Patent Publication Number: US-11396398-B2

Title: Shipping and display container and method of making the same

Description:
PRIORITY CLAIM 
     This divisional patent application claims priority to U.S. patent application Ser. No. 16/067,979 filed on Jul. 3, 2018. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates, in general, to stackable containers which are effective for shipping goods to a point of sale and for being easily and reliably converted into a merchandise display case after delivery. 
     BACKGROUND 
     Containers made of corrugated fiberboard are in widespread use for shipping and selling goods. Flat sheets of corrugated fiberboard, referred to as blanks, are typically used as starting material to form corrugated containers such as boxes. One or more blanks may be cut to a desired shape, having a plurality of sections that will form side panels, end panels, top flaps, bottom sections, and other components of a box. The panels are generally defined by scored, perforated, slotted or cut lines in locations which form joints where the blank is folded into an assembled box. Some sections of a blank may be attached to other sections by adhering means, for example, glue or double-sided tape. 
     There is an increasing demand for multipurpose shipping containers that can be quickly and efficiently converted into display cases. Such containers minimize the amount of container material while maximizing the display space available. They also minimize the amount of time and labor a retail establishment must provide to display goods for sale. 
     In order to be economically viable, the containers must be capable of being shipped in flattened form to the location where the goods will be packaged, then assembled, or erected, into box form. The flattened forms are known in the industry as knocked down flats (KDFs) or pre-assemblies, because the flattened forms have panels which are glued or otherwise joined together, such that the box is in a pre-assembled state. Assembling or erecting the boxes requires that panels be squared up, flaps folded, and typically tape applied one or more flaps to maintain the box in an assembled state. It is desirable to use as little corrugated material as needed to deliver a box with the required strength that is easily assembled into box form. 
     A blank or blanks constructed from a material which may be easily cut, scored and folded, such as corrugated fiberboard, may be configured into pre-assembled boxes (KDFs). These flattened forms may have members or panels which have been affixed to one another but not finally erected or assembled into a box. Thus, the KDFs may be shipped more 35 efficiently in flattened form and subsequently erected or assembled into boxes when a shipping container is required. The filled boxes may then be shipped to a point of sale where they are converted into a display case by removing a window panel which has been designed to tear away from the box. 
     Once the boxes are formed and filled, they are typically sealed by sequentially folding and overlapping the top and bottom panels and securing them with adhering means, for example, tape. Standard shipping practices call for filled boxes to be stacked into pallet loads requiring the boxes to be strong enough to be stacked in multiple layers when filled with goods. 
     Constructing containers that are constructed to be in a knock-down flat configuration when not filled with product typically requires a relatively complex blank and a relatively 10 complex assembly process—typically requiring manual labor, which results in relatively high manufacturing costs. 
     Upon delivery to a retail establishment, it is desirable that the boxes be easily and reliably converted into attractive display cases, preferably without the need for cutting tools which create a workplace safety hazard and risk of damage to the goods. A removable (or tear away) window is one means of providing such conversion. In prior container designs, however, tear away windows frequently do not open quickly or easily to form display cases, or they may do so in a way that rips the corrugated material or leaves jagged openings which create unattractive displays. In addition, many removable windows of prior designs are also susceptible to being prematurely separated from the box. 
     It is also desirable for such boxes to be stacked when on display, in order to optimize floor or shelf space. Many prior art containers do not have sufficient strength to support the weight of goods and containers. This either limits the height of displays and/or results in a damaged or unattractive display. 
     Prior designs for multipurpose shipping boxes which convert into display cases suffer from a number of other disadvantages. They may be labor intensive or expensive to manufacture and assemble. They may require excessive materials or elaborate construction to meet the need for strength and the ability to open into a display case. Some designs may require retail employees to use cutting tools to open the boxes, creating the risk of workplace injury or damage to products inside the boxes. 
     Therefore, there is an unmet need for a multipurpose shipping container that is economical to build, uses as little material as possible, is easy to assemble, and is strong, stackable, and efficiently and reliably converts into an attractive retail display case. There is also a need to provide a method of manufacturing such multipurpose shipping containers and their associated pre-assembled knock down flat formations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Configurations for a shipping, storage and display box, blanks for forming the box, and related methods according to the present invention are further described with reference to the accompanying drawings. 
         FIG. 1  is a plan view of a unitary blank according to a first exemplary embodiment of the present invention; 
         FIG. 2  is a plan view of a unitary blank according to a second exemplary embodiment of the present invention; 
         FIG. 3  is a plan view of the blank of  FIG. 2 , shown with adhesive applied to the inner front panel and showing the axis along about which the inner portion is rotated in order to position it atop the outer portion; 
         FIG. 4  is a plan view of the blank of  FIG. 2 , shown with the inner portion having been folded and positioned atop the outer portion; 
         FIG. 5  is a plan view of the blank of  FIG. 2 , shown with the inner right back panel folded over the inner right side panel; 
         FIG. 6  is a plan view of the blank of  FIG. 2 , shown with the outer right back panel folded over the outer and inner right side panels; 
         FIG. 7  is a plan view of the blank of  FIG. 2 , shown with the inner left side panel folded inwardly along a joint between the inner left side panel and the inner front panel; 
         FIG. 8  is a plan view of the blank of  FIG. 2 , shown with the outer left side panel folded along a joint between the outer left side panel and the outer front panel, which is a now a fully assembled know down flat; 
         FIG. 9  is a front right perspective view of a fully assemble box constructed from the blank of  FIG. 2  and erected from the knock down flat of  FIG. 8 ; 
         FIG. 10  is a top view of the assembled box of  FIG. 9 , shown with the top flaps open; 
         FIG. 11  is a front right perspective view of the container of  FIG. 9 , shown with the window removed; 
         FIG. 12A  is a plan view of first blank that forms the inner portion of a box of third exemplary embodiment; 
         FIG. 12B  is a plan view of a second blank that forms the inner portion of the box of the third exemplary embodiment; 
         FIG. 12C  is a plan view of the first blank of  FIG. 12A  positioned atop the second blank of  FIG. 12B ; 
         FIG. 13  is an enlarged partial view of the inner front panel of  FIG. 2 ; and 
         FIG. 14  is an enlarged partial view of the top right corner of the fully assembled box if  FIG. 9 , shown with the top back major flap taped down. 
     
    
    
     SUMMARY OF THE INVENTION 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. 
     Described embodiments, as described below and as defined by the claims which follow, comprise improvements to the structure and methods of making a container that is designed to be converted into a display. 
     Several specific aspects of the apparatus and methods of the present invention are outlined below. 
     Aspect 1: A container comprising:
         an outer portion comprising an outer front panel having an outer fixed portion an outer removable portion, an outer left side panel extending from a left edge of the outer front panel, an outer right side panel extending from a right edge of the outer front panel, and at least one outer back panel, the outer front panel, the outer left side panel, the outer right side panel, and the at least one outer back panel forming an enclosed perimeter wall;   an inner portion comprising an inner front panel having an inner fixed portion and an inner removable portion, an inner left side panel, an inner right side panel, an inner left back panel, an inner right back panel, the inner front panel being affixed to the outer front panel, the inner back left back panel and the inner right back panel being affixed to the at least one outer back panel, the inner left side panel extending from the inner front panel to the inner left back panel in spaced apart relation to the outer left side panel, the inner right side panel extending from the inner front panel to the inner right back panel in spaced apart relation to the outer right side panel;   a top front major flap extending from one of the outer front panel and the inner front panel, a top left minor flap extending from the outer left side panel, a top right minor flap extending from the outer right side panel, and at least one top back major flap, each of the at least one top back major flap extending from one of at least one outer back panel, the top front major flap, a top left minor flap, the top right minor flap, and the at least one top back major flap being shaped and positioned to form a substantially enclosed top surface;   a bottom front major flap extending from one of the outer front panel and the inner front panel, a bottom left minor flap extending from the outer left side panel, a bottom right minor flap extending from the outer right side panel, and at least one bottom back major flap, each of the at least one bottom back major flap extending from one of at least one outer back panel, the bottom front major flap, a bottom left minor flap, the bottom right minor flap, and the at least one bottom back major flap being shaped and positioned to form a substantially enclosed bottom surface;   a removable window comprising the outer removable portion and the inner removable portion; and   an inner separation line that defines a border between the inner fixed portion and the inner removable portion and an outer separation line that defines a border between the outer fixed portion and the outer removable portion.       

     Aspect 2: A method of forming a container, comprising:
         (a) providing an outer portion comprising an outer front panel, an outer left side panel located adjacent to a left edge of the outer front panel, an outer right side panel located adjacent a right edge of the outer front panel, and at least one outer back panel, the outer front panel, the outer left side panel;   (b) providing an inner portion comprising an inner front panel having an inner fixed portion, an inner left side panel, an inner right side panel, an inner left back panel, an inner right back panel;   (c) providing a top front major flap extending from one of the outer front panel and the inner front panel, a top left minor flap extending from the outer left side panel, a top right minor flap extending from the outer right side panel, and at least one top back major flap, each of the at least one top back major flap extending from one of at least one outer back panel, the top front major flap, a top left minor flap, the top right minor flap, and the at least one top back major flap being shaped and positioned to form a substantially enclosed top surface;   (d) providing an outer separation line in the outer front panel that defines a border between an outer removable portion and an outer fixed portion;   (e) providing an inner separation line in the inner front panel that defines a border between an inner removable portion and an inner fixed portion;   (f) providing a bottom front major flap extending from one of the outer removable portion and the inner removable portion, a bottom left minor flap extending from the outer left side panel, a bottom right minor flap extending from the outer right side panel, and at least one bottom back major flap, each of the at least one bottom back major flap extending from one of at least one outer back panel, the bottom front major flap, a bottom left minor flap, the bottom right minor flap, and the at least one bottom back major flap being adapted to form a substantially enclosed bottom surface;   (g) positioning the inner portion atop the outer portion so that the inner removable portion overlaps with at least a portion of the outer removable portion;   (h) affixing the inner front panel to an inner side of the outer front panel in the position of step (g);   (i) affixing the inner left back panel and the inner right back panel to an inner side of the at least one outer back panel in a location that results in the inner left side panel extending from the inner front panel to the inner back left panel in spaced apart relation to the outer left side panel and the inner right side panel extending from the inner front panel to the inner back right panel in spaced apart relation to the outer right side panel; and   (j) forming an enclosed perimeter wall comprising the outer front panel, the outer left side panel, the outer right side panel, and the at least one outer back panel.       

     Aspect 3: A container comprising:
         an outer front panel having an outer fixed portion and an outer removable portion, an inner front panel having an inner fixed portion and an inner removable portion, an outer left side panel located adjacent to a left edge of the outer front panel, an outer right side panel located adjacent a right edge of the outer front panel, and at least one outer back panel, the outer front panel, the outer left side panel, the outer right side panel, and the at least one outer back panel forming an enclosed perimeter wall, the inner front panel being affixed to the outer front panel;   a top front major flap extending from one of the outer front panel and the inner front panel, a top left minor flap extending from the outer left side panel, a top right minor flap extending from the outer right side panel, and at least one top back major flap, each of the at least one top back major flap extending from one of at least one outer back panel, the top front major flap, a top left minor flap, the top right minor flap, and the at least one top back major flap being shaped and positioned to form a substantially enclosed top surface;   a floor that forms a substantially enclosed bottom surface;   a removable window comprising the inner removable portion and the outer removable portion;   a plurality of projections, each of the plurality of projections being part of one of an inner separation line and an outer separation line;   wherein when the removable window is separated from the container, the removable window is adapted to separate from the outer fixed portion along the outer separation line and to separate from the inner fixed portion along the inner separation line;   wherein when the removable window is attached to the container, any of the plurality of projections that is part of the outer fixed portion overlap with the inner removable portion, any of the plurality of projections that is part of the outer removable portion overlaps with the inner fixed portion, any of the plurality of projections that is part of the inner fixed portion overlap with the outer removable portion, any of the plurality of projections that is part of the inner removable portion overlaps with the outer fixed portion.       

     Aspect 4: A corrugated fiberboard blank comprising:
         an outer portion comprising an outer front panel having an outer fixed portion and an outer removable portion, an outer left side panel located adjacent to a left edge of the outer front panel, an outer right side panel located adjacent a right edge of the outer front panel, a left outer back panel located adjacent to a left edge of the outer left side panel, a right outer back panel located adjacent to a right edge of the outer right side panel;   the outer front panel, the outer left side panel, the outer right side panel, and the at least one outer back panel forming an enclosed perimeter wall;   an inner portion comprising an inner front panel having an inner fixed portion and an inner removable portion, an inner left side panel adjacent to a left edge of the inner front panel, an inner right side panel adjacent to a right edge of the inner front panel, an inner left back panel adjacent to a left edge of the inner left side panel, an inner right back panel adjacent to a right edge of the inner right side panel,   a top front major flap extending attached at an upper edge of one of the outer front panel and the inner front panel, a top left minor flap extending from an upper edge of the outer left side panel, a top right minor flap extending an upper edge of the outer right side panel, a left top back major flap extending from an upper edge of the left outer back panel, a right top back major flap extending from an upper edge of the right outer back panel,   a bottom front major flap extending from a bottom edge of the outer front panel, a bottom left minor flap extending from a bottom edge of the outer left side panel, a bottom right minor flap extending from a lower edge of the outer right side panel, a left bottom back major flap extending from a bottom edge of the left outer back panel, a right bottom back major flap extending from a bottom edge of the right outer back panel;   an outer separation line that defines a border between the outer fixed portion and the outer removable portion, an inner separation line the defines a border between the inner fixed portion and the outer removable portion;   a plurality of connection tabs that connect the inner portion to the outer portion, each of the plurality of tabs being located within one of the bottom right minor flap and the left bottom back major flap;   wherein the inner portion is connected to the outer portion only by the plurality of connection tabs.       

     DETAILED DESCRIPTION OF THE INVENTION 
     The ensuing detailed description provides preferred exemplary embodiments and/or example configurations illustrating features and combinations of features of the inventions, and is not intended to limit the scope, applicability, or configuration of the herein disclosed inventions. Rather, the ensuing detailed description of the preferred exemplary embodiments and example configurations will provide those skilled in the art with an enabling description for implementing preferred exemplary embodiments and other example configurations in accordance with the invention. It is understood that various changes maybe made in the function and arrangement of elements, the features and combination of features and other aspects of the invention without departing from the spirit and scope of the invention, as set forth in the appended claims. 
     To aid in describing the invention, directional terms may be used in the specification and claims to describe portions of the present invention e.g., upper, lower, left, right, etc., which generally applies to the box or components when oriented in their typical usage configuration, such as with the bottom of the box being oriented in a horizontal direction or with the blank lying flat. These directional definitions are merely intended to assist in describing and claiming the invention and are not intended to limit the invention in any way. In addition, reference numerals that are introduced in the specification in association with a drawing figure may be repeated in one or more subsequent figures without additional description in the specification, to provide context for other features. 
     Embodiments and example configurations of the present invention disclosed herein describe a multipurpose box designed for storing, shipping and displaying items offered for sale in retail stores. The box is strong, cost effective to manufacture, stackable, and easily and reliably convertible into a retail display. The box may be constructed from one or more corrugated fiberboard blanks or other similar material. The blanks and/or KDFs and/or containers of the embodiments and configurations described herein are typically manufactured using corrugated fiberboard, for example. It is to be understood that the principles in one or more of the embodiments and/or configurations of this disclosure may be made to containers made of other materials, shapes or styles. 
     As used herein, the terms “adhered” or “affixed” (and other formatives of these terms) are intended to mean that one surface is attached to another using an adhesive, such as glue, tape, cement, or paste. The adhesive may be placed on either one or both of the surfaces being adhered. Adhesive materials are represented in the drawings as “X”s or striped tape. 
     As used herein, the terms “major” or “minor” are intended to mean the larger dimension of an element or group of elements. For example, a minor flap is shorter in length than a major flap for that same container. 
     As used herein, the term “blank” means a planar piece of material that has been cut into a shape that is then used to create a container. 
     As used herein, a “unitary blank” means a blank that consists of single sheet of material, for example corrugated fiberboard, at the start of assembly process. In the case of a multi-layer box (such as those disclosed in this application), all of the layers are included in the unitary blank and none of the layers that form part of the finished box are separated from each other before being positioned and affixed to each other. 
     As used herein the terms “cut” and “cut line” mean a continuous incision in the material which penetrates the entire thickness of the material. 
     As used herein the term “perforation” means an alternating pattern of cuts and connected portions in the material. As used herein, the term “nick” means a portion of 15 material, preferably between 1/32 and ⅛ inch in width, which connects two adjacent portions of a material and is located along a line along which the two pieces of material are cut apart. A “nick” is distinguished from a perforation in that each nick is located along a line or curve in which the materials are separated by cut portions on either side of the nick and the cut portions are preferably at least five times (more preferably, at least ten times) the width of each nick. Perforations are characterized by alternating connected and cut portions which are much more proportional in size (typically a width difference of no more than 2-3 times between connected portions and cut portions). A nick can be formed by grinding away a small portion of the cutting die knife rule. 
     As used herein the terms “score” and “score line” mean a crease or shallow cut that does not fully penetrate the entire thickness of the material which serves to make folding the material easier along the score line than along an unscored line. The score acts as a joint in the material, along which portions of the material may be more easily folded. 
     As used herein, the term “separation line” means a line or curve formed of any combination of cut, nicked, and perforated portions that defines a border between two adjacent, connected elements. The weakened connection provided by the separation line enables the elements adjacent to the separation line to be more easily and predictably separated along the separation line than if the separation line were not present. 
     As used herein, the term “corrugated” means a material consisting primary of a fluted corrugated sheet and at least one flat linerboard. 
     A first exemplary embodiment of a blank  1100  that is used to form a container is shown in  FIG. 1 .  FIG. 1  shows the pattern of panels, flaps, cuts, perforations, nicks and scores which are created in the corrugated material to create the blank  1100 , which will be folded into a KDF, and can subsequently be assembled into a box. In this example, blank  1100  is a single, unitary blank. The blank  1100  includes an inner portion  1220  and an outer portion  1190 . As described in greater detail below, the inner portion  1220  is contained within the outer portion  1190  when the box is fully assembled.  FIG. 2  shows a second embodiment of a blank  2100  of the present invention which is also created from a unitary blank and has the same configuration panels and flaps as the blank  1100  of  FIG. 1 . An advantage of using a unitary blank is that it simplifies the KDF assembly process by eliminating the need to align separate blanks when forming a multi-layer box. 
     The blank  1100  is preferably scored along joints  1152 ,  1154 ,  1156 ,  1158 ,  1160 ,  1201 ,  1203 ,  1205 ,  1207  and  1209  to form panels which, when folded along the scored lines, will form the side panels, end panels, top flaps and bottom of the box. The scored lines serve as joints such that adjacent panels of the blank may be folded along the scored lines such that a substantially right angle exists at each joint. Some structural features may utilize joints forming angles which are not substantially right angles. Joints and other features of the box may alternatively make use of cuts, nicks and perforations in the blank. It should be noted that, in order to comply with the limitations of black and white formal patent drawings, the symbols used in the drawings to identify scores, cuts, nicks, and perforations are different that those typically used in technical drawings in the art. 
     Each panel and flap of the blank  1200  has an inside and outside surface. When the box is assembled, the inner portion  1220  is generally contained within the outer portion  1190 . Unless otherwise specified herein “inner” and “outer” refer to the relative position of blanks, panels and other features when the box is fully assembled and erected. 
     The outer portion  1190  includes a plurality of panels in a generally linear arrangement. In other words, the uppermost and lowermost edges of all of the panels in the outer portion  1190  are preferably aligned. An outer front panel  1101  having an outer fixed portion  1117  and an outer removable portion  1116  is centrally located in the outer portion  1190 . An outer left side panel  1114  is located to the left of the outer front panel  1101  and is attached thereto along joint  1154 . An outer right side panel  1118  is located to the right of the outer front panel  1101  and is attached thereto along joint  1156 . A left outer back panel  1112  is located to the left of the outer left side panel  1114  and is attached thereto along joint  1152 . A right outer back panel  1120  is located to the right of the outer right side panel  1118  and is attached thereto along joint  1158 . When the container is fully assembled, the left outer back panel  1112  and right outer back panel  1120  are affixed to one another to collectively form a back panel. In addition, the left outer back panel  1112 , the outer left side panel  1114 , the outer front panel  1101 , the outer right side panel  1118 , and the right outer back panel  1120  collectively form an enclosed perimeter wall when the container is fully assembled. 
     The outer portion  1190  also includes a top flap extending upwardly from each of the outer panels and a bottom flap extending downwardly from each of the outer panels. A top front major flap  1106  extends upwardly from the outer front panel  1101  and is attached thereto along joint  1160 . In an alternate embodiment, it would be possible to have the top front major flap extend upwardly from the inner front panel  1135 . A top left minor flap  1104  extends upwardly from the outer left side panel  1114  and is attached along joint  1203   a . A top right minor flap  1108  extends upwardly from the outer right side panel  1118  and is attached along a joint  1203   b . A left top back major flap  1102  extends upwardly from the left outer back panel  1112 . A right top back major flap  1110  extends upwardly from the right outer back panel  1120  and is attached thereto along joint  1201   a.    
     As will be described in greater detail herein, the top front major flap  1106  includes cut-away portions  1109   a ,  1109   b  in upper left and right corners of the top front major flap  1106 . These cut-away portions  1109   a ,  1109   b  each define a bearing edge  1111   a ,  1111   b  that is below the uppermost edge  1107  of the outer portion  1190  and abuts edges of the top rear major flap when the container is fully assembled and the top rear major flap is taped down. 
     The top left minor flap  1104  and the top right minor flap  1108  each include outer edges having portions  1103   a  and  1103   b  that taper inwardly in the direction of the uppermost edge of the blank  1100 . These tapered portions  1103   a ,  1103   b  reduce the likelihood of the outer edges being curled upwardly when tape is applied to the top flaps by a tape roller. 
     When the container is fully assembled, the left top back major flap  1102  and the right top back major flap  1110  collectively form the top back major flap. In addition, the top front major flap  1106 , the top left minor flap  1104 , the top right minor flap  1108 , left top back major flap  1102 , and the right top back major flap  1110  are shaped and positioned to form the top of the container and provide a substantially enclosed top surface when all are folded inwardly and secured in the folded position. As used in the specification and claims, “substantially enclosed” means a surface having no openings with a major dimension larger than 1.0 cm. 
     The outer portion  1190  also includes a bottom flap extending downwardly from each of the outer panels. A bottom front major flap  1126  extends downwardly the outer front panel  1101  and is affixed thereto along joint  1209 . A bottom left minor flap  1124  extends downwardly from the outer left side panel  1114  and is attached thereto along joint  1207   a . A bottom right minor flap  1128  extends downwardly from the outer right side panel  1118  and is attached thereto along joint  1207   b . A left bottom back major flap  1122  extends downwardly from the left outer back panel  1112  and is attached thereto along joint  1205   a . A right bottom back major flap  1130  extends downwardly from the right outer back panel  1120  and is attached thereto along joint  1205   b.    
     When the container is fully assembled, the left bottom back major flap  1122  and the right bottom back major flap  1130  collectively form the bottom back major flap. In addition, the bottom front major flap  1126 , the bottom left minor flap  1124 , the bottom right minor flap  1128 , left bottom back major flap  1122 , and the right bottom back major flap  1130  are shaped and positioned to form the bottom of the container and provide a substantially enclosed bottom surface when all are folded inwardly and secured in the folded position. 
     The inner portion  1220  also includes a plurality of panels in a generally linear arrangement. An inner front panel  1135  is centrally located in the inner portion  1220 . An inner left side panel  1134  extends to the left of the inner front panel  1135  and is attached thereto along joint  1215   a . An inner right side panel  1138  extends to the right of the inner front panel  1135  and is attached thereto along joint  1215   b . A left inner back panel  1132  extends to the left of the inner left side panel  1134  and is attached thereto along joint  1213   a . A right inner back panel  1140  extends to the right of the inner right side panel  1138  and is attached thereto along joint  1213   b.    
     The outer front panel  1101  includes an outer fixed portion  1117  and a removable portion  1116 . An outer separation line  1180  defines the border between the outer fixed portion  1117  and a removable portion  1116 . Similarly, the inner front panel  1135  includes a fixed portion  1137  and a removable portion  1136 . An inner separation line  1162  defines the border between the fixed portion  1137  and a removable portion  1136 . When the container is fully assembled, the removable portions  1116 ,  1136  form part of a window that is removed when the container is opened on a display. 
     The outer removable portion  1116  of the outer front panel  1101  includes a pair of parallel scored lines  1182 . A similar pair of parallel scored lines  1184  is located on the inner removable portion  1136  of the inner front panel  1135 , positioned to overlap with the pair of parallel scored lines  1182  when the inner front panel  1135  is affixed to the outer front panel  1101  (as described herein). This feature enables a user to push his or her hand through a corner portion  1185  which folds along the parallel scored lines  1182 , thereby creating a handle that can be used to pull the removable window up and away from the container while protecting the user&#39;s hands from edges of the removable portion. This feature also enables the removable window to be removed more easily without cutting tools and works well with additional inventive features discussed herein. In an alternate embodiment, the inner removable portion  1136  could remove the corner portion, leaving a space behind the corner portion  1185  of the outer removable portion  1116 . 
     A left pivot arm  1144   a  is contained within the bottom left minor flap  1124  and connects an upper edge of the inner left side panel  1134  to the bottom left minor flap  1124  along a left pivot connection joint  1146   a . Similarly, a right pivot arm  1144   b  is contained within the bottom right minor flap  1128  and connects an upper edge of the inner right side panel  1138  to the bottom right minor flap  1128  along a left pivot connection joint  1146   b . As will be described herein, the left and right pivot connection joints  1146   a ,  1146   b  define a pivot axis  1212 , about which the inner portion  1220  is folded as part of the assembly of the blank  1100  into a knock down flat. 
     A handle  1174  is cut into the inner left side panel  1134  and a separation line  1164  located in the outer left side panel  1114 , which defines a similarly-shaped handle that folds inwardly and upwardly when pressed in. The handle  1174  is located in a position so that it overlaps with the separation line  1164  when the container is fully assembled. 
     A handle  1178  is cut into the inner right side panel  1138  and a separation line  1168  located in the outer right side panel  1118 , which defines a similarly-shaped handle that folds inwardly and upwardly when pressed in. The handle  1178  is located in a position so that it overlaps with separation line  1168  when the container is fully assembled. 
     Referring now to  FIG. 2 , a unitary blank  2100  is generally shown according to an embodiment of the invention for forming a storage, shipping and display box having a stacked arrangement of two blank layers along portions of the box, including at least along a front wall of the box. Blank  2100  is formed as a unitary blank that is configured to be folded along an offset pivot line to form a blank having stacked portions with two layers stacked over each other connected to each other at least along a front wall panel portion of the blank. The blank has an inner portion  2220  and outer portion  2190 . 
       FIGS. 3 through 9  show steps in the method by which the blank  2100  is assembled into a KDF. An identical method could be used to assemble blank  1100  into a KDF. 
     The outer portion  2190  is separated from the inner portion  2220  by a cut line  2211  extending across a width of blank  2100 , except where the left and right pivot arms  2144   a ,  2144   b  connect to the inner portion  2220 . As described above with respect to blank  1100 , the left and right pivot connection joints  2146   a ,  2146   b  define a pivot axis  2212 , about which the inner portion  2220  is folded. As indicated by the curved arrows in  FIG. 3 , showing the direction of rotation of inner portion  2220 , the inner portion  2220  folded over along the pivot axis  2212  connections  2146  located at the distal ends of pivot arms  2144   a ,  2144   b , such that the inner portion  2220  is positioned atop, and properly aligned with, the outer portion  2190  (see  FIG. 4 ). 
     The pivot arms  2144   a ,  2144   b  allow the inner portion  2220  to be rotated in a manner that is predictable, but offset from the cut line  2211  separating the outer portion  2190  from the inner portion  2220 . This offset folding arrangement allows both the outer portion  2190  from the inner portion  2220  to be formed from a single, unitary blank, which significantly simplifies the manufacturing and assembly of the blank to provide a box blank having two layers stacked on each other without incurring the additional costs of manufacturing and assembling two separate blanks. 
     An adhesive, such as glue or strips of double-sided tape  2230   a  is applied to the inner front panel  2135  so that the inner front panel  2135  becomes affixed to the outer front panel  2101  when folded over. It is preferable that adhesive be located on both the inner fixed portion  2137  and the inner removable portion  2136  so that both are securely affixed. It is also preferable that any tape strips not cross the inner separation line  2162 , so as to not impede removal of the removable window, when desired. 
       FIG. 4  shows the blank  2210  with the inner portion  2220  folded over the outer portion  2190 . The inner portion  2220  is preferably aligned with the outer portion  2290  so that the inner portion  2220  is parallel to the outer portion  2290  and the inner portion  2220  is preferably positioned between joints  2160  and  2126 . Moreover, the upper edge of the inner portion  2220  (identified by reference number  2105  in  FIG. 4 ) is preferably positioned below the joint  2160  that separates the outer front panel  2101  from the top front major flap  2106 . More preferably, the upper edge  2105  of the inner portion  2220  is preferably positioned below the joint  2160  by a distance equal to one to three times (most preferably about one times) the thickness of the outer portion  2190 . This offset enables the left and right top minor flaps  2104 ,  2018  to sit lower when folded inwardly, providing a flatter top surface for the container and provide improved strength characteristics for the fully assembled container. 
       FIG. 5  shows the next steps in forming the KDF. The right inner back panel  2140  is folded over the inner right side panel  2138  along joint  2213   b  (see  FIG. 2 ). Adhesive is then applied to the outer side of the right inner back panel  2140 , as shown by the striped areas  2230   b . The right outer back panel  2120  is then folded inwardly along joint  2158 , in the direction indicated by the arrow at the right side of the  FIG. 5 , where it is affixed to the right inner back panel  2140 , as shown in  FIG. 6 . 
     Referring to  FIG. 7 , the left outer back panel  2112  is then folded along joint  2154  in the direction shown by the arrow at the left-hand side of the  FIG. 5 , then unfolded. During the fold, the perforation between pivot arm  2144  and the bottom left minor flap  2124  will break, as shown in  FIG. 7 . The inner left side panel  2134  and left inner back panel  2132  are then folded over along joint  2215   a . Adhesive is then applied to the right outer back panel  2120  and the left inner back panel  2132  as shown by the striped areas  2230   c . The outer left side panel  2114  and left outer back panel  2112  are then folded along joint  2154 , which results in the left outer back panel  2112  becoming affixed to the right outer back panel  2120  and the left inner back panel  2132  to form the finished KDF. Once affixed to each other, the left outer back panel  2112  and the right outer back panel  2120  combine to form the outer back panel of the container. 
     The finished KDF can be assembled into a box by squaring the sides to form a box (see  FIG. 8 ). In assembled form, the outer right side panel  2118  and outer left side panel  2114  form substantially right angles with the outer front panel  2101 . 
     It should be noted that the KDF shown in  FIG. 8  is a right handed KDF, meaning that the right side of the KDF is lifted to erect the KDF and from an assembled box (see  FIG. 9 ). The same blank  2210  can be used to form a left-handed KDF simply be reversing each of the steps performed in  FIGS. 5-8  to the opposite side (i.e., each step performed on a left side is performed on the right side, and vice-versa). 
       FIG. 10  provides an interior view of a container  1000  assembled from the blank  1100  according to the first embodiment of the invention, as seen in  FIG. 1 . As can be seen in  FIG. 10 , the left and right inner side panels  1134 ,  1138  extend from the inner front panel  1135  to the left and right inner rear panels  1132 ,  1140  in spaced apart relation to the outer left and right side panels  1114 ,  1118 . In this context, “spaced apart relation” means that the left and right inner side panels  1134 ,  1138  are spaced apart from (i.e., not in contact with) outer left and right side panels  1114 ,  1118  along their entire length. In this embodiment, the left and right inner rear panels  1132 ,  1140  are parallel to the outer left and right side panels  1114 ,  1118 , respectively. This configuration adds stability to the box, particularly when multiple boxes are stacked upon each other. 
       FIG. 11  shows the container  1000  with the removable window, which includes the inner and outer removable portions  1136 , 1116  and the top front major flap  1106 . As can be seen in  FIG. 11 , the structure of the removable window and the separation lines  1162 ,  1180  as described above, enables the window to be removed easily, without cutting tools, and leaves a clean edge behind. 
     As best seen in  FIGS. 10 and 11 , container  1000  is an entirely self-contained structure, providing side walls, a top surface, and a bottom surface without any additional components such as a top, cover, attachment or accessories. Further, container  1000  preferably includes a removable window  1216  formed in an upper, central section of the outer front panel  1101 , which extends upward to include the top front major flap  1106 , and which is preferably easily removed from box  12100  along with the inner removable window (not visible in these figures, to convert the container  1000  from a shipping and storage configuration into a display configuration. 
     A third exemplary embodiment of a container in  FIGS. 12A, 12B &amp; 12C . In this example, the box is constructed from two corrugated fiberboard blanks, an inner blank  3001  and an outer blank  3002 . The outer blank  3002  has the same panel and flap elements as the outer portion  1190  of blank  1100 , with the exception of the pivot arms  1144   a ,  1144   b . The inner blank  3001  has the same panel elements as the inner portion  1220 . As shown in  FIG. 12C , instead of being aligned by folding pivot arms that connect the blanks, the inner blank  3001  must be manually aligned by a person or piece of machinery when placed atop and affixed to the outer blank  3002 . Although this configuration requires additional machinery precision to properly align the inner and outer blanks  3001 ,  3002 , it allows each of the blanks  3001 ,  3002  to be less complex that than the unitary blank  1100  of  FIG. 1 . 
       FIG. 13  shows another exemplary embodiment of the inner front panel  5135  and outer front panel (positioned behind the inner front panel  5135  in  FIG. 13 ). In this embodiment, the inner separation line  5162  includes projections  5662   a - e ,  5664   a - g  that function as mechanical locks for the removable window. In this embodiment, the inner  15  separation line  5162  would define a substantially a plurality of linear segments with rounded corners connecting the linear segments (resulting in a rectangular perimeter) in the absence of the projections. The raised projections  5662   a - e  are each protrusions in the inner separation line  5162  that are part of the inner fixed portion  5137 , extend across the outer separation line  5180  (shown in phantom in  FIG. 13 ), and overlap with the outer removable portion. The recessed projections  5664   a - g  are protrusions that are part of the inner removable portion  5136 , extend outwardly across the outer separation line  5180  and overlap with the outer fixed portion. 
     In the illustrated embodiment, each of the raised projections  5662   a - e  and recessed projections  5664   a - g  are in the shape of an isosceles trapezoid with rounded corners. Other shapes could be used, such as triangular, rectangular, or ovoid polygons, but it is preferable that the shape taper from the base edge to the end edge in order to facilitate removal of the removable window. 
     In the illustrated embodiment, each of the raised projections  5662   a - e  has parallel base and end edges of non-equal length and two nonparallel left and right edges of equal length. The raised projections  5662   a - e  each has an approximate base edge of ¾-inch (1.9 cm), an approximate end edge width of ½ inch (1.3 cm), an approximate height of ¼ inch (0.64 cm), and interior angles between the base edge and each of the left and right edges of approximately 60-65 degrees. The preferred dimensions of the raised projections  5662   a - e  could range from ⅛ inch (0.32 cm) to ¾ inch (1.9 cm) in height, ½ inch (1.3 cm) to 1¾ inch (3.2 cm) in base edge width, and ¼ (0.64 cm) to 1 inch (2.5 cm) in end edge width. These dimensions are exemplary and not limiting. 
     In the illustrated embodiment, the substantially trapezoidal recessed projections  5664   a - g  have parallel base and end edges of non-equal length and nonparallel left and right edges of equal length. The recessed projections  5664   a - g  have an approximate base edge width of ¾ inch (1.9 cm), an end edge width of ⅜ inch (0.96 cm), a height of ½ inch (1.3 5 cm), and interior angles between the base edge and each of the left and right edges of approximately 69.4 degrees. The preferred dimensions of the raised projections will range from ⅛ inch (0.32 cm) to ¾ inch (1.9 cm) in height, ½ inch (1.3 cm) to 1¼ inch (3.2 cm) in base edge width, and ¼ (0.64 cm) to 1 inch (2.5 cm) in end edge width. These dimensions are intended to be exemplary and not limiting. 
     In the illustrated embodiment, projections  5662   a - e ,  5664   a - g  are spaced approximately 3 inches apart (on center) in an alternating configuration (i.e., a raised projection  5662   a - e  followed by a recessed projection  5664   a - g ). In other embodiments, the spacing of the raised and recessed projections  5662   a - e ,  5664   a - g  could be determined by the preferred durability of the container, nature of the contents, and other factors. In addition, only one type of projection (i.e., either raised or recessed) could be provided. In many applications, the projections are preferably between two inches (5.1 cm) and five inches (13 cm) apart (on center). 
     The raised projections  5662   a - e  of the inner portion  5735  reinforce the removable window of the outer portion (not visible in this figure) by preventing it from collapsing inward during the packaging and shipping processes. The recessed projections  5664   a - g  of the inner portion prevent the window from falling out during shipping. 
     A scored joint  5666   a - g  is preferably provided along the base edge of each of the recessed projections  5664   a - g , which coincides with the path that the outer separation line  5180  would follow in the absence of projections. Each of the scored joints  5666   a - g  provides a weakened line along which the recessed projection  5664   a - g  can bend/fold as when the removable window is being removed from the container, allowing each projection  5664   a - g  to pass over the outer fixed portion. 
     In order to further reinforce the outer window, the inner separation line  5162  and the outer separation line  5180  are preferably offset (preferably by between 1/32 and ¼ inch, more preferably 1/16-¼) when the container is fully assembled. This offset reinforces the outer window panel during packaging and shipping. 
     Aspects of the window locking and retention features of container  5100  can be configured and customized in a variety of ways, options and arrangements, for providing advantages as desired and as appropriate for particular implementations and anticipated uses of the container  5100 . For example, it may be beneficial for smaller implementations that are configured to be stacked in large numbers and that are expected to encounter relatively small stresses during shipping and storage, to configure locking and retention features in way that favors providing quick and easy removal of inner removable portion  5136 , versus providing structural reinforcement and enhanced retention features for outer removable window (not shown). Such a customization can reduce the costs and time required to convert a stacked arrangement of the smaller boxes located at a point of sale into a stacked arrangement of display boxes. 
     In other implementations, aspects and options for locking and retention features can be configured differently to provide enhanced structural integrity features for container  5100 , along with providing features for quickly and easily converting the container  5100  into a display. A wide variety of options, aspects, preferences and customizations of features and combinations of features for container  5100  can be selected according to embodiments of the invention, which can provide significant benefits including enhancing the structural integrity for container  5100  when retaining good during shipping and storage, along with providing improved removability of the window. 
     As shown, in  FIG. 13 , the inner separation line  5162  preferably includes an intermeshed configuration of alternating inward-oriented, raised projections  5662   a - e  and outward-oriented, recessed projections  5664   a - g . The intermeshed configuration increases the surface area of frictional contact between the outer front panel and the inner front panel  5135 , along with increasing the amount of interfering contact along inner separation line  5162  due to its convoluted, alternating path that forms the intermeshed projections, which increases retention forces for maintaining inner removable portion  5136  within the inner front panel  5135 . At the same time, the intermeshed projection configuration provides only minimal or negligible impact on the amount of force and effort a user needs to exert to remove the window when converting the container  5100  into a display, due to pulling the window outward in a rolling motion, which moves the window in a direction that is generally normal to the interface formed along the inner separation line  5162 . 
     Raised projections  5662   a - e  preferably differ from recessed projections  5664   a - g  in ways that further enhance retention of the window within the inner front panel  5135  prior to converting the container  5100  into a display, as well as improving the removability of the window. As can be seen in  FIG. 13 , recessed projections  5664   a - g  are generally taller, as they extend away from inner separation line  5162  than the raised projections  5662   a - e . The raised projections  5662   a - e  are generally wider along inner separation line  5162  than the recessed projections  5662   a - g , both of which help retention of removable window while in a storage configuration and also improve its removability for converting into a display. The taller recess projections  5664   a - g  are connected to the inner removable portion  5136  and, thus, are removed along with inner removable portion  5136  when converting the box into a display. The greater height and shorter width recess projections  5664   a - g  make it easier for them to bend while the window is being removed. 
     Recessed projections  5664   a - g  are also primarily oriented in a downward direction, and several downward-directed recessed projections  5664  are preferably provided along a bottom portion of inner separation line  5162 . Conversely, the recessed projections  5664   a - g  act as generally vertical columns to enhance the transmission of downward forces through inner front panel  5135  of the container  5000  while used as a shipping and storage container. 
     The raised projections  5662   a - e  also differ from the recessed projections  5664   a - g  in that they are attached to the inner fixed portion  5137  of the inner front panel  5135 , extend upwardly into the removable window, and remain attached to the inner fixed portion  5137  even after removal of the window. Further, the raised projections  5662   a - e  abut the removable portion of the outer front panel. Thus, the raised projections  5662   a - e  can act as rearward stops to restrict inward movement of the outer removable portion, and can help prevent the outer removable portion from translating inward when the outer front panel encounters a lateral, inwardly-directed force normal to the front face of the container  5100 . 
     In alternate embodiments, it would be possible to include recessed and/or raised projections on the outer front panel, either in addition to or instead of, the recessed and raised projections shown in the embodiment of  FIG. 13 . In this embodiment, the projections are provided solely on the inner front panel  5135  to create a cleaner appearance from outside the container  5100 . 
     An inner left corner portion  5185  of the inner removable portion  5136  is shown, which is bordered by a pair of scored joints  5184 . In addition, no raised projections  5662   a - e  are located along the portion of the inner separation line  5162  that borders the corner portion  5185 . These features combine to enable the corner portion  5185  to be easily pushed in by the fingers of a user and function as a handle to grab and pull the removable window away from the inner fixed portion  5137  in a generally arcuate path. 
     The presence of the projections  5662   a - e ,  5664   a - g  also enables the inner and outer separation lines  5162 ,  5180  to be formed with less connected area than would be required to keep the inner removable portion  5136  intact during shipping. In this embodiment, the inner separation line  5162  preferably consists entirely of cuts and nicks. Preferably at least one nick is provided on each projection  5662   a - e ,  5664   a - g  and along the inner separation line between each projection  5662   a - e ,  5664   a - g . More preferably, at least two nicks are provided on each recessed projection  5664   a - g . Alternatively, if additional durability is needed, up to 25% of each section of the inner separation line  5162  between each projection  5662   a - e ,  5664   a - g  could be perforated. In this embodiment, the outer separation line  5180  also consists entirely of nicks and cuts, with at least two nicks being preferably present on each linear segment. 
     As shown in  FIGS. 1 and 14 , generally rectangular cut-away portions  1109   a  and  1109   b  are formed at what would typically be the rear, corner portions of top front major flap  1106 . Cut-away portions  1109   a  and  1109   b  are disposed at opposite ends of the top front major flap  1106  and include a stop edge  1199  that is generally parallel with the front of the outer removable portion  1116  and the forward lateral edge  1198  of left top back major flap  1102 . As such, when container  1000  is fully closed and top major flaps  1102  and  1106  are secured down along the top of container  1000 , stop edge  1199  is aligned with and disposed proximate to and opposing forward lateral edge  1198  at each side of container  1000 . This enables any lateral forces or frontal impacts applied to upper portions of the outer removable portion  1116  and/or to outer front panel  1101  of container  1000  to be transmitted through top front major flap  1106  until it reaches stop edge  1199 , which impacts against forward lateral edge  1198  if the top portion of outer removable portion  1116  is translated rearward. 
     The interface between stop edge  1199  and forward lateral edge  1198  during contact that occurs due to rearward forces being transmitted through top front major flap  1106  will produce interfering contact with between edges  1199  and  1198 . The interfering contact acts as a stop that can prevent deformation of the top portion of container  1000  and avoid premature separation of removable window from the box. Such a stop feature can significantly reinforce and strengthen the box and its removable window  1116  while having little or no effect on the removability of the window. Preferably, these stop features are combined with other reinforcement and strengthening features discussed above and associated with the inner front panel  1135  of the blank  1100  to provide a container  1000  that also has the ability to be quickly and easily be converted into a display. 
     It will be appreciated that the invention is not restricted to the details described above with reference to the preferred embodiments but that numerous modifications and variations can be made without departing from the spirit or scope of the invention as defined in the following claims.