Patent Document

BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention is broadly concerned with a storage container which can be alternately configured for storage, carrying and mailing purposes, and also to provide convenient access to materials within the container, and selective configuration as a tray or activity surface. More particularly, the invention is concerned with such a multiple function container, and blanks used in fabricating the container, wherein the container is especially adapted to hold a video cassette or book, as well as other activity items.  
         [0003]     2. Description of the Prior Art  
         [0004]     Containers of various types and configuration have been produced in myriad styles and forms. These range from simple paperboard boxes to more complicated designs having specialized internal compartments. See, e.g., U.S. Pat. Nos. 3,899,119, 2,249,657 and 2,758,774. Other references describing boxes and containers of different designs include: U.S. Pat. Nos. 4,739,921, 1,783,453, 2,168,387, 2,117,502, 2,645,407, 2,795,368, 3,269,637, 2,981,458, 3,355,086, 3,625,410, 4,530,459, 4,637,544, 4,757,937, 5,144,914, 5,984,755, 6,527,123, 6,948,616, 2003/0015579, 2004/0200891, 3,724,650, 4,090,608, 5,788,081, 5,934,551, 5,794,631.  
         [0005]     Many children like to watch prerecorded videos on video tapes or the like. Such child-oriented tapes may also come with associated activity items. For example, a video tape directed to prehistoric dinosaurs may come with associated dinosaur toys. However, the toys are often lost because there is no convenient way to store them along with the video tape. Further, storage of such items subsequent to mailing is often difficult. Similarly, food items, prepared or packaged, are often stored and carried in suitable containers, but such containers can be cumbersome when accessing and consuming the food items therefrom.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention overcomes the problems outlined above and provides an improved container which can be used for storage, carrying and mailing, and can be alternately configured to allow ready access to the contents thereof, as well as to provide a convenient tray or activity surface. In preferred forms, the container of the invention is designed to store a video tape, book, prepackaged food or other like items, along with associated items such as toys or the like.  
         [0007]     Broadly speaking, the container of the invention includes a primary container having a bottom wall panel and opposed sidewall panels and a front panel, and a shelf within the primary container so as to define a storage space between the shelf and bottom wall having a rearwardly facing access opening. Preferably, a tray insert is also provided which sits atop the shelf and provides space for other items. The container also has a closure assembly operatively secured to the rear margin of the bottom wall panel and configured to cover the rearward access opening of the storage space and also the open top of the primary container. The closure assembly in one configuration is used to completely close the container for storage, carrying and/or mailing. In another orientation, the closure assembly is reconfigured by folding so as to open the storage area and allow access to and easy use of the storage area and the upper shelf or tray area, and can be selectively secured in such open configuration so as to effectively convert the container to a tray or activity surface.  
         [0008]     In another aspect of the invention, blanks are provided for the fabrication of the components making up the preferred container. These include a primary container blank, a shelf insert blank and a tray insert blank. The blanks are appropriately folded and cooperatively form the desired container or activity surface. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a plan view of the primary container blank of the invention;  
         [0010]      FIG. 2  is a perspective view of a partially constructed primary container formed from the blank of  FIG. 1 ;  
         [0011]      FIG. 3  is a plan view of a shelf insert blank;  
         [0012]      FIG. 4  is a perspective view illustrating the shelf insert formed from the blank of  FIG. 3 ;  
         [0013]      FIG. 5  is a plan view of a tray insert blank;  
         [0014]      FIG. 6  is a perspective view of the tray insert formed from the blank of  FIG. 5 ;  
         [0015]      FIG. 7  is a perspective view illustrating the primary container, together with the shelf insert partially installed in the primary container;  
         [0016]      FIG. 8  is a sectional view taken along line  8 - 8  of  FIG. 7 ;  
         [0017]      FIG. 9  is an exploded perspective view illustrating the formed primary container and shelf insert, together with the tray insert, and also showing a video tape package for insertion into the primary container;  
         [0018]      FIG. 10  is a perspective view opposite to that  FIG. 9 , and showing the video cartridge and tray within the primary container;  
         [0019]      FIG. 11  is a perspective view similar to that of  FIG. 10 , but depicting the next step in fabrication of the complete container through use of the closure assembly forming a part of the primary container;  
         [0020]      FIG. 12  is a perspective view similar to that of  FIG. 11 , but illustrating the final construction step to complete the container;  
         [0021]      FIG. 13  is a perspective view of the completed container of the invention;  
         [0022]      FIG. 14  is a perspective view of the completed container, but showing the alternate use of the closure assembly in order to create an open-top container; and  
         [0023]      FIG. 15  is a perspective view with parts broken away and similar to that of  FIG. 14 , but showing the final alternate configuration of the container. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     Turning now to the drawings, a multiple use or function container  20  is illustrated which can assume a closed, carrying position as seen in  FIG. 13 , or alternately an open use position depicted in  FIG. 15 . Broadly speaking, the container  20  is made up of a primary box-like container  22 , a shelf insert  24  within the container  22 , and an optional tray insert  26  likewise positioned within primary container  22  atop insert  24 . The primary container  22  is fabricated from primary container blank  28 , while shelf insert  24  is fabricated from shelf insert blank  30 , and tray insert  26  is fabricated from tray insert blank  32 .  
         [0025]     In more detail, turning initially to  FIGS. 1 and 2 , the primary container blank  28  is in the form of an integral sheet of paperboard or the like, presenting a front panel  34 , bottom panel  36  and closure assembly  38 . The front panel  34  is rectangular and presents front and rear margins  40 ,  42 , and opposed side margins  44  and  46 . When including an optional handle feature, the panel  34  has a pair of spaced handle-receiving apertures  48  formed therein. A pair of first flaps  50 ,  52  are respectively secured to the side margins  44 ,  46  of panel  34 , along fold lines  54 ,  56 .  
         [0026]     The bottom panel  36  is likewise rectangular in configuration and is secured to front panel  34  along lateral fold line  58 . The panel  36  has a front margin  60 , rear margin  62  and side margins  64 ,  66 . A pair of second flaps  68 ,  70  are secured to and extend from each of the side margins  64 ,  66 , along respective fold lines  72 ,  74 . Each of the flaps  68 ,  70  has an outermost connection tab  76 ,  78 , the purpose of which is to be described below. In addition, each of the flaps  68 ,  70  has an intermediate fold line  80 ,  82 , which divides the flaps into respective sections  68   a ,  68   b  and  70   a ,  70   b . It will be observed that the fold lines  80 ,  82  are located such that the distance between the fold lines  80 ,  82  and the corresponding adjacent fold lines  72 ,  74  is greater than the distance between the fold lines  80 ,  82  and the corresponding outer free edges of the flaps  68  and  70 .  
         [0027]     The closure assembly  38  is secured to the rear margin  62  of bottom panel  36  along fold line  84 . The assembly  38  also presents side margins  86 ,  88 , as well as outboard, transverse margin  90 . The assembly  38  has first, second and third mutually parallel and spaced apart intermediate fold lines  92 ,  94  and  96 , thereby defining a rear panel  98  between fold line  84  and first intermediate fold line  92 ; a top panel  100  between first and third intermediate fold lines  92 ,  96 ; and a connection panel  101  between third intermediate fold line  96  and outboard margin  90 .  
         [0028]     It will be observed that the distance between fold lines  84  and  94  is substantially equal to the distance between fold lines  58  and  84 . The first intermediate fold line  92  is also oriented such that the distance between it and third intermediate fold line  96  is also substantially equal to the distance between fold lines  58  and  84 . In addition, the distance between fold line  84  and fold line  92  is substantially equal to the distance between front and rear margins  40  and  42  of front panel  34 .  
         [0029]     The connection panel  101  optionally includes a central handle-clearing slot opening  102 , and also includes laterally extending third connection flaps  104 ,  106  secured along respective fold lines  108 ,  110 .  
         [0030]     Turning next to  FIGS. 3 and 4 , the shelf insert blank  30  is integrally formed from paperboard or the like, and has a front step panel  112 , top panel  114  and sidewall panel  116 . Step panel  112  is generally rectangular, presenting a forward margin  118 , rear margin  120  and side margins  122 ,  124 . As illustrated, the step panel  112  also has an intermediate, laterally extending fold line  126  extending between side margins  122 ,  124  and parallel with the front and rear margins  118 ,  120 .  
         [0031]     The top panel  114  is generally rectangular, having front margin  128 , rear margin  130  and side margins  132 ,  134 . The top panel  114  is connected to step panel  112  via fold line  136 . The sidewall panel  116  is generally rectangular, having front margin  138 , rear margin  140  and side margins  142 ,  144 . The sidewall panel  116  is connected to top panel  114  via fold line  137 .  
         [0032]     The blank  30  also includes sidewall flaps  146  and  148  which are secured to sidewall panel  116  and top panel  114  along fold lines  150 ,  152 . The flaps  146 ,  148  also extend beyond the fold line  136 , but are not connected with step panel  112 . As shown, each of the flaps  146 ,  148  is somewhat of inverted L-shape, and has a diagonal fold line  154 ,  156  extending from the adjacent end of fold line  130  to the juncture of the “L.” Finally, it should be noted that a pair of connection slots  158 ,  160  are provided along the fold lines  150 ,  152 , at the central region of top panel  114 .  
         [0033]     Turning next to  FIGS. 5 and 6 , the tray insert blank  32  is integrally formed of paper board or the like, including food safe cardboard, and has a bottom wall panel  162 , a sidewall  164  and an apertured top panel  166 . The bottom panel  162  has front and rear margins  168 ,  170 , and side margins  172 ,  174 . Panel  164  is secured to the panel  162  along fold line  176  and has front and rear margins  178 ,  180  and side margins  182 ,  184 . The apertured top panel  166  is secured to panel  164  along fold line  186 , and has front and rear margins  188 ,  190 , and side margins  192 ,  194 . As shown, the panel  166  has a circular opening  196  as well as a rectangular opening  198 .  
         [0034]     The panels  162  and  164  each have a rectangular flap  200 ,  202  secured thereto along individual fold lines  204 ,  206 . Each of the flaps  200 ,  202  has a lateral fold line  208 ,  210  extending from fold line  176  to the outer margin of the respective flap. In addition, each of the flaps  200 ,  202  has a diagonal fold line  212 ,  214  extending from the fold line  176  as shown.  
         [0035]     The top panel  166  also includes a pair of flaps  216 ,  218  secured along respective fold lines  220 ,  222 . Finally, the panel  166  also has a side flap  224  secured thereto along fold line  226 .  
         [0036]     The container  20  is fabricated from the blanks  28 ,  30  and  32 . Generally, this construction proceeds by first fabricating the shelf insert  24 , using blank  30 . This involves folding the step panel  112  about fold lines  126  and  136  ( FIG. 4 ), and then folding the sidewall flaps  146 ,  148  about fold lines  150 ,  152  and  154 ,  156 , and sidewall panel  116  about fold line  137 . This opens the slots  158 ,  160  and creates the shelf insert  24  which is inserted within the primary container  22  as will be described.  
         [0037]     In the next step ( FIG. 2 ), the primary container  22  is partially fabricated. If an optional handle is desired, this step involves first installing a flexible, synthetic resin handle  228  within the apertures  48 . Next, front panel  34  is folded upwardly along fold line  58 , with the first flaps  50 ,  52  folded inwardly along fold lines  54 ,  56 . Next, the second flaps  68  and  70  are folded upwardly along fold lines  72  and  74 , and flap sections  68   b  and  70   b  are folded upwardly along fold lines  80  and  82 , until the blank assumes the  FIG. 2  configuration.  
         [0038]     At this point ( FIGS. 7 and 8 ), the insert  24  is positioned over bottom panel  36  with the front margin  118  abutting the inner surface of front panel  34  and with the sidewall flaps  146 ,  148  essentially in face-to-face contact with the inner surfaces of the second flap sections  68   a ,  70   a . The second flap sections  68   b  and  70   b  are then folded along fold lines  80 ,  82  over the upper edges of first flaps  50 ,  52 , and the sidewall flaps  146 ,  148 . Thereupon, the tabs  76 ,  78  are inserted into the slots  158 ,  160 . This serves to lock the shelf insert  24  in place within the confines of primary container  22 .  
         [0039]     In this condition, it will be seen that the container  22  has a lower storage compartment  229  between top panel  114 , bottom panel  36 , second flaps  68 ,  70  and step panel  112 . The compartment  229  also has a rearwardly facing access opening  229   a.    
         [0040]     As seen in  FIGS. 5 and 6 , the tray insert  26  is constructed by folding panel  164  upwardly about fold line  176  and also folding the flaps  200 ,  202  upwardly about fold lines  204 ,  206 . Also, the ends of the flaps  200 ,  202  are folded inwardly along lines  208 ,  210 , thereby allowing the flap ends to be secured via adhesive  230  to the adjacent face of panel  164 . In order to complete the insert, the flaps  216 ,  218  and  224  are folded downwardly about lines  220 ,  222  and  226 . Upon completion, the insert  26  is placed within primary container  22 , atop panel  114 . This construction is illustrated in  FIGS. 9 and 10 , for example.  
         [0041]     The container  20  is next loaded with a video cassette  232 , book, prepackaged food item or other appropriately sized item as well as associated activity materials (not shown). In particular, the cassette  232  is inserted into space  229  through opening  229   a , and the other associated activity materials are placed on bottom panel  162  and within the openings  196  and  198  as required.  
         [0042]     Once loaded, the closure assembly  38  is used to close the container  20 , as illustrated in  FIGS. 11 and 12 , until it assumes the storage, carrying, or mailing position depicted in  FIG. 13 . Specifically, the closure assembly  38  is grasped and folded about fold line  84  so that rear panel  98  comes into facing and covering relationship with upstanding flap  202  (or shelf sidewall panel  116  if tray insert  26  is not utilized in a particular configuration) and compartment access  229   a . The assembly is then further folded about line  92  so that the top panel  100  is moved into full covering relationship with the open top of container  22 . Finally, the connection panel  101  is folded downwardly about line  96  and the flaps  104 ,  106  are folded about lines  108 ,  110 . These flaps  104 ,  106  are inserted between the side margins  44 ,  46  of front panel  34 , and the adjacent segments  68   a  and  70   a  of second flaps  68  and  70 . Handle  228  is then passed through slot  102 .  
         [0043]     When it is desired to access the contents of container  20 , the connection panel  101  is folded upwardly and outwardly until the flaps  104 ,  106  are free, and the closure assembly  38  is lifted upwardly about fold line  92  until top panel  100  is no longer in covering relationship with the open top of container  22 , allowing access to the contents above top panel  114 . Closure assembly  38  is then unfolded about fold line  84  to allow access to storage compartment  229 , as in  FIG. 10 . When it is desired to secure closure assembly  38  when in an open configuration, such that closure assembly  38  is stowed out of the way of the user, closure assembly  38  is folded under container  22  about fold line  84 , and is placed beneath bottom panel  36 . In this manner, rear panel  98  and the portion of top panel  100  between fold line  92  and fold line  94  are positioned in facing and contacting relationship with bottom panel  36 . The assembly  38  is then folded upwardly about intermediate fold line  94 , while reverse folding the connection panel  101  against the face of the portion of top panel  100  between fold lines  94  and  96  (see  FIG. 14 ). Then, assembly  38  is folded upwardly along fold line  94 , such that connection panel  101  is positioned in facing contact with front panel  34 , as the flaps  104 ,  106  are again inserted between the side margins  44  and  46  of front panel  34  and the adjacent segments  68   a  and  70   a  of second flap  68 ,  70 , so that the container  20  assumes the position depicted in  FIG. 15 . In this orientation, the user can access storage compartment  229  and also the contents placed within tray insert  26  (or on shelf top panel  114  if tray insert  26  is not utilized in a particular configuration) without any interference from closure assembly  38 , effectively converting container  20  into a tray or activity surface.  
         [0044]     It will be appreciated that the blanks and fabricated container components can be produced from a variety of materials, so long as they are suitable for container and activity usage. In addition, in the illustrated embodiment, the fold lines shown as dashed lines are perforation lines, whereas solid fold lines are score lines. Here again, the use of particular types of fold lines is a matter of design choice.

Technology Category: 7