Abstract:
Specially designed shipping containers and a method of packing the containers are disclosed which orient carded packages having a bottom portion substantially larger than a top portion in alignment to facilitate efficient packing with reduced empty space in the containers for shipping of the carded packages and facilitate easy removal of the carded packages from the shipping container for display. The shipping containers use less packing material per carded package the resulting lighter smaller containers require less fuel to ship and producing less waste resulting in a “Green” shipping container. A method of packing such shipping containers is disclosed.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to a shipping container which orients display card packages in alignment to facilitate efficient, space saving packing for shipping of the packages and facilitates easy removal of the carded packages from the shipping container for display such as in a retail outlet. Specially designed shipping containers are used to orient display card packages in alignment to facilitate efficient packing with reduced empty space in the shipping containers for storage and transport of the carded packages. The shipping containers use less packing material per carded package the resulting lighter smaller containers require less fuel to ship and result in less waste resulting in a “Green” shipping container. The shipping container further prevents damage or bending of the carded package, thus reducing scrap or waste. A method of packing such shipping containers is disclosed. 
       BACKGROUND OF THE INVENTION 
       [0002]    In retail stores such as grocery stores, drug stores, convenience stores and “outlet” stores, smaller items can be packaged in sealed plastic or other display card packaging for display and ultimate purchase by the consumer. Non-limiting examples of such display card packaging include items such as batteries and household items such as bowl cleaning tablets, detergents and small parts and the like are often packaged in carded display packs. Products packaged in this way are often displayed in paper trays which allow for easy shelf restocking. Once the supply of packages is exhausted, the stock can be resupplied by placing additional trays containing display card packages onto the shelf. The trays may also be stacked on shelves. 
         [0003]    Since the margins for these types of retail stores are razor-thin, operators of such stores are constantly looking for ways to decrease their cost of operating the stores. One cost is the labor needed to move retail items from storage and place them onto the display case for consumers to purchase. It is typically time consuming for a stock person to remove the items from a shipping container and to place them on a display case. This is especially difficult when handling large numbers of packages that need to be placed on a shelf or in a display case. The stock person must align the packages on the shelf or in the display case. Thus, the stockperson typically places packages on the shelf one at a time or only a few at a time. This is inefficient and time consuming. This problem is exacerbated when the need arises to rotate stock, such as the case with items having an expiration date. Rotation of the stock involves moving the older items to the front of the shelf to ensure those items are sold first and placing the newer stock along the rear of the shelf. To accomplish this, the stock person needs to remove all of the old stock from the shelf, place the new stock on the shelf and then return the old stock to the front of the shelf in front of the new stock. This can become quite a time consuming chore if the packages are placed on the shelf one at a time or only a few at a time. 
         [0004]    Existing shipping containers such as those disclosed in U.S. Pat. Nos. 7,549,542; 5,730,296 and 6,953,118 provide for efficient removal and display of carded packages, however, these container can waste 50 percent or more of the internal volume of the container as a result of inefficient packing of the carded packages. There has not been a shipping container that would provide for an efficient method for packing and removing such tray packed carded packages from a shipping container and placing them on shelf. An efficient container will reduce shipping and packaging costs. The present invention to provides a shipping container and method to facilitate the efficient space saving packing, shipping and quick and efficient transfer of packaged items from a shipping container to a shelf or a display case in a retail store or other outlet. 
       SUMMARY OF THE INVENTION 
       [0005]    Specially designed shipping containers have been developed to ship and orient display carded packages in alignment to facilitate efficient packing with reduced empty space in the shipping containers and facilitate easy removal of the carded packages from the shipping container for display. The shipping containers use less packing material per carded package the resulting lighter smaller containers require less fuel to ship and result in less waste resulting in a “Green” shipping container. The shipping container further prevents damage or bending of the carded package, thus reducing scrap or waste. Carded packages referred to herein have a bottom portion of each carded package substantially thicker than the top portion, 
         [0006]    To facilitate the transfer of packages from the shipping container, the packages to be shipped should be oriented in the shipping container so the carded end. This alignment allows the stock person to easily thread the rod of the transfer tool through the openings of a number of packages for transfer to the peg of the display board. The shipping containers, or cartons, of this invention are designed to allow the packages to be placed in the containers lying down yet opened in such a way that the packages are oriented vertically with the openings, adjacent to the upper portion thereof, substantially aligned. This facilitates the placement of the transfer tool through the openings in the packages. One embodiment of the shipping container includes a divider that keeps the rows of packages separate and helps to maintain proper orientation and alignment of the packages. 
         [0007]    A method of this invention comprises, removing tear strips from the side walls of a packed and sealed shipping container thereby dividing the container into two parts and with the aid of dividers placed in the container at the time of packing, dividing the oriented and pushed together carded display packages such that each shipping container portion contains one tray of carded display packages ready to be placed on a shelf. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The preferred embodiments of the present invention are illustrated in the appended drawings in which like reference numbers refer to like elements and in which: 
           [0009]      FIG. 1  is a plan view of a first embodiment of a blank for the shipping container; 
           [0010]      FIG. 2  is a plan view of a second embodiment of a blank for the shipping container; 
           [0011]      FIG. 3  is a perspective view of a partially erected shipping container made from the first embodiment of the blank of  FIG. 1 ; 
           [0012]      FIG. 4A  is a perspective view of a tray containing carded packages; 
           [0013]      FIG. 4B  is a perspective view of a tray containing carded packages; 
           [0014]      FIG. 5  is a plan view of a tray; 
           [0015]      FIG. 6  is a perspective view of two opposing trays containing carded packages with one tray rotated 180 degrees pushed together; 
           [0016]      FIG. 7A  is a perspective view of a two opposing separators; 
           [0017]      FIG. 7B  is a plan view of a single unit separator; 
           [0018]      FIG. 8  is a perspective view of a shipping container containing two opposing trays and two separators; 
           [0019]      FIG. 9  is a perspective view of a shipping container containing two opposing trays and two separators positioned for closure of the shipping container; 
           [0020]      FIG. 10  is a perspective view of a shipping container containing two opposing trays and two separators about to be closed; 
           [0021]      FIG. 11  is a perspective view of a shipping container containing two opposing trays filled with carded display packages after the shipping container has been opened. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]      FIG. 1  is a plan view of a paperboard blank  100 , that can be used to make a shipping container that is particularly useful in combination with carded blister or carded box packs. This blank includes a pair of tear strips that facilitate opening the container after it has been shipped to a retail outlet or other final destination. Referring to  FIG. 1 , paperboard blank  100  incorporates an adhesive tab  105  and four main panels  110 ,  120 ,  130  and  140 . Adhesive tab  105  is connected along its right edge to the left edge of first main panel  110  along score line  111 . First main panel  110  is connected along its right edge to the left edge of second main panel  120  along score line  121 . Second main panel  120  is connected along its right edge to the left edge of third main panel  130  along score line  131 . Third main panel  130  is connected along its right edge to the left edge of fourth main panel  140  along score line and  141 . Each main panel  110 ,  120 ,  130 , and  140  adjoins a top flap and a bottom flap, wherein the main panels are separated from the top flaps by a top score line  150  extending across the entire blank and the main panels are separated from the bottom flaps by a bottom score line  160  extending across the entire blank. 
         [0023]    Above first main panel  110  is first top flap  115 A. Above second main panel  120  is second split top flap  125 A 1  and  125 A 2 . Above third main panel  130  is third top flap  135 A. Above fourth main panel  140  is fourth split top flap  145 A 1  and  145 A 2 . 
         [0024]    Below first main panel  110  is first bottom flap  115 B. Below second main panel  120  is second split bottom flap  125 B 1  and  125 B 2 . Below third main panel  130  is third bottom flap  135 B. Below fourth main panel  140  is fourth split bottom flap  145 B 1  and  145 B 2 . 
         [0025]    A first vertical perforation  126  extends from the top right edge of bottom flap  125 B 1  through second main panel  120  to the bottom right edge of top flap  125 A 1 . A second vertical perforation  128  extends from the top left edge of bottom flap  125 B 2  through second main panel  120  to the bottom left edge of top flap  125 A 2 . The two vertical perforations  126  and  128  define a tear strip  127 . 
         [0026]    A third vertical perforation  146  extends from the top right edge of bottom flap  145 B 1  through second main panel  140  to the bottom right edge of top flap  145 A 1 . A fourth vertical perforation  148  extends from the top left edge of bottom flap  145 B 2  through second main panel  140  to the bottom left edge of top flap  145 A 2 . The two vertical perforations  146  and  148  define a tear strip  147 . 
         [0027]      FIG. 2  is a plan view of a paperboard blank  200 , that can be used to make a shipping container that is particularly useful in combination with carded blister or carded box packs. The container formed by paperboard blank  200  has top and bottom flaps  225 A 1 ;  225 A 2  and  245 A 1 ;  245 A 2  and  225 B 1 ;  225 B 2  and  245 B 1 ;  245 B 2  respectively that are not initially split resulting a tighter sealed and stronger container when such properties are desired. This blank includes a pair of tear strips that facilitate opening the container after it has been shipped to a retail outlet or other final destination. Referring to  FIG. 2 , paperboard blank  200  incorporates an adhesive tab  205  and four main panels  210 ,  220 ,  230  and  240 . Adhesive tab  205  is connected along its right edge to the left edge of first main panel  210  along score line  211 . First main panel  210  is connected along its right edge to the left edge of second main panel  220  along score line  221 . Second main panel  220  is connected along its right edge to the left edge of third main panel  230  along score line  231 . Third main panel  230  is connected along its right edge to the left edge of fourth main panel  240  along score line and  241 . Each main panel  210 ,  220 ,  230 , and  240  adjoins a top flap and a bottom flap, wherein the main panels are separated from the top flaps by a top score line  250  extending across the entire blank and the main panels are separated from the bottom flaps by a bottom score line  260  extending across the entire blank. 
         [0028]    Above first main panel  210  is first top flap  215 A. Above second main panel  220  is top flap  225 A which is divided by tear strip  227  into  225 A 1  and  225 A 2 . Above third main panel  230  is top flap  235 A. Above fourth main panel  240  is top flap  240 A which is divided by tear strip  247  into  245 A 1  and  245 A 2 . 
         [0029]    Below first main panel  210  is first bottom flap  215 B. Below second main panel  220  is top flap  225 B which is divided by tear strip  227  into  225 B 1  and  225 B 2 . Below third main panel  230  is bottom flap  235 B. Below fourth main panel  240  is bottom flap  240 B which is divided by tear strip  247  into  245 B 1  and  245 B 2 . 
         [0030]    A first vertical perforation  226  extends from the bottom right edge of bottom flap  225 B 1  through second main panel  220  to the top right edge of top flap  225 A 1 . A second vertical perforation  228  extends from the bottom left edge of bottom flap  225 B 2  through second main panel  220  to the top left edge of top flap  225 A 2 . The two vertical perforations  226  and  228  define a tear strip  227 . 
         [0031]    A third vertical perforation  246  extends from the bottom right edge of bottom flap  245 B 1  through second main panel  240  to the top right edge of top flap  245 A 1 . A fourth vertical perforation  248  extends from the bottom left edge of bottom flap  245 B 2  through second main panel  240  to the top left edge of top flap  245 A 2 . The two vertical perforations  246  and  248  define a tear strip  247 . 
         [0032]    Tear strips  127 ;  147  and  227 ;  247  can be formed by standard packaging techniques. For example, this can be done by employing parallel cut lines that define both sides of the tear strips so as to form the outer boundary of the tear strips. Alternatively, the cut lines may be obliquely arranged like legs extending into the center portion of the tear strips and where the legs diverge in the direction of the tear of the tear strip. In addition, a tab may be formed at one end of any of the tear strips. Tabs may be easily grasped by the user to pull off tear strips  127 ;  147  and  227 ;  247  respectively to thereby open the container formed from blank  100  or blank  200 . 
         [0033]    The tear strips may be strengthened with tape, ribbon, cord, plastic, wire and the like. It is preferred that the strengthening material be located on the inside of container on the inside facing surface of the tear strip. Alternately, the strengthening material may be embedded between multiple layers of corrugated material and other outer and inner box layers. 
         [0034]    To form a container from blanks  100  or  200 , adhesive tab  105 ,  205  is folded about score line  111 ,  211  so adhesive tab  105 ,  205  is generally perpendicular to first main panel  110 ,  210 , which is folded about score line  121 ,  221  so first main panel  110 ,  210  is generally perpendicular to second main panel  120 ,  220 , which is folded about score line  131 ,  231 , so second main panel  120 ,  220  is generally perpendicular to third main panel  130 ,  230 , which is folded about score line  141 ,  241  so third main panel  130 ,  230  is generally perpendicular to fourth main panel  140 ,  240 . This results in adhesive tab  105 ,  205  being adjacent to the right edge of fourth main panel  140 ,  240 . Adhesive tab  105 ,  205  can be adhered to the right portion of fourth main panel  140 ,  240  by glue or other mechanical or adhesive means, such as staples or hot melt adhesives to provide the general configuration for the desired container. The joint formed between adhesive tabs  105 ,  205  with the right portion of main panel  140 ,  240  is known in the art as a lap joint. Bottom flaps  115 B,  215 B,  125 B 1  and  125 B 2 ,  225 B 1  and  225 B 2 ,  135 B,  235 B and  145 B 1  and  145 B 2 ,  245 B 1  and  245 B 2  are folded inwardly toward each other and adhered to each other by standard means, such as by glue or other mechanical or adhesive means to form a bottom for the desired container. Preferably, bottom flaps  125 B 1 ,  125 B 2 , and  145 B 1 ,  145 B 2 , are the inner flaps of the bottom of the box  100 . Preferably, bottom flaps  225 B 1 ,  225 B 2 , and  245 B 1 ,  245 B 2 , are the outer flaps of the bottom of the box  200 . 
         [0035]    The configuration of such a container  100 , at this stage of erection is shown in  FIG. 3 . 
         [0036]    After paperboard blank  100  or  200  is folded as discussed above, it is filled with carded packages  400  preferably contained in tray  500  to be shipped, for example to a retail outlet. There can be two rows of packages or multiples of two rows located in shipping container  100  or  200 . The number of rows is not critical as long as there are an even number of rows and there are a number of carded packages  400  in each row and each of the packages is oriented in each row so that card portions  410  of the packages are substantially aligned upward as shown in  FIGS. 4A and 4B . The carded packages  400  are shown in optional tray  500 . 
         [0037]    The tray of the present invention may be any tray suited for holding carded packages. The sides of the tray may be of uniform height as illustrated in  FIGS. 4A and 4B ,  5  and  6  or with slanted sides or with sides containing various shapes and figures. 
         [0038]    Tray Nesting with Fingers and Insertion into the Shipping Container: 
         [0039]    Lay 2 loaded trays opposing one another on their sides, with one tray rotated 180 degrees so it is inverted with respect to the other tray. Thereby aligning the carded side  410 ,  FIG. 4A , with the box (package) side  420   FIG. 4B  of the carded packages in the opposing tray. Merge the two trays partially together such that a portion of the carded portion of each carded package is pushed between the package portion and carded portion of two adjacent carded packages in the opposing tray. The two trays are aligned such that if the were pushed tightly together the two trays would fit together as illustrated in  FIG. 6 . 
         [0040]    Once the carded packages are partially pushed together, insert 2 finger separators,  700  in  FIG. 7A , fingers down as illustrated in  FIGS. 8 and 9 , then completely push the trays together. with the un-die-cut flat surface over the carded packages in the tray. Preferably, the carded packages are about 75% pushed together before inserting the 2 finger separators  700  in  FIG. 7A , fingers down as illustrated in  FIG. 8 , then completely push the trays together. with the un-die-cut flat surface folded over the carded packages in the tray. The width of fingers  720  is up to about 95% of the width of package portion  420  of the carded packages. The space between fingers  720  is not less than the thickness of two cards  410 . Separator fingers  720  are connected to separator panel  710  along score line  740 . 
         [0041]    A blank for forming a separator of  FIG. 7A  comprises a paperboard blank having a first portion of a plurality of parallel extensions and a second portion of a panel; wherein adjacent fingers are separated from one another by parallel spaces; and wherein the plurality of extensions are connected on one end to a second portion of the separator, a panel portion and are not connected on the opposing end, the first portion of the separator adjoining the second portion of the separator along a score line extending substantially perpendicular to the parallel fingers; 
         [0042]    An alternative finger separator formed of a single blank,  FIG. 7B , may be used to separate the carded packages upon opening of the container. Separator  800  is folded along score line  735  thereby forming fingers  720 . Once the carded packages are partially pushed together, insert the finger separator  800  fingers down as illustrated in  FIGS. 8 and 9 , then completely push the trays together, with the un-die-cut flat surfaces  710  folded at score line  740  to lie flat over the carded packages in the tray. Preferably, the carded packages are about 75% pushed together before inserting the finger separator,  800  in  FIG. 7B , fingers down as illustrated in  FIG. 8 , then completely push the trays together, with the un-die-cut flat surfaces folded over the carded packages in the tray. The width of fingers  720  is up to about 95% of the width of package portion  420  of the carded packages. The space between fingers  720  is not less than the thickness of two cards  410 . Separator fingers  720  are connected to separator panel  710  along score line  740 . 
         [0043]    A method of packing a shipping container without using optional trays comprises; forming an open shipping container for carded display packages from a container blank; comprising; forming two rows of carded display packages; 
         [0000]    positioning the two rows on their side; rotating one row such that it is inverted with respect to the other row; aligning the carded side of carded packages in one row with the package side of the carded packages in the other row; merging the two rows partially together; inserting the fingers of one or two finger separators into the space between the two partially merged rows of carded packages; merging the two rows completely together; placing the merged rows and one or two separators into the shipping container; and closing the shipping container. 
         [0044]    A blank for forming a separator of  FIG. 7B  comprises a paperboard blank having a central portion and two end portions separated by the central portion, wherein the central portion comprises a plurality of parallel cut outs of about the same length and width positioned at about the same distance from the outer blank edge of the end portions, said central portion forming fingers when folded along a center score line perpendicular to the cut outs at about the center of the blank the end portions of the separator adjoining the central portion of the separator along a score line extending substantially perpendicular to the parallel cut outs at the ends of the cutouts ends which ends are aligned along the perpendicular score lines. 
         [0045]    For a container from blank  100 , put the tray-finger assembly in to the box. Fold the 4 small flaps,  145 A 1 ,  145 A 2 ,  125 A 1  and  125 A 2 , inward, then while applying hot melt adhesive to the two large flaps  115 A and  135 A, or the two top surfaces of the small flaps, fold and seal the 2 large flaps to the top surface of the small flaps.  FIG. 10  illustrates the shipping container about to be sealed. The container flaps may be sealed with conventional adhesives, staples and tapes known in the art and used for this purpose. 
         [0046]    For a container from blank  200 , put the tray-finger assembly in to the box. Fold the 2 top flaps,  245 A 1 ,  245 A 2 , and  225 A 1 ;  225 A 2 , inward, then while applying hot melt adhesive to the two flaps  215 A and  235 A, or the two top surfaces of the top flaps,  245 A 1 ,  245 A 2 , and  225 A 1 ;  225 A 2 , fold and seal the 2 flaps  215 A and  235 A, to the top surface of the flaps,  245 A 1 ,  245 A 2 , and  225 A 1 ;  225 A 2 . The container flaps may be sealed with conventional adhesives, staples and tapes known in the art and used for this purpose. 
         [0047]    Shipping container  100  can be easily opened by pulling the end of tear strips  127  and  147  to remove tear strips  127  and  147  respectively. Shipping container  200  can be easily opened by pulling the end of tear strips  227  and  247  to remove tear strips  227  and  247  respectively. With any embodiment of the shipping container, opening the shipping container as set forth above will allow the shipping container to be separated into two portions. A method for opening a shipping container of the present invention comprises locating the two tear strips; pulling the two tear strips wherein the two tear strips are completely removed from the container; separating the container at the two finger dividers and pulling apart the container resulting into two separate containers,  FIG. 11 ; and lifting the tray containing carded packages out of the shipping container. 
         [0048]    Thus, as seen in  FIGS. 10 and 11 , when the shipping container is placed on a horizontal surface and the tear strips removed, the shipping container separates into two portions not connected to each other, that is two separate partial containers. The display card packages in each portion are separated from each other by the finger separators which provide for easy separating of the oriented carded display packages  400  in trays  500 . The trays containing the carded packages are easily removed from the divided shipping container for easy placement on a shelf. The flaps of the shipping container partial portions may be pulled to separate them from the inner flaps thereby giving greater access to the contents of the container. Optionally, the shipping container may be packed with display card packages that are not contained in a tray. 
         [0049]    This application claims priority of U.S. Provisional Patent Application Ser. No. 61/540,746, entitled “SHIPPING CONTAINER FOR CARDED PACKAGES,” filed on Sep. 29, 2011, which is incorporated by reference herein. 
         [0050]    The description of illustrative and preferred embodiments of the present invention is not intended to limit the scope of the invention. Various modifications, alternative constructions and equivalents may be employed without departing from the true spirit and scope of the appended claims.