# US 6,044,490 A · Paper product and method of making

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- Number: US 6,044,490 A
- Document ID: US6044490A
- Status: Granted
- Kind: A
- Application number: 09/277,899
- Filed: 1999-03-29
- Granted: 2000-04-04
- Earliest claimed: 1994-08-05
- Assignees: Volkert, Inc.
- Inventors: Carolyn K. Volkert; Andrew M. Volkert
- Web page: https://patentgrep.com/patent/US6044490A

## CPC

- B31D 5/04: including folding or pleating, e.g. Chinese lanterns
- B42D 15/008: {Foldable or folded sheets}
- B42D 15/042: {Foldable cards or sheets (B42D15/045 and B42D15/08 take precedence)}
- G09F 1/06: to be erected in three dimensions [3D] (G09F1/08 takes precedence)
- Y10T 428/15: Sheet, web, or layer weakened to permit separation through thickness
- B31D: MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C (manufacture by dry processes of articles made from particles or fibres consisting of wood or other lignocellulosic or like organic material B27N; making layered products not composed wholly of paper or cardboard B32B; making articles from cellulosic fibrous suspensions, e.g. wood pulp, D21J)
- B42D: BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
- G09F: DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Various sheet material blanks comprising one or a plurality of interconnected panels are fabricated so that a stand-out structure die-cut into one panel upon manipulation assumes an attention-attracting, 3-dimensional orientation. The various configurations are such that particular advantages may be obtained through mass production,and machine-assembly methods can profitably be used to construct certain configurations. A variety of methods are shown for efficiently producing such pieces via mass-production, including items having multiple stand-out structures. Flat individual blanks in sheet form are particularly adapted to be conveyed through laser printers, copy machines and other suitable imprinting equipment in order to inexpensively personalize such blanks, which can be used to create a variety of different 3-dimensional items, including novelty sunvisors.

## Claims

### Claim 1

A blank designed for fabrication into a 3-dimensional item, said blank comprising
a planar sheet of sheet material having an upper surface and an undersurface,
die-cut means in said sheet forming a stand-out structure including a main body portion having at least one line of weakness therein which forms a hinged subpanel,
said die-cut means also forming link means in said sheet, said link means being hinged to said main body portion of said stand-out structure and to the remainder of said sheet, and
bonding means for interconnecting said subpanel of said stand-out structure to another region of said sheet so that interconnection between said subpanel and said sheet causes said stand-out structure to move prominently away from the remainder of said sheet, guided by said link means, and assume an attention-attracting orientation.

### Claim 2 (depends on 1)

A blank according to claim 1 which is designed to be formed into a plurality of planar sections wherein said die-cut means is located along one edge of said planar sheet and in one said section of said planar sheet that is adapted to be superimposed upon another said section of said planar sheet and wherein said interconnection between said subpanel and said sheet that is accomplished through said bonding means connects the upper surface of said subpanel to a surface of another said section of said planar sheet.

### Claim 3 (depends on 2)

A blank according to claim 2 wherein said link means includes a pair of first and second hinge lines which are parallel to each other and also to said edge of said planar sheet, said first hinge line being disposed between said edge of said planar sheet and said second hinge line and being located closer to said edge than to said second hinge line.

### Claim 4 (depends on 1)

A blank according to claim 1 wherein said planar sheet has formed therein a second line of weakness which divides said planar sheet into at least first and second planar sections, with said die-cut means being located in said first section, wherein said bonding means is located on the undersurface of said second section, and wherein means defining an aperture is contained in one said section other than said second section and is located adjacent said hinged subpanel so that, after folding said second section beneath said other section along said second line of weakness, said bonding means is aligned with said aperture so as to permit said connection of said hinged subpanel to said second section through said aperture.

### Claim 5 (depends on 4)

A blank according to claim 4 wherein said means defining said aperture comprises plug means connected by perforations to facilitate its removal.

### Claim 6 (depends on 1)

A blank according to claim 1 wherein said planar sheet is designed to be formed into panels A, B and C, with said die-cut means being located in panel A, wherein panel A also includes a backbone subpanel connected to an edge of said hinged subpanel opposite to said at least one line of weakness, wherein said link means is connected by a hinge line to a link subpanel along an edge opposite from that at which it is hinged to said main body portion, wherein said blank is designed to be manipulated so that panel A is sandwiched between panels B and C, wherein said bonding means is located to interconnect said subpanel to panel B, and wherein additional bonding means is provided for interconnecting said link subpanel to panel C.

### Claim 7 (depends on 1)

A blank according to claim 1 wherein said planar sheet is designed to be formed into panels A, B and C, with panel B being located between panels A and C and with said die-cut means being located in panel A, wherein said subpanel is located generally along one edge of panel A and said subpanel is connected to the remainder of panel A by frangible perforations, wherein said bonding means is located to interconnect said subpanel to panel B, and wherein additional bonding means is located to interconnect portions of panel A generally adjacent said frangible perforations to panel C.

### Claim 8 (depends on 1)

A blank according to claim 1 wherein said hinged subpanel is generally T-shaped having a leg and a crossbar, said crossbar being hinged to said remainder of said sheet at the two spaced-apart locations, and wherein said remainder of said sheet includes a frame section which surrounds said main body portion.

### Claim 9 (depends on 8)

A blank according to claim 8 wherein said bonding means comprises adhesive means located on said undersurface of said sheet which is positioned so as to bond portions of the undersurface of said subpanel to a supporting surface.

### Claim 10

A blank for fabricating an attention-attracting sunvisor, said blank comprising
a planar sheet of sheet material having first die-cut means therein creating a generally crescent-shaped sunvisor that has a pair of opposite ends, said ends being formed with means for attaching band means for securing said sunvisor to the head of a user,
said sheet also having second die-cut means forming a stand-out structure in association with said sunvisor, which structure includes a main body portion having at least one line of weakness which forms a subpanel connected thereto,
said second die-cut means also forming link means in said sheet which hingedly connects said main body portion of said stand-out structure to said sunvisor, and
bonding means on said sheet for interconnecting said subpanel and said sunvisor so that such interconnection causes said stand-out structure to move prominently away from the remainder of said sunvisor guided by said link means to assume an attention-attracting orientation.

### Claim 11 (depends on 10)

A blank according to claim 10 wherein said bonding means comprises adhesive means located either (a) on said subpanel of said stand-out structure or (b) on said crescent-shaped sunvisor of said planar sheet at a location generally adjacent said subpanel of said stand-out structure and in a position so as to interconnect said subpanel to said sunvisor.

### Claim 12 (depends on 10)

A blank according to claim 10 wherein said stand-out structure is die-cut from said planar sheet in regions lying both inside and outside of said crescent-shaped sunvisor and wherein said link means is hinged to said sunvisor generally along a peripheral edge thereof.

### Claim 13 (depends on 10)

A blank according to claim 10 wherein said stand-out structure is die-cut from said portion of said planar sheet material that forms said generally crescent-shaped sunvisor.

### Claim 14 (depends on 13)

A blank according to claim 13 wherein said planar sheet has a planar upper surface and a planar undersurface, with said planar upper surface having printing at least in the region of said stand-out structure,
wherein means defining an aperture is provided in said crescent-shaped sunvisor generally adjacent said subpanel of said stand-out structure,
wherein a hinged filler panel of a size larger than said stand-out structure is die-cut in said planar sheet along a peripheral edge of said sunvisor, and
wherein said bonding means is located on the undersurface of said filler panel at a location so as to be aligned with said aperture when said hinged filler panel is pivoted by folding along said peripheral edge so as to lie in surface-to-surface contact with the undersurface of said crescent-shaped sunvisor, whereby said bonding means forms said interconnection with said stand-out subpanel through said aperture and whereby said filler panel blocks openings in said sunvisor created when said stand-out structure is moved out of the plane of said sunvisor, which openings might otherwise permit passage of the sun's rays therethrough into the eyes of the wearer.

### Claim 15 (depends on 13)

A blank according to claim 13 wherein said planar sheet has a planar upper surface and a planar undersurface, with said planar upper surface having printing upon at least the region of said stand-out structure,
wherein a hinged filler panel of a size larger than said stand-out structure is die-cut in said planar sheet along a peripheral edge of said sunvisor, said hinged filler panel being located so that, upon folding to a location in juxtaposition with the undersurface of said crescent-shaped sunvisor, said filler panel blocks an opening in said sunvisor which is created when said stand-out structure is moved out of the plane of said sunvisor, and
wherein means is provided for securing said filler panel in juxtaposition with the undersurface in said blocking position.

### Claim 16 (depends on 15)

A blank according to claim 15 wherein said securing means constitutes adhesive.

### Claim 17

A planar item for producing an attention-attracting sunvisor, said planar item comprising
planar sheet material having the general shape of a crescent-shaped sunvisor that has a pair of opposite ends, said ends being formed with means for attaching band means for securing said sunvisor to the head of a user,
said item also having a die-cut stand-out structure formed in association with said sunvisor, which structure includes a main body portion having at least one line of weakness which forms a subpanel connected thereto and link means which hingedly connects said main body portion of said stand-out structure to said sunvisor, and
said sheet material having bonding means for interconnecting said subpanel and said sunvisor so that such interconnection causes said stand-out structure to move prominently away from the remainder of said sunvisor, guided by said link means, to assume an attention-attracting orientation.

### Claim 18 (depends on 17)

A planar item according to claim 17 wherein said bonding means comprises adhesive means located either (a) on said subpanel of said stand-out structure or (b) on said crescent-shaped sunvisor at a location generally adjacent said subpanel of said stand-out structure and in a position so as to interconnect said subpanel to said sunvisor.