CONVERTIBLE SHELF-READY SHIPPING CONTAINER

Abstract

A shelf-ready shipping container, including a cardboard shipping box, the cardboard shipping box including a base tray, a removable top formed continuously with the base tray, a tear strip disposed at an interface of the base tray and the removable top, where tearing away the tear strip separates the removable top from the base tray. The base tray includes a bottom panel and sidewall panels, where the base tray is separable into a first shelf-display tray and a second shelf-display tray along an interface between the first shelf-display tray and the second shelf-display tray, where the interface is defined by a weakened portion of the base tray.

Claims

1. A shelf-ready shipping container, comprising: a cardboard shipping box comprising: a base tray, a removable top formed continuously with the base tray, a tear strip disposed at an interface of the base tray and the removable top, wherein tearing away the tear strip separates the removable top from the base tray, wherein the base tray comprises: a bottom panel; and sidewall panels, wherein the base tray is separable into a first shelf-display tray and a second shelf-display tray along an interface between the first shelf-display tray and the second shelf-display tray, wherein the interface is defined by a weakened portion of the base tray.

2. The shelf-ready shipping container of claim 1, wherein the weakened portion of the base tray is defined by openings and perforations extending between the openings.

3. The shelf-ready shipping container of claim 2, wherein the perforations extend to an upper edge of a front sidewall panel of the base tray and to an upper edge of a rear sidewall panel of the base tray.

4. The shelf-ready shipping container of claim 2, wherein a first one of the openings extends from the bottom panel to a front sidewall panel of the base tray, and wherein a second one of the openings extends from the bottom panel to a rear sidewall panel of the base tray.

5. The shelf-ready shipping container of claim 4, wherein a third one of the openings is entirely disposed in the bottom panel, between the first opening and the second opening.

6. The shelf-ready shipping container of claim 1, further comprising a second tear strip, wherein the first tear strip is disposed at an upper edge of a front sidewall panel of the base tray, wherein the second tear strip is disposed at an upper edge of a rear sidewall panel of the base tray, and wherein the second tear strip is disposed a greater vertical distance from the bottom panel than the first tear strip.

7. The shelf-ready shipping container of claim 6, wherein the cardboard box defines openings above and defined in part by upper edges of side sidewalls of the base tray, and wherein ends of the first tear strip are separated from ends of the second tear strip by the openings.

8. A shelf-ready shipping container, comprising: a top portion; a bottom portion comprising a front panel, a rear panel, and a bottom panel, and comprising a perforation extending centrally across the front panel, the bottom panel, and the rear panel, wherein the bottom portion is separable along the perforation into a first bottom portion and a second bottom portion, wherein the top portion and the bottom portion together form an enclosure configured to house products; and a tear strip disposed between the top portion and the bottom portion, wherein the top portion is separably coupled to the bottom portion along the tear strip.

9. The shelf-ready shipping container of claim 8, wherein the bottom portion defines die cuts that interrupt the perforation.

10. The shelf-ready shipping container of claim 8, wherein the top portion comprises a front panel and a rear panel, and wherein a height of the top-portion front panel is greater than a height of the top-portion rear panel, and a height of the bottom-portion front panel is less than a height of the bottom-portion rear panel such that when the top portion is removed, the bottom portion forms a tray for displaying the products, the tray having a front wall lower than a rear wall.

11. The shelf-ready shipping container of claim 10, wherein, when the bottom portion is separated along the perforation, the tray is separated into a first display tray and a second display tray for displaying the products.

12. The shelf-ready shipping container of claim 8, wherein the perforation bisects the bottom portion.

13. The shelf-ready shipping container of claim 8, further comprising the products, wherein the products are disposed in rows, each row extending in direction from the front panel to the rear panel, and wherein the perforation is disposed at an interface between two adjacent rows of products.

14. A product display system, comprising: a top; and two product-display trays, wherein the top and the two product-display trays together form a shipping container for transporting product arranged therein, wherein the two product-display trays together form a base of the shipping container, wherein, upon removal of the top and separation of the two product-display trays, the two product-display trays display the product with no need for further alteration or arrangement of the product or the product-display trays.

15. The product display system of claim 14, further comprising a tear strip, wherein, when in the form of the shipping container, the tear strip connects the top to the two product-display trays.

16. The product display system of claim 14, wherein the two product-display trays are coupled to form a single product-display tray.

17. The product display system of claim 16, wherein the products are arranged in two adjacent rows within the single product-display tray.

18. The product display system of claim 14, wherein the products are arranged in a single row in each of the two product-display trays.

19. A blank for forming a shelf-ready shipping container, the blank comprising: a central series of rectangular panels, each panel of the central series of panels connected to an adjacent panel of the central series of panels by a fold line, the central series of panels comprising: a line of weakness extending through the central series of panels; and a plurality of openings disposed along the score line; a first outer series of panels, each panel of the first outer series of panels connected to the central series of panels by a fold line along a first side of the central series of panels; a second outer series of panels, each panel of the second outer series of panels connected to the central series of panels by a fold line along a second side of the central series of panels; a third outer series of panels, each panel of the third outer series of panels connected to the central series of panels by a fold line along a third side of the central series of panels; a first tear strip extending across a first panel of the first outer series of panels, a first panel of the central series of panels, and a first panel of the second outer series of panels, wherein the first tear strip is parallel to the fold lines of the central series of panels; and a second tear strip extending across a second panel of the first outer series of panels, a second panel of the central series of panels, and a second panel of the second outer series of panels, wherein the second tear strip is parallel to the fold lines of the central series of panels.

20. The blank of claim 19, wherein the first tear strip is disposed adjacent to a first opening, and the second tear strip is disposed adjacent to a second opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a front perspective view of a shelf-ready shipping container according to some embodiments.

[0010] FIG. 2A is a front view of the shelf-ready shipping container of FIG. 1.

[0011] FIG. 2B is a rear view of the shelf-ready shipping container of FIG. 1.

[0012] FIG. 3 is a left side view of the shelf-ready shipping container of FIG. 1.

[0013] FIG. 4A is a front view of a base tray of shelf-ready shipping container according to some embodiments.

[0014] FIG. 4B is a side view of the base tray of FIG. 4A.

[0015] FIG. 5 is a top view of the base tray of FIG. 4A.

[0016] FIG. 6 is a front view of the base tray of FIG. 4A that has been separated into two smaller trays according to some embodiments.

[0017] FIG. 7 is a top view of the base tray of FIG. 6.

[0018] FIG. 8 shows a blank for forming a shelf-ready shipping container according to some embodiments.

DETAILED DESCRIPTION

[0019] The following examples are illustrative, but not limiting, of the present disclosure. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the disclosure.

[0020] Shipping containers (sometimes called cases) for packaging and shipping consumer products, such as, for example, cereal, granola bars, fruit snacks, breakfast pastries, cookies, baking mixes, and other boxed or otherwise packaged goods, may be manufactured from corrugated cardboard because of its structural strength and its ready availability. The sizes of the shipping containers may be selected to maximize the number of boxes of products that may be packed, as well as to optimize shipping efficiency by ensuring that a certain number of cases fit on a shipping pallet in an efficient and structurally-sound way.

[0021] Once the shipping containers are delivered to retailers, the products are then unpacked to stock shelves or other product displays. This stocking step can be very time consuming, as each individual box of products needs to be transferred from the shipping container to the shelf or product displayoften in a space significantly narrower than the shipping container, and then arranged neatly. Additionally, product displays are typically manufactured separately from the shipping containers, which have their own separate and additional cost of materials, potential line inefficiencies during manufacturing, capital expenditures on display designs, and variable costs at supplier facilities.

[0022] Some embodiments described herein help increase shipping and stocking efficiencies while reducing overall costs by providing a shipping container that may convert into a product display, for example a shelf display, and may do so in a smaller (e.g., narrower) and more flexible footprint than that of the shipping container. For example, in some embodiments, a convertible shelf-ready shipping container may include a base tray connected to a top by at least one tear strip.

[0023] In some embodiments, the tear strip may be a strip laminated within at least one panel of the shipping container by scoring the panel. The tear strip may include a pull tab at one or both of its ends, which may be pulled to initiate a tear along the scored areas of the panel. The tear strip may be fully torn from the panel, thereby separating it into two portions.

[0024] The tear strip may allow the top of the shipping container to be easily removed from the base tray when the time comes to unpack, and until then may maintain a conventional box shape having high structural strength such that the products packed therein remain protected during shipping. Furthermore, the shipping containers may be large enough to maintain the same case counts as with conventional shipping containers such that the same number of products may be shipped.

[0025] Once the tear strip is removed, the top may be removed and discarded, leaving the base tray with the products packed therein. In some embodiments, the base tray may form a four-walled, multi-facing display, meaning that at least two rows of products may be displayed next to each other within the same product-display tray.

[0026] Additionally, in some embodiments the base tray has a weakened portion, such as a perforation, extending across the base tray and bisecting it into two equal portions such that it may be split in half, forming two smaller trays. For example, each of the two smaller trays may be at least a single-facing product-display tray (e.g., having three walls each, with no wall on the side that was previously joined to the other product-display tray).

[0027] In both instances, the base tray forms at least one shelf display that may be placed directly on a shelf without requiring any rearrangement of the products packed therein, thereby eliminating the need for production of separate shelf displays and improving the efficiency of the shelf-stocking process. And the same shelf display can be used in-tact as a single product-display tray (e.g., if there is a wide shelf space available for it) or split apart into two product-display trays (e.g., if there is a narrower shelf space available for it).

[0028] FIGS. 1-3 show different views of a shelf-ready shipping container 100 according to some embodiments. Shipping container 100 may be configured to package a plurality of products. Shipping container 100 may include a top 110 separably coupled to a base tray 120, along tear strips 102 and 104. Tear strips 102 and 104 may connect top 110 to base tray 120 such that top 110 and base tray 120 form a sealed box. In some embodiments, shipping container 100 may be made from cardboard, specifically corrugated cardboard.

[0029] Top 110 may include a front panel 114 and a rear panel 118. Base tray 120 may include a front panel 124 and a rear panel 128. Front panels 114 and 124, and rear panels 118 and 128, may wrap around and extend onto sides of shipping container 100 (e.g., by folding at edges thereof). As shown in FIGS. 2A and 2B, for example, in some embodiments, front panel 114 of top 110 may have a height 115 greater than a height 119 of rear panel 118 of top 110. For example, height 115 of front panel 114 may be at least 125% of height 119 of rear panel 118. This difference in height helps base tray 120 display products while maintaining a high degree of structural stability, as will be explained further below. Conversely, in some embodiments, front panel 124 of base tray 120 may have a smaller height than rear panel 128 of base tray 120. Additionally top 110 and base tray 120 may include sidewall panels 116 and 126, respectively.

[0030] As shown in FIG. 3, for example, sidewall panel 116 of top 110 may have a rectangular shape such that a bottom edge 142 of sidewall panel 116 is parallel to top panel 112 of top 110. However, since front panel 124 of base tray 120 has a height 125 smaller than a height 129 rear panel 128, a top edge 144 of sidewall panel 126 of base tray 120 may slope downward from its interface with rear panel 128 to its interface with front panel 124.

[0031] In some embodiments, the difference in height of the front and rear panels of top 110 and base tray 120, along with the sloped top edge 144 of sidewall panel 126 create a low wall tray, or a tray having a front panel with a smaller height than that of a rear panel of the tray, when top 110 is removed from base tray 120. Rear panel 128 and sidewall panels 126 may support the product boxes and help prevent them from falling over (e.g., during arrangement and re-arrangement of product boxes on shelves, or while customers are removing product boxes), while front panel 124 may provide some support while simultaneously maximizing visibility of the products due to its lower height. The relatively small height of front panel 124 may allow, for example, a majority of a front face of a product box to be visible. Similarly, the sloped top edge 144 of sidewall panels 126 may allow for a large portion of a side of a product box to be visible. In some embodiments, to effect the above-mentioned features, height 125 of front panel 124 of base tray 120 is less than 50% of height 115 of front panel 114 of top 110. Also, height 129 of rear panel 128 of base tray 120 may be greater than 150% of height 125 of front panel 124 of base tray 120.

[0032] In some embodiments, first tear strip 102 may be disposed at an upper edge of front panel 124 of base tray 120, and second tear strip 104 may be disposed at an upper edge of rear panel 128 of base tray 120. Furthermore, second tear strip 104 may be disposed a greater vertical distance from a bottom of base tray 120 than first tear strip 102 (e.g., measured from bottom panel 450 shown in FIGS. 4A-5).

[0033] Top 110 may be removed from base tray 120 by pulling on pull tabs 106 attached to tear strips 102 and 104, thereby removing tear strips 102 and 104, which separates top 110 from base tray 120. After removal, top 110 may be discarded. FIGS. 4A and 4B show shipping container 100 with top 110 removed from base tray 120. Product boxes 410 may be packed within base tray 120 (e.g., in rows).

[0034] As shown in FIGS. 4A and 4B, in some embodiments, by removing top 110 via tear strips 102, 104, as described above, shipping container 100 may be converted into a product-display tray 120 (also referenced as base tray 120) (e.g., forming a dual-facing shelf display as shown), with product boxes 400 already arranged therein such that no further arrangement of the boxes is necessary for their display. Rather, base tray 120 may simply be placed on a shelf, thereby significantly reducing shelf-stocking times.

[0035] In addition to forming a single product-display tray, in some embodiments, base tray 120 may be separated into two product display trays 150 and 160 (e.g., two single-facing three-walled shelf displays, with one row of product boxes 400 displayed in each). As shown in FIG. 5, for example, a bottom panel 170 of base tray 120 may have a weakened portion 130 (e.g., a line of weakness that disrupts the material integrity of bottom panel 170) disposed down the center of bottom panel 170, parallel to sidewall panels 126, thereby bisecting base tray 120 into two equal portions. Weakened portion 130 may be weakened in any manner that facilitates splitting of base tray 120 into product-display trays 150 and 160. In some embodiments, weakened portion 130 may be weakened by a series of perforations in, or by one or more score lines in, bottom panel 450. Weakened portion 130 may also extend up front panel 124 and rear panel 128 to extend completely across base tray 120.

[0036] Base tray 120 may additionally include a plurality of openings 132, 134, and 136 (e.g., die-cut openings) disposed along and interrupting weakened portion 130 such that the perforations extend between die-cut openings 132, 134, and 136. First die-cut opening 132 may extend from bottom panel 450 to a front panel 124 (thereby extending across a bottom front corner of base tray 120), third die-cut opening 136 may extend from bottom panel 170 to rear panel 128 (thereby extending across a bottom rear corner of base tray 120), and second die-cut opening 134 may be entirely disposed in bottom panel 170, between first die-cut opening 132 and third die-cut opening 136.

[0037] Die-cut openings 132, 134, and 136 may further facilitate splitting of base tray 120, as they create locations to begin tearing along weakened portion 130. For example, openings 132, 134, and 136 create multiple places where a tear along weakened portion 130 can be easily initiated, so that tear initiation is not limited to outer edge locations at front panel 124 and rear panel 128. Further, positioning die-cut openings 132 and 136 across front and rear bottom edges helps facilitate separation of base tray 120 into product-display trays 150 and 160 by taking the place of what might otherwise be a perforation, as perforations may be difficult to cleanly navigate across corners. Die-cut openings 132, 134, and 136 are shown in an oval shape, but may be formed in any shape.

[0038] FIGS. 6 and 7 show base tray 120 split into two halves, according to some embodiments, thereby forming two product-display trays 150 and 160. As shown in FIGS. 6 and 7, left product-display tray 150 may include a front panel 154 sidewall panel 126, and a rear panel 158. Right product-display tray 160 may be a mirror image of left product-display tray 150, and may include a front panel 164, sidewall panel 126, and a rear panel 168. Each of left product-display tray 150 and right product-display tray 160 may be half the width of base tray 120, from which they were formed. For example, where base tray 120 was a multi-facing shelf display, each of product-display trays 150 and 160 may be a three-walled shelf display, each having at least one row of product boxes 400 packed therein, where the number of rows of product boxes 400 in each of product-display trays 150 and 160 is fewer than were in base tray 120 before it was separated into product-display trays 150 and 160.

[0039] Like with base tray 120, left product-display tray 150 and right product-display tray 160 may be placed directly onto a shelf without requiring any rearrangement of the product boxes 400. And because left product-display tray 150 and right product-display tray 160 are each half the width of base tray 120, they may be positioned in a narrower shelf space (e.g., one behind the other on a shelf), such that the same number of product boxes 400 may be stocked while occupying less front space on the shelf.

[0040] Because less shelf space may be occupied by left and right product-display trays 450 and 460, retailers have greater flexibility in arranging products on their shelves. For example, a greater number of different products may be stocked on a single shelf such that the shelf's frontage is more varied, which may increase ease of shopping for consumers. Also for example, because base tray 120 can be split into two product-display trays 150 and 160, a retailer has the flexibility to easily spread the product throughout a store without removing it from its original packaging, by placing product-display tray 150 in one location, and product-display tray 160 in a different location. Or the retailer may choose not to split base tray 120, and instead to keep it in-tact and make use of its wider display frontage. Since base tray is not split until it reaches the retailer, the retailer retains the flexibility to decide how best to use it according to the retailer's present needs.

[0041] And, since base tray 120 is not split into left and right product-display trays 450 and 460 until it reaches the retailer, the size of the overall shipping container, for example shipping container 100, may be comparable to conventional shipping containers. Accordingly, at least the same number of convertible shipping containers may fit on a shipping pallet as with conventional shipping containers, thereby maintaining the structural integrity of the pallet and preserving shipping efficiency.

[0042] FIG. 8 shows a blank 800 for forming a shelf-ready shipping container according to some embodiments. Blank 800 may include a central series of panels 810, each connected to an adjacent panel by a fold line 814. Blank 800 may additionally include a first outer series of panels, 822, 824, 826, and 828, each connected to one of the central panels 810 by a fold line 812, and a second outer series of panels 842, 844, 846, and 848, each connected to one of the central panels 810 by a fold line 816. Panels 822, 824, 826, and 828 are spaced apart from each other such that each panel is connected to one of the central panels 810, but not to an adjacent outer panel. Similarly, panels 842, 844, 846, and 848 are also spaced apart from each other such that each panel is connected to one of the central panels 810, but not to an adjacent outer panel.

[0043] In some embodiments, when folded along fold lines 814, central panels 810 may form, for example, top, bottom, front, and rear panels of shipping container 100. Panels 822, 826, 842, and 846 may be folded inward along fold lines 812 and 816 to create side portions of, for example, shipping container 100, which may extend between the front and rear panels. Panels 824 and 844 may also be folded inward along fold lines 812 and 816 and may, for example, extend from the top panel of shipping container 100 to form, for example, sidewall panels 116 of top 110. Similarly, panels 828 and 848 may be folded inward along fold lines 812 and 816 and may, for example, extend from the bottom panel of shipping container 100 to form, for example, sidewall panels 126 of base tray 120. In some embodiments, panels 828 and 848 may have a sloped shape in order to interface with, for example, the sloped top edge 144 of sidewall panel 126.

[0044] Blank 800 may also include a third outer series of panels 850, each connected to one of the central panels 810 by a fold line 818.

[0045] In some embodiments, blank 800 may include a first tear strip 802 extending from an outer edge of outer panel 826, through a central panel 810, to an outer edge of outer panel 846. Tear strip 802 may be disposed parallel to fold lines 814, and may include pull tabs 806 disposed at one or both of its ends. Blank 800 may also include a second tear strip 804 extending from an outer edge of outer panel 822, through a central panel 810, to an outer edge of outer panel 842. Like tear strip 802, tear strip 804 may also be disposed parallel to fold lines 814, and may include pull tabs 806 disposed at one or both of its ends.

[0046] In some embodiments, blank 800 may include weakened portions 830 which may be disposed within central panels 810, and may be parallel to fold lines 812 and 816. In some embodiments, weakened portions 830 may be score lines or perforations, and correspond to weakened portions 130 described above.

[0047] In some embodiments, blank 800 may have a plurality of openings 832, 834, and 836 (e.g., die-cut openings, corresponding to, for example, openings 132, 134, and 136) disposed along weakened portions 830 (corresponding to, for example, weakened portion 130 of base tray 120).

[0048] In some embodiments, opening 832 may correspond to, for example, opening 132, and may be disposed at an end of a central panel 810 between outer panels 850, and may be closed on only one end. Outer panels 850 may be folded to form, for example, a flap extending from bottom edge 121 of base tray 120 underneath bottom panel 170 of base tray 120. As shown in FIG. 1, opening 132 within front panel 124 may be closed on a top end, but open on the bottom. Accordingly, opening 832 may also include a closed end and an open end such that opening 132 may extend all the way down to a bottom edge 121 of base tray 120 to facilitate, for example, separation of base tray 120 into left and right product-display trays 150 and 160.

[0049] In some embodiments, opening 836 may be disposed within a central panel 810, and may overlap a fold line 814 such that when blank 800 is folded into a box configuration, opening 836 is disposed on a corner of a box. For example, opening 836 may correspond to opening 136 shown in FIG. 5, which extends from rear panel 128 of base tray 120 to bottom panel 170 of base tray 120. The positioning of opening 836 may, for example, facilitate a clean separation of base tray 120 into left and right product-display trays 150 and 160, as it may be difficult to tear the cardboard material along a corner.

[0050] At least one opening 836 may be disposed adjacent to first tear strip 802, and at least one die-cut opening 832 may be disposed adjacent to second tear strip 804. Weakened portions 830 may be disposed within central panels 810, and may be parallel to fold lines 812 and 816. In some embodiments, weakened portions 830 may extend between die cut openings 832.

[0051] In some embodiments, blank 800 may be folded to form a shipping container, for example shipping container 100. For example, blank 800 may first be folded inwardly along fold lines 814 to form a box-like configuration with open sides. To form the sides, panels 822, 824, 826, and 828 may be folded inward along fold lines 812 while panels 842, 844, 846, and 848 may be folded inward along fold lines 816. Panels 822 and 826 may overlap panels 824 and 828 and panels 842 and 846 may overlap panels 844 and 848. The overlapped portions of the panels may then be fixed together. In some embodiments the overlapped portions of the panels may be fixed together with an adhesive, such as glue.

[0052] To complete the box configuration of the shipping container, panels 850 may be folded inward along fold lines 818, and may be fixed to a surface of the central panel 810, which may form a bottom panel, for example bottom panel 450, of the shipping container. In some embodiments, panels 850 may be fixed to central panel 810 with an adhesive, such as glue.

[0053] It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.

[0054] The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

[0055] The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents.