Wraparound clamshell display

A shipping container convertible to a display container formed from a one-piece blank of sheet material. The container comprises an inner front panel, a bottom panel, a back panel, a top panel, and an outer front panel connected in series at respective first, second, third, and fourth fold lines. Inner front side flaps joined to the inner front panel and back side flaps joined to the back panel extend along lateral sides of the container. Bottom side flaps joined to the bottom panel overlap the inner front side flaps and the back side flaps. Top side flaps joined to the top panel overlap an outer surface of at least the back side flaps. Outer front side flaps joined to the outer front panel overlap outer surfaces of the top side flaps and the bottom side flaps.

FIELD OF THE INVENTION

This invention relates generally to containers for shipping products to points of sale. More particularly, the invention is a shipping container that is convertible to a display container at the point of sale.

BACKGROUND OF THE INVENTION

It is common practice to load a quantity of individual packages of consumer products into corrugated paperboard shipping containers for bulk shipment of the packages to a point of sale. At the point of sale, the individual packages may be removed from the shipping container and placed on a shelf for display and sale to the consumer.

In some instances, the product packages may be left in the shipping container which then also serves to support and display the packages for sale. If the shipping container is a conventional box, then the retailer must cut away a portion of the box in order to expose the product packages and provide access to them by the consumers. In order to provide a more attractive display and facilitate ease of use by the retailer, combination of shipping and display containers have been developed which have one or more sections that may be removed along weakened lines to expose the product packages and provide access to them.

SUMMARY OF THE INVENTION

In accordance with an aspect of the invention, a shipping container convertible to a display container formed from a one-piece blank of sheet material is provided. The container comprises an inner front panel, a bottom panel, a back panel, a top panel, and an outer front panel connected in series at respective first, second, third, and fourth fold lines. Inner front side flaps are foldably joined to the inner front panel and back side flaps are foldably joined to the back panel. The inner front side flaps and back side flaps extend along lateral sides of the container. Bottom side flaps are foldably joined to the bottom panel and overlap outer surfaces of the inner front side flaps and the back side flaps. Top side flaps are foldably joined to the top panel and overlap an outer surface of at least the back side flaps. Outer front side flaps are foldably joined to the outer front panel and overlap outer surfaces of the top side flaps and the bottom side flaps.

A joint may be formed adhering at least one of the bottom side flaps to at least one of the back side flaps wherein the top side flaps are not adhered to the back side flaps.

A joint may be formed adhering at least one of the outer front side flaps to at least one of the top side flaps wherein the outer front side flaps are not adhered to the bottom side flaps.

The third fold line between the top panel and the back panel may comprise a separation line.

At least one of the inner front panel and the outer front panel may include a separable panel portion defined by a pair of spaced separation lines extending from a lower front edge of the container.

One of the inner and outer front panels may include an opening having opposed lateral ends and the separation lines may extend from the opposed lateral ends of the opening.

A belly band may extend between the separation lines across a portion the inner front panel and may include a joint adhering the outer front panel to the belly band.

In accordance with another aspect of the invention, a one-piece blank of sheet material for forming a shipping container convertible to a display container is provided. The blank comprises an inner front panel, a bottom panel, a back panel, a top panel, and an outer front panel connected in series at respective first, second, third, and fourth fold lines. Inner front side flaps are foldably joined to the inner front panel, back side flaps are foldably joined to the back panel, bottom side flaps are foldably joined to the bottom panel, top side flaps are foldably joined to the top panel, and outer front side flaps are foldably joined to the outer front panel. A first one of the inner and outer front panels define a first longitudinal end of the blank and includes an opening having opposed lateral ends, and a second one of the inner and outer front panels includes a recess cut into the second one of the inner and outer panels from a second longitudinal end of the blank.

A pair of laterally spaced separation lines may extend from the lateral ends of the opening toward the first longitudinal end of the blank.

The third fold line between the top panel and the back panel may comprise a separation line.

A longitudinal length of the outer front panel may be substantially equal to a longitudinal length of the back panel.

A longitudinal length of the inner front panel may be less than the longitudinal length of the outer front panel.

In accordance with a further aspect of the invention, a method of forming a shipping container convertible to a display container from a one-piece blank of sheet material is provided. The blank comprises an inner front panel, a bottom panel, a back panel, a top panel, and an outer front panel connected in series at respective first, second, third, and fourth fold lines. The method comprises folding the inner front panel upward from the bottom panel to a generally vertical position; folding the back, top and outer front panels about the second, third and fourth fold lines; folding inner front side flaps joined to the inner front panel to extend along lateral sides of the container; folding back side flaps joined to the back panel to extend along the lateral sides of the container; folding bottom side flaps joined to the bottom panel to overlap a lower portion of the inner front side flaps and the back side flaps; folding top side flaps joined to the top panel to overlap an upper portion of at least the back side flaps; and folding outer front side flaps joined to the outer front panel to overlap front portions of the top side flaps and bottom side flaps.

A joint may be formed adhering at least one of the bottom side flaps to at least one of the back side flaps, and wherein the top side flaps are not adhered to the back side flaps.

A joint may be formed adhering at least one of the bottom side flaps to at least one of the inner front side flaps.

A joint may be formed adhering at least one of the outer front side flaps to at least one of the top side flaps, and wherein the outer front side flaps are not adhered to the bottom side flaps.

A joint may be formed adhering the outer front panel to at least one of the inner front panel and the bottom panel.

A pair of laterally spaced separation lines may be provided on at least one of the inner front panel and the outer front panel, and the container may be converted to a display container by separating a portion of the at least one panel along the separation lines.

The portion of the at least one panel may comprise a portion of the inner front panel that is adhered to an inner surface of the outer front panel, and wherein the portion of the inner panel may remain adhered to the outer front panel when the portion of the inner front panel is separated along the separation lines.

The third fold line between the top panel and the back panel may comprise a separation line, and converting the container to a display container may include separating the top panel from the back panel along the third fold line.

DETAILED DESCRIPTION OF THE INVENTION

The present description is directed to a container construction comprising a one-piece wraparound blank that is folded around a product to form a clamshell container having a lid comprising a tear-away element that can be removed to form a display case for the product. The described container can be formed from a blank processed either with equipment designed for this purpose or by hand. For example, the blank may be folded using currently available case forming equipment to form the clamshell container enclosing the product for shipping the product to a point of sale, or the container can be formed around the product through manually executed steps, or through a combination of machine implemented and manual steps.

Referring toFIG. 1, a die cut blank10is shown for illustrating one or more aspects of the container described herein. In a use of the blank to form a one-piece container8, seeFIG. 5, the blank10may be formed of a corrugated cardboard material and may be die cut to the shape shown herein, although other materials and variations of the illustrated shape may be provided within the scope of the container described and claimed herein. The blank10illustrated inFIG. 1is a planar piece of material in which an inner side12is shown facing out of the page and an outer side14, seeFIG. 5, is facing an opposite direction from the inner side12.

As seen inFIG. 1, the blank10extends in a longitudinal direction L between first and second longitudinal ends, generally designated16and18, respectively, and further extends in a lateral direction between first and second lateral edges, generally designated20and22, respectively. The blank10comprises an inner front panel24, a bottom panel26, a back panel28, a top panel30, and an outer front panel32connected in series. The inner front panel24is connected to the bottom panel26at a first lateral fold line34, the bottom panel26is connected to the back panel28at a second lateral fold line36, the back panel28is connected to the top panel30at a third lateral fold line38, and the top panel30is connected to the outer front panel32at a fourth lateral fold line40. A longitudinal length of the outer front panel32, extending in the longitudinal direction L, is substantially equal to a longitudinal length of the back panel28, and a longitudinal length of the inner front panel24is less than the longitudinal length of the outer front panel32.

The third fold line38comprises a separation line that may be defined, for example, by a partial cut through at least one layer of the corrugated material or a cut line interrupted by short sections of bridging (uncut) material. As will be further understood from the description below, the separation line defined at the third fold line38forms a structurally weakened line that can permit separation of the top panel30from the back panel28.

The outer front panel32includes an elongated opening66located intermediate the fourth fold line40and the first longitudinal end16. The opening66is defined by longitudinally spaced edges65,67connected by opposed laterally spaced edges or ends66a,66b. A separable panel portion68is defined between two laterally spaced separation lines70,72that extend from the lateral ends66a,66bof the opening66toward the first longitudinal end16of the blank10. The separation lines70,72may be defined, for example, by a partial cut through at least one layer of the corrugated material or a cut line interrupted by short sections of bridging (uncut) material. The separation lines70,72permit separation of the separable panel portion68from the outer front panel32, as described further below.

The second longitudinal end18of the blank comprises a recess76cut into the inner front panel24from the second longitudinal end18of the blank18. In particular, the recess76is defined by lateral edges76a,76bthat angle inward toward each other from the second longitudinal end18toward an inner recess edge76cthat is generally aligned with, e.g., collinear with, the first fold line34.

Inner front side flaps46,48are foldably joined to laterally opposed sides of the inner front panel24along respective first and second longitudinal fold lines42,44. Bottom side flaps50,52are foldably joined to the bottom panel26at the respective longitudinal fold lines42,44. Back side flaps54,56are foldably joined to the back panel28at the respective longitudinal fold lines42,44. Top side flaps58,60are foldably joined to the top panel30at the respective longitudinal fold lines42,44. Outer front side flaps62,64are foldably joined to the outer front panel32at the respective longitudinal fold lines42,44.

Referring toFIGS. 2-5, a series of folding steps for performing a wraparound folding operation using the blank10ofFIG. 1is described for forming a shipping container8, seeFIG. 5. Although the preferred embodiments presented herein describe applying an “adhesive” forming a joint between adjacent flaps and panels, or forming a “joint adhering” adjacent flaps and panels, it should be understood that such a joint or connection between the flaps and panels can be formed by gluing or can be equivalently formed through other attachment mechanisms for connecting the flaps and panels together, and may alternatively encompass, without limitation, gluing, taping, stapling or stitching.

As illustrated inFIG. 2, a product78to be packaged in the container8is initially placed on the bottom panel26of the blank10. The product78is of a size having an outer perimeter equal to or less than the outer perimeter of the bottom panel26. As illustrated inFIG. 3, the inner front panel24and back panel28are folded upward from the bottom panel26about the respective first and second fold lines34,36to a generally vertical position, and the inner front side flaps46,48and the back side flaps54,56are folded relative to the inner front panel24and back panel28, respectively, to extend along the lateral sides of the container. Subsequently, the bottom side flaps50,52are folded upward to overlap outer surfaces of the inner front side flaps46,48and back side flaps54,56at a lower portion of the container. Adhesive may be applied between the overlapping flaps46,48,50,52,54and56to form joints adhering the flaps46,48,50,52,54and56to one another at the locations that the bottom side flaps50,52overlap the inner front side flaps46,48and the back side flaps54,56to form a bottom portion86of the container8, seeFIG. 3.

As illustrated inFIG. 4, the top flap30is folded about the third fold line38to extend across the top of the product78, and the outer front panel32is folded about the fourth fold line40to extend down in overlapping relationship across the inner front panel24, placing the opening66in alignment with the recess76. The outer front side flaps62,64are folded to overlap front portions of the respective top side flaps58,60and bottom side flaps50,52, seeFIG. 5, and a joint, e.g., adhesive joint, is formed adhering the outer front side flaps62,64to outer surfaces of the top side flaps58,60. It should be noted that the overlapped area between the outer front side flaps62,64and outer surfaces of the bottom side flaps50,52is without a joint adhering the respective flaps62,64and50,52together. That is, the outer front side flaps62,64remain movable without attachment to the bottom side flaps50,52in the completed container8for shipping the product78. The completed container8is retained closed by a clip of tape79, seeFIG. 5, such as packaging tape, extending across a portion of the separable panel portion68and a portion of the bottom panel26.

The assembled container8comprises a box that can be opened as a clamshell, including a lid portion84that is pivotally connected to the base portion86at the third fold line38. The base portion86is defined by the inner front panel24and inner front side flaps46,48, the bottom panel26and bottom side flaps50,52, and the back panel28and back side flaps54,56, seeFIG. 6. The inner front side flaps46,48and back side flaps54,56are located inward of the bottom side flaps50,52, and are preferably attached to the bottom side flaps50,52with an adhesive, such as glue, to define the base portion86.

The lid portion84is defined by the top panel30and top side flaps58,60, and by the outer front panel32and outer front side flaps62,64, seeFIG. 6. Further, as a result in part of the unique folding sequence described above, the outer front side flaps62,64are located outward of the top side flaps58,60, and are preferably attached to the top side flaps58,60with an adhesive, such as glue, to define the lid portion84. The lid portion84is unattached, e.g., without glue or other adhesive, to the lateral sides of the base portion86and is free to pivot relative to the base portion86when the joint adhering the outer front panel32to the bottom panel26is released, as described below.

The container8can be converted to a display case comprising the base portion86and enclosed product78by removing the lid portion84. For example, at the point of sale, the separable panel portion68can be grasped through the opening66and pulled down to separate the separable panel portion68from the outer front panel32along the separation lines70,72, thereby releasing the outer front panel32from the taped connection to the bottom panel26, seeFIG. 6. The lid portion84can then be pivoted up without releasing any further connection between the lid portion84and the base portion86, such that the exposed surfaces of the base portion86are not disrupted or marred by separation from the lid portion84. Further, the recess76exposed by removal of the lid portion84forms a display opening81on the front of the base portion86. Subsequently, the lid portion84can be separated from the base portion86along the separation line defined at the third fold line38, and the base portion86with product78may be used as a display at the point of sale.

It should be understood that, although the present description references use of the container8at a point of sale, use of the container8is not limited to this particular application and may be implemented for other shipping operations.

Referring toFIG. 7, an alternative configuration of a die cut blank110is shown for illustrating one or more aspects of the container described herein. In a use of the blank to form a one-piece container108, seeFIG. 9, the blank110may be formed of a corrugated cardboard material and may be die cut to the shape shown herein, although other materials and variations of the illustrated shape may be provided within the scope of the container described and claimed herein. The blank110illustrated inFIG. 7is a planar piece of material in which an inner side112is shown facing out of the page and an outer side114, seeFIG. 9, is facing an opposite direction from the inner side112.

As seen inFIG. 7, the blank110extends in a longitudinal direction between first and second longitudinal ends, generally designated116and118, respectively, and further extends in a lateral direction between first and second lateral edges, generally designated120and122, respectively. The blank110comprises an inner front panel124, a bottom panel126, a back panel128, a top panel130, and an outer front panel132connected in series. The inner front panel124is connected to the bottom panel126at a first lateral fold line134, the bottom panel126is connected to the back panel128at a second lateral fold line136, the back panel128is connected to the top panel130at a third lateral fold line138, and the top panel130is connected to the outer front panel132at a fourth lateral fold line140. A longitudinal length of the outer front panel132, extending in the longitudinal direction L, is substantially equal to a longitudinal length of the back panel128, and a longitudinal length of the inner front panel124is less than the longitudinal length of the outer front panel132.

The third fold line138comprises a separation line that may be defined, for example, by a partial cut through at least one layer of the corrugated material or a cut line interrupted by short sections of bridging (uncut) material. As will be further understood from the description below, the separation line defined at the third fold line138forms a structurally weakened line that can permit separation of the top panel130from the back panel128.

The inner front panel124includes an elongated opening166defined by longitudinally spaced edges165,167. The edge165coincides with a longitudinal side of the bottom panel126and is generally aligned with, e.g., collinear with, the first fold line134. The edge167comprises an inner edge of a separable panel portion168. The separable panel portion168comprises a belly band defined between two laterally spaced separation lines170,172that extend from opposed lateral ends166a,166bof the opening166toward the first longitudinal end116of the blank110. The separation lines170,172may be defined, for example, by a partial cut through at least one layer of the corrugated material or a cut line interrupted by short sections of bridging (uncut) material. The separation lines170,172permit separation of the separable panel portion168from the inner front panel124, as described further below.

A first recessed area174of the first longitudinal end116of blank110is defined by an outer edge169of the separable panel portion168. A second recessed area176is cut into the outer front panel132from the second longitudinal end118of the blank110.

Inner front side flaps146,148are foldably joined to laterally opposed sides of the inner front panel124along respective first and second longitudinal fold lines142,144. Bottom side flaps150,152are foldably joined to the bottom panel126at the respective longitudinal fold lines142,144. Back side flaps154,156are foldably joined to the back panel128at the respective longitudinal fold lines142,144. Top side flaps158,160are foldably joined to the top panel130at the respective longitudinal fold lines142,144. Outer front side flaps162,164are foldably joined to the outer front panel132at the respective longitudinal fold lines142,144.

A wraparound folding operation using the blank ofFIG. 7, may be performed generally following the steps described with reference toFIGS. 2-5of the previous embodiment, and differing from the previous embodiment in that the lid portion184, seeFIG. 9, of the presently described embodiment is held in place by an adhesive, e.g., glue, rather than the tape clip79described for the previous embodiment. Specifically, a product178to be packaged in the container108of the present embodiment is initially placed on the bottom panel126of the blank110. The product178is of a size having an outer perimeter equal to or less than the outer perimeter of the bottom panel126. The inner front panel124and back panel128are folded upward from the bottom panel126about the respective first and second fold lines134,136to a generally vertical position, and the inner front side flaps146,148and the back side flaps154,156are folded relative to the inner front panel124and back panel128, respectively, to extend along the lateral sides of the container. Subsequently, the bottom side flaps150,152are folded upward to overlap outer surfaces of the inner front side flaps146,148and back side flaps154,156at a lower portion of the container. Adhesive may be applied between the overlapping flaps146,148,150,152,154and156to form joints adhering the flaps146,148,150,152,154and156to one another at the locations that the bottom side flaps150,152overlap the inner front side flaps146,148and the back side flaps154,156to form a bottom portion186of the container108, seeFIG. 8.

The top flap130is folded about the third fold line138to extend across the top of the product178, and the outer front panel132is folded about the fourth fold line140to extend down in overlapping relationship across the inner front panel124. Prior to positioning the outer front panel132over the inner front panel124, adhesive is preferably applied on an outward facing surface of the separable panel portion168laterally inward from the separation lines170,172to form a joint adhering an inner surface of the outer front side panel132to an outer surface of the separable panel portion168. Alternatively, the adhesive may be applied to the inner surface of the outer front side panel132for engaging and forming a connection with the separable panel portion168.

The outer front side flaps162,164are folded to overlap front portions of the respective top side flaps158,160and bottom side flaps150,152, seeFIG. 9, and a joint, e.g., adhesive joint, is formed adhering the outer front side flaps162,164to outer surfaces of the top side flaps158,160. It should be noted that the overlapped area between the outer front side flaps162,164and outer surfaces of the bottom side flaps150,152is without a joint adhering the respective flaps162,164and150,152together. That is, the outer front side flaps162,164remain movable without attachment to the bottom side flaps150,152in the completed container108for shipping the product178.

The assembled container108, seeFIG. 9, comprises a box that can be opened as a clamshell, including a lid portion184that is pivotally connected to the base portion186at the third fold line138. The base portion186is defined by the inner front panel124and inner front side flaps146,148, the bottom panel126and bottom side flaps150,152, and the back panel128and back side flaps154,156. The inner front side flaps146,148and back side flaps154,156are located inward of the bottom side flaps150,152, and are preferably attached to the bottom side flaps150,152with an adhesive, such as glue, to define the base portion186.

The lid portion184is defined by the top panel130and top side flaps158,160, and by the outer front panel132and outer front side flaps162,164. Further, as a result in part of the unique folding sequence described above, the outer front side flaps162,164are located outward of the top side flaps158,160, and are preferably attached to the top side flaps158,160with an adhesive, such as glue, to define the lid portion184. The lid portion184is unattached, e.g., without glue or other adhesive, to the lateral sides of the base portion186and is free to pivot relative to the base portion186when the joint adhering the outer front panel132to the inner front panel124is released, as described below.

The container108can be converted to a display case comprising the base portion186and enclosed product178by removing the lid portion184. For example, at the point of sale, the second recessed area176in the outer front panel132permits access to a lower edge of the separable panel portion168, i.e., at the inner edge167of the separable panel portion168, such that the separable panel portion168can be pulled upwardly with the lid portion184, seeFIG. 10. The separable panel portion168remains attached to the interior surface of the outer front panel132and separates from the inner front panel124along the separation lines170,172, thereby releasing the outer front panel132from the inner front panel124. The lid portion184can then be pivoted up without releasing any further connection between the lid portion184and the base portion186, such that the exposed surfaces of the base portion186are not disrupted or marred by separation from the lid portion184. Further, separation of the separable panel portion168from the inner front panel124during removal of the lid portion184forms a display opening181on the front of the base portion186. Subsequently, the lid portion184can be separated from the base portion186along the separation line defined at the third fold line138, and the base portion186with product178may be used as a display at the point of sale.