Packaging system

A packaging system for packaging individual objects, for example confectioneries such as chocolates includes an outer container for shipping various combinations of inner containers, themselves containing the objects in a number proportional to their external volumes. The dimensions and external volumes of the., inner containers are so related that the outer canon can be filled with almost any combination of the inner containers housing the total number of objects to be shipped in the outer container. This eliminates inventory problems with slow moving package sizes.

FIELD OF THE INVENTION 
The present invention relates to packaging and has particular utility in 
the packaging of confectionery products, for example chocolates. 
BACKGROUND 
For retail sales purposes, confections are often packaged in boxes, each 
containing a specified net weight of the confections. For example, with 
chocolates 1/4 lb., 1/2 lb., 1 lb. and 2 lb. net weight boxes are common 
sizes. The retailer ordering these confections must order a complete case 
of the retail boxes, because that is how they are packaged. This creates 
inventory problems with slow moving sizes and discourages the retailer 
from carrying anything but the most popular sizes of retail package. 
The present invention addresses this concern and aims at the provision of a 
system that will allow the retailer to order only those container sizes 
and quantifies that are appropriate for the individual retailer's trade. 
SUMMARY 
With the present invention, the packaging system includes sets of 
containers of different sizes that may be assembled in a large number of 
combinations to fill an outer shipping container of a predetermined size. 
According to one aspect of the present invention there is provided a 
packaging system comprising: 
an outer container having a rectangular interior with predetermined 
internal lateral length and width dimensions and a predetermined internal 
height dimension: 
a plurality of rectangular inner containers, each with predetermined 
lateral length and width dimensions and a predetermined height dimension, 
the inner containers being in plural sets with the containers of each set 
having common dimensions and differing in at least one dimension from the 
containers of each other set, the different lateral dimensions of the 
containers being related to one another by integral factors, and different 
height dimensions of the containers being related to one another by 
integral factors. 
Plural smaller inner containers can thus be assembled into the same space 
as a larger inner container, thus providing considerable flexibility in 
the packaging of a variety of container sizes for transport. 
According to another aspect of the present invention there is provided a 
packaging system for packaging a predetermined number of individual 
objects, said system comprising: a plurality of sets of rectangular inner 
containers, the inner containers of each set being of the same shape and 
external volume, and differing at least in external volume from the inner 
containers of each other set, the different external volumes of the 
containers being related by integral factors i.e. whole numbers greater 
than zero, the inner containers containing the individual objects in 
numbers that are proportional to the external volumes of the inner 
containers; and an outer rectangular container having a predetermined 
internal volume that is an integral multiple of the external volume of 
each inner container whereby all combinations of the inner containers that 
will fill the outer container will contain, in total, the same number of 
said objects. 
By proportioning the contents of the inner containers according to their 
external volumes, the contents of the outer container will always be the 
same when it is filled. Thus, with chocolates, a retailer ordering one 
carton will always get the same number of chocolates, regardless of the 
combination of box sizes specified in the order. 
According to a further aspect of the present invention there is provided a 
packaging system for packaging individual objects, comprising: 
a set of rectangular first containers, each first container having lateral 
dimensions W and aW and a height H where a is an integer, each first 
container containing a number N of said objects; 
a plurality of additional sets of rectangular containers, the containers of 
each set being of the same size and differing in size from those of the 
other sets, each container of each additional set having lateral 
dimensions bW and cW and a height dimension dH, where, b, c and d are 
integers, and each container containing (b.times.c.times.d.times.N) of 
said objects.

DETAILED DESCRIPTION 
Referring to the accompanying drawings, FIG. 1 illustrates an overall 
package 10 according to the present invention. This includes an outer 
container in the form of a rectangular carton 12 with a body 14 and a set 
of cover flaps 16 for closing the carton. As illustrated in FIG. 1, the 
carton has, internally, a length 12W, a width 4W and a height 8H, which 
are internal dimensions. 
FIG. 2 illustrates an assembly of inner containers for boxes that will 
partially fill the carton 12. The individual containers are themselves 
illustrated in FIGS. 3 through 7. In the present example, these boxes are 
intended to carry individual chocolates. 
FIG. 3 illustrates a rectangular box 20 with external length and width 
dimensions 2W and W, and an external height H. 
FIG. 4 illustrates a box 22 with external length and width dimensions 2W 
and 2 W and an external height dimension. 
In FIG. 5, the illustrated box 24 has a height dimension H, a width 
dimension 2 W and a length dimension 4 W. 
The box 26 illustrated in FIG. 6 has the same length and width dimensions 
as box 24 and a height 2H. 
FIG. 7 illustrates the largest of the boxes. This has length and width 
dimensions 4W and a height 2H. 
Given the dimensions of the boxes, it will be readily apparent that the 
length and width dimensions of the boxes are all related by integral 
factors. More specifically, they are related by a factor of 2 or a 
multiple thereof. Similarly, the different height dimensions are related 
by integral factors, in this case the factor being 2. 
Similarly, the external volumes of the containers are related by integral 
factors, and particularly by a factor of 2 or multiples thereof. Thus, box 
22 has twice the volume of box 20, box 24 has twice the volume of box 22, 
box 26 has twice the volume of box 24 and box 28 has twice the volume of 
box 26. 
Because of this relationship amongst the external dimensions and the 
volumes of the boxes, they can be arranged in most any combination inside 
the outer carton 12. The partial assembly shown in FIG. 2 contains two 
boxes 20, a single box 22, a single box 24, a single box 26 and a single 
box 28. As will be apparent, it may also contain two boxes 28 or 
thirty-two boxes 20. 
As illustrated most particularly in FIG. 3, each of the inner boxes 20 
through 28 includes a base 30 of a rectangular shape containing an inner 
formed liner 32, The liner is formed with a number of pockets 34 to 
contain the individual chocolates 36. With the box 20, the liner is formed 
to hold two chocolates 36. Box 22 contains four chocolates, while box 24 
contains eight chocolates. In box 26, there are sixteen chocolates in two 
layers. Box 28 contains thirty-two chocolates in two layers. This 
arrangement of the chocolates means that the number of chocolates in each 
container is proportional to the external volume of the container. It also 
means that no matter what combination of the boxes is used to fill the 
outer canon 12, the same number of chocolates will be included in the 
outer canon. In the present case, this is 384 chocolates. 
Reverting to FIG. 3, each individual inner box is equipped with a cover 
flap 38 with a tuck in edge flap 40. The sides of the cover panel are 
connected to the sides of the box by side panels 42 with fold lines 44 
extending across the side panels so they will fold into the box when the 
cover panel is closed. 
The complete packaging system includes the outer container and a set of 
plural inner containers of each size. Inner containers are selected from 
the sets according to an order, and are stacked into the outer container 
for shipping and handling. A complete order must total 384 chocolates, but 
apart from that, there is no limit on what combination of inner containers 
can be ordered. The proportional relationship extends from the box size to 
the net weight of its contents as well. The five box sizes of the 
illustrated embodiment may thus contain 1 oz., 2 oz., 4 oz. (1/4 lb.), 8 
oz. (1/2 lb.) and 16 oz. (1 lb.) net weight of chocolates respectively. 
While one particular embodiment of the present invention has been described 
in connection with the packaging of chocolates, it is to be understood 
that other embodiments are possible and may be used for packaging other 
articles as well. The invention is therefore to be considered limited 
solely by the scope of the appended claims.