DUAL LID SHIPPING CONTAINER

Abstract

A container is disclosed with two lids, the first or outer lid can be torn off and discarded after a product is received by a recipient, such as a customer. Alternatively, the outer lid may be left in place with the container then being used as a return shipper with the outer lid remaining as part of the returned container.

Claims

1. A container comprising: a bottom panel having an upper surface; first and second opposed wall panels and third and fourth opposed wall panels; the first, second, third and fourth wall panels each extending upwardly from the bottom panel and each having a respective upper edge; a first lid having first and second opposed side edges and first and second opposed end edges, the first side edge of the of the first lid being foldably coupled to the upper edge of the first wall panel; a second lid having third and fourth opposed side edges and third and fourth opposed end edges, the third side edge of the second lid being foldably coupled to the upper edge of the second wall panel; the first lid being foldable about the upper edge of the first wall panel to a closed position overlaying the bottom panel, and the second lid being foldable about the upper edge of the second wall panel to a closed position overlaying the first lid and the bottom panel; a first end flap foldably coupled to and extending downwardly from the first end edge of the first lid and a second end flap foldably coupled to and extending downwardly from the second end edge of the first lid, wherein in the first lid closed position the first and second end flaps engage the upper surface of the bottom panel; and a third end flap foldably coupled to and extending downwardly from the third end edge of the second lid and a fourth end flap foldably coupled to and extending downwardly from the fourth end edge of the second lid, wherein in the second lid closed position the third and fourth end flaps engage the upper surface of the bottom panel.

2. A container according to claim 1 comprising a first interior end panel wall section having upper and lower side edges, the upper side edge of the first interior end panel wall section being foldably coupled to and extending downwardly from the upper edge of the third wall panel and the lower side edge of the first interior end panel wall section being spaced from the upper surface of the bottom panel section by a first gap; and further comprising a second interior end panel wall section having upper and lower side edges, the upper side edge of the second interior end panel wall section being foldably coupled to and extending downwardly from the upper edge of the fourth wall panel and the lower side edge of the second interior end panel wall section being spaced from the upper surface of the bottom panel section by a second gap.

3. A container according to claim 2 wherein the first gap is at least one-fourth of the distance between the upper surface of the bottom panel and the upper edge of the third wall panel and the second gap is at least one one-fourth of the distance between the upper surface of the bottom panel and the upper edge of the fourth wall panel.

4. A container according to claim 2 wherein the first gap is from one-fourth to seven-eighths of the distance between upper surface of the bottom panel and the upper edge of the third wall panel and the second gap is from one-fourth to seven-eighths of the distance between the upper surface of the bottom panel and the upper edge of the fourth wall panel.

5. A container according to claim 2 wherein each of the first and second wall panels has a respective opposed first and second ends, the first wall panel includes a first locking tab receiving opening positioned at the first end of the first wall panel and a third locking tab receiving opening positioned at the second end of the first wall panel, the second wall panel includes a second locking tab receiving opening positioned at the first end of the second wall panel and opposed to the first locking tab receiving opening, the second wall panel includes a fourth locking tab receiving opening positioned at the second end of the second wall panel and that is opposed to the third locking tab receiving opening, the first interior end panel has opposed first and second side edges and the third interior end panel has opposed third and fourth side edges, a first locking tab projecting outwardly from the first side edge of the first interior end panel into the first locking tab receiving opening, a second locking tab projecting outwardly from the second side edge of the first interior end panel into the second locking tab receiving opening, a third locking tab projecting outwardly from the third side edge of the second interior end panel into the third locking tab receiving opening, and a fourth locking tab projecting outwardly from the fourth side edge of the second interior end panel into the fourth locking tab receiving opening.

6. A container according to claim 5 formed from a single piece paperboard blank.

7. A container comprising: a container bottom; a container first side wall extending upwardly from the container bottom, the first side wall comprising a first side wall upper edge portion spaced from the container bottom; a container second side wall opposed to the container first side wall and extending upwardly from the container bottom, the second side wall comprising a second side wall upper edge portion spaced from the container bottom; a first container end wall extending upwardly from the container bottom wall at a first end of the container; a second container end wall extending upwardly from the container bottom at a second end of the container opposite to the first end of the container; an interior top panel having first and second interior top panel side edge portions and first and second interior top panel end edge portions, the first interior top panel side edge portion being coupled to the first side wall upper edge portion, the interior top panel having a first end flap portion extending from the first interior top panel end edge portion towardthe container bottom and into engagement with the container bottom, the interior top panel having a second end flap portion extending from the second interior top panel end edge portion toward the container bottom and into engagement with the container bottom; and a cover top panel having first and second cover top panel side edge portions and first and second cover top panel end edge portions, the first cover top panel side edge portion being coupled to the second side wall upper edge portion, the cover top panel having a third end flap portion extending from the first cover top panel end edge portion toward the container bottom and into engagement with the container bottom, the cover top panel having a fourth end flap portion extending from the second cover top panel end edge portion toward the container bottom and into engagement with the container bottom, the third end flap portion being positioned between the first container end wall and the first end flap portion, and the fourth end flap portion being positioned between the second container end wall and the second end flap portion.

8. A container according to claim 7 wherein container is formed of corrugated paper board comprising at least one corrugated layer between paper sheets, each of the side walls and the end walls comprising at least one layer of the corrugated paper board with corrugations extending in an upright direction.

9. A container according to claim 7 comprising a first side wall end flap extending outwardly from a first end of the first side wall and a second side wall end flap extending outwardly from a second end of the first side wall opposite to the first end of the first side wall, a third side wall end flap extending outwardly from a first end of the second side wall and a fourth side wall end flap extending outwardly from a second end of the second side wall opposite to the first end of the second side wall, the first, second, third and fourth side wall end flaps each having an exterior surface and an interior surface, a first bottom panel end flap extending outwardly from a first end of the container bottom and a second bottom panel end flap extending outwardly from a second end of the container bottom opposite to the first end of the container bottom, the first bottom panel end flap comprising a first proximal end flap portion coupled to the container bottom and a first distal end flap portion spaced from the container bottom, the second bottom panel end flap comprising a second proximal end flap portion coupled to the container bottom and a second distal end flap portion spaced from the container bottom, the first container end wall comprising the first and second side wall end flaps positioned with the first proximal end flap portion facing the exterior surface of the first and second side wall end flaps and the first distal end flap portion facing the interior surface of the first and second side wall end flaps, and the second container end wall comprising the third and fourth side wall end flaps positioned with the second proximal end flap portion facing the exterior surface of the third and fourth side wall end flaps and the second distal end flap portion facing the interior surface of the third and fourth side wall end flaps.

10. A container according to claim 9 wherein the first proximal end flap portion is joined to the first distal edge portion by a first section of the first bottom panel end flap and the second proximal end flap portion is joined to the second distal edge portion by a second section of the second bottom panel end flap, the first proximal end flap portion and first distal end flap portion being folded to position the first section of the first bottom panel end flap overlaying the first and second side wall end flaps, the second proximal end flap portion and second distal end flap portion being folded to position the second section of the second bottom panel end flap overlaying the third and fourth side wall end flaps.

11. A container according to claim 10 wherein the first section of the first bottom panel end flap includes first and second spaced apart fold lines that extend perpendicularly to the first and second side walls, and wherein the second section of the second bottom panel end flap includes third and fourth spaced apart fold lines that extend perpendicularly to the first and second side walls.

12. A container according to claim 11 wherein container is formed of corrugated paper board comprising at least one corrugated layer between paper sheets, the first and second side walls comprising corrugations that extend in an upright direction from the bottom panel, and wherein the first, second, third and fourth side wall end flaps each comprise corrugations that extend in an upright direction from the bottom panel.

13. A container according to claim 7 wherein the first side wall panel includes a first locking tab receiving opening positioned at a first end of the first side wall panel and a third locking tab receiving opening positioned at a second end of the first side wall panel opposite to the first end of the first side wall panel, the second side wall panel includes a second locking tab receiving opening positioned at a first end of the second side wall panel and opposed to the first locking tab receiving opening, the second side wall panel includes a fourth locking tab receiving opening positioned at a second end of the second side wall panel that is opposite to the first end of the second side wall panel and that is opposed to the third locking tab receiving opening, the first bottom panel end flap comprises first and second bottom panel end flap side edges and the second bottom panel end flap comprises third and fourth bottom panel end flap side edges, a first locking tab projecting outwardly from the first bottom panel end flap side edge into the first locking tab receiving opening, a second locking tab projecting outwardly from the second bottom panel end flap side edge into the second locking tab receiving opening, a third locking tab projecting outwardly from the third bottom panel end flap side edge into the third locking tab receiving opening, and a fourth locking tab projecting outwardly from the fourth bottom panel end flap side edge into the fourth locking tab receiving opening.

14. A container according to claim 11 wherein the first side wall panel includes a first locking tab receiving opening positioned at a first end of the first side wall panel and a third locking tab receiving opening positioned at a second end of the first side wall panel opposite to the first end of the first side wall panel, the second side wall panel includes a second locking tab receiving opening positioned at a first end of the second side wall panel and opposed to the first locking tab receiving opening, the second side wall panel includes a fourth locking tab receiving opening positioned at a second end of the second side wall panel that is opposite to the first end of the second side wall panel and that is opposed to the third locking tab receiving opening, the first bottom panel end flap comprises first and second bottom panel end flap side edges and the second bottom panel end flap comprises third and fourth bottom panel end flap side edges, a first locking tab projecting outwardly from the first bottom panel end flap side edge into the first locking tab receiving opening, a second locking tab projecting outwardly from the second bottom panel end flap side edge into the second locking tab receiving opening, a third locking tab projecting outwardly from the third bottom panel end flap side edge into the third locking tab receiving opening, and a fourth locking tab projecting outwardly from the fourth bottom panel end flap side edge into the fourth locking tab receiving opening.

15. A container comprising: a first top panel comprising first and second top panel side edges, first and second top panel end edges, a first top panel interior surface and a first top panel exterior surface; first and second top panel end flaps, the first top panel end flap being foldably coupled to the first top panel end edge such that the first top panel end flap is foldable relative to the first top panel along the first top panel end edge, the second top panel end flap being foldably coupled to the second top panel end edge such that the second top panel end flap is foldable relative to the first top panel along the second top panel end edge, the first top panel end flap comprising a first top panel end flap interior surface and a first top panel end flap exterior surface, and the second top panel end flap comprising a second top panel end flap interior surface and a second top panel end flap exterior surface; a first side wall panel comprising first and second side wall panel side edges, first and second side wall panel end edges, a first side wall panel interior surface and a first side wall panel exterior surface; the second top panel side edge being foldably coupled to the first side wall panel side edge such that the first top panel is foldable relative to the first side wall panel along the second op panel side edge; first and second side wall panel end flaps, the first side wall panel end flap being foldably coupled to the first side wall panel end edge such that the first side wall panel end flap is foldable relative to the first side wall panel along the first side wall panel end edge, the second side wall panel end flap being foldably coupled to the second side wall panel end edge such that the second side wall panel end flap is foldable relative to the first side wall panel along the second side wall panel end edge, the first side wall panel end flap comprising a first side wall panel end flap interior surface and a first side wall panel end flap exterior surface, and the second side wall panel end flap comprising a second side wall panel end flap interior surface and a second side wall panel end flap exterior surface; a bottom panel comprising first and second bottom panel side edges, first and second bottom panel end edges, a bottom panel interior surface and a bottom panel exterior surface; the first bottom panel side edge being foldably coupled to the second side wall panel side edge such that the first side wall panel is foldable relative to the bottom panel along the first bottom panel side edge; first and second bottom panel end flaps, the first bottom panel end flap being foldably coupled to the first bottom panel end edge such that the first bottom panel end flap is foldable relative to the bottom panel along the first bottom panel end edge, the second bottom panel end flap being foldably coupled to the second bottom panel end edge such that the second bottom panel end flap is foldable relative to the bottom panel along the second bottom panel end edge, the first bottom panel end flap comprising a first bottom panel end flap interior surface and a first bottom panel end flap exterior surface, and the second bottom panel end flap comprising a second bottom panel end flap interior surface and a second bottom panel end flap exterior surface; the first bottom panel end flap comprising a first proximal end flap portion coupled to the first bottom panel end edge and a first distal end flap portion spaced from the first bottom panel end edge, the first proximal end flap portion being joined to the first distal edge portion by a section of the first proximal end flap portion that includes parallel spaced apart first and second fold lines extending parallel to the first bottom panel end edge, the second bottom panel end flap comprising a second proximal end flap portion coupled to the second bottom panel end edge and a second distal end flap portion spaced from the second bottom panel end edge, the second proximal end flap portion being joined to the second distal edge portion by a section of the second proximal end portion including parallel spaced apart fold lines extending parallel to the second bottom panel end flap; a second side wall panel comprising third and fourth side wall panel side edges, third and fourth side wall panel end edges, a second side wall panel interior surface and a second side wall panel exterior surface; the second bottom panel side edge being foldably coupled to the third side wall panel side edge such that the second side wall panel is foldable relative to the bottom panel along the second bottom panel side edge; third and fourth side wall panel end flaps, the third side wall panel end flap being foldably coupled to the third side wall panel end edge such that the third side wall panel end flap is foldable relative to the second side wall panel along the third side wall panel end edge, the fourth side wall panel end flap being foldably coupled to the fourth side wall panel end edge such that the fourth side wall panel end flap is foldable relative to the second side wall panel along the fourth side wall panel end edge, the third side wall panel end flap comprising a third side wall panel end flap interior surface and a third side wall panel end flap exterior surface, and the fourth side wall panel end flap comprising a fourth side wall panel end flap interior surface and a fourth side wall panel end flap exterior surface; a second top panel comprising third and fourth top panel side edges, third and fourth top panel end edges, a second top panel interior surface and a second top panel exterior surface; third and fourth top panel end flaps, the third top panel end flap being foldably coupled to the third top panel end edge such that the third top panel end flap is foldable relative to the second top panel along the third top panel end edge, the fourth top panel end flap being foldably coupled to the fourth top panel end edge such that the fourth top panel end flap is foldable relative to the second top panel along the fourth top panel end edge, the third top panel end flap comprising a third top panel end flap interior surface and a third top panel end flap exterior surface, and the fourth top panel end flap comprising a fourth top panel end flap interior surface and a fourth top panel end flap exterior surface; wherein the first top panel end edge is positioned inwardly of the first sidewall panel end edge a first distance, the second top panel end edge is positioned inwardly of the second sidewall end edge a second distance, the third top panel end edge is positioned inwardly of the third side wall end edge a third distance, and the fourth top panel side edge is positioned inwardly of the fourth side wall end edge a fourth distance, wherein the first and second distances are the same and the third and fourth distances are the same, and wherein the third and fourth distances are greater than the first and second distances; wherein the container has a container bottom comprising the bottom panel, a container first side wall comprising the first side wall panel folded to extend perpendicularly upwardly from the bottom panel, the first side wall having a first side wall height; the container comprising a container second side wall comprising the second side wall panel folded to extend perpendicularly upwardly from the bottom panel, the second side wall having a second side wall height; the bottom panel comprises the bottom of the container; the container comprising a first container end wall extending perpendicularly upwardly from the bottom wall at a first end of the container, the first container end wall having a first end wall height, the first container end wall comprising the first and third side wall end flaps folded to extend in a direction between the first and second container side walls and perpendicular to the first and second container side walls, the first proximal end flap portion abutting the exterior surface of the first and third side wall end flaps and the first distal end flap portion being folded to abut the interior surface of the first and third side wall end flaps; the container comprising a second container end wall extending perpendicularly upwardly from the bottom panel at a second end of the container opposed to the first end of the container, the second container end wall having a second end wall height, the second container end wall comprising the second and fourth side wall end flaps folded to extend in a direction between the first and second container side walls and perpendicular to the first and second container side walls, the second proximal end flap portion abutting the exterior surface of the third and fourth side wall end flaps and the second distal end flap portion being folded to abut the interior surface of the second and fourth end flaps; the container comprising an interior top portion comprising the second top panel folded to be parallel to the container bottom, the third top panel end flap being folded to a position interiorly of the first container end wall and the fourth top panel end flap being folded to a position interiorly of the second container end wall; and the container comprising a covering top portion comprising the first top panel folded to be parallel to the container bottom, the first top panel end flap being folded to a position between the first end wall and the third top panel end flap and the second top panel end flap being folded to a position between the second end wall and the fourth top panel end flap.

16. A container according to claim 15 wherein the container is formed from a single sheet of corrugated paper board having a first thickness, and wherein the first and second distances are equal to the thickness of the corrugated paperboard and the third and fourth distances are equal to twice the thickness of the corrugated paper board.

17. A container according to claim 15 wherein the first side wall panel includes a first locking tab receiving opening positioned inwardly of the first side wall panel end edge and a second locking tab receiving opening positioned inwardly of the second side wall panel end edge, the second side wall panel includes a second locking tab receiving opening positioned inwardly of the third side wall panel end edge and a fourth locking tab receiving opening positioned inwardly of the fourth wall panel end edge, the first bottom panel end flap comprises first and second bottom panel end flap side edges and the second bottom panel end flap comprises third and fourth bottom panel end flap side edges, a first locking tab projecting outwardly from the first bottom panel end flap side edge into the first locking tab receiving opening, a second locking tab projecting outwardly from the second bottom panel end flap side edge into the second locking tab receiving opening, a third locking tab projecting outwardly from the third bottom panel end flap side edge into the third locking tab receiving opening, and a fourth locking tab projecting outwardly from the fourth bottom panel end flap side edge into the first locking tab receiving opening.

18. A container according to claim 15 wherein the first distal end flap portion has a first distal end flap edge spaced from the first proximal end flap portion and spaced by a first gap from the bottom panel interior surface, and wherein the second distal end flap portion has a second distal end flap edge spaced from the second proximal end flap portion, and spaced by a second gap from the bottom panel interior surface, and wherein the first gap is from one-fourth to seven-eighths of the height of the first container end wall and the second gap is from one-fourth to seven-eighths of the height of the second container end wall 19A container according to claim 18 wherein the first side wall panel includes a first locking tab receiving opening positioned inwardly of the first side wall panel end edge and a second locking tab receiving opening positioned inwardly of the second side wall panel end edge, the second side wall panel includes a second locking tab receiving opening positioned inwardly of the third side wall panel end edge and a fourth locking tab receiving opening positioned inwardly of the fourth wall panel end edge, the first bottom panel end flap comprises first and second bottom panel end flap side edges and the second bottom panel end flap comprises third and fourth bottom panel end flap side edges, a first locking tab projecting outwardly from the first bottom panel end flap side edge into the first locking tab receiving opening, a second locking tab projecting outwardly from the second bottom panel end flap side edge into the second locking tab receiving opening, a third locking tab projecting outwardly from the third bottom panel end flap side edge into the third locking tab receiving opening, and a fourth locking tab projecting outwardly from the fourth bottom panel end flap side edge into the first locking tab receiving opening.

20. A container according to claim 19 wherein the first and second end wall heights and the first and second side wall heights are the same height.

Description

DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 illustrates an embodiment of an exemplary blank that can be used to form an embodiment of a container in accordance with this disclosure.

[0016] FIG. 2 illustrates the blank of FIG. 1 in a first stage of erection into a container.

[0017] FIG. 3 illustrates the blank of FIG. 2 in a second stage of erection into a container.

[0018] FIG. 4 illustrates the blank of FIG. 3 in a third stage of erection into a container.

[0019] FIG. 5 illustrates the blank of FIG. 4 in a fourth stage of erection into a container.

[0020] FIG. 6 illustrates the blank of FIG. 5 in a fifth stage of erection into a container.

[0021] FIG. 7 illustrates the erected container with the outer lid open and showing the inner lid closed, the upper surface of the inner lid being available for printing with information such as promotional material.

[0022] FIG. 8 illustrates the erected container with the outer lid in a closed position and showing an exemplary location for affixing a product shipping label.

DETAILED DESCRIPTION

[0023] Throughout this disclosure, when a reference is made to a first element being coupled to a second element, the term coupled is to be construed to mean both direct connection of the elements as well as indirect connection of the elements by way of one or more additional intervening elements. Also, the singular terms a, and, and first, mean both the singular and the plural unless the term is qualified to expressly indicate that it only refers to a singular element, such as by using the phase only one. Thus, for example, if two of a particular element are present, there is also a or an of such element that is present. In addition, the term and/or when used in this document is to be construed to include the conjunctive and, the disjunctive or, and both and and or. Also, the terms includes and has have the same meaning as comprises and the terms including and having have the same meaning as comprising. A description of top, sides, bottom and ends refers to the position of container components oriented with the bottom at a lower elevation than the top. These elements are still present if the orientation of the container is changed as one can still identify the elements. The term same, equal or perpendicular includes variations of up to plus or minus one percent. The term substantially with respect to a quantity, value or direction means within plus or minus five percent. The term upright means within plus or minus ten percent of being perpendicular to a bottom surface. The term exterior with respect to a surface refers to a surface the faces the exterior (away from the content receiving volume of a container) of the container when erected. The term interior with respect to a surface refers to a surface that faces the interior (toward the content receiving volume) of the container when erected container

[0024] With reference to FIGS. 7-9, one embodiment of a container 10 in accordance with this disclosure is shown. In these FIGS. the container 10 is shown comprising a container bottom 22 and opposed first and second container side walls 20, 24 extending upwardly from the container bottom 22. The side walls 20, 22 are desirably perpendicular to the bottom 22. The first side wall 20 comprises a first side wall upper edge portion 50 spaced from the container bottom and the second side wall comprises a second side wall upper edge portion 112 spaced from the container bottom. The illustrated container also comprises opposed first and second container end walls 23, 25 extending between the first and second side walls 20, 24 respectively. End wall 20 is at a first end of the container 10 and extends upwardly from, and is desirably perpendicular to, the container bottom 22. End wall 22 is at a second end of the container 10 and extends upwardly from, and is desirably perpendicular to, the container bottom 22.

[0025] The illustrated container 10 also comprises an interior top panel or lid 26 having a first and second interior top panel side edge portions 200, 202 (FIG. 6) and first and second interior top panel end edge portions 204, 206. The top panel side edge portion 200 is foldably coupled to the second side wall upper edge portion 112 for folding about a fold line 208. The interior top panel 26 comprises a first end flap portion or flap 210 extending from the end portion 204 of the first interior top panel 26 toward the container bottom 22 and a second end flap portion or flap 214 extending from end portion 206 of the top panel 26. The end flaps referred to herein can also be called ears. The flaps 210, 214 each comprise a respective distal edge 211, 215. When the lid is closed, the flaps 210, 214 extend toward the bottom panel 22. For added crush strength, desirably the flaps 210, 214 have a height such that the distal ends 211, 215 of these flaps engage, and desirably abut, the interior surface of the container bottom of the assembled container. The top panel or lid 26 is shown closed in FIG. 7.

[0026] The illustrated container further comprises a cover or top panel 18 having first and second cover top panel side edge portions 30, 32 and first and second cover top panel end edge portions 34, 36. The first cover top panel side edge portion 32 is coupled to the second side wall upper edge portion 50. The cover top panel has a third end flap portion or end flap 40 extending outwardly from the first cover top panel end edge portion 34 and a fourth end flap portion or end flap 42 extending outwardly from the first cover top panel end edge portion 36. The end flaps 40, 42 have respective distal ends or edges 41, 43. When the outer lid or cover 18 is closed, the flaps 40, 42 extend toward the bottom panel 22. For added crush strength, desirably the flaps 40, 42 have a height such that the distal ends 42, 43 of these flaps engage, and desirably abut, the interior surface of the container bottom of the assembled container. The top panel or lid 18 is shown closed in FIG. 8.

[0027] Each of the end flaps 40, 44, 60, 62, 90, 92, 170, 176, 210, and 214 have respective exterior and interior surfaces. In addition, the first bottom panel end flap comprises a first proximal end flap portion 170 coupled to the first bottom panel end edge 84 (FIG. 1) of the bottom panel 22 and a first distal end flap portion 172 spaced from the bottom panel. In addition, the second bottom panel end flap 92 comprises a second proximal end flap portion 176 coupled to the second bottom panel end edge 86 (FIG. 1) of the bottom panel 22 and a second distal end flap portion 178 spaced from the bottom panel. In this embodiment, with reference to FIG. 6, the first end wall 21 in this embodiment comprises the first and second side wall end flaps 60, 120 positioned with the first proximal end flap portion 170 abutting the exterior surface of the first and second side wall end flaps 60, 120 and the first distal end flap portion 172 abutting the interior surface of the first and second side wall end flaps 60, 120. In addition, with further reference to FIG. 6, the illustrated second end wall 23 in this embodiment comprises the third and fourth side wall end flaps 62, 121 positioned with the second proximal end flap portion 176 abutting the exterior surface of the third and fourth side wall end flaps 62, 121 and the second distal end flap portion 178 abutting the interior surface of the third and fourth side wall end flaps 62, 121. Thus, this embodiment has end walls 21, 23 that comprise three layers of material, such as three layers of corrugated paper board. Alternatively, fewer layers of material may be included in the end walls. For example, the distal end flap portions of the end walls can be eliminated with the proximal portions of the end walls adhesively or otherwise secured to the end flaps. The proximal end flap portions are each one form of a container wall or end wall and the distal end flap portions are each one form of an interior end wall panel section.

[0028] With reference to FIGS. 1 and 5, the distal end flap portions 172, 178 can have a height such that the distal edges of the portions 172, 178 abut the upper surface of the bottom panel 22 of the assembled container to further enhance the crush strength of the container. However, in a more desirable construction, the height of distal end flap portions 172, 178 is less than the height of the proximal end flap portions 170, 176 so as to create a gap between the lower edge of each distal end flap portion and the upper surface of the bottom panel. For example, the distal end flap portions can have a height that is in the range of from three-fourths to one-eighth of the height of the proximal end flap portions (which results in gaps of from one-fourth to seven-eighths of the height of the end wall panels or proximal panel portions) and more desirably in a range of from one-quarter to one-half of the height of the proximal end flap portions. By shortening the height of the distal end flap portions 172, 178, the total length of bottom panel 22 and the end flaps 90, 92 is reduced. In addition, this reduces the extent to which the distal end flap portions 172, 176 project outwardly beyond the distal ends of the end flaps of the side walls and top panels of the blank (FIG. 1). As a result, the overall shape of the blank is more rectangular and less material is wasted as scrap when the blank is cut from corrugated sheet material.

[0029] In the embodiment of FIG. 6, the first proximal end flap portion 170 is joined to the first distal end flap portion 172 by a first transversely extending section 177 of the first proximal end flap portion of the bottom panel end flap. In addition, second proximal end flap portion 176 is joined to the second distal edge portion 178 by a transversely extending second section 179 of the second proximal end flap portion of the second bottom panel end flap. Also, the first proximal end flap portion 170 and first distal end flap portion 172 are folded over the side wall end flaps 60, 120 and positions the first section 177 of the first bottom panel end flap 90 to overlay the first and second side wall end flaps 60. 1120 (see FIGS. 7 and 8). In addition, the second proximal end flap portion 176 and second distal end flap portion 178 can be folded to position the second section 179 of the second bottom panel end flap 92 to overlay the third and fourth side wall end flaps.

[0030] As a more specific feature of embodiments, the first section 177 of the first bottom panel end flap 90 can be located between first and second parallel spaced apart fold lines 160, 162 (FIG. 1) that extend perpendicularly to the first and second side walls 20, 24. In addition, the second section 179 of the second bottom panel end flap 92 can be located between third and fourth parallel spaced apart fold lines 164, 166 that extend perpendicularly to the first and second side walls 20, 24.

[0031] Desirably, a container 10 is formed of corrugated paper board comprising at least one corrugated layer between paper sheets. The first and second side walls 20, 24 can comprise corrugations that extend in an upright direction or perpendicularly from the bottom panel 22. In addition, the first, second, third and fourth side wall end flaps (60, 62, 120. 121) each can comprise corrugations that extend in an upright direction or perpendicularly from the bottom panel 22. This is achieved by, for example, having a corrugated layer with corrugations that extend in the direction 16 in FIG.1.

[0032] Although adhesive, staples, tape or other fastening approaches can be used to hold the assembled container together. A desirable approach is to use locking tabs and locking tab receiving openings alone or in combination with other fastener approaches to interconnect container components. In a specific example, the first side wall panel 20 includes a first locking tab receiving opening 70 (FIG. 1) positioned at a first end of the first side wall panel and a third locking tab receiving opening 72 positioned at a second end of the first side wall panel opposite to the first end of the first side wall panel. Also, in this example, the second side wall panel 24 includes a second locking tab receiving opening 128 positioned at a first end of the second side wall panel 24 and opposed to the first locking tab receiving opening 70 when the container is erected. The second side wall panel can also include a fourth locking tab receiving opening 130 positioned at a second end of the second side wall panel that is opposite to the first end of the second side wall panel. The opening 128 can be opposed to the third locking tab receiving opening 72. In this example, the first bottom panel end flap 90 comprises first and second bottom panel end flap side edges and the second bottom panel end flap 92 comprises third and fourth bottom panel end flap side edges. In addition, in the erected container, a first locking tab 140 projects outwardly from the first bottom panel end flap side edge into the first locking tab receiving opening 70, a second locking tab 146 projects outwardly from the second bottom panel end flap side edge into the second locking tab receiving opening 72, a third locking tab 142 projects outwardly from the third bottom panel end flap side edge into the third locking tab receiving opening 128, and a fourth locking tab 148 projects outwardly from the fourth bottom panel end flap side edge into the fourth locking tab receiving opening 130 (See FIGS. 1, and 6-8).

[0033] When the outer lid or cover 18 is closed, in this illustrated construction, the outer panel end flap 40 is positioned between the first container end wall 21 and the inner top panel end flap 210 and the outer panel end flap 44 is positioned between the end wall 23 and the inner top panel end flap 214.

[0034] With reference to FIG.1, a blank for forming a container 10 in accordance with a first embodiment of this disclosure is illustrated. The illustrated blank is desirably formed of paperboard, having one or more outer layers and one or more inner corrugated layers. In the FIG. 1 embodiment, corrugations of an inner layer extend in the direction indicated by double headed arrow 16.

[0035] The illustrated blank 10 comprises a first or outer container lid panel portion 18, a first side wall panel portion 20, a bottom panel portion 22, a second side wall panel portion 24 and a second or inner panel portion 26.

[0036] The outer panel portion 18 comprises a first side edge 30, a second side edge 32, a first end edge 34 and a second end edge 36. A first outer panel end flap 40 is coupled to first outer panel portion 18 and more specifically to the end edge 34 of panel section 18 along a fold line 42. Fold line 42, as well as other fold lines in this disclosure, can be formed in any suitable manner, such as by spaced apart perforations along the fold line, scoring one surface of the corrugated board along the fold line, crushing the blank along the fold line, or otherwise weakening the blank along the fold line. Any combination of these fold line forming approaches can be used. A second end flap portion 44 is coupled to panel section 18 and more specifically to the edge 36 of panel section 18 along a fold line 46.

[0037] The first side wall panel section 20 comprises a first side edge 50, a second side edge 52, a first end edge 54 and a second end edge 56. Panel section 18 is shown coupled to the panel section 20 along a fold line 58 extending between side edges 32 and 50. Although not required, the fold line 58 between outer top panel 18 and side wall 20 can be weakened, such as perforated, to comprise a tear line. Such a tear line facilitates removal and recycling of the outer top panel 18 and connected end flaps 40, 42. As an alternative, a tear strip can be provided in side wall panel 20, such as one-fourth inch wide, with one side of the tear strip comprising a weakened, e.g. perforated, fold line 58 and another side of the tear strip being a perforated or otherwise weakened line extending parallel to fold line 58 spaced from the edge 50 of side wall 20. End panel sections 40, 44 can be of any desirable shape, such as rectangular or, as shown, a trapezoidal shape in that side edge portions of these panel sections converge toward one another moving away from the panel section 18. In addition, the distal most corner portions of the panel sections 40, 44 can be rounded. This rounded configuration facilitates insertion of the panel sections 40, 44 into end flap receiving gaps provided in the container as it is erected.

[0038] The first side wall panel section 20 comprises respective first and second end flaps 60, 62 shown in this embodiment spaced from the end flaps 40, 44 by respective gaps between the adjacent end flaps. End flap 60 is coupled to panel section 20 and more specifically to end edge 54 of panel section 20 along a fold line 64. End flap 62 is coupled to panel section 20 and more specifically to end edge 56 of the panel section 20 along a fold line 66. Although the container can be interconnected in numerous ways, including adhesively securing selected panels of the container together when assembled, in the embodiment shown in FIG. 1, the panel section 20 is provided with respective locking tab receiving openings 70, 72 adjacent the respective fold lines 54, 66 and in this example inwardly of the respective side wall end flaps 60, 62.

[0039] The bottom panel section 22 has a first side edge 80, a second side edge 82, a first end edge 84, and a second end edge 86. Bottom panel section 22 is coupled to the panel section 20 alongside edge 80 and more specifically to side edge 52 of panel section 20 along a fold line 88. Bottom panel section 22 comprises respective first and second bottom panel end flaps or end wall forming portions 90, 92. Bottom panel end flap 90 is separated from side wall end flap 60 by a cut line 94 in this example. In addition, bottom panel end flap 92 is separated from side wall end flap 62 by a cut line 96. Another cut line 98 separates end flap 90 from a side wall end flap 120 an end flap coupled to panel section 24 as described below. In addition, a cut line 100 separates bottom panel end flap 92 from another side wall end flap 121 coupled to panel section 24.

[0040] Bottom panel end flap 90 is coupled to bottom panel section 22 and more specifically coupled to end edge 84 of bottom panel section 22 along a fold line 102. In addition, end flap 92 is coupled to the panel section 22, and in this embodiment, more specifically, to the end edge 86 of bottom panel section 22 along a fold line 104.

[0041] The illustrated second side wall panel section 24 comprises a first side edge 110, a second side edge 112, an end edge 114, and a second end edge 116. Side wall panel section 24 is coupled to the bottom panel section 22 alongside side edge 110. More specifically, side edge 110 of side wall panel section 24 is coupled to side edge 82 of bottom panel section 22 along a fold line 118. An end panel section 120 is coupled to one end of side wall panel section 24 and, more specifically in the illustrated embodiment, is coupled to end edge 114 of side wall panel section 24 along a fold line 122. A second side wall end flap 121 is coupled to panel section 24 and, in the illustrated embodiment, to end edge 116 of panel section 24 along a fold line 126. The panel section 24 is provided with respective locking tab receiving openings 128 at end 114 and 130 at end 116.

[0042] The end flaps 60, 120, 62, 121 can be of variable shapes, however, in the example shown in FIG. 1, they are desirably rectangular in shape. Side wall end panel or flap 60 is separated from bottom wall end panel 90 by cut line 94 to permit folding of side wall end flap 60 relative to end panel 90. In addition, side wall end panel or flap 120 is separated from end panel 90 by a cut line 98 to permit folding of side wall end flap 120 relative to end panel 90. Moreover, side wall end panel or flap 62 is separated from end panel 92 by a cut line 96 allowing side wall end flap 62 to be folded relative to end panel 92. Furthermore, side wall end panel or flap 121 is separated from end panel 92 by a cut line 100 allowing side wall end flap 121 to be folded relative to end panel 92.

[0043] The end panel 90 can be provided with first and second locking tabs 140, 142 opposed from one another and adjacent to the distal end 144 of panel section 90. As explained below, when the panel sections are erected into a container 10, locking tab 140 is inserted into opening 70 and locking tab 142 is inserted into opening 128. Similarly, end panel 92 can be provided with respective locking tabs 146, 148 adjacent to the distal end 150 of end panel 92. When the container 10 is erected, locking tab 146 is inserted into opening 72 and locking tab 148 is inserted into opening 130. The end panel 90 can be provided with respective spaced apart fold lines 160, 162 and that can be parallel to one another and can extend transversely from side to side of the end panel 90, for example, parallel to the bottom panel edge 84. In addition, end panel 92 can be provided with respective spaced apart fold lines 164, 166 that can be parallel to one another and that can extending from side to side of the end panel 92, for example parallel to bottom panel edge 86.

[0044] FIG. 2 illustrates one stage of container erection. In the description below, various stages of container erection are described. It is to be understood that the stages are not required to be accomplished in the order that they are being described, although the sequential method of erection shown in FIGS. 2-8 is advantageous. In FIG. 2, the side wall end flaps 60, 62, 120, 121 have been folded upwardly about their respective fold lines 64, 66, 122 and 129 to extend away from the plane of the blank of FIG. 1 with the respective distal ends 61, 63, 119 and 123 of these side wall end flaps positioned in at an upward location.

[0045] In the stage of container erection shown in FIG. 3, the side walls 20, 24 have been folded upwardly relative to the bottom panel 22. In addition, the distal end 61 of side wall end flap 60 is facing, and desirably abutting, the distal end 119 of side wall end flap 120. Also, the distal end 63 of side wall end flap 62 is facing, and desirably abutting, the distal end 123 of the side wall end flap 121.

[0046] In the stage of container erection shown in FIG. 4, the end wall panels 90, 92 have been folded upwardly relative to the bottom panel 22. In FIG. 4, the interior surface of proximal panel portion 170 of end panel 90 is positioned adjacent to the exterior surfaces of, and desirably abutting the exterior surfaces of, the side wall end flaps 60, 120. In FIG. 4, the interior surface of proximal panel portion 176 of end panel 92 is positioned adjacent to the exterior surfaces of, and desirably abutting the exterior surfaces of, the side wall end flaps 62, 121.

[0047] FIG. 5 illustrates a further stage of erection of the container 10. In this stage, the distal portion 172 of end panel 90 has been folded over the side wall end flaps 60, 121 and locking tab 140 has been inserted into opening 70 and locking tab 142 has been inserted into opening 128. In addition, the distal portion 178 of end panel 92 has been folded over the end flaps 62, 121 (not visible in FIG. 5) with the locking tabs 146, 148 of end panel 92 inserted into the respective locking tab receiving openings (locking tab 148 is shown inserted into opening 130 in FIG. 5, whereas the locking tab 146 and locking tab receiving opening 72 is not visible in FIG. 5). Thus, the distal end portion 172 of end panel 90 ends up positioned interiorly of, and desirably abutting, the interior surfaces of side wall end flaps 60, 120. Also, distal end portion 178 of end panel 92 ends up positioned inwardly of, and desirably abutting, the interior surfaces of the side wall end flaps 62, 121. In the position shown in FIG. 5, the interior surface of the distal end portion 178 of end panel 92 and the interior surface of the distal end portion 172 of end panel 90 face one another with their inwardly facing surfaces being across the interior of the container from one another.

[0048] With this construction, the strength of the end walls 21, 23 of the container is enhanced as in effect there are three layers, such as of corrugated paperboard, at these end walls. At end wall 90, these layers more specifically comprise the layer 172, the layer formed by side wall end flaps 60 and 120 and the layer comprising proximal end portion 170 of end panel 90. At end wall 92, these layers more specifically comprise the layer 178, the layer formed by side wall end flaps 62, 121, and the layer comprising proximal end portion 176 of end panel 92.

[0049] FIG. 6 illustrates another stage of erection of the container. In FIG. 6, the interior top panel end flaps 210, 214 that are joined to inner top panel section 26 are folded toward one another such that they are perpendicular to the inner top panel 26 in this example.

[0050] In the stage of container erection shown in FIG. 7, the inner top panel 26 and the end flaps 210, 214 have been folded to a horizontal position where the inner top panel 26 is parallel to the bottom panel 22. In this position, the interior top panel end flaps 210 and 214 have been inserted into the interior of the container with distal edges 211, 215 of these end flaps facing and more desirably abutting the interior surface of the bottom panel. Also, in this position, the exterior surface of interior top panel flap 210 is spaced from the interior surface of distal end portion 172 of end panel 90. In addition, in this stage of erection, the exterior surface of interior top panel end flap 214 is spaced from the interior surface of the distal end portion 178 of end panel 92. As a result, a gap 270 is provided between the interior surface of distal end panel section 172 and the exterior surface of interior top panel end flap 210 and a gap 272 is provided between the interior surface of distal end panel section 178 and the exterior surface of interior top panel end flap section 214. This is apparent from the FIG. 7 embodiment. In FIG. 7, the end flaps 40, 42 have also been folded to be perpendicular to the outer top panel section 18. In addition, end flap 40 is positioned for insertion into the gap 270 and end flap 42 is positioned for insertion into the gap 272 upon folding of first or outer panel section 18 toward the second or inner top panel section 26.

[0051] As illustrated in FIG. 7, indicia such as promotional materials or advertising, can be placed on the exterior or upper surface of interior lid or top panel section 26.

[0052] FIG. 8 illustrates the fully assembled container with outer top panel 18 folded over inner top panel 26 and with the interior surface of outer top panel 18 adjacent to and more desirably abutting the exterior surface of the interior top panel 26. In addition, in this construction the outer top panel end flaps 40, 42 have been inserted into the respective gaps 270, 272 (the gaps being shown in FIG. 7). As can be seen in FIG. 8, the shipping label can be affixed to the outer surface of outer top panel section 18.

[0053] When a container arrives following shipping or other delivery, the individual receiving the container can open the container by lifting up the top panel 18 to shift the container from the position shown in FIG. 8 to the position shown in FIG. 7. In addition, the recipient can insert her or his finger in an opening or gap in the interior top cove, such as arcuate gap 218 provided in the side edge 202 (FIG. 1), to facilitate lifting the interior lid or panel 26 and its panel end flaps 210, 214 away from the bottom of the container to expose the contents of the container. If a recipient decides not to accept the shipment, the user can simply reverse this process to close the interior top panel section 26 followed by closing the outer top panel section 18. Following closure, the user can affix a return shipping label to the exterior surface of top panel 18 and ship the container back to the source.

[0054] Alternatively, if the user desires to keep the contents, assuming a tear line is provided alongside edge 32 of the outer top panel 18, the user can readily tear the outer top panel section 18 and end flaps 40, 42 from the remaining portions of the container to leave the single lid or interior top panel 26 in place. When this is done, the top panel 18 and flaps 40, 42 can be recycled. In addition, the user has a convenient container for storing the contents of the original box. The fold line 58 between outer top panel 18 and side wall 20 can be weakened, such as perforated, to comprise a tear line.

[0055] With this construction, the need for an outer shipping container is eliminated. The dual top shipping container of this disclosure facilitates initial shipment, protects the contents, and allows easier return shipment in the event the recipient desires to return the contents.

[0056] Having illustrated and described the principles of this disclosure with reference to an embodiment, it should be apparent to those of ordinary skill in the art that this embodiment can be modified in arrangement and detail without departing from the inventive principles disclosed herein. All such modifications that fall within the scope of the claims are within the scope of this disclosure.