Abstract:
A display package ( 10 ) including a package sleeve ( 14 ) and one or more end caps ( 16,18 ) slideably inserted into the package sleeve. The package sleeve may have at least one open sleeve end and may define at least one transparent viewing window. The package sleeve may also have at least one foldable end flap ( 24 ) which may be folded inward toward the main end cap section with a portion thereof inserted through a respective lock slot ( 32 ) in the main cap section, thus locking the end cap in place. The one or more end caps may be designed to alter the shape of a package sleeve such as to increase the efficiency and ease of both the package assembly and product loading. The sleeve and end caps may be formed from a variety of materials including paper based materials or plastic based materials.

Description:
BACKGROUND 
       [0001]    The present application is directed to a package design incorporating end caps and, more particularly, is directed to a package having at least one foldable end cap. 
         [0002]    Current package designs are available that provide for easy viewing of the product stored therein, such as seen in US 2005/0247578; US 2006/0175339; U.S. Pat. No. 7,000,775; and US 2007/0246114, each of which is commonly assigned and hereby incorporated by reference thereto. These packages provide a clear plastic sleeve, facilitating viewing, and a pair of end caps. Such packages use pre-molded end caps and a snap-fit mechanism for attachment of at least the top end cap to the sleeve. Each of these two features has its drawbacks. First of all, the pre-molded end caps require a fairly complex injection molding and/or thermo-forming process to be produced, which unfavorably impacts both their production time and cost and which, further, may require an increased amount of material. Secondly, the snap-fit mechanisms of these packages do not generally promote easy removal of a given end cap by the consumer. 
         [0003]    Thus, what is needed in the art is a clear package design that provides an end cap that is simple and inexpensive to produce and that allows at least one end cap to be locked in place yet readily removed from the package. In addition, a package design that allows for efficient product loading and/or package end cap placement is desirable. Further, what is desired in the art is clear package design that is more sustainable. 
       SUMMARY 
       [0004]    The present display package may generally include a package sleeve and at least one first end cap slidably inserted into the package sleeve. The package sleeve may have at least one open sleeve end and may define at least one transparent viewing window. The package sleeve may also have at least one foldable end flap. Each respective end flap may extend directly from a given sleeve end and be foldable proximate thereto. Additionally, each first end cap may include a main cap section (i.e., a cap base) and at least one folding cap flap/side. More specifically, each cap flap may slidably impinge the package sleeve. Yet further, the main cap section may be positioned within the package sleeve. Also, each cap flap may extend from the main cap section and be foldable proximate thereto. Furthermore, each such cap flap may further have a lock slot associated therewith. Moreover, each end flap may be folded toward the main cap section. Additionally, a portion thereof may be inserted through a respective lock slot in the main cap section to hold a given end flap in place relative to the corresponding first end cap. Also, each cap flap may be designed to alter the shape of a package sleeve such as to increase the efficiency and ease of both the package assembly and product loading. 
         [0005]    Other aspects of the disclosed display package will become apparent from the following description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a front perspective view of one embodiment of the disclosed display package for carrying and displaying a product; 
           [0007]      FIG. 2  is an isometric, perspective view of the display package of  FIG. 1 ; and 
           [0008]      FIG. 3  is a disassembled, perspective view of the display package of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0009]    Referring to  FIGS. 1 and 2 , a display package, generally disclosed as  10 , may be used for carrying and displaying a product  12  (e.g., a jar, bottle, can, etc.). The display package  10  may include a package sleeve  14 , a first package end cap  16 , and second package end cap  18 . 
         [0010]    The package sleeve  14  may define an open-ended polyhedron having at least three sleeve sides  20  (of which, four are illustrated), with each sleeve side  20  being one of flat or curved. The package sleeve  14  further defines at least one open sleeve end  22 . The package sleeve  14  may include at least one transparent window (not labeled) in order to facilitate viewing/display of the product  12 . Thus, the package sleeve  14  could, for example, be formed of a plastic (e.g., polypropylene) or paperboard material, with at least one PLA or plastic window incorporated therein. Alternatively, the package sleeve  14  could be made (e.g., via direct forming, a die-cut process, etc.) entirely of a transparent material, with each sleeve side  20  effectively acting as a window (as illustrated). Further, it is to be understood that the material(s), thickness/gauge, window coloration, level of transparency, etc. may be chosen according to the application (e.g., desired package strength, presentation/appearance, etc.). As a further alternative, the package sleeve  14  could be produced without any sort of window therein, e.g., as part of a window-less package (not shown) or as part of a package in which one or both package end caps  16 ,  18 , instead, employ a window (not shown). A window-less sleeve could, for example, be employed as part of a sustainable package effort and/or to allow for more printable space. 
         [0011]    At least one sleeve side  20  has a respective sleeve flap  24  extending directly therefrom, relative to a given open sleeve end  22 . In accordance with the embodiment illustrated in  FIGS. 1 and 2  and best seen in  FIG. 3 , a pair of sleeve flaps  24  may, for example, respectively extend from opposed flat sleeve sides  20 . The opposed flat sleeve sides  20 , further, may be shorter than the other opposed pair of sleeve sides  20  (e.g., curved sides  20  in the illustrated embodiment), such that the longer opposed pair of sleeve sides  20  effectively act as the main viewing panels for the product  12 . It is to be understood that the sleeve sides  20 , could also be the same length. By placing the sleeve flaps  24  at the shorter flat sleeve slides  20 , the sleeve flaps  24  would interfere less with the viewing of the product  12  stored within the display package  10  (i.e., not be as readily seen when looking at the main face(s) of the display package  10 ). It is, however, to be understood that, alternatively, a given sleeve flap  24  could be attached to one of the other set of opposed pair of sleeve sides  20  (e.g., one of the curved ones in  FIGS. 1-3 ). In fact, each sleeve side  20 , potentially, could have a sleeve flap  24  associated therewith. Yet further, each sleeve flap  24  may also, respectively, particularly include a flap tab  25  at a free distal end thereof. Each respective flap tab  25  may be narrower in width than the corresponding sleeve flap  24  and, even further, may have rounded corners. Such narrowed width and/or rounded corners may aid a given flap tab  25  when in use. 
         [0012]    One facet potential worth considering is how to facilitate the bending and/or folding a given sleeve flap  24  relative to the respective sleeve side  20 . For one, having a given sleeve flap  24  extend from a flat sleeve side  20  instead of a curved one may allow for easier bending/folding of that given sleeve flap  24 . Besides the possibility of connecting a given sleeve flap  24  relative to a flat sleeve side  20 , at least one other means of promoting sleeve flap folding may be available. In particular, the sleeve flap  24  may be provided with a fold line  26 , proximate a given open sleeve end  22  associated with a corresponding sleeve side  20 . Each fold line  26  may, for example, defined by a scored and/or thinned joint at the connection of a given sleeve flap  24  and a corresponding sleeve side  20 . 
         [0013]    The first package end cap  16  and the second package end cap  18  may, respectively, be slidably inserted into the two opposed open sleeve ends  22  of the package sleeve  14 . Given the nature of each of the first package end cap  16  and the second package end cap  18 , it is understood that such elements may, for example, be considered to be an insert, end, and/or cap. Merely by way of example, as per  FIGS. 1-3 , the first package end cap  16  and the second package end cap  18  may serve, respectively, as the top and bottom end caps for the display package  10 . 
         [0014]    At least one of the first package end cap  16  and the second package end cap  18  may include a cap/end base  28  and at least one cap side/flap  30  (e.g., four cap sides  30 , as per  FIGS. 1-3 ). Each cap side  30  may integrally extend from a given edge/side of the cap base  28 . More particularly, the cap base  28  and the at least one cap side  30  may, for example, be molded together as a single piece or be die-cut and scored. In an instance where the cap base  28  and the at least one cap side  30  may be molded or die-cut as a single piece, the cap base  28  and the at least one cap side  30  may initially form a flat blank requiring folding to arrive at the final end cap shape or may, alternatively, in the case of molding be directly molded into the final end cap shape. If the at least one cap side  30  needs to be folded relative to the cap base  28  in order to arrive at the final end cap shape, each respective joint region between a given cap side  30  and the cap base  28  may, for example, be provided with scoring, a thinned region, and/or another means for easing folding thereat. Once the cap base  28  and the at least one cap side  30  are in their final alignment (especially, where a plurality of cap sides  30  are used), a given package end cap  16 ,  18  may have hollow-box construction, thereby, for one, helping to minimize the amount of material used for each such constructed end cap  16 ,  18 . Furthermore, the first package end cap  16  and/or the second package end cap  18  may be formed, for example, of plastic (e.g., polypropylene), paperboard, or another similar sheet stock. The combination of the cap base/side configuration and the materials used for such may allow such end caps to be light weight and have a simple construction. 
         [0015]    The first package end cap  16  and/or the second package end cap  18  may, in particular, include four sides, as per the illustrated example. In the illustrated example, each of the first package end cap  16  and the second package end cap  18  may have a pair of opposed flat cap sides  30  and, extending therebetween, a further pair of opposed curved/arcuate cap sides  30 . Additionally, the cap base  28  of each of the first package end cap  16  and the second package end cap  18  may, as shown, present a curved/arcuate face. The arrangement of the flat cap sides  30  and the curved cap sides  30  may particularly be chosen so as to facilitate a slide mounting/fit of a given package end cap  16 ,  18  in a respective open sleeve end  22  of the package sleeve  14 . More broadly considered the individual cap sides  30  could potentially be flat, curved, wavy, etc., and/or, in total, be of any number. Also, it is to be understood that the geometry (e.g., flat, curved, etc.) of a given cap side  30  may be yielded by, e.g., the initial blank forming process, a folding process, etc., so long as the final desired shape results. Such cap sides  30  may be chosen, for example, so as, at least in part, to facilitate insertion (e.g., a slide fit) thereof into a given open sleeve end  22  and/or to influence the shape (e.g., deflect) of a corresponding sleeve side  20 . Such insertion could, for example, be achieved by providing sleeve sides  20  that generally mate with the respective cap sides  30  (i.e., similarly configured in shape and/or number). Such insertion could also change an initially flat sleeve side into a curved sleeve side. 
         [0016]    At least one of the first package end cap  16  and the second package end cap  18  may be configured, upon insertion thereof into a given open sleeve end  22  of the package sleeve  14 , to be locked in place relative to the package sleeve  14  via at least one sleeve flap  24  and, potentially, more particularly, via a given flap tab  25 . In particular, a given folded/shaped end cap  16 ,  18  may be inserted cap base  28  first, so that the hollow portion of the given folded/shaped end cap  16 ,  18  opens outwardly toward the corresponding open sleeve end  22 . Upon insertion in this manner, a given sleeve flap  24  may be folded inwardly toward the sleeve interior and the hollow portion of the given folded/shaped end cap  16 ,  18 . Folding a given sleeve flap  24  as such would cause it, ultimately, to overlap the corresponding cap side  30 , with the sleeve fold line  26  and adjoining sleeve and sleeve flap regions acting to retain a given cap side  30  within the package sleeve  14 . 
         [0017]    At least one of the first package end cap  16  and the second package end cap  18  may be further provided with at least one lock slot  32 , each lock slot  32  being configured for lockingly receiving a respective sleeve flap  24  and, potentially, more particularly, a given flap tab  25 . Depending at least in part on the length of the corresponding sleeve flap  24 , a given lock slot  32  may be located in the cap base  28 , the corresponding cap side  30 , or at the joint therebetween. Each lock slot  32  should be sized (e.g., width) so as to be able to lockingly receive an end portion (e.g., a given flap tab  25 , if such flap tabs  25  are available) of the respective sleeve flap  24  therein, with the given sleeve flap  24  being able to click into place. As such, the flap tab width and/or rounded corners may aid in the insertion thereof into a corresponding lock slot  32 . The sleeve flap  24 /lock slot  32  combination may be released, by pressing gently on the end cap adjacent to the locking location (e.g. right in front or just to either side). The pressure applied at this location allows the sleeve flap to pop out of the end cap lack slot and a user to then be able lift the unlocked sleeve flap and remove the end cap. An alternate means to open the end package could be for example, by pressing on the opposed long sides of package sleeve  14  (i.e., the sides interposed between the sleeve flaps  24 ) until each flap tab  25  snaps out locking engagement with a corresponding lock slot  32 . Yet, alternatively, the lock release could potentially be achieved by a user pulling a sleeve flap  24  out of the corresponding lock slot  32 . Accordingly, the folding of a given sleeve flap  24  over an edge of a corresponding cap side  30  and then inserting of an end (e.g., a flap tab  25 ) of the given sleeve flap  24  into a respective lock slot  28  may facilitate the fastening of the given end cap  16 ,  18  in place within the corresponding open sleeve end  22 . 
         [0018]    A given cap base  28  may, yet further, include a main base section  34  and a pair of opposed secondary base sections  36 . The main base section  34  may be configured for impinging and resisting a corresponding face (not labeled) of the product  12 . Additionally, upon assembly of the display package  10  with the product  12  therein, the shortest distance between the opposed main base sections  34  of the respective end caps  16 ,  18  may be about the height of the product  10  or slightly less (i.e., yielding a resilient, force fit therebetween). Further, each secondary base section  36  may particularly serve, respectively, to interconnect the main base section  34  with a corresponding cap side  30 . To facilitate such respective interconnections, each secondary base section  36  may have a pair of base fold lines  38  associated therewith, with one such base fold line  38  providing a foldable link with the main base section  34  and the other providing a foldable connection with the corresponding cap side  30 . A given base fold line  38  could be, for example, defined by a scored and/or thinned joint between otherwise integral portions. 
         [0019]    The main base section  34  and the opposed secondary base sections  36  may, potentially, be designed in a manner so as to facilitate the release of a given flap tab  25  from a respective lock slot  32  while at the same time effectively increasing the stiffness of the given cap base  28 . One such configuration may be seen from the illustrated embodiment. In particular, the folding relative to the opposed secondary base sections  36  may yield a convexly bowed/curved main base section  34  (i.e., the bowing being directed away from the given end cap  16 ,  18 ). The convex bowing/curvature may facilitate the selectable relative motion (e.g., rocking action and/or face flexure) of a given main base section  34 , for example, with respect to the product  12 . Such relative motion can, in turn, aid in the release of a given flap tab  25  from a corresponding lock slot  32 . Besides possibly aiding the release process, the convexity of the given main base section  34  may improve the stiffness thereof, thereby helping to resist sagging when a product  12  is positioned between the first package end cap  16  and the second package end cap  18 . 
         [0020]    One base layout for yielding a convex main base section  34  may be seen from the figures, especially  FIG. 3 . Each given base fold line  38  providing a foldable link between a given secondary base section  36  and the main base section  34  may be curved/arcuate. Each such base fold line  38  may be curved inwardly (i.e., concavely) toward the main base section and, concordantly, curved outwardly from the corresponding secondary base section  36 . Upon folding relative to a given base fold line  38  that is curved in this manner, the main base section  34  may tend to bow outwardly away from the corresponding package end cap  16 ,  18 , while the secondary base section  36  may tend to curve inwardly theretoward. 
         [0021]    Yet further, each given base fold line  38  providing a foldable link between a given secondary base section  36  and a corresponding cap side  30  may be curved/arcuate, as well. Such a base fold line  38  may, particularly, be curved outwardly relative to the given secondary base section  36  (i.e., concave relative to the respective cap side  30 ). If so curved, the related secondary base section  36  will tend to be concave relative to the corresponding package end cap  16 ,  18 , while the respective cap side  30  will tend to be convex thereto. The convexity of a given cap side  30  may improve the stiffness thereof and also promote convex curvature in the corresponding sleeve side  20 . Moreover, such convexity in both a given cap side  30  and a corresponding sleeve side  20  may help make the overall display package  10  more resistant to impact/crushing. Finally, the resulting overall shape of a chosen secondary base section  36  having the base fold lines  38 , as illustrated, may be, for example, described as being a dual-pointed oval (i.e., football-shaped). It is, however, to be understood that other shapes might be employed for the chosen secondary base section  36 , if such a section is used at all. 
         [0022]    Further embodiments and variations may be possible and still be within the scope of the present display package  10 . For one, the first package end cap  16  and/or the second package end cap  18  may be further sealed to the package sleeve  14 , e.g., via tape, adhesive/glue, etc., as needed for improved mounting strength, child safety, etc. Secondly, additional structure could be associated with at least one cap base  28  (e.g., extension/protrusion, hole(s)/slot(s), etc.) to better hold a product in place within the display package  10 . Also, while the illustrated design may rely on the product  12  to limit the distance each end cap  16 ,  18  can slide into the package sleeve  14 , it is to be understood that additional structure could be provided (e.g., a stop member (not shown) on the interior of the package sleeve  14 ) to limit such sliding. 
         [0023]    Furthermore, it may be understood that the inserted portion of a given sleeve flap  24  may be narrower than the remainder thereof, with the width difference acting as a mechanical stop (i.e., limiting a flap-insertion distance). Also, it is to be understood that the inserted portion of a given sleeve flap  24  could be slightly wider than the corresponding lock slot  32  to thereby effect an interference/force fit therebetween for improved locking Yet additionally, it is to be understood that the sleeve sides  20 , individually or collectively, could potentially be, e.g., flat, curved, wavy, etc., and could attain such shape via an initial forming process and/or as a by-product of assembly (e.g., the insertion of an arcuate-faced cap could cause bowing/curving thereof). Further, with respect to the sleeve sides  20 , the size (e.g., length, width) and overall shape (e.g., rectangle, square) may be chosen based on the particular application (e.g., based, in part, on the sizes and shapes of the product  12  and/or the end caps  16 ,  18 ).