B and the interconnecting support walls 22 are integral structures in a unitary embodiment of the panel 12, although in other embodiments the interconnecting support walls 22 may be attached at either or both ends thereof to the interior faces of the foils 20A, 20B. In any case, the exposed, exterior faces of the panel foils 20A, 20B each define the major exterior surfaces of the panel 12 between the width W₂ and the height H thereof (both defined above), and each panel foil 20A, 20B has a thickness 11 as illustrated in FIG. 5B. In the illustrated embodiment, the interconnecting support walls 22 are elongated, generally linear support walls, each extending in the panel zones 19A-19D of the panel 12 in and along the machine direction E (see FIG. 1).

The interconnecting support walls 22 each have a height J defined by the distance between the opposed, interior faces of the panel foils 20A, 20B, a length H defined by the height of the panel 12 and a thickness K1 as illustrated in FIG. 5A. Each support wall 22 is spaced apart from an adjacent support wall 22, or from a foil interconnecting structure in the panel end area or zone 16A or from a foil interconnecting structure in the living hinge area or zone 18A, by a space 24. Each space 24 has a height J, a length H, and a width L2 as illustrated in FIG. 5A.

The foregoing dimensions of the panel members 20A, 20B, the interconnecting support walls 22 and the spaces 24 between the interconnecting support walls 22 are typically selected based on a number of considerations such as the desired performance characteristics of the panel 12, the weight of the finished panel 12, the cost of producing the panel 12 (including material cost), and/or the like. In one specific example embodiment, the width W₂, of the panel 12 is approximately 93 inches, the widths of the areas A-D are approximately 5 inches, 22.5 inches, 48 inches and 17.5 inches respectively and the height H is approximately 45 inches, such that the resulting closed-sided container sleeve 17 illustrated in FIGS. 2-4 is approximately 48 inches (along the sides 19C) by approximately 45 inches (along the sides 19A, 19B, 19D) by approximately 45 inches (height H), and the thickness, K2, of each panel foil 20A, 20B is approximately 1.25 mm, the thickness, K1, of each interconnecting support member 22 is approximately 1 mm, the width, L1, of the space 24 is approximately 10 mm and the height, J, of the interconnecting support members 22 and the spaces 24 is approximately 7.5 mm. It will be understood, however, that such dimensions are provided only by way of example and should not be considered limiting in any way, and that other dimensions of the width W₂, the widths of the areas A-D, the height H, the thickness K1, the thickness K2, the width L1 and/or the height J are contemplated by this disclosure.

It is desirable to provide collapsible container sleeves 17 of the type illustrated in FIGS. 2-4 using panels 12 constructed using only the components just described, i.e., panel foils 20A, 20B interconnected via an interconnecting structure 31 in the form of a plurality of transverse support members 22 spaced apart along the total width W₂ of the panel 12. However, as described in connection with FIGS. 2-4, such collapsible containers 17 include a number of living hinges, and using panels 12 of the type just described would require orienting such living hinges parallel with the longitudinal axes of the interconnecting support members 22, i.e., in the machine direction E. In embodiments of the panel 12 in which the width, L2, of the spaces 24 between interconnecting support members 22 is relatively large as compared with the thickness, K1, of the interconnecting support members 22, such as in the specific example described above, forming such living hinges in parallel with the interconnecting support members 22 may result in weakness and/or failure in one or more such living hinges as a result of insufficient material in and along the length of the relatively large spaces 24 for supporting the structure and operation thereof. Moreover, the lack of sufficient material in and along the length of the relatively large spaces 24 may likewise result in weak or insufficient joining of the two panel ends 10A′, 10B′ when implemented as container sleeves 17 or other implementations that include joinder of two or more panels 12 along their edges 10A′ and/or 10B′. Further still, the lack of sufficient material in and along the length of the relatively large spaces 24 may result in weak or insufficient deformation resistance to compression forces applied to the outer surfaces of the foils 20A, 20B. In the embodiment of the panel 12 illustrated in FIGS. 5A-5B, the panel end zones 16A, 16B and each of the zones 18A-18C are modified for one or more such implementations thereof, e.g., during formation of the panel stock 10, to distribute the same amount of material in the interconnecting support members 22 more evenly or uniformly, i.e., with greater mass density and surface area density, across the widths of these areas or zones, i.e., in the cross-machine direction of the panel 12, than occurs in the panel zones 19A-19D, to thereby provide sufficient material in an along the zones 16A, 16B to facilitate joinder of two panels 12 along their edges 10A′, 10B′, and sufficient material in and along the zones 18A-18C to support the structure and operation of living hinges to be subsequently formed in these areas or zones, and/or to enhance deformation resistance to compression forces applied to the outer surface of the foil 20A and/or the foil 20B in the area(s) or zone(s) 16A, 16B, 18A, 18B and/or 18C.

In the embodiment illustrated in FIGS. 5A-5B, the living hinge area or zone 18A is shown having a width G which extends in the cross-machine direction of the panel 12. The volume, V_18A, of the living hinge area or zone 18A is thus V_18A=H× G×J, where G is the width of the living hinge area or zone 18A (extending in the cross-machine direction of the panel 12), H is the height of the panel 12, which is also the length of the living hinge area or zone 18A, and J is the distance between the opposed interior surfaces of the panel members 20A, 20B. Within this volume V_18A, a distributed interconnecting structure 30, made up of a plurality of interconnecting support members 32 spaced apart and interconnected with each other via upper and lower support members 36A, 36B respectively, is illustratively formed between and connected to the opposed interior surfaces of the panel members 20A, 20B along the length H and width G thereof.

The interconnecting support members 32 illustrated in FIGS. 5A and 5B are each illustratively provided in the form of linear ribs or flutes having a length or height J, which is the distance between the opposed interior surfaces of the panel members 20A, 20B, and a thickness K2 as illustrated in FIG. 5A. Adjacent interconnecting support members 32, e.g., also in the form of linear ribs or flutes, are spaced apart by spaces 34 each having a length or height J and a width L2. Illustratively, L2 is less than L1, and K2 is less than K1. Adjacent interconnecting support members 32 are interconnected with each other via laterally extending (i.e., transversely relative to the width G of the living hinge area or zone 18A and in a direction parallel to the cross-machine direction of the panel 12, upper support members 36A and laterally extending lower support members 36B. Each of the upper support members 36A has a thickness N1, a length L2 and is spaced apart from the interior surface of the panel member 20A by a distance M1. Each of the lower support members 36B has a thickness N2, a length L2 and is spaced apart from the interior surface of the panel member 20B by a distance M3, and the upper and lower support members 36A, 36B are spaced apart from each other by a distance M2. In the illustrated embodiment, N1=N2 and M1=M2=M3, although in some alternate embodiments N1 may be different from N2 and/or any of M1, M2 and M3 may be different one or both of the remaining values of M1, M2 and M3. In other alternate embodiments, either or both of the sets of lateral support members 36A and 36B may be positioned linearly, non-linearly or piecewise-linearly anywhere along the lengths of the interconnecting support members 32. In still other alternate embodiments, the distributed interconnecting structure 30 may include only a single set of lateral support members 36A or 36B connecting together adjacent ones of the interconnecting support members 32, wherein such a single set of lateral support members 36A or 36B may be positioned linearly, non-linearly or piecewise-linearly anywhere along the lengths of the interconnecting support members 32. In the illustrated embodiment, the interconnecting support members 32, the upper support members 36A and the lower support members 36B are all shown as being generally linear rib or flute-type structures, although it will be understood that in alternate embodiments one or more of the support members 32, one or more of the upper support members 36A and/or one or more of the lower support members 36B may be non-linear or piecewise linear.

In embodiments in which panels 12 are extruded, either individually or in the form of a continuous panel stock 10 from which individual panels 12 are separated as illustrated in FIG. 1, and/or in embodiments in which panels 12 are fabricated using any process or technique in which a flowable material is used to form the panels 12 and is thereafter cooled or cured to produced finished panels 12, it is desirable to have such panels 12 and/or panel stock 10 cool or cure to create relatively uniform surfaces along their lengths and also across their widths (W₁/W₂) so as to minimize, or at least reduce the likelihood of, warpage, bubbling and/or other non-uniformities in, on and/or along the panels 12. In this regard, it is desirable in some such embodiments to promote uniform cooling or curing of the panels 12 and/or panel stock 10 across the lengths and widths thereof by forming the distributed interconnecting structure 30 in the volume, V_18A, of the living hinge area or zone 18A with the same, or substantially the same, amount of material along the length H of the zone 18A and across the width G of the zone 18A as used to form the portion of the interconnecting structure 31 along the lengths and across the widths in and of adjacent, contiguous panel zones 19A-19D having the same volume as V_18A. This is illustrated graphically in FIG. 5B in which F identifies the width of an area of the panel 12 which contains a portion of the interconnecting structure 31 made up of a number of interconnecting support walls 22 separated by spaces 24, and which is adjacent, contiguous to, and also equal to the width G of, the living hinge area or zone 18A in which the distributed interconnecting structure 30 is formed.

Thus, in order to promote uniform cooling or curing of the panels 12 and/or panel stock 10 across the lengths and widths thereof, the total amount, i.e., the total mass, of material A_M1 used to form the distributed interconnecting structure 30 within the volume V_18A, i.e., the amount of material used to form the distributed interconnecting structure 30 along the length H and across the width G of the volume V_18A, should be the same, or substantially the same, as the total amount, i.e., the total mass, of material A_M2 used to form the portion of the interconnecting structure 31 contained within the adjacent and contiguous volume V_FJH, i.e., the amount of material used to form the number of interconnecting support walls 22 along the length H and across the width F of the volume V_FJH, wherein V_FJH=F×J×H. In the example illustrated in FIGS. 5A-5B, the amount of material A_M2 can be computed using the known dimensions of the 6 interconnecting support members 22 contained within the volume V_FJH. If, as illustrated in FIG. 5B, N1=N2, the amount of material A_M1 is given by A_M1=[10× (amount of material used to form each of the interconnecting support members 32)]+[18× (amount of material used to form each of the lateral support members 36A, B)]=[10× (K2×J×H)]+[18×(L2×N1×H)]U³, where U corresponds to the units of measure (e.g., mm, cm, inches, etc.). Assuming N1=K2 and G≈10×L2+10×K2, the foregoing equations can be solved for values of K2 and L2.

Whereas the amount of material A_M1 is to be distributed with greater density across the width G of the volume V_18A than the amount of material A_M2 is distributed across the width F of the volume V_FJH in order to provide sufficient material in and along the lengths of the area or zone 18A, e.g., for supporting the structure and operation of a living hinge formed in this area or zone, it is further desirable to use the same amount of material A_M1 in the volume V_18A as the material A_M2 used in the volume V_FJH, and to distribute of this amount of material A_M1 along the length H of the volume V_18A substantially as the amount of material A_M2 is distributed along the length H of the volume V_FJH to thereby promote uniform cooling or curing of the panels 12 and/or panel stock 10 along the height H of the panels 12 (i.e., along the machine direction E). In the example illustrated in FIGS. 5A and 5B, this is illustratively accomplished by extending the distributed interconnecting structure 30 in the volume V_18A continuously along the machine direction of the panel stock 10 (i.e., to completely traverse the height H of each panel 12) as are the interconnecting support walls 22 of the interconnecting structure 31 in the Volume V_FJH.

As just described above, the distributed interconnecting structure 30 is illustratively designed relative to the volume V_18A of the panel stock 10 and panels 12 within which it is formed such that the material making up the distributed interconnecting structure 30 is illustratively distributed across the width G of the volume V_18A with greater density than is the material making up the portion of the interconnecting structure 31 defined by the number of interconnecting walls 22 spanning the width of an adjacent, contiguous and equal volume V_FJH of the panel 12. This is illustratively the case not only with respect to the volume V_FJH of the panel 12 to the left of the volume V_18A but also with respect to an identical adjacent, contiguous and equal volume V_FJH of the panel 12 to the right of the volume V_FJH. As used herein, the term “density” is defined as a degree of consistency measured by the quantity of mass and/or surface area per unit volume. In the example illustrated in FIGS. 5A and 5B, the distributed interconnecting structure 30 is distributed across the width G of the volume V_18A with greater density than is the material making up the portion of the interconnecting structure 31 within the width of an adjacent, contiguous and equal volume V_FJH of the panel 12 by using a greater number of thinner but more closely spaced interconnecting support members 32 as compared to the lesser number of more thick and spaced-apart interconnecting support members 22, and by also laterally interconnecting the support members 32 with lateral support members 36A, 36B. The result is that the amount, i.e., mass, of material used to form the distributed interconnecting structure 30 is substantially equal to the amount of material used to form the portions of the interconnecting structure 31 within the adjacent, contiguous and equal volumes V_FJH of the panel 12 on either side of the volume V_18A, but the material used to form the distributed interconnecting structure 30 is distributed across the width G of the volume V_18A with greater density, i.e., with greater mass and/or surface area per unit volume, than that of the portion of the interconnecting structure 31 within the adjacent, contiguous and equal volumes V_FJH of the panel 12 on either side of the volume V_18A. In any case, such distribution of material across the width G of the volume V_18A provides sufficient material in and along the lengths of the area or zone 18A for supporting the structure and operation of a living hinge formed in this area or zone and/or for enhancing deformation resistance to compressive forces applied to the foil 20A and/or to the foil 20B at or near this area or zone. The former is illustrated by example in FIGS. 6-8 in which a conventional living hinge formation die or press 40 is used to form a living hinge 38 in and at the living hinge area or zone 18A.

In the example living hinge formation process of FIGS. 6-8, the panel 12 is illustratively at an elevated temperature, at least locally at or in the area of the living hinge area or zone 18A, at which the material making up the panel 12 can flow or otherwise be permanently altered in shape via the die or press 40. In some embodiments in which the panel 12 is fabricated using an extrusion or other thermal process, the living hinge 38 may be formed as a part of the process of providing the panel stock 10, e.g., during or just after formation of the stock 10 while the temperature of the stock 10 is still sufficiently elevated. Alternatively, the living hinge 38 may be formed after the panels 12 are formed, in which case the panels 12 will typically be reheated using conventional techniques to a suitable temperature or temperature range at which the living hinge 38 may be formed using the die or press 40.

In the simplified diagram illustrated in FIG. 6, the living hinge formation die or press 40 illustratively includes a top plate 42 positioned above the panel member 20A, and a bottom plate 44 positioned below the panel member 20B. The underside of the top plate illustratively defines a substantially planar surface 50. The bottom plate 44 illustratively has a pair of truncated protrusions 46A, 46B extending upwardly from upwardly facing planar surfaces 52A and 52B respectively, wherein the two truncated protrusions define a truncated valley region 48 therebetween. As illustrated in FIG. 7, the top plate 40 and the bottom plate 42 are pressed toward and into contact with the panel 12 with the living hinge area or zone 18A positioned therebetween, and as the plates 40, 42 are advanced toward each other the contours of the protrusions 46A, 46B, valley 48 and planar surfaces 52A, 52B of the bottom plate 44 permanently deform the heated panel members 20A, 20B and distributed interconnecting structure 30 to produce a resulting living hinge 38 having angled outer hinge edges 60, 72, angled inner hinge edges 64, 68, substantially planar hinge edges 62, 70 at the truncated valleys between the angled edges 60, 64 and 68, 72 respectively and a substantially planar hinge edge 66 at the truncated peak between the angled edges 64 and 68. In one embodiment, the angles of the angled edges are multiples of 45 degrees such that the resulting living hinge 38 is foldable about the truncated peak 66 with the panel member 20B one side of the living hinge 38 facing the panel member 20B on the other side of the living hinge 38 as illustrated in FIG. 8.

It will be appreciated, as evident from FIGS. 6 and 7, that inclusion of the distributed interconnecting structure 30 within the living hinge area 18A provides some amount of lateral alignment tolerance of the die or press 40 relative to the location of the living hinge 38 while still providing for a solid and stable living hinge 38. For example, the die or press 40 could move to the right up to a distance that places the right edge of the planar peak 70 under the first interconnecting member 22 to the right of the distributed interconnecting structure 30, or to the left up to a distance that places the left edge of the planar peak 62 under the first interconnecting member 22 to the left of the distributed interconnecting structure 30 (e.g., see FIG. 6) without creating a material change in the performance of the resulting living hinge 38.

It will be understood that the description of the distributed interconnecting structure 30 with respect to FIGS. 5A and 5B was limited to the living hinge area or zone 18A only by way of example, and that the distributed interconnecting structure 30 is illustratively formed within the volume of each living hinge area or zone of the panel 12. In the embodiment illustrated in FIGS. 1-4, for example, the distributed interconnecting structure 30 is formed within each of the remaining living hinge areas or zones 18B, 18C, and that the living hinge formation process illustrated in FIGS. 6-8, or similar such process, is carried with respect to each such living hinge area or zone 18B, 18C to form living hinges 38 of the type illustrated in FIGS. 7 and 8 along each such living hinge area or zone 18B, 18C. It will be further understood that while the living hinge 38 of FIGS. 7 and 8 is illustrated and described as forming a so-called double score living hinge, e.g., one in which a substantially planar lower hinge edge 66 is formed between two substantially planer upper hinge edges 62, 70, the living hinge 38 may alternatively be formed using other conventional living hinge designs. Examples of such other conventional living hinge designs include, but are not limited to, a bi-stable hinge, a triple score hinge, e.g., one which includes three substantially planar upper hinge edges and two substantially planar lower hinge edges each positioned between a center one of the upper hinge edges and a different outer one of the upper hinge edges, or the like.

Referring again to FIGS. 5A-5B, in embodiments of the panel 12 in which the width, L1, of the spaces 24 between interconnecting support members 22 is relatively large as compared with the thickness, K1, of the interconnecting support members 22, as described above, joining panel ends 10A′ and 10B′ may result in weakness and/or failure of such a joint as a result of insufficient material in and along the lengths of the relatively large spaces 24 as also described above. In the embodiment of the panel 12 illustrated in FIGS. 5A-5B, the panel end areas or zones 16A, 16B are therefore modified, e.g., during formation of the panel stock 10, similarly as described with respect to the living hinge area or zone 18A, to form in each panel end area or zone 16A, 16B a distributed interconnecting structure 35 similar to the distributed interconnecting structure 30 formed in the living hinge area or zone 18A. As shown in FIG. 5B, the distributed interconnecting structure 35 is illustratively designed and positioned such that the panel end or edge 10A′ is defined at or through one of the interconnecting support members 32. Locating the panel end or edge 10A′ at or adjacent to such an interconnecting support member 32 illustratively provides a structure to and with which a suitable bond may be formed when joining panel edges 10A′, 10B′. Even if the panel end or edge 10A′ deviates from the interconnecting support member 32 illustrated in FIG. 5B, this will expose free ends of the lateral support members 36A, 36B which will provide additional structure along the panel edges 10A′, 10B′ with which to secure a suitable bond therebetween.

In embodiments in which it is desirable to have the panels 12 and/or panel stock 10 cool or cure to create relatively uniform surfaces along their lengths and widths, the amount of material used to form the distributed support structure 35 within the volume of the panel defined by the panel end area or zone 16 is illustratively selected to be the same, or approximately the same, as the amount of material used to form the number of interconnecting support members 22 within adjacent and contiguous volumes of the panel 12 on either side of the panel end area or zone 16 as described above with respect to the distributed interconnecting structure 30 formed within the volume V_18A.

Referring now to FIG. 9, a cross-sectional view similar to FIG. 5B is shown illustrating an alternate embodiment 30′ of the distributed interconnecting structure formed in the living hinge area or zone 18A of a panel 12′. In the illustrated embodiment, the distributed interconnecting structure 30′ is illustratively provided in the form of a number of closely spaced interconnecting support members 82 each extending between and connected to the interior surfaces of the panel members 20A and 20B. In embodiments in which it is desirable to have the panels 12′ and/or panel stock 10 cool or cure to create relative uniform surfaces, the amount of material used to form the distributed support structure 30 within the volume V_18A of the panel is, as described above with respect to FIGS. 5A and 5B, illustratively selected to be the same, or approximately the same, as the amount of material used to form the portion of the interconnecting structure 31 within adjacent and contiguous volumes of the panel 12′ on either side of the volume V_18A.

FIG. 9 also illustrates an alternate embodiment 35′ of the distributed interconnecting structure formed in the panel end area or zone 16A of the panel 12′. In the illustrated embodiment, the distributed interconnecting structure 35′ is illustratively provided in the form of a plurality of spaced-apart lateral support members 80 each connected to and between two interconnecting support members 22 located at the boundaries of the panel end area or zone 16A. In embodiments in which it is desirable to have the panels 12′ and/or panel stock 10 cool or cure to create relatively uniform surfaces, the amount of material used to form the distributed support structure 35′ within the volume of the panel defined by the panel end area or zone 16A is illustratively selected to be the same, or approximately the same, as the amount of material used to form the portion of the interconnecting structure 31 within adjacent and contiguous volumes of the panel 12′ on either side of the panel end area or zone 16A.

Referring now to FIGS. 10A and 10B, top plan and cross-sectional views similar to FIGS. 5A and 5B respectively are shown illustrating another alternate embodiment 30″ of the distributed interconnecting structure formed in the living hinge area or zone 18A of another panel 12″. In the illustrated embodiment, the distributed interconnecting structure 30″ is illustratively provided in the form of a number of spaced-apart interconnecting support members 96 each extending laterally across the living hinge area or zone 18A along the width H of the panel 12″ and each connected to and between the foils 20A, 20B as well as to and between two interconnecting support members 22 located at the boundaries of the living hinge area or zone 18A. In some embodiments, the two interconnecting support members 22 located at the boundaries of the living hinge area or zone 18A are respective parts of adjacent panel zones 19A, 19B as shown in the illustrated embodiment. In some alternate embodiments, either or both of the two interconnecting support members 22 may be part of the living hinge zone 18A, and in other alternate embodiments the number of spaced-apart interconnecting support members 96 may each be connected to and between other support members connected within the living hinge area or zone 18A between either or both of the opposing surfaces of the foils 20A, 20B. In any case, in embodiments in which it is desirable to have the panels 12″ and/or panel stock 10 cool or cure to create relatively uniform surfaces, the amount of material used to form the distributed support structure 30″ within the volume V18A of the panel is, as described above with respect to FIGS. 5A and 5B, illustratively selected to be the same, or approximately the same, as the amount of material used to form the portion of the interconnecting structure 31 within adjacent and contiguous volumes of the panel 12″ on either side of the volume V18A.

FIGS. 10A and 10B also illustrate another alternate embodiment 35″ of the distributed interconnecting structure formed in the panel end area or zone 16A of the panel 12″. In the illustrated embodiment, the distributed interconnecting structure 35″ is illustratively provided in the form of a plurality of spaced-apart lateral support members, e.g., 90, 92, 94, each connected to and between two interconnecting support members 22 located at the boundaries of the panel end area or zone 16A. In some embodiments, the one of the two interconnecting support members 22 located at the boundary of the panel end area or zone 16A and the panel zone 19A is part of adjacent panel zones 19A as shown in the illustrated embodiment. In some alternate embodiments, this interconnecting support member 22 may instead be part of the panel end area or zone 16A, and in other alternate embodiments the plurality of spaced-apart lateral support members, e.g., 90, 92, 94, may each be connected to and between other support members connected within the panel end area or zone 16A between either or both of the opposing surfaces of the foils 20A, 20B. In the embodiment illustrated in FIGS. 10A and 10B, the thickness of the lateral support members increases such that the thickness of the lateral support member 92 is greater than that of the lateral support member 90, the thickness of the lateral support member 94 is greater than that of the lateral support member 92, and so forth. In some alternate embodiments, the thickness of the lateral support members may decrease in the same direction just described. In any case, in embodiments in which it is desirable to have the panels 12″ and/or panel stock 10 cool or cure to create relatively uniform surfaces, the amount of material used to form the distributed support structure 35″ within the volume of the panel defined by the panel end area or zone 16 is illustratively selected to be the same, or approximately the same, as the amount of material used to form the portion of the interconnecting structure 31 within adjacent and contiguous volumes of the panel 12″ on either side of the panel end area or zone 16.

The interconnecting structure 31 has been illustrated and described hereinabove in the form of a plurality of elongated, spaced-apart members 22 affixed to and extending substantially perpendicularly between the opposed interior surfaces of the panel foils 20A, 20B. It will be understood that such members 22 represent only one non-limiting example embodiment of the interconnecting structure 31, and that this disclosure contemplates myriad other forms of the interconnecting structure 31 that may be formed within any one or more of the panel zones 19A-19G. As one example, FIG. 11A shows a first alternative embodiment of an interconnecting structure 31′ in which additional elongated members 100, 102 extend diagonally between the opposed interior surfaces of the planar panel members 20A, 20B in the spaces between the elongated members 22. In the illustrated embodiment, each elongated member 100 extends in one direction from an area of the interior surface of the planar panel member 20A adjacent to one of the elongated members 22 downwardly to an area of the interior surface of the planar panel member 20B adjacent to the elongated member 22 located to the right of the first elongated member 22, and each elongated member 102 extends in an opposite direction from an area of the interior surface of the planar panel member 20A adjacent to the one of the elongated members 22 downwardly to an area of the interior surface of the planar panel member 20B adjacent to the elongated member 22 located to the left of the first elongated member 22. In some embodiments, the elongated, diagonal members 100 and/or the elongated, diagonal members 102 contact the corresponding elongated members 22 at each end thereof, while in other embodiments the interface between the panel foil 20A and the elongated members 100 and/or 102 may be spaced apart from the elongated members 22 and/or the interface between the panel foil 20B and the elongated members 100 and/or 102 may be spaced apart from the elongated members 22. In still other embodiments, the diagonally extending members 100, 102 may all extend in the same direction.

In another example, FIG. 11B shows a second alternative embodiment of an interconnecting structure 31″ in which additional X-shaped members 110 extend between the opposed interior surfaces of the panel foils 20A, 20B in the spaces between the elongated members 22. In some embodiments, the X-shaped members 110 contact the corresponding elongated members 22 at each end thereof, while in other embodiments the interfaces between the panel foil 20A and the X-shaped members 110 may be spaced apart from either of both of the corresponding elongated members 22 and/or the interfaces between the panel foil 20B and the X-shaped members 110 may be spaced apart from either or both of the corresponding the elongated members 22.

In yet another example, FIG. 11C shows a third alternative embodiment of an interconnecting structure 31′″ in which additional opposing U-shaped members extend between the opposed interior surfaces of the panel foils 20A, 20B in the spaces between the elongated members 22. In the illustrated example, each U-shaped member includes a first U-shaped structure 120 having a pair of legs each extending downwardly from the interior surface of the panel foil 20A adjacent to a corresponding one of the elongated members 22 to a closed “U,” and a second U-shaped structure 122 having a pair of legs each extending upwardly from the interior surface of the panel foil 20B adjacent to a corresponding one of the elongated members 22 to another closed “U,” wherein the closed “U” portions of each opposing U-shaped structures 120, 122 are connected. In some embodiments, the legs of the U-shaped members 120 and/or 122 contact the corresponding elongated members 22 at each end thereof, while in other embodiments the interfaces between the panel foil 20A and either or both of the legs of the U-shaped members 120 may be spaced apart from either of both of the corresponding elongated members 22 and/or the interfaces between the panel foil 20B and either or both of the legs of the U-shaped members 122 may be spaced apart from either or both of the corresponding the elongated members 22. In some embodiments, the U-shaped members 120 may be separate from the U-shaped members 122, and in other embodiments each set of U-shaped members 120, 122 may be a unitary structure.

In still another example, FIG. 11D shows a fourth alternative embodiment of an interconnecting structure 31^IV in which additional hollow cylinders 130 extend between the opposed interior surfaces of the panel foils 20A, 20B in the spaces between the elongated members 22. In some embodiments, as illustrated in FIG. 11D, the hollow cylinders 130 do not contact either of the corresponding elongated members 22, while in other embodiments the hollow cylinders 130 may contact and/or connect to either or both of the elongated members 22.

It will be understood that the various interconnecting structures 31′-31^IV illustrated FIGS. 11A-11D are provided only by way of example, and should not be considered to be limiting in any way. It will further be understood that other linear, piece-wise linear, non-linear or a combination of linear/piece-wise linear and non-linear structures may be interconnected between the opposed interior surfaces of the panel foils 20A, 20B in the spaces between two or more of the elongated members 22 in any one or more of the panel zones 19A-19G, and any such structures are contemplated by this disclosure. Examples of such other structures include, but are not limited to, D-shaped structures, arcuate-shaped structures, oval structures, polygonal structures, K-shaped structures, and the like. In any such embodiments, and/or in any of the embodiments illustrated in FIGS. 11A-11D, one or more, or all, of the elongated structures 22 may be omitted.

The various distributed interconnecting structures 30, 30′, 30″ and 35, 35′, 35″ within the living hinge zones 18A-18D and end zones 16A, 16B respectively have been illustrated and described hereinabove in the form of various ones and/or combinations of generally linear, elongated support members, e.g., 32, 36A, 36B, 80, 82, 90, 92, 94, 96. However, at least within the living hinge zones 18A-18C, the panel foils 20A, 20B are compressed toward each other during the living hinge formation process, e.g., as illustrated by example in FIGS. 6-8, and during such compression perpendicularly extending support members, e.g., 32, 82, may collapse (or “fail”) in one direction or the other (i.e., to the left or to the right) or a combination thereof (e.g., like an accordion) as the panel foils 20A, 20B move toward each other. The latter phenomenon is illustrated somewhat in FIGS. 7 and 8. It is desirable, in some embodiments, to control the direction of such collapse of support members extending between the interior surfaces of the planar panel members 20A, 20B such that some or all of the support members within one or more of the living hinge zones 18A-18C collapse in at least one common direction, e.g., either to the left or to the right, or some to the left and others to the right, as the panel foils 20A, 20B are compressed toward each other during formation of one or more living hinges. Such control should, for example, ensure, or at least facilitate, more uniform distribution of the distributed interconnecting structure 30 across the widths and/or lengths of the living hinge zones during formation of the living hinges.

Referring to FIGS. 12A-12D, one embodiment of such an alternative distributed interconnecting structure 30′″ is shown in which the structure 30′″ is provided in the form of a plurality of curved, i.e., arcuate-shaped, spaced-apart, elongated members 140 each extending and connected between the opposed interior surfaces of the panel foils 20A, 20B within, for example, the living hinge zone 18A. Each elongated member 140 is illustratively curved in the same direction, e.g., to the right in FIGS. 12A-12D, although in other embodiments one or more, or all, of the elongated members 140 may alternatively be curved in the opposite direction, e.g., to the left in FIGS. 12A-12D. In the illustrated embodiment, each elongated member 140 has a uniform radius of curvature, although in other embodiments such curvature may not be uniform along the length of one or more of the elongated members 140.

In any case, FIG. 12A shows the distributed interconnecting structure 30′″ prior to any compression of the panel foils 20A, 20B within the living hinge zone 18A. FIGS. 12B-12D illustrate the controlled collapse of the various curved, elongated members 140 of the distributed interconnecting structure 30′″ as the panel foils 20A, 20B are compressed toward each other in the directions of the compression arrows CP. As shown in FIGS. 12B-12D, each of the curved, elongated structures 140 collapses in the same direction 142, e.g., to the right, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process, and such controlled collapse necessarily results from the pre-curved shape of the elongated members 140.

In some embodiments, it is desirable to minimize, or at least reduce, the number and/or size of voids formed between adjacent elongated members as they collapse during the living hinge formation process. In such embodiments in which the distributed interconnecting structure 30′″ is provided in the form of a plurality of arcuate-shaped elongated members 140 as illustrated in FIGS. 12A-12D, it may accordingly be desirable to select the lengths, radius of curvature, thickness and/or spacing between, the elongated members 140 such that a portion of each elongated member 140, e.g., at least the central portion, contacts an elongated member 140 to the right thereof during the controlled collapse of the various curved, elongated members 140, thus minimizing, or at least reducing, the number and/or size of voids formed between adjacent elongated members 140 during the living hinge formation process.

Referring now to FIGS. 13A and 13B, another embodiment of an alternative distributed interconnecting structure 30^IV is shown in which the structure 30^IV is provided in the form of a plurality of opposing, curved, spaced-apart, elongated members 150 and 154 each extending and connected between the opposed interior surfaces of the panel foils 20A, 20B within, for example, the living hinge zone 18A. Each elongated member 150 is illustratively curved in the same direction, e.g., to the right in FIGS. 13A and 13B, and each elongated member 154 is likewise curved in the same but opposite direction, e.g., to the left in FIGS. 13A and 13B. In the illustrated embodiment, each elongated member 150, 154 has a uniform radius of curvature, although in other embodiments such curvature may not be uniform along the length of one or more of the elongated members 150 and/or 154. In any case, FIG. 13A shows the distributed interconnecting structure 30^IV prior to any compression of the panel foils 20A, 20B within the living hinge zone 18A, and FIG. 13B shows that each of the curved, elongated structures 150 collapses in the same direction 152, e.g., to the right, and each of the curved, elongated structures 154 collapses in the same but opposite direction 156, e.g., to the left, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process. Such controlled collapse necessarily results from the pre-curved shape of the elongated members 150 and 154.

Referring now to FIGS. 14A and 14B, yet another embodiment of an alternative distributed interconnecting structure 30^V is shown in which the structure 30^V is provided in the form of a plurality of elongated, linear, diagonal, spaced-apart, elongated members 160 each extending and connected between the opposed interior surfaces of the panel foils 20A, 20B within, for example, the living hinge zone 18A. Each elongated member 160 is illustratively diagonally disposed in the same direction, e.g., to the left in FIGS. 14A and 14B. FIG. 14A shows the distributed interconnecting structure 30^V prior to any compression of the panel foils 20A, 20B within the living hinge zone 18A, and FIG. 14B shows that each of the elongated, linear, diagonal, spaced-apart structures 160 collapses in the same direction 162, e.g., to the left, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process. Such controlled collapse necessarily results from the diagonal shape of the elongated members 160.

Referring now to FIGS. 15A and 15B, still another embodiment of an alternative distributed interconnecting structure 30^VI is shown in which the structure 30^VI is provided in the form of a plurality of cylindrical, spaced-apart, elongated members 170 each extending and connected between the opposed interior surfaces of the panel foils 20A, 20B within, for example, the living hinge zone 18A. Each elongated member 170 illustratively has the same radius, although in alternate embodiments one or more of the members 170 may have a different radius than one or more others of the members 170. FIG. 15A shows the distributed interconnecting structure 30^VI prior to any compression of the panel foils 20A, 20B within the living hinge zone 18A, and FIG. 15B shows that each of the cylindrical, elongated structures 160 collapses in each lateral direction 172 and 174, e.g., to the right and to the left respectively, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process. Such controlled collapse necessarily results from the circular shape of the elongated members 170.

Referring now to FIGS. 16A and 16B, another embodiment of an alternative distributed interconnecting structure 30^VII is shown in which the structure 30^VII is provided in the form of a curved, elongated member 180 and a plurality of linear, spaced-apart, elongated members 182 each extending and connected between the opposed interior surfaces of the panel foils 20A, 20B within, for example, the living hinge zone 18A. Each linear, elongated member 182 is connected to adjacent linear, elongated members 182 via a laterally extending member 186 connected therebetween, and the linear, elongated member 182 adjacent to the curve, elongated member 180 is connected thereto by a lateral member 186 extending therebetween. FIG. 16A shows the distributed interconnecting structure 30^VII prior to any compression of the panel foils 20A, 20B within the living hinge zone 18A, and FIG. 16B shows that as the curved, elongated structure 180 collapses in the direction 188, e.g., to the right, by virtue of its curvature, each of the linear, spaced-apart, elongated members 182 is pulled from its center in the direction 188 by the lateral members 184, 186 as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process. Such controlled collapse necessarily results from the pre-curved shape of the elongated member 180.

Referring now to FIG. 17, a further embodiment of an alternative distributed interconnecting structure 30^VIII is shown in which the structure 30^VIII is provided in the form of a two-tiered structure having a laterally extending elongated member 200, e.g., an intermediate foil, which illustratively bisects the space J, and further having a plurality of curved, elongated members 202 each extending and connected between the opposed interior surface of the panel foil 20A and the laterally extending elongated member 200 and another plurality of curved, elongated members 202 each extending and connected between the opposed interior surface of the panel foil 20B and the laterally extending elongated member 200. In the embodiment illustrated in FIG. 17, the curved, elongated members 202 are all curved, and therefore predisposed, to collapse in the same direction 204, e.g., to the right, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process.

In still a further embodiment illustrated in FIG. 18, another alternative distributed interconnecting structure 30^Ix is shown which is similar to the structure 30^VIII illustrated in FIG. 17 but in which the plurality of curved, elongated members 202 extending and connected between the opposed interior surface of the panel foil 20B and the laterally extending elongated member 200 is replaced with a plurality of curved, elongated members 206 curved in an opposite direction. Thus, the curved, elongated members 202 are predisposed to collapse in the direction 204, e.g., to the right, and the curved, elongated members 206 are predisposed to collapse in the opposite direction 208, e.g., to the left, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process.

In yet a further embodiment illustrated in FIG. 19, yet another alternative distributed interconnecting structure 30^X is shown which is similar to the structure 30^IX illustrated in FIG. 18 but in which the plurality of curved, elongated members 202 extending and connected between the opposed interior surface of the panel foil 20A and the laterally extending elongated member 200 is replaced with a plurality of linear, diagonally-disposed, elongated members 210 and the plurality of curved, elongated members 206 extending and connected between the opposed interior surface of the panel foil 20B and the laterally extending elongated member 200 is replaced with another plurality of linear, diagonally-disposed, elongated members 212. The linear, diagonally-disposed, elongated members 210 are predisposed to collapse in the direction 208, e.g., to the left, and the linear, diagonally-disposed, elongated members 212 are predisposed to collapse in the opposite direction 204, e.g., to the right, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process.

In still a further embodiment illustrated in FIG. 20, yet another alternative distributed interconnecting structure 30^XI is shown which is similar to the structure 30^VIII illustrated in FIG. 17 but in which the plurality of curved, elongated members 202 extending and connected between the opposed interior surface of the panel foil 20A and the laterally extending elongated member 200 is replaced with a plurality of cylindrical, elongated members 214, and the plurality of curved, elongated members 202 extending and connected between the opposed interior surface of the panel foil 20B and the laterally extending elongated member 200 is replaced with a another plurality of cylindrical, elongated members 214. Each of the cylindrical, elongated members 214 is predisposed to collapse in both lateral directions 204 and 208, e.g., to the right and to the left respectively, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process. FIG. 21 shows a further alternative distributed interconnecting structure 30^XII which is similar to the structure 30^XI illustrated in FIG. 20 but in which the laterally extending elongated member 200 is omitted and two tiers of cylindrical, elongated members 216 are connected to each other and to each of the panel foils 20A, 20B. As in the structure 30^XI illustrated in FIG. 20, each of the cylindrical, elongated members 216 is predisposed to collapse in both lateral directions 204 and 208, e.g., to the right and to the left respectively, as the panel foils 20A, 20B are compressed toward each other during the living hinge formation process.

It will be understood that, while not shown detail in FIGS. 12A-21 for ease of illustration, some or all of the members of the illustrated distributed interconnecting structures will thicken as the panel foils 20A, 20B are compressed toward each other, as shown by example in FIGS. 7 and 8. Moreover, it will be appreciated that, while also not shown in detail in FIGS. 12A-21 for ease of illustration, some such members of the illustrated distributed interconnecting structures may form complex shapes as they contact adjacent members during the living hinge formation process.

Referring now to FIGS. 22A and 22B, an embodiment is shown of a panel 12 cut, or otherwise separated, from a panel stock 10 having end zones 16A, 16B and living hinge zones 18A-18C sized and located along each panel 12 to provide for the formation of hinged container sleeves of at least two different dimensions. It will be understood that FIGS. 22A and 22B are vertically aligned with each other such that the left edge 10A′, the end zones 16A, 16B and the living hinge zones 18A-18C align between the two panels 12, 12′. In the example embodiment illustrated in FIG. 22A, the locations of the living hinges 38₁, 38₂ and 38₃ are all located so as to provide for a width A of approximately 5 inches, a width B of approximately 22.5 inches, a width C of approximately 48 inches and a width D of approximately 17.5 inches, such that the width of the panel 12, equal to the sum of A-D, is approximately 93 inches. The height, H, of the panel 12, which extends in the machine direction as described above with respect to FIG. 1, is, for example, approximately 45 inches. As such, when two such panels 12 are end-joined along their edges 10A′, 10B′, and living hinges are formed in and along each of the living hinge zones 18A, 18B and 18C, a closed-sided container sleeve 17, as illustrated in FIGS. 2-4 is formed having dimensions 48″ (length)×45″ (width)×45″ (height) as described with respect to FIG. 2.

In the example illustrated in FIG. 22B, the locations of the living hinges 38₁, 38₂ and 38₃ are all located so as to provide for a width A of approximately 130 millimeters, a width B of approximately 500 millimeters, a width C of approximately 1200 millimeters and a width D of approximately 370 millimeters, and the panel is cut along the edge 10B′ such that the resulting width of the panel 12, equal to the sum of A-D, is approximately 2,200 millimeters. The height, H, of the panel 12′, which extends in the machine direction as described above with respect to FIG. 1, is, for example, approximately 1,150 millimeters. As such, when two such panels 12′ are end-joined along their edges 10A′, 10B′, and living hinges are formed in and along each of the living hinge zones 18A, 18B and 18C, a closed-sided container sleeve 17, as illustrated in FIGS. 2-4 is formed having dimensions 1200 millimeters (length)×1000 millimeters (width)×1,150 millimeters (height).

The dimensions of the panel 12 illustratively represent one dimensional configuration used to produce one common closed-container sleeve widely used in the U.S., and the dimensions of the panel 12′ illustratively represent another dimensional configuration used to produce another common closed-container sleeve widely used in Europe. By designing an extrusion tool to selectively expand and place the living hinge zones 18A, 18B and 18C relative to, for example, the left (or right) edge 10A′ (or 10B′) of the panel stock 10 such that living hinges 38₁, 38₂ and 38₃ can be formed within such zones for each panel 12, 12′, a common panel stock 10 may thus be used to provide both types of panels 12, 12′ using a single extrusion tool. In the illustrated embodiment, the width (along the cross-machine direction) of the living hinge zone 18A need not be expanded since 130 millimeters (distance A) is substantially close to 5 inches. However, the difference between the distances B of the two the panels 12 and 12′ is approximately 2.8 inches and the width (along the cross-machine direction) of the living hinge zone 18B should thus be at least approximately 3.5 inches. The difference between the distance C of the two panels 12 and 12′ is approximately 0.75 inches, and the width (along the cross-machine direction) of the living hinge zone 18C should thus be at least approximately 4.5 inches. As the total length of the panel 12 is approximately 93 inches and the total length of the panel 12′ is only approximately 2, 200 millimeters, the width of the end zone 16B should be at least approximately 6.5-7 inches to account for the loss of a portion of the width of the panel 12′.

FIG. 22A further illustrates another implementation of zones 18D, 18E containing distributed interconnecting structures of the type illustrated and described hereinabove. In the embodiment illustrated in FIG. 22A, for example, a portion 220 of the panel zone 19D defines a pivoting panel 220 which may illustratively pivot outwardly and/or inwardly relative to the panel zone 19D about a lateral hinge 222 extending along the portion 220 of the panel zone 19D in the cross-machine direction between the foil ends. A zone 18D is formed between the planar foils 20A, 20B adjacent to one side of the portion 220 of the panel zone 19D, and the zone 18D illustratively has a length that extends in the machine direction along the height H of the panel 12 between the opposing foil ends and a width that extends in the cross-machine direction along a portion of the width of the panel 12. Another zone 18E is formed between the planar foils 20A, 20B adjacent to the opposite side of the portion 220 of the panel zone 19D, and the zone 18E likewise illustratively has a length that extends in the machine direction along the height H of the panel 12 between the opposing foil ends and a width that extends in the cross-machine direction along another portion of the width of the panel 12.

As illustrated in FIG. 22A, one end of the lateral hinge 222 extends from the portion 220 of the panel zone 19D into the zone 18D, and an opposite end of the lateral hinge 222 extends from the portion 220 of the panel zone 19D into the zone 18E. The panel 12 is separated, e.g., by cutting or other panel separation technique, along a first path 224 that extends in the machine direction through the zone 18D from the foil end to the one end of the lateral hinge 222, and also along a second path 226 that extends in the machine direction through the zone 18E from the foil end to the opposite end of the lateral hinge 222. The pivoting panel 220 is thus defined between the lateral hinge 222 and each of the first and second panel separation paths 224, 226. Along the first panel separation path 224, the panel 12 defines a pair of opposing panel edges 224A, 224B, and along the second panel separation path 226 the panel 12 likewise defines another pair of opposing panel edges 226A, 226B. Illustratively, each panel edge 224A, 224B, 226A, 226B is sealed, e.g., via a conventional hot melting or other sealing operation, along the machine direction between the foil end and a respective end of the lateral hinge 222.

Referring now to FIG. 23, an embodiment is shown of a panel 12 from which a panel product 300 is to be cut and in which a number of zones 18₁, 18₂ and 18₃ containing distributed interconnecting structures of the type illustrated and described hereinabove have been selectively formed to provide enhanced structural support in a corresponding number of selected areas of the panel product 300. In the illustrated embodiment, the panel 12 is illustratively cut, or otherwise separated, from panel stock 10 formed generally as illustrated and described above. From such panels, a panel product 300 is illustratively cut or otherwise separated. Alternatively, the panel product 300 may be cut or otherwise separated directly from the panel stock 10. In any case, the panel stock 10 is illustratively designed to selectively include one or more zones containing distributed interconnecting structures as described herein to selectively locate along the panel stock 10 areas or zones which provide enhanced structural integrity in the form of enhanced deformation resistance to compression forces applied to the outer surface of the foil 20A and/or the foil 20B in such zone(s).

In the illustrated embodiment, the panel product 300 may illustratively include edge areas 302A, 302B and 304 that may be particularly weak or otherwise exhibit insufficient deformation to compression forces applied to the outer surfaces of the foils 20A, 20B if the panel 12 includes, for example, only the interconnecting structures 31 of the type described used in the panel zones 19A-19D as described with respect to FIGS. 5A and 5B, wherein the elongated members 22 of such interconnecting structures 31 extend along the machine direction of the panel 12, i.e., in the direction of the height, H, of the panel 12. The panel stock 10 may thus be formed to include zones 18₁, 18₂ and 18₃ in which contain one of the embodiments 30, 30′, 30″, etc. of the distributed interconnecting structure illustrated and described herein. Inclusion of such a distributed interconnecting structure within the zones 18₁, 18₂ and 18₃ illustratively enhance deformation resistance to compression forces applied to the outer surface of the foil 20A and/or the foil 20B in the areas 302A, 302B and 304 of the panel product 300 in which the zones 18₁, 18₂ and 18₃ are located.

In the illustrated embodiment, the panel product 300 may further include an internal area 306 that is particularly susceptible to compressive forces and/or is subject to substantial and/or repeated compressive forces. The panel stock 10 may accordingly be formed to include a zone 18₄ which contains one of the embodiments 30, 30′, 30″, etc. of the distributed interconnecting structure illustrated and described herein. Inclusion of such a distributed interconnecting structure within the zone 18₄ illustratively enhances deformation resistance of the area 306 to compression forces applied to the outer surface of the foil 20A and/or the foil 20B in such an area 306 of the panel product 300. Referring now to FIG. 24, an example embodiment of a panel 12 is shown in which a secondary foil 20C is illustratively formed on or attached to the exterior surface of the top foil 20A. Alternatively or additionally, a secondary foil 20D may be formed on or attached to the exterior surface of the bottom foil 20B as illustrated by dash-lined representation in FIG. 24. Such co-extruded secondary foil(s) 20C and/or 20D may be included to provide for selective coloring of the foil(s) 20A and/or 20B, to enhance the stiffness and/or structural integrity of the foil(s) 20A and/or 20B and/or one or more other reasons relating to the appearance and/or structure of the foil(s) 20A and/or 20B.

In embodiments in which the secondary foil 20C is formed on the exterior surface of the top foil 20A and/or the secondary foil 20D is formed on the exterior surface of the bottom foil 20B, such formation may illustratively be accomplished, in one embodiment, using a conventional co-extrusion process. Those skilled in the art will recognize other techniques for forming the secondary foil 20C on the exterior surface of the top foil 20A and/or forming the secondary foil 20D on the exterior surface of the bottom foil 20B, and it will be understood that any such other techniques are contemplated by this disclosure. In embodiments in which the secondary foil 20C is attached to the exterior surface of the top foil 20A and/or the secondary foil 20D is attached to the exterior surface of the bottom foil 20B, such attachment may illustratively be accomplished via a conventional foil attachment structure(s), medium (media) or technique(s), examples of which include, but are not limited to, one or more adhesives or other foil bonding media, a conventional thermal bonding technique, or the like. Those skilled in the art will recognize other foil attachment structure(s), medium (media) or technique(s) for attaching the secondary foil 20C to the exterior surface of the top foil 20A and/or attaching the secondary foil 20D to the exterior surface of the bottom foil 20B, and it will be understood that any such other foil attachment structure(s), medium (media) or technique(s) are contemplated by this disclosure.

It will be understood that any combination of the embodiments 30, 30′, 30″, etc. of the distributed interconnection structures may be formed in any one or more of the living hinge areas or zones 18A-18C of any panel 12 described herein, and that any combination of the embodiments 35, 35″, 35″ of the distributed interconnection structures may be formed in either or both of the panel end areas or zones 16A, 16B of any panel 12 described herein. It will further be understood that any embodiment 30, 30′, 30″, etc. of the distributed interconnection structures may be alternatively or additionally used in whole or in part as a distributed interconnection structure in either or both of the panel end areas or zones 16A, 16B of any panel, and/or that any embodiment 35, 35′, 35″ of the distributed interconnection structures may be alternatively or additionally used in whole or in part as a distributed interconnection structure in any of the living hinge areas or zones 18A-18D.

The various embodiments of the interconnecting structures, e.g., 31, 31′, 31″, 31′″, 31^IV, have been described herein as being provided in the form of a plurality of elongated support members, e.g., 22, 100, 110, 120, 122, 130, affixed to the interior surfaces of the planar foils 20A, 20B within one or more of the panel zones, e.g., 19A-19D. It will be understood that while such interconnecting structures in the form of a plurality of such elongated support members are indeed affixed to the interior surfaces of both planar foils 20A, 20B within any one panel zone, one or more of the individual elongated support members within such a plurality may be affixed to the interior surface of only one or the other of the planar foils 20A, 20B. For example, one or more of the elongated support members 22, 100, 110, 120, 122, 130 illustrated in the attached figures may, in alternate embodiments, include a gap between opposing ends thereof, or may not otherwise extend fully from the interior surface of one of the planar foils 20A, 20B to the other. As another example, one or more of the elongated support members 120 in the embodiment illustrated in FIG. 11C may not be connected to respective ones of the elongated support members 122.

Similarly, the various distributed interconnecting structures, e.g., 30, . . . 30^XII and 35, 35′, 35″ have been described herein as being affixed to the interior surfaces of the planar foils 20A, 20B. In some of the various embodiments of such distributed interconnecting structures provided in the form of a plurality of elongated support members, e.g., 32, 80, 82, 90, 92, 94, 96, 140, 150, 154, 160, 170, 180, 182, 100, 110, 120, 122, 130, the plurality of such elongated support members have also been described herein as being affixed to the interior surfaces of the planar foils 20A, 20B within one or more of the zones 18A-18E. It will be understood that while such distributed interconnecting structures are indeed affixed to the interior surfaces of both planar foils 20A, 20B within any one such zone, and such distributed interconnecting structures provided in the form of a plurality of elongated support members are likewise affixed to the interior surfaces of both planar foils 20A, 20B within any one such zone, one or more of the individual elongated support members within any such distributed interconnecting structure or plurality of elongated support members may be affixed to the interior surface of only one or the other of the planar foils 20A, 20B. For example, one or more of the elongated support members 32, 82, 96, 140, 150, 154, 160,270 180, 182 illustrated in the attached figures may, in alternate embodiments, include a gap between opposing ends thereof, or may not otherwise extend fully from the interior surface of one of the planar foils 20A, 20B to the other. Likewise, one or more of the elongated support members 202, 206, 210, 214, 216, 218 may be affixed only to the interior surface of the planar foil 20A, to the interior surface of the planar foil 20B, to one surface of the intermediate foil 200 or to the opposite surface of the intermediate foil 200. Thus, while it is true that the plurality of elongated support members within any of the panel zones, e.g., 19A-19D, the distributed interconnecting structure within any of the various zones 16A, 16B and/or 18A-18E and/or 18₁-18₄, and the plurality of elongated support members within any of the various zones 16A, 16B and/or 18A-18E and/or 18₁-18₄, are generally affixed within such zones to the interior surfaces of both of the planar foils 20A, 20B, one or more of the individual elongated support members within any such distributed interconnecting structure or plurality of elongated support members may be affixed to the interior surface of only one or the other of the planar foils 20A, 20B.

It will be further understood that the various embodiments of the distributed interconnecting structures illustrated in FIGS. 12A-21 are simplified diagrams intended to illustrate some of the general concepts thereof such as, for example, configuring the various elongated interconnecting members to collapse in a controlled cross-machine direction, e.g., to the left or right. Such embodiments are generally not intended to accurately depict various dimensions of the illustrated distributed interconnecting structures, such as material thickness, spacing between individual members, and the like. Those skilled in the art will recognize that some additional configuration of some of the embodiments illustrated in FIGS. 12A-21 may be desired in order to ensure the controlled collapse of the illustrated elongated support members in the desired direction(s). For example, in the embodiments illustrated in FIGS. 12A-12D, 13A-13B, 15A-15B, 20 and 21, it may be desirable to separate each of the individual elongated support members in the cross-machine direction by an amount equal to approximately ½ of the diameter of the curvature thereof, although it will be understood that such spacing may further vary depending upon any of a number of factors including, for example, but not limited to the thickness of the elongated support members, distance J between the planar foils 20A, 20B, the diameter(s) of the curvatures of the elongated support members, and the like.

While the invention has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as illustrative and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, some embodiments have been described herein with which it is desirable to promote uniform cooling or curing of the panels 12 and/or panel stock 10 across the lengths and widths thereof by forming the distributed interconnecting structure 30 in the volume, V_18A, of the living hinge area or zone 18A with the same, or substantially the same, amount of material along the length H of the zone 18A and across the width G of the zone 18A as used to form the portion of the interconnecting structure 31 along the lengths and across the widths in and of adjacent, contiguous panel zones 19A-19D having the same volume as V18A. This disclosure further contemplates alternate embodiments in which the interconnecting structures between the planar foils 20A, 20B are not necessarily uniform across the panel length and/or width, but in which such interconnecting structures may be concentrated and/or compressed, and in some embodiments solid, in and along, for example, one or more of the zones in which a living hinge is to be formed. In such embodiments, for example, any warping, curling and/or other such undesirable resulting effects on the panel stock 10 and/or of the individual panels 12 that may occur in the area(s) of such one or more living hinge zones during cooling and/or curing thereof may be overcome, i.e., straightened and/or otherwise corrected, by heat and/or compression applied in such areas via a living hinge formation tool, die or press such as that described herein and/or via one or more other processing techniques that will occur to those skilled in the art.

Claims

1. An opposing-foil panel, comprising:

first and second planar foils each defining a foil height extending linearly along a machine direction between first and second foil ends, a foil width extending linearly along a cross-machine direction, normal to the machine direction, between first and second foil sides and an interior surface between the first and second foil ends and the first and second foil sides, the interior surface the first planar foil spaced apart from the interior surface of the second planar foil,

a first zone between the first and second planar foils, the first zone defining a first zone length extending along the machine direction and coextensive with the foil height and a first zone width parallel to and extending in the cross-machine direction across a first portion of the foil width,

a first plurality of elongated support members affixed to the interior surfaces of the first and second planar foils in the first zone, the first plurality of elongated support members extending along the first zone length in the machine direction and spaced apart along the first zone width in the cross-machine direction,

a second zone between the first and second planar foils adjacent to the first zone, the second zone defining a second zone length extending along the machine direction and coextensive with the foil height and a second zone width parallel to and extending in the cross-machine direction across a second portion of the foil width, and

a distributed interconnecting structure affixed to the interior surfaces of the first and second planar foils in the second zone and extending along the second zone length in the machine direction, the distributed interconnecting structure including a plurality of support members distributed across the second zone width with greater density than the first plurality of elongated support members is distributed across the first zone width.

2. The opposing-foil panel of claim 1, wherein the plurality of support members comprises a second plurality of elongated support members each affixed to the interior surface of at least one of the first and second planar foils in the second zone, the second plurality of elongated support members extending along the second zone length in the machine direction and spaced apart along the second zone width in the cross-machine direction.

3. The opposing-foil panel of claim 2, wherein the first plurality of elongated support members defines a first distance along the first width of the first zone between each adjacent one of the first plurality of elongated support members,

and wherein the second plurality of elongated support members defines a second distance along the second width of the second zone between each adjacent one of the second plurality of elongated support members,

and wherein the first distance is greater than the second distance.

4. The opposing-foil panel of claim 2, wherein the distributed interconnecting structure further comprises a first plurality of lateral support members affixed to and between adjacent ones of the second plurality of elongated support members and spaced apart from the interior surfaces of the first and second foils, each of the first plurality of lateral support members extending between adjacent ones of the first plurality of lateral support members in the cross-machine direction and extending along the second zone length in the machine direction.

5. The opposing-foil panel of claim 4, wherein the distributed interconnecting structure further comprises a second plurality of lateral support members affixed to and between the adjacent ones of the second plurality of elongated support members and spaced apart from the interior surfaces of the first and second foils and from the first plurality of lateral support members, each of the second plurality of lateral support members extending between the adjacent ones of the first plurality of lateral support members in the cross-machine direction and extending along the second zone length in the machine direction.

6. The opposing-foil panel of claim 2, wherein the second plurality of elongated support members comprises at least one of a plurality of linear or arcuate-shaped ribs.

7. The opposing-foil panel of claim 2, wherein at least one of the second plurality of elongated support members extends diagonally from the interior surface of at least one of the first and second planar foils along the cross-machine direction.

8. The opposing-foil panel of claim 2, wherein at least one of the second plurality of elongated support members defines a cylindrical or oval cross-section in the cross-machine direction.

9. The opposing-foil panel of claim 2, further comprising an intermediate planar foil disposed between the first and second planar foils, the intermediate planar foil defining a height extending linearly along the machine direction between the first and second foil ends of the first and second planar foils, a width extending linearly along the cross-machine direction between the first and second foil sides of the first and second planar foils, a first planar surface facing the interior surface of the first planar foil and a second planar surface, opposite the first planar surface, facing the interior surface of the second planar foil,

wherein a first subset of the second plurality of elongated support members is affixed to and between the interior surface of the first planar foil and the first planar surface of the intermediate planar foil in the second zone, and a second subset of the second plurality of elongated support members is affixed to at least one of the interior surface of the second planar foil and the second planar surface of the intermediate planar foil in the second zone.

10. The opposing-foil panel of claim 1, wherein the second zone comprises a living hinge zone,

and wherein the opposing-foil panel further comprises a living hinge formed along the length of the living hinge zone with the first and second planar foils and at least a portion of the distributed interconnecting structure.

11. The opposing-foil panel of claim 1, wherein the second zone comprises an end zone positioned between the first zone and the first or second sides of the first and second planar foils.

12. The opposing-foil panel of claim 1, wherein the second zone defines a zone of the panel in which the distributed interconnecting structure provides enhanced deformation resistance, as compared with the first zone, to compressive forces applied to an external surface of at least one of the first and second planar foils.

13. The opposing-foil panel of claim 1, wherein the first zone defines a first volume between the interior surfaces of the first and second planar foils, the first zone length and a portion of first zone width adjacent to the second zone, and the second zone defines a second volume between the interior surfaces of the first and second planar foils, the second zone length and the second zone width,

and wherein the first plurality of elongated support members disposed within the first volume defines a first mass of material, and the distributed interconnecting structure disposed within the second volume defines a second mass of material,

and wherein the first volume is approximately equal to the second volume and the first mass of material is approximately equal to the second mass of material.

14. The opposing-foil panel of claim 13, further comprising:

a third zone defined between the first and second planar foils, the third zone defining a third zone length extending along the machine direction and coextensive with the foil height and a third zone width parallel to and extending in the cross-machine direction across a third portion of the foil width, the third zone adjacent to the second zone with the second zone disposed between and contiguous with each of the first and third zones, and

a third plurality of elongated support members affixed to and between the interior surfaces of the first and second planar foils in the third zone, the third plurality of elongated support members extending along the third zone length in the machine direction and spaced apart along the third zone width in the cross-machine direction,

wherein the third zone defines a third volume between the interior surfaces of the first and second planar foils, the third zone length and a portion of the third zone width adjacent to the second zone,

and wherein the third plurality of elongated support members disposed within the third volume defines a third mass of material,

and wherein the third volume is approximately equal to each of the first and second volumes and the third mass of material is approximately equal to each of the first and second masses of material.

15. The opposing-foil panel of claim 1, wherein the first planar foil, the second planar foil, the first plurality of elongated support members and the distributed interconnecting structure are all of unitary construction.

16. The opposing-foil panel of claim 1, further comprising a lateral hinge extending in the cross-machine direction between the first and second foil ends along at least a portion of the first zone, the lateral hinge having a first end extending from the at least a portion of the first zone into the second zone and a second end opposite the first end,

wherein the opposing-foil panel is separated along a first path extending in the machine direction through the second zone from the first foil end to the first end of the lateral hinge,

and wherein the opposing-foil panel is separated along a second path extending in the machine direction from the first foil end to the second end of the lateral hinge to define a pivoting panel between the lateral hinge and the first and second paths.

17. The opposing-foil panel of claim 16, further comprising:

a third zone between the first and second planar foils adjacent to a second side of the at least a portion of the first zone opposite the first side, the third zone defining a third zone length extending along the machine direction and coextensive with the foil height and a third zone width parallel to and extending in the cross-machine direction across a third portion of the foil width, and

a second distributed interconnecting structure affixed to the interior surfaces of the first and second planar foils in the third zone and extending along the third zone length in the machine direction, the second distributed interconnecting structure including a plurality of support members distributed across the third zone width with greater density than the first plurality of elongated support members is distributed across the first zone width,

wherein the second path extends in the machine direction through the third zone from the first foil end to the second end of the lateral hinge.

18. An opposing-foil panel, comprising:

first and second planar foils each defining a foil height extending linearly along a machine direction between first and second foil ends, a foil width extending linearly along a cross-machine direction, normal to the machine direction, between first and second foil sides and an interior surface between the first and second foil ends and the first and second foil sides, the interior surface the first planar foil spaced apart from the interior surface of the second planar foil,

a plurality of panel zones between the first and second planar foils each defining a panel zone length extending along the machine direction and coextensive with the foil height and a panel zone width parallel to and extending in the cross-machine direction across a different portion of the foil width, each of the plurality of panel zones including therein multiple elongated support members affixed to the interior surfaces of the first and second planar foils with each of the multiple elongated support members extending along the panel zone length of the corresponding panel zone in the machine direction and spaced apart along the panel zone width of the corresponding panel zone in the cross-machine direction,

a plurality of living hinge zones defined between the first and second planar foils and spaced apart along the foil width, each of the plurality of living hinge zones defining a living hinge zone length extending along the machine direction and coextensive with the foil height and a living hinge zone width parallel to and extending in the cross-machine direction across a different portion of the foil width between and adjacent to different ones of the plurality of panel zones, each of the plurality of living hinge zones including therein a distributed interconnecting structure affixed to the interior surfaces of the first and second planar foils and extending along the corresponding living hinge zone length in the machine direction and distributed across the corresponding zone width with greater density than the multiple elongated support members are distributed across the panel widths of each of the plurality of panel zones, and

a plurality of living hinges each formed along the length of a different one of the plurality of living hinge zones with the first and second planar foils and at least a portion of the corresponding distributed interconnecting structure.

19. An opposing-foil panel for a collapsible container sleeve, comprising:

a first planar foil having a foil height extending and a foil width,

a second planar foil also having the foil height and the foil width and spaced apart from the first planar foil, the foil height defining a machine direction parallel therewith and the foil width defining a cross-machine direction parallel therewith, the cross-machine direction normal to the machine direction, the foil width terminating at each of first and second opposite sides of the first and second planar foils to define respective first and second panel sides,

a first panel zone defined between the first and second planar foils and having a length extending across the foil height and a width extending along a first portion of the foil width,

a first plurality of elongated support members affixed to the opposed interior surfaces of the first and second planar panel members in the first panel zone, each of the first plurality of elongated support members extending across the length of the first panel zone and spaced apart along the width of the first panel zone,

a panel end zone defined between the first and second planar foils and having a length extending across the foil length and a width extending along a second portion of the foil width with one side thereof adjacent to the first panel zone and an opposite side thereof terminating at the first panel side, and

a distributed interconnecting structure affixed to the opposed interior surfaces of the first and second planar foils along the length of the panel end zone and distributed across the width of the panel end zone with greater density than the first plurality of elongated support members is distributed across the width of the first panel zone, the first panel side being joinable with one of the second panel side and a panel side of another panel to form the collapsible container sleeve.

20. The opposing-foil panel of claim 19, further comprising a plurality of spaced apart living hinges each extending along the panel in the machine direction.