Abstract:
A container for packaging a product is provided. The container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface. The container includes a top panel having a top edge, a bottom edge, and opposing side edges. The container further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, a rear panel connected to the hinge panel along a second fold line and connected to the top panel, and a first adhesive coating applied on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving a product. Moreover, after the product is placed in the compartment, the top panel and the rear panel are folded about the hinge panel such that at least a portion of the internal surfaces of the top and rear panels are attached to one another. A method of constructing the same is also provided.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to containers and, more particularly, to a container for shipping a product stored within the container, and a method of constructing the container. 
         [0002]    Containers are oftentimes used to store, display, and/or transport a product or a plurality of products. For example, a distributor of media products, such as compact discs (CDs) and digital video discs (DVDs), may have to place their products within a container for shipment to consumers. At least some known containers are fabricated from rigid cardboard, filled with a digital media product, and closed for transportation to a home or retail store. Some known cardboard containers are constructed such that the cardboard is wrapped around the contents of the container and then sealed to retain the contents within the container. The cost to construct and transport rigid cardboard containers is ever increasing, particularly when the cardboard container is shipped through the mail or through a delivery service. Thus, a flexible container for housing products such as digital media products that can easily be produced and that facilitates reducing the expense of transporting the products is needed. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0003]    In one aspect, a container for packaging a product is provided. The container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface. The container includes a top panel having a top edge, a bottom edge, and opposing side edges. The container further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, a rear panel connected to the hinge panel along a second fold line and connected to the top panel, and a first adhesive coating applied on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving a product. Moreover, after the product is placed in the compartment, the top panel and the rear panel are folded about the hinge panel such that at least a portion of the internal surfaces of the top and rear panels are attached to one another. 
         [0004]    In a further aspect, a blank of sheet material for constructing a container used for shipping a product is provided. The blank has an internal surface and an opposing external surface. The blank includes a top panel having a top edge, a bottom edge, and opposing side edges, a hinge panel connected to the bottom edge of the top panel along a first fold line, and a rear panel connected to the hinge panel along a second fold line and connected to the top panel, wherein the rear panel includes a first adhesive coating applied thereto on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge to a perimeter of a compartment for receiving the product. 
         [0005]    In a further aspect, a method of constructing a container used for shipping a product is provided. The container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface. The blank includes a top panel having a top edge, a bottom edge, and opposing side edges. The blank further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, and a rear panel connected to the hinge panel along a second fold line and connected to the top panel. The method includes providing the blank of sheet material, applying a first adhesive coating to a portion of the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving the product, placing the product within the compartment of the container, folding the top panel towards the interior surface of the rear panel along the hinge panel, and applying at least one of heat and pressure in the area of the coating to seal the container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a plan view of a blank of sheet material for constructing a container according to one embodiment. 
           [0007]      FIG. 2  is a perspective view of a container partially constructed from the blank shown in  FIG. 1 . 
           [0008]      FIG. 3  is a perspective view of a container constructed from the blank shown in  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0009]    The present invention is described below in reference to its application in connection with and operation of a container for mailing digital media products (e.g., compact discs (CDs), digital video discs (DVDs), a minidisc, a digital video, a video game, a record, etc.). However, it will be apparent to those skilled in the art and guided by the teachings herein provided that the invention is likewise applicable to any suitable storage and/or container including, without limitation, a carton, a tray or a box. 
         [0010]    In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the teachings herein provided. The container may have any suitable size, shape and/or configuration, i.e. number of sides, whether such sizes, shapes and/or configurations are described and/or illustrated herein. For example, in one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates transporting the container and/or a shape that facilitates stacking and/or arrangement of a plurality of containers. 
         [0011]      FIGS. 1-3  illustrate the construction of one embodiment of a container. Specifically,  FIG. 1  illustrates a plan view of one embodiment of a blank of sheet material designated in its entirety by element reference number  10 .  FIG. 2  is a perspective view of a container partially constructed designated in its entirety by element reference numeral  12  constructed from blank  10  shown in  FIG. 1 .  FIG. 3  is a perspective view of container  12  in the constructed configuration. 
         [0012]    Referring to  FIG. 1 , blank  10  is made of flexible paperboard material including a first corrugated surface or internal surface  14  and an opposing second surface or external surface  16 . In one embodiment, first surface  14  is blank or void of any marking, such as a graphic and/or other printing, and second surface  16  includes at least one print screen thereon. The print screen includes any suitable markings including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. In a particular embodiment, the print screen is positioned on one or more panels (as described in greater detail below) on second surface  16  of blank  10  and corresponds to a visible surface, such as an exterior surface or a second surface, of constructed container  12 . 
         [0013]    Blank  10  includes a first edge  30 , an opposing second edge,  32 , and two substantially parallel edges  34  and  36  extending therebetween. Blank  10  has a width W 1  defined between edges  30  and  32 , and a length L 1  defined between edges  34  and  36 . Moreover, blank  10  includes a first panel or top panel  18 , an opposing second panel or rear panel  20 , and a folding panel or hinge panel  22  extending therebetween. First panel  18  is hingeably coupled to second panel  20  along a fold line  24  extending partially between edges  30  and  32 . In one embodiment, fold line  24  includes a hinge line and/or a line of separation, such as a die cut, defined along a portion of fold line  24 . It is apparent to those skilled in the art and guided by the teachings herein provided that fold line  24 , as well as other fold lines described herein, may include any suitable line or lines of weakening. 
         [0014]    In one embodiment, first and second panels  18  and  20  have a substantially similar shape. Specifically, first and second panels  18  and  20  have a substantially square shape. Moreover, first panel  18  has a length L 3  defined between edge  34  and fold line  24 , and second panel  20  has a length L 2  defined between edge  36  and fold line  24 . In one embodiment, length L 2  and length L 3  are substantially equal, and are approximately half the length of L 1 . In an alternative embodiment, first and second panels  18  and  20  may have any suitable shape to facilitate forming container  12 , and length L 2  and length L 3  have different lengths. 
         [0015]    In one embodiment, folding panel  22  is defined by two arcuate score lines  26  and  28 . Score lines  26  and  28  intersect forming at least two intersections  38  and  40  defined along fold line  24 . In an alternative embodiment, score lines  26  and  28  intersect forming more than two intersections. In an alternative embodiment, blank  10  does not include folding panel  22  and score lines  26  and  28 ; rather, blank  10  includes a single transverse score line (not shown) extending between edges  30  and  32 . 
         [0016]    Moreover, blank  10  includes a display window  42  defined within a portion of panel  20 . In one embodiment, display window  42  forms an opening within panel  20  and is substantially square in shape. Specifically, display window  42  includes a first edge  44 , an opposing second edge  46 , and two substantially parallel edges  48  and  50  extending therebetween. In an alternative embodiment, display window  42  has any suitable shape. In a further alternative embodiment, blank  10  does not include display window  42 . In a further alternative embodiment, both first and second panels  18  and  20  include display window  42 . In one embodiment, a substantially transparent plastic material (not shown) is coupled to surface  14  such that the plastic material is adjacent to at least a portion of display window  42 . 
         [0017]    First surface  14  of first panel  18  includes a coating  54  that is applied to first panel  18 , and first surface  14  of second panel  20  includes a coating  56  that is applied to second panel  20 . Coatings  54  and  56  are configured to facilitate coupling first and second panels  18  and  20  together. In one embodiment, coatings  54  and  56  are co-adhesive coatings. In an alternative embodiment, coatings  54  and  56  are heat activated sealants and/or any suitable coating that facilitates the coupling of first and second panels  18  and  20 . 
         [0018]    In one embodiment, coating  54  is applied to the entire first surface  14  of first panel  18 , and coating  56  is applied to first surface  14  of second panel  20  in a U-shape. Coating  56  includes a first portion  58 , an opposing second portion  60 , and a third portion  62  extending therebetween. Specifically, first portion  58  of coating  56  is applied parallel and adjacent to a portion of edge  30 , second portion  60  of coating  56  is applied parallel and adjacent to a portion of edge  32 , and third portion  62  of coating  56  is applied parallel and adjacent to a portion of edge  36  defining a perimeter for a compartment. Moreover, coating  56  is applied outward of display window  42 . In an alternative embodiment, coating  54  is applied to only a portion of first surface  14  of first panel  18 , and coating  56  is applied to first surface  14  of second panel  20  in any suitable shape that facilitates coupling first surface  14  of first panel  18  to first surface of second panel  20  while providing space for a product to be placed between first panel  18  and second panel  20  for sealing the product within container  12 . 
         [0019]      FIG. 2  shows container  12  in a partially constructed open configuration  61 . Container  12  is constructed from blank  10 . Container  12  is flexible and is configured to receive contents  63 , such as, but not limited to, a compact disc (CD), a digital video disc or a digital versatile disc (DVD), a minidisc, a digital video, a video game, and/or a record. 
         [0020]    In use, coatings  54  and  56  are applied to first panels  18  and  20 , respectively, and contents  63  are positioned adjacent first surface  14  of first panel  18 . In one embodiment, contents  63  are positioned such that a portion of contents  63  is adjacent score line  26  and/or folding panel  22 . Moreover, in one embodiment, contents  63  are positioned adjacent first surface  14  of first panel  18  with a high-speed automatic system. 
         [0021]      FIG. 3  shows container  12  in a fully constructed closed configuration  64 . In use, after contents  63  are positioned adjacent first panel  18 , second panel  20  is folded along score lines  26  and  28  towards first surface  14  forming folding panel  22 . Second panel  20  is coupled to first panel  18  by coupling a portion of coating  54  to a portion of coating  56  using a heat sealing tool. Specifically, the heat sealing tool heats coatings  54  and  56  activating the adhesive and/or sealant properties of coatings  54  and  56 . Once the adhesive properties are activated, second surfaces  16  of first panel  18  and second panel  20  are compressed together to continuously seal first, second, and third portions  58 ,  60 , and  62  of coating  56  to coating  54  closing container  12  and forming the compartment configured to receive contents  63  therein. As shown in  FIG. 3 , an imprint  66  on second surface  16  of second panel  20  is generally shown in the location of the heat sealing on first surface  14  of second panel  20 . The heat sealing tool provides an efficient high-speed means to construct container  12  from open configuration  61  to closed configuration  64 . 
         [0022]    In an alternative embodiment, coatings  54  and  56  do not require heat to activate the adhesive and/or sealant properties of coatings  54  and  56 . Moreover, in the alternative embodiment, container  12  is rotated from open configuration  61  to closed configuration  64  using any suitable mechanism, and first panel  18  and second panel  20  are coupled together solely by applying pressure to the second surfaces  16  of first panel  18  and second panel  20  to seal first, second, and third portions  58 ,  60 , and  62 . 
         [0023]    Once container  12  is in closed configuration  64 , coating  54  substantially prevents contents  63  of container  12  from shifting within container  12 , and contents  63  are visible through display window  42 . Moreover, to enhance security against theft, coatings  54  and  56  provide a tamper-resistant measure and a tamper-evident measure for container  12  in closed configuration  64 . 
         [0024]    The above-described container and method of constructing the container provides a container that is easily constructed from a flexible unitary blank of paperboard and transports contents such as digital media. Moreover, the container includes an opening formed within a portion of the container such that contents of the container are visible when the container is in a constructed configuration. As a result, consumers can transport contents within a flexible container while viewing the contents of the closed container. 
         [0025]    Exemplary embodiments of a container have been described above in detail. The apparatus is not limited to the specific embodiments described herein, but rather, components of the container and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. Further, the described apparatus components and/or method steps can also be defined in, or used in combination with, other apparatus and/or methods, and are not limited to practice with only the apparatus and method as described herein. 
         [0026]    While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.