Injection-molded composite construct
View Patent ↗A frame is injection molded onto a group of panels to form a container. The panels extend at least partially around, and at least partially define, a cavity of the container.
1. A blank, comprising:
a base panel;
a plurality flaps respectively connected to and extending outwardly from the base panel, wherein
the plurality of flaps includes a first flap and a second flap that is adjacent to the first flap;
a gap is defined between the first and second flaps,
at least an inner portion of the gap becomes wider farther from the base panel,
the first flap has a feature that has a reducing effect on how width of the gap changes as a function of increased distance outwardly from the base panel, the feature is a protruding portion of the first flap, and
the second flap has a protruding portion that has a reducing effect on how width of the gap changes as a function of increased distance outwardly from the base panel, the protruding portion of the second flap extends farther into the gap than does the protruding portion of the first flap.
2. The blank of claim 1 , wherein the blank is a laminate including a releasable adhesive positioned between and at least indirectly joining together a substrate and a polymer film.
3. The blank of claim 1 , wherein:
at least a portion of the blank comprises microwave energy interactive material, paperboard and polymer film, and
the microwave energy interactive material is positioned between the paperboard and the polymer film.
4. The blank of claim 1 , wherein the protruding portion of the first flap and the second flap are configured so that the protruding portion of the first flap and the protruding portion of the second flap are in an overlapping relationship with respect to one another when the blank is erected into a construct in which the gap is at least partially maintained.
5. A construct erected from the blank of claim 1 and including an injection-molded frame, wherein:
the blank has been erected so that the gap has been at least partially maintained, and the protruding portion of the first flap and the protruding portion of the second flap are in an overlapping relationship with respect to one another; and
a portion of the frame covers the gap.
6. The construct of claim 5 , wherein the gap is filled by a protruding portion of the frame.
7. The blank of claim 1 , wherein:
the first flap includes an outwardly extending edge;
the second flap includes an outwardly extending edge that is proximate to the edge of the first flap;
at least portions of the edges of the first and second flaps are spaced apart from one another so that the gap is defined between the edge of the first flap and the edge of the second flap;
an outer portion of the gap is farther from the base panel than the inner portion of the gap,
an inner portion of the edge of the first flap partially defines the inner portion of the gap,
an outer portion of the edge of the first flap at least partially defines both the outer portion of the gap and the feature, which has the reducing effect on how the width of the gap changes as a function of increased distance outwardly from the base panel,
an angle is defined between the inner and outer portions of the edge of the first flap, and
the angle is less than 180 degrees so that that the angle at least partially provides the reducing effect on how width of the gap changes as a function of distance outwardly from the base panel.
8. The blank of claim 7 , wherein the angle, which is defined between the inner and outer portions of the edge of the first flap, is an obtuse angle.
9. The blank of claim 7 , wherein width of the inner portion of the gap changes at a greater rate, as a function of distance outwardly from the base panel, than width of the outer portion of the gap.
10. The blank of claim 7 , wherein with respect to extending outwardly from the base panel, the outer portion of the edge of the first flap extends convergently with respect to a centerline of the gap.
11. The blank of claim 7 , wherein with respect to extending outwardly from the base panel, the outer portion of the edge of the first flap extends divergently with respect to a centerline of the gap.
12. The blank of claim 11 , wherein:
an inner portion of the edge of the second flap partially defines the inner portion of the gap,
an outer portion of the edge of the second flap partially defines the outer portion of the gap, and
an angle of less than 180 degrees is defined between the inner and outer portions of the edge of the second flap, and
with respect to extending outwardly from the base panel, the outer portion of the edge of the second flap extends convergently with respect to the centerline of the gap.