E-COMMERCE PACKAGING SYSTEM

Abstract

In the context of e-commerce, the packaging system of the present invention provides the necessary protection of consumer goods from rigors of transportation and parcel delivery while providing significant environment and cost savings.

Claims

1. A packaging system comprising a plurality of personal care consumer goods contained in a plurality of six-sided 3-ply corrugated cardboard boxes, wherein the plurality of six-sided 3-ply corrugated cardboard boxes containing consumer goods are contained within a five-sided 3-ply corrugated carboard tray, wherein the 3-ply cardboard, of said boxes, comprising a flute type selected from A flute, C flute, B flute, or combination thereof; wherein the 3-ply cardboard, of said tray, comprises a flute type selected from A flute, C flute, or B flute, or combination thereof.

2. The packaging system of claim 1, wherein the plurality of said boxes is selected from 2 to 10.

3. The packaging system of claim 1, wherein the interior volume of each of said plurality of boxes (when devoid of contents) is from 1000 cm.sup.3 to 8000 cm.sup.3.

4. The packaging system of claim 1, wherein the height of the tray is from 20% to 90% relative to the height of said boxes contained in the tray.

5. The packaging system of claim 1, wherein the overall mass of the system is from 3 kg to 23 kg.

6. The packaging system of claim 1, wherein the mass of each of the plurality of boxes is 0.5 kg to 5 kg.

7. The packaging system of claim 1, wherein the personal care consumer goods are selected from liquid body wash, hair shampoo, or hair conditioner.

8. The packaging system of claim 7, wherein the plurality of boxes is six boxes, and wherein the personal care consumer goods are bottles of hair shampoo product, there are 2 to 8 bottles of hair shampoo product contained in each of the six boxes, and wherein the mass of each bottle of hair shampoo product is from 50 g to 750 g.

9. The packaging system of claim 1, wherein the number of personal care consumer goods contained in each box is from 1 to 10.

10. The packaging system of claim 1, wherein each of the outer plies, of the six-sided 3-ply corrugated cardboard box, is independently comprised of paper having a density from 100 grams per square meter (gsm) to 400 gsm.

11. The packaging system of claim 1, wherein each of the outer plies, of the five-sided 3-ply corrugated cardboard tray, is independently comprised of paper having a density from 75 gsm to 275 gsm.

12. The packaging system of claim 1, wherein the interior (flute) ply, of the six-sided 3-ply corrugated cardboard box, is comprised of paper having a density from 70 gsm to 270 gsm.

13. The packaging system of claim 1, wherein the interior (flute) ply, of the five-sided 3-ply corrugated cardboard tray, is comprised of paper having a density from 80 gsm to 280 gsm.

14. The packaging system of claim 1, wherein the cardboard blank, used to assemble the five-sided 3-ply corrugated cardboard tray, has a mass less than 0.90 kg.

15. The packaging system of claim 1, wherein the cardboard blank, used to assemble the six-sided 3-ply corrugated cardboard box, has a mass less than 0.3 kg.

16. The packaging system of claim 1, wherein the plurality of said boxes is selected from 4 to 8; and wherein the interior volume of each of said plurality of boxes (when devoid of contents) is from 3000 cm.sup.3 to 5000 cm.sup.3.

17. The packaging system of claim 16, wherein the height of the tray is from 40% to 60% relative to the height of said boxes contained in the tray.

18. The packaging system of claim 17, wherein the overall mass of the system is from 8 kg to 16 kg; and wherein the mass of each of the plurality of boxes (containing consumer goods) is from 1 kg to 3.5 kg.

19. The packaging system of claim 18, wherein each of the outer plies, of the six-sided 3-ply corrugated cardboard box, is independently comprised of paper having a density from from 240 gsm to 260 gsm; and wherein each of the outer plies, of the five-sided 3-ply corrugated cardboard tray, is independently comprised of paper having a density from 160 gsm to 190 gsm.

20. The packaging system of claim 19, wherein the interior (flute) ply, of the six-sided 3-ply corrugated cardboard box, is comprised of paper having a density from 155 gsm to 185 gsm; and wherein the interior (flute) ply, of the five-sided 3-ply corrugated cardboard tray, is comprised of paper having a density from 165 gsm to 195 gsm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] While the specification concludes with claims that particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of the accompanying figures.

[0006] FIG. 1 is a perspective of a packaging system comprising a tray and plurality of boxes (containing goods) contained within the tray.

[0007] FIG. 2 is a top view of a cardboard blank used to assemble the plurality of boxes of FIG. 1.

[0008] FIG. 3 is a top view of a cardboard blank used to assemble the tray of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

[0009] The term comprising as used herein means that steps and ingredients other than those specifically mentioned can be added. This term encompasses the terms consisting of and consisting essentially of. The compositions of the present invention can comprise, consist of, and consist essentially of the essential elements and limitations of the invention described herein, as well as any of the additional or optional ingredients, components, steps, or limitations described herein.

[0010] All percentages, parts and ratios are based upon the total weight of the compositions of the present invention, unless otherwise specified. All such weights as they pertain to listed ingredients are based on the active level and, therefore do not include solvents or by-products that may be included in commercially available materials, unless otherwise specified.

[0011] As used herein, the articles including a and an when used in a claim, are understood to mean one or more of what is claimed or described.

[0012] As used herein, the words preferred, preferably and variants refer to embodiments of the invention that afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0013] FIG. 1 is a perspective view of a packaging system (1) of the present invention. The system (1) is comprised of an assembled five-sided 3-ply corrugated carboard tray (5), wherein the tray (5) contains a plurality of assembled six-sided 3-ply corrugated cardboard boxes (3). In turn, the boxes (3) each contain a plurality of consumer goods (not shown). The system (1) provides adequate protection to goods associated with the stress of e-commerce while minimizing the amount of paper. The system saves up to 70% of the paper material that is used in some currently used systems. Accordingly, the present invention provides cost savings and helps with environmental sustainability efforts.

[0014] Turning to FIG. 2, a top view of a blank (2) of 3-ply corrugated cardboard used to assemble the six-sided 3-ply corrugated cardboard box, is shown. Cardboard is die-cut into the shape of blank (2) including fold-lines impressions. Generally, corrugated cardboard can be characterized by a number of elements including the number of plies, flute type, and paper density. The corrugated cardboard of the box (3) consists of two outer plies and an interior ply that is fluted in between said outer plies. Each ply is made from paper of a defined density. The fluted interior ply is adhered to the outer plies by an adhesive.

[0015] The 3-ply corrugated cardboard, of the six-sided 3-ply corrugated cardboard box (3), comprises a flute type selected from group consisting of: A flute (5 mm), C flute (4 mm), or B flute (3 mm), preferably A flute (5 mm) or C flute (4 mm), more preferably C flute (4 mm). The 3-ply corrugated cardboard of the box has opposing outer plies and an interior ply (in between the outer plies) that forms the corrugation. Each of the outer plies is preferably comprised from paper having a density from 100 grams per square meter (gsm) to 400 gsm, preferably from 150 gsm to 350 gsm, more preferably from 200 gsm to 300 gsm, yet more preferably from 225 gsm to 275 gsm, yet still more preferably from 240 gsm to 260 gsm, yet still even more preferably from 245 gsm to 255 gsm. The density of these outer plies may be the same or different. One non-limiting example is where both outer plies have a density of 250 gsm. Each of the outer most plies, of the 3-ply corrugated cardboard (of the tray), may comprise virgin or recycled material or combination thereof. In one non-limiting example, both outer plies have from 50-90 wt % recycled material, alternatively about 80 wt % of recycled materials. Turning to the interior (flute) ply, it is preferably comprised of paper having a density from 70 gsm to 270 gsm, preferably from 95 gsm to 245 gsm, more preferably from 120 gsm to 220 gsm, yet more preferably from 145 gsm to 195 gsm, yet still more preferably from 155 gsm to 185 gsm, yet still even more preferably from 165 gsm to 175 gsm. One non-limiting example is where the interior ply has a density of 170 gsm. The interior ply may be made from virgin or recycled material or combination thereof. In one non-limiting example, the interior ply has from 50-90 wt % of recycled material, alternatively about 80 wt % of recycled material.

[0016] Still referring to FIG. 2, a longitudinal axis (99) extends along the length of the blank (2). The blank (2) comprises an adhering tab (15) that extends from the right side panel (17) along the longitudinal axis (99), with a fold line separating the adhering tab (15) and the right side panel (17). When assembling the blank (2) into the six-sided 3-ply corrugated cardboard box (3), the adhering tab (15) is adhered to what will become the inside surface of the backside panel (27) (on the opposing end of the blank (2)) to provide an intermediate to the final box (3). Along the longitudinal axis (99), the backside panel (27), in the assembled box (3), opposes the front side panel (37). The backside panel (27) and frontside panel (37) have the largest panel area dimensions of the blank (2), and preferably have about the same dimensions. A left side panel (31), along the longitudinal axis (99), is in between the backside panel (27) and the frontside panel (37). In the assembled box (3), the left side panel (31) opposes the right side panel (17). Referring to the blank (2), in a plane orthogonal to the longitudinal axis (99), the top backside panel (25) connects via fold line to the superior end of the backside panel (27); and whereas a bottom exterior panel (29) connects via a fold line to the opposing inferior end of the backside panel (27). In the assembled box (3), the top backside panel (25) and bottom exterior panel (29) are on opposing sides of the box (3). Referring to the blank (2), in a plane orthogonal to the longitudinal axis (99), a top left panel (23) connects via a fold line to the superior end of the left side panel (31); and whereas a bottom left panel (33) connects via a fold to the opposing inferior end of the left side panel (31). In the assembled box (3), the top left panel (23) and bottom left panel (33) are on opposing sides of the box (3). Referring to the blank (2), in a plane orthogonal to the longitudinal axis (99), a top exterior panel (21) connects via a fold line to the superior end of front side panel (37); and whereas a bottom front panel (35) connects via fold line to the opposing inferior end of the front side panel (37). In the assembled box (3), the top exterior panel (21) and the bottom front panel (35) are on opposing sides of the box (3). Referring to the blank (2), in a plane orthogonal to the longitudinal axis (99), a top right panel (19) connects via a fold line to the superior end of the right side panel (17); and whereas a bottom right panel (39) connects via a fold line to opposing inferior end of the right side panel (17). In the assembled box (3), the top right panel (19) and the bottom right panel (39) are on opposing sides of the box (3).

[0017] In the assembled box (3), the bottom exterior panel (29) is the most exterior panel of the four total panels (29, 33, 35, 39) that constitute the bottom side of the box (3), i.e., bottom exterior panel (29), bottom left panel (33), bottom front panel (35), and bottom right interior panel (39). Accordingly, the bottom exterior panel (29), inclusive of the fold line, has a rectangular shape. That is, this panel (29) has two relatively sharp 90 degree corners on the opposing ends relative to the folding line (wherein the folding line is in between the backside panel (27) and the bottom exterior panel (29)). In contrast to the other three panels (33, 35, 39) making the bottom side of the box (3), these three panels (33, 35, 39) have the sharp corners cut as to help facilitate the folding of the panels to form the bottom side rapidly. That is, the corners can be cut in an arc or one quarter circle or simply cut in a 45 degree angle as illustrated in FIG. 2. As seen in the blank (2), there is a gap between all four of these panels (29, 33, 35, 39) to also facilitate rapid folding/assembling of the blank (2) into the box (3). In forming the bottom side of the box (3), the bottom left panel (33) and the bottom right panel (39) form the most interior panel, i.e., they are the first two panels moved into place, then the bottom front panel (35) is the next panel moved into place. The last panel moved into place, to form the bottom side of the box (3), is the bottom exterior panel (29) (forming the most exterior panel of the bottom side of the box (3)).

[0018] In the assembled box (3), the top exterior panel (21) is the most exterior panel of the four total panels (23, 19, 25, 21) that constitute the top side of the box (3), i.e., top left panel (23), top right panel (19), top backside panel (25), top exterior panel (21). Accordingly, the top exterior panel (21), inclusive of the fold line, has a rectangular shape. That is, this panel (21) has two relatively sharp 90 degree corners on the opposing ends relative to the folding line (wherein the folding line is in between the front side (37) and the top exterior panel (21)). In contrast to the other three panel (25, 23, 19) making the top side of the box (3), these three panels (25, 23, 19) having sharp corners cut as to help facilitate the rapid folding of the panels to form the top side. That is, the corners can be cut in an arc or one-quarter circle, or simply cut in a 45 degree angle as illustrated in FIG. 2. As seen in the blank (2), there is a gap between all four of these panels (25, 23, 21, 19) to also facilitate rapid folding/assembling the blank (2) in the box (3). In forming the top side of the box (3), the top left panel (23) and top right panel (19) form the most interior panel, i.e., they are the first panels moved into place, then the top backside panel (25) is the next panel moved into place. The last panel moved into place, to form the top side of the box (3), is the top exterior panel (21) (forming the most exterior panel of the top side of the box (3)). Of course, in the assembled box (3), the top side and bottom side are opposing sides.

[0019] The interior volume of each of said plurality of boxes (3) (when devoid of contents) is from 1000 cm.sup.3 to 8000 cm.sup.3, preferably from 2000 cm.sup.3 to 6000 cm.sup.3, more preferably from 3000 cm.sup.3 to 5000 cm.sup.3. Preferably each of said plurality of boxes having the same volume. Significant savings in material costs in assembled the boxes (3) are provided. For example, the cardboard blank (2), used to assemble the six-sided 3-ply corrugated cardboard box, is less than 0.3 kg, preferably less than 0.25 kg, more preferably less than 0.2 kg, alternatively form 0.2 kg to less than 0.3 kg.

[0020] A plurality of consumer goods (not shown) are contained in the plurality of six-sided 3-ply corrugated cardboard boxes (3). These consumer goods are preferably fast-moving consumer goods, including but limited to, intended to the public (vs. institutional consumers). In one example, the fast-moving consumer goods are bottles of cleaning product. These cleaning products could be those specifically designed for cleaning carpet, floors, dishes, laundry, (or other household related items). Cleaning products typically comprise a surfactant and are typically liquid compositions. In another example, the fast-moving consumer goods are bottles of personal care product. Preferably the personal care product is selected from liquid body wash, hair shampoo, or hair conditioner. Each individual consumer good may have a mass from 5 g to 1000 g, preferably 30 g to 750 g, more preferably 50 g to 500 g. The mass of each of the plurality of boxes (containing consumer goods) is from 0.5 kg to 5 kg, preferably from 1 kg to 3.5 kg, more preferably from 2 kg to 2.5 kg. The number of (fast-moving) consumer goods contained in each box is from 1 to 10, preferably from 2 to 8, more preferably from 3 to 6. In one non-limiting example, there are six boxes (3) and wherein the contained consumer goods are bottles hair shampoo product, and wherein the mass of each bottle of hair shampoo product is from 50 g to 750 g, and there are 4 to 6 bottles of hair shampoo product contained in each of the six boxes (3).

[0021] Turning to FIG. 3, a top view of a blank (6) of 3-ply corrugated cardboard, used to assemble the five-sided 3-ply corrugated cardboard tray, is shown. Cardboard is die-cut into the shape of blank (6) including fold-line impressions. Generally, corrugated cardboard can be characterized by a number of elements including number of plies, flute type, and paper density. The corrugated cardboard of the tray (5) consists of two outer plies and an interior ply that is fluted in between said outer plies. Each ply is made from paper of a defined density. The fluted interior ply is adhered to the outer plies by an adhesive. The 3-ply corrugated cardboard, of the five-sided 3-ply corrugated cardboard tray, comprises a flute type selected from group consisting of: A flute (5 mm), C flute (4 mm), B flute (3 mm), or combination thereof. Preferably this 3-ply corrugated cardboard (of the tray) is either B flute or C flute, more preferably B flute. The 3-ply corrugated cardboard of the tray has opposing outer plies and an interior ply (in between the outer plies) that forms the corrugation. Each of the outer plies is preferably comprises from paper having a density from 75 gsm to 275 gsm, preferably from 100 gsm to 250 gsm, more preferably from 125 gsm to 225 gsm, yet more preferably from 150 gsm to 200 gsm, yet still more preferably from 160 gsm to 190 gsm, yet still even more preferably from 170 gsm to 180 gsm. The density of these outer plies may be the same or different. One non-limiting example is where both outer plies have a density of 175 gsm. Each of the outer most plies, of the 3-ply corrugated cardboard (of the tray), may comprise virgin or recycled material or combination thereof. In one non-limiting example, the both outer plies have from 50-90 wt % of recycled material, alternative about 80% of recycled material. Turning to the interior (flute) ply, it is preferably comprised from paper having a density from 80 gsm to 280 gsm, preferably from 105 gsm to 255 gsm, more preferably from 130 gsm to 230 gsm, yet more preferably from 155 gsm to 205 gsm, yet still more preferably from 165 gsm to 195 gsm, yet still even more preferably from 175 gsm to 185 gsm. The density of these outer plies may be the same or different. One non-limiting example is where the interior ply has a density of 180 gsm. The interior ply may be made from virgin or recycled material or combination thereof. In one non-limiting example, the interior ply has from 50-90 wt % of recycled material, alternative about 80 wt % of recycled material.

[0022] Still referring to FIG. 3, a longitudinal axis (98) extends along the length of the blank (6). The blank (6) comprises an adhering tab (13) that extends from the backside panel (67) along the longitudinal axis (98), with a fold line separating the adhering tab (13) and the backside panel (67). When assembling the blank (6) into the five-sided 3-ply corrugated carboard tray (5), the adhering tab (13) is adhered to what will become the inside surface of the right panel (65) (on the opposing end of the blank (6)) to provide an intermediate to the final tray (5). Along the longitudinal axis (98), the backside panel (67), in the assembled tray (5), opposes the frontside panel (63). A left side panel (61), along the longitudinal axis (98), is in between the backside panel (67) and the frontside panel (63). In the assembled tray (5), the left side panel (61) opposes the right side panel (65). Referring to the blank (6), in a plane orthogonal to the longitudinal axis (98), the bottom backside panel (69) connects via a fold line to the inferior end of the backside panel (67). Still referring to the blank (6), in a plane orthogonal to the longitudinal axis (98), the bottom left panel (71) connects via a fold line to the inferior end of the left side panel (61). In a plane orthogonal to the longitudinal axis (98), the bottom front panel (73) connects via a fold line to the inferior end of the front side panel (63). And still referring to the blank (6), in a plane orthogonal to the longitudinal axis (98), the bottom right panel (75) connects via a fold line to the inferior end of the right side panel (65). The backside panel (67) and the front side panel (63) have about the same dimensions, and the left side panel (61) and the right side panel (65) have about the same dimensions. The bottom side panel (69) and bottom front panel (73) have about the same dimensions, and the bottom left panel (71) and the bottom right panel (75) have about the same dimensions. To facilitate assembling the blank (6) into the tray, there is a space in between: the bottom backside panel (69) and bottom left panel (71); bottom left panel (71) and bottom front panel (73); and bottom front panel (73) and bottom right panel (75). In assembling the tray (5) preferably the bottom left panel (71) and bottom right panel (75) are inner most layers forming the bottom side of the tray (5). Consequently, the bottom left panel (71) and bottom right panel (75) are in between these outer most panels (69, 73). Adhesive tape is used to reinforce the structure of the assembled tray.

[0023] Referring back to FIG. 1 and the packaging system (1), the single assembled six-sided 3-ply corrugated cardboard box (3a) (of six total boxes (3)) is highlighted. The front side panel (37) of the box (3a) is visible. Superiorly adjacent this front side panel (37) is the top exterior panel (21). Adjacent to both the front side panel (37) and the top exterior panel (21), is the left side panel (31). A circumferential edge (77) defines the opening of the tray (5). This circumferential edge (77) defines the height of the assembled tray (5). The height of the circumferential edge (77) is preferably the same circumferentially around the tray (5). Preferably the height of the circumferential edge (77), and thus the tray (5), is 20% to 90%, preferably 30% to 80%, more preferably 35% to 70%, even more preferably 40% to 60%, yet even more preferably from 45% to 55%, relative to the height of the plurality of boxes (3) contained within the tray (5)). One benefit of having a tray configuration, compared to a box configuration, is the environmental and cost savings provided in having five sides (vs. six). Even more cost is saved by having the height of the circumferential edge (77) (i.e., height of the tray (5)) below the height of the plurality of boxes (3) contained within the tray (5). For example, the mass of the cardboard blank (6) of the tray (5) is less than 0.90 kg, preferably less than 0.7 kg, more preferably less than 0.5 kg, yet even more preferably less than 0.3 kg, alternatively from 0.2 kg to 0.5 kg. The interior volume of the assembled five-sided 3-ply corrugated cardboard tray is from 4,000 cm.sup.3 to 30,000 cm.sup.3, preferably from 7,000 cm.sup.3 to 20,000 cm.sup.3, more preferably from 10,000 cm.sup.3 to 15,000 cm.sup.3. Although six boxes (3) are shown in FIG. 1, in other examples, the plurality of boxes (3), contained within the tray (5), are from 2 to 10, preferably from 3 to 9, more preferably from 4 to 8. The packaging system (1), with goods contained therein, may have an overall mass from 3 kg to 23 kg, preferably form 6 kg to 18 kg, more preferably from 8 kg to 16 kg. Another benefit of having a tray configuration, compared to a box configuration, is the operation productivity improvement in e-retail warehouse provided in having five sides (vs. six).

[0024] Compressive strength is one way to measure the ability of the assembled six-sided 3-ply corrugated cardboard box (3a), assembled five-sided 3-ply corrugated carboard tray (5), and a plurality of said boxes (3) contained within said tray (5); to withstand the demands of e-commerce. Preferably the resistance of each empty box (3a) is at least 900 Newtons (N), preferably at least 1,200 N, more preferably at least 1,500 N, even more preferably at least 1700 N, based on GB/T 4857.4-2008/ISO 12048:1994 The Packaging Compression and Stacking tests using a compression tester. In another example, six empty assembled six-sided 3-ply corrugated cardboard boxes (3) are contained in the assembled five-sided 3-ply corrugated carboard tray (5), having a resistance of at least 2,500 N, preferably 3,000 N, more preferably 4,000 N, even more preferably 5,000 N, spread evenly across the top of the six empty boxes (3) contained in the tray (5), based on GB/T 4857.4-2008/ISO 12048:1994 The Packaging Compression and Stacking tests using a compression tester.

[0025] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as 40 mm is intended to mean about 40 mm.

[0026] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.