Multilayer single wrap container and method and blank therefor

Abstract

The present invention provides a single wrap container and a method for forming such a container and a blank therefor. The blank and, hence, the container are formed of a multilayer web that has an inner liner ply and an outer label ply, each adhered to opposite sides of a paper ply, which can be recycled paper. The multilayer web is cut to a predetermined shape, for example, using a rotary die, thereby forming the blank. The container can then be formed by singly wrapping the blank so that helical wrapping is not required and a seam formed by joining the edges of the blank is linear.

1 . A method of constructing a single wrap container, the method comprising: 
 providing a paper ply having first and second opposite sides;    adhering a liner ply to the first side of the paper ply and a label ply to the second side of the paper ply to thereby form a multilayer web;    cutting the multilayer web with a die to form a substantially flat blank for forming the single wrap container; and    bending the blank and joining first and second edges of the blank to form a single wrap container defining an interior space.    
     
     
         2 . A method according to  claim 1  wherein said providing step comprises providing paperboard formed at least partially of recycled paper.  
     
     
         3 . A method according to  claim 1  wherein said adhering step comprises substantially covering the first and second sides of the paper ply.  
     
     
         4 . A method according to  claim 1  wherein said adhering step comprises disposing an adhesive between the liner ply and the paper ply and between the label ply and the paper ply and passing the multilayer web through a nip formed by opposing rollers.  
     
     
         5 . A method according to  claim 1  further comprising coiling the multilayer web after said adhering step to form a roll before said cutting step.  
     
     
         6 . A method according to  claim 1  further comprising heating the multilayer web and thereby conditioning the multilayer web to adjust a moisture content of the web to a predetermined level.  
     
     
         7 . A method according to  claim 1  further comprising printing indicia on the label before said adhering step.  
     
     
         8 . A method according to  claim 7  wherein said printing and adhering steps comprise printing a first side of the label ply and adhering a second side of the label ply to the paper ply such that the first side of the label ply is directed away from the paper ply.  
     
     
         9 . A method according to  claim 1  wherein said cutting step comprises cutting more than one blank from a width of the multilayer web.  
     
     
         10 . A method according to  claim 1  wherein said cutting step comprises urging the multilayer web against an outer cutting surface of a rotary die and rotating the rotary die.  
     
     
         11 . A method according to  claim 1  wherein said bending step comprises bending the blank to form a linear interface between the first and second edges of the blank.  
     
     
         12 . A method according to  claim 1  wherein said bending step comprises bending the blank by about 360 degrees to form the single wrap container.  
     
     
         13 . A method according to  claim 1  wherein said cutting step comprises cutting the multilayer web to define the first and second edges of the blank in a nonparallel configuration, and wherein said bending step comprises bending the blank to form the container such that the container is at least partially conical.  
     
     
         14 . A method according to  claim 1  further comprising attaching at least one end member to the container, thereby closing at least one end of the container.  
     
     
         15 . A method of forming a blank for use in constructing a single wrap container, the method comprising: 
 providing a paper ply having first and second opposite sides;    adhering a liner ply to the first side of the paper ply and a label ply to the second side of the paper ply to thereby form a multilayer web; and    cutting the multilayer web with a die to form a substantially flat blank for forming the single wrap container.    
     
     
         16 . A method according to  claim 15  wherein said providing step comprises providing paperboard formed at least partially of recycled paper.  
     
     
         17 . A method according to  claim 15  wherein said adhering step comprises substantially covering the first and second sides of the paper ply.  
     
     
         18 . A method according to  claim 15  wherein said adhering step comprises disposing an adhesive between the liner ply and the paper ply and between the label ply and the paper ply and passing the multilayer web through a nip formed by opposing rollers.  
     
     
         19 . A method according to  claim 15  further comprising coiling the multilayer web after said adhering step to form a roll before said cutting step.  
     
     
         20 . A method according to  claim 15  further comprising conditioning the multilayer web to adjust a moisture content of the web to a predetermined level.  
     
     
         21 . A method according to  claim 15  further comprising printing indicia on the label before said adhering step.  
     
     
         22 . A method according to  claim 15  wherein said printing and adhering steps comprise printing a first side of the label ply and adhering a second side of the label ply to the paper ply such that the first side of the label ply is directed away from the paper ply.  
     
     
         23 . A method according to  claim 15  wherein said cutting step comprises cutting more than one blank from a width of the multilayer web.  
     
     
         24 . A method according to  claim 15  wherein said cutting step comprises urging the multilayer web against an outer cutting surface of a rotary die and rotating the rotary die.  
     
     
         25 . A single wrap container formed from a blank, the container comprising: 
 a multilayer web sidewall extending circumferentially between first and second edges joined at a seam, the sidewall having a paper ply with first and second opposite sides, a liner ply adhered to the first side of the paper ply and a label ply adhered to the second side of the paper ply, the sidewall being singly wrapped such that the seam is substantially linear.    
     
     
         26 . A container according to  claim 25  wherein the paper ply is formed at least partially of recycled paper.  
     
     
         27 . A container according to  claim 25  wherein the liner and label plies substantially cover the first and second sides of the paper ply.  
     
     
         28 . A container according to  claim 25  wherein the label ply is opaque and defines indicia printed on an outer surface thereof.  
     
     
         29 . A container according to  claim 25  further comprising an end member joined to the sidewall to at least partially close the container.  
     
     
         30 . A container according to  claim 25  wherein at least one of the liner and label plies are formed of a polymer.  
     
     
         31 . A container according to  claim 25  wherein the liner comprises a material which is substantially impermeable to gas and moisture, the label ply comprises a material capable of being printed, and the paper ply comprises recycled paper.