Abstract:
A package according to a preferred embodiment of the present invention comprises a main body portion defined by a bottom wall and one or more upstanding sidewalls. The sidewalls cooperate to define an open top of the main body portion of the package. A lid is provided and is defined by a top wall and one or more downwardly-depending sidewalls. The lid is sized to fit over the open top of the main body portion of the package. At least one sidewall of the lid is secured to at least one sidewall of the main body portion. At least one sidewall of the lid includes a take-up strip positioned between the top wall and a distal edge of the at least one lid sidewall. The take-up strip permits movement of the lid relative to the main body portion without separating the at least one lid sidewall from the main body portion sidewall to which it is secured.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S)  
       [0001]     The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/633,015, filed 3 Dec. 2005 and hereby incorporates by reference the disclosure set forth therein. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Technical Field of the Invention  
         [0003]     The present invention relates generally to a lidded container for shipping, storing and handling a plurality of items. More particularly, the present invention relates to a lidded container for shipping, storing and handling a plurality of items, wherein the container includes a tear-away strip for opening the container and a lid deflection take-up means for preventing damage to the container during shipping, storing and handling.  
         [0004]     2. Brief Description of the Related Art  
         [0005]     In the shipping, storing and handling of prepackaged items, such as individually-wrapped reams of cut-size paper for use in photocopiers and desktop printers, it is customary for a plurality of such items to be shipped, stored and handled in a corrugated container. For example, an individual ream of cut-size paper may contain 500 sheets of 8½″×11″ printer paper, which are stacked and then bundled together with a paper (or polymeric) wrapping material.  
         [0006]     A plurality of reams are then stacked (for example, 2 columns of 5 reams stacked in a side-by-side arrangement) in a rectangular container constructed from conventional corrugated material. The corrugated container serves to protect the reams of paper during transit and to bundle a plurality of individual reams together to simplify shipment. It is typical for the corrugated containers to include a lid, which typically telescopes over an open upper end of the container, thereby containing the reams therein to prevent spillage or damage thereto. The dimensions of the lidded container typically are only slightly larger than the contents stacked therein, and accordingly, such containers are considered “dense” in that very little void space is present therein. It is desirable, therefore, to provide a lidded container for shipping, storing and handling a plurality of items, such as, for example, prepackaged reams of paper.  
         [0007]     It is typical for such corrugated containers to experience rough handling and shipping practices. For example, because corrugated containers containing reams of paper are heavy, they are oftentimes dropped inadvertently. Also, because the contents of such containers typically are not considered “breakable”, shippers and other handlers do not exert significant care in moving the containers about. Therefore, it is desirable to provide a container for shipping, storing and handling a plurality of items therein, wherein the container is constructed so as to inhibit the bursting thereof, and so as to minimize the extent to which the contents thereof are damaged during shipping, storing and handling.  
         [0008]     This is difficult to achieve because most containers are formed from a foldable blank (i.e., flat) sheet of corrugated material that includes a plurality of flaps that are folded relative to one another to form sidewalls, a bottom wall and (in the case of the lid) a top wall. Adhesives, such as glues and tapes, as well as mechanical fasteners, such as staples, are used to affix the flaps to one another for the purpose of defining a rigid, box-like structure for the purposes herein described. Similarly, adhesives and/or mechanical fasteners are used typically to secure the lid over the open upper end of the container main body. During rough handling of the containers, it is common for the adhesives and mechanical fasteners to fail and/or tear from the corrugated material, thereby resulting in failure of the container and in potential spillage of the items contained therein. It is therefore desirable to provide a container that is adapted to withstand rough handling that may be encountered during typical shipping operations.  
         [0009]     During shipping and storing, containers such as those related to the present invention, are stacked one atop another, sometimes forming a stack of 5 or more in height. The weight of the containers (and their contents) typically is large, especially for those containers on the very bottom of the stack. It is desirable, therefore, to provide not only a stackable container, but a stackable container that is resistant to failure loading, such as bursting. It has been observed that one cause leading to failure of the adhesives and/or mechanical fasteners used to construct the container is the large weight resting on those containers having additional containers stacked thereon.  
         [0010]     This is especially problematic with the adhesive used to secure the lid to the container main body. As packed containers are stacked on one another, the weight of the stack creates significant shear stress in the adhesives securing the lids to the main bodies of the containers below the stack. It has been observed that under such circumstances, the adhesives fail under this shear stress, thereby detaching the lids from the container main bodies.  
         [0011]     One solution to this problem is to use poly straps or films to encircle the lidded container for the purpose of holding the lid tight against the open upper end of the container main body. However, this solution also is problematic in that the straps and/or films needs to be disposed of once the containers are opened at their final destination. The straps and/or films also creates opportunities for the containers to be snagged on jutting objects encountered during shipping, storing and handling. It is desirable, therefore, to provide a lidded container wherein the lid is secured to the open upper end of the container main body without the use of straps, films or the like. It is also desirable to provide a lidded container having means for opening the container easily, when desired.  
         [0012]     In view of the desire to provide a lidded container having a lid adhesively secured to the open upper end of the container main body, it is furthermore desirable to provide take-up means to inhibit failure of the adhesive during shipping, storing and handling.  
         [0013]     Finally, it is desirable to provide a lid for use with a container main body, wherein the lid includes take-up means to inhibit failure of the container during shipping, storing and handling thereof.  
       SUMMARY OF THE INVENTION  
       [0014]     The present invention provides a container for shipping, storing and handing a plurality of items, such as, for example, a plurality of reams of paper. The container includes a box-shaped main body portion and a lid that is sized and configured to fit over an open upper end of the main body. Sidewalls of the lid telescope over mating sidewalls of the main body and are adhered thereto, such as by adhesive or tape. One sidewall of the lid includes a tear strip defined by two parallel perforation lines running along the length of the middle of the sidewall. One end of the tear strip includes a tab for gripping by the user. Alternatively, a tear strip might be provided in additional sidewalls of the lid.  
         [0015]     An elongated take-up region is provided along the length of at least one of the lid sidewalls and is oriented generally to be in parallel with the tear strip. The take-up region is positioned between the tear strip and the top wall panel of the lid and is in the form of a collapsible accordion structure defined by a plurality of fold lines. Compression of the container, such as by applying a downward force to the lid to urge the lid towards the main body, is absorbed by the take-up region, thereby minimizing shear stress in the adhesive used to adhere the lid sidewalls to the main body sidewalls.  
         [0016]     According to one aspect of the present invention, a package according to a preferred embodiment of the present invention comprises a main body portion defined by a bottom wall and one or more upstanding sidewalls. The sidewalls cooperate to define an open top of the main body portion of the package. A lid is provided and is defined by a top wall and one or more downwardly-depending sidewalls. The lid is sized to fit over the open top of the main body portion of the package. At least one sidewall of the lid is secured to at least one sidewall of the main body portion. At least one sidewall of the lid includes a take-up strip positioned between the top wall and a distal edge of the at least one lid sidewall. The take-up strip permits movement of the lid relative to the main body portion without separating the at least one lid sidewall from the main body portion sidewall to which it is secured.  
         [0017]     It is an object of the present invention to provide a lidded container for shipping, storing and handling a plurality of items, such as, for example, prepackaged reams of paper.  
         [0018]     It is another object of the present invention to provide a container for shipping, storing and handling a plurality of items therein, wherein the container is constructed so as to inhibit the bursting thereof, and so as to minimize the extent to which the contents thereof are damaged during shipping, storing and handling.  
         [0019]     It is yet another object of the present invention to provide a container that is adapted to withstand rough handling that may be encountered during typical shipping operations.  
         [0020]     It is still another object of the present invention to provide not only a stackable container, but a stackable container that is resistant to failure loading, such as bursting  
         [0021]     It is another object of the present invention to provide a lidded container wherein the lid is secured to the open upper end of the container main body without the use of straps, films or the like.  
         [0022]     It is also an object of the present invention to provide a lidded container having means for opening the container easily, when desired.  
         [0023]     It is furthermore an object of the present invention to provide take-up means to inhibit failure of the adhesive during shipping, storing and handling.  
         [0024]     It is yet another object of the present invention to provide a lid for use with a container main body, wherein the lid includes take-up means to inhibit failure of the container during shipping, storing and handling thereof.  
         [0025]     These and other objects, features and advantages of the present invention will become apparent to those of ordinary skill in the art from the description which follows, and may be realized by means of the instrumentalities and combinations particularly pointed out therein, as well as by those instrumentalities, combinations and improvements thereof which are not described expressly therein, but which would be obvious to those of ordinary and reasonable skill in the art. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0026]     The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:  
         [0027]      FIG. 1  is a plan view of a first blank used to form main body portion of a container according to a preferred embodiment of the present invention;  
         [0028]      FIG. 2  is a plan view of a second blank used to form a lid of the container according to a preferred embodiment of the present invention;  
         [0029]      FIG. 3  is a perspective view of the container according to a preferred embodiment of the present invention, showing the lid adhered to the main body portion, and showing a tear strip partially removed from one sidewall of the lid;  
         [0030]      FIG. 4  is a perspective view of the container according to a preferred embodiment of the present invention, showing the tear strip completely removed from one sidewall of the lid, and showing the lid pivoted to an open position;  
         [0031]      FIG. 5  is a perspective view of a take-up region provided on the lid of a container according to a preferred embodiment of the present invention;  
         [0032]      FIG. 6 , is a cross-sectional view of the take-up region shown in  FIG. 5 , showing the take-up region in a relaxed state;  
         [0033]      FIG. 7  is a cross-sectional view of the take-up region shown in  FIG. 5 , showing the take-up region in a compressed state;  
         [0034]      FIG. 8  is a plan view of a first blank used to form a main body portion of a container according to one alternative embodiment of the present invention;  
         [0035]      FIG. 9  is a plan view of a first blank used to form a main body portion of a container according to another alternative embodiment of the present invention; and,  
         [0036]      FIG. 10  is a plan view of a second blank used to form a lid of a container according to still yet another alternative embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0037]     With reference to  FIG. 1 , a first blank  10  used to form a main body portion B ( FIG. 3 ) of the container C is shown and is constructed from a foldable material such as, for example, corrugated paperboard or the like. The blank  10  is generally rectangular in shape and is divided by first and second longitudinal foldlines  12 ,  14 , respectively, into a center panel  20  and outwardly extending side panels  40 .  
         [0038]     Center panel  20  is divided by left and right foldlines  21   a ,  21   b  into bottom wall panel  22 , and outwardly extending endwall panels  24 . Endwall panels  24  are foldable relative to the bottom wall panel  22  about foldlines  21   a ,  21   b  to define a pair of opposing, upwardly-extending endwalls of the main body portion B of the container C.  
         [0039]     Each side panel  40  is divided by left and right foldlines  23   a ,  23   b  into sidewall panels  42  and interior endwall wings  44 . Sidewall panels  42  are foldable relative to the bottom wall panel  22  about foldlines  12 ,  14  to define a pair of opposing, upwardly-extending sidewalls of the main body portion B of the container C.  
         [0040]     Main body portion B is constructed by first folding the endwall wings  44  upwardly relative to the sidewall panels  42  about foldlines  23   a ,  23   b  and then folding sidewall panels  42  upwardly relative to the bottom wall panel  22  about foldlines  12 ,  14  so that distal edges  44   a ,  44   b  of opposing endwall wings  44  meet near a midpoint of foldlines  21   a ,  21   b , respectively.  
         [0041]     Endwall panels  24  are then folded upwardly relative to the bottom wall panel  22  about foldlines  21   a ,  21   b  and adhesively secured to endwall wings  44 , such as, for example, with one or more strips  46  of hotmelt adhesive applied to the endwall panels  24  prior to folding. Alternatively, hotmelt adhesive may be applied to the mating surface of the endwall wings  44  prior to folding the endwall panels  24 . Double-sided adhesive tape may be used instead of hotmelt adhesive.  
         [0042]     Optionally, pop-out handles  47  may be provided in each of the endwall panels  24  by providing a generally curved first die-cut slit  47   a , a second die-cut slit  47   b  and cooperating foldlines  47   c . Mating handle segments  48  may be defined in endwall wings  44  to be superimposed over pop-out handles  47  provided in endwall panels  24  when the main body portion is folded as described herein.  
         [0043]     Referring now to  FIG. 2 , a second blank  50  used to form a lid L ( FIG. 3 ) of the container C is shown and is constructed from a foldable material such as, for example, corrugated paperboard or the like. The blank  50  is generally rectangular in shape and is divided by first and second longitudinal foldlines  52 ,  54 , respectively, into a center panel  60  and outwardly extending side wall panels  80 .  
         [0044]     Center panel  60  is divided by left and right foldlines  61   a ,  61   b  into top wall panel  62 , and outwardly extending endwall panels  64 . Endwall panels  64  are foldable relative to the top wall panel  62  about foldlines  61   a ,  61   b  to define a pair of opposing, upwardly-extending endwalls of the lid L of the container C.  
         [0045]     Each side panel  80  is divided by left and right foldlines  63   a ,  63   b  into sidewall panels  82  and interior endwall wings  84 . Sidewall panels  82  are foldable relative to the top wall panel  62  about foldlines  52 ,  54  to define a pair of opposing, upwardly-extending sidewalls of the lid L of the container C.  
         [0046]     One sidewall panel  82  includes a pair of perforation lines running lengthwise generally parallel to foldline  52 . Perforations  85  are of any conventional form and preferably cut through the sidewall panel  82  completely, although one or more of the perforations  85  may not extend through the entire thickness of the sidewall panel  82 , but may instead only cut partially therethrough. Optionally, both sidewall panels  82  may include perforation lines  85 .  
         [0047]     Perforation lines  85  cooperate to define a tear strip  86  therebetween, one end  86   a  of which may include a pull-tab for the purpose of gripping, as will be described in greater detail below. Tear strip  86  is positioned near a centerline of the sidewall panel  82 .  
         [0048]     A first elongated take-up region  87   a  is provided in one of the sidewall panels  82  and runs generally parallel to the tear strip  86  provided therein. The take-up region  87   a  is positioned on the sidewall panel  82  such that the tear strip  86  is positioned between the take-up region  87   a  and foldline  52 . The structure of the first take-up region  87   a  will be described in greater detail below.  
         [0049]     A second elongated take-up region  87   b  is provided in other of the sidewall panels  82  and runs generally parallel to foldline  54 . The take-up region  87   b  is positioned near a centerline of the sidewall panel  82 , if no tear strip  86  is provided in the sidewall panel  82 . The structure of the second take-up region  87   b  will be described in greater detail below.  
         [0050]     Lid L is constructed by first folding the endwall wings  84  upwardly relative to the sidewall panels  82  about foldlines  63   a ,  63   b  and then folding sidewall panels  82  upwardly relative to the top wall panel  62  about foldlines  52 ,  54  so that distal edges  84   a ,  84   b  of opposing endwall wings  84  face one another.  
         [0051]     Endwall panels  64  are then folded upwardly relative to the top wall panel  62  about foldlines  51   a ,  51   b  and adhesively secured to endwall wings  84 , such as, for example, with one or more strips (not shown) of hotmelt adhesive applied to the endwall panels  64  prior to folding. Alternatively, hotmelt adhesive may be applied to the mating surface of the endwall wings  84  prior to folding the endwall panels  64 . Double-sided adhesive tape may be used instead of hotmelt adhesive.  
         [0052]     With reference to  FIG. 3 , the container C is formed by positioning the lid L, erected from the blank  50  as described above, over an open upper end of the main body portion B, which has been erected as described above. Lid L is secured to the main body B by one or more strips  88  of hotmelt adhesive applied between the sidewalls  82  of the lid L and their respective sidewalls  42  of the main body portion B. Adhesive strips  88  preferably are positioned between the take-up regions  87   a ,  87   b  and distal edges  89  of the lid sidewalls  82 . Alternatively, other means may be used to secure the lid L to the main body B, such as double-sided tape (not shown). Thus configured, items I ( FIG. 4 ) may be shipped and stored in the container C.  
         [0053]     With reference back to  FIG. 1 , sidewall panels  42  of the main body portion B (i.e., first blank  10 ) may include perforated regions  45  near a centerline region thereof. Individual perforations of the perforated regions  45  preferably do not cut through the entire thickness of the sidewall panels  42 . Perforated regions  45  are provided for the purpose of enhancing the grip of the adhesive strips  88  used to secure the lid L on the main body portion B, thereby permitting use of less adhesive. Perforations may, alternatively, cut through the entire thickness of the sidewall panels  42  of the main body portion B.  
         [0054]     Referring now to  FIG. 4 , items I may be removed from the container C by first tearing the tear strip  86  from the sidewall panel  82  of the lid L, thereby detaching a leave-on portion  82   a  of the sidewall panel  82  from the lid L. The leave-on portion  82   a  remains adhered to the sidewall  42  of the main body portion B of the container C. After the tear strip  86  had been removed from the sidewall panel  82  and the leave-on portion  82   a  has been detached from the lid L, lid L may be pivoted about the second take-up region  87   b  of the opposing sidewall panel  82  of the lid L, thereby exposing the open upper end of the main body portion B so that items I may be removed therefrom. Lid L may be positioned back over the open upper end of the main body portion B, thereby reclosing the container C for safekeeping of unused items I. Optionally, if a tear strip has been provided in both sidewall panels  82  of the lid L, the lid L may be removed entirely from the main body portion B, as will be obvious to those of ordinary skill in the art, upon reading the within disclosure.  
         [0055]     With reference now to  FIG. 5 , the first and second take-up regions  87   a ,  87   b  are formed by a plurality of parallel foldlines  90  which extend lengthwise along the sidewall panels  82  of the lid L. Foldlines  90  cooperate with one another to create a generally zig-zagged, accordion-style construction capable of absorbing compressive forces, as well as of providing an area of increased flexibility in the sidewalls  82 . Referring now also to  FIGS. 6 and 7 , foldlines  90  are formed in the sidewalls  82  of the lid L by a conventional punch-and-die operation wherein the sidewall  82  is crimped between mating dies  95 . It will be appreciated by those or ordinary skill in the art, upon reading the within description, that foldlines  90  will absorb compression of the sidewalls  82  from a change in length from first length L 1  to second length L 2 , wherein L 1 &gt;L 2 .  
         [0056]     Referring back to  FIG. 3 , it will be apparent to those of ordinary skill in the art that by providing take-up regions  87   a ,  87   b  in the lid sidewalls  82 , when a compressive force is applied to the container C, as when several containers are stacked on top of one another, the take-up regions  87   a ,  87   b  will allow the lid L to be displaced closer to the main body portion B without imparting significant shear stress in the adhesive strips  88 , thereby reducing or eliminating the possibility of the lid L becoming detached from the main body portion B inadvertently.  
         [0057]     With reference to  FIG. 8 , a blank used to form a main body portion of a container according to one alternative embodiment of the present invention is shown, wherein the endwall wings overlap one another partially when the main body portion is erected.  
         [0058]     With reference to  FIG. 9 , a blank used to form a main body portion of a container according to yet another alternative embodiment of the present invention is shown, wherein construction of the pop-out handles has been simplified.  
         [0059]     With reference to  FIG. 10 , a blank used to form a lid of a container according to yet another alternative embodiment of the present invention is shown, wherein the widths of the sidwall panels is less than those according to the preferred embodiment hereof. Also, the blank shown in  FIG. 10  represents an alternative embodiment wherein the take-up strip also functions as a tear strip. That is, perforation lines  85  permit flexing of combo strip  87   a ,  86  so as to permit movement of the lid L relative to the main body portion B without shearing the adhesive used to secure the two.  
         [0060]     It should be recognized by those of ordinary skill in the art that those aspects of the present invention that meet the objectives stated herein are provided substantially by the lid portion L of the container, and as such, it is within the spirit and the scope of the present invention to provide only the lid L for use on main body portions not otherwise described expressly herein.  
         [0061]     While the invention has been described with reference to preferred embodiments, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only and should not be deemed limitative on the scope of the invention set forth herein.