Laminated Blank, Packaging Formed Therefrom, and Method

This application claims the priority benefit of U.S. provisional application No. 63/571,691 filed Mar. 29, 2024. The aforementioned application is incorporated herein by reference in its entirety.

The present invention relates to packaging and, in particular, to packaging blanks that are formable into boxes with a sealed base.

Most packaging boxes are shipped in a flat state that may then be assembled into a three-dimensional box. This is generally true regardless of the industry and type of box. It is convenient to ship boxes in such a collapsed state, so as to take up less space during shipping than the fully assembled, empty box. Shipping boxes, for example, are typically partially assembled and then provided in collapsed, flat stacks that are then fully assembled with adhesive. Other boxes may be formed from a blank that is a pre-scored and/or pre-cut sheet of the material out of which the box is made. The end user then folds the sheet at the scoring and takes other necessary steps to assemble the box out of the blank. In these examples, the base of the box that is formed is not sealed. Depending on the design, there may be openings along the edges. Even in very sturdily constructed boxes, there will commonly be at least tiny pin holes in the corners of the base, where the various sides meet.

Such gaps and holes will allow gases, such as air, and liquids to traverse the box boundary. This is acceptable in many applications, but limits such boxes' use in food packaging, for example. If the contents of the box are perishable, then the ability for gases to move in and out of the space within the box will shorten the shelf life of the contents. Any contents that are partially or fully liquid, such as a food item with a sauce or a soup, could also not be loaded into a box that has any gaps or holes because the liquid element would pour or seep out and make a mess. A food item with a liquid element therefore must be packaged in a container that has at least a fully sealed base. For the purposes of food preservation, moreover, it is preferable that the container be fully sealable.

Therefore, there is a need for a box that may be shipped in a collapsed, flat state, such as a blank, but may be assembled into a fully sealable box that would be suitable for food packaging.

The present disclosure contemplates new and improved blanks that are formable into fully sealable boxes and methods for manufacture of the blanks and assembly of the blanks into the boxes.

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

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

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

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

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

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

The illustrated pack, formed from the blank, has six sides, as do typical boxes. These six sides are present in the blank, including the lid, a rear face, a front face,, a base, a first side panel, and a second side panel. The front faceis connected to the basevia a first transverse away fold linealong a first transverse edgeof the base. The rear faceis connected to the basevia a second transverse away fold linealong a second transverse edgeof the base. The baseis bound by the first transverse edgedisposed between the baseand the front face; the second transverse edgedisposed between the baseand the rear face; and first and second longitudinal edges,extending perpendicularly between the first and second transverse edges,. The lidis connected to the rear facevia a fourth transverse away fold linealong an upper edgeof the rear face. The front facehas opposing longitudinal edgesextending between the first transverse edgeof the baseand the upper edgeof the front face. The rear facehas opposing longitudinal edgesextending between the first transverse edgeof the baseand the upper edgeof the rear face.

The first and second side panels,are mirror images of one another, and, as such, their first and second designations are arbitrary. For consistency herein and with the figures, from the perspective of the viewer, the first side panel and any first features associated therewith are depicted on the left side of the blank/packand the figure. The second side panel and any second features associated therewith are depicted on the right side of the blank/packand the figure. The exceptions to this are, which are rear and bottom views of the assembled pack, respectively, so that the second side panel is on the left and the first side panel is on the right. Also, for consistency, in at leastand, rear features of the blank/packare toward the top of the respective figures and front features are toward the bottom.

In this blankform, the first side panelis divided into a first rear side panel segmentand a first front side panel segmentand the second side panelis divided into a second rear side panel segmentand a second front side panel segment. As will be apparent, when the blankis assembled into the pack, the first rear and front side panel segments,and the second rear and front side panel segments,will come together to form the united first and second side panels,, respectively. The first rear side panel segmenthas an upper edge. The first front side panel segmenthas an upper edge. The second rear side panel segmenthas an upper edge. The second front side panel segmenthas an upper edge. The rear facehas an upper edge. The front facehas an upper edge. When the blankis formed into the pack, the upper edges,,,,,form an openinginto the pack, as shown in. The first front side panel segmenthas a transverse edge, collinear with the first transverse edgeof the base. The second front side panel segmenthas a transverse edge, collinear with the first transverse edgeof the base. The first rear side panel segmenthas a transverse edge, collinear with the second transverse edgeof the base. The second rear side panel segmenthas a transverse edge, collinear with the second transverse edgeof the base.

In addition to the six sides described above, the blankincludes various flaps and features integral to the assembly of the blankinto the pack. As discussed in more detail below with respect to, the entirety of the viewable surface of the substrateincludes the film layer, including the cutout regions, as illustrated by diagonal surface lines in a window region, a first cutout region, and a second cutout region. Excluding the windowand the first and second cutout regions,, the blankconsists of the substratelaminated with the film layer. At the windowand the first and second cutout regions,, the blankconsists of only the film layer, unsupported by the substrate. The surface of the substratethat faces away from the viewer, i.e., the surface that will form the outside surface of the assembled pack, may also be laminated with a film layer, but this is not required. Although the film layer in the window regionand the cutout regions,is depicted as shaded for illustration purposes, it will be recognized that a transparent film layeris also contemplated.

The blankalso includes first and second tabs,, disposed adjacent to the first and second front side panel segments,, respectively. The first and second tabs,will be adhered to the respective adhesive regions,of the first and second rear side panel segments,, respectively, to form the united first and second side panels,in pack. As will be discussed below with respect to the method, the adhesion of the first and second tabs,to the respective adhesive regions,of first and second rear side panel segments,is advantageously achieved with a hot melt adhesive, although other types of adhesives are contemplated.

The blankalso includes first and second upper rear flaps,, extending transversely from the upper edges,of the first and second rear side panel segments,, respectively; first and second upper front flaps,, extending transversely from the upper edges,of the first and second front side panel segments,, respectively; and a front face flap, extending transversely from the upper edgeof the front face. The blankmay also include a lid flap, extending transversely from the lid. The lid flapwill be adhered to the front face flap, when the blankis formed into the pack. The lidincludes the first and second lid overlap portions,on either side of the lid. The first upper rear and front flaps,will be adhered to the first lid overlap portion. The second upper rear and front flaps,will be adhered to the second lid overlap portion. As will be discussed below with respect to the method, in certain embodiments, the adhesion of the lip flapto the front face flap; the first upper rear and front flaps,to the first lid overlap portion; and the second upper rear and front flaps,to the second lid overlap portion, is achieved through heat sealing of the film layer. It is understood that “upper” as used with reference to the first and second upper rear and front flaps,,,, is referring to the upper portion of the packthat may be assembled out of the blank.

First and second base support panels,are disposed on either side of the baseand include the first and second cutout regions,; first and second front support arms,; first and second rear support arms,, and first and second cutout connectors,, as detailed below with reference to.

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

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

Unlike fold lines, which are perforated lines in embodiments as described above, as used herein, “cuts” are continuous cuts that extend completely along the length of the cut and entirely through the substrate(in the case of cuts made prior to the lamination step) or through the substrateand the film layer(for cuts made after the lamination step). The fold lines and first cuts illustrated inrepresent the fold lines and cuts, respectively, made during the first cutting stepof the method, as discussed below with reference to.

In certain embodiments, the blankincludes a lid flap away fold linedisposed between the lidand the lid flap, although this fold lineis eliminated in embodiments that do not include the lid flap. The blankalso includes the fourth transverse away fold line, along the rear face upper edgeand disposed between the lidand the rear face; a second transverse away fold linealong the second transverse edgeof the base, and disposed between the rear faceand the base; a first transverse away fold linealong the first transverse edgeof the base, disposed between the front faceand the base; and a front face toward fold line, along the upper edgeof the front face, disposed between the front faceand the front face flap. A third transverse toward fold lineis formed in the baseintermediate the first transverse and second away fold lines,. The lip flap away fold line(when included), the fourth transverse away fold line, the second transverse away fold line, the third transverse toward fold line, the first transverse away fold line, and the front face toward fold lineare all generally parallel to one another.

The blankalso includes first and second rear face away fold lines,, disposed between the rear faceand the first and second rear side panel segments,, respectively. First and second front face away fold lines,are disposed between the front faceand the first and second front side panel segments,, respectively. The rear faceis delineated by the fourth transverse away fold line, the second rear face away fold line, the second transverse away fold line, and the first rear face away fold line. The front faceis delineated by the first transverse away fold line, the second front face away fold line, the front face toward fold line, and the first front face away fold line. The blankalso includes a first flap toward fold linebetween the first front side panel segmentand the first flap. A second flap toward fold lineis disposed between the second front side panel segmentand the second flap.

The blankincludes a first upper rear flap toward fold linealong the upper edgeof the first rear side panel segment, disposed between the first rear side panel segmentand the first upper rear flap. A first upper front toward fold linealong the upper edgeof the first front side panel segmentis disposed between the first front side panel segmentand the first upper front flap. A second upper rear flap toward fold lineis disposed along the upper edgeof the second rear side panel segment, disposed between the second rear side panel segmentand the second upper rear flap. A second upper front flap toward fold linealong the upper edgeof the second front side panel segment, is disposed between the second front side panel segmentand the second upper front flap. Again, in the context of the first and second upper rear and front flap toward fold lines,,,, the term “upper” refers to the upper edge of the packthat may be assembled out of the blank.

As shown, the fold lines,,,are slightly angled toward the base, as compared with the fourth transverse away fold lineand the front face toward fold line. In the illustrated embodiment, the angling shown is approximately 170 degrees. In certain embodiments, the angling is in the range of about 160 to about 175 degrees. The purpose of this angling is to offset any upward tendencies caused by the inward folding of the first and second base support panels,, as described in detail below with respect to. This offset ensures that the upper edges,,,,,will present an even, flush surface when the blankis formed into the pack. The even, flush upper edges,,,,,allow for a secure seal when the lidis closed and sealed. Thicker substratesmay require greater angled offsets, i.e., more acute angles between the fold lines,,,and the fourth transverse away fold lineand the front face toward fold line. In certain embodiments, no offset is provided, such that there is no such angling and the first and second upper rear flap toward fold lines,are essentially linear extensions of the fourth transverse away fold lineand the first and second upper front flap toward fold lines,are essentially linear extensions of the front face toward fold line.

The first and second cutout regions,, described in more detail with respect tobelow, are cut out of the substratewith first and second cutout cuts,(see).

The windowis cut out of the lidwith a window cutaround the perimeter of the window. For ease of removal of the entire area that is cut out to form the window, an additional bisecting cutmay be made, as shown. Although the illustrated packincludes the window, it is understood that some embodiments of packdo not include a windowin the lid. In such embodiments, the blankdoes not include the windowor the window cut. In certain embodiments, the lidmay be omitted.

Now referring to, along with, there appear detailed diagrams of the first and second base support panel,, respectively.

In the illustrated exemplary embodiment, the first cutout regionhas a generally isosceles trapezoidal shape having a first long parallel side(which is the first longitudinal edgeof the base), a first short parallel side, a first pair of opposing angled sidesconnecting the first long and short parallel sides,, and a first trapezoid heightthat is the perpendicular distance between the first long and short parallel sides,. The second cutout regionhas a generally isosceles trapezoidal shape having a second long parallel side(which is the second longitudinal edgeof the base), a second short parallel side, a second pair of opposing angled sidesconnecting the second long and short parallel sides,, and a second trapezoid heightthat is the perpendicular distance between the second long and short parallel sides,.

The first and second cutout regions,are formed by the first and second cutout cuts,, respectively, as shown in. The blankalso includes a first rear support away fold linealong the transverse edgeof the first rear side panel segment, disposed between the first rear side panel segmentand the first rear support arm. A first front support away fold line, along the transverse edgeof the first front side panel segment, is disposed between the first front side panel segmentand the first front support arm. A second rear support away fold line, along the transverse edgeof the second rear side panel segment, is disposed between the second rear side panel segmentand the second rear support arm. A second front support away fold line, along the transverse edgeof the second front side panel segment, is disposed between the second front side panel segmentand the second front support arm. The first and second rear support away fold lines,are essentially extensions of the second transverse away fold line. The first and second front support away fold lines,are essentially extensions of the first transverse away fold line.

The first base support panelis bound by the first rear support away fold line, the first long parallel sideof the first cutout region, the first front support away fold line, and a first base support panel side, which is a segment of the perimeter of the blank, parallel to the first long parallel sideand perpendicular to the first rear and front support away fold lines,. The second base support panelis bound by the second rear support away fold line, the second long parallel sideof the second cutout region, the second front support away fold line, and a second base support panel side, which is a segment of the perimeter of the blank, parallel to the second long parallel sideand perpendicular to the second rear and front support away fold lines.. The first base support panelhas a first support panel width, which is the shortest, i.e., perpendicular, distance between the first base support panel sideand the first long parallel sideof the first cutout region. The first support panel widthis greater than the first trapezoid height. The second base support panelhas a second support panel width, which is the shortest, i.e., perpendicular, distance between the second base support panel sideand the second long parallel sideof the second cutout region. The second support panel widthis greater than the second trapezoid height.

The difference between the first support panel widthand the first trapezoid heightand between the second support panel widthand the second trapezoid heightallows for the disposition of the first and second cutout connectors,. The first cutout connectoris bound between the first rear and front support arms,and the first short parallel sideof the first cutout region. In certain embodiments, the second cutout connectoris bound between the second rear and front support arms,and the second short parallel sideof the second cutout region. In the illustrated exemplary embodiment, the first and second cutout connectors,are generally isosceles triangle-shaped, having first and second triangle bases,and first and second triangle legs,that connect the first and second triangle bases,to the first and second intersections,bisecting the first and second base support panel sides,. As such, the first short parallel sideof the trapezoidal shape of the first cutout regionis also the first triangle baseof the first cutout connector. Similarly, the second short parallel sideof the trapezoidal shape of the second cutout regionis also the second triangle baseof the second cutout connector.

Between the first front and rear support arms,, the first cutout connectorincludes a first connector rear away fold line, a first connector center toward fold line, and a first connector front away fold line. Between the second front and rear support arms,, the second cutout connectorincludes a second connector rear away fold line, a second connector center toward fold line, and a second connector front away fold line. The first connector rear and front away fold lines,follow the first triangle legsto the first intersection. Fold lines,follow the same angled trajectory as the first angled sidesof the trapezoidal shape of the first cutout region. The second connector rear and front away fold lines,follow the second triangle legsto the second intersection. Fold lines,follow the same angled trajectory as the second angled sidesof the trapezoidal shape of the second cutout region. The first connector center toward fold lineextends the shortest, i.e., perpendicular, distance between the first short parallel side/the first triangle baseand the first intersection. The second connector center toward fold lineextends the shortest distance between the second short parallel side/second triangle baseand the second intersection.

In embodiments, the first and second cutout connectors,are omitted and the first and second cutout regions,are generally isosceles triangle-shaped, rather than isosceles trapezoid-shaped, with the first and second angled sides,extending all the way to the first and second intersections,.

The film layercovers the first and second cutout regions,, so that at the first and second cutout regions,, the blankconsists of only the film layerand not substrate, i.e., unsupported film. The first and second cutout cuts,are therefore through the substrateonly and occur before the substrateis laminated with film layer.

When packis assembled from blank, the combination of the first cutout region, the first rear and front support arms,, and the first cutout connectorwith the first connector rear away fold line, the first connector center toward fold line, and the first connector front away fold line, will fold inward toward the base. Similarly, the combination of the second cutout region, the second rear and front support arms,, and the second cutout connectorwith the second connector rear away fold line, the second connector center toward fold line, and the second connector front away fold linewill fold inward toward the base. These inward folds result in the first and second rear and front support arms,,,being substantially parallel to the base. It is understood that, as the arms,,,are folded and part of the same blankas the base, they are not perfectly parallel to the base, but rather folded at a very acute angle. This distinction from being truly parallel is what is meant by “substantially parallel” in this context.

The film layerprovides a completely sealed base. The film layer, lacking the paper substrate layer in the first and second cutout regions,, makes those sections less thick than other sections of the blankthat include both the substrateand the film layer. The use of the first and second cutout regions,therefore ensures that the inward-folding combinations are not too thick with too many layers of paper board/substrate. The first and second cutout connectors,are relatively small so as to maximize the area of the first and second cutout regions,, thereby minimizing the thickness of the first and second base support panels,as they fold inward.

Now referring to, there appears an illustration of the laminating stepof method, as discussed below with reference to. The fold line formation and cutting illustrated inwas performed on the unlaminated substrate. In this step, the entire surface of the blankthat faces the viewer ofis laminated with film layer. As discussed above, this film layeris the only substance of the window(when included) and the first and second cutout regions,. In some embodiments, the surface of the blankthat faces away from the viewer may also be laminated, but this is not required. Laminating after making the fold lines and first cuts ensures that any small perforations of substratemade while making the fold lines are sealed.

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

Now referring to, there appears a diagram of final cuts of the blankand an illustration of the perimeter and final cuts stepof method, as discussed below with reference to. After the film layerhas been applied, the perimeter cutis made, which forms the entire outer shape of the blank, as shown in. First and second lid flap cutsandare also made between the lidand the first and second upper rear flaps,, respectively. First and second face cuts,are also made between the front face flapand the first and second upper front flaps,, respectively.

Now referring to, there appear diagrams illustrating the first folding stepof the present method, as discussed below with reference to. In, the blankis folded along the second transverse away fold lineso that the laminated surface of the blankis folded flush against itself. Specifically, the blankis folded so that the baseand the front faceare folded flush against the rear faceand the lid. In, the blankis folded down along the third transverse toward fold lineand the first and second connector center toward fold lines,. In embodiments, this fold bisects the baseand the first and second base support panels,, including the first and second cutout regions,. Adhesiveis applied to the first and second rear side panel segments,, near the perimeter cut. In certain embodiments, the adhesive is a hot melt adhesive. Alternately, the adhesivemay be any suitable adhesive including single component adhesives, two component adhesives, solvent-based adhesives, solventless adhesives, water-based adhesives, and others as would be understood by persons skilled in the art. In, the blankis folded along the first transverse away fold line. This places the adhesive regions,of the first and second rear side panel segments,flush against the respective first and second tabs,so that the first adhesive regionis adhered to the first taband the second adhesive regionis adhered to the second tab. The blankis now in a convenient form to be stacked and shipped to an end user.

Now referring to, a diagram indicating exemplary dimensions of an exemplary blankof the present disclosure is provided. The dimensions indicated are merely exemplary and should not be considered to be limiting on the various dimensions of the various features of the blank. One skilled in the art will recognize that the blankand its features may have a range of dimensions. All dimensions shown are in mm. In this exemplary embodiment, the lidhas a width of 151.93 mm, including 34 mm on either side of the window, which has dimensions of 55×83.93 mm. There is 14 mm between the windowand the fourth transverse away fold line. The length of the fourth transverse away fold linebetween the first and second rear face away fold lines,is 120 mm. The basehas dimensions of 65×110 mm, where the 65 mm height is bisected by the third transverse toward fold line. The first and second base support panels,each have a height of 65 mm. The front facehas a height of 60 mm, as measured along the shortest, i.e., perpendicular, distance between the first transverse away fold lineand the front face toward fold line. The front face flaphas a width, meaning the shortest, i.e., perpendicular, distance between the front face toward fold lineand the perimeter of the blank, of 12 mm. The overall dimensions of the blankare 288×234.15 mm.

Now referring to, a flow chart illustrating the steps of a methodfor the production of a blank in accordance with this disclosure is provided. In its most basic form, methodincludes the stepof providing a substrate sheet; the stepof making first cuts and fold lines in the substrate; the stepof laminating at least one surface of the substrate sheetwith film layer; and the stepof making perimeter and final cuts through the substrate sheet.

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

The first cuts and fold lines made in stepare detailed above with respect to. The first cuts include the window cut(when the windowis included) and the first and second cutout region cuts,. Once these cuts,,are made, the substrate material for those cutouts is removed. Stepis performed through a cutting process, e.g., die cutting process. The substeps of step, of making first cuts in the substrateand fold lines in the substrate, are performed substantially simultaneously, which is why they are listed as a single combined step.

The step of making fold lines in the substrateincludes at least the substeps of making the second transverse away fold line; making a first transverse away fold line, thereby delineating a basebound by the two longest sides,of the first and second trapezoid cutout regions,/first and second longitudinal edges,of the base, the second transverse away fold line, and the first transverse away fold line; making the third transverse toward fold lineparallel to the second transverse away fold linethat connects the first and second trapezoid cutout regions,and divides the base; making the first and second rear face away fold lines,extending longitudinally from the second transverse away fold line, thereby delineating the rear facebound by the second transverse away fold lineand the first and second rear face away fold lines,; making the first and second front face away fold lines,extending longitudinally from the first transverse away fold line, thereby delineating the front facebound by the first transverse away fold lineand the first and second front face away fold lines,; making the first flap toward fold lineextending longitudinally from the first transverse away fold line, thereby delineating the first front side panel segmentbound by the first transverse away fold line, the first front face away fold line, and the first flap toward fold line; and making the second flap toward fold lineextending longitudinally from the first transverse away fold line, thereby delineating the second front side panel segmentbound by the first transverse away fold line, the second front face away fold line, and the second flap toward fold line.

The step of making fold lines in the substrate, as shown in, includes at least the substeps of making the fourth transverse away fold line; making the second transverse away fold lineparallel to the fourth transverse away fold line; making the first transverse away fold line, thereby delineating a basebound by the two longest sides,of the first and second trapezoid cutout regions,, the second transverse away fold line, and the first transverse away fold line; making the third transverse toward fold lineparallel to the second transverse toward fold linethat connects the first and second cutout regions,and divides the base; making the front face toward fold lineparallel to the first transverse away fold line; making the first and second rear face away score lines,between the fourth transverse away fold lineand the second transverse away fold line, thereby delineating a rear wallbound by the fourth transverse away fold line, the second transverse away fold line, and the first and second rear face away fold lines,; making the first and second front face away fold lines,between the first transverse away fold lineand the front face toward fold line, thereby delineating a front facebound by the first transverse away fold line, the front wall toward fold line, and the first and second front face away fold lines,; making the first connector back and front away fold lines,following the trajectory of the angled sidesof the first cutout regionand ending at the first intersectionone with the other; making the second connector rear and front away fold lines,following the trajectory of the angled sidesof the second cutout regionand ending at the second intersectionone with the other; making the first connector center toward fold linebisecting an angle created by the first connector rear and front away fold lines,and ending at the first intersection; making the second connector center toward fold linebisecting an angle created by the second connector rear and front away fold lines,and ending at the second intersection; making the first flap toward fold linebetween the first transverse away fold lineand the front face toward fold line, thereby delineating the first front side panel segmentbound by the first transverse away fold line, the first front face away fold line, the front face toward fold line, and the first flap toward fold line; and making the second flap toward fold linebetween the first transverse away fold lineand the front wall toward fold line, thereby delineating the second front side panel segmentbound by the first transverse away fold line, the second front wall away fold line, the front face toward fold line, and the second flap toward fold line.

In embodiments, the stepof making first cuts also includes the substeps of cutting out the windowfrom the lidand removing the sheet material that previously occupied the window cutout region. In embodiments, the substep of making fold lines in the substratealso includes the substep of making the lid flap away fold linewhich is parallel to the fourth transverse away fold lineand on another side of the fourth transverse away fold lineas the second transverse away fold line.

In embodiments, the substep of making the fourth transverse away fold linecomprises making the fourth transverse away fold linebetween the first and second rear face away fold lines,; making the first upper rear flap toward fold lineintersecting with the fourth transverse away fold lineat about a 160-175 degree angle and intersecting with the first rear face away fold lineat about an 80-85 degree angle; and making the second upper rear flap toward fold lineintersecting with the fourth transverse away fold lineat about a 160-175 degree angle and intersecting with the second rear face away fold lineat about an 80-85 degree angle. In embodiments, the substep of making a front face toward fold linecomprises making the front face toward fold linebetween the first and second front face away fold lines,; making the first upper front flap toward fold lineintersecting with the front face toward fold lineat about a 160-175 degree angle and intersecting with the first front face away fold lineat about an 80-85 degree angle, such that the first front side panel segmentis bound by the first transverse away fold line, the first front face away fold line, the first upper front flap toward fold line, and the first flap toward fold line; and making the second upper front flap toward fold lineintersecting with the front face toward fold lineat a about 160-175 degree angle and intersecting with the second front face away fold lineat about an 80-85 degree angle, such that the second front side panel segmentis bound by the first transverse away fold line, the second front face away fold line, the second upper front flap toward fold line, and the second flap toward fold line.