Note: Descriptions are shown in the official language in which they were submitted.
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EASY OPEI'~T COiT7i'AINER.
This application claims the benefit of U.S. Provisional Application No.
60/601,269,
filed August 13, 2004, the entire contents of which are hereby incorporated by
reference.
FIELD OF THE L'lYTIOl'~T
The present invention relates to shipping containers and methods of
manufacturing
shipping containers that may easily be converted to display containers. The
containers are
provided with a tear strip that does not rip the outermost layer of the
container, allowing
graphics to remain intact, preventing a ragged edge, and allowing the
container to be easily
opened while still protecting the contents during shipping.
B AC K, G R TIJT',T
It is often desirable for shipping containers to be converted to display trays
at a retail
point of sale, avoiding the need to unpack the product from a shipping
container and restack
it in a separate display tray. Often, display/shipping containers are opened
by removing a
tear strip that is embedded in (or provided on the inside layer of) the
shipping container upon
arrival of the container at the retail point of sale, allowing a portion of
the container to be
removed and display the remaining product in a portion of the container.
For example, the top (or cover) of the container may be removed while the
product
sits in the bottom (or lower tray) on a store shelf or display unit. These
containers have a
removable tear strip of cardboard that encircles a portion of the container.
Removal of the
strip releases the top portion of the container.
Such tear strips are problematic, however, because the cardboard does not
always tear
evenly, or rips off before being fully removed, requiring the use of a knife
to finish opening
the container. If a knife is used, the product in the container may be damaged
during opening
if the knife inadvertently penetrates the packaged product during opening,
rendering the
damaged product useless. The use of knives may also result in cutting an
uneven edge on the
display container, causing the display to look sloppy and undesirable.
The use of typical tear strips is also problematic because the removal of the
tear strip
often causes the outermost portion of the resulting display tray to be torn or
otherwise
damaged. Again, this results in an unattractive display tray that is not
suitable for displaying
product at a retail point of sale. This may result in the need to remove and
re-arrange the
contents of the container, occupying valuable employee time, negating the
benefits of using
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the tear strip in the first place, and requiring additional storage units for
the product (e.g., if
the product is not being restocked onto a shelf but onto a separate display
unit).
Another probleni with typical tear strips is that a relatively large amount of
effort may
be required to remove them because the tear strip is applied to the inside of
the container.
The tear strips are typically embedded between multiple layers of corrugated
material and
other outer and inner box layers, requiring the user to use a substantial
amount to force to
remove the strip. This force may cause the tear strip itself to rip off before
the container is
actually opened. Tear strips can also be difficult to predict and may tear a
substantial portion
of the display tray, particularly the outer layer, wllich is typically the
portion that displays
graphics and preferably presents a pleasing, finished edge,
Some manufacturers have attempted to solve these problems by forming the
corrugated inaterial and then perforating the outer layer, presumably to make
the container
easier to open. This attempted solution has actually presented a number of
additional
problems. First, a perforated outer layer does not provide a clean edge when
the tear strip is
removed. Graphics are still damaged and ran the risk of being delaminated.
Second, the act
of perforating the outer layer necessarily causes damage to the corrugated
flutes underneath
the layer. For example, the flutes can be crushed from the pressure of the
cutting machine or
they may be nicked or cut themselves during the cutting process. Damage to the
corrugated
flutes causes the structural integrity of the container to weaken.
Accordingly, these solutions
are not sufficient.
Other manufacturers have sought to develop containers that have two portions
that
can be separated, but without using tear strips at all, in an attempt to
prevent some of these
problems. For example, one option has been to use an adhesive to attach two
separable
halves of a container. Another option has been to use a piece of wide tape
with an embedded
filament that holds the two halves together. Removing the filament separates
the two halves,
allowing the container to be opened to display product. However, renloval of
the filament
requires tearing through the wide tape, which may result in the display tray
having an
unattractive appearance due to the edges of the torn wide tape that remain on
the tray and are
visible. Such unattractive display trays are not suitable for displaying
product at a retail point
of sale.
As discussed, many systems for opening boxes have been developed that use tear
strings, adliesive, and other securing mechanisms. In corrugated boxes, the
string must tear
through the paper liners and corrugated medium. This often results in a ragged
edge being
left and the de-lamination of the outside liner. With the introduction of new
paper to meet the
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ECT standards, the tear quality has become even worse. If an adhesive is used,
there exists
some concern about the securing and integrity of the container prior to its
being opened.
Consequently, there exists a need for a tearing system that will tear cleanly,
maintain most of
the box strength, and yet be economical to manufacture. It is important to
retailers that a
shipping container can be easily opened, without requiring a knife or other
tools, but that it
also attractively displays a product at a retail poiixt of sale once opened.
It is also important
to be able to include, and protect, graphics, such as advertisements, on the
display portion of
the tray. Various embodiments and aspects according to the present invention
provide one or
more, and sometimes combinations, of these aspects.
SIJMI11ARY
There is provided a shipping container and methods of manufacturing a shipping
container that may be opened using a tear strip to sever a cover portion of
the container from
a tray portion of the container. The container is preferably formed from
corragated cardboard
that includes an outer layer, an inner liner, and a corrugated medium disposed
between the
outer layer and the inner liner. The tear strip is preferably located on the
inside of the inner
liner, beginning at the glue flap. In certain embodiments, the glue flap has a
die cut portion
that may be used as a pull tab. Additionally, the one of the body panels (and
preferably the
last body panel) of the container has another die cut portion that covers the
pull tab and tear
strip. The outer layer, but not the corrugated medium or the inner liner, is
provided in at least
two separate pieces (for example, from two different rolls, in two different
materials, or from
a single sheet that is severed) such that the outer layer has a division to
facilitate pulling the
tear strip through the outer layer to separate the cover from the tray
portion.
In order to manufacture a container having such a divided or severed outer
layer and
tear strip, the inner liner and the corrugated medium are adhered to one
another, and then the
outer layer is applied separately to the corrugated material, leaving a slit
or a space between
the two separate outer layer portions. A tear strip is then adhered to the
inside area of the
inner liner adjacent to or above the area where the slit is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A shows a side perspective view of a container according to one
embodiment
of this invention.
Figure 1B shows a side perspective view of another embodiment of a container
having a pull tab and a flap separated from the body of the container.
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Figure 2A shows a top view of a blank that may be used to manufacture
containers
according to certain embodiinents of this invention.
Figure 2B shows the opposite side of the blank of Figure 1.
Figure 3 shows a cross-sectional view of one embodiment of the material used
to
make a container according to certain embodiments of this invention.
Figure 4 shows a tray of a container in use.
Figure 5 shows a container according to certain embodiments of the invention
being
opened.
Figure 6 shows a container according to certain embodiments of the invention
after
being opened.
Figure 7 shows a container according to alternate embodiments of the
invention.
DETAILED DESCRIPTION OF TIRE DRAVANGS
Various embodiments of aspects of this invention provide a shipping container
10 that
may easily be converted to a display container with minimal effort, wliile
also providing an
attractive display unit without ragged and rough edges. As shown in Figure 1,
container 10
includes a body portion 12 with a lower tray 14 and a cover 16. The lower tray
14 and cover
16 are separated by a division 18 and a tear strip 20.
Generally, certain embodiments include a container 10 (or corrugated box)
having an
inner liner 32, a corrugated (or fluted) middle material or medium 36, and an
outer layer 34.
(Although single walled corrugated material will be described throughout this
application, it
should be understood that various aspects of the invention may be used with
materials having
multiple layers of corrugated material separated by imier liners, such as
double and triple
walled corrugated material, each having more than one layer of corrugated
material separated
by inner liners.)
Attached to the inside of the inner liner 32 is a tear strip 20. The outside
layer 34 is
provided in at least two separate pieces (for example, from two different
rolls, in two
different materials, or from a single sheet that is severed). This divided
outer layer 34
provides an upper portion 70 of the outer layer that forms a cover 16 of the
container 10 and a
lower portion 72 of the outer layer that forms a tray 14 once the tear strip
20 is removed.
As shown in Figures 2A and 2B, the body portion 12 is made up of a series of
panels,
such as wall panels 26, end flap panels 28, and a glue flap 38. (Note that the
glue flap need
not have upper and lower flaps, although it may, if desired.) The wall panels
26 form the
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sides 40 of container 10 (as shown in Figure 5), and the end flap panels 28
fold over one
another to form the top 42 and bottom 44 of the container 10, also shown in
Figure 5.
As shown in Figure 3, container 10 is preferably formed from corrugated
cardboard
that includes an outer layer 34, an inner liner 32, and a corrugated material
36 disposed
between the outer and inner liners. More specifically, Figure 3 shows a
portion of a container
that is formed from corrugated cardboard. As shown, the outer layer 34 is
provided in at least
two separate pieces. (Only two portions are shown, because most shipping units
only need to
be divided into a tray and a cover, but if additional divisions are desired,
it is possible to
provide more than two portions of outer layer 34.) The pieces may be referred
to as upper
and lower portions, and they may be formed in any number of ways.
For example, the material that forms outer layer 34 may be fed from rolls on
two
different machines to form two separate layers and adhered to the inner liner
32 and
corrugated material 36 so that the separate layers lie adjacent to one
another. The completed
blank may then be cut to the desired form. (Note that the materials may be cut
to the desired
form before being adhered to the inner liner and corrugated material 36, if
desired.) In this
embodiment, the outer layer 34 may be formed from two different types of
material. For
example, the lower portion 72 may be made out of a sturdy plastic (since it
will form the
ultimate tray 14 and may need more structure) and upper portion 72 may be made
out of
paperboard. This combination may be reversed, or the saine type of materials
may be used,
or any other types of material may be used.
It is also possible to prepare the outer layer 34 by using a single piece of
material and
severing before it is applied to the inner liner 32 and corrugated material
36. In other words,
outer layer 34 may be pre-cut prior to application. One way to provide such a
pre-cut is by a
knife cut or any other device that can sever the outer layer into two separate
portions 70 and
72. For example, during the manufacturing process, the inner liner 32 (shown
in Figure 2B)
and the corrugated material 36 may be adhered to one another. As shown in
Figure 2A, the
outer layer 34 may be cut into two separate portions - an upper portion 70 and
a lower
portion 72 -- by a knife or other cutting device (non-limiting examples of
which include a
water jet, a laser, or scissor rollers) along the desired location.
Any appropriate method of cutting, dividing, or using separate pieces of
material for
outer layer 34 will be referred to throughout this document as providing a
divided outer layer
34 or a division 18. In short, whereas previous containers were made out of
three continuous
layers, the present container comprises three layers, but the third layer is
provided in two
separate pieces. This severing or dividing of outer layer 34 facilitates
pulling the tear strip 20
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through the container 10 to separate the cover 16 from the tray portion 14,
which will be
described in more detail below.
Referring generally to Figures 1A, 1B, and 2A, a division 18 is formed along
an outer
portion of container 10. Division 18 may be created to provide an upper
portion 70 and a
lower portion 72 using any of the above-described methods. The upper and lower
portions
70, 72 are then adhered to the corrugated material 36, leaving a slit or a
division 18 between
the two portions 70 and 72. Although some manufacturers may prefer a small and
barely
noticeable slit between the portions 70 and 72, there may be some instances
when a larger
space is desired. Accordingly, it is possible to adhere upper and lower
portions 70 and 72 in
positions that are further apart from one another, for example, a few
centimeters apart to a
few inches apart or even wider, if desired.
Manufacturing the container 10 by providing separate pieces of outer layer 34
or by
separately cutting the outer layer 34 and then attaching it to the container
to create a division
18 helps protect the structural integrity of the container. Other containers
that are
manufactured by scoring the outer liner once it has already been attached to
the corrugated
material crush and damage the corrugated flutes, deforming the material and
compromising
its strength. By contrast, the present invention maintains the box strength
and provides
enhanced structural integrity to the container 10. With the outer layer 34
completely
separated from the comxgated material 36 during the cutting process, no
tearing of the outer
layer 34 takes place when the container 10 is opened. During use, the
completely severed or
divided outer layer prevents delamination and tearing of the graphics that
typically occurs
without the use of the present invention. This is because the tear strip 20
does not ever have
to actually tear through any part of the outer layer 34 since it is already
divided from itself
along division 18.
In certain embodiments, the division 18 is preferably a relatively thin cut,
e.g., a knife
cut as shown in Figures 1A and 1B. This sever occurs before the outer layer is
adhered to the
corrugated material, which protects the corrugated material from the knife
cut, prevents it
from being nicked during manufacture, and prevents the corrugated material 36
from being
easily cut or crushed during shipping, helping to maintain the strength of the
box. In other
embodiments, the division 18 may be wider than a knife cut. Likewise, by
providing upper
and lower portions 70 and 72 out of two different rolls of material that are
pre-cut or that are
cut immediately before being applied to inner liner 32 and corrugated
materia136, there is no
need to cut outer layer 34 while it is applied to the corrugated materia136,
preventing the risk
of damaging the flutes of the materia136.
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Although not shown, it is also possible to provide more than one division 18
(for
example, if it is desired to protect the cover from being delaminated and
torn, providing two
severed portions, or a division between two separate pieces of material may
help prevent
tearing of the cover as well.)The division 18 may be in a relatively straight
line, to provide a
lower tray 14 and cover 16 of similar shape, (for example, the rectangular
shape as shown in
Figure 5), or it may be diagonal across body to provide a tray 14 and cover 16
having
different shapes (such as those shown in Figure 6), or it may travel in any
other desired
direction.
It is particularly preferred that the division extend entirely around the
periphery of the
container and provide two distinct portions 70 and 72. It is also particularly
preferred that the
division 18 be located at a lower portion of the container, such that a
shallow tray 14 is
formed, as shown in Figure 4.
However, as shown in Figure 7, it is also possible to use to present invention
to create
stadium-type trays, with high sides and a low front. In these embodiments, the
division 18 is
preferably provided at an upper area 80 of container so that the upper lid 82
(or cover) is
removed, leaving high sides 84. High sides 84 foml the sides of tray 14. There
is a
removable section 86 at the front portion 92 of the container that can be
removed to provide
an opening 88 and a low front 90 for the stadium-tray, making it easier for a
consumer to
access a product contained therein. The removable section 86 may be provided
by
perforations, another tear strip (for example, using the same division 18
concept) or any other
method that is appropriate for removing material.
Again, using the division 18 on this type of tray helps stabilize the strength
of the
container during shipping and allows the lid 82 to be removed without ruining
or
delaminating the graphics of the container. If a division 18 is used to create
the removable
area 86, it can provide for increased strength of that area and again, can
help protect the
graphics that could otherwise be disturbed during removal of removable section
86.
As shown in Figure 2B, a tear strip 20 is applied along the inside of the wall
panels 26
on the inner liner 32. The tear strip 20 is adhered to the liner 32 such that
it runs substantially
parallel to the division 18 that is located on the outside of the container.
Tear strip 20 may be
formed from the same material as the iimer liner and outer layer, such as
paperboard or
plastic or any other desired material, or it may be formed from a different
material, such as
wire, plastic ribbon, or any other type of material that is strong enougli to
cut through
corrugated material but malleable enough to be adhered to the inside of a
container. Tear
strip 20 may be applied using glue or any other appropriate securing
mechanism. It is
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particularly preferred that the tear strip 20 be located on the inside of
container 10 about even
or parallel to the area where the division 18 is located on the outside of
container 10 (as
shown in Figure 2A), or slightly above it. In other words, the tear strip on
the inside of the
container runs about parallel to the division 18 on the outside of the
container. The tear strip
20 has a top edge 60 and a bottom edge 62, and the bottom edge 62 is
preferably aligned with
or slightly above the division 18 of the outer layer.
When the tear strip is pulled, it tears through the inside liner or liner/s
and the
corrugated medium/s, and then pulls through the division 18, which avoids the
tearing of the
outside liner. As described above, the division 18 is slit in such a way that
only the outside
liner has been cut and no weakening to any other part of the substrate occurs.
This allows the
tearing to be clean, preventing delamination of the graphics on the tray 14
and preventing the
formation of ragged edges.
In order to fully understand the cooperation between tear strip 20, the
division 18, and
the tray 14 and cover 16, it is useful to refer to blank 30 prior to assembly
of container 10,
shown in Figures 2A and 2B. Figure 2A shows the outer layer 34 of blank 30 and
Figure 2B
shows the inner layer 32 of blank 30. Both figures show wall panels, end flap
panels 28 and
glue flap 38 prior to assembly.
The glue flap 38 is used to secure the wall panels 26 together and is shown in
phantom lines in Figure 5 (to illustrate that glue flap 38 is preferably on
the inside of the last
body panel, although it may also be adhered to the outside of the body.) Glue
flap 38 has one
or more die cuts 46 (which are shown as forming a triangular shaped tab) that
form a pull tab
24, which is connected to an end of the tear strip 20. A user accesses the die
cuts 46 to pull
out the pull tab 24.
Once the container 10 has been assembled, there is a need to protect the die
cut pull
tab 24 and tear strip 20 in order to prevent the tear strip from being toni
before the container
should be opened, for exainple, during shipping or storage. Accordingly, it is
preferred for
pull tab 24 to be protected by an optional cover flap 48 formed in one of the
body panels, and
preferably the last body panel 50.
As shown in Figure 2A, cover flap 48 may be die cut out of one of the body
panels,
and is preferably die cut out of the last body panel 50. The cover flap 48 may
be cut out of
the end edge of the panel 50 or it may be cut out from anywhere on the panel.
It is preferred
that the die cut be made around the cover flap 48, leaving a small portion 54
where cover flap
48 remains attached to panel once separated around the remaining die cut area.
This small
portion 54 that remains attached to the panel 50 allows the cover flap 48 to
be placed back
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into alignment with the panel to complete the tray 14. It is also possible for
the cover flap 48
to be completely removable.
As shown in Figure 1B, once the die cut cover flap 48 is pulled back from the
container 10, it presents the die cut portion 46 and opening 66. (Opening 66
is formed at the
end of glue panel 38, which is shown in phantom on Figure lfl.) Opening 66
provides an
area for the user's finger to grasp underneath the die cut member 46 and
release it from glue
flap 38, thus providing a pull tab 24. The use then grasps the pull tab, to
which tear strip 20
is attached, and opens the container 10. It is also possible for the user to
access the tear strip
20 directly, once cover flap 48 is pulled back.
In another embodiment, the tear strip 20 is comiected directly to cover flap
48. The
user grasps the cover flap 48 and by pulling on it, rips the tear strip 20
across the container
and through the division 18 to open the container 10. Although the die cuts 46
and pull tab
24 are preferably formed on the glue flap 38 and although the cover flap 48 is
preferably
formed on the last body panel 50, it should be understood that the die cut
member 46, pull tab
24, and/or cover flap 48 may be formed on any of wall panels 26.
In other embodiments, the tear strip 20 need not be covered by a flap, but is
secured in
place and covered by a removable section, such as piece of tape or so forth,
that helps prevent
the tear strip 20 from being toni during sliipping or any time prior to when
separation of the
tray 14 and cover 16 is desired.
Although a preferred embodiment of a die cut pull tab 24 has been described as
formed directly from the blank 30 (and thus, is comprised of the same material
as container),
it should also be understood the pull tab may be formed from a separate
structure that is
connected to the tear strip or it just may be an end of tear strip, that is,
for example, enlarged.
In still other embodiments, the tear strip may protrude from the box and be
formed into a loop
to facilitate pulling the tear strip to open the box. If provided outside the
container, there may
be a piece of adhesive or tape the prevents it from being pulled before
disassembly of the
container is desired.
In other embodiments, the tear strip 20 need not be covered by a flap, but is
secured in
place and covered by a removable section, such as piece of tape or so forth,
that helps prevent
the tear strip 20 from being torn during shipping or any time prior to when
separation of the
tray 14 and cover 16 is desired.
Once the upper and lower portions 70 and 72 of the outer layer 34 have been
adhered
to the inner liner 32 and the corrugated material 36, the container 10 may be
assembled by
folding the panels 26 to create sides 40 and adhering the glue flap 38 to the
inside of the last
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body panel 50. End flap panels 28 on one side are folded over one another to
form a bottom
44. The container 10 may then be filled with the desired product. Once ready
for closure, the
end flap panels 28 on the other side are folded over one another to form a top
42. (Note that
the blank 30 may be manufactured and shipped in a flattened position to a
distributor who
assembles and packs the container for shipping to the ultimate retailer.)
Once the container 10 arrives at its desired location, a user may separate
cover flap 48
that is formed in one of the body panels (and preferably from the last body
panel 50) to reveal
die cut area 46 and opening 66, as shown in Figure 1B. The user lifts the die
cut portion 46,
which forms a pull tab 24. The user grasps and pulls the tab 24 to activate
the tear strip 20 to
tear strip 20 tears through the inner liner 32 and the corrugated material 36.
The tear strip 20
does not cut through the outer layer 34 because, as discussed, the outer layer
34 features the
division 18 that allows tear strip 20 to pass without roughing up the edges or
ruining the
graphics on outer layer 34. In other words, the inner liner 32 and corrugated
material 36
remain intact while the outer layer 34 has separate upper 70 and lower 72
portions. This
division or separation makes separating the tray 14 and cover 16 easier than
current methods
because there is less resistance. This feature also allows the container to be
torn open without
ruining the graphic image and the structural integrity of the remaining tray.
Changes and modifications, additions and deletions may be made to the
structures and
methods recited above and shown in the drawings without departing from the
scope or spirit
of the invention and the following claims.
