Flat panel sleeve with folded portions and method of manufacturing

FLAT PANEL SLEEVE WITH FOLDED PORTIONS AND METHOD OF MANUFACTURING

0002[0001]

FIELD OF THE INVENTION

0004[0002] This invention relates to sleeves, covers or containers used to (i)

0005wrap flower pots or other items, (ii) contain or display floral groupings or other

0006items, or (iii) cultivate or display botanical items and methods of use thereof

0007and (iv) methods of their manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

0009[0003] Figure 1 is a plan view of a square sheet of material used to form

0010a decorative cover in accordance with the present invention.

0011[0004] Figure 2 is an elevational view of the sheet of material of Figure 1 having a first folded portion.

0012[0005] Figure 3 is a cross-sectional view of the sheet of material of Figure

00132 taken along line 3-3.

0014[0006] Figure 4 is an elevational view of the sheet of material of Figure 2 having a second folded portion. [0007] Figure 5 is a cross-sectional view of the sheet of material of Figure

00154 taken along line 5-5.

0016[0008] Figure 6 is an elevational view of the sheet of material of Figure 4

0017having a third folded portion.

0018[0009] Figure 7 is a cross-sectional view of the sheet of material of Figure

00196 taken along line 7-7.

0020[0010] Figure 8 is an elevational view of the sheet of material of Figure 6

0021having a fourth folded portion forming a decorative cover.

0022[0011] Figure 9 is a cross-sectional view of the decorative cover formed by

0023the sheet of material of Figure 8 taken along line 9-9.

0024[0012] Figure 10 is a bottom view of the decorative cover of Figure 8 after

0025it is formed into an open position.

0026[0013] Figure 11 is a perspective view of the opened decorative cover of

0027Figure 10 having a pot and floral grouping disposed therein.

0028[0014] Figure 12 is a plan view of an alternate version of a sheet of

0029material used to form a decorative cover in accordance with the present

0030invention.

0031[0015] Figure 13 is an elevational view of a decorative cover formed using

0032the sheet of material of Figure 12.

0033[0016] Figure 14 is a plan view of an alternate version of a sheet of material used to form a decorative cover in accordance with the present invention.

0034[0017] Figure 15 is an elevational view of a decorative cover formed using

0035the sheet of material of Figure 14.

0036[0018] Figure 16 is a plan view of an alternate version of a sheet of

0037material used to form a decorative cover in accordance with the present

0038invention.

0039[0019] Figure 17 is an elevational view of a decorative cover formed using

0040the sheet of material of Figure 16.

DETAILED DESCRIPTION OF THE INVENTION

0042[0020] The present invention contemplates a floral cover which is manufactured from a flat sheet of material by folding and securing portions of

0043the sheet of material in a particular sequence into the shape of a tubular sleeve which is then formed into an opened container to contain a pot, floral grouping,

0044botanical item or growing material. It will be appreciated that the examples of

0045the invention provided herein are not intended to limit the scope and extent of the claimed invention but are only intended to exemplify various of the

0046embodiments of the invention contemplated herein.

0047[0021] Referring now to the drawings, Figures 1-9 show a process of

0048folding a sheet of material 10 into a decorative cover 108 (Figures 8-11) which can be used to contain a potted plant, floral grouping or botanical item. [0022] The sheet of material 10 (also referred to herein as sheet 10)

0049shown in Figure 1 and in Figures 2-9 in various stages of folding, has a first apex 12, a second apex 14, a third apex 16, a fourth apex 18, a first edge 20,

0050a second edge 22, a third edge 24, and a fourth edge 26. The sheet 10 has a

0051first fold line 28 (which may or may not constitute an actual crease or scored line) which extends between third apex 16 and fourth apex 18. The first fold

0052line 28 effectively separates the sheet 10 into a first triangular portion 30 which

0053comprises the portion of sheet 10 between the first fold line 28 and the first

0054apex 12, and a second triangular portion 36 which comprises the portion of the

0055sheet 10 between the first fold line 28 and the second apex 14. The first

0056triangular portion 30 has an inner surface 32 and an outer surface 34 (e.g., Figure 2). The second triangular portion 36 has an inner surface 38 and an

0057outer surface 40 (e.g., Fig. 3). A first connecting bonding material 42 such as

0058an adhesive is disposed upon a portion of the inner surface 38 of the second

0059triangular portion 36, preferably near the fourth apex 18 for bondingly connecting the first triangular portion 30 to the second triangular portion 36.

0060Alternatively, the first connecting bonding material 42 could be disposed upon

0061a portion of the inner surface 32 of the first triangular portion 30 for bonding

0062the first triangular portion 30 to the second triangular portion 36. Alternately, when the first connecting bonding material 42 is a cohesive material, it may be disposed on portions of both the first triangular portion 30 and second triangular portion 36.

0063[0023] In a first folding step, the first triangular portion 30 is folded upon

0064the second triangular portion 36 in a direction 44 resulting in the sheet 10 being

0065folded into two triangular halves: a first folded portion 48 and the second

0066triangular portion 36, as shown in Figures 2 and 3. The first folded portion 48 is the first triangular portion 30. The sheet 10, now folded, has a first corner

006750, generally in the same location as the third apex 16 and, a second corner

006852, generally in the same location as the fourth apex 18. The connecting

0069bonding material 42 connects the first folded portion 48 to the second triangular portion 36. The first edge 20 is adjacent and parallel to the third edge 24, and

0070the second edge 22 is adjacent and parallel to the fourth edge 26. The first

0071apex 12 is adjacent the second apex 14. A bottom edge 54 of the sheet 10

0072extends between first corner 50 and second corner 52.

0073[0024] A second fold line 56 (which may or may not constitute an actual crease or score line) extends between first edge 20 and second edge 22 in the

0074first folded portion 48. The portion of the first folded portion 48 between first

0075apex 12 and the second fold line 56 comprises an upper triangular portion 58.

0076In a second folding step, the upper triangular portion 58 is folded in a second

0077direction 60 to lie against a portion of the outer surface 34 of the first folded portion 48 to form a second folded portion 62 (Figures 4 and 5). The second folded portion 62 (also referred to herein as the "apical portion") has a left edge 64, a right edge 66, an upper edge 68, a first corner 70 and a second corner

007872. When the second folded portion 62 in the first folded portion 48 is formed, a skirt portion 74 is formed in a portion of the first triangular portion 36

0079between the second apex 14 and the upper edge 68 of the second folded

0080portion 62, the skirt portion 74 has an edge 76.

0081[0025] A third fold line 78 (which may or may not constitute an actual

0082crease or score line) extends in the first folded portion 48 and the second

0083triangular portion 36 between the second corner 72 of the second folded portion 62 and the bottom edge 54. The portions of the first folded portion 48 and the

0084second triangular portion 36 which extend between first corner 50 and third fold line 78 comprise a left triangular portion 80. In a third folding step, the left

0085triangular portion 80 is folded in direction 82 wherein first corner 50 is disposed

0086generally adjacent the first corner 70 of the second folded portion 62 wherein the left triangular portion 80 forms a third folded portion 84 (Figures 6-7) and

0087which is also referred to herein as the first corner portion, which entirely or

0088substantially covers second folded portion 62 and a portion of the outer surface 34 of the first folded portion 48. The third folded portion 84 has a left edge 86,

0089a right edge 88 which extends from first corner 70 of the second folded portion

009062 to the bottom edge 54, and an upper edge 90 which is adjacent and generally parallel to the upper edge 68 of the second folded portion 62. [0026] A fourth fold line 92 (which may or may not constitute an actual crease or score line) in the first folded portion 48 and the second triangular portion 36 extends between the first corner 70 of the second folded portion 62

0091and the bottom edge 54. The portions of the first folded portion 48 and the

0092second triangular portion 36 which extend between the second corner 52 and

0093the fourth fold line 92 comprise a right triangular portion 94. [0027] Disposed upon a portion of the outer surface 34 of the right

0094triangular portion 94 is a second connecting bonding material 96 preferably

0095near second corner 52. The second connecting bonding material 96 is

0096preferably disposed on the right triangular portion 94 but may alternatively be

0097disposed upon an exposed surface portion of the third folded portion 84. The

0098second connecting bonding material 96 may alternately be disposed upon portions of both the right triangular portion 94 and the third folded portion 84,

0099for example when the second connecting bonding material 96 is a cohesive

0100material. In a fourth folding step the right triangular portion 94 is folded in

0101direction 98 wherein second corner 52 is disposed generally adjacent second corner 72 of the second folded portion 62 wherein the right triangular portion

010294 forms a fourth folded portion 100 (Figures 8 and 9) and which is also

0103referred to herein as the second corner portion, which covers a portion of the

0104third folded portion 84 and a portion of the outer surface 34 of the first folded portion 48. The fourth folded portion 100 has a left edge 102 which extends from near the second corner 72 of second folded portion 62 to the bottom edge 54, a right edge 104, and an upper edge 106 which is adjacent and generally parallel to upper edge 90 of the third folded portion 84. The fourth folded portion 100 is connected to the third folded portion 84 via the second connecting bonding material 96. It will be understood by a person of ordinary skill in the art that the second connecting bonding material 96 may not be applied until just before the right triangular portion 94 is folded to form the fourth folded portion 100, or it may be applied to a portion of the sheet 10 well before the forming of the fourth folded portion 100, in a manner similar to the sheet 10 in the embodiment shown in Figures 1, 2 or 4. [0028] The fourth folding step results in the sheet 10 having been formed into a decorative cover 108 (Figures 8-11) which comprises essentially two components, a base portion 110 constructed from the first, second, third and fourth folded portions 48, 62, 84 and 100, respectively, and the skirt portion 74 which extends generally from the base portion 110, and beyond the upper edge 106 of the fourth folded portion 100. The base portion 110 preferably has a tapered, or frustoconical sidewall 112 when opened as shown in Figures 10 and 11. Figure 10 shows a bottom view of the decorative cover 108 expanded from a flat condition to an opened condition.

0105[0029] The decorative cover 108 is opened manually or automatically and in a preferred embodiment is disposed over a pot-shaped mold or mandrel (not shown). Once disposed upon the mold or mandrel, the decorative cover 108 can be secured in an opened position by forming a first bottom fold 114 and a

0106second bottom fold 116 in a lower end 117 of the decorative cover 108. The first bottom fold 114 and the second bottom fold 116 are secured by a bottom

0107fold securing element 118 such as a tape, adhesive material, or heat seal

0108thereby forming a substantially flat bottom 120 in the decorative cover 108.

0109The decorative cover 108 is thereby formed into an opened position and has an upper opening 122 and an inner retaining space for containing a pot 126, which

0110has an upper rim 128. A plurality of the decorative covers 108 thus formed can

0111be stacked to form a nested set of decorative covers 108 for shipping.

0112[0030] As noted, the decorative cover 108 has an inner retaining space 124

0113(also referred to herein as an interior space) into which the pot 126 having a floral grouping 130 has been disposed. The skirt portion 74 extends a distance

0114above an upper rim 128 of the pot 126 and the upper edge 106 is positioned,

0115preferably, near a portion of the upper rim 128 of the pot 126.

0116[0031] Figures 1-9 show how the square sheet of material 10 is formed into the decorative cover 108 (also referred to herein simply as a "cover") having the skirt portion 74, however, it will be apparent to a person of ordinary

0117skill in the art that sheets of material having other shapes (non-square) could

0118also be used to form decorative covers in accordance with the methods designed herein. Examples of such sheets of material and the decorative covers formed therefrom are shown in Figures 12-17. [0032] Shown in Figure 12 is a sheet of material 132 having a pentagonal

0119shape (a truncated square) which when formed into a decorative cover 134

0120(Figure 13) in the manner described herein lacks a skirt portion similar to the

0121skirt portion 74 of decorative cover 108.

0122[0033] Shown in Figure 14 is a sheet of material 136 which when formed

0123into a decorative cover 142 in the manner described herein has a skirt portion

0124138 which has a non-linear or curved edge 140 (Figure 15). Shown in Figure

012516 is a sheet of material 144 which when formed into a decorative cover 150 has a skirt portion 146 which has a non-linear or curved edge 148 (Figure 17)

0126which has a different configuration than curved edge 140.

0127[0034] Any of the embodiments of decorative covers 108, 134, 142, or 150

0128described herein, or any other decorative covers which may be constructed by the methods described herein, may have other structural or decorative features.

0129[0035] The decorative covers 108, 134, 142, or 150 may comprise a

0130bonding material (not shown) disposed on an inner portion thereof for

0131bondingly connecting the decorative covers 108, 134, 142, or 150 to the pot

0132126 disposed therein. Or, a bonding material (not shown) may be disposed on

0133an outer surface thereof for securing a plurality of crimped folds formed in the

0134decorative covers 108, 134, 142, or 150.

0135[0036] The skirt portions 74, 138 or 146 may be adapted so the decorative covers 108, 134, 142, or 150, respectively, can be supported via a support assembly such as a wicket (for example, by having apertures therein).

0136Such devices for supporting flattened covers such as floral sleeves are well

0137known in the art. Any of the decorative covers 108, 134, 142, or 150 may

0138be equipped with drainage holes, and may be constructed from water

0139permeable or impermeable materials.

0140[0037] The material from which the decorative covers 108, 134, 142,

0141or 150 are constructed preferably has a thickness in a range from about

01420.1 mil to about 30 mils (0.0025-0.75mm). Often, the thicknesses of the

0143material employed to construct the decorative covers 108, 134, 142, or

0144150 are in a range from about 0.5 mil to about 10 mils (0.01-0.25mm) or

0145preferably, in a range from about 1.0 mil to about 5 mils (0.25-0.125mm).

0146Preferably, the decorative covers 108, 134, 142, or 150 are constructed

0147from a material which is flexible, semi-rigid, rigid, or any combination

0148thereof. The decorative covers herein before described may be

0149constructed of a single layer of material or a plurality of layers of the same

0150or different types of materials. Any thickness of the material may be

0151utilized as long as the material functions in accordance with the present

0152invention as described herein. The layers of material comprising the

0153decorative covers may be connected together or laminated or may be

0154separate layers. Such materials used to construct said decorative covers

0155are described in U.S. Patent No. 5,111,637, which is hereby expressly

0156incorporated herein by reference. However, any thickness of material may

0157be utilized in accordance with the present invention as long as the

0158decorative covers may be formed as described herein. Additionally, an insulating material such as bubble film, preferable as one of two or more layers,

0159can be utilized in order to provide additional protection for the item, such as the

0160floral grouping, contained therein.

0161[0038] The decorative covers 108, 134, 142, or 150 are constructed from

0162any suitable sheet of material that is capable of being folded into such a

0163decorative cover. Preferably, the material comprises treated or untreated

0164paper, metal foil, polymeric film, non-polymeric film woven, or nonwoven

0165fabric, or synthetic or natural fabric, cardboard, fiber, cloth, burlap, or

0166laminations or combinations thereof.

0167[0039] The term "polymeric film" when used herein means a film made of a synthetic polymer such as a polypropylene or a naturally occurring polymer

0168such as cellophane. A polymeric film is relatively strong and not as subject to

0169tearing (substantially non-tearable), as might be the case with paper or foil.

0170[0040] In one embodiment, the decorative cover 108, 134, 142, or 150

0171may be constructed from sheets comprising one or two polypropylene films.

0172The two polypropylene films may be connected together or laminated or may be separate layers.

0173[0041] The materials comprising the decorative covers 108, 134, 142, or

0174150 may vary in color and as described herein consist of designs or decorative patterns which are printed, etched, and/or embossed thereon using inks or other printing materials well known in the art.

0175[0042] In addition, the material may have various colorings, coatings, flocking and/or metallic finishes, or other decorative surface ornamentation applied separately or simultaneously or may be characterized totally or partially by pearlescent, translucent, transparent, iridescent, neon, or the like, qualities. The material may further comprise, or have applied thereto, one or more scents. Each of the above-named characteristics may occur alone or in combination. The material may be opaque, translucent, transparent, or partially clear or tinted transparent.

0176[0043] The term "floral grouping" as used herein means cut fresh flowers, artificial flowers, a single flower or other fresh and/or artificial plants or other floral materials and may include other secondary plants and/or ornamentation or artificial or natural materials which add to the aesthetics of the overall floral grouping. The floral grouping comprises a bloom or foliage portion and a stem portion. Further, the floral grouping may comprise a growing potted plant having a root portion (not shown) as well. However, it will be appreciated that the floral grouping may consist of only a single bloom or only foliage, or a botanical item (not shown), or a propagule (not shown). The term "floral grouping" may also be used interchangeably herein with the terms "botanical item" and/or "propagule".

0177[0044] The term "growing medium" when used herein means any liquid, solid or gaseous material used for plant growth or for the cultivation of propagules, including organic and inorganic materials such as soil, humus, perlite, vermiculite, sand, water, foam, and including the nutrients, fertilizers or hormones or combinations thereof required by the plants or propagules for

0178growth.

0179[0045] The term "botanical item" when used herein means a natural or artificial herbaceous or woody plant or mushroom, taken singly or in

0180combination. The term "botanical item" also means any portion or portions of

0181natural or artificial herbaceous or woody plants including stems, leaves, flowers,

0182blossoms, buds, blooms, cones, or roots, taken singly or in combination, or in

0183groupings of such portions such as bouquets or floral grouping s.

0184[0046] The term "propagule" when used herein means any structure

0185capable of being propagated or acting as an agent of reproduction including

0186seeds, shoots, stems, runners, tubers, plants, leaves, roots, or spores.

0187[0047] The term " pot" as used herein refers to any type of container used for holding a floral grouping, botanical item, or plant, including vases.

0188Examples of pots, used in accordance with the present invention include, but

0189not by way of limitation, clay pots, wooden pots, foam pots, plastic pots, pots

0190made from natural and/or synthetic fibers, or materials and/or any combination thereof. As used herein, the term "pot" preferably means a standard flower pot

0191such as a 3-inch, 3 ¹/2-inch, 4-inch, 4 ¹/_-inch, 5-inch, 5 ¹/2-inch, 6-inch, 6 Vz-

0192inch, 7-inch or 8-inch pot for example, or any other pot typically commercially

0193available. The pot is adapted to receive a floral grouping in a retaining space thereof. The floral grouping may be disposed within the pot along with a suitable growing medium described elsewhere herein, or other retaining medium, such as a floral foam. It will also be understood that a floral grouping, botanical item or propagule and any appropriate growing medium or other

0194retaining medium, may be disposed in the decorative cover 108, 134, 142, or

0195150 without a pot for displaying, transporting or cultivating the item disposed

0196within the decorative covers 108, 134, 142, or 150.

0197[0048] It should be further noted that various features of the versions of

0198the present invention such as described herein as well as, handles or handle

0199apertures, additional perforations, and ventilation holes, may be used alone or

0200in combination as elements of any of the embodiments described above herein.

0201[0049] Changes may be made in the construction and the operation of the various components, elements and assemblies described herein or in the steps or the sequence of steps of the methods described herein without departing

0202from the spirit and scope of the invention as defined in the following claims.