Abstract:
A package is disclosed comprising a shell and a slidable tray received therein, and having at least two access modes for dispensing contents from the package.

Description:
BACKGROUND 
       [0001]    The present application is directed to paperboard packages and, more particularly, to packages for containing multiple consumer items and having more than one mode of opening the package for access to the contents. 
         [0002]    Manufacturers and retailers of consumer goods, such as health and beauty products, food and beverage products and the like, typically package their products in paperboard packages. For example, many consumer goods are packaged in containers having a tear-away opening (such as a tissue box) or having an outer shell with an inner sliding tray (such as for holding cotton swabs or medicine). 
         [0003]    To increase the usefulness and visual appeal of a package with a sliding tray, a package with alternative access modes is desired. 
       SUMMARY 
       [0004]    In one aspect, a package for housing an item or items is disclosed comprising an outer shell and a sliding tray, with access to the items provided by sliding the tray out of the shell, and access to the items also provided through at least one additional access opening in the package. 
         [0005]    Other aspects of the disclosed package will become apparent from the following description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1A  is a view of a blank for forming a shell; 
           [0007]      FIG. 1B  is a perspective view of the blank of  FIG. 1A ; 
           [0008]      FIG. 2  is a perspective view of a step in forming a shell from the blank of  FIGS. 1A and 1B ; 
           [0009]      FIGS. 3A and 3B  are perspective views of additional steps in forming a shell from the blank of  FIGS. 1A and 1B ; 
           [0010]      FIG. 4A  is a view of a blank for forming a tray; 
           [0011]      FIG. 4B  is a perspective view of the blank of  FIG. 4A ; 
           [0012]      FIGS. 5 ,  6 A,  6 B,  7 A, and  7 B are perspective views of steps in the forming of the blank of  FIGS. 4A and 4B  into a tray; 
           [0013]      FIG. 8A  is a perspective view of a finished tray formed from the blank of  FIGS. 4A and 4B ; 
           [0014]      FIG. 8B  is a perspective view of a finished package comprised of a shell and a tray; 
           [0015]      FIG. 9A  is a view of another blank for forming a tray; 
           [0016]      FIG. 9B  is a perspective view of the blank of  FIG. 9A ; 
           [0017]      FIGS. 10 ,  11 A, and  11 B are perspective views of steps in the forming of the blank of  FIGS. 9A and 9B  into a tray; 
           [0018]      FIG. 12A  is a perspective view of a finished tray formed from the blank of  FIGS. 9A and 9B ; 
           [0019]      FIG. 12B  is a perspective view of a finished package comprised of a shell and a tray; and 
           [0020]      FIGS. 13A and 13B  are perspective views of other packages comprised of another shell. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The package structure described below may be made of a variety of materials including, but not limited to paperboard (treated or untreated), plastic, APET, PLA and more. In addition, the package may be made of a combination of materials with the outer shell being made of one material and the inner container being made of another material. The material may be chosen based on manufacturing preferences for the type of product contained within. It is to be understood that a variety of locking mechanism may be added to the package at one or more openings to prevent unwanted access. 
         [0022]      FIG. 1  shows a plan view of shell blank  10 , and  FIG. 2  shows the same blank in perspective view. Certain exemplary parts of shell blank  10  will now be described. Generally solid lines are used to denote cut lines or edges, and dashed lines to denote fold or score lines. However, dashed lines are sometimes used to show hidden lines in a folded structure, in which case some fold lines in the same drawing may be shown as solid lines to avoid confusion. 
         [0023]    The major panels of shell blank  10  may include shell bottom panel  12 , shell side panels  14 , and shell top panel  16 , hingedly attached together by fold or score lines. The major panels may be hingedly attached to shell bottom back flap  12 B, shell top back flap  16 B, and shell side back flaps  14 B. The major panels may further be hingedly attached to shell bottom front flap  12 F, shell top front flap  16 F, and shell side front flaps  14 F. The shell top panel  16  may be hingedly attached to shell glue flap  16 G. At the hinged connection line between side panels  14  and shell side front flap  14 F there may be provided an aperture  15  such as a circular- or other-shaped opening. 
         [0024]    Shell blank  10  may be formed into shell  20  through a series of folding operations. The folding steps may be performed in a variety of sequences. An example sequence of steps is shown here.  FIG. 2  shows shell bottom front flap  12 F folded inwardly upon shell bottom panel  12 , to which it may be glued or attached by other means. Shell top front flap  16 F is shown folded inwardly upon shell top panel  16 , to which it may be glued or attached by other means, and shell side front flaps  14 F folded inwardly upon shell side panels  14 , to which they may be glued. Thus, a smooth front edge of the structure is provided along the resulting folded edge. Also, the aperture  15  upon folding forms a cutaway access area whose use will be explained later. It is to be understood that other means of attaching including but not limited to stapling, sealing, taping, or even foldably attaching with or without using interlocking mechanisms, may be used in the place of gluing for any aspect of this invention as determined appropriate based on manufacturing preferences. 
         [0025]      FIG. 3A  shows shell top panel  16 , shell side panels  14 , and shell bottom panel  12  folded into a four-sided tube, which may be held together by shell glue flap  16 G being glued to the inside of a now adjacent one of shell side panels  14 . Note that a portion of the adjacent shell side front flap  14 F may be cutaway to provide clearance for shell glue flap  16 G.  FIG. 3B  shows the back of the shell closed by shell side back flaps  14 B being folded inward, shell top back flap  16 B being folded downward, and shell bottom back flap  12 B being folded upward. These flaps may be glued to hold shut the back of the shell  20 . Thus a partially enclosed box is formed as shell  20  that may receive a sliding tray to be described next. 
         [0026]      FIG. 4A  shows a plan view of tray blank  30  and  FIG. 4B  shows the same blank in perspective view. Certain exemplary parts of tray blank  30  will now be described. Generally solid lines are used to denote cut lines or edges, and dashed lines to denote fold or score lines. However, dashed lines are sometimes used to show hidden lines in a folded structure, in which case some fold lines in the same drawing may be shown as solid lines to avoid confusion. 
         [0027]    The major panels of tray blank  30  may include tray back panel  36 , tray side panels  34 , and tray front panel  38 , hingedly attached together by fold or score lines. The tray back panel  36  at its lower edge may be hingedly attached to tray bottom panel  32 , which is at an opposite edge is attached to bin panel  40 . Tray back panel  36  at its upper edge may be hingedly attached to tray back top flap  36 T, while tray front panel  38  at its upper edge may be hingedly attached to tray front top flap  38 T. Tray side panels  34  at their lower edge may be hingedly attached to tray side bottom flaps  34 B. The tray side bottom flaps  34 B may comprise interlocking fingers  34 X. A tray bottom catch tab  32 B may be formed in tray bottom panel  32 . 
         [0028]    Tray blank  30  may be formed into tray  50  through a series of folding operations. The folding steps may be performed in a variety of sequences. An example sequence of steps is shown here.  FIG. 5  shows tray back top flap  36 T folded inwardly upon tray back panel  36 , to which it may be glued. Tray front top flap  38 T is shown folded inwardly upon tray front panel  38 , to which it may be glued. Folding of such flaps creates a smooth edge along the fold which will be present along certain top edges of the finished tray. If desired, similar top flaps could be provided for the tray side panels  34 . 
         [0029]      FIG. 6  shows a common fold created along the fold lines between tray bottom panel  32  and tray back panel  36 , and between tray side panels  34  and tray side bottom flaps  34 B. Next, a series of right angle folds is made between tray back panel  36 , tray side panels  34 , and tray front panel  38  (with attached tray front top flap  38 T), to form a four-sided tube as shown in  FIG. 7A , which may be held together by tray glue flap  36 G being glued to the inside of a now adjacent tray side panel  34 . As a result of folding into the four-side tube shape shown in  FIG. 7A , tray side bottom flaps  34 B may come together above tray bottom panel  32 . The tray side bottom flaps  34 B may interlock through interlocking fingers  34 X. Thus a partially enclosed box is formed as tray  50 , that may be slidably received into shell  20  previously described. 
         [0030]    Tray  50  as formed has an open top side, providing a first access point  51  through which items may be placed into or removed from the tray. Further, a second access point  52  may be provided through an opening in a portion of the front of tray  50 , positioned as shown below tray front panel  38 . This second access point  52  may be reversibly opened or closed with a tilting bin door  40 , which comprises side wings  40 W that may be folded to fit within tray  50  as shown in  FIGS. 7B and 8A . 
         [0031]    As shown in  FIG. 8B , tray  50  may be slidably inserted into shell  20 . When bin door  40  is closed, and the tray  50  is slid within shell  20 , the contents may be completed enclosed. If bin door  40  is opened, items may be removed from within tray  50 . Also, if tray  50  is slid out of shell  20 , items may be removed through the open top of the tray. When tray  50  is slid forward, catch tab  32 B on the tray bottom panel  32  may engage a portion of shell  20 , such as an inward edge of shell bottom front flap  12 F, to prevent tray  50  from coming completely out of shell  20 . 
         [0032]      FIG. 9A  shows a plan view of another tray blank  130  and  FIG. 9B  shows the same blank in perspective view. Certain exemplary parts of tray blank  130  will now be described. The major panels of tray blank  130  may include tray back panel  136 , tray side panels  134 , and tray front panel  138 , hingedly attached together by fold or score lines. Tray front panel  138  at its lower edge may be hingedly attached to tray bottom panel  132 , which is at an opposite edge is attached to tuck flap  132 F. Tray front panel  138  at its upper edge may be hingedly attached to tray front top flap  138 T. Tray side panels  134  at their lower edge may be hingedly attached to tray side bottom flaps  134 B. Tray back panel  136  may have hingedly attached at its bottom edge a tray back bottom flap  136 B, and hingedly attached at a side edge a glue flap  136 G. 
         [0033]    Tray blank  130  may be formed into tray  150  through a series of folding operations. The folding steps may be performed in a variety of sequences. An example sequence of steps is shown here.  FIG. 10  shows tray back bottom flap  136 B folded inwardly upon tray back panel  136 , to which it may be glued or left unglued. Tray front top flap  138 T is shown folded inwardly upon tray front panel  138 , to which it may be preferably glued. Folding of front top flap  138 T creates a smooth edge along the fold which will be present along a top edge of the finished tray. If desired, similar top flaps could be provided for the tray side panels  134  and back panel  136 . 
         [0034]      FIG. 11A  shows the form of the tray after a series of right angle folds is made between tray back panel  136 , tray side panels  134 , and tray front panel  138  (with attached tray front top flap  138 T), to form a four-sided tube as shown in  FIG. 7A , which may be held together by tray glue flap  136 G being glued to the inside of a now adjacent tray side panel  134 . Then, as shown in  FIG. 11B , tray side bottom flaps  134 B may be folded inward, and tray bottom panel  132  folded upward and inward, closing one end of the tubular structure. Tuck flap  132 F may be folded and inserted inside the tray to hold the back closed. Thus a partially enclosed box is formed as tray  150 , that may be slidably received into shell  20  previously described. Although the tray  150  as shown in  FIG. 11B  is open on a side, in actual use it may be rotated to the position shown in  FIG. 12A  with the open end at the top. 
         [0035]    Tray  150  as formed thus has an open top side, providing a first access point through which items may be placed into or removed from the tray.  FIG. 13A  shows how, with another shell  22 , a second access point may be provided through an opening  24  in the top of shell  22 , through which contents may be dispensed from the package, even when tray  150  is completely slid into the shell  22 . It is to be understood that the opening  24  may be positioned on eth side of the shell. Opening  24  may comprise a membrane  26  such as a transparent plastic film that may be cut through with slit  28  to provide access to the contents. Alternately the opening may not have such a membrane. Opening  24  may be provided as a tear-away portion of shell  22 , to protect the contents during shipping and handling. 
         [0036]    As shown in  FIG. 13B , such an opening  24  may also be provided in shell  22  that may be used with tray  50 . Thus, the package shown in  FIG. 13B  may have three access points: first the bin  40 , second the open top of tray  50  when slid out from the shell, and third the opening  24  in shell  22 . 
         [0037]    For any combination of shell and tray, a feature such as catch tab  32 B, described earlier for tray  50 , may be used to prevent a tray once inserted into a shell from being pulled completely of the shell. A catch tab may be provided on the bottom or sides of a tray, to interact with a complimentary feature on the inside of the shell. Such a complimentary feature may be a tab, an aperture, or even a paperboard edge (such as the edge of shell bottom front flap  12 F) folded inward inside the shell. 
         [0038]    Alternative embodiments are possible for the shell and the tray. For example, the shell may have an enclosed back as shown in the Figures. However, as will be understood by one skilled in the art, the shell may also have an open back. Also, while exemplary designs have been used to show the construction of a shell or tray, these are not meant to be limiting as other embodiments are possible. 
         [0039]    In certain embodiments, die-cutting may be used as an exemplary method to make blanks for the shell and tray. It will be understood that other methods may be utilized, for example laser cutting, roller cutting, match metal tooling, shearing, knife cuts, and other methods to provide continuous or discontinuous cuts, cuts to varying depths, or any other methods that would provide cuts, scores, perforations or other operations useful for creating separation lines or folding lines. 
         [0040]    In certain embodiments, the contents of the packages described herein may be, for example, cotton swabs, contact lens packages, medicine tablets or packages, hair accessories, candy, packages of nuts or fruit, chap-sticks, soaps, travel size products, razors, cigarettes, alternative tobacco products, gum, diapers or other small items, but it will be understood that many items may be contained within and dispensed from the package. It is to be further understood that the package could be made of stronger material or reinforced so that it may contain and dispense larger products, such as canned or bottled beverages, beverage bags (such as a wine bag for wine in a box) or other heavier products. It addition it is to be understood that this package design could be partitioned such that more than one product could be contained and dispensed within. The partition may be within the body as well as the opening areas and more than one additional opening may be added such that the products may be accessed individually. It is to be understood that one benefit this product may have is for restocking at the retailers&#39; level. 
         [0041]    It is to be understood that the one or more additional openings on the tray may be permanently removed. In addition it may be perforated such that it may only be opened once the consumer or end user breaks the perforations. The one or more secondary openings may be round (such as to hold a spout), oval, rectangular, square, or any other shape preferred by the manufacturer. The one or more secondary openings may run up to 1/10 of the height and/or length across the front of the tray, up to ⅛ of the height and/or length of the tray, up to ¼ of the height and or length of the tray, up to ½ of the height and or length of the tray, up to ¾ of the height and or length of the tray, or up to the entire length of the tray. It is to be understood that the height and length of the one or more additional openings may be different from one another (such as ¼ the height of the tray and ½ the length of the box) depending upon manufacturing preferences. 
         [0042]    It is to be understood that the tray and/or shell may be lined with foil, paper, insulating material, or some other type of material to provide additional protection to the product within. It is to be understood that this liner may be perforated such that it is removed at the two or more openings to the package. 
         [0043]    Although various aspects of the disclosed packaging structures have been shown and described, modifications may occur to those skilled in the art upon reading the specification.