Composite flat blank for containers and method

Claim 2

A paperboard flat blank, scored for folding to form a container, which flat blank comprises: at least first and second flat paperboard blank portions sealed together along seal line means to form the entire flat blank, each flat blank portion having a portion thereof that is free of contact with the other flat blank portion; said first flat blank portion exhibiting at least one physical property that is different from the corresponding physical property of said second flat blank portion, other than the scoring, and the shape and size in the plane of said flat blank by having a different physical property of strength based on the organic macromolecules present in said paperboard that relates at least to one of the properties that include amount of macromolecules and type of macromolecules present in the paperboard of the blank portions.

Claim 3

The flat blank of claim 1 in which one of said blank portions is made of printed, sheet-fed stock, and the other of said blank portions is of roll-fed stock.

Claim 4

The flat blank of claim 1, wherein a container can be formed therefrom.

Claim 5

The flat blank of claim 1, whereby a rectangular container can be formed therefrom.

Claim 6

A paperboard six-sided rectangular container, formed from a flat blank, which flat blank comprises: at least first and second flat blank portions sealed together along seal line means to form the entire flat blank, said first blank portion being made of a recycled paperboard and said second blank portion is made of virgin paperboard, and each flat blank portion having a portion thereof that is free of contact with the other flat blank portion, said first flat blank portion exhibiting the physical property of less crush resistance than the crush resistance of said second flat blank portion, said first flat blank portion defining a major rectangular container side and four minor container sides formed with edges, said minor container sides being scored and attached by fold lines to said edges of said major rectangular container side, said second blank portion also defining one major rectangular side that is sized to be positioned opposed to said major rectangular container side of at least first and second flat paperboard blank portions sealed together along seal line means to form the entire flat blank, each flat blank portion having a portion thereof that is free of contact with the other flat blank portion; said first flat blank portion exhibiting at least one physical property that is different from the corresponding physical property of said second flat blank portion, other than the scoring, and the shape and size in the plane of said flat blank by having a different physical property of strength based on the organic macromolecules present in said paperboard that relates at least to one of the properties that include amount of macromolecules and type of macromolecules present in the paperboard of the blank portions.

Claim 7

A paperboard six-sided rectangular container, formed from a flat blank, which flat blank comprises: at least first and second flat blank portions sealed together along seal line means to form the entire flat blank, said first blank portion being made of a recycled paperboard and said second blank portion is made of virgin paperboard, and each flat blank portion having a portion thereof that is free of contact with the other flat blank portion, said first flat blank portion exhibiting the physical property of less crush resistance than the crush resistance of said second flat blank portion, said first flat blank portion defining a major rectangular container side and four minor container sides formed with edges, said minor container sides being scored and attached by fold lines to said edges of said major rectangular container side, said second blank portion also defining one major rectangular side that is sized to be positioned opposed to said major rectangular container side of at least first and second flat paperboard blank portions sealed together along seal line means to form the entire flat blank, each flat blank portion having a portion thereof that is free of contact with the other flat blank portion; said first flat blank portion exhibiting at least one physical property that is different from the corresponding physical property of said second flat blank portion, other than the scoring, and the shape and size in the plane of said flat blank by having a different physical property of strength based on the organic macromolecules present in said paperboard that relates at least to one of the properties that include amount of macromolecules and type of macromolecules present in the paperboard of the blank portions.

Claim 10

The method of claim 6 in which one of said flat blank portions is made of printed, sheet-fed stock, and the other of said flat blank portions is of roll-fed stock.

Claim 11

The method of claim 6 in which said flat blank formed from the joined flat blank portions is further processed in automated machinery into a container sleeve that can be collapsed and shipped to another plant where it can be formed into a closed carton.

Claim 12

The method of claim 8 in which said further processing comprises printing on said flat blank.

Claim 13

The method of claim 8 in which said further processing comprises forming of fold lines in said flat blank.

Claim 14

The method of claim 8 in which said container sleeve is filled with merchandise and then flaps at each end of said sleeve are glued together.