Patent Publication Number: US-2011049142-A1

Title: Display ready container

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to containers used for packaging, shipping, and displaying goods. More particularly, the invention relates to containers having a bottom or inner container section for holding goods therein, and an upper or outer cover section for covering the bottom section. 
     2. Description of the Related Art 
     Display ready containers have become very popular, particularly in retail stores where goods for sale are displayed in the container. A typical display ready container has separate top and bottom sections formed from separate corrugated blanks. The bottom section, also referred to as an inner container, has side walls and flaps for forming the container bottom. The upper section, also referred to as the outer cover section, has side walls and flaps for forming the container top. The upper section fits over the side walls of the bottom section to enclose the interior of the container and protect the goods inside. The upper and bottom sections can then be secured together for shipping. Once the container is at the retailer, the upper section can be removed to display the goods within the container. 
     Display ready 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 removes the upper section of the container and places the bottom container section containing the goods on the retail floor. 
     A previous disadvantage of such two piece containers is the number of steps necessary to assemble the container. This disadvantage was overcome with the development of display ready containers that allow for the automation of the set up, packaging and sealing of such containers. One such display ready container is disclosed in U.S. Pat. No. 5,505,368 which is hereby incorporated herein by reference. This patent provides a container assembly having an unopened outer sleeve (that forms the outer cover section when erected), and an unopened inner sleeve (that forms the inner container section when erected) positioned inside the outer sleeve. The inner and outer sleeves, in a flat unopened form also known as a knockdown, are adhered together relative to one another in the positional relationship of the final erected container assembly which allows the top forming flaps of the container assembly to be closed. This allows the container to be filled with goods with the outer cover section (upper section) already secured to the bottom container section. Once the container is filled with the goods, the top forming flaps attached to the outer cover section are folded over and sealed shut to enclose the container for shipment, thereby eliminating the step of placing the outer cover section over the bottom section, and thereby improving the automation of the packaging process. The retailer then separates the two container sections by breaking the adhesive joints between the two container sections, discarding the upper cover section, and using the bottom container section to hold and display goods on the retail floor. 
     One problem with such improved display ready containers is that when breaking the adhesive joints between the two container sections, the outer surface of the inner container can tear, marring the printed image visible to the customer. Accordingly, one object of the present invention is to provide an improved display ready container that avoids this problem. Other advantages will be obvious or may be learned by practice of the invention. 
     SUMMARY OF THE INVENTION 
     In one form the present invention provides a container assembly having an inner container and an outer cover that fits over the inner container. The inner container has multiple wall panels that form inner container sidewalls for holding the goods within the container assembly. The inner container also has a top edge and bottom forming flaps that extend from a bottom end of the side walls to form the container bottom. The outer cover has multiple wall panels that form outer cover sidewalls for fitting over the sidewalls of said inner container, and also has a bottom edge and top forming flaps extending from a top end of the outer cover side walls to form the container top. The inner container is positioned within the outer cover. The outer cover further includes an overlay formed in the outer cover sidewalls by a tear line allowing the overlay to be detached from the outer cover along the tear line. An adhesive secures the inner container and the outer cover together with the adhesive disposed between the inner container side walls and the overlay of the outer cover so that the overlay can remain attached to the inner container over the adhesive when the outer cover is removed from the inner container. Thus, when the outer cover is removed from the inner container, the adhesive joint between the inner container and outer cover is not broken. Instead, the outer cover is detached from the overlay which remains attached to and over the adhesive, thereby avoiding the tearing or marring of the surface of the inner container which might otherwise happen should the adhesive joint be broken. 
     The present invention also provides a container knockdown assembly capable of being erected into a container assembly that has an inner container for holding goods within it and an outer cover enclosing the inner container. The knockdown assembly includes an inner sleeve capable of forming the inner container when the knockdown assembly is erected, and an outer sleeve capable of forming the outer cover when the container assembly is erected. The inner sleeve has first and second inner sleeve walls which include the container sidewalls, a top edge, and a bottom forming flap opposite the top edge which can form the container assembly bottom. The outer sleeve has first and second outer sleeve walls which include the outer cover sidewalls, a bottom edge, and a top forming flap opposite the bottom edge which can form the container assembly top. The inner sleeve is positioned within and relative to the outer sleeve in a positional relationship of the erected container assembly. The outer sleeve further includes an overlay formed in the outer cover sidewalls by a tear line allowing the overlay to be detachable from the outer sleeve along the tear line. Adhesive secures the inner and outer sleeves together in the aligned positional relationship of the erected container assembly, the adhesive being provided between the side walls of the inner sleeve (inner container) and the adhesive overlay of the outer sleeve (outer cover) so that the overlay can remain attached to the inner container over the adhesive if the outer cover is removed from the inner container. The knockdown is ideal for automated packaging equipment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the invention, there are shown in the drawings preferred embodiments. It is understood, however, that this invention is not limited to these embodiments and are to be limited only by the appended claims. 
         FIG. 1  is a perspective view of a container assembly made in accordance with the present invention showing the inner container within the outer cover, and the top flaps folded outwardly; 
         FIG. 2  is a plan view of a blank section for forming the outer container section of the container assembly in  FIG. 1 ; 
         FIG. 3  is a plan view of a blank section for forming the inner section of the container assembly in  FIG. 1 ; 
         FIG. 4  is a perspective view showing a step of making the container assembly of  FIG. 1 , where the inner sleeve is positioned on the inner face of the blank that will form the outer sleeve; 
         FIG. 5  is a perspective view showing a step of making the container assembly of  FIG. 1  that comes after the step shown in  FIG. 4 ; 
         FIG. 6  is an exploded view of the container of  FIG. 1  showing the two container sections separated from one another; 
         FIG. 7  is a cross-sectional view of the container assembly of  FIG. 1  taken along lines  7 - 7 ; 
         FIG. 8  is an exploded view of another embodiment of the present invention showing two container assembly sections separated from one another and the top flaps folded inward to enclose the container; 
         FIG. 9  is a plan view of a blank section for forming the outer container section of the container assembly in  FIG. 8 ; 
         FIG. 10  is a cross-sectional view of the container assembly of  FIG. 8  taken along lines  10 - 10 ; 
         FIG. 11  is an exploded view of a third embodiment of the present invention showing two container sections separated from one another and the top flaps folded inward to enclose the container; 
         FIG. 12  is a plan view of a blank section for forming the outer container section of the container assembly in  FIG. 11 ; and 
         FIG. 13  is a cross-sectional view of the container assembly of  FIG. 11  taken along lines  13 - 13 . 
     
    
    
     DETAILED DESCRIPTION 
     The invention disclosed herein provides a novel container assembly and a container knockdown assembly. Described below are several illustrative embodiments of the invention suited for containers used for shipping and displaying goods for retail. It is understood, however, that the present invention is not so limited and can be adapted to other containers. 
     Reference now will be made in detail to the embodiment shown in  FIGS. 1 through 7 . With initial reference to  FIG. 1 , display ready container assembly  10  has an inner container  12 , shown partially in dotted line where hidden, which is adapted to fit within an outer container cover  14 . These two container sections  12  and  14 , with the inner container  12  fixedly secured within the outer cover  14 , form the display ready container assembly  10 . The inner container  12  holds the goods to be contained within, and the outer cover  14  will ultimately enclose the inner container  12 . The individual display ready container sections  12  and  14  are now described separately in more detail. 
     With further reference to  FIG. 6 , showing the inner container  12  removed from the outer cover  14 , the inner container  12  includes inner container sidewalls  16  which form the front wall  18 , side wall  20 , rear wall  22  and second side wall  24 , and which are attached to one another at corners  26   a,    26   b,    26   c,  and  26   d.  The container sidewalls  16  have a top edge  28  and a lower end  30 . Bottoms forming flaps  32 , which include flaps  32   a,    32   b,    32   c , and  32   d,  attached to and extending from the lower end  30  of the sidewalls  16 , are foldable to form the bottom  34  of the inner container  12 . The sidewalls  16  have an outer surface  36  and an inner surface  38 . A display opening  40  is formed in the front wall  18  as shown. 
     The inner container  12  is preferably formed or cut from a unitary blank  42 , preferably of corrugated paper board as shown in  FIG. 3  which shows the inner surface  38 . A glue tab  44  attached to the end of the side wall  24  is provided to connect one end  46   a  of the blank  42  to the other end  46   b  to form the inner container  12 . Lines of weakness  48 , such as scores or creases formed in corrugated paperboard, define the various sidewalls  16  and bottom forming flaps  32  and predispose the various sidewalls and flaps of the inner container  12  to fold easily along such lines. Any such line of weakness as known as the art may be used. 
     The blank  42  for the inner container  12  is formed preferably into a two sided inner sleeve  50  as shown in  FIG. 4 , also referred to as a knockdown form or state, which can be erected into the inner container  12  as shown in  FIG. 1 . With reference to  FIGS. 3 and 4 , the inner sleeve  50  is formed by folding the side wall  24  and bottom flap  32   d  together as a unit, along the line of weakness  48  that will form the container corner  26   d,  onto the inner face  38  of adjacent side wall panel  22 . Next, adhesive  52 , such as a hot melt glue as known in the industry, is applied to the outside face  36  of the glue tab  44 . Then the front side wall  18  and bottom flap  32   a  are folded as a unit, along the line of weakness  48  that will form the container corner  26   b , onto the inner face  38  of adjacent side panel  20  and a portion of rear wall  22  such that the blank end  46   b  contacts the glue tab  44  to adhesively secure the two walls  18 ,  24  together, and thereby form the two sided inner sleeve  50  as shown in  FIG. 4 . It is seen, with reference to  FIG. 4 , that the sleeve  50  has two sleeve walls  54  and  56  attached to one another at the corners  26   b  and  26   d.  The first sleeve wall  54  (the upper wall) includes the inner container walls  18  and  24  and bottom flaps  32   a  and  32   d  in a substantially same plane, and the second sleeve wall  56  (the lower wall) includes the walls  20  and  22  and bottom flaps  32   b  and  32   c  in a substantially same plane parallel to the first sleeve wall  54 . The corners  26   a  and  26   c  of the inner container  12  are not yet folded or formed. The inner sleeve  50  is erected into the inner container  12  in a manner further described below. 
     The outer cover  14  is now described with reference to  FIGS. 1 ,  2 ,  4 ,  6  and  7 . With initial reference to  FIGS. 6 and 7 , the outer cover  14  includes outer cover sidewalls  58  which form the cover front wall  60 , side wall  62 , rear wall  64  and second side wall  66 , and which are attached to one another at corners  70   a,    70   b,    70   c,  and  70   d.  The sidewalls  58  have a bottom edge  72  and an upper end  74 . Top forming flaps  76 , which include flaps  76   a,    76   b,    76   c , and  76   d  attached to and extending from the upper end  74 , can be folded to form the top  77  of the outer cover  14  as shown in  FIG. 6 . The sidewalls  66  have an outer surface  78  and an inner surface  80 . 
     The outer cover  14  is preferably formed or cut from a unitary blank  82  preferably of corrugated paper board as shown in  FIG. 2  which shows the inner surface  80 . A glue tab  84  attached to the end of side wall  66  connects one end  86   a  of the blank  82  to the other end  86   b  to form the outer cover  14 . Lines of weakness  48  define the various sidewalls  58 , top forming flaps  76  and glue tap  84 , and predispose the various wall and flap panels of the outer cover  14  to fold easily along such lines. 
     The outer cover  14  includes an adhesive overlay  88  formed in the sidewalls  58  of the outer cover  14  by a tear line  90  which allows the overlay  88  to be detached from the outer cover  14  along this tear line. The tear line  90  can be formed in any suitable manner which allows separation of the overlay from the outer cover, such as perforations or cuts in corrugated paperboard. The overlay  88  is used to cover adhesive  96  securing the inner container  12  and outer cover  14  to one another and prevent tearing of the container assembly when the two container assembly sections  12  and  14  are separated from one another. 
     In the presently illustrated embodiment, four overlays  88  are provided. With reference to  FIGS. 1 ,  2 , and  7 , it is seen that the overlays  88  are formed along a section of the bottom edge  72  of the two side walls  62  and  66  of the outer cover  14  and extends vertically there from. The tear line  90 , in conjunction with the bottom edge  72 , defines the overlays  88  and allows the overlays to be separated from the outer cover  14  as illustrated in  FIG. 6 , which shows the overlay  88  detached from the outer cover  14  and attached to the inner container  12  for reasons further discussed below. For the present, it is sufficient to understand that inner container  12  and outer cover  14  are attached or fixed to one another with adhesive at the overlays  88 . 
     Description of the formation of the outer cover  14  from the blank  82  as shown in  FIG. 2  is continued with reference to  FIGS. 2 ,  4  and  5 . The blank  82  for the outer cover  14  is preferably formed into an outer sleeve  92  around the inner sleeve  50  (which forms the inner container  12 ), to form a container knockdown assembly  94  as illustrated in  FIG. 5  (although the final knockdown  94  would be substantially flat after the two sidewalls  60  and  66  are adhered together as further described below). With initial reference to  FIG. 2 , an adhesive  96  is applied to the inner face  80  of the blank  82  within the area defined by the overlays  88 . Any suitable adhesive of sufficient strength and amount can be used, such as hot melt glue. The adhesive should preferably hold the overlays in place and break the tear line  90  when the inner container  14  is removed. Next, as illustrated in  FIG. 4 , the inner sleeve  50  is laid onto the inner face  80  of the blank  82  and positioned relative to the blank  82  in a positional relationship of the inner container  12  and outer cover  14  when the container assembly  10  is erected as shown in  FIG. 1 . Accordingly, in the illustrated embodiment shown in  FIG. 4 , the inner container walls  20  and  22  of the inner sleeve  50  (inner container  12 ) are positioned on and aligned with the outer cover side walls  62  and  64  respectively of the blank  82  (outer cover  14 ); the fold line  48  of the inner sleeve  50  that will form the inner container corner  26   c  is aligned with the fold line  48  that will form the outer cover corner  70   c ; the top edge  28  of the inner container sleeve  12  is aligned with or below the top end  74  of the outer cover side walls  58  so as not to prevent the top forming flaps  76   a,    76   b,    76   c,  and  76   d  from folding to form the top  77  enclosing the erected container  10  as shown in  FIG. 6 . Preferably, as illustrated, the top edge  28  of the inner container sleeve  12  aligns with the top end  74  of the outer cover  14  so that the top edge  28  of the inner container can provide additional support for the top flaps  76  when they are folded. Moreover, it is seen that the overlays  88   a  and  88   b,  with adhesive on the inside face of the overlays, are adhered at this time to the outer face of the sidewall  20  of the inner container sleeve  50 . 
     Next, with further reference to  FIG. 5 , the side wall  66  and top flap  76   d  are folded as a unit along the line of weakness  48  that will form the outer cover corner  70   d,  onto the outside face  36  of side wall  24  of the inner container sleeve  50  (upper container  12 ). The overlays  88   c  and  88   d,  with adhesive  96 , contact and adhere to the outer face of the sidewall  24  of the inner container sleeve  50 . 
     Adhesive  52 , such as a hot melt glue, is then applied to the outside face  78  of the glue tab  84 , and then the front wall  60  and top flap  76   a  of the blank  82  are folded as an integral unit along the line of weakness  48  that will form the container corner  70   b,  onto the outer face  36  of side wall  18  of the inner container sleeve  50  such that the end  86   b  of the blank  82  contacts the adhesive  52  of the glue tab  84 , thereby forming the two sided outer sleeve  92  (outer cover  14 ) which, in combination with the inner sleeve  50  (inner container  12 ), forms the display ready knockdown assembly  94 . It is seen, with reference to  FIG. 5 , that the outer sleeve  92  has two sleeve walls  98  and  100  attached at the corners  70   b  and  70   d.  The first sleeve wall  98 , the upper wall, includes the outer cover walls  60  and  66  and top flaps  76   a  and  76   d  in a substantially same plane as seen in  FIG. 5 . The second sleeve wall  100 , the lower wall, includes the outer cover walls  62  and  64  and top flaps  76   b  and  76   c  in a substantially same plane parallel to the first sleeve wall  98 . The corners  70   a  and  70   c  of the outer cover  14  are not yet folded or formed. The outer sleeve  92  is erected into the outer cover  14  as further described below. 
     Once the outer sleeve  92  is formed with the inner sleeve  50  secured within it, it is seen that a flat container knockdown assembly  94  is formed. Such flat assemblies are efficiently stacked for storage and shipment. 
     The “positional relationship” of the inner container  12  and outer cover  14  of the erected container assembly  10  as discussed above is the relative position of the inner container  12  and outer cover  14  relative to one another in the erected container assembly  12  as seen in  FIG. 1  and as closed as shown in  FIG. 6 . By securing the two sections  12  and  14  at this relative position to one another during the manufacture of the knockdown assembly  94 , it is appreciated that no further handling of the cover  14  relative to the inner container is to be made. For example, with reference to  FIGS. 5 and 1 , the knockdown assembly  94  is opened into the erected configuration of  FIG. 1  and the bottom flaps  32  folded to form the bottom  34 . With the top flaps  76  open, goods can be loaded into the container  12 . Once loaded, the container assembly  10  is closed simply by folding the top flaps  76  of the outer cover  14 . Since the outer cover  14  was previously attached to the inner container  12  at the positional relationship of the erected and closed container assembly  10 , the enclosure process is complete and the container  10  is ready for stacking with other containers and shipping. This eliminates the step of placing a separate outer cover section over an inner container after the loading of the goods. 
     Referring to  FIG. 1 , container knockdown assembly  94  is erected by pushing the corners  70   b  and  70   d  toward each other, folding and forming the corners  70   a  and  70   c  of the outer cover  14  and corners  26   a  and  26   c  of the container  12  until an erected container assembly  10  is formed as shown in  FIG. 1 . It is seen that this opens both of the inner and outer sleeves  50 ,  92  as a single unit. The bottom forming flaps  32  of the inner container  12  are then folded and secured to form the container bottom  34 , allowing the container assembly  10  to be loaded with goods. Once the goods are loaded, the top forming flaps  76  of the outer cover  14  are folded and secured to form the top  77  to enclose the goods within the container  10  for shipment. It is seen that in this preferred embodiment, the height of the sidewalls  16  and  54  of respective inner container  12  and outer cover  14  are substantially the same so that the outer cover  14  fully covers the inner container  12  and positions the overlays  88  along the bottom of the inner container  12 . Moreover, this configuration provides two layers of support on each side of the container assembly  10  which increases the strength of the assembly  10 . 
     As illustrated in  FIG. 6 , the outer cover  14  is removed from the inner container  12  to display the goods held within the inner container  12 . This is accomplished by detaching the overlays  88  from the outer cover  14  and lifting the outer cover  14  from the inner container  12  as shown. Openings  89  are seen in the outer cover  14  from where the overlays  88  were detailed. In one preferred embodiment, using a sufficiently strong adhesive  96  between the overlays  88  and the inner container  14 , each of the lower ends of the outer cover sidewalls  62  and  64  are gripped with a person&#39;s hands between the two overlays  88  and pulled away from the inner container  12  so as to break the overlays  88  from the outer cover  14  along the tear line  90 . 
     Since the inner container  12  may be used to display the goods on the retail floor, the outer face  36  of the side walls  16  may be printed with an esthetic design or some suitable promotional information. The overlays  88 , through which the inner container  12  is adhesively fixed to the outer cover  14 , remains with and adhered to the inner container  12  when the outer cover  14  is removed, thereby avoiding the need to break the adhesive joints between the overlays  88  and the inner container  12 , and thereby prevent the tearing and marring of the outer face  36 . The outer face  78  of the overlays  88  can be printed to match the design on the inner container  12 . 
     The present invention thereby provides a container knockdown assembly  94 , which is simple and efficient to make, and a container assembly  10  which in a preferred form, is easily erected from a knockdown assembly  94 , both of which are improved over previously known display ready containers. 
     A container assembly  120  of a second embodiment of the present invention is now described with reference to  FIGS. 9 and 10 . The container assembly  120  is similar in construction to the container assembly  10  of  FIG. 1  and can be erected from a container knockdown in a similar manner. Accordingly, like elements in the drawings will be referenced with the same reference numbers as those used for the container assembly  10  describe previously. The inner container  12  is identical to that in  FIG. 1 , and overlay  88  is formed as a vertical strip extending vertically from the bottom  72  of the outer cover  14  similar to the overlay  88  of the container assembly  10 . Here, however, there is only one overlay  88  formed in each of the two outer cover sidewalls  62  and  64 , in these overlays  88  extend vertically to near the top end  74  of the side walls  62  to  64 . 
       FIG. 9  shows the inside face  80  of a preferred blank  82   a  for forming the outer cover  14  for the container assembly  120 . It is identical to the blank  82  of the container assembly  10  shown in  FIG. 2  with the exception that the overlays  88  extend vertically from the bottom edge  72  to the top end  74  of the side walls  62  and  66 . A tear line  90  forms the overlays  88 . An adhesive  96  for adhering the outer cover  14  to the inner container  12  is provided. 
     The container assembly  120  can be erected from a knockdown constructed similarly to that described previously with reference to  FIG. 5 . Likewise, the container assembly  120  can be erected from a knockdown assembly in a similar manner as the container assembly  10 . Moreover, the container assembly  120  is erected, filled with goods, and enclosed in a similar manner as container assembly  10 , the main difference being the number and vertical length of the overlays  88 , highlighted in  FIG. 8 , which shows the overlays  88  detached from the outer cover  14  after the outer cover  14  has been removed. 
     A container assembly  140  of a third embodiment is now described with a reference to  FIGS. 11 ,  12  and  13 . The container assembly  140  is similar to the container assemblies  10  and  120  described above with like elements referenced with the same reference numbers. The inner container  12  is identical to those of the two embodiments described previously. 
     Here, the overlay  88  differs from the overlays of the previous two embodiments and is now described in further detail. The overlay  88  includes all of the bottom edge  72  of the outer cover  14  and has a tear line  90  extending horizontally around the perimeter of the outer cover  14  spaced from the lower edge  72 . A tear section  142 , formed as a horizontal tear strip, is likewise formed in the outer cover  14  between the overlay  88  and the remainder  146  of the outer cover  14 . The tear strip  142  can include two tabs  144  separated by cuts  146  which can be gripped and pulled to remove the tear strip  142 . The tear strip has two separation sides, one side (the lower side) formed by the tear line  90  of the overlay  88 , and the other separation side (the upper side) formed by a second tear line  148  between the tear strip  142  and the remainder of the outer cover  14 . 
       FIG. 12  illustrates a preferred blank  82   b  for forming the outer cover  14 , the inner face  80  of the blank being shown. Suitable amounts of adhesive  96  are provided between the overlay  88  of the outer cover  14  and the inner container  12 . A knockdown assembly can be formed with the blank  82   b  for the outer cover  14  and the blank  42  of  FIG. 3  for the inner container  14  in a similar manner as described above with reference to the container assembly  10  of  FIG. 1 . Likewise, the container assembly  140  can be erected from a knockdown assembly in a similar manner as the container assembly  10 . To separate the container sections  12 ,  14 , with specific reference to  FIG. 11 , tab  144  is pulled to remove the tear strip  142  and thereby separate the outer cover  14 , i.e., the remainder  144 , from the inner container  12 . As with the previous embodiments, the overlay  88  remains adhered to the inner container  12  so that the adhesive  96  does not have to be broken, thereby avoiding any marring of the outer surface  36  of the inner container  12 . 
     While particular embodiments of the invention are 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, 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. Additionally, the overlay  88  can take on any suitable shape or configuration, including different widths, heights, and shapes from those illustrated above, as well as different numbers of overlays and alternative placements of the overlays from those illustrated above.