Materials for and method for manufacturing packaging and resulting packaging

In accordance with the invention, a method of manufacturing packaging and resulting packaging and associated pre-assemblies and blanks are provided, which, when utilized, result in packaging that has increased side panel strength and corner strength so as to enable effective vertical stacking of packaging when the packaging includes product.

The invention relates in general to the manufacture of packaging that may be readily used as to display the contents of the packaging following delivery of the packaging, as specified in the independent claims.

BACKGROUND OF THE INVENTION

Various packages and containers are conventionally provided for transporting product to and storing product in a retail environment and for display to prospective customers. As is conventionally known in the packaging industry, such packages can be transported to manufacturing and/or retail environments for display in knock-down form; i.e., flattened but otherwise being glued, stapled or otherwise secured together, such that they are already substantially pre-assembled; in such a knock-down state, personnel assembling the product display need only open the sides and or ends of the package and affix the package bottom wall into its assembled condition. As a result, such package assembly may be performed prior to loading manufactured product. Alternatively, such package assembly may be performed such that the product can be placed into a resulting assembled display package for ready display.

Conventionally, it has been deemed advantageous at times to stack a plurality of such packages, one on top of the other for the purposes of transport to a retail environment or during display in the retail environment. In this use, it is necessary that the packages stacked above the bottom-most package are amply supported also that a stack of a number of such packages, when filled with product, will not collapse.

SUMMARY

In accordance with illustrated embodiments, a method of manufacturing packaging and resulting packaging and associated pre-assemblies and blanks, which, when utilized, results in a packaging that has increased side panel strength and corner strength so as to enable effective vertical stacking of packaging when the packaging includes product.

Additionally, in accordance with illustrated embodiments, the manufactured packaging provides the dual use of both a transporting container for transporting product to a retail environment and a display container configured to display the product in that retail environment. This is achieved by a combination of features recited in each independent claim. Accordingly, dependent claims prescribe further detailed implementations of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The manufacture and use of packages that may be used for more than one purpose, e.g., for transport of product and subsequent display of product in a retail environment, are becoming increasingly popular among both manufacturers and retailers because such packages enable a reduction or minimization of the amount of package material while increasing or maximizing the amount of display space available for product. Thus, it is conventionally known that blanks (e.g., made from some type of paperboard and/or other material that is die-cut and scored for subsequent manipulation to form a pre-assembly), pre-assemblies (e.g., a partially assembled package wherein the blank is manipulated and affixed to itself but is not fully assembled) and packaging (e.g., cartons, boxes, etc.) may be provided that enable product to be transported to a retail environment in a transporting package and displayed in the retail environment within the transporting package following minor modification of the transporting package.

The durability, strength and stackability of such packaging often requires increasing the amount of material content within the packaging. However, further reducing the amount of material content within packaging has become a significant goal of many manufacturers and retailers because of the adverse effect that packaging has on landfills and the environment in general as well as the cost of manufacturing, transporting and disposing of such packaging.

Thus, both manufacturers and retailers are recognizing a need to reduce the amount of packaging used to provide product to an end-consumer in a retail supply chain in an effort to conserve natural resources, reduce an impact on the environment and reduce costs associated with product manufacture and sale. In an effort to achieve these goals, various initiatives have been put in place by both suppliers and retailers to reduce overall product packaging by some percentage, e.g., five percent.

One conventional mechanism for reducing the amount of packaging necessary to provide product to potential consumers in a retail environment is by providing dual-use packaging wherein a package can be used both to contain product during transporting and also to display the product once that product has arrived in a retail environment, e.g., a store or other environment offering product for sale.

Further, in an effort to further use available space in a retail environment, retailers may be interested in using the display function of such dual-use packages in a manner such that packages may be stacked on top of one another to improve or optimize vertical space utility in the retail environment. Simply put, having the ability to be able to stack display cartons enables a store operator to present more product and/or different types of product in a manner that a customer can see. For example, by providing the opportunity to stack such packages, e.g., display cartons, on a counter, a store operator is able to increase the use of counter space such that more than one carton can occupy the same horizontal counter foot print. As is understood in the retail industry, such a configuration increases sales because customers are able to see more available product and product types for sale.

However, a problem with stacking such display cartons, whether such cartons be dual-use transporting/display packages or otherwise, is that the weight of the carton(s) in combination with the weight of the product(s) stored in the carton(s) can cause one or more cartons to be damaged or collapse. As a result, a store operator is left with damaged, ineffective or completely non-functioning display carton(s), which causes operational problems and reduces likelihood of sales to consumers.

Accordingly, based on all of these factors, there is a need to provide a method of manufacturing reduced material content packaging and resulting packages and associated pre-assemblies and blanks, which, when utilized, results in a package that provides the dual use of both as a transporting container for transporting product to a retail environment and a display container configured to display the product in that retail environment and has significantly improved stacking strength over conventional packaging.

With this understanding of one area of packaging utility in mind, a description of various invention embodiments is now provided.

According to as least one illustrated embodiment, there is provided equipment configured to manufacture dual-use packages, e.g., for transporting product and subsequent display of the product (as well as corresponding package pre-assemblies and blanks) that include a reduced amount of material content while maintaining or increasing the stacking strength of such packages. In view of recent retailer initiatives to reduce the amount of material content in packaging, such packages may have increased utility to manufacturers and retailers.

Understanding of the manufacturing of a package, blanks and/or pre-assemblies in accordance with invention embodiments may best be understood by first reviewing an illustration of a manufactured package provided in accordance with one illustrated embodiment. As illustrated inFIG. 1, one example of such a package100may include one or more auxiliary support sections102affixed at the corners of a box101, which in this illustrated example is a dual-use package of the type referred to in the packaging industry as a half regular, fifth panel carton with cut-outs for display purposes (however, it should be understood that the manufactured package may be any type of carton, package, box, etc. of any suitable type. As used inFIG. 1(andFIG. 6), solid lines indicate those edges visible from the illustrated perspective and dashed lines indicate those edges not visible from the illustrated perspective.

As will be appreciated from the remaining disclosure by one of ordinary skill in the art, the box100may be used for transport of product therein when a top and the side cut-outs are in place. Subsequent to arrival at a retail environment, for example, the top and side cut-outs may be removed to provide a display for product included therein.

FIG. 2provides a top view of the package100, illustrated inFIG. 1. As shown inFIG. 2, the auxiliary support sections102are configured so as to be provided at comers of box101. As explained in connection withFIG. 5, the auxiliary support sections102are hingedly connected (e.g., coupled together so as to allow alteration of the angle therebetween) to a central portion (245illustrated inFIG. 5) that is affixed to lateral sides of the box101. In an illustrated embodiment, the auxiliary support sections102are formed by bending the auxiliary support sections along the line that separate the sections102from the central portion.

FIG. 3illustrates an example of a blank for what is conventionally known as a half regular slotted bottom, fifth-panel carton such as the one illustrated inFIG. 1. As used inFIG. 3(andFIGS. 4-5), solid lines indicate edges of the blanks illustrated whereas dashed lines indicate perforation, folding or scoring lines provided as part of manufacturing to enable folding of the blanks along the dashed lines.

The blank illustrated inFIG. 3corresponds to the box101illustrated inFIGS. 1-2; therefore, for convenience, the box and blank will both be referred to using reference numeral101.

The blank101includes five side panels: two side panels105, a first back panel110and second back panel115(which overlap to form the back panel of the box101), a front panel120and a divider panel125that divides the box101into two separate compartments and provides added stackability when the box101is assembled.

The blank101also includes five bottom sub-panels130,135, which cooperate and interact to form a bottom panel when the box101is assembled. As part of pre-assembly manufacturing, the first back panel110and the second back panel115are positioned so as to partially overlap and adhesive is applied to one or both sides of the overlapping areas so as to affix the overlapping areas to one another. Also, as part of that pre-assembly manufacturing, the side panels105-120are folded in on themselves to form a shell and adhesive is applied to an adhesive panel140neighboring the divider panel125. The adhesive panel140is used to couple the proximate end of the divider panel125to the interior side of the front panel120, e.g., horizontally bisecting an area150between the two display cut-outs145provided in front panel120. The two display cut-outs145may be removed to provide access openings (265as illustrated inFIG. 6), defined by substantially U-shaped cut-outs in the front panel120of the package100, for ready access to product displayed in the package100. These cut-outs145may be in communication with the open top end of the package100, which (during use as a display) is free of any top wall or panel following modification of the package100for the display function of the dual-use package. Thus, the removable access panels or cut-outs145included in the front panel120(and optionally a top panel not shown) may be readily removable therefrom once transport of the package100is completed by separating the cut-outs145from the front panel120along pre-cut score lines to enable easy display of the product contained in the package100and use of the package100as a display of the product.

The blank101may include scored holes155for enabling an individual to carry the box101once assembled. Alternatively, as illustrated inFIG. 4, the scored holes155may be omitted.

Although it should be understood that both the type of box formed in accordance with the invention as well as the dimensions of the box101and corresponding package are not determinative of the utility of the invention, the following explanation of one example of the relative dimensions are provided so as to disclose one example of the dimensions of a blank101used in conjunction with the illustrated embodiment. However, it should be understood that the component dimensions disclosed herein (both relative to other disclosed component dimensions and absolute dimensions of the resulting package) are not limiting but merely illustrative.

Thus, the blank101has various width dimensions including the width160(e.g., 23.25 inches or 59.1 cm) of the front panel120, the width165,170(e.g., 12.75 inches or 32.4 cm for one side panel and 12.625 inches or 32.1 cm for the other side panel) of the side panels105, the width175(e.g., 14.5 inches, 36.8 cm) of the first back panel110, the width180(e.g., 11.9375 inches or 30.3 cm) of the second back panel115, the width185(e.g., 12.5 inches or 31.8 cm) of the divider panel125, the total width190(e.g., 88.5625 inches or 224.9 cm) of the blank101, and the width195(e.g., 6.375 inches or 16.2 cm) of the cut-out145. Likewise, the blank101has various length dimensions including the length200(e.g., 18.5 inches or 47 cm) of the first back panel110in combination with the length of the bottom panel130, the length205(e.g., 6.25 inches or 15.9 cm) of the bottom panel135, the length210(e.g., 11 inches or 27.9 cm) of the side panels105, the length215(e.g., 1 inch or 2.5 cm) of the scored hole155(as opposed to the width205, e.g., 4 inches or 10.2 cm, of the hole155, if included in the blank101), the length225(e.g., 2.25 inches or 5.7 cm) between the top edge of the side panel105and the scored hole155, the length230(e.g., 8 inches or 20.3 cm) of the cut-out145, the length235(e.g., 3 inches or 7.6 cm) between the bottom edge of the front panel120and the cut-out145and the length240(e.g., 1.25 inches or 3.2 cm) of the indentation on the edge of the bottom panel135.

FIG. 5illustrates an example of second type of blank245used to provide the auxiliary support sections102illustrated inFIG. 1. The auxiliary support sections102are divided from the remaining width of the blank245by scoring lines250that enable bending of the material of the blank245along the lines250. This deformation or bending of the blank245enables the entire width of the blank245to fit in the interior confines of the box101substantially parallel to the side panels105although the width dimensions of the blank245(i.e., widths255, e.g., 2.25 inches or 5.7 cm, and width260, e.g., 10 inches or 25.4 cm, for a total of 14.50 inches or 36.8 cm) are greater than that of the side panels105(e.g., approximately 12.5 inches or 31.8 cm). Although the blank145includes the slotted hole opening for overlapping the scored hole opening155illustrated inFIG. 3, there scored hole opening of blank245may be omitted if the blank101does not include corresponding scored hole openings.

As part of manufacturing, a portion of the lateral face of the blank245is affixed to one or both of the interior faces of the side panels105. The faces may be affixed in one or more suitable manners including application of adhesive on one or both of the affixed faces, use of staples, tape, etc. The portion of the blank's245lateral face affixed to the side panel105includes at least some or all of the portion of the blank245spanning the width260(i.e., the central portion), thereby leaving the widths255to remain free to bend back towards the interior of the manufacture preassembly of the box101. Accordingly, the auxiliary support sections are bent back towards the interior of the box101and make contact with the neighboring sides of the box101, e.g., the front panel120or the back panels110,115, as illustrated inFIG. 6(showing a fully assembly package100). Thus, each of the auxiliary support sections102are affixed at one lateral end thereof to the corresponding side panel and rigidly (e.g., without bending or substantial deformation) abut either the front or back panel at the other lateral end of the auxiliary support section.

The package100is thus formed in a rectangular configuration, with the side panels105and back panels110,115and front panel120forming a pair of opposing walls. Further, the package includes both increased strength on the side panels by the span260of blank245affixed to the side panels105and the inclusion of the auxiliary support sections102at the corners of the box101wherein the various side panels intersect.

AlthoughFIGS. 1-6illustrate one example of a package that may be manufactured in accordance with illustrated embodiments, various different types of blanks and pre-assemblies may be used to produce various different types of packages. Thus, although one or more of the side panels may be configured in a rectangular shape, various other shapes are also suitable. Further, although not illustrated inFIGS. 1-6, a blank used to construct a box included in the package may also include a top panel of various suitable shapes and sizes.

FIG. 7illustrates a functional block diagram showing the operation of various method functions performed in accordance with a method of producing pre-assemblies in conjunction with illustrated embodiments. With regard to the manufacturing of packages such as the one illustrated inFIGS. 1-6, the manner of manufacturing such packages may be conveniently described in two phases: pre-assembly and final assembly/use.

Pre-assembly is normally performed at a package manufacturing facility to produce a pre-assembly which may also be thought of and referred to as a knock-down of the package. These pre-assemblies may be shipped to a customer location such as a product manufacturing facility. At the product manufacturing facility, the customer may perform final assembly/use of the packages by, for example, folding and assembling various panels of the package to provide a package that is configured to hold manufacture product, e.g., for shipping and/or display.

In such operations, the labelling of the resulting packages may be performed by the customer of the pre-assemblies and/or as part of manufacture of the pre-assemblies as illustrated inFIG. 7.

FIG. 7illustrates various functional operations performed as part of the manufacture of a pre-assembly by, for example, a package manufacturer. The operations may begin, for example, with printing705of package material prior to the package material being diecut and/or scored710as part of an overall blank manufacturing operation715. The manufactured blanks730may or may not be printed on one or both sides of the blanks730depending on customer requirements. Accordingly, the printing operation705may be omitted.

Subsequent, to blank manufacturing705, multi-blank pre-assembly operations may be performed in various suitable manners by hand or using various commercially available machines (for example, those produced by Bahmueller Technologies, Inc. of Charlotte, N.C., USA or Bobst Group North America of Roseland, N.J., USA), to produce pre-assemblies for reinforced packaging such as that illustrated inFIG. 1, for example.

Thus, at the beginning of such operations, raw material725is used to produce blanks730. Such raw materials725may include but are not limited to various grades, types, configurations and combinations of corrugated fiberboard and/or solid paperboard, liner board, board of various fluting types and combinations as well as various types of sealants, non-organic materials and inks and dies of various suitable types.

It should be understood that implementation of the method and system of the present invention involves performing or completing certain selected tasks or steps manually, automatically, or a combination thereof.

It should be understood that invention embodiments are capable of variations practiced or carried out in various ways. Therefore, it should be appreciated that, in accordance with at least one embodiment of the invention, any and all of the walls may be constructed of corrugated cardboard. However, it should be understood that the walls, panels, any tabs on various panels, etc., may be constructed of various industry recognized appropriate materials that meet various transporting and/or display criteria. As a result, it should be understood that packages manufactured in accordance with at least one embodiment of the invention may also be considered “cartons,” which may be considered packaging containers, commonly made from cardboard. Further, it should be understood that cartons come in many different varieties but most cartons can be folded and assembled from a flat form, known as a carton blank. Thus, it should be understood that the pattern for any blank, pre-assembly or package may be different than those described herein.

Alternatively, or more specifically, the packaging containers may be made using corrugated board, e.g., material made by a corrugator (a machine that produces corrugated board by attaching fluting to liners) which is a structured board formed by gluing one or more arched layers of corrugated medium to one or more flat-facing linerboards.

Additionally, it should be appreciated that material used in accordance with at least one embodiment of the invention may be laminated to provide barrier properties. Further, other barrier materials may be used including Ultra Violet (UV), moisture and gas barriers. Additionally, though not discussed in detail herein, it should be understood that any adhesive used to provide a bond between materials used in packages provided in accordance with the invention may include any substance that helps bond two materials together, examples including but not limited to glue and paste.

Additionally, it should be understood that the functionality described in connection with various described components of various invention embodiments may be combined or separated from one another in such a way that the architecture of the invention is somewhat different than what is expressly disclosed herein. Moreover, it should be understood that, unless otherwise specified, there is no essential requirement that methodology operations be performed in the illustrated order; therefore, one of ordinary skill in the art would recognize that some operations may be performed in one or more alternative order and/or simultaneously.

As a result, it will be apparent for those skilled in the art that the illustrative embodiments described are only examples and that various modifications can be made within the scope of the invention as defined in the appended claims.