Source: http://www.google.com/patents/US7243815?dq=oakley+D523,461&ei=qiI4T-CjGqXf0QHz_PSUCA
Timestamp: 2014-03-09 22:35:44
Document Index: 239697914

Matched Legal Cases: ['art 156', 'art 158', 'art 156', 'art 158', 'arts 156', 'arts 156']

Patent US7243815 - Thermoformed package - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA container is formed in a blank having two body halves interconnected by a hinge. The container body is at least partially clear to allow inspection of an article held in the interior. The container optionally includes an integrally formed carrying handle. Empty containers are nested to minimize shipping...http://www.google.com/patents/US7243815?utm_source=gb-gplus-sharePatent US7243815 - Thermoformed packageAdvanced Patent SearchPublication numberUS7243815 B2Publication typeGrantApplication numberUS 10/368,043Publication dateJul 17, 2007Filing dateFeb 14, 2003Priority dateSep 23, 2002Fee statusLapsedAlso published asUS20040056030Publication number10368043, 368043, US 7243815 B2, US 7243815B2, US-B2-7243815, US7243815 B2, US7243815B2InventorsJohnny Coppedge, Salvatore Cesario, Nicholas MaloneOriginal AssigneeSee The Shoes, LlcExport CitationBiBTeX, EndNote, RefManPatent Citations (29), Referenced by (5), Classifications (7), Legal Events (3) External Links: USPTO, USPTO Assignment, EspacenetThermoformed packageUS 7243815 B2Abstract A container is formed in a blank having two body halves interconnected by a hinge. The container body is at least partially clear to allow inspection of an article held in the interior. The container optionally includes an integrally formed carrying handle. Empty containers are nested to minimize shipping space. Each container optionally includes stack-stabilizing structure so that plural containers may be stacked into stable stacks, and any selected container may be easily removed from the stack. The inventive container protects articles held therein during shipping and storage, and displays the articles both before and after sale.
RELATED APPLICATION DATA This is a Continuation in Part of PCT/US02/30075, filed Sep. 23, 2002.
FIELD OF THE INVENTION This invention relates to the field of packaging, and more particularly, to a thermoformed package designed for use with any variety of goods, but especially for footwear.
BACKGROUND Thermoformed containers are used ubiquitously as packaging for innumerable objects. Generally speaking, containers formed by thermoforming processes offer economical packaging options for a variety of consumer goods, and at many different distribution levels. For example, thermoformed containers may be used as competitive replacements for paperboard and cardboard-based packages for many items. The following description of the packaging industry as it relates to footwear is just one example of the demands for packaging.
But in addition to their functional benefits, traditional rectangular shoeboxes serve another purpose, and that is as a part of the marketing plan. Nearly all shoe manufacturers try to use their product packaging as part of their overall marketing programs designed to sell the product. Thus, many shoe manufacturers print graphics and other promotional information on their boxes. Even though this marketing information may be visible only on the sides of the boxes since boxes are usually stacked, the space can be used as advertising space. Moreover, the box may be printed with information about the shoes�sizes and the like.
Second, most shoeboxes are made of some form of paper�usually cardboard or a heavy paperboard. While such materials tend to make a relatively strong container, the can be crushed and are subject to moisture absorption and damage. Moisture damage to cardboard can be a significant problem. And even broken-down cardboard boxes designed for shoes tend to take up a significant amount of space. Further, the boxes must be manufactured in one location as blanks, shipped to another location where they are set up as boxes. Finally, raw material costs for cardboard are increasing at a steady rate, making the economics of using cardboard less and less favorable.
But perhaps the greatest shortcoming of traditional, rectangular shoeboxes is their limited ability to enhance product sales. As noted above, most shoe manufacturers print promotional information of one kind or another on their shoeboxes, including trademarks, logos and the like. This is valuable to a degree in selling the product. But cardboard is inherently opaque, and as such, a consumer must open the box to look at the shoes contained inside. Shoe manufacturers want their consumers to look at their shoes�the appearance of the shoe is an important factor in the consumer's decision on what to buy. It can be difficult to pull a box out of a stack of boxes, open it to look at the shoe, and then replace the shoe in the box in even a relatively neat fashion. Stated in another way, a large part of the consumer's buying decision is based upon the appearance of the shoe. As a result, shoe manufacturers spend a great deal of time and money in making their shoes look attractive to consumers�the manufacturers want consumers to see the product. But for all of this, shoes are almost always hidden in a shoebox.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the container of the present invention are shown in the FIGS. 1 through 9. The invention is described at times herein with respect to an exemplary design intended for use with footwear such as athletic shoes. However, the invention as defined in the appended claims is not limited to a container for shoes, and those of ordinary skill in the art will instead recognize that the invention applies to containers for any kind of goods.
Cooperatively formed tabs and tab-receiving recesses may be formed along the mating edges of flanges 117 and 115 to assist in maintaining the two body halves in the closed position shown in FIG. 1. Thus, when the two body halves 102 and 104 are closed�that is, moving the halves from the position shown in FIG. 2 into the position shown in FIG. 3�flange 115 mates with and is received into flange 117, and the flanges thus align to define the joint 107 (FIG. 1). There is a friction fit between flanges 117 and 115, which contributes to holding the two halves in the closed position of FIG. 1. Referring now to FIG. 4, the friction fit between the two halves is aided by tabs 160 formed around the periphery of flange 115 in body half 104. When the body halves are closed, the tabs 160 are received into cooperatively formed recesses 162 spaced around the periphery of flange 117 of body half 102 and located such that each tab 160 is received into a recess 162 when the body halves are closed together.
With reference now to FIGS. 1 through 3, the specific construction of handle 126 may be detailed. Thus, handle 126 is defined by a integral pocket 131 formed into and projecting outwardly from side panel 120 of body half 102. Flanges 117 and 115, and thus joint 107 extend around the outer periphery of pocket 131. At its lowermost point, pocket 131 extends below joint 107. A cooperative pocket 133 is formed in side panel 120 of body half 104 in a position to receive the lower portions of pocket 131 when the two body halves are in the closed position as seen in FIG. 3. A protrusion 135 formed on flange 115 is received in an opening 137 that is formed in flange 117 during formation of the container. The combination of protrusion 135 as it fits into opening 137 helps stabilize the handle, as does the combination of pocket 131 as it fits into cooperative pocket 133 when the container is closed. As used herein, relative directional terms such as �inwardly� or �outwardly� are used to refer to directions relative to the inside and outside of the container when it the two body halves are closed. Likewise, �upwardly� and �downwardly� are used in reference to the ground plane, which for purposes herein is the plane that is parallel to bottom panel 118 (FIG. 2). It will be appreciated that protrusion 135 may be used as an alternate way to grasp container 100, and thus allows the container to be picked from a stack with a long rod having a tip on the end that is capable of fitting into the protrusion from the lower side of the container. As noted above, many stores and warehouses place inventory on racks that may be quite high. A specific container that may otherwise be out of reach may be obtained by inserting a rod tip into protrusion 135 and pulling the container out of the stack.
Container 100 also includes optional stack stabilization structures that allow numerous containers to be stacked atop one another in a stable stack, yet so that a selected container may easily be pulled out of the stack without unstacking or upsetting the stability of the remaining containers in the stack. An outwardly projecting �foot� in body half 102 is configured to mate with a cooperatively formed �recess� in the body half 104 of the next adjacent container 100 when more than one containers 100 are stacked. The �foot� formed in body half 102 is a rail 128 that in a side view of the container (e.g. FIG. 2) generally is semi-cylindrical, and which extends across the entire top panel 116 (FIG. 1) along its longest dimension. The cooperatively formed �recess� 130 that receives rail 128 on an adjacent, stacked container, may be seen in FIGS. 2 and 3 and is seen to be a cooperatively shaped, generally semi-cylindrical recess that extends across the entire bottom panel 118 along its longest dimension. Together, rail 128 and recess 130 define a secure nesting system in which multiple adjacent containers 100 stacked atop one another are interlocked, as shown in FIG. 5. Although a stack of containers as shown in FIG. 5 is stable, a selected container may easily be removed from the stack by pulling on handle 126 such that the selected container slides laterally out of the stack. If a stack includes many containers 100, even removing one individual container from the bottom or lower portion of the stack will not upset the stack. Instead, the containers above the removed container drop downwardly such that they nest again in a stable stack with rails 128 interlocking recesses 130.
Moreover, the position of rail 128 and recess 130 relative to top panel 116 and bottom panel 118 may be varied. For example, in FIG. 6 it may be seen that rail 128 and recess 130 are formed in approximately the center of top panel 116 between corner stabilizer 132, which is described below, and hinge 106, and in a corresponding position in bottom panel 118 about midway between corner stabilizer 132 and edge 115. Positioning the rail in the middle of the panels as shown in FIG. 6 allows one container to be stacked such that is rotated 180� relative to adjacent containers. Furthermore, with rail 128 and recess 130 positioned as in FIG. 6, containers 100 of differing sizes may be stacked atop one another with the stack stabilization structures (rail 128 and recess 130) maintaining a stable stack.
Moreover, as noted, the stack stabilization features defined by rail 128 and recess 130 are optional features, and a container according to the present invention may be manufactured without the rail and recesses. With reference to FIG. 9, a container 180 that is alike container 100 in all other respects is shown without either a rail 128 or a recess 130. Owing to the manner in which the containers are formed, as described below, and particularly, the manner of forming hinge 106, the container 180 may be stacked on any one of the four main sides�back panel 110, front panel 114, top panel 116 and bottom panel 118. Thus, the two body halves 102 and 104 are formed such that the geometry of hinge 106 results in a hinge that lies completely within the intersection of the planes defined by adjacent main panels. Stated another way, and with reference to FIG. 9, the hinge 106 does not interrupt or extend into the planes defined by either the back panel 110 or the top panel 116, and there are no parts of the container that extend through the planes defined by these panels. This allows the container 180 to be stacked stably on any of those panels. In FIG. 9, the planes defined by the main panels 110, 114, 116 and 118 are shown in dashed lines labeled �P�. The main panels define planar sections that, as illustrated with the dashed lines P, intersect at right angles. The main panels 110, 114, 116 and 118 in FIG. 9 are flat surfaces. In some instances, it may be desirable to alter those surfaces so that they incorporate other structural components, for example, a series of reinforcing ribs that extend along the surfaces to strengthen the panels. While the surface of a panel having such reinforcing ribs would not be planar, the combined upper portions of the reinforcing ribs would define a planar surface. Accordingly, it is to be understood that as used herein, the word �plane� refers to the characteristic of a surface that extends across the main panels, regardless of whether the panels are �flat� in section or otherwise.
Container 100 is preferably fabricated from a clear material so that goods held within the container are plainly visible through the container panels. As used herein, the word �clear� refers to any transparent or translucent material used to fabricate the container and through which the interior of the container may be seen. Many materials may be used to fabricate the container. These include numerous grades of PET (polyethylene terephthalate), high density polyethylene (HDPE), low density polyethylene (LDPE), and vinyls such as various grades of polyvinyl chloride (PVC). Those or ordinary skill in the art will recognize that the material selected will depend upon the structural and cosmetic requirements of the particular package. The polymers used to manufacture container 100 may include modifier compounds such as softeners, impact modifiers and the like, depending upon the application. In a preferred embodiment the material selected for manufacturing the container will include a high percentage of recycled material.
The container of the present invention is preferably formed using a thermoforming processes whereby a blank of material is pulled into a tool or mold, for instance with a vacuum, to form the container. With reference to FIG. 8 it may be seen that container 100 is formed in an inverted position such that a blank of plastic material 150, illustrated in dashed lines, is positioned over the forming tool 152, which is shown in section, and schematically. Tool 152 is the type of tool known in the industry as a �male� tool. A male tool is preferably used to thermoform container 100 because during the thermoforming process, those portions of material 150 that are nearest the tool when thermoforming occurs are the thickest portions of the finished part. Tool 152 comprises a first male part 156 and a second male part 158, each of which is roughly triangular in cross section and each of which has an apex 154 that lies closest to the plastic material 150 prior to the forming process. It will be appreciated that first male part 156 forms body half 104 and that second male part 158 forms body half 102. The two parts 156 and 158 are positioned close together to define hinge 106 at the junction between the two parts. The hinge 106 formed from the combination of the two parts 156 and 158 is, as described above, unobtrusive with respect to the main panels of the container. Additionally, the hinge is formed without the need for cutting any of the material 150.
It will further be noted that the tool 152 is formed such that there are no �reverse drafts� or �negative drafts� in the container 100. For example, and with reference to the cross sectional configuration of rail 128 and recess 130, the rail is generally cylindrical in shape, but as best seen in FIG. 7, is non-concentric. Because these portions are not perfectly rounded, the container is easily separate from tool 152 after container 100 is formed. Moreover, numerous empty containers may be nested within one another yet easily separated.
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