The present invention relates generally to containers. In particular, the present invention relates to displayable shipping containers having superior compression features.
Flat sheets of corrugated paperboard, typically referred to as blanks, have been used for many years as the starting material to form containers. Corrugated paperboard generally refers to a multi-layer sheet material comprised of two sheets of liner bonded to a central corrugated layer of medium. Given a basic size requirement specified by the customer, industry standards, and the preference for low cost, paperboard container manufacturers strive to provide structural stacking strength with a minimal amount of corrugated paperboard.
In shipping and displaying products, particularly in a retail setting, it is desirable to have a container which is easy to pack, sturdy and fully enclosed for protection of contents during storage and shipping, and also suitable for display at a retail site. For example, it is beneficial to have a container which allows a customer at a retail site to easily reach into the container and remove products for purchase. Of course, the access opening through which a consumer can access the products must also be closed during shipment and storage to prevent spilling of the product out of the container. This has resulted in the development of a variety of containers which are configured to be convertible from a shipping configuration to a display configuration, which permits the converted container to be placed directly upon a shelf, or floor display, without having to remove the individual product items from the container. Typically, this is accomplished by providing the container with removable portions of the container that create apertures through which customers may then help themselves to the products within the converted container.
Such convertible containers represent a challenge in that they must be readily convertible into a form presentable to customers, while at the same time maintaining certain shipping performance characteristics, suitable for the shipment of non-self-supporting or even fragile products. Prior attempts at providing a displayable shipping container may suffer from a number of disadvantages. For example, prior displayable shipping containers often are either lacking in the necessary shipping performance characteristics or, in order to provide such performance, have structural elements that remain in position after converting to a display configuration that make access to the product inconvenient. Other displayable shipping containers are labor intensive to manufacture, assemble, or convert. And still other containers require excessive materials or, in some cases, extraneous components (e.g., a tie or a wrap) to secure a lid on a body of the container. Once converted to a display configuration, many displayable shipping containers often also include rough, unfinished, jagged, and uneven surfaces in prominent locations that are somewhat unsightly and do not provide the appeal of a neat, clean and presentable display.
Therefore, it would be desirable to have a container that addresses many, if not all, of these disadvantages.
According to some aspects of the present disclosure, a container includes a first blank and a second blank. The first blank includes a first plurality of panels and a first plurality of flaps integrally formed from a first sheet of material. The first plurality of panels includes a first side panel, a second side panel opposing the first side panel, a back panel, and a front panel of the container. The first plurality of flaps define a bottom of the container and a first portion of a top of the container. The front panel includes a window portion. The second blank includes two or more panels and two or more top flaps integrally formed from a second sheet of material. The two or more panels include a cover front panel and a first side panel. The two or more top panels define a second portion of the top of the container. The cover front panel is attached to the window panel.
According to some additional aspects of the present disclosure, a container includes a first blank and a second blank. The first blank includes a first plurality of panels and a first plurality of flaps. The first plurality of panels includes a first side panel, a second side panel opposing the first side panel, a back panel, and a front panel of the container. The first plurality of flaps defines a bottom of the container and a first portion of a top of the container. The front panel includes a removable window portion. The second blank includes a first cover side panel, a cover front panel, and a second cover side panel, and a plurality of top flaps. The plurality of top flaps define a second portion of the top of the container. The cover front panel is attached to the removable window portion of the front panel. The first cover side panel and the second cover side panel are attached to one or more of the first plurality of panels.
According to some additional aspects of the present disclosure, a container includes a first blank and a second blank. The first blank includes a first side panel, a front panel, a second side panel, and a back panel. The first blank further includes a plurality of bottom flaps that define a bottom of the container, a first minor top flap, and a first major top flap. The front panel includes a removable window portion. The second blank includes a cover side panel, a cover front panel, a second minor top flap connected to the first cover side panel, and a second major top flap connected to the cover front panel. An interior surface of the cover front panel is attached to an exterior surface of the removable window portion of the front panel. An interior surface of the cover side panel is attached to an exterior surface of the first side panel.
The above summary is not intended to represent each embodiment or every aspect of the present invention. Additional features and benefits of the present invention are apparent from the detailed description and figures set forth below.
Other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
The enclosure blank 12 further includes a first minor bottom flap 24, a first major bottom flap 26, a second minor bottom flap 28, and a second major bottom flap 30 hingedly connected to the first side panel 16, the front panel 18, the second side panel 20, and the back panel 22, respectively, by fold lines. The enclosure blank 12 also includes a first major top flap 32 hingedly connected to the back panel 22 by a fold line 33. The first major top flap 32 includes a separation element 34 at or near the fold line 33 that connects the first major top flap 32 and the back panel 22. The separation element 34 is configured to permit separation and removal of first major top flap 32 (or a portion thereof) from the back panel 22. In the illustrated embodiment, the separation element 34 comprises a zipper rule; however, it is contemplated that the separation element 34 can comprise any suitable feature for separating and removing the first major top flap 32 (or a portion thereof) from the back panel 22 (e.g., a perforation line, a tear-strip, etc.).
The front panel 18 of the enclosure blank 12 includes a line of weakness 36 that defines a removable window portion 38. The window portion 38 is separable and removable from the remainder of the enclosure blank 12 via the line of weakness 36. It is contemplated that the window portion 38 is not limited to the particular shape, size, and configuration illustrated in
The first side panel 16 includes a line of weakness 40a that defines a removable first breakaway portion 42a and the second side panel 20 includes a line of weakness 40b that defines a removable second breakaway portion 42b. As will be described below, the first breakaway portion 42a and the second breakaway portion 42b are configured to be separable and removable from the remainder of the enclosure blank 12 during conversion from a shipping configuration to a display configuration.
Turning now to
The first cover side panel 46 includes a first breakaway-assist portion 60a defined by a line of weakness 58a and a fold line 59a and a second breakaway-assist portion 60b defined by a line of weakness 58b and a fold line 59b. The first cover side panel 46 also includes a first recessed surface 62a and the second cover side panel 50 includes a second recessed surface 62b.
The assembly of the enclosure blank 12 and the cover blank 44 to form the displayable shipping container 10 (see
With the cover blank 44 attached to the enclosure blank 12, the adhesive area 64a is aligned with the adhesive area 66a, the adhesive area 64b is aligned with the adhesive area 66b, the adhesive area 64c is aligned with the adhesive area 66c, and the adhesive area 64d is aligned with the adhesive area 66d. Accordingly, the cover front panel 48 is attached to the window portion 38, the first breakaway-assist portion 60a is attached to the first breakaway portion 42a, and the second breakaway-assist portion 60b is attached to the second breakaway portion 42b. By attaching the cover blank 44 to the removable breakaway portions 42a, 42b and the removable window portion 38 of the enclosure blank 12, the cover blank 44 can be secured to the enclosure blank 12 when the container 10 is in a shipping configuration and fully removed (i.e., no portion of the cover blank 44 remains attached to the container 10) when the container 10 is converted to a display configuration. While the breakaway-assist portions 60a, 60b are illustrated as having a size and shape that is similar to the size and shape of the breakaway portions 42a, 42b, it is contemplated that the breakaway-assist portions 60a, 60b can have a size and shape that is different from the shape of the breakaway portions 42a, 42b.
After the cover blank 44 has been attached to the enclosure blank 12, the blanks 12, 44 can then be erected to form the assembled container 10 in a shipping configuration as shown in
The sealing of the first major bottom flap 26 and the second major bottom flap 30 and the sealing of the first major top flap 32 and the second major top flap 54 can be configured to allow (i.e., to not prevent or inhibit) separation and removal of the cover blank 44 from the enclosure blank 12 when the container 10 is later converted to a display configuration. For example, in the embodiment illustrated in
It is contemplated that the assembly of the container 10 described above can be achieved with or without the assistance of a case erector. Additionally, it is contemplated that some of these steps can be performed in a different order than is described above. For example, the top 70 of the container 10 can be formed before forming the bottom 68 of the container 10 or the cover blank 44 can be attached to the enclosure blank 12 after the overlap panel 14 is attached to the back panel 22.
As described above,
After shipping the container 100 to a retail site, the container 10 can be converted from the shipping configuration (
With the window portion 38, the first major top panel 32, and the cover blank 44 removed from the remainder of the enclosure blank 12, the remainder of the enclosure blank 12 forms the container 10 in the display configuration. As shown in
As mentioned above, the container 10 in the display configuration does not include any portion of the cover blank 44 because, in the shipping configuration, the cover blank 44 is only attached to removable portions of the enclosure blank 12 (i.e., the first major top panel 32, the window portion 38, the first breakaway portion 42a, and the second breakaway portion 42b). As such, the container 10 in the display configuration provides a neat, clean, and presentable display for goods and products within the container 10.
It is contemplated that the container 10 may include advertising features, descriptions, graphics, or other information. Further, it is contemplated that the exterior surface of the cover blank 44 can itself be printed with graphics or text for use during shipment—for example, shipping instructions or information about placement of the item within a store—which are removed along with the cover blank 44 for display of the container 10. In other words, the cover blank 44 can be provided with distribution information thereon, which is unimportant to an end user such as a retail customer and is easily removed for display of the container.
Turning now to
The cover blank 144 includes a first cover side panel 146, a cover front panel 148, a second cover side panel 150, a first minor top flap 152, a second major top flap 154, a second minor top flap 156, recessed surfaces 162a, 162b, and adhesive areas 164a-d, which are similar to the similarly numbered features illustrated in
To assemble the enclosure blank 112 and the cover blank 144 to form a container in a shipping configuration, the cover blank 144 is attached to the enclosure blank 112 via adhesive(s) applied at or near the adhesive areas 164a-d, 166a-d, the overlap panel 114 is attached to the first side panel 116, the bottom flaps 124, 126, 128, 130 are folded inwards and sealed to form a bottom surface, and the top flaps 152, 154, 156, 132 are folded inwards and sealed to form a top surface as described above. To convert the container from the shipping configuration to a display configuration, the separation elements 134a, 134b and the lines of weakness 186a, 186b are actuated or torn out to separate the adhesive area 164a from the first cover side panel 146 and the adhesive area 164d from the second cover side panel 150. Then the assist tab portion 178 can be pulled in the general direction from the front panel 118 to the back panel 122 to separate and remove the window panel 138 from the front panel 118 along the line of weakness 136. Because the first major top panel 132 is sealed to the cover blank 144 (e.g., via a piece of tape), the first major top panel 132 can then separated and removed from the back panel 122 along the line of weakness 184, for example, by continuing to pull the cover blank 144 in the direction away from the back panel 122. With the window portion 138, the first major top panel 132, and the cover blank 144 removed from the remainder of the enclosure blank 112, the remainder of the enclosure blank 112 forms a container in a display configuration, including a window opening and a top opening.
As described above with respect to the container 10 formed from the enclosure blank 12 and the cover blank 44 (
Turning now to
The cover blank 244 includes a first cover side panel 246, a cover front panel 248, a second cover side panel 250, a first minor top flap 252, a second major top flap 254, a second minor top flap 256, and recessed surfaces 262a, 262b, which are similar to the similarly numbered features illustrated in
To assemble the enclosure blank 212 and the cover blank 244 to form a container in a shipping configuration, the cover blank 244 is attached to the enclosure blank 212 via adhesive(s) applied at or near the adhesive areas 264b-c, 266b-c, the overlap panel 214 is attached to the back panel 222, the adhesive areas 264a, 264d of the cover overlap panels 288a, 288b are attached to the adhesive areas 266a, 266d of the back panel 222, the bottom flaps 224, 226, 228, 230 are folded inwards and sealed to form a bottom surface, and the top flaps 252, 254, 256, 232 are folded inwards and sealed to form a top surface as described above. To convert the container from the shipping configuration to a display configuration, the separation elements 234a-c are actuated or torn out, and the window portion 238 is separated and removed from the front panel 218 along the line of weakness 236. The resulting container in the display configuration includes a window opening and a top opening. Similar to the container formed from the blanks 112, 144 described above with respect to
Turning now to
The cover blank 344 includes a first cover side panel 346, a cover front panel 348, a first minor top flap 352, a second major top flap 354, and recessed surfaces 362, which are similar to the similarly numbered features illustrated in
To assemble the enclosure blank 312 and the cover blank 344 to form a container in a shipping configuration, the cover blank 344 is attached to the enclosure blank 312 via adhesive(s) applied at or near the adhesive areas 364a-g, 366a-g, the overlap panel 314 is attached to the back panel 322, the bottom flaps 324, 326, 328, 330 are folded inwards and sealed to form a bottom surface, and the top flaps 352, 354, 356, 332 are folded inwards and sealed to form a top surface as described above. To convert the container from the shipping configuration to a display configuration, the lines of weakness 386a-b and the separation elements 334a-c are actuated or torn out, and the window portion 338 is separated and removed from the first side panel 316 and the front panel 318 along the line of weakness 336. The resulting container in the display configuration includes a window opening and a top opening. In particular, the window opening spans two sides of the container in the display configuration to allow for even greater access to goods or products within the container. Similar to the container formed from the blanks 112, 144 described above with respect to
It is contemplated that the features described above for the various embodiments illustrated in the figures can be combined. For example, the breakaway portions and the breakaway-assist portions, the assist tab portion, the cover overlap flaps, the window portion spanning multiple panels, or any of the separation elements can be provided in any combination in accordance with the concepts of the present disclosure. Additionally, although the overlap panel has been illustrated and described as being attached to either a first side panel or a back panel, it will be appreciated that an overlap panel can be connected to a second side panel or a front panel in some embodiments.
The above containers provide a number of advantages over other displayable shipping containers. It has been discovered that prior containers that had a cover that encompassed all sides of the inner enclosure tend to have an imbalance of compression strength from front to back (due, in part, to the window in the front of the container). As a result such prior containers required additional material or different strengths of material to compensate for the lack or non-uniformity of compressions strength at the front of the container. The containers of the present disclosure provide improved and more uniform compression strength characteristics due to the cover panels being located over the window portion(s) and one or two side panels, while at the same time reducing the amount of material required and lowering the costs of manufacture.
Additionally, for example, when the cover includes a front panel and two side panels, important graphics on the exterior can be protected during transit. Generally, the graphics on the back panel are not as important to protect because the customer is not likely to see the back panel when the container is being used in a display configuration. Moreover, for example, providing a cover blank that includes two or three panels reduces binding during manufacture and assembly of the containers. Additionally, for example, the containers of the present disclosure can include window openings that span multiple sides of the container, thus providing greater access to goods and products within the containers. And still further, for example, the containers of the present disclosure can be configured such that no portion of the cover blank remains attached to the container in the display configuration or the containers can be configured such that the portions of the cover blank that remain attached to the container in the display configuration are relatively small in size and located in non-prominent locations on the container (e.g., on or near the back panel of the container).
The containers of the embodiments described herein are typically manufactured using corrugated paperboard, preferably with the corrugations running in a vertical direction for increased strength. As non-limiting examples, the container is manufactured from C-flute, EB-flute, E-flute or B-flute corrugated paperboard. It is to be understood that the principles of this invention could be applied to containers made of other materials, such as non-corrugated paperboards, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, polymeric materials, and other foldable materials.
While the containers of the embodiments described above include glue or adhesive for attaching various panels and flaps of the containers, it is contemplated that any other suitable method of joining or attaching panels and flaps may be utilized such as, for example, staples, tapes, a system of corresponding slits and tabs, combinations thereof, and/or the like.
While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims.
This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/590,642, titled “Displayable Shipping Container” and filed on Jan. 25, 2012, which is incorporated herein by reference in its respective entirety.
Number | Date | Country | |
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61590642 | Jan 2012 | US |
Number | Date | Country | |
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Parent | 13749560 | Jan 2013 | US |
Child | 15937973 | US |