Folded Sleeve and Methods for Forming and Assembling the Same

The present disclosure relates generally to a folded sleeve, more particularly, to a folded sleeve for containing a plurality of consumer products and methods for forming and assembling a folded sleeve.

In general, shaving razor cartridges of the wet shave type include a cartridge or blade unit with at least one blade with a cutting edge which is moved across a surface of a user's skin being shaved by means of a handle to which the shaving razor cartridge is attached. The shaving razor cartridge may be mounted detachably on the handle to enable the shaving razor cartridge to be replaced by a fresh shaving razor cartridge when the blade sharpness has diminished to an unsatisfactory level, or it may be attached permanently to the handle with the intention that the entire shaving razor be discarded when the blade or blades have become dulled (i.e., disposable razor).

Consumers are starting to demand products and packages that are more sustainable and have less waste and a smaller environmental impact. However, consumer product dispensing systems, such as shaving razor cartridge dispensing systems, are often formed of plastic and are rarely recycled by the consumer. Furthermore, sustainable materials may be limited as to design features that may be incorporated. For example, unlike plastic injection molded dispensing systems, pulp-formed materials cannot be easily manufactured with cut outs, undercuts, or lugs to retain the shaving razor cartridges.

Despite the use of known packaging techniques, there remains a need to further modify consumer product dispensing systems, for example, shaving razor cartridge dispensing systems to provide a folded sleeve for receiving, retaining, and/or dispensing consumer product containers that is sustainable, user-friendly, effectively retains the consumer product containers until dispensed, and also provides cost savings from the use of materials.

In accordance with one aspect, a folded sleeve, for example, a folded sleeve for containing a plurality of consumer product containers, e.g., shaving razor cartridge containers, is provided, comprising: a first wall; a second wall opposite the first wall; a pair of side walls that are opposite each other and connect the first and second walls to define a sleeve cavity configured to receive the plurality of shaving razor cartridge containers; and one or more notches, in which at least one notch of the one or more notches is formed by at least one of a part of the first wall and a part of the second wall and at least one of a part of one side wall and a part of the other side wall, and in which at least a portion of the at least one notch extends into the sleeve cavity of the folded sleeve.

In another aspect, a method for forming a sleeve blank is provided, comprising: providing a precursor sleeve blank; creating a plurality of fold lines within the precursor sleeve blank to define a first wall portion, a second wall portion, and a pair of side wall portions, in which at least one of the side wall portions is connected to both the first wall portion and the second wall portion; and forming one or more notch portions in the precursor sleeve blank by (i) cutting at least one notch cut line in the precursor sleeve blank that extends from a part of at least one of the first wall and the second wall to a part of at least one of the pair of side walls, and (ii) creating a notch fold line between the part of at least one of the first wall and the second wall and the part of at least one of the pair of side walls to form the sleeve blank.

In another aspect, a method for assembling a folded sleeve, for example, a folded sleeve for containing a plurality of shaving razor cartridge containers is provided, comprising: providing a sleeve blank comprising a plurality of fold lines that define at least a first wall portion, a second wall portion, and a pair of side wall portions, in which at least one of the side wall portions is positioned between the first wall portion and the second wall portion; forming one or more notch portions including a notch fold line and a notch cut line in the sleeve blank; folding the sleeve blank along the plurality of the fold lines to form a folded sleeve comprising a sleeve cavity defined by a first wall corresponding to the first wall portion, a second wall corresponding to the second wall portion, and a pair of side walls corresponding to the pair of side wall portions; forming at least one notch by folding at least one of the one or more notch portions along a corresponding notch fold line, in which the at least one notch protrudes into the sleeve cavity of the folded sleeve; and inserting a plurality of shaving razor cartridge containers into the sleeve cavity of the folded sleeve, wherein the at least one notch engages at least one of the plurality of shaving razor cartridge containers.

Referring to, perspective and cross section views of examples of a folded sleeve, which may be hollow, in accordance with the present disclosure is illustrated. The folded sleevemay comprise a first wall, a second wallopposite the first wall, and a pair of side walls,, in which the side walls,are opposite each other and connect the first walland the second wallto define a sleeve cavityof the sleeve. Although the sleeveis depicted inas having a substantially rectangular cross-section, it may be understood that other cross-sectional geometries are possible, including circular, semi-circular, square, etc. In addition, while the first and second walls,are depicted as having a larger surface area than the side walls,, it may be understood that other configurations are possible. The sleevemay further comprise one or more pliable tabs, in this case, a first pliable tabA and a second pliable tabB (referred to herein collectively with reference numeral), that protrude or extend, for example, at least partially into the sleeve cavity. “Pliable” as used herein with reference to the tabsmeans that the tabsare easily bent, flexible, foldable, and/or movable between positions under normal consumer use conditions for consumer products, as opposed to being rigid and not designed to be bent and/or movable without sustaining damage, for example without buckling and/or compressing.

The folded sleevemay comprise one or more notchesA,B (collectively referred to herein with reference numeral), also referred to as stop folds. At least one of the one or more notchesis formed by at least one of a part of the first walland a part of the second walland at least one of a part of one side wall, e.g., side wall, and a part of the other side wall, e.g., side wall. For example, the one or more notchesmay be formed by a part′ of the side walland a part′ of the second walland/or a part′ of the side walland a part″ of the second wall. In the example shown in, the folded sleevecomprises two or more notchesA andB, in which a first notchA is formed by the part′ of the second walland the part′ of the side walland a second notchB is formed by the part″ of the second walland the part′ of the side wall.

As shown in, at least a portion of one of the one or more notchesprotrudes and/or extends at least partially into the sleeve cavityof the folded sleeve. In one example, the part′ of the second walland the part′ of the side wallare connected along a notch fold lineA at an angle β of from about 60° to about 120° and/or from about 75° to about 110° and/or from about 85° to about 100° with respect to each other. In one example, the part″ of the second walland the part′ of the side wallare connected along a notch fold lineB at an angle β of from about 60° to about 120° and/or from about 75° to about 110° and/or from about 85° to about 100° with respect to each other. At least one of the notchesA,B may comprise a notch openingA,B. In one example, as shown in, the part′ of the second wallof the first notchA extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance Dfrom the second wallto the first wall. In one example, the part′ of the side wallof the first notchA extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance Dfrom the side wallto the side wall. In one example, the part″ of the second wallof notchB extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance Dfrom the second wallto the first wall. In one example, the part′ of the side wallof notchB extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance Dfrom the side wallto the side wall.

With reference to step V of, another example of a folded sleeve, for example a folded sleeve, is illustrated. The folded sleeveofmay comprise structures similar to the folded sleeveofas described herein. The description of these structures applies equally to the example shown in, where applicable. The folded sleevemay comprise a first wall, a second wallopposite the first wall, and a pair of side walls,that connect the first walland the second wallto define a sleeve cavityof the folded sleeve. Although the sleeveis depicted inas having a substantially rectangular cross-section, it may be understood that other cross-sectional geometries are possible, including circular, semi-circular, square, etc. In addition, while the first and second walls,are depicted as having a larger surface area than the side walls,, it may be understood that other configurations are possible. The sleevemay further comprise one or more pliable tabs, in this case, a first pliable tabA and a second pliable tabB (referred to herein collectively with reference numeral), that protrude or extend, for example, at least partially into the sleeve cavity.

The folded sleevecomprises one or more notchesA,B (collectively referred to herein with reference numeral), also referred to as stop folds. At least one of the one or more notchesis formed by at least one of a part of the first walland a part of the second walland at least one of a part of one side wall, e.g., side wall, and a part of the other side wall, e.g., side wall. For example, the one or more notchesmay be formed by a part′ of the side walland a part′ of the first walland/or a part′ of the side walland a part″ of the first wall. In the example shown in, the folded sleevecomprises two or more notchesA andB, wherein a first notchA is formed by the part′ of the first walland the part′ of the side walland a second notchB is formed by the part″ of the first walland the part′ of the side wall. At least one of the notchesA,B may comprise a notch openingA,B. With continued reference to step V of, at least a portion of one of the one or more notchesprotrudes and/or extends at least partially into the sleeve cavityof the folded sleeve. In one example, the part′ of the first walland the part′ of the side wallare connected along a notch fold lineA at an angle β of from about 60° to about 120° and/or from about 75° to about 110° and/or from about 85° to about 100° with respect to each other. In one example, the part″ of the first walland the part′ of the side wallare connected along a notch fold lineB at an angle β of from about 60° to about 120° and/or from about 75° to about 110° and/or from about 85° to about 100° with respect to each other.

In one example, the part′ of the first wallof notchA extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance (not labeled in; see Din) from the second wallto the first wall. In one example, the part′ of the side wallof notchA extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of a distance Dfrom the side wallto the side wall. In one example, the part″ of the first wallof notchB extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance from the first wallto the second wall. In one example, the part′ of the side wallof notchB extends into the sleeve cavitygreater than 5% and/or greater than 10% and/or greater than 15% and/or greater than 20% of the distance Dfrom the side wallto the side wall.

With reference toand step V of, in one example, the first wall,, the second wall,, and pair of side walls,and,of the respective folded sleeve,may define a first end openingA,A and a second end openingB,B opposite the first end openingA,A (referred to herein collectively with reference numeralor), in which the first end openingA,A and/or the second end openingB,B may be configured for at least one of receiving into or dispensing from the sleeve cavity,at least one of a plurality of consumer product containers, such as shaving razor cartridge containers (not shown; see). In one example, the first end openingA,A defined in the folded sleeve,may be dimensioned to receive into and dispense from the sleeve cavity,of the folded sleeve,at least one consumer product container, e.g., a shaving razor cartridge container.

In one example, at least one of the first and second end openingsA,B andA,B may comprise at least one of the one or more notches,. In another example, at least one of the first and second end openingsA,B andA,B may comprise at least two notches,. In one example, one or more notches,may be more proximate to one end opening,A,B andA,B, as compared to the other end openingA,B andA,B. In the example shown in, the second end openingB of the sleevemay comprise the first notchA formed by the part′ of the second walland the part′ of the side walland the second notchB formed by the part″ of the second walland the part′ of the side wall. In the example shown in step V of, the second end openingB of the sleevemay comprise the first notchA formed by the part′ of the first walland the part′ of the side walland the second notchB formed by the part″ of the first walland the part′ of the side wall.

To aid in the receiving and/or dispensing of the consumer product containers (not shown; see), the folded sleeve,may further comprise one or more cutouts,. The one or more cutouts,may be configured to permit access to at least one consumer product container during dispensing by a user. For example, the first and/or second wall,and,may comprise the cutout,at one or more of the end openings,. The one or more cutouts,when present, may form at least a part of at least one of the end openings,, for example, the first end openingA,A. In the example shown in, the first wallcomprises two cutoutsA,B at the first openingA. In the example shown in step V of, the first wallcomprises a cutout, e.g., one cutout, at the first end openingA.

With reference to the example shown in, a consumer product dispensing system is illustrated, which comprises the folded sleeveand a plurality of consumer product containers, e.g., shaving razor cartridge containersA-F (referred to herein collectively with reference numeral), which may contain one or more consumer products, e.g., one or more shaving razor cartridges (not shown). The first end openingA and/or the second end openingB of the sleevemay be configured to receive into and/or dispense from the sleeve cavitythe plurality of shaving razor cartridge containers. At least one of the notchesmay be configured to engage one or more of the plurality of consumer product containers present within the sleeve cavityof the folded sleeve. In one example, as described herein, at least one of the notchesmay be configured to retain the shaving razor cartridge containerwithin the sleeve cavityof the folded sleeve. The one or more cutouts, when present, may be configured to permit access to at least one of the one or more shaving razor cartridge containersduring dispensing by a user. In particular, the one or more cutoutsmay facilitate grasping of a shaving razor cartridge containercontaining a shaving razor cartridge by a user, for example, by grasping a shaving razor cartridge container wall (not labeled). By grasping the shaving razor cartridge container, the user avoids inadvertently contacting a blade (not visible) of the shaving razor cartridge. The shaving razor cartridge containerthus provides safety for the user when dispensing, as the shaving razor cartridge containerfunctions as an “overcap” by covering the blades of the shaving razor cartridge contained therein and preventing a user from contacting the blade.

With reference to the example shown in, the folded sleevemay further comprise one or more inner wallsthat define two or more consumer product container compartmentsA,B within the sleeve cavityof the folded sleevethat are configured to receive, retain, and/or dispense one or more of the plurality of consumer product containers, e.g., shaving razor cartridge containers(see), present within the consumer product container compartmentsA,B (also referred to herein as shaving razor cartridge container compartmentsA,B). At least one of the inner wallsmay be attached to at least one of the first and second walls,of the sleeve. At least one of the inner wallsmay comprise an inner wall flapthat, when present, may assist in the attaching of the inner wallto the first and/or second walls,(see also). For example, the inner wall flapmay facilitate easier forming of the sleeveby providing a bonding or affixing portion that helps to hold the sleevetogether after the first, second, and pair of side walls,,,have been folded to form the folded sleeve. The bonding and/or affixing portion may be adhesively attached to one or more of the first, second, and pair of side walls,,,, as described herein.

At least one of the inner wallsmay extend at least partially between the first end openingA and the second end openingB of the sleeve cavityof the sleeve, as shown in. At least one of the inner wallsmay extend at least partially between the first walland the second wallof the sleeveto define the two or more shaving razor cartridge container compartmentsA,B. The two or more shaving razor cartridge container compartmentsA,B may be completely separated from one another by the one or more inner walls. Alternatively, in other examples (not shown), the two or more shaving razor cartridge container compartmentsA,B may be functionally separated from one another, even though at least one of the inner wallsis not fully attached to one or both of the first walland the second wall(in other words, there may be a gap or space between an end of the inner walland the first walland/or the second wall, so long as the inner wallphysically keeps the consumer product containers, e.g., shaving razor cartridge containers, in the shaving razor cartridge container compartmentA from moving into the shaving razor cartridge container compartmentB and vice versa).

In the example shown in, the shaving razor cartridge container compartmentsA,B comprise substantially similar dimensions, such that the sleeveis substantially symmetrical. In other examples (not shown), one of the shaving razor cartridge container compartmentsA,B may comprise a dimension that is different from the other of the shaving razor cartridge container compartmentsA,B, e.g., one of the shaving razor cartridge container compartmentsA,B may be wider than the other, to, for example, accommodate consumer product containers of differing sizes or types (not shown).

At least one of the shaving razor cartridge container compartmentsA,B may comprise the one or more notchesA,B. In one example, the first shaving razor cartridge container compartmentA comprises the first notchA. In one example, the shaving razor cartridge container compartmentB comprises the second notchB. As shown in, the notches, when present, may be configured to prevent the consumer product containers, e.g., the shaving razor cartridge containers, from inadvertently moving, slipping, or falling out of the sleeve cavityof the sleeve. The notchesmay be configured to contact at least a part of the shaving razor cartridge containerspresent within the sleeve cavityof the sleeve. In the example shown in, the first notchA engages at least a part of an adjacent one of the shaving razor cartridge containers, i.e., shaving razor cartridge containerA, present in the first shaving razor cartridge container compartmentA, and the second notchB engages at least a part of an adjacent one of the shaving razor cartridge containers, i.e., shaving razor cartridge containerD, present in the second shaving razor cartridge container compartmentB. Although not shown, the notchesA,B of the sleeveshown in step V ofmay similarly contact at least a part of one or more consumer product containers present within the sleeve cavity.

In one example, the sleevemay comprise at least one of the first wall, second wall, and/or side walls,that comprises two or more layers of material. For example, as shown in, the first wallcomprises two or more layers of materialA,B. The two or more layers of materialA,B may comprise identical features, for example, one or more cutoutsand/or windowsas described herein, when the two or more layers of materialA,B are commensurate in surface area and share a common interface between one or more surfaces of the two or more layers of materialA,B (such as in a laminate configuration). Alternatively, the two or more layers of materialA,B do not have to fully align and/or share the same features as each other, such as when the surface area of the layer of materialB is less than the surface area of the layer of materialA, as best seen in. In one example (not shown), the layer of materialB may be a strip of material that only contacts a portion, i.e., less than all, of the layer of materialA.

In the example shown in, in addition to the first wall, the second wall, and the pair of side walls,, the sleevemay further comprise an overlap flapthat facilitates easier forming of the sleeveby providing a bonding or affixing portion that helps to hold the sleevetogether after the first, second, and pair of side walls,,,have been folded to form the folded sleeve. The bonding and/or affixing portion may be adhesively attached to one or more of the first, second, and pair of side walls,,,, as described herein.

The folded sleeve,of the present disclosure is configured to receive, retain, and/or dispense a plurality of consumer product containers, e.g., shaving razor cartridge containers, for example, from four to ten, for example, from six to eight, shaving razor cartridge containerswithin the sleeve cavity,of the folded sleeve,. In the case of the folded sleeveshown in, each of the one or more shaving razor cartridge container compartmentsA,B may be configured to receive three consumer product containers, e.g., shaving razor cartridge containersA-C andD-F. Although not shown, the exemplary folded sleeveillustrated in step V ofmay be configured to receive, for example, four consumer product containers.

With reference to the folded sleeveshown in, at least one of the one or more pliable tabsmay be in a first position, e.g., see pliable tab portionsA,B (referred to herein collectively with reference numeral) shown in, during formation of the sleevefrom a precursor sleeve blank, where the pliable tab, prior to bending and/or folding, is substantially coplanar with a respective wall, e.g., the first walland/or the second wall(see first and second wall portions,as shown in), which permits a consumer product container, e.g., a shaving razor cartridge container(see), to slide by the pliable tabwithout the pliable tabengaging the consumer product container. In other words, when the pliable tabis in the first position, the pliable tabdoes not engage the consumer product container as the consumer product container slides past the pliable tabwithin the sleeve cavity. At least one of the one or more pliable tabsmay be in a second position, where the pliable tabprotrudes into the sleeve cavityof the sleeve. In one example, when the pliable tabis in the second position, the pliable tabforms a maximum angle α with the respective wall, for example, the first wallor the second wall, of from about 90° to about 170°, for example, or from about 90° to about 105°. For example, as shown inwith respect to the first pliable tabA, the first pliable tabA forms a maximum angle α with the first wallof from about 90° to about 170°, for example, or from about 90° to about 105°. The second pliable tabB may similarly form a maximum angle (not shown) with the first wallof from about 90° to about 170°, for example, or from about 90° to about 105°.

In one example, with reference to, upon introducing one or more consumer product containers, e.g., shaving razor cartridge containers, into the sleeve cavityof the folded sleevethrough at least one end opening, for example, the first end openingA and/or the second end openingB, of the folded sleeve, at least one of the one or more pliable tabsmay engage at least one of the shaving razor cartridge containersif the pliable tab is in the second position when the shaving razor cartridge containeris present within the folded sleeve. In the example shown in, the first pliable tabA may engage at least part of one of the consumer product containers, i.e., shaving razor cartridge containerC, if the first pliable tabA is in the second position when the shaving razor cartridge containerC is present within the shaving razor cartridge container compartmentA. In another example, the pliable tabB may engage at least part of one of the consumer product containers, e.g., shaving razor cartridge containerF, if the second pliable tabB is in the second position when the shaving razor cartridge containerF is present within the shaving razor cartridge container compartmentB. In the example shown in, the first and second notchesA,B and the first and second pliable tabsA,B engage one or more of the shaving razor cartridge containersto inhibit the shaving razor cartridge containerspresent within the sleeve cavityof the folded sleevefrom unintentionally and/or inadvertently moving, slipping, dislodging, and/or falling out of the sleeve cavityduring shipping and/or when handled by a user.

Although not illustrated, it is understood that the pliable tabsof the folded sleeveshown inmay similarly comprise a first position (as illustrated with respect to corresponding pliable tab portionsA,B), in which the one or more pliable tabsdo not engage the consumer product container, and a second position, in which the one or more pliable tabseach form a maximum angle (not shown) with the first wallor the second wallof from about 90° to about 170°, for example, or from about 90° to about 105°. The pliable tabsof the folded sleevemay similarly engage at least one of the consumer product containers.

In one example, the folded sleeve,may further comprise one or more windows formed in one or more of the first wall,and the second wall,. With reference to, the folded sleeve may comprise, for example, a first windowA and a second windowB (referred to herein collectively with reference numeral), both of which are formed in the first wall. In the example shown in, the sleevecomprises a first windowA and a second windowB (referred to herein collectively with reference numeral), in which the first windowA is formed in the first walland the second windowB is formed in the second wall. In other examples (not shown), the first wall,may be devoid of windows, and the second wall,may comprise two or more windows.

In one example, at least one of the one or more pliable tabs,may be associated with one of the windows,, and the pliable tab,, when associated with the window,, may extend at least partially into the sleeve cavity,of the sleeve,from the window,, specifically from a perimeter of the window,, for example, at least one perimeter edge,of the window,. In the example shown in, the first wallcomprises the first windowA having a perimeter edgeA from which a pliable tab, e.g., the first pliable tabA, extends at least partially into the sleeve cavityof the sleeve, and the first wallcomprises the second windowB having a perimeter edgeB from which a pliable tab, e.g., the second pliable tabB, extends at least partially into the sleeve cavityof the sleeve. In the example shown in, the second wallis devoid of any windows. In the example shown in, the first wallcomprises the first windowA having a perimeter edgeA from which a pliable tab, e.g., the first pliable tabA, extends at least partially into the sleeve cavityof the sleeve, and the second wallcomprises a second windowB having a perimeter edgeB from which a pliable tab, e.g., the second pliable tabB, extends at least partially into the sleeve cavityof the sleeve.

With reference to the exemplary folded sleeveshown inin which the first and second windowsA,B are formed in the first wall, the perimeter of the first windowA may be substantially the same as the perimeter of the second windowB, i.e., dimensions of the first and second windowsA,B may be substantially the same. In other examples (not shown), the first wallmay comprise the first and second windowsA,B, and one of the first windowA or the second windowB may have a greater perimeter than the other of the first windowA or the second windowB, i.e., the first windowA comprises at least one dimension that is less than or greater than at least one corresponding dimension of the second windowB. With reference to the exemplary folded sleeveshown in, the first windowA may have a different perimeter than the second windowB. In the illustrated example, the first windowA is present in the first wall, and the second windowB is present in the second wall, in which the first windowA has a greater perimeter than the second windowB, i.e., the first windowA comprises at least one dimension that is greater than at least one corresponding dimension of the second windowB. In other examples (not shown), the first and second windowsA,B may comprise substantially similar perimeters.

When the folded sleeve,comprises one or more windows,, at least a portion of the sleeve cavity,of the folded sleeve,may be visible through at least one of the one or more windows,. At least a portion of the sleeve cavity,of the folded sleeve,may also be accessible through at least one of the one or more windows,by a user. As shown in, when one or more consumer product containers, e.g., one or more shaving razor cartridge containersare present within the sleeve cavityof the sleeve, at least a portion of at least one of the one or more consumer product containers may be visible through at least one window.

The folded sleeve,ofmay comprise a recyclable material or a biodegradable material or a compostable material or a natural material, such as pulp, for example, wood pulp, or paper or paperboard. The sleeve,may comprise a folded sleeve that comprises one or more fold lines, as described herein. In some examples, the folded sleeve,may comprise a contiguous material and may be, for example, formed from a single piece or sheet of material, such as paperboard. In some particular examples, the sleeve,may be formed from a single sleeve blank (see). The consumer product containers, e.g., the shaving razor cartridge containersA-F, may also comprise a recyclable material or a biodegradable material or a compostable material or a natural material, such as pulp, for example, wood pulp, or paper or paperboard. In some examples, the sleeve,and the consumer product containers may comprise the same material(s).

Referring to, perspective views and a flow chart of possible methods for forming a sleeve blank,, as shown in, from a precursor sleeve blank, as shown in, suitable for assembling into a folded sleeve,of the present disclosure is illustrated.

As shown in, a precursor sleeve blankcomprises a sleeve blank material. As shown in, the sleeve blank materialmay be cut, for example, to form any windows,as described herein; any pliable tab portions,(see) associated with the window(s),to permit the pliable tab portions,to be folded away from their respective windows,to ultimately form the pliable tabs,in the resulting sleeve,as described herein; any cutouts,as described herein; any overlap flap portions,that may form one or more inner wall flapsor overlap flapsas described herein; any notch portions,that can be folded to create notches,in the resulting sleeve,as described herein; and/or any inner wall portionsthat can be folded to create inner wallsin the resulting sleeveas described herein.

Referring to, one possible methodfor forming an example of a sleeve blanksuitable, for example, for use as a folded sleeve(see) includes stepof providing a precursor sleeve blank. In step, the precursor sleeve blankmay optionally be cut, if necessary, to a size suitable for the folded sleeve. Once the precursor sleeve blankis of a size suitable for the folded sleeve, one or more notch portionsmay be formed in stepby cutting one or more notch cut linesin the precursor sleeve blank. The notch portions, when folded, form the notchesin the folded sleeve, as described herein. Stepmay include optionally forming, e.g., cutting, one or more windows, in this case, windowsA andB. Stepmay include optionally cutting, for example, along a perimeter edgeof the one or more windowsto form any pliable tab portions, for example, a first pliable tab portionA and a second pliable tab portionB, such that each of the one or more pliable tab portionsis associated with one of the one or more windows. Stepmay include optionally forming, e.g., cutting, any cutoutsin the precursor sleeve blank. The methodmay further comprise optionally cutting any overlap flap portionsin step. In step, an adhesivemay be applied to the sleeve blankand/or the precursor sleeve blank, for example, the adhesivemay be applied in the form of a landing stripsuitable for receiving a portion of the sleeve blankto assist in forming and holding the folded sleevetogether.

Referring to, one possible methodfor forming another example of a sleeve blanksuitable, for example, for use as a folded sleeve(see) includes stepof providing a precursor sleeve blank. In step, the precursor sleeve blankmay optionally be cut, if necessary, to a size suitable for the sleeve. Once the precursor sleeve blankis of a size suitable for the folded sleeve, one or more notch portionsmay be formed in stepby cutting one or more notch cut linesin the precursor sleeve blank. The notch portions, when folded, form the notchesin the folded sleeve, as described herein. Stepmay include optionally forming, e.g., cutting, one or more windows, in this case, windowsA-C. Stepmay include optionally cutting, for example, along a perimeter edgeof the one or more windowsto form any pliable tab portions, for example, a first pliable tab portionA and a second pliable tab portionB, such that each of the one or more pliable tab portionsis associated with one of the one or more windows. Stepmay include optionally forming, e.g., cutting, any cutoutsin the precursor sleeve blank. The methodmay further comprise optionally forming, i.e., cutting, any overlap flap portionsin step, and optionally forming, i.e., cutting any inner wall portionsin step. In step, an adhesivemay be applied to the sleeve blankand/or the precursor sleeve blank, for example, the adhesivemay be applied in the form of a landing stripsuitable for receiving a portion of the sleeve blankto assist in forming and holding the folded sleevetogether.

The sleeve blank materialmay comprise a recyclable material or a biodegradable material or a compostable material or a natural material such as pulp, for example, wood pulp, or paper or paperboard. In one example, as shown in, the precursor sleeve blankand the sleeve blank materialmay comprise a contiguous material, for example, a single piece of material, that can be cut and/or imparted with fold lines to achieve a sleeve blanksuitable for folding into a sleeve,of the present disclosure.

Referring to, one methodfor forming or assembling a folded sleeve, e.g., the folded sleeve,(see), is illustrated, in which the folded sleeve,may be for containing a plurality of consumer product containers, e.g., shaving razor cartridge containers(see). In step, a precursor sleeve blankis provided, which may include the precursor sleeve blankshown in. In step, a plurality of fold lines may be created in the precursor sleeve blank, in which the fold lines may comprise crease lines, perforations, and the like and may assist with making a predetermined fold. The plurality of fold lines define a first wall portion, a second wall portion, and a pair of side wall portions, in which at least one of the side wall portions is connected to both the first wall portion and the second wall portion, as described herein. One or more notch portions are formed in stepby (i) cutting at least one notch cut line in the precursor sleeve blank that extends from a part of at least one of the first wall and the second wall to a part of at least one of the pair of side walls, and (ii) creating a notch fold line between the part of at least one of the first wall and the second wall and the part of at least one of the pair of side walls to form a sleeve blank, e.g., the sleeve blank,(see), as described herein. In step, the sleeve blank is folded along a plurality of the fold lines to form a folded sleeve,as described herein, in which the folded sleeve,includes a sleeve cavity defined by a first wall corresponding to the first wall portion, a second wall corresponding to the second wall portion, and a pair of side walls corresponding to the pair of side wall portions, as described herein. In step, at least one notch is formed by folding at least one of the notch portions along a corresponding notch fold line to form the at least one notch, in which the at least one notch protrudes into the sleeve cavity of the folded sleeve, as described herein. In step, a plurality of consumer product containers, e.g., a plurality of shaving razor cartridge containersA-F (see) into the sleeve cavity of the folded sleeve,, in which the at least one notch engages at least one of the plurality of consumer product containers, e.g., at least one of the shaving razor cartridge containersA-F, as described herein.

Referring to, perspective views of one possible method for folding a sleeve blankto form a folded sleevesuitable for use in a consumer product dispensing system, for example, a shaving razor cartridge dispensing system (see), is illustrated.

In this example, the method for folding a sleeve blankinto a folded sleevecomprises providing a sleeve blankin step I of. The sleeve blankmay be formed, as described herein. The sleeve blankcomprises a plurality of fold lines-(referred to herein collectively with reference numeral). As described herein, the fold linesmay include crease lines, perforations, and the like and may assist with making a predetermined fold. The fold linesmay define at least a first wall portion(between fold linesand), a second wall portion(between fold lineand one outer edge (not labeled) of the sleeve blank), and a pair of side wall portions,(between fold linesandand fold linesand, respectively). One of the pair of side wall portions,, for example, side wall portion, may be positioned between the first wall portionand the second wall portion.

The sleeve blankcomprises one or more notch portions(stop fold portions), e.g., a first notch portionA and a second notch portionB (referred to herein collectively with reference numeral) formed by cutting a respective notch cut line,, for example, by cutting the sleeve blankbetween one or more of the side wall portions,and adjacent portions of one or more of the first wall portionand/or the second wall portion. As shown in, one notch portion, i.e., the first notch portionA, is formed by creating a first notch cut linebetween a part of the side wall portionand a part of the first wall portion, and another notch portion, i.e., the second notch portionB, is formed by creating a second notch cut linebetween a part of the side wall portionand a part of the first wall portion. The notch portionsA,B each further comprise two additional sets of fold linesand, respectively.

In one example, if at least one windowis not present in the sleeve blank, then one or more windowsmay be formed, i.e., cut, into the sleeve blank, and if at least one pliable tab portionis not present in the sleeve blank, then one or more pliable tab portionsmay be formed in the sleeve blank, as described above. At least one fold linemay be associated with at least one of the windowsto define one or more pliable tab portions, such that each of the one or more pliable tab portionsis associated with one of the one or more windows. As shown in, a first windowA is formed in the first wall portion, and a first pliable tab portionA is associated with the first windowA, with fold linedefining the first pliable tab portionA. In one example, in addition to a first pliable tab portionA, the sleeve blankmay further comprise another fold lineassociated with a second windowB to define a second pliable tab portionB. As shown in, the second windowB is formed in the second wall portion, and the second pliable tab portionB is associated with the second windowB. The first pliable tab portionA and/or second pliable tab portionB may be associated with their respective windowsA,B along at least one perimeter edgeA,B of the windowsA,B, along which the pliable tab portionsA,B may be folded along their respective fold lines,. To aid in folding of the pliable tab portionsA,B, sidesof the pliable tab portionsA,B may be cut from adjacent portions of the respective first and second wall portions,during formation of the pliable tab portionsA,B.

In one example, the sleeve blankfurther comprises an overlap flap portion. The overlap flap portionmay further comprise an adhesiveon one or more surfaces of the overlap flap portion. The overlap flap portionmay be connected to one of the first wall, second wall, or pair of side wall portions,,,, along at least one fold line. In the example shown in, the overlap flap portionis connected to the side wall portionalong fold line. An edge of the overlap flap portionmay define the other outer edge (not labeled) of the sleeve blank.

As shown in step II of, the overlap flap portionis folded over toward the side wall portionalong the fold linebetween the overlap flap portionand the side wall portion. The exposed surface of the overlap flap portionmay comprise the adhesive, e.g., in the form of a landing stripas described herein. It is understood that the sleeve blankmay vary with respect to the relative locations of the first wall, second wall, and side wall portions,,,, overlap flap portion, fold lines, notch portionsand associated notch cut lines, pliable tab portions, and/or windows.

Steps III and IV ofinclude folding the sleeve blankalong the fold linebetween the first wall portionand the side wall portionand along the fold lines,between the side wall portionand the first and second wall portions,, such that the landing stripof adhesivecontacts an inner surface (not labeled) of the second wall portionand attaches, for example, by bonding such as with the adhesive, the overlap flap portionto at least the second wall portion. In step IV of, the overlap flap portioncorresponds to the overlap flap, and folding of the sleeve blankalong the plurality of fold linesand the attachment of the overlap flap portionto the second wall portionforms the folded sleevehaving a sleeve cavitydefined by the first wallcorresponding to the first wall portion, the second wallcorresponding to the second wall portion, and the pair of side walls,, corresponding to the pair of side wall portions,. At least one end opening, for example, end openingsA andB, is formed in the sleeve, as shown in step IV of. The sleeve blankmay comprise a cutoutin at least one of the first and second wall portions,and/or resulting first and second walls,that is located at at least one end opening, for example, end openingA. The cutoutmay exhibit a radius (R; see) of from about 5 mm to about 40 mm and/or from about 10 mm to about 30 mm and/or from about 10 mm to about 20 mm.

With continued reference to step IV of, the notch portionsmay be formed into notches, for example, a first notchA and a second notchB. The first notchA may be formed by folding a part′ of the first walland a part′ of the side wallinward along fold lines, e.g., into the sleeve cavityand toward the second walland the side wall. The second notchB may similarly be formed by folding a part″ of the first walland a part′ of the side wallinward along fold lines, e.g., into the sleeve cavityand toward the second walland the side wall.

In one example, the part′ of the first walland the part′ of the side wallthat define the first notchA are connected along a notch fold lineA and define an angle (not labeled) of from about 60° to about 120° and/or from about 75° to about 110° and/or from about 85° to about 100° with respect to each other. In one example, the part″ of the first walland the part′ of the side wallthat define the second notchB are connected along a notch fold lineB and define an angle (not labeled) of from about 60° to about 120° and/or from about 75° to about 110° and/or from about 85° to about 100° with respect to each other. In the example shown in step IV of, the angle may be about 90°.

In step V of, the pliable tab portionA is folded along the associated fold lineto form a pliable tabA that protrudes at least partially into the sleeve cavityof the sleeve. Further, the pliable tab portionB is folded along the associated fold lineto form a pliable tabB that protrudes at least partially into the sleeve cavityof the sleeve. Although the folding of the pliable tab portionsA,B is depicted as occurring in step V of, it may be understood that the pliable tab portionsA,B may also be folded in step III prior to formation of the first and second notchesA,B.

Prior to formation of the first and second notchesA,B (prior to or after folding of the pliable tab portionsA,B to form the pliable tabsA,B), a plurality of consumer product containers, for example, shaving razor cartridge containersA-F (see) containing one or more consumer products, for example, shaving razor cartridges (not shown), may be inserted into the sleeve cavityof the sleeve. At least one of the one or more pliable tabsA,B engages at least one of the plurality of consumer product containers, for example, the shaving razor cartridge containers, as described herein. The first and second notchesA,B may then be formed to further secure the consumer product containers within the sleeve cavity.

Even thoughillustrate a method for forming one example of a folded sleeve, for example, a folded sleevesuitable for use with a four-count consumer product dispensing system, the disclosure is not limited to such a folded sleeve.