SHIPPING AND DISPLAY CONTAINER

Techniques and/or systems are disclosed for a container including a plurality of panels and a plurality of flaps integrally formed in a blank. The plurality of panels includes a front panel, a top panel adjacent the front panel, a back panel adjacent the top panel, a bottom panel adjacent the back panel, and a support panel adjacent the bottom panel, wherein adjacent panels are connected with one another. The plurality of flaps are configured to cooperate with each other to enclose the container at its ends. A first line of weakness is formed in the front and top panels and defines a first severable portion of the container. A second line of weakness is formed in the support panel and defines a second severable portion of the container, the support panel being fixedly attached to the front panel such that the first and second severable portions are generally aligned.

FIELD

The present disclosure relates generally to displayable shipping containers that may be used for shipping products and then converted to display and provide access to the products for individual sale. In particular, the present application relates to displayable shipping containers formed from a single blank and including reinforcement features.

BACKGROUND

Dual-purpose containers have been developed that can be used for both shipping and displaying goods. Generally, the containers start as flat sheets of corrugated paperboard, typically referred to as blanks. The blanks can then be assembled into containers for shipping goods, which can also be converted into a display for the goods contained therein. This practice reduces costs to stores because merchandise does not need unloaded from the shipping boxes and arranged on the shelves.

In shipping and displaying products, particularly in a retail setting, it is desirable to have a container, which is easy to pack, sturdy and fully enclosed for protection of contents during storage and shipping, while also being suitable for store display. A container can be provided that is convertible from a shipping configuration to a display configuration, which permits the converted container to be placed directly upon a shelf, or floor display, without having to remove the individual product items from the container. Typically, this is accomplished by providing the container with removable portions of the container that create apertures through which customers may access the products within the converted container.

Some displayable shipping containers are comprised of multiple components requiring several steps to assemble the container and often requiring multiple machines, some of which are specialized, to assist in assembly of the container, such as by applying adhesive.

SUMMARY

In one implementation, there is provided a container comprising a plurality of panels and a plurality of flaps integrally formed in a blank. The plurality of panels includes a front panel, a top panel adjacent the front panel, a back panel adjacent the top panel, a bottom panel adjacent the back panel, and a support panel adjacent the back panel, wherein adjacent panels are connected with one another. The plurality of flaps are configured to cooperate with each other to enclose the container at ends of the container. A first line of weakness is formed in the front panel and top panel, wherein the first line of weakness defines a first severable portion of the container that is configured to be removable. A second line of weakness formed in the support panel, wherein the second line of weakness defines a second severable portion of the container that is configured to be removable. The support panel is fixedly attached to an inner surface of the front panel such that the first severable portion and the second severable portion are generally aligned

DETAILED DESCRIPTION

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter.

Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure includes all such modifications and alterations and is limited only by the scope of the following claims. In particular regard to the various functions performed by the above described components (e.g., elements, resources, etc.), the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary implementations of the disclosure.

In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”

Referring now toFIGS.1-3, by way of examples, the present disclosure is generally directed to containers for shipping and display of product. More specifically, the present disclosure is directed to a blank comprising a one sheet of material that can be converted into a one-piece product container, or package, that holds bagged items, such as candy.

The container can be machine glued as part of the assembly from the flat blank. The assembled container needs sufficient strength and durability to survive shipping environments and be equipped with a removable portion to display the bagged items enclosed therein. Thus, the container disclosed herein should be produced at the lowest cost possible and have a removable portion for displaying and accessing the contents (e.g., bagged items) of the container.

Blank

Referring toFIG.1, an example of a blank100suitable for forming a display container according to this disclosure is schematically illustrated. The blank100comprises a plurality of panels and a plurality of flaps that are integrally formed from one sheet of material. The blank100can be a die-cut out. In one or more examples, the blank100can comprise a front panel102, a top panel104, a back panel106, a bottom panel108, and a support panel110. The front panel102and the support panel110can be disposed at opposite ends of the blank100. The top panel104can be disposed adjacent the front panel102and the back panel106with the top panel104positioned between the front panel102and the back panel106. The bottom panel108can be disposed adjacent the back panel106and the support panel110with the bottom panel108positioned between the back panel106and the support panel110. In these examples, adjacent panels102,104,106,108, and110are connected with one another at fold lines122(e.g., predefined creases). In one or more examples, the fold lines122can be substantially parallel. The support panel110is configured to be attached to the front panel102as described in further detail below.

In one or more examples, the blank100can further comprise a first front panel flap112a, a first top panel flap114a, a first back panel flap116a, and a first bottom panel flap118ahingedly connected to the front panel102, the top panel104, the back panel106, and the bottom panel108, respectively, at fold lines124a. The blank100also comprises a second front panel flap112b, a second top panel flap114b, a second back panel flap116b, and a second bottom panel flap118bhingedly connected to the front panel102, the top panel104, the back panel106, and the bottom panel108, respectively, at fold lines124b. In these examples, the flaps112a,114a,116a, and118aare configured to cooperate with each other to enclose an end of the container formed from the blank100. Similarly, the flaps112b,114b,116b, and118bare configured to cooperate with each other to enclose another end of the container formed from the blank100. In one or more examples, the fold lines124aand124bare parallel or substantially parallel.

In one or more examples, the blank100further comprises a first support panel flap120ahingedly connected to the support panel110at fold line126aand a second support panel flap120bhingedly connected to the support panel110at fold line126b. The first support panel flap120acan include a flap fold line130aor perforated channel that promotes folding of the first support panel flap120aalong the flap fold line130a. In some non-limiting examples, the flap fold line130amay divide the first support panel flap120ainto a first portion132aand a second portion134a. The first portion132acan be positioned between the second portion134aand the support panel110with the first portion132adirectly, hingedly attached to the support panel110. The second support panel flap120bcan include a flap fold line130bor perforated channel that promotes folding of the second support panel flap120balong the flap fold line130b. In some non-limiting examples, the flap fold line130bmay divide the second support panel flap120binto a first portion132band a second portion134b. The first portion132bcan be positioned between the second portion134band the support panel110with the first portion132bdirectly, hingedly attached to the support panel110.

In one or more examples, the fold line126acan extend parallel or substantially parallel to the fold line124aand may be offset from the fold line124aby a predefined distance. The first support panel flap120acan include an angled cut128athat is formed at an angle Θaand extends between the offset fold lines124aand126a. In some non-limiting examples, the angle Θais approximately 45°. Similarly, the fold line126bcan extend parallel or substantially parallel to the fold line124bbut offset from the fold line124bby a predefined distance. The second support panel flap120bcan include an angled cut128bthat is formed at an angle Θb and extends between the offset fold lines124band126b. In some non-limiting examples, the angle Θb is approximately 45°. In one or more examples, the angle Θb is substantially the same size as the angle Θa.

The blank100can have various dimensions. In one or more examples, the blank100comprises a front panel102and back panel106that are substantially the same size and a top panel104and bottom panel108that are substantially the same size so that the container formed from the blank100has the shape of a rectangular prism to promote the stacking of containers. In one example, the blank100is 59½ in (L)×35¾ in (W) and comprises a front panel102having a length of approximately 12 in, a top panel104having a length of approximately 11⅞ in, a back panel106having a length of approximately 11 15/16 in, a bottom panel108having a length of approximately 11¾ in and a support panel110having a length of approximately 11 15/16 in. It is contemplated that the blank100can be designed to have other dimensions and/or relative size proportions. Additionally, it is contemplated that the relative dimensions of the various panels102,104,106,108,110and/or flaps112,114,116,118,120can take into account any spacing requirements for providing separation or gaps between the flaps112,114,116,118,120, and/or the thickness of the support panel110that is attached to the front panel102.

The blank100can also be made out of various materials including recycled materials. As an example, the blank100may be fabricated from a wide variety of suitable materials including, but not limited to, paper, cardboard (corrugated and otherwise), wood, metal, and plastic. For reasons of strength and economy, materials for containers according to the present disclosure typically include corrugated cardboard.

The blank100includes a first line of weakness136that defines a first severable portion138formed in the front panel102and top panel104. The first severable portion138is configured to be separable and removable from the remainder of the blank100, in particular from the front panel102and top panel104, via the first line of weakness136. It is contemplated that the first severable portion138is not limited to the particular shape and configuration illustrated inFIG.1and can be formed in other shapes, sizes, and/or locations on the front panel102and top panel104.

In one or more examples, the first severable portion138of the front panel102and top panel104is generally rectangular in shape and includes an aperture140adjacent to the midpoint of a lower part of the first line of weakness136. In one example configuration, as depicted inFIG.1, the aperture140is semi-circular in shape with its lower edge adjacent the front panel102and its midpoint extending upwardly into the severable portion136such that its upper edge is arcuate in shape. In these examples, the aperture140provides a means of grasping the edge of the first severable portion138and initiating the tearing or severing operation along the first line of weakness136.

The blank100further includes a second line of weakness142that defines a second severable portion144formed in the support panel110. The second severable portion144is configured to be separable and removable from the remainder of the blank100, in particular from the support panel110, via the second line of weakness142. The second severable portion144is configured with dimensions that generally align with the first severable portion138for reasons that will be described in further detail below. In some non-limiting examples, the second severable portion144is rectangular with a width that generally corresponds to the width of the first severable portion138. It is contemplated that the second severable portion144is not limited to the particular shape and configuration illustrated inFIG.1and can be formed in other shapes, sizes, and/or locations on the support panel110provided the second severable portion144generally aligns with the first severable portion138.

In one or more examples, the second severable portion144of the support panel110is generally rectangular in shape and includes an aperture146adjacent to the midpoint of a lower part of the second line of weakness142. In one example configuration, as depicted inFIG.1, the aperture146is semi-circular in shape with its lower edge adjacent the support panel110and its midpoint extending upwardly into the second severable portion144such that its upper edge is arcuate in shape. In these examples, the aperture146provides a means of grasping the edge of the second severable portion144and initiating the tearing or severing operation along the second line of weakness142.

The weakening of the region of the front and top panels102and104, which comprises the first line of weakness136, and the weakening of the region of the support panel110, which comprises the second line of weakness142, may be accomplished by full or partial perforation of the relevant panel material, full or partial scoring thereof, partial severing, or any other suitable method known in the art. Whatever the method of forming the lines of weakness, the lines of weakness can exhibit sufficient strength to survive shipping and handling of the container without premature rupture while remaining sufficiently easy to rupture to facilitate opening and leave a reasonably well defined opening upon removal of the first and/or second severable portions138and144.

Assembly

Referring now toFIGS.2A-2I, there are schematic illustrations of the steps for forming a product container200from the blank100inFIG.1. The product container200can be hand assembled and packed by a person or automated.

Referring toFIGS.2A-2B, the blank100is assembled, or converted, into the product container200by folding the support panel110along fold line122cin the direction150of the top panel104such that the support panel110is disposed over the top panel104. The support panel110is folded so that an outer surface of the support panel110, which can include an adhesive156, such as glue, is exposed. In some non-limiting examples, the support panel110may include multiple strips of adhesive156, as shown inFIG.2B. It is contemplated that the surface of the support panel110may contain any suitable adhesive pattern and is not limited to any specific number of strips.

In one or more examples, the front panel102is then folded along fold line122ain the direction152of the support panel110for attachment to the support panel110. In this example, the strips of adhesive156are disposed on the support panel110. But, in other examples, the strips of adhesive may be disposed on the front panel102(e.g.,148inFIG.1) or on both the front panel102and the support panel110. The strips of adhesive156are then adhered, or otherwise affixed to an inner surface, or mating surface, of the front panel102thereby securing the front panel102to the support panel110. In this manner, the front panel102overlaps with the support panel110and the support panel110reinforces the front panel102by providing a double layer of material. This provides increased thickness at the front panel102resulting in improved structural integrity and stacking strength of the container200while simultaneously making the container200more resistant to inadvertent perforations of the first and second lines of weakness136,142. At this stage, the panels102,104,106,108, and110form the general three-dimensional shape of the container200, but the flaps112-120are still unsecured, as shown inFIGS.2D-2E.

One particular advantage of this disclosure is that the process of folding panels and adhering panels together (e.g., adhering the front panel102to the support panel110) described above can be performed by one standard machine. This process does not require any operations, such as applying glue, to be performed by a second specialty machine. Thus, the container200formed by the blank100of this disclosure can be assembled in a simple, cost-effective manner using a single standard machine (e.g., for gluing).

In one or more examples, the first and second support panel flaps120aand120bcan be folded inwardly (i.e., into the interior of the container200) along fold lines126aand126brespectively, as shown inFIG.2E. Then, the remaining flaps112a-118acan be folded inwardly along fold lines124aorthogonal to the panels102,104,106, and108, respectively. Similarly, the flaps112b-118bcan be folded inwardly along fold lines124borthogonal to the panels102,104,106, and108, respectively. In one non-limiting example, the flaps114band118bcan be folded inwardly orthogonally to panels104and108, respectively, and the flaps112band116bare folded inwardly154orthogonally to overlie the flaps114band118b, as shown inFIG.2F. A length of tape158can be adhered to the seam where the flaps112band116bmeet, although it will be appreciated that other suitable means of securing the container200in its assembled condition may be used, such as staples, adhesives, etc. With one side assembly sealed, goods, such as individually packaged foods, can be loaded into the opposing end of the container200before sealing the side in a similar manner with a length of tape158resulting in the formation of an enclosed container.

The first and second support panel flaps120a,120badvantageously provide improved structural integrity and stacking strength to the container200formed from the blank. Additionally, the first and second support panel flaps120a,120bprovide reinforcement to the front panel102as will be described in further detail.

In one or more examples, the second support panel flap120bis folded inwardly along fold line126b. The first portion132bof the second support panel flap120bextends diagonally across an interior corner of the container200that is formed where the front panel102meets the orthogonally disposed flaps112b,114b, and118b, as shown inFIGS.3A-3B. In these examples, a space166bis formed in the interior of the container200that is defined by the first portion132band the corner formed by the flaps112b,114b,118band the front panel102, as shown inFIG.3B. The space166bcan be in the shape of a triangle, but is not so limited. The second portion134bof the second support panel flap120bis folded along fold line130bin order to place the second portion134bflush against the surface of one or more flaps112b,114b, and118b.

In these examples, the first portion132bthereby forms a support structure in the interior corner of the container200defined by the first portion132b, the front panel102, and flaps112b,114b,118b. Additionally, the angled cut128bof the second support panel flap120bcan add significant packing strength to the container200.

Similarly, in some non-limiting examples, the first support panel flap120ais folded inwardly along fold line126a. The first portion132aof the first support panel flap120aextends diagonally across an interior corner of the container200that is formed where the front panel102meets the orthogonally disposed flaps112a,114a, and118b(not shown). In these examples, a space is formed in the interior of the container200that is defined by the first portion132aand the corner formed by the flaps112a,114a,118aand the front panel102. The space can be in the shape of a triangle, but is not so limited. The second portion134aof the first support panel flap120ais folded along fold line130ain order to place the second portion134aflush against the surfaces of one or more flaps112a,114b, and118a.

In these examples, the first portion132athereby forms a support structure in the interior corner of the container200defined by the first portion132a, the front panel102, and flaps112a,114a,118a. Additionally, the angled cut128aof the second support panel flap120bcan add significant packing strength to the container200.

To open the container200for access to the products therein, the consumer or customer inserts one or more fingers or a tool into the apertures140and146that are aligned as a result of the attachment of the support panel110to the front panel102. The one or more fingers or tool are then hooked around the edges defining the apertures140,146, the edges comprising part of the first and second severable portions138,144. The consumer or customer may then pull outwardly and upwardly, as shown by direction arrow160inFIG.2G, so as to tear the first and second severable portions138and144, which are attached to one another, free along the respective first and second lines of weakness136,142. The first and second lines of weakness136,142, which form preferential tearing zones, may be defined by full or partial perforation of the front panel material and support panel material, full or partial scoring thereof, partial severing, or any other suitable method known in the art.FIG.2Hdepicts the container200after this tearing open sequence has concluded in which the first and second several portions are entirely free (i.e., removed) from the container, as shown inFIG.2I. Removing the first and second severable portions138and144that are adhered/fixed to one another, removes portions of the front panel102, top panel104, and support panel110. In some non-limiting examples, a pair of top panel segments164a,164bmay be formed which each provide a ledge upon which other containers can be supported. After removal, the first and second severable portions138,144can be disposed.

Tearing away the first and second severable portions138,144provides a consumer or customer with access to product housed within the container200. The support panel110attached to the front panel102strengthens the container200, but does not deter the ease with which the first and second severable portions138,144can be torn away to expose the product for shoppers. Because the first and second severable portions138,144are completely removed, products may be extracted from the resulting opening even though other containers or articles may be stacked both above and below the subject container200. Note that, as best depicted inFIG.2H, the tearing of the first severable portion138from the front panel102leaves behind a generally U-shaped front portion102having front panel segments162a,162b, which define sides of the opening. The first and second support panel flaps120aand120b, respectively, reinforce these front panel segments162aand162b. In particular, the first portions132a,132bof the first and second support panel flaps120a,120are each arranged at an angle resulting from the first portions132a,132beach extending diagonally between a respective interior corner of the container200that is formed where the front panel102meets the front panel flaps112a,112b.

The container200can be placed on a shelf as a single display as well as stacked in a pallet configuration such as, for example, a stack four layers high. The container200can be configured to carry a product weight of approximately 25 lbs.

One advantage of this disclosure concerning a blank100comprising a plurality of panels and a plurality of flaps that are integrally formed from one sheet of material, is that a standard piece of machinery can apply the adhesive156(e.g., glue) to a single surface on the support panel110to assemble the container200from the blank100. Thus, the present disclosure eliminates any need to use multiple machines to apply adhesive and eliminates the need to perform multiple operations to attach separate components together to form the container because the container is formed from a single blank. Additionally, because of the increased stacking strength that is achieved by the features of the container200(e.g., a support panel110attached to and reinforcing the front panel102with support panel flaps120a,120bthat strengthen the interior corners of the container200at the front panel102), lighter materials can be used, which in turn results in reduced material usage and lower cost of manufacture. Accordingly, it is believed the present disclosure provides reduces the production costs, material, and assembly time, especially given that multi-component solutions often require a specialized machine to apply adhesive.