Abstract:
A reusable combined multi-part product shipping box and display tray. In one arrangement, the box includes two generally rectangular trays, each defining four sides, with four barrier portions projecting upward from each tray proximate its edges, one barrier portion at about the center of each of the sides, and four corner posts, one projecting up from each corner of the tray. The box includes a generally rectangular sleeve defining four sides and four corners, and open ends that are about the same size and shape as the trays, the sleeve adapted to engage with the trays to close its open ends and form a shipping container, the sleeve adapted to sit on the tray inside of and up against the barrier portions, with each corner of the sleeve located outside of and against a corner post, such that the sleeve is tightly engaged with the trays.

Description:
RELATED APPLICATIONS 
       [0001]    This patent application is a continuation-in-part of U.S. patent application Ser. No. 12/640,246, entitled “Reusable, Combined Multi-Part Product Shipping Box and Display Tray,” filed on Dec. 17, 2009 which claims priority to U.S. Provisional Patent Application Ser. No. 61/138,220, entitled “Reusable, Combined Multi-Part Product Shipping Box and Display Tray,” filed on Dec. 17, 2008. The entire contents of the priority applications are hereby incorporated by reference in their entirety. 
     
    
     BACKGROUND 
       [0002]    Bananas currently and historically have been shipped in a corrugated paper box consisting of a double wall Half Slotted Container (HSC) body covered by a single wall HSC full depth telescoping cover. These paper boxes are typically fabricated local to the banana plantations where they are assembled on a box-forming machine or by hand at the packing sheds on the banana plantations. The double wall bottom of the box is formed, in a secondary operation, and then packed with the bananas inverted or crown up to minimize transportation damage. Another box-making machine or individual forms the single wall top of the box which is then slid over the bottom of the box to the full depth of the container. When completed, the bananas are protected by the combined wall thicknesses in a paper box that has triple thick sidewalls, double wall bottom flaps and single wall top flaps. 
         [0003]    The finished box is relatively expensive, typically over $1.25 per box and gets thrown out at the store level. It is a one-time use shipping container that generates about 2.5 pounds of waste for each 40 pound box of bananas. 
         [0004]    After packing in boxes, the bananas are loaded into refrigerated containers and shipped to market. Another mode of transport to market is when the boxes of bananas are loaded into the hold of a ship without the container, just packed on pallets. With either method, upon arrival at port the bananas are shipped to ripening companies in various markets where they are ripened by a gas process. After the bananas are ripened, they are shipped to the stores. 
         [0005]    At the store level, store personnel have to manually unpack each box of bananas and put them on display on store shelves, crown down, for customers to view and purchase. Accordingly, either the ripening supplier or the store personnel have to invert the cases or bunches of bananas by hand prior to lifting each bunch out and putting them on a display stand. Bananas are a high volume retail item. The unpacking and handling of bananas at the store level is very time consuming and labor intensive, costing the supermarkets labor and wasted time. 
       SUMMARY 
       [0006]    By contrast to conventional packing boxes, embodiments of the present innovation relate to a reusable combined multi-part product shipping box and display tray. In one arrangement, the box or container can be used to ship bananas, other produce, or other goods, multiple times. The box, thus reduces the environmental impact of shipping millions of cases of bananas to market. The innovation reduces solid waste, energy consumption and greenhouse gases by approximately 60% when compared to the disposable paper box system described above. 
         [0007]    The container also greatly reduces the costs associated with shipping. The paper box described above currently costs over $1.25 per unit. The container of the present innovation can decrease the cost per shipping cycle to approximately $0.20. 
         [0008]    The three-part shipping container can minimize or eliminate the in-store labor associated with unloading each case of bananas by hand. This allows the supplier to invert each case of bananas prior to sending them to the store. Alternatively, the store personnel can invert an entire case at a time, place the case in the display area, remove the straps and lift the top tray and sleeve off the case, and the bananas are ready for display on the lower tray. This allows an entire tray of bananas to be displayed for sale with no further handling. A huge reduction of labor is thus achieved. 
         [0009]    The container can be used for almost any other merchandise such as floral products that require lightweight, flexible display shippers. The size, strength and structure of the container can be readily modified as desired to suite the product being shipped. It can be customized to each specific item. 
         [0010]    In one arrangement, embodiments of the innovation relate to a reusable combined multi-part product shipping box and display tray. There are two generally rectangular trays, each defining four sides, with four barrier portions projecting upward from each tray proximate its edges, one barrier portion at about the center of each of the sides, and four corner posts, one projecting up from each corner of the tray. There is also a generally rectangular sleeve defining four sides and four corners, and open ends that are about the same size and shape as the trays, the sleeve adapted to engage with the trays to close its open ends and form a shipping container, the sleeve adapted to sit on the tray inside of and up against the barrier portions, with each corner of the sleeve located outside of and against a corner post, such that the sleeve is tightly engaged with the trays. 
         [0011]    In one arrangement, the trays are made of plastic and define an opening just inside of each post and that is sized and shaped to accept an identical post of another tray, to allow nesting of the trays. In one arrangement, the sleeve is manufactured of corrugated plastic and foldable into a flat form. In one arrangement, the posts are tapered from top to bottom where the bottom of the posts defines a wall portion that is essentially perpendicular to the top of the tray. The posts can include two sections at essentially ninety degrees to one another to form an “L” shaped configuration, one such section located on each of the two adjacent sides of the tray, so that each post engages with the two sides of the sleeve that meet at a corner of the sleeve. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the innovation, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the innovation. 
           [0013]      FIG. 1  is a top perspective view of an embodiment of a tray for a box assembly. 
           [0014]      FIG. 2  is an exploded view of a sleeve for the box assembly in the process of being placed on the tray of  FIG. 1 . 
           [0015]      FIG. 3  is an assembled view of the sleeve and tray of  FIG. 2 , illustrating the partially-assembled box ready to be filled with merchandise (such as bananas) that will be shipped in the box. 
           [0016]      FIG. 4  shows the box assembly of  FIGS. 1-3  fully assembled, with a second tray covering the open top of the assembly of  FIG. 3 ; the Figure does not shown the removable bands or other devices used to hold the trays and sleeve together after the box has been filled. 
           [0017]      FIG. 5  is an enlarged side view of one corner of the tray of  FIG. 1 , showing the post and barrier detail. 
           [0018]      FIG. 6  is a top view of the die-cut blank used to make the sleeve shown in  FIG. 2-4 . 
           [0019]      FIG. 7  is an enlarged view of the undersides of one corner of two of the trays shown in  FIGS. 1-5 , detailing the manner in which such trays nest for storage and shipment. 
           [0020]      FIG. 8  illustrates an arrangement of a sleeve for the box assembly, according to one arrangement. 
           [0021]      FIG. 9  illustrates an example of a schematic view of sleeve wall prior to sealing of the ends of the wall, according to one arrangement. 
           [0022]      FIG. 10  illustrates an example of a schematic view of sleeve wall following the sealing of the ends of the wall, according to one arrangement. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    As illustrated in  FIGS. 1-4 , a container or box assembly  10  consists of two substantially identical, injected molded tray, and one corrugated plastic sleeve that folds flat to minimize the storage and shipping space required once the box is broken down into its three parts. 
         [0024]    The trays are relatively lightweight and strong. The trays are configured to be nested with each other for condensed return freight efficiencies. Also, each tray includes corner posts that help to align the corrugated plastic sleeve and locate the sleeve snugly on the tray. The corner posts include a tapered entry which transitions to a vertical 90-degree wall, which helps to lock the sleeve into position and pulls the sleeve sidewalls into a tight, rigid position for improved sleeve (container sidewall) stacking strength. 
         [0025]    The trays further include vertical projections or barriers projecting upward from each of the four edges of the tray. These barriers limit or inhibit the sidewalls of the sleeve from expanding beyond the external perimeter of the tray. In one arrangement, the barriers are located centered on each of the four sides of the tray, at or close to the edges of the tray. The sleeve sits inside these barriers and rests up against them by the weight of the product pushing against the sleeve sidewalls. 
         [0026]    The trays define ventilation holes in the center to provide weight reduction and top provide cooling and gas applications when pallets are shipped in the holds of ships, for example. The cooling gases come up from the floor of the pallet. Also, the trays can define various additional holes and cutouts in the tray for weight reduction. Weight control of the combined two trays and sleeve is important since a full truckload of bananas approaches the legal limit of weight a truck can safely carry. 
         [0027]    The sleeve can be manufactured from a variety of materials. For example, the sleeve can be manufactured from corrugated polypropylene (i.e., plastic), such as 5 mm corrugated polypropylene, or any malleable material such as corrugated paper, injection molded plastic or corrugated polyethylene. When configured from corrugated plastic, the sleeves are relatively strong, lightweight, and unaffected by moisture or humidity. Additionally, when made from corrugated plastic, the sleeves can be machined on specialized machinery at a relatively low cost. Corrugated plastic can be mass produced at low cost to meet the volume requirements of a vast market. However, the sleeve could be made from any other material that has similar properties. 
         [0028]    The sleeve, in one arrangement, has a desired quantity and size of ventilation holes cut out of the appropriate panels to provide airflow for cooling and ripening purposes in desired locations of the assembled box. The sleeve can also include two handholds at each end. The purpose of having two handholds is that the box is packed with the bananas crown up and stacked at the plantation with the bananas oriented in this position, meaning that they are shipped in this position. When the bananas leave the ripening rooms, many times the cases are inverted either individually or entire pallets at a time so the bananas are orientated crown down for consumer display; this prevents the need for supermarket personnel to invert each bunch of bananas. Having a mirror image handhold allows the box of bananas to be conveniently carried at both the plantation and at the store level. 
         [0029]    The radius on the cut out portion of the handhold can be included, as it helps reduce tearing associated with having a cut end on a vertical flute line. Relief may be cut into the length panel that marries to the glue flap so the sleeve can be put over the corner posts on the tray. The size of the sleeve and trays can be easily modified to accommodate different case counts, products and other desirable variables. 
         [0030]    With reference to  FIG. 4 , the box assembly or container  10  is made up of two of trays  12 , and one sleeve  80 . In one arrangement, the trays  12  are injection molded from a plastic material having the requisite strength and weight, but could be made of other materials such as metal. As shown in  FIG. 1 , tray  12  defines sides  38 - 41 . Projecting corner posts  14  are located slightly inside of each corner on the top side  50 , at a distance from the edges that is approximately equal to the thickness of sleeve  80 . As further shown in  FIGS. 1 and 5 , each post  14  defines integral sections  16  and  18 , one located parallel to each of the edges, and having a length that is approximately related to the length of the side on which it resides; thus section  16  is longer than section  18 . Both of sections  16  and  18  have an upper tapered wall portion  20  and a lower vertical wall portion  22 . Openings  70  are located just inside of posts  14  and define an open area that is about the size of the area circumscribed by a post, so that the trays can be nested for storage and shipment, as shown in  FIG. 7 . Trays  12  further comprise four projecting walls or barrier portions  42 , one located at about the center of each side of the tray, at the edge. 
         [0031]    In one embodiment, tray  12  is about 16 by 20 inches, and posts  14  are about 0.50 inches high. Lower wall portion  22  has a height of about 0.13 inches. Upper wall portion  20  has a height of about 0.37 inches, and is tapered inward at a shallow angle. Barrier portions  42  are about 0.38 inches high and about 4 inches long. Central opening  62  is about 4 by 6 inches. The outer rim of the trays has a thickness of about 0.31 inches, and feet  64  and  65  project below the rim by about 0.19 inches. These dimensions are not critical but are illustrative of a tray that can be used as part of a box for shipping and displaying bananas, as further explained herein. 
         [0032]    In one arrangement, the sleeve  80  is die cut from 5 mm thick corrugated polypropylene material, and defines handle cutouts  92  and openings  94 , both located on the short sides of the assembled sleeve and shown in  FIG. 2 ; more or fewer openings and/or openings on other of the sleeve sidewalls can be used as desired. In one arrangement, there are two sets of handle cutouts  92  at each short side of the assembled sleeve. These mirror-image handle cutouts allow the assembled box to be easily handled regardless of the orientation of the box. When used for bananas, for example, the mirror-image handle cutouts allow the box to be easily handled whether the product is in the “crown up” or “crown down” positions. Assembly is accomplished by gluing the end flaps together to create a joint area. As shown in  FIG. 6 , the assembled sleeve can be folded flat along score lines  96 - 99 , as desired. When expanded, sleeve  80  defines open ends  82  and  83  that are sized and shaped to fit a tray  12 . When box  10  is assembled, trays  12  comprise the bottom and top, and sleeve  80  defines the box sidewalls  84 ,  85 ,  86 ,  87 . One or more strong removable straps of a type known in the art (not shown in the drawings) are used to keep box  10  fully assembled, once the product to be shipped and displayed has been placed into the box. 
         [0033]    Box  10  is used as follows. As shown in  FIG. 1 , a tray  10  is placed on a surface with top  50  facing up. As shown in  FIGS. 2 and 3 , sleeve  80  is placed edge down on tray  12  such that the sleeve corners are located just outside of posts  14 , and the sleeve sidewalls are located just inside of barriers  42 . Upper tapered post portions  20  help to guide sleeve  80  into place as it is slipped over the posts, while lower vertical portions  22  help to hold sleeve  80  squared tightly in place. Barriers  42  help to prevent the sleeve sidewalls from bowing outward appreciably when product is placed into the open-top box. 
         [0034]    When sleeve  80  is properly located on tray  12 , bananas or other product being shipped are placed into the container through open end  82  of sleeve  80 , which is the open top of the container. Bananas are placed in the normal shipping position—crown up. When the container is sufficiently filled (typically with about 40 pounds of bananas), a second tray  12  is placed upside down on the open top, with its bottom side  60  facing out, as shown in  FIG. 4 . One or more straps or other releasable devices that hold the assembly together are then placed, and box  10  is ready to be shipped. Openings  62  and  94  allow for flow of cooling and ripening gases. 
         [0035]    For retail display, box  10  is flipped over and placed on a display shelf. The straps are removed. Upper tray  12  and sleeve  80  are removed. This leaves lower tray  12  with product (e.g., bananas) sitting thereon. Store personnel do not need to lift the bananas from the box or turn them upward (crown down) for display. In fact, personnel do not need to handle the bananas in any way. 
         [0036]    Once all of the bananas are sold, the empty trays can be stacked and placed on pallets for shipment back to the packing location. Likewise, the sleeves can be folded flat, palletized, and returned for re-use. 
         [0037]    As indicated above, the sleeve  80  can be manufactured from a corrugated material, such as a corrugated plastic material. In one arrangement, as indicated in  FIG. 2 , the sidewalls  84 - 87  are configured with corrugations  91  that extend from a first end  81  to a second end  83  of the sleeve  80 . In such an arrangement, the ends  81 ,  83  of the sleeve  80  are open to the environment to allow air and fluid to pass there through. In another arrangement, as illustrated in  FIG. 8 , the walls  84 - 87  at the first end  81  and the second end  83  of a sleeve  180  are sealed together, to define a set of sealed flutes  126  within the sleeve  80 . Each of the sealed flutes  126  includes a longitudinal axis extending between the first end  81  of the sleeve  180  and the second end  83  of the sleeve  80 . 
         [0038]    For example with reference to  FIG. 9 , a wall  84  of the sleeve  180  includes a first linerboard  120  and a second linerboard  122  spaced apart from the first linerboard  120 . The wall  84  further includes a corrugated sheet  124  disposed between the first and second linerboards  120 ,  122 . During a manufacturing process, a manufacturer compresses the linerboards  120 ,  122  together at both ends  81 ,  83  of the sleeve  180  and secures the linerboards  120 ,  122  to each other at these ends  81 ,  83 . For example, in the case where the linerboards  120 ,  122  and corrugated sheet  124  are formed from a plastic material, the manufacturer can pinch the linerboards  120 ,  122  together at respective ends  81 ,  81  and secure the linerboards  120 ,  122  together using a mechanical coupling, an adhesive, heat, or an ultrasonic welding process. As indicated in  FIG. 10 , the manufacturing process creates a set of sealed flutes  126  within the wall  84  where each sealed flute  126  contains a volume of air. 
         [0039]    With such a configuration, because the sealed flutes  126  trap air within the wall  84 , the sleeve  180  can be manufactured using less material (e.g., plastic) and can be manufactured with a greater stacking strength than conventional sleeves. Additionally, the seal at either end  81 ,  83  minimizes the introduction of vermin (e.g., insects) and dirt between the linerboards  120 ,  122   
         [0040]    While various embodiments of the innovation have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the innovation as defined by the appended claims.