Abstract:
A shipping container reusable as a hanging file folder container includes a base panel, first and second laterally spaced side panels extending upwardly from the base panel, and third and fourth laterally spaced side panels extending upwardly from the base panel and extending between the first and second side panels. Each of the first, second, third and fourth panel includes inside and outside surfaces and a top edge portion, and together define an interior recess of the container. A first spacer member removably engages one of the first, second, third and fourth panels. The first spacer member has a predetermined width to maintain a clearance between one of the first, second, third and fourth panels and an article being shipped in the container. The first spacer member includes a channel for engaging the top edge portion of one of the panels. The shipping container may be converted to a hanging file folder container by mounting one, and preferably two spacer members over the corresponding top edge portions of two opposite panels and suspending hanging file folders therebetween.

Description:
FIELD AND HISTORICAL BACKGROUND OF THE INVENTION 
     The present invention is directed to a shipping container, and more particularly to a container for shipping or packaging cut sheets of paper, which can be reused as a hanging file folder container after the sheets of paper have been removed. 
     The usefulness of the present invention will become easily apparent as we follow the life of cut sheets of paper. At the manufacturing facility, sheets of paper are cut from larger size paper rolls. A predetermined volume of the cut sheets of paper is packed with a sheet of wrapping paper. Several of these volumes of paper are packed into a carton for shipping. For a typical office use, 500 cut sheets are packed into a “ream”, and ten reams are normally packaged in a container. The container is typically made of a corrugated fiber board or paper board material. 
     A business or home-office user normally purchases these boxes of cut paper, each typically containing ten reams. The cut sheets are taken from the container one ream at a time for use with office equipment, such as photocopiers, laser or ink-jet printers, and plain paper facsimile machines. Once all the reams of paper are exhausted, the container is usually discarded. It is not uncommon for a user, however, to remove all the reams from a container and stock them up in a convenience place, such as near a photocopy machine, etc. The discarded paper shipping boxes often become a significant part of the trash picked up at the end of the day, particularly in a office environment where the consumption of paper is high and a large number of boxes are purchased at one time. 
     As noted above, typically ten reams of cut paper are packed into a container. The dimensions of the most commonly used paper include 8.5″×11″ or 8.5″×14″. Currently, the industry practice is to provide a shipping container the interior volume of which is nearly identical to the overall volume of two five-ream stacks of paper placed side-by-side. As a result, the reams of paper are tightly packaged in a container, leaving almost no appreciable clearance between the container and the stacks of paper. This leads to significant problems in that it is very difficult to remove the reams without either causing damage to the paper or injuring a person&#39;s fingers. In particular, the absence of a clearance between the container and the reams makes it nearly impossible to sufficiently grasp a ream about its perimeter, which remains in tight engagement with the container walls, to take it out therefrom. Many users simply dismantle the container by pulling outwardly the panels to gain easy access to the reams. This practice is, however, not desirable, time-consuming, and completely destroys the container leaving no alternative for its reuse other than to discard it. 
     A large number of the cut sheets purchased in an office or the like environment, become documents, such as letters, reports, faxes, etc., that must be stored or filed. A popular method of filing or grouping the documents includes using hanging file folders. Hanging file folders generally have a pair of metal or plastic rods, that support a folded fiber board material into which documents and the like are stored and organized. The rods have notched ends which are received on support rods within office furniture, such as a filing cabinet, desk drawer, and a portable hanging file folder box. 
     Hanging file folders, for example those disclosed in U.S. Pat. No. 5,494,161 to Herbst, U.S. Pat. No. 5,842,570 to Turnbull, and U.S. Pat. No. 5,887,782 to Mueller, are usually manufactured as flat corrugated boards with fold line, cut lines, and flaps and shipped in an unassembled state to the consumer, thus minimizing the transport costs. The consumers usually assemble these boards into a box by quickly folding panels in a certain sequence, although the instructions accompanying these boxes may recommend using an adhesive for a sturdier construction. Hanging file folder boxes assembled in such a fashion are usually less sturdier than the cartons (used for shipping cut-sheets of paper) which are assembled in the factory with industrial adhesives. 
     In a typical office or a small business, several containers of cut sheets of paper are purchased on a regular basis and the containers are discarded after the cut sheets are removed therefrom. It is not unusual or uncommon for the same office or small business to separately purchase large quantities of hanging file folders to organize, store and archive the documents. 
     Various other examples of shipping or related types of containers and packages, and hanging file folder boxes, and the like are disclosed in U.S. Pat. Nos. 3,910,411; 4,624,380; 4,844,262; 5,190,152; 5,193,701; 5,381,890; 5,622,309; 5,779,129; 5,794,770; 5,815,903; and 5,819,922. 
     There remains a need in the industry, however, for a container which, after shipping, for example, the cut paper, may be converted to a hanging file folder container. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     The principal object of the present invention is to provide a shipping container which is reusable as a hanging file folder container. 
     An object of the present invention is to provide a shipping container which promotes recycling of fiber board containers that are otherwise discarded. 
     Another object of the present invention is to provide a shipping container which is environment-friendly in that it is recycled or reused as a storage box. 
     An additional object of the present invention is to provide a shipping container which is reusable usually in the same end-user location and eliminates waste and therefore significantly reduces the usage of landfills that are otherwise in short supply. 
     Yet an additional object of the present invention is to provide a shipping container which leads to significant cost reduction in that separate purchase of hanging file folder containers is eliminated. 
     Still yet an additional object of the present invention is to provide a shipping container which can be very easily and economically reused by converting it into a hanging file folder container. The conversion is fast and can be quickly done without any special skill or training. 
     A further object of the present invention is to provide a shipping container which includes a clearance, preferably between two opposed side panels of the container and the articles, for example, paper, being shipped, thereby making it easy for a user to remove the articles from the container by inserting the hands in the clearance and grasping the articles. 
     In summary, the main object of the present invention is to provide a shipping container which can be reused as a hanging file folder container and therefore leads to significant cost savings and is environment and user-friendly. 
     In accordance with the present invention, a shipping container reusable as a hanging file folder container includes a base panel, first and second laterally spaced side panels extending upwardly from the base panel, and third and fourth laterally spaced side panels extending upwardly from the base panel and extending between the first and second side panels. Each of the first, second, third and fourth panel includes inside and outside surfaces and a top edge portion, and together define an interior recess of the container. A first spacer member removably engages one of the first, second, third and fourth panels. The first spacer member has a predetermined width to maintain a clearance between one of the first, second, third and fourth panels and an article being shipped in the container. The first spacer member includes a channel for engaging the top edge portion of one of the panels. The shipping container may be converted to a hanging file folder container by mounting one, and preferably two spacer members over the corresponding top edge portions of two opposite panels and suspending hanging file folders therebetween. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects, novel features and advantages of the present invention will become apparent from the following detailed description of the invention, as illustrated in the accompanying drawings, in which: 
     FIG. 1 is a perspective view of a shipping container of the present invention, shown packed with reams of paper for shipping; 
     FIG. 2 is a perspective view of the box of FIG. 1, shown without the paper and the container lid; 
     FIG. 3 is a view similar to FIG. 2, showing the container converted into a hanging file folder container; 
     FIG. 4 is a partial sectional view taken along line  4 — 4  of FIG. 2; 
     FIG. 5 is a partial enlarged sectional view taken along line  5 — 5  of FIG. 1; 
     FIG. 6 is a view taken along line  6 — 6  of FIG. 3; 
     FIG. 7 is a partial enlarged view of the box shown in FIG. 3, showing one of the spacer members mounted on the top edge portion of one of the panels; 
     FIG. 8 is an enlarged view showing the details of the portion encircled in FIG. 6, showing one end of a hanging file folder prior to being fully mounted over a spacer member; 
     FIG. 9 is a perspective view of an alternative embodiment of the shipping container of the present invention, showing reams of paper in phantom lines; 
     FIG. 10 is a sectional view taken along line  10 — 10  of FIG. 9, shown without the reams of paper; and 
     FIG. 11 is a perspective view of one of the spacer member of FIG. 9, shown with one hanging file folder support member removed therefrom. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As best shown in FIGS. 1-2, the shipping container SC of the invention is preferably a generally rectangularly shaped box which includes a base panel  10 , two laterally spaced side panels  12  and  14  disposed generally opposite to each other, and two laterally spaced side panels  16  and  18  extending generally between the side panels  12  and  14 . The side panels  12  and  14  are slightly longer than the side panels  16  and  18 . The base panel  10  and the side panels  12 ,  14 ,  16  and  18 , when erected upwardly extending from the base panel  10 , define an interior recess  20 . A lid  22  is provided to selectively close the top opening  24  of the shipping container SC. 
     The entire shipping container SC, including all of the panels  10 ,  12 ,  14 ,  16  and  18 , and the lid  22 , are made from a suitable material, such as a corrugated paper board, fiber board, or plastic material. As best shown in FIG. 1, the overall size of the container SC is such that the recess  20  accommodates two side-by-side stacks each including five reams R of 8.5″×11″ or 8.5″×14″ size cut paper. Particularly, the internal dimensions of the recess  20  would be designed to accommodate the reams R shipped in the container and the spacers  26 . (Although the invention is equally applicable for international paper sizes, for example, size A 4 , for illustration, the paper sizes discussed herein correspond to those commonly used in the U.S. It is noted that the size of the container SC may further be varied to accommodate a different quantity or size of paper.) In particular, for 8.5″×11″ size paper, the length and width dimensions of the container SC would be at least about 17″×12″, providing two one-half inch clearances along both sides. Likewise, for 8.5″×14″ size paper, the length and width dimensions of the container SC would be at least about 17″×15″, providing two on-half inch clearances along both sides. 
     As best shown in FIGS. 2,  4  and  5 , preferably a pair of vertically spaced spacer bars  26  is provided in the interior recess  20 , on each of the side panels  12  and  14 . As shown in FIG. 2, the spacer bars  26  are preferably disposed horizontally on the side panels  12  and  14 . It is noted herewith that the spacer bars  26  may be disposed vertically or diagonally, and may alternatively be provided on the side panels  16  and  18 . It is further noted that while two spacer bars  26  are provided on each of the panels  16  and  18 , only one is necessary for each panel to attain the objective of the invention. Moreover, it is within the scope of the invention to provide two spacer bars only on one of the side panels  12 ,  14 ,  16  or  18 . 
     As best shown in FIGS. 4-5, the spacer bars  26  are preferably mounted on the inside surfaces  13  of the panels  16  and  18 , by thin glue strips  28  that allow easy removal thereof by a user to convert the shipping container SC into a hanging file folder container, as described below in more detail. 
     The length of each spacer bar  26  is selected so as to correspond to the inside-length of the side panel on which it will later be mounted to support hanging file folders HF. For instance, as illustrated in FIGS. 2-3, the lengths of the spacer bars  26  correspond to the lengths of side panels  12  and  14  on the top edge portions  36  of which they are mounted when the container SC is converted to a hanging file folder container. If desired, the spacer bars  26  may be shorter in length to be mounted on side panels  16  and  18 , which are shorter in length than the panels  12  and  14 . 
     As best shown in FIG. 5, each spacer bar  26  is wedge-shaped in cross-section and includes a somewhat narrow, tapered section  30  and a contiguous wider section  32 . A channel  34  is cut into the wider section  32  and extends towards the tapered section  30 . The width of the wider section  32  is selected so as to provide a predetermined amount of clearance C between an adjoining panel ( 12  in FIG. 5) and the reams of paper R in the shipping container SC. It is preferred that the clearance C be about one-half to one inch. The width of the channel  34  is selected to correspond to, or be slightly less than, the thickness of a panel such that when the spacer bar  26  is placed over the top edge portion  36  of any of the side panels, the spacer bar  26  is frictionally stabilized thereon (FIGS.  6 - 8 ). 
     As best shown in FIGS. 5 and 8, each spacer bar  26  includes a substantially straight or rectilinear side wall  38  and an opposed inclined side wall  40 . The straight side wall  38  is positioned against the inside surface  13  of a panel (such as  12  in FIG. 5) when the shipping container SC is used for shipping purposes. 
     The tapered or wedge-shaped configuration of the spacer bar  26  is selected to conform with the tapered configuration of a notch  44 , typically provided in an end portion  46  of a support rod  48  of a conventional hanging file folder HF (FIG.  8 ). 
     In particular, the notch  44  typically includes a straight wall  50  disposed in an opposed relationship to an inclined wall  52 . As best shown in FIG. 8, the straight and inclined side walls  38  and  40  of the spacer bar  26  slidably engage the corresponding straight and inclined side walls  50  and  52 , respectively, of the notch  44 . In this manner, the tapered end portion  30  of the spacer bar  26  is slidably, yet firmly, received in the notch  44 . As will be appreciated, a similar connection is made on the opposite end  54  of the hanging file folder HF (FIG.  6 ). These oppositely situated connections reinforce the top edge portions  36  of, for example, the panels  12  and  14 , thereby providing a stronger support for the hanging file folder HF, when suspended in the container SC on the panels  12  and  14 . 
     FIGS. 9-11 illustrate an alternative embodiment of the shipping container SCA of the invention. In this embodiment, preferably two spacer boards  56  and  58  are provided adjacent the side panels  55  and  57 , respectively. (It is within the scope of the invention to provide only one spacer board of a sufficient thickness, i.e., one-half to one inch, adjacent only one panel.) 
     The spacer boards  56  and  58  are, preferably, made of a solid foam or the like material which is light-weight yet strong enough to sustain the pressure that may be exerted by the reams R during shipping. The spacer boards  56  and  58  generally correspond to the side panels  55  and  57  in length and width dimensions, and have a thickness that corresponds to a preselected clearance C, as noted above in connection with the embodiment shown in FIGS. 1-7. In other words, the boards  56  and  58  are provided between, for example, the side panels  55  and  57  of the shipping container SCA and the reams of cut sheets R. Although not necessary, the spacer boards  56  and  58  may be immobilized on the corresponding panels  55  and  57  by utilizing a small amount of glue or the like material to prevent unnecessary movement during shipping. 
     As best shown in FIGS. 10-11, each spacer board  56  and  58  includes, preferably two vertically spaced, horizontally extending recesses  60 , each accommodating therein a hanging file folder support or mounting bar  62  therein. The mounting bar  62  is identical in configuration to the spacer bar  26  discussed above in connection with the first embodiment. 
     It is noted that while two mounting bars  62  are illustrated as being contained in each board  56  and  58 , only a total of two mounting bars are required to convert the container SCA into a hanging file folder container, as described below. Also, the container SCA may be shipped with two sets of spacer bars for hanging file folders suitable for either letter-size (8.5″×11″) or legal-size (8.5″×14″) papers. The end-user may decide to use one set of spacer bars and discard the other. 
     It is noted that the spacer bars  26  of the first embodiment, shown in FIGS. 1-7, first provide clearances C during shipping of reams R, and then function as mounting bars to support hanging file folders HF when the container SC is converted to be reused as a hanging file folder container. On the other hand, the spacer boards  56  and  58  of the second embodiment, shown in FIGS. 9-11, provide sufficient, preselected clearances between the reams R and the container panels during shipping and when the reams R are being removed by a user. The boards  56  and  58  also provide means to accommodate and store mounting bars  62  during shipping and until the user is ready to convert the shipping box SCA to be reused as a hanging file folder container. 
     USE AND OPERATION 
     The use and operation of the shipping container SC illustrated in FIGS. 1-7 will first be described. The shipping container SC will either be available in an assembled or erected form shown in FIG. 2 (which is the most likely and preferred form), or be in a blank form that can be folded in a known manner to form a container. Whether in a blank form, or assembled as a container, one or more spacer bars  26  will either be already attached to the desired panels, or thin adhesive strips will be provided to attach them to the desired panels. Once assembled in the form shown in FIGS. 1-2, reams of cut paper R would be placed in side-by-side stacks for shipping. 
     A user, upon purchase of the boxed paper, would remove the reams R until the container SC is empty. In order to convert the shipping container SC into a hanging file folder container, the user would remove the spacer bars  26  from the panels of the container and place one each on, for example, each side panels  12  and  14 , such that the channels  34  thereof firmly engage the top edge portions  36  thereof (FIG.  7 ). Hanging file folders HF may then be suspended in the shipping container SC by engaging the ends  46  and  54  with the tapered sections  30  of the spacer bars  26  (FIGS.  3  and  8 ). 
     The use of the alternative embodiment of the shipping container SCA shown in FIG. 9-11 will now be described. In order to easily remove the reams R from the container SCA, a user would first grab and slide out the spacer boards  56  and  58 , to create clearances adjacent panels  55  and  57  to allow the user to insert hands to grasp and pull out the reams. Once all the reams R have been removed, the user would snap out two mounting bars  62  from the boards  56  and  58  and place one each on the corresponding top edge portions of, for example, the opposed side panels  55  and  57 , in the manner described above. Once the mounting bars  62  are in place, the container SCA would be ready to receive the hanging file folders HF in the same manner as the first embodiment described above. 
     It is appreciated that hanging file folders are currently available in letter and legal sizes to accommodate 8.5″×11″ (letter) and 8.5″×14″ (legal) size paper. Thus, in a shipping container of the invention that is dimensioned to accommodate two side-by-side stacks of 8.5″×11″ size paper, letter size hanging file folders would be used. On the other hand, in a shipping container of the invention that is dimensioned to accommodate two side-by-side stacks of 8.5″×14″ size paper, legal size hanging file folders would be used. The shipping container of the invention may also be designated to contain five reams of paper (either letter or legal size) resulting in half of the length of the carton, shown in FIG.  1 . It is also possible to design a shipping container for 8.5″×11″ (letter) size paper such that the container may be converted to accommodate hanging file folders for either 8.5″×11″ (letter) size or 8.5″×14″ (legal) size paper. This may be achieved by stacking five reams of paper flatly on top of each other, and three reams of paper each standing on its edge and placed side-by-side to fill the container. This arrangement may be visualized by removing one of the two stacks of reams R in FIG. 1, and placing three reams vertically on edges, thus reducing the length of panels  12  and  14 . The manufacturers may choose such a design if there is sufficient market demand. In this regard, it is noted that once the manufacturers of cut-sheet paper realize that they are catering to the hanging-file folder users also, they may provide alternative arrangements, or number of reams in a shipping container. 
     As can be seen from the above, the shipping container SC (or SCA) of the invention is first used to ship reams of cut paper and may then be very easily converted to be reused as a hanging file folder container by a user. 
     As can be further readily observed from the above, the clearance C created by the spacer bars  26  (FIG. 5) or by the boards  56  and  58  (FIGS. 9-11) allows a user to insert hands to manipulate and grasp the reams R to easily lift them out of the container without injuring the user&#39;s fingers or damaging the paper. 
     While this invention has been described as having preferred ranges, steps, materials, or designs, it is understood that it is capable of further modifications, uses and/or adaptations of the invention following in general the principle of the invention, and including such departures from the present disclosure, as those come within the known or customary practice in the art to which the invention pertains and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention and of the appended claims. It is further understood that the present invention is not limited to the claims appended hereto.