STRUCTURED PACKAGE FOR SHIPPING AND DISPLAYING GOODS
20260070699 ยท 2026-03-12
Inventors
- Ross A. FEILER (Alexandria, MN, US)
- Jonas A. CAPISTRANT (Alexandria, MN, US)
- Jesse MALAND (Alexandria, MN, US)
Cpc classification
B65D5/5016
PERFORMING OPERATIONS; TRANSPORTING
B65D5/0236
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D5/50
PERFORMING OPERATIONS; TRANSPORTING
B65D5/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A package assembly is used for both shipping products to a retail facility, and for displaying the products at the retail facility. In its shipping configuration the container is enclosed to carry the products. In its display configuration, portions of at least the top and front of the package assembly are removed to permit the customer to view the products on display. The package assembly is formed from a single piece of package material and includes a base panel, a back panel and first and inner sidewalls connected at the opposing second and third sides of the base panel. Folded retaining flaps are connected along sides of the respective first and second inner sidewalls. A front panel is connected at a fourth side of the base panel opposing the first side of the base panel. The retaining flaps are used to support the product in the package.
Claims
1. A package assembly, comprising: a single piece of package material, comprising a base panel; a back panel connected at a first side of the base panel; first and second inner sidewalls connected at opposing second and third sides of the base panel; first and second folded retaining flaps along sides of the respective first and second inner sidewalls opposing the base panel; a front panel connected at a fourth side of the base panel opposing the first side of the base panel; first and second front tabs connected at opposing sides of the front panel, inner surfaces of the first and second front tabs respectively attached to outer surfaces of the first and second inner sidewalls; and first and second back tabs connected at opposing sides of the back panel, inner surfaces of the first and second back tabs respectively attached to outer surfaces of the first and second inner sidewalls; wherein the package assembly forms a cavity and wherein the first and second folded retaining flaps project into the cavity from the respective first and second sidewalls.
2. The package assembly of claim 1, wherein the single piece of package material further comprises: a top panel at a side of the back panel opposing the base panel; and a front cover panel connected at a side of the top panel opposing the back panel, a lower portion of the front cover panel located inside the front panel; wherein a perforation in the package material permits at least a portion of the top panel and at least a portion of the front cover panel to be removed from the package assembly, the package assembly being in a shipping configuration before the at least a portion of the top panel and the at least a portion of the front cover panel are removed and in a display configuration after the at least a portion of the top panel and at least a portion of the front cover are removed.
3. The package assembly of claim 1, further comprising first and second top side tabs connected at opposing sides of the top panel.
4. The package assembly of claim 3, wherein the perforation crosses the first and second top side tabs, at least a portion of the top panel and at least a portion of the back panel, forming an access tab on the portion of the back panel between the perforation and the connection between the back panel and the top panel.
5. The package assembly of claim 4, further comprising first and structural members on the top panel formed between the perforation, the connection between the top panel and the back panel and, respectively, the first and second top side tabs.
6. The package assembly of claim 3, wherein the perforation crosses the first and second top side tabs, and lies along at least a portion of the connection between the first top side tab and the top panel, along the connection between top panel and the rear panel, and along at least a portion of the connection between the second top side tab and the top panel.
7. The package assembly of claim 6, wherein at least a portion of the perforation along the connection between the top panel and the back panel comprises a cut through the package material to provide a grippable edge.
8. The package assembly of claim 2, wherein the perforation crosses the first and second back tabs and at least a portion of the back panel, forming an access tab on a portion of the back panel between the perforation and the connection between the back panel and the top panel.
9. The package assembly of claim 2, wherein the perforation crosses the first and second back tabs, and lies along at least a portion of the connection between the first back tab and the back panel, along the connection between top panel and the back panel, and along at least a portion of the connection between the second back tab and the back panel.
10. The package assembly of claim 8, wherein at least a portion of the perforation along the connection between the top panel and the rear panel comprises a cut through the package material to provide a grippable edge.
11. The package assembly of claim 2, wherein a lower edge of the front cover panel touches in inner surface of the base panel when the top panel is parallel to the base panel and the package is in the shipping configuration.
12. The package assembly of claim 1, wherein the front panel comprises a recess.
13. The package assembly of claim 1, further comprising first and second extension flaps respectively connected on sides of the first and second folded retaining flaps opposing the first and second sidewalls, the first inner sidewall having a length, L1, the first folded retaining flap having a length L2 and the first extension flap having a length, L3, as measured from the base panel, wherein L1<(L2+L3).
14. The package assembly of claim 1, wherein the first and second folded retaining flaps have respective first and second distal edges, the first and second distal edges being die cut.
15. The package assembly of claim 1, wherein the first and second folded retaining flaps have respective first and second distal edges, the first and second distal edges being torn perforations.
16. The package assembly of claim 1, wherein the first and second folded retaining flaps are free of slots for securing goods stored in the cavity.
17. The package assembly of claim 1, wherein the first and second folded retaining flaps have respective first and second distal edges that are shaped to complement products stored in the package.
18. The package assembly of claim 1, wherein the first inner sidewall has a length L1 and the first folded retaining flap has a length L2, L1 and L2 being measured in a direction from the base panel, wherein L2<L1.
19. The package assembly of claim 1, wherein the first inner sidewall has a length L1 and the first folded retaining flap has a length L2, L1 and L2 being measured in a direction from the base panel, wherein L2>L1.
20. The package assembly of claim 19, further comprising respective first and second flap extensions at the distal ends of the first and second folded retaining flaps, the first and second flap extensions being attached to the base panel.
21. The package assembly of claim 20, wherein the first and second folded retaining flaps are slotted.
22. The package assembly of claim 1, further comprising at least one product carton sitting on the base panel within the cavity, the product of goods having a center of mass that is at a first distance above the base panel, and wherein a distal edge of the first folded retaining flap touches the at least one carton of goods at a point that is a second distance above the base panel, the second distance being greater than the first distance.
Description
BREIF DESCRIPTION OF THE DRAWINGS
[0030] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0031]
[0032]
[0033]
[0034]
[0035]
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[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
[0049] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0050] The present invention relates to a packaging assembly suitable for storing and shipping a plurality of products or product containers, and which is readily converted to a shelf-ready product display by removing a portion of the packaging assembly. Some embodiments of the invention are advantageously used to ship and to display relatively heavy products, such as batteries. The invention is not limited in this manner however, and other embodiments are suitable for shipping and displaying a wide variety of products.
[0051] As used herein, and in the appended claims, the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a panel can refer to one panel or more than one panel, and reference to the method includes reference to equivalent steps and/or methods known to those skilled in the art, and so forth.
[0052] Directional terms such as up, upwards, top, down, downwards, and bottom may be used to describe spatial relationships between different portions of the package. As such, these terms are not intended to be used in an absolute sense, but in a relative sense when the package is sitting on its base, with the top panel uppermost. Thus, the top of the package refers to the panel opposite the base panel, the base panel being the panel the package sits on when in its display configuration. In some embodiments, the package is also intended to sit on its base panel when being shipped.
[0053] The terms inner and outer refer to the position of a portion of the package relative to the cavity within the package that holds the products. An inner surface of a panel is that surface that faces in towards the cavity. An outer surface of a panel is that surface that faces away from the package cavity.
[0054] It is desirable to provide a package that can be used to ship goods from the manufacturer (shipping configuration) and that also may be used to display the goods on a retailer's shelf (display configuration). Advantageously the package is sturdy enough in the shipping configuration to be stacked multiple times so that many packages can be palletized for shipping. It is preferred that the package provides easy access to a customer to retrieve a product or product container from the package when in the display configuration.
[0055] The material used for the package may be any suitable type of foldable material such as cardboard, corrugated card, plastic, corrugated plastic, paperboard, fiberboard and pulp. The type of material used for the package may depend on the type of products it is being used to ship and display. In some embodiments where the products are relatively heavy, such as batteries, meat products, liquid products, other food products and household items, the package may be formed from corrugated cardboard. Suitable types of corrugated cardboard may include A flute to N flute board. In other embodiments where the products are lighter, for example food products packaged in sachets, leaflets, brochures, household products in a blister package, the package may be formed from a paperboard.
[0056] The package is typically formed from a single package blank that is die cut and folded to form panels. Some panels overlap each other and are supplied with an adhesive therebetween so that they hold together and the package retains its desired form. The adhesive may be a hot melt adhesive, a thermoset plastic, pressure activated adhesive, or other suitable adhesive. In other embodiments, panels may be joined together using mechanical means, such as staples or clips.
[0057]
[0058] The base panel 104 forms the base of the package. The base panel 104 is typically rectangular and is connected on one side to the back panel 106 which forms the back of the package. The term connected is used herein to describe where two panels adjoin via a fold in the package material.
[0059] The base panel 104 is connected to the front display panel 108 at a side opposite to the back panel 106. The front display panel 108 may be rectangular in shape or, as in the illustrated embodiment, be provided with a recess 110 to allow the products contained in the package to be more clearly seen when in the display configuration. First and second front side tabs 112, 114 are connected at opposing sides of the front display panel 108.
[0060] First and second inner sidewalls 116, 118 are connected to the base panel 104 at the two remaining sides of the base panel 104. Each inner sidewall 116, 118 is connected to a respective folded retaining flap 120, 122, whose purpose will be explained below. The width, W1, of the folded retaining flaps 120, 122 may be the same as the width, W2, of the respective inner sidewalls to which they are connected, but this need not be the case and in some embodiments, W1 may be less than W2. Additionally, the width of the first folded retaining flap 120 need not be the same as the length of the second folded retaining flap 122. The length, L1, of the inner sidewalls 116, 118 is greater than the length, L2, of the folded retaining flaps 120, 122, where L1 and L2 are measured in a direction from the base panel 104, as seen in
[0061] The back panel 106 is connected at opposing sides to first and second back tabs 124, 126. The back panel 106 is also connected to the top panel 128, at the side opposite the base 104. The top panel 128 is connected at opposing sides to first and second top side tabs 130, 132. The top panel 128 is also connected to the front cover panel 134. When the package is in the shipping configuration, the front display panel 108 and the front cover panel 134 together form the front surface of the package. The front cover panel 134 is connected to first and second removable front tabs 136, 138.
[0062] The perforation 102 crosses the blank 100, splitting the first top side tab 130 into first and second parts 130a, 130b. The perforation 102 also crosses the top panel 128 to form a removable top panel section 128a, a first structural top panel section 128b and a second structural top panel section 128c. The perforation 102 also crosses part of the back panel 106. That part of the back panel bounded by the perforation 102 and the connection between the back panel 106 and top panel 128 is referred to as an access tab 140, for reasons explained below. The perforation 102 also splits the second top side tab 132 into first and second parts 132a, 132b.
[0063] Those parts of the blank 100 to the right side of the perforation 102 may be considered to be part of a removable hood that is removed when the package is converted from its shipping configuration to its display configuration. In this embodiment, the removable hood includes the access tab 140, the removable top panel section 128a, the second parts 130b, 132b of the first and second top side tabs 130, 132, the front cover panel 134 and the first and second removable front tabs 136, 138. Thus, when converting the package from the shipping configuration to the display configuration, the first and second top side tabs 130, 132 are each split into two parts, with the second parts 130b, 132b being removed with the hood.
[0064]
[0065] The outer surfaces of the inner sidewalls 116, 118 are attached to the inner surfaces of the first and second front side tabs 112, 114, and the inner surfaces of the first and second back tabs 124, 126. Likewise, the outer surfaces of the first and second top side tabs 130, 132 are attached to the inner surfaces of the first and second back tabs 124, 126, and to the inner surfaces of the first and second removable front tabs 136, 138. The different panels may be attached to each other using any suitable method. In one embodiment, a hot melt adhesive is applied to the outer surfaces of the inner sidewalls 116, 118 and the outer surfaces of the first and second top side tabs 130, 132 after these panels have been folded inwards, but before the first and second front side tabs 112, 114, the first and second back tabs 124, 126, and the first and second removable front tabs 136, 138 are folded in. In other embodiments, an adhesive may be applied to the inner surfaces of the first and second front side tabs 112, 114, the inner surfaces of the first and second back tabs 124, 126, and the inner surfaces of the first and second removable front tabs 136, 138 before these panels are folded in. In other embodiments, adhesive may be applied to the outer surfaces of the inner sidewalls 116, 118 and the outer surfaces of the first and second top side tabs 130, 132, as well as to the inner surfaces of 136, 138 are folded in. In other embodiments, an adhesive may be applied to the inner surfaces of the first and second front side tabs 112, 114, the inner surfaces of the first and second back tabs 124, 126, and the inner surfaces of the first and second removable front tabs 136, 138.
[0066] The base of the completed package comprises a single layer of package material, the base panel 104. The top layer of the completed package comprises a single layer of package material, the top panel 128. The back of the package comprises a single layer of package material, the back panel 106. As just discussed, the sides of the package substantially comprise two layers of package material.
[0067]
[0068] In its shipping configuration, the two back vertical corners 325, 327, respectively formed by folds between the back panel 106 and the first and second back tabs 124, 126, are free of any perforation, this providing increased vertical strength to the package 300.
[0069] The package 300 may be converted into the display configuration by removing the top panel 128 and those other panels connected to the top panel 128 that were shown to the right of the perforation 102 in
[0070]
[0071] The perforation used to separate the removable part from the package to achieve the display configuration may be different from that shown in
[0072]
[0073] In some embodiments, the package is provided with an access panel. An embodiment of a pre-cut package blank 1000 is schematically illustrated in
[0074]
[0075]
[0076] In some embodiments the folded retaining flaps have a substantially straight distal edge. In other embodiments the folded retaining flaps have a shaped distal edge. One embodiment of a package 1500 that has folded retaining flaps 1520, 1522 with a shaped distal edge 1521, 1523 is schematically illustrated in
[0077] Another embodiment of a package 1700 that has folded retaining flaps 1720, 1722 with a shaped distal edge 1721, 1723 is schematically illustrated in
[0078] Another embodiment of a package 1900 is schematically illustrated in
[0079] Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification. The claims are intended to cover such modifications and devices. For example, a small number of possible embodiments have been illustrated herein, showing packages having only a small number of aspect ratios, i.e. ratios of height, length and width. It will be appreciated that packages according to the present invention may be formed that have aspect ratios very different from those illustrated. Furthermore, the various embodiments of folded retaining flap were illustrated in a package using only a single type of perforation. It should be understood that the different types of folded retaining flaps may be used with any of the different perforation types described herein.
[0080] As noted above, the present invention is applicable to packaging for shipping and displaying products in a retail environment. Accordingly, the present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims.