Abstract:
A container preassembly which has an inner sleeve in a flat unopened position disposed within an outer sleeve in a flat unopened position, where in the inner sleeve is substantially shorter than the outer sleeve. The two sleeves are adapted for form the top and bottom ends of the final opened container. The inner sleeve is cut so that gaps at the top of the inner sleeve form notches at the corners of the final opened container. The shorter outer sleeve rests on these notches preventing the pieces from shifting during the manufacturing process and to allow the preassembly to be folded into the final container using current machine technology.

Description:
This application claims the benefit of U.S. Provisional Patent Application No. 61/595,060 filed on Feb. 4, 2012, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Statement of the Technical Field 
     The invention pertains to containers used for packaging, shipping, and displaying goods. More particularly, the invention relates to containers formed from at least two sections. 
     2. Description of the Related Art 
     Two piece containers are extremely popular and in widespread use. Typical two piece containers have separate top and bottom sections formed from separate blanks. A first section has side walls and flaps for forming the container&#39;s bottom. A second section has side walls and flaps for forming the top, and fits over the side walls of the bottom section to enclose the interior of the container. These top and bottom sections are sometimes referred to as half slotted containers since both are necessary to form a single fully enclosed container. In contrast, a regular slotted container is formed from a single blank section having both bottom and top forming flaps. 
     Two piece containers are extremely useful for packaging, storing, shipping, and displaying goods. After the goods are placed into the interior of the bottom section, the top section is placed over the bottom section to fully enclose the contents. The top and bottom sections can then be secured together for shipping. 
     Two piece containers are particularly useful as shipping-display containers. Used to package and ship goods for retail, the outside face of the bottom section can be printed and/or designed with promotional information suitable for display on the retail floor. The retailer simply removes the top section of the container and places the bottom display section containing the goods on the retail floor. Unlike regular slotted containers, no cutting or tearing of the container is required to open it. This type of container is very popular for food items which are easily displayed in the bottom display section. 
     One disadvantage of present two piece containers is the number of steps necessary to assemble the container. The user begins with the two separate container sections, both in a flat unfolded position. The bottom section is opened to form the sides and its flaps folded and secured to form the container bottom. The top piece is likewise opened and its flaps folded and secured to form the top. After the bottom section is loaded with the goods, the top section, slightly larger than the bottom, is placed over the bottom section to form a completely enclosed container. If desired, the two sections can be secured together. 
     U.S. Pat. No. 5,505,368 to Kanter et al., teaches a two section container with an inner sleeve and an outer sleeve, both adapted to form the two ends of the container in an aligned relationship of the final open container. This allows preassembly of a container, by an automated process, into a “knockdown” that may be opened to form the final container without requiring further adjustment. Once opened, the flaps for forming the container bottom are folded to create a container ready for use. This container has many advantages, but further improvements are believed possible. Such improvements would include using less material to create less waste while lowering costs, and also maintaining strength while using less material. 
     SUMMARY OF THE INVENTION 
     The present invention improves the two piece container to create one that is more useful and cost effective. 
     In at least one aspect, the present invention provides a container preassembly for opening into a container having top and bottom ends. The container preassembly includes an unopened outer sleeve having panels for forming outer sleeve sides, and flaps integrally connected to the panels for forming one end of the container and an unopened inner sleeve positioned inside the outer sleeve, the inner sleeve having panels for forming inner sleeve sides and flaps integrally connected to the panels for forming the other end of the container. At least one tear away line is defined through one of the panels of the inner sleeve to define at least one tear away section of the inner sleeve. The outer and inner sleeves are secured together in an aligned relationship of the opened container wherein the securement of the sleeves is defined between respective portions of the outer sleeve and the at least one tear away section of the inner sleeve. 
     In another aspect, the present invention provides a container preassembly adapted to open into a container having top and bottom ends. The container preassembly includes an outer sleeve in a flat unopened position and having panels for forming outer sleeve sides, and flaps for forming one end of the opened container, wherein a respective fold line is defined between adjacent outer sleeve panels. An inner sleeve is in a flat unopened position and have panels for forming inner sleeve sides, and inner sleeve flaps for forming the other end of the opened container, wherein a respective fold line is defined between adjacent inner sleeve panels within a lower portion thereof and a respective slot is defined between adjacent inner sleeve panels within an upper portion thereof, each slot co-linear with a respective fold line. The outer and inner sleeves are permanently secured together in an aligned relationship of the container when opened such that the outer sleeve fold lines are positioned over the respective inner sleeve slots. 
     Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments will be described with reference to the following drawing figures, in which like numerals represent like items throughout the figures, and in which: 
         FIG. 1  is a top perspective view of the assembled container with the top and bottom flaps unfolded; 
         FIG. 2A  is a plan view of a blank section for forming the inner section of the container; 
         FIG. 2B  is a plan view of a blank section for forming the outer section of the container; 
         FIG. 3A  is a view of the inner section positioned over the outer section for assembly into a knockdown; 
         FIG. 3B  is a view of the inner section positioned over the outer section showing the assembly of the container; 
         FIG. 4  is a side view of a knockdown; 
         FIG. 5  is a side view of the reverse side of a knockdown from that of  FIG. 4 ; 
         FIG. 6  is a cross-sectional view along the lines  6 - 6  in  FIG. 1 ; 
         FIG. 7  is a perspective bottom view of a completed container; 
         FIG. 8  is a perspective view of a completed container; 
         FIG. 9  is a perspective view of the completed container illustrating the initial step of separating the outer section from the inner section; 
         FIG. 10  is a partial cross-sectional, exploded view illustrating a portion of the outer container removed from the inner container; 
         FIG. 11  is a cross-sectional view along the lines  11 - 11  in  FIG. 8 ; 
         FIG. 12  is a cross-sectional view along the lines  12 - 12  in  FIG. 11 ; 
         FIG. 13  is a cross-sectional view along the lines  13 - 13  in  FIG. 11 ; 
         FIG. 14  is a perspective view of a completed container shown with the outer section removed; and 
         FIG. 15  is a perspective view showing the removable display panel removed. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention is described with reference to the attached figures. The figures may not be drawn to scale and they are provided merely to illustrate an exemplary embodiment of the instant invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the invention. One having ordinary skill in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the invention. The present invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the present invention. 
     The word “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is if, X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. 
     Referring to  FIG. 1 , an opened container  10  is shown with its top and bottom forming flaps unfolded. Container  10  comprises inner (lower) sleeve  12  and outer (upper) sleeve  14 . The inner sleeve  12  includes side panels  101 ,  102 ,  103  and  104 , panel  104  being formed by panels  104   a  and  104   b . The inner sleeve further includes bottom forming flaps  106  integrally attached to respective side panels  101 - 104 . The illustrated embodiment further includes a divider panel  105  separating the interior of the container  10  into two sections  16   a  and  16   b  as shown. 
     The outer sleeve  14  forms a removable cover for the inner sleeve  12  and includes side panels  201 ,  202 ,  203  and  204 , panel  204  being formed by panels  204   a  and  204   b  (not shown in  FIG. 1 ). The outer sleeve further includes top forming flaps  205  integrally attached to respective side panels  201 - 204 . As will be described below, the inner and outer sleeves  12 ,  14  are formed separately from blanks  100  and  200  which are assembled into a knockdown form which can be opened into the final container  10  as shown in  FIG. 1 . 
     Referring to  FIG. 2A , a blank  100  for forming the inner sleeve  12  of the display ready container  10  includes the side panels  101 ,  102 ,  103 ,  104   a , and  104   b  for forming the sides of the container  10  ( 104   a  and  104   b  form side  104  as described below), and further includes the divider panel  105 . The panels are preferably integrally formed and separated by score lines (crease)  111  at the lower portion of the panels  101 - 104  and slots or gaps  112  at the upper portion of the panels  101 - 104 . The score lines  111  are impressed into the blank  100  as shown to act as a fold line and aid in folding. Slots or gaps  112  separate the upper portions of adjacent side panels, the purpose of which will be described below. Slots or gaps  112  have a bottom  135  after which the score lines  111  extend. The upper portions have a height H 1  and the lower portions have a height of H 2 . The ratio H 1 /H 2  is preferably less than or equal to 0.5 and more preferably is in the range of about 0.25 to 0.4, although other ratios may be utilized. Bottom forming flaps  106  are integrally connected to the lower portions of the side panels by score (fold) lines  120 , and are separated from each other by slots  119 . 
     Tear away lines  113  formed by a series of perforations or cuts are provided on the front side panel  101  and the rear side panel  104  to form tear away sections  114 . Tear away sections  114  facilitate separating the inner and outer sleeves  12 ,  14  as further described below. While tear away sections  114  are illustrated on the front and rear side panels  101 ,  104 , they may additionally or alternatively be provided on the right and left side panels  102 ,  103 . Below each of the tear away sections  114  is a pair of push in tabs  115  formed preferably by a continuous perforation line or cut encircling the two adjacent tabs with the exception of small uncut sections  115   a  along the left side of the left tab and along the right side of the right tab of each of the pair of tabs as seen in  FIG. 2A . The uncut sections  115   a  act as a hinge about which the individual tabs  115  can fold. The push tabs are pushed in using a finger to gain access to the tear away sections  114  from inside the container  10  to enable removal of the tear away sections  114  as further described below. 
     The side panel  101  of the illustrated embodiment further includes a removable display section  101   a  that can be removed to form a display opening in the container  10 . The removable section  101   a  is formed by perforations and cut lines  116 . A push in section  117 , formed by line of perforations  118 , can be pushed in to allow the user to grab the removable section  101   a  from inside the container  10  and pull it outwardly for removal. The divider panel  105  has glue tabs  108 ,  110  having fold lines  107 ,  109 , respectively, for attaching to the inside face of the side panel  101 . Fold line  109  is preferably formed with a score, fold line  107  preferably formed by a series of perforations so as be easily tearable for removal with the removable section  101   a.    
     It is seen that the inner sleeve  12  is formed by folding the blank  100  along the fold lines (score)  111  to form the inner sleeve sides  101 - 104 . (It is recognized that some of the fold lines  111  form the side corners of the inner sleeve  12 ). Side panels  104   a  and  104   b  are secured together as shown in  FIG. 1  to form the back side and to make the continuous sleeve  12 . The divider panel  105  is folded along its fold (score) lines  107 , 109 , and its glue tabs  108 , 110  secured to the side panel  101 . Any suitable means for securing the panels together may be used as is well known in the art, including adhesives such as glue. 
     Referring to  FIG. 2B , a blank  200  for forming the outer sleeve  14  includes the side panels  201 ,  202 ,  203 ,  204   a , and  204   b  for forming the side walls of the sleeve  14  (panels  204   a  and  204   b  are combined to form panel  204 ). Fold lines comprising score lines  207  are impressed between the side panels to aid in folding the blank  200 , and which form the side corners of the outer sleeve  14 . The flaps  205  for forming the top  18  are separated by slots  206  and integrally attached to the side panels at a score line  208 . A glue tab area  210  is provided to secure one end  211  of the blank  200  with the other end  212  when forming the continuous sleeve  14 . 
     The blanks  100 ,  200  are each preferably formed from a unitary piece of corrugated paperboard. Once formed, the blanks  100 ,  200  are preferably combined and folded to form a flat preassembled container, called a knockdown ( FIG. 4 ), that can be stored and shipped efficiently and which is easily erected into an open container for shipping goods. Illustrated in  FIGS. 3-12  is an exemplary method of assembling and using the flat preassembled container. 
     Referring first to  FIG. 3A , the outer blank  200  is laid flat with its inner face  220  facing upwardly as shown. Adhesive, such as a hot melt glue, is provided on the inner face  220  in areas  222  which will align with the tear away sections  114  of the inner sleeve  100  ( FIG. 2A ). The inner blank  100  in a flat unfolded position (as shown in  FIG. 2A ), with its inner face  130  facing upwardly and an outer face, not shown, facing the inner face  220  of the outer blank  200 , is placed on top of the inside face  220  of the outer blank  200  in the aligned position of the final opened container such that the adhesive in areas  222  adheres to the tear away sections  114 , thereby securing the two blanks  100  and  200  together. Pressure can be applied to the glued areas to ensure good adhesion between the two blank sections  100 , 200 . 
     As shown, the blanks  100  and  200  are combined in the aligned relationship of the final erected (opened) container  10 ; i.e., the side panels of the inner blank  100  align with and are adjacent to the respective side panels of the outer blank  200  in the same relationship as the final container  10 . Thus the front inner sleeve side panel  101  will align with the front outer sleeve side panel  201 , the back inner sleeve side panels  104   a ,  104   b  will align with the back outer side panels  204   a ,  204   b , etc. Moreover, the fold lines  111  and slots  112  of the inner sleeve blank  100  align with the respective fold lines  207  of the outer sleeve blank  200  to form adjacent corners of the inner and outer sleeves of the final container  10 . With the fold lines  111 ,  207  aligned, the two sleeves  12 ,  14  open together as a single unit as described below. The top edge  122  of the inner blank  100  is aligned with or below the fold line  208  of the blank  200  such that the flaps  205  may be folded to form the top  18  of the final container  10  as shown in  FIG. 8 . Preferably, as illustrated, the top edge  122  of the inner sleeve  12  aligns with the fold line  208  about which the flaps  205  of the outer sleeve fold to form the top  18  so that the top  18  of the final container  10  is positioned just above the edge  122 , thereby providing additional support for the top  18 . 
     Referring to  FIG. 3B , next adhesive is applied to the inner face  130  of glue tabs  108  and  110 , and then panels  104   a ,  105 , and  106   a  of the inner blank  100  and panel  204   a  and  205   a  of the outer blank  200  are folded as a unit about fold line FL- 1  such that the glue tabs  108  and  110  adhere to the inside face  130  of the panel  101 . Pressure can be applied to ensure good adhesion. 
     Next, referring to  FIGS. 3B and 4 , adhesive is applied to glue area  210  of the outer blank  200  (panel  204   b ) and glue area  180  of the inner blank  100  (panel  104   b ). Panels  104   b ,  106   b ,  103  and  106   c  of the inner blank  100  and panels  204   b ,  205   b ,  203  and  205   c  of the outer blank are then folded about fold line FL- 2  to form the knock down container. The adhesive in areas  180  and  210  combines the side panels  104   a  and  104   b , and panels  204   a  and  204   b  to form the complete side panels  104  and  204  respectively. Pressure can be applied to the glued areas to ensure good adhesion. Once the outer sleeve  14  is formed and secured around the inner sleeve  12 , it is seen that a flat preassembled knockdown container comprising the unopened inner and outer sleeves  12 ,  14  is formed. Such flat assemblies are efficiently stored and shipped in stacked form.  FIG. 5  illustrates the reverse side of the knockdown showing outer sleeve  14  wrapped around inner sleeve  12 . As is seen, the fold lines  207  align with the fold lines  111 , and fold lines  207  are positioned over gaps  112 , with the lower edges  235  of the outer sleeve  14  at score line  207  being aligned with the bottom  135  of the gap  112 . 
     Using the container  10  is very simple and efficient. Referring to  FIGS. 1 and 5 , the user erects the completed flat container preassembly by pushing the ends  88 ,  90  toward each other until an opened container  10  is formed as shown in  FIG. 1 . It is seen that this opens both sleeves  12 ,  14  as a single unit. As mentioned above, the slots  112  of the inner sleeve  12  align with the respective fold lines  207  of the outer sleeve  14  at the container corners. As the two blanks  100 ,  200  are folded into the knockdown and then unfolded into the final container  10 , given that the two blanks  100  and  200  are adhered together prior to the folding steps, the corners of the outer sleeve  14  will move or nest into the gaps  112  of the inner sleeve  12  during the unfolding process as shown in  FIG. 6 . The lower edge  235  of the sleeve  14  will rest on the edge  135  of the respective slot or gap  112 . This nesting within the gaps  112  and resting of the edge  235  on the edge  135  of the gap allows for the outer sleeve  14  to firmly situate on the corners of inner sleeve  12 , and provides additional strength to the overall container structure. 
     In this regard, the side panels  201 - 204   b  are substantially equal in height to the height H 1  of the upper portion of the lower panels  101 - 104 , thereby extending preferably less than 50% of the full height of the inner sleeve  12  side panels  101 - 104 , although other ratios, including greater than 50% may be utilized. Full length side panels for the outer sleeve are not necessary for the strength normally added by the full length panels given the strength of the container. Additionally, the sleeve  14  may be constructed using thinner corrugated or paper board than the inner sleeve  12 , i.e. the outer sleeve has a material thickness less than the inner sleeve. It is seen this configuration as described herein allows for side panels  201 - 204   b  to be constructed using less material than conventional display ready containers without sacrificing strength. Further, the gaps  112  allow the outer sleeve  14  to rest securely on inner sleeve  12  thereby preventing slippage during assembly. 
     After the container has been unfolded to the configuration illustrated in  FIG. 1 , the flaps  106  of the inner sleeve  12  are then folded and secured to form the container bottom  20  as illustrated in  FIG. 7 . In this configuration, the container  10  is ready to be loaded with goods. Once loaded with goods, the flaps  205  of the outer section  14  are folded and secured to form the top  18 , thereby enclosing the goods within the container  10 , as shown in  FIG. 8 . 
     Referring now to  FIGS. 9-13 , removal of the container outer section  14  to expose the goods within is now described. The push tabs  115  are pushed in using a person&#39;s finger to access the inside wall of the tear way sections  114  above each of the push tabs  115 . The user then pulls each tear away section  114  outwardly to detach the tear away sections  114  from the inner sleeve  12  along the lines  113 . Since the tear away sections  114  are glued to the outer sleeve  14 , once all of the tear away sections  114  are torn free of the inner sleeve  12 , the outer sleeve  14  can be lifted off of the inner sleeve  12  as seen in  FIG. 10 . 
     After the outer sleeve  14  is removed, the container and its contents my be displayed without further adjustment as shown in  FIG. 14 . However, the removable display panel  101   a  can be removed to further expose the goods. With reference to  FIGS. 14 and 15 , the push in section  117 , formed by line of perforations  118 , can be pushed in to allow the user to grab the removable section  101   a  from inside the container and pull it outwardly for removal as shown in  FIG. 15 . The tear line  107  allows the glue tab  108  to be easily removed with the removable display panel  101   a.    
     The present invention thereby provides a flat container preassembly which is simple and efficient to make, and which is easily erected into a completed container. Because forming the flat container preassembly as well as erecting and loading the fully formed container requires a few simple steps, the assembly and use of the container can be readily automated. 
     While a particular embodiment of the invention is described herein, it is not intended to limit the invention to such disclosure. Changes and modifications may be incorporated and embodied within the scope of the appended claims. For example, the illustrated embodiment shows the inner sleeve having flaps for forming the container bottom. Those skilled in the art readily recognize that the inner sleeve could be made to form the top of the container, or that the container could be positioned on its side for side loading. 
     Those skilled in the art will also recognize that the present invention is not limited to the blanks illustrated. Other types of blanks may include self locking flaps for forming both top and bottom, and may include fold line means between the panels other than scored lines. 
     Furthermore, the present invention is not limited to rectangular containers. Any suitably shaped container, having inner and outer sleeves can incorporate the invention, including, but not limited to, hexagonal and pentagonal shaped containers. 
     While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.