Patent Publication Number: US-2005139502-A1

Title: Innovative shipping package

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application is a continuation-in-part of U.S. patent application Ser. No. 10/668,646, filed Sep. 23, 2003, which is a continuation-in-part (CIP) of 10/388,100, filed Mar. 13, 2003 (now abandoned) which is a continuation of U.S. patent application Ser. No. 09/902,971, which was filed Jul. 11, 2001 and issued as U.S. Pat. No. 6,588,594 the entire contents of each being incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION  
      Devices for packing and shipping products and/or containers of products are known. Such devices are available in a wide variety of shapes, sizes and styles. Often a package is designed to contain a number of different containers, such as several containers of a product, in a single package for delivery from one location to another, such as from a manufacturer to a wholesaler or retail seller. Sometimes the shipping package is also used to display the product once the shipping package is opened at the retail seller.  
      There remains a need for a cost effective low-bulk package which is capable of shipping a small number of containers, and which transitions to a display package and/or is capable of readily transferring the containers directly onto a display shelf, without a need for cutting or tearing of the cardboard or other fairly rigid material of the package, and provides full consumer view and access to the containers, yet also meets the strength, durability, palletizing, and general industry standards for shipping packages of like containers to market.  
      Without limiting the scope of the invention, a brief summary of various embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below.  
      A brief abstract of the technical disclosure in the specification is provided as.  
     BRIEF SUMMARY OF THE INVENTION  
      In one embodiment, the invention is directed to a container package assembly which includes a plurality of trays for supporting containers thereon, a top pad which is placed over the containers and at least one layer of encapsulating film which at least partially covers the combination top pad, containers and trays. The package may be used for shipping and, optionally, for retail display.  
      In at least one embodiment of the invention, the container package assembly comprises two or more trays which are positioned horizontally adjacent to one another. A plurality of containers is disposed on each tray and a top pad extends atop the containers over at least a portion of each of the trays. The trays, containers and top pad are at least partially encapsulated by a polymeric packaging film such as shrink-wrap, stretch-wrap, plastic or other type of thin pliable membrane. The top pad provides stability to the individual containers positioned on the trays during distribution of the shipping package as well as maintaining stability of the entire package by structurally linking the two independent trays.  
      The top pad, in accordance with the invention, typically has a surface area equal to or less than the area of the tray positioned there under.  
      Typically, the trays comprise a fairly rigid horizontal support surface. Desirably, the trays may have one or more vertical sides or walls to help retain the containers on the horizontal support surface. These side walls function to retain the containers on the horizontal support surfaces during the packaging process, during distribution, and during the transfer of the display package to the retail shelf. The walls may be of uniform height, may be tapered, or may have other configurations.  
      In at least one embodiment a tray is provided with three side walls and one “open” side.  
      In some embodiments the product containers to be placed on the tray have a tapered shape such that the bottom of the product container that sits on the support surface of the tray has a smaller diameter than the top of the product container. Where such tapered product containers are present the vertical sides of the tray are constructed to arranged to engage at least a portion of the tapered sides of the product containers adjacent thereto. In some embodiments the length and/or width of the horizontal support surface is less than the effective length and/or width of the arranged tops of the product containers.  
      In some embodiments the assembly comprises a single tray.  
      In some embodiments the top pad and/or layer of encapsulating film are optional or not a required component of the assembly.  
      In some embodiments the assembly is encapsulated in a shipping material other than encapsulating film. For example, in at least one embodiment one or more trays and their associated containers, are placed within or encapsulated in a cardboard or corrugated cardboard box.  
      In at least one embodiment the tray is provided with an adhesive on its surface to at least temporarily engage one or more rows of the product containers positioned thereon. In some embodiments the adhesive is may be a permanent or temporary adhesive, such as a removable adhesive, time release adhesive, biodegradable adhesive and/or any combination thereof. In some embodiments all of the product containers on the tray are at least temporarily affixed to the tray. In some embodiments only some product containers are at least temporarily affixed to the tray.  
      In some embodiments the temporary adhesive is in the form of a line or strip of temporary adhesive which engages the row of products proximate to the open side of the tray. In some embodiments the temporary adhesive is placed in a series of individual distinct spots on the tray surface, with each point corresponding to the eventual position of a single product container.  
      Further aspects of the invention will become apparent form the detailed description which follows. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
      A detailed description of the invention is hereafter described with specific reference being made to the following drawings.  
       FIG. 1  is a perspective view of an embodiment of the invention.  
       FIG. 2  is a perspective view of the embodiment shown in  FIG. 1  wherein the left and right side walls have a tapered height.  
       FIG. 3  is a perspective view of the embodiment shown in  FIG. 2  wherein the assembly is shown with no top pad.  
       FIG. 4  is a perspective view of an embodiment of the invention wherein the assembly is provided with a single tray configuration.  
       FIG. 5  is a perspective view of the embodiment shown in  FIG. 4  wherein the assembly is shown with no top pad.  
       FIG. 6  is a perspective view of the embodiment shown in  FIG. 4  wherein the assembly is shown with no encapsulating film.  
       FIG. 7  is a perspective view of the embodiment shown in  FIG. 4  wherein the assembly is shown with no top pad and no encapsulating film.  
       FIG. 8  is a perspective view of an embodiment shown in  FIG. 7  wherein the product containers have a tapered vertical shape and wherein the tray is configured to have side walls that abut the product containers adjacent thereto.  
       FIG. 9  is a perspective view of the embodiment shown in  FIG. 8  wherein the assembly is shown with encapsulating film but without a top pad.  
       FIG. 10  is a perspective view of the embodiment shown in  FIG. 8  wherein the assembly is shown with a top pad and with encapsulating film.  
       FIG. 11  is an exploded view of an embodiment of the invention wherein the tray is provided with at least one strip of adhesive to engage the bottom one or more rows of product containers placed thereon.  
       FIG. 12  is a perspective view of the embodiment shown in  FIG. 11  wherein the adhesive is provided in individual areas corresponding to the bottom of one or more individual product containers.  
       FIG. 13  is a perspective view of the embodiment shown in  FIG. 12  wherein the tray is provided with an individual spot of adhesive to correspond to each and every product container.  
       FIGS. 14-17  is a series of perspective views of an embodiment of the invention which depicts a method of encapsulating one or more of the assemblies shown in  FIG. 8  within a shipping container.  
       FIGS. 18-20  is a perspective view of an exemplary retail display wherein a method of transferring product containers from the assembly tray to the display is shown. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      While this invention may be embodied in many different forms, there are described in detail herein specific embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.  
      For the purposes of this disclosure, unless otherwise indicated, identical reference numerals used in different figures refer to the same component.  
      An embodiment of the inventive container package assembly is shown generally at  10  in  FIG. 1 . In the embodiment of  FIG. 1 , the container package assembly  10 , comprises a pair of support members or trays  12 . The edges of each tray  12  are defined by three side walls  14  and an open side  16 . The trays  12  may be constructed of any substantially rigid material suitable for shipping and displaying containers  20 . For example, the trays may be constructed from cardboard (corrugated or otherwise), press-board, chipboard, SBS board, wood, one or more paper product derivative, plastic, metal or other materials. Preferably, the trays are constructed from a light weight material that may be easily and inexpensively recycled or disposed of Trays  12  support a plurality of containers  20  as shown.  
      The containers  20  may be arranged on a tray  12  in any manner desired. For improved stability and strength, the containers are preferably arranged in a uniform pattern of rows and or columns. Such an arrangement has the added benefit of providing ready viewability and ease of access when the trays  12  of containers  20  are placed in a retail environment.  
      Once the containers  20  are placed on the trays  12  in a desired arrangement, a top pad  22  is placed on top of the containers  20 . The top pad  22  may have a horizontal surface  24  having an area which extends at least partially over each of the trays  12 . The horizontal surface  24  of the top pad  22  may be greater than, equal to, or less than the area of the combined trays  12  positioned there under. Typically, the top pad will have an area slightly less than the combined area of the trays over which the top pad extends. Once the top pad  22  is in place on top of the containers  20 , the combined assembly of trays  12 , containers  20 , and top pad  22  may be in-whole or in-part encapsulated by a film  30 .  
      The top pad  22  forms a supporting linkage between the trays  12 . The top pad  22  may further act as a cutting surface once the package assembly  10  is received in a retail environment. The film  30  may be cut and opened, through application of a knife or other cutting means. The presence of the top pad  22  prevents the cutting means from contacting and damaging the containers  20  positioned there under. After the film  30  is cut and the assembly  10  opened, the top pad  22  may then be removed from the containers  20 , and the two independent trays  12  may be used as shelf ready displays.  
      While the use of a top pad  22  is often desired to provide additional support and structural rigidity to assembly configurations, such as those depicted in  FIGS. 1 and 2 , the use of a top pad on all assemblies  10  is not required. For example, in the embodiment shown in  FIG. 3 , the package assembly  10  is not provided with a unitizing top pad, such as is shown in  FIGS. 1 and 2 . In embodiments such as that which is shown in  FIG. 3  the nature and/or relationship of the particular types of product containers  20 , the configuration and relationship of the trays  12  and/or the nature of the encapsulating wrap  30  may act to provide the desired strength and rigidity characteristics otherwise provided by the top pad.  
      In the various embodiments of the invention where the package  10  includes an encapsulating film  30 , the film  30  may be any type of retaining film or material. For example the film  30  may be shrink-wrap, stretch wrap, plastic sheeting or netting, or any other type of retaining material. The film  30  may partially or entirely encapsulate the entire combination of trays  12 , containers  20 , and the optional top pad  22 , such as is in the manner shown in  FIGS. 1-3 . The film  30  may be transparent, translucent or opaque; however, a transparent film may be more preferable for retail display purposes as it is desirable to allow wholesale or retail consumers to be able to view the containers  20  even when the film  30  is in place.  
      In the various embodiments shown and described herein each tray  12  comprises a horizontal support surface  40  upon which the containers  20  are placed along with the three side walls  14  and an open side  16 . A three-walled tray provides improved stability while ensuring that the “front” or label information of the containers  20  is fully exposed for retail viewing.  
      As shown in  FIGS. 1 and 3  two of the side walls  14 , such as right side wall  17  and left side wall  18  optionally taper from a greater height at the back wall  19  of the tray to a lesser height at the open front side  16  the tray. The extent of the taper may vary greatly. Alternatively, the side walls may also be of uniform height as shown in  FIG. 2 . In some embodiments the side walls  14  may have any of a variety of height configurations.  
      The inclusion of walls  14  on the trays  12 , improves the stability of the package  10 , by confining the containers  20  within the confines of the tray  12 . The use of walls  14  may help retain the containers  20  on the trays  12  even when the film  30  is removed. As is discussed in greater detail below the height of the walls as well as their proximity to the product containers  20  also affects stability of the package  10 .  
      In the embodiments shown in  FIGS. 1-3  the package  10  is shown comprising at least two trays  12 , in a side by side arrangement. In some embodiments however, it is desired to provide a package assembly having only a single tray  12 , such as is shown in  FIGS. 4-10 .  
      As mentioned above, in multiple tray package assemblies, such as those depicted in  FIGS. 1-2 , the top pad  22  acts as a unitizing structure which provides reinforcing strength and rigidity to the assembly  10 . The use of encapsulating film  30 , also adds stability to the multiple tray assembly by securing the trays  12  and/or product containers  20  together in a single package, such as is illustrated by the embodiment shown in  FIG. 3 . In single tray assemblies however, such as are shown in  FIGS. 4-10  the presence of only a single tray  12  within the assembly  10  reduces much of the need of extra reinforcing mechanisms such as the top pad and/or film, though such elements may still be utilized individually or in combination.  
      For example, in the embodiment shown in  FIG. 4 , a package assembly  10  is shown wherein the assembly is comprised of only a single tray  12 , which supports a plurality of containers  20 , and which further comprises a top pad  22  and encapsulating film  30 . Though the assembly is provided with only a single tray  12 , in many instances it may still be desirable to provide the assembly with additional support and/or strength, such as is provided by the use of a top pad  22  and/or encapsulating film  30 . For example, where the product containers  20  are particularly large, heavy, and/or it is desirable to minimize or limit their potential movement (e.g. fragility, etc), the additional top pad  22 , and/or encapsulating film  30  may be utilized to provide additional support to the assembly by minimize flexing of the tray  12  and unitizing the product containers  20  on both their bottom and top surfaces.  
      Depending on the nature of the product containers, the shipping conditions, display conditions, etc. it may be more cost effective to eliminate the top pad from the assembly  10  such as in the manner shown in  FIG. 5 . Alternatively, the top pad  22  may by provided to the assembly  10 , but the encapsulating film left out, such as in the embodiment depicted in  FIG. 6 . A package assembly  10 , such as is shown in  FIG. 7 , may similarly be provided wherein both the top pad and film are avoided.  
      Reducing the components of the package assembly  10 , by avoiding the use of a top pad and/or encapsulating film may naturally provide for a less stable shipping package. Such instability however may be offset in a number of ways. For example in the embodiment depicted in  FIG. 7  the vertical side walls  14  of the tray  12  may be configured to abut or engage the sides  50  of the containers  20  which are adjacent thereto. In at least one embodiment the shape of one or both of the containers  20  and side walls  14  may be configured for complementary engagement (such as for example by scalloping the side walls  14  to provide gripping regions for the product containers  20 , etc.). By providing a tray  12  with a size and shape such that position of the side walls  14  confine the support surface  40  of the tray  12  to closely match the dimensions of the space needed for the arrangement of product containers  20  thereon, the stability of the assembly  10  may be enhanced.  
      In some embodiments however the particular dimensions of the support surface  40  of the tray  12  is not as significant to pack stability as the relationship between the product containers  20  and the side walls  14 . For example, as is shown in  FIGS. 8-10 , product containers may often time have a shape other that cylindrical. In the embodiments shown, the product containers  20  have a tapered or inverted frusto-conical shape wherein the area of an individual product container&#39;s base or bottom  52  is less than that of the product container&#39;s top portion  54 .  
      With such tapered containers  20  the dimensions of the support surface of the tray  12  may be configured to substantially match the general length and width dimensions of the arranged of the container bases  52 . However in such an embodiment the side walls  14  would necessarily be forced to angle outward from the support surface  40  in order to follow the angle defined by the sides  50  of the product containers  20 . An alternative configuration is that which is shown in  FIGS. 8-10  wherein the support surface  40  of the tray is somewhat larger in length and width than the general length and width dimensions of the arranged of the container bases  52  so that the side walls  14  maintain their substantially vertical orientation relative to the support surface  40 . The side walls  14 , are configured however to engage at least the sides  50  of each product container  20  adjacent thereto.  
      The engagement of the side walls  14  against the sides  50  of the tapered containers  20  may be made more secure by providing the package assembly  10  with encapsulating film  30  such as is shown in  FIG. 9 . A top pad  22  may also be utilized to provide the assembly  10  with increased stability as well, such as is shown in the embodiment of  FIG. 10 .  
      As discussed above the stability, strength, and other characteristics of the package assembly may be modified or enhanced through the use of particular tray configurations, product container configurations, the optional use of a top pad, encapsulating film, etc. Yet another way in which the stability of the package assembly may be improved is through the use of one or more adhesives between the tray and the product containers contained placed thereon.  
      Any type of adhesive may be used to secure product containers  20  to the support surface  40  of the tray  12 . It is preferable however, particularly in applications wherein the product containers  20  will eventually be placed in a retail setting, that the adhesive be a temporary bond self-removing adhesive, a time release adhesive, a biodegradable adhesive, etc. Some examples of suitable adhesives are described in U.S. Pat. Nos. 6,182,422, 6,499,596; as well as in U.S. Pub. App. No. 2003-0150760-A1 the entire contents of each of which are incorporated herein by reference. In at least one embodiment the adhesive is a temporary bond self-releasing adhesive with a viscosity of less than about 1800 centipoises. In some embodiments the temporary bond self-releasing adhesive has a viscosity of less than about 1500 centipoises.  
      In typical packaging systems, an adhesive is applied to the packaging substrate in one or more strips or “lines” which are positioned to correspond to each row or column of product containers so that all of the containers are adhesively engaged to the packaging substrate. While engagement of all of the containers to the substrate in this manner provides for a high degree of stability between the substrate and product, engagement of all the containers to the substrate is may not be necessary For example, in the embodiment depicted in  FIG. 11 , the unique three sided tray  12  provides a support surface  40  which is open on only one side  16 . Because the walls  14  act to substantially contain the product containers  20  on the support surface  40  of the tray, a single strip or line  62  of adhesive  60  may be provide under only those product containers  20  immediately adjacent to the open side  16  of the tray  12  to adequately secure all of the containers  20  on the tray  12 .  
      In at least one embodiment, an example of which is shown in  FIG. 12  adhesive  60  is selectively applied to the tray  12  in individual areas or “spots”  64 , rather than one or more “lines” such as described above. Each spot  64  is positioned on the support surface  40  to correspond to the eventual position of at least a portion of each container&#39;s base  52 . Through the use of computer controlled adhesive applicators or “guns” (not shown) the spots of adhesive may be very precisely sized and arranged to minimize the amount of adhesive necessary to secure a product container  20  to the support surface  40 . As shown in  FIG. 12 a  spot  64  of adhesive  60  is provided only to each of the product containers immediately adjacent to the open side  16  of the tray  12 . If desired, all of the product containers  20  on a tray  12  may be provided with adhesive spots  64 , such as is shown in  FIG. 13 .  
      In some embodiments of the invention, particularly those wherein the adhesive described above is utilized, a tray  12  and its associated product containers  20 , may be readily placed within a box or other conventional shipping container  70  such as is shown in  FIGS. 14-17 . In at least one embodiment, wherein the product containers  20  are adhesively engaged to the tray  12 , the combined tray  12  and it products  20  may be lifted (by the product containers  20  or by the tray  12 ) or otherwise mechanically placed into the shipping container  70 . Depending on the manner in which the tray  12  and products  20  are eventually encapsulated within container  70  the use of an adhesive may be unnecessary or limited to only specific containers such as has been described above.  
      If desired the tray  12  and product containers  20  may be provided with a top pad and/or encapsulating film in the manner previously described.  
      As indicated the shipping container  70  may be any type of conventional shipping container, such for example a corrugated cardboard box, a wooden shipping container, etc. Any type of container may be utilized in the manner shown in  FIGS. 14-17 .  
      As illustrated in  FIG. 15 , multiple levels of trays  12  may be placed within the shipping container  70 . While in the embodiment shown only two levels of trays and products are depicted, depending on the size and weight of the products  20  and the strength of the shipping container  70 , additional levels may be contained within a given shipping container. In some embodiments, a shipping container  70  may be configured to contain multiple columns of trays and products as well.  
      As shown in  FIG. 16  when the shipping container  70  has a sufficient quantity of trays and products  20  contained therein, the shipping container may be sealed in any conventional way for delivery. In some embodiments however, a top pad  22  may be provided on the top level of products  20  to protect the products from contact with implements such as for example a box cutter when the shipping container  70  is opened subsequent to delivery. In at least one embodiment the top pad  22  is provided with indicia  80  such as labeling and/or barcode information which identifies the product containers thereunder. In some embodiments a top pad may be provided between each level of product trays in the same shipping container in order to identify each level of product. Such use of top pads between levels is particularly useful if the products on different levels are themselves different.  
      As previously mentioned, the three-sided tray  12  described above is particularly suited to act as a display tray in a retail setting. It is recognized however, that in some retail settings it is preferable to place the product containers  20  directly onto a display shelf  90  such as is shown in  FIGS. 18-20 .  
      In such instances, the open side  16  of the three-sided tray  12  makes it particularly easy to unload product containers  20  directly from the tray  12  to the display shelf  90  with a minimum of effort. As is shown in  FIGS. 18-20  by simply aligning the open side  16  of the tray  12  with the empty region  92  of the shelf  90  and then pushing the product containers  20  onto the shelf  90  a self can be readily and efficiently restocked. The now empty tray  12  may be discarded, recycled or reused.  
      In the various embodiments depicted herein, the assembly may be provided with any of a variety of containers, which may be varied in size, shape, number, and arrangement. Similarly, the support members, including the walls thereof and the top pad may likewise be provided in a variety of shapes and sizes.  
      The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.  
      Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim  1  should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.