Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: Container Package Assembly With Two Support Members
FIELD OF THE INVENTION
This invention relates generally to package assemblies and in particular
to a package assembly suitable for shipping as well as product display, which
features
open portions in its front and rear.
BACKGROUND OF THE INVENTION
Devices for packing and shipping products and/or containers of products
are known. Such devices are available in a wide variety of shapes, sizes and
styles.
Often a package assembly is designed to contain a number of different
containers, such
as several containers of a product, in a single package assembly for delivery
from one
location to another, such as from a manufacturer to a wholesaler or retail
seller.
Sometimes the shipping package assembly is also used to display the product
once the
assembly is opened at the retail seller.
In many cases, the package assembly used to ship containers of product
from the manufacturer to the retailer is of such type that the containers need
to be
removed from the assembly prior to displaying the containers in the retail
environment.
Removing the containers from the package assembly is often time and labor
intensive.
Therefore package assemblies are often used that are suitable both for
shipping as wells
as retail display.
There has been a trend toward decreasing the size of the display package
assembly, due in part to the expense of shelf space in the retail environment.
The need
for smaller display assemblies is growing as more and more products compete
for
limited shelf space.
The trend toward smaller display package assemblies is also driven by
the need to reduce production costs, reduce waste, and reduce our consumption
of
natural resources. In our global economy, reducing production costs is
critical for
maintaining competitiveness. Any design change that results in savings is
critical. And,
retailers are concerned with reducing waste after they receive shipments¨there
is a
large cost associated with managing and disposing of waste after the
containers have
been removed from the package assemblies. Finally, creating or even recycling
paper
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board and corrugated fiberboard, two staples in creating package assemblies,
along with
a number of other materials used in creating package assemblies, consume
enormous
amounts of natural resources. Whether it is the clear-cutting of forests, use
of massive
amounts of water, or consumption of large amounts of fuel in their production,
there is
no doubt package assemblies have a large environmental impact.
As such, there is a need for a cost effective low-bulk package assembly
that is capable of shipping a plurality of containers and then transitioning
to retail
display.
The art referred to and/or described above is not intended to constitute an
admission that any patent, publication or other information referred to herein
is "prior
art" with respect to this invention. In addition, this section should not be
construed to
mean that a search has been made or that no other pertinent information as
defined in 37
C.F.R. 1.56(a) exists.
Without limiting the scope of the invention, a brief summary of some of
the claimed embodiments of the invention is set forth below. Additional
details of the
summarized embodiments of the invention and/or additional embodiments of the
invention may be found in the Detailed Description of the Invention below.
A brief abstract of the technical disclosure in the specification is
provided for the purposes of complying with 37 C.F.R. 1.72.
SUMMARY OF THE INVENTION
At least some embodiments of the present invention are directed to
package assemblies that provide a material savings of approximately 15% to
approximately 30% per assembly when compared to known package assemblies used
for
shipping equivalent products. For example, in at least one embodiment, the
inventive
package assembly has been determined to utilize approximately 23% less
corrugate (by
surface area) than a Bliss style box, about 19% less than an RSC case, and
about 11%
less than a 'short-flap' RSC case. The reduction in packaging material reduces
production costs and conserves material. At the same time however, such a
package
assembly provides equivalent, if not greater, structural strength,
particularly stacking
strength (vertical), as that exhibited by the more material intensive known
package
assemblies mentioned above.
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In at least one embodiment, the invention is directed to a container
package assembly which includes a first support member and a second support
member.
Both the first support member and the second support member have a top, a
bottom, a
first side, a second side, and a vertical support. For each support member,
the vertical
support is integrally engaged to the top, the bottom, the first side, and the
second side.
For each support member, the top is substantially parallel to the bottom, the
first side is
substantially parallel to the second side, and the vertical support is
substantially
perpendicular to the top and the bottom. For each support member, the first
side and the
second side have a top edge and a bottom edge, the top edge having a top edge
length
and the bottom edge having a bottom edge length, the top edge length being
less than
the bottom edge length. The vertical support of the first support member is
immediately
adjacent the vertical support of the second support member.
In some embodiments, one or both of the first support member and the
second support member further include a transition region between the top and
the first
side and/or the second side. The transition region extends at an oblique angle
relative to
the first side and/or the second side. Oblique is defined herein to mean
"neither
perpendicular nor parallel to a given line or surface; slanting; sloping."
(www.dictionary.com)
In at least one embodiment, the assembly further includes a plurality of
containers positioned on the bottom of the first support member and the second
support
member.
In some embodiments, the assembly further includes a film, wherein the
assembly is at least partially encapsulated by the film.
In at least one embodiment, the assembly further includes a top pad. A
first portion of the top pad is engaged to a portion of the top of the first
support member
and a second portion of the top pad is engaged to a portion of the top of the
second
support member.
In some embodiments, the vertical support of the first support member is
adhesively engaged to the vertical support of the second support member.
In at least one embodiment, the assembly has a substantially trapezoidal
shape in side view.
In some embodiments, each of the first support member and the second
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support member has a substantially trapezoidal shape in side view.
In at least one embodiment, each of the first support member and the
second support member are formed from a respective unitary, folded cardboard
blank.
In some embodiments, the assembly defines at least one handgrip.
In at least one embodiment, the handgrip is at least partially defined by
one or both of the first side and the second side.
In some embodiments, the handgrip is at least partially defined by the
vertical support.
In at least one embodiment, the invention is directed to a container
package assembly which includes a first support member and a second support
member.
The first support member and the second support member each have a bottom, a
first
side, a second side, and a vertical support. The vertical support is
integrally engaged to
the bottom, the first side, and the second side. For each support member, the
first side is
substantially parallel to the second side, and the vertical support is
substantially
perpendicular to the bottom. For each support member, each of the first side
and the
second side have a top edge and a bottom edge, the top edge having a top edge
length
and the bottom edge having a bottom edge length, the top edge length being
less than
the bottom edge length. The vertical support of the first support member is
immediately
adjacent the vertical support member of the second support member.
These and other embodiments which characterize the invention are
pointed out with particularity in the claims annexed hereto and forming a part
hereof.
However, for further understanding of the invention, its advantages and
objectives
obtained by its use, reference should be made to the drawings which form a
further part
hereof and the accompanying descriptive matter, in which there is illustrated
and
described embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention is hereafter described with
specific reference being made to the drawings.
FIG. 1 is a perspective view illustrating an exemplary support member in
accordance with one embodiment of the present invention.
FIG. 2 is a perspective view illustrating an exemplary assembly of two of
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the support members shown in FIG. 1, in accordance with one embodiment of the
present invention.
FIG. 3 is a perspective view illustrating the assembly shown in FIG. 2,
along with product containers, in accordance with one embodiment of the
present
5 invention.
FIG. 4 is a side view of the assembly shown in FIG. 3, in accordance
with one embodiment of the present invention.
FIG. 5 is a plan view illustrating a typical blank construction for making
the support member shown in FIG. 1, in accordance with one embodiment of the
present
invention.
FIG. 6 is a perspective view illustrating an exemplary assembly with
product containers, the assembly including transition regions, in accordance
with one
embodiment of the present invention.
FIG. 7 is a perspective view illustrating an exemplary assembly with
product containers, the assembly including transition regions, in accordance
with one
embodiment of the present invention.
FIG. 8 is a perspective view illustrating two support members with
transition regions, along with product containers, in accordance with one
embodiment of
the present invention.
FIG. 9 is a perspective view illustrating the assembly shown in FIG. 3
and including a top pad, in accordance with one embodiment of the present
invention.
FIG. 10 is a perspective view illustrating an exemplary support member
without a top, in accordance with one embodiment of the present invention.
FIG. 11 is a perspective view illustrating an exemplary assembly of two
of the support members shown in FIG. 10, in accordance with one embodiment of
the
present invention.
FIG. 12 is a perspective view illustrating the assembly shown in FIG. 11,
along with product containers, in accordance with one embodiment of the
present
invention.
FIG. 13 is a perspective view illustrating the assembly shown in FIG. 12
and including a top pad, in accordance with one embodiment of the present
invention.
FIG. 14 is a perspective view illustrating the assembly shown in FIG. 3
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encapsulated by film, in accordance with one embodiment of the present
invention.
FIG. 15 is a perspective view illustrating the assembly shown in FIG. 14
and including a top pad, in accordance with one embodiment of the present
invention.
FIG. 16 is perspective view illustrating several of the assemblies shown
in FIG. 15 stacked vertically.
FIG. 17 is a perspective view illustrating an exemplary assembly of two
of the support members shown in FIG. 1, along with six product containers, in
accordance with one embodiment of the present invention.
FIG. 18 is a perspective view illustrating an exemplary assembly of two
of the support members shown in FIG. 17, along with protective flaps, in
accordance
with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention may be embodied in many different forms, there are
described in detail herein specific preferred embodiments of the invention.
This
description is an exemplification of the principles of the invention and is
not intended to
limit the invention to the particular embodiments illustrated.
For the purposes of this disclosure, like reference numerals in the figures
shall refer to like features unless otherwise indicated.
Referring first to FIG. 1, the support member shown generally at 10
includes a top 15, a bottom 20, a pair of sides (25, 30), and a vertical
support 35. As
best seen in FIG. 5, the top 15, the bottom 20, and the sides (25, 30) are all
foldably and
integrally engaged to the vertical support. The support member 10 may be
constructed
from any material suitable for shipping and displaying containers. Such
materials may
include paperboard, corrugated fiberboard, press-board, chipboard, SBS board,
wood,
one or more paper product derivatives, plastic, metal or other materials.
Preferably, the
support members are constructed from a light weight material that may be
easily and
inexpensively recycled or disposed of.
The support member 10 is constructed so that the top 15 and bottom 20
are substantially parallel with one another. Likewise, the sides (25, 30) are
substantially
parallel with one another. To provide superior strength, the vertical support
35 is
integrally engaged such that it is substantially perpendicular to the top and
bottom as
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well as the sides.
Still referring to FIG. 1, both of the sides (25, 30) have a top edge 40
having a length 45, and a bottom edge 50 having a length 55. In a preferred
embodiment, as seen in FIG. 1, the length 45 of the top edge of the support
member 10
is less than the length 55 of the bottom edge. A trapezoid is a quadrilateral
plane figure
having two parallel and two nonparallel sides. (www.dictionary.com). The top
edge 40
and the bottom edge 50 are substantially parallel, and because the length 45
and the
length 55 are not equal, the edges 51 and 52 are nonparallel. As such, in side
view the
support member has a substantially trapezoidal shape.
FIG. 2 depicts a preferred embodiment of the assembly, shown generally
at 100. In FIG. 2, two support members (10, 12) immediately adjacent one
another,
form a container package assembly 100. As seen in FIG. 2, the two support
members
are in opposition such that the vertical support 35 of one support member 10
is
immediately adjacent the vertical support 35 (not shown) of the other support
member
12. Orienting the support members in such a manner provides a number of
structural
benefits to the assembly. By orienting the two support members such that the
two
vertical supports are abutting, vertical support is concentrated at the center
of the
assembly, thereby increasing the compression strength, and thus the stacking
capability,
of an assembly. Furthermore, because the bottom edges 50 of each support
member is
longer than the top edges of each support member, such an orientation provides
the
assembly with excellent stability both alone and, most importantly, when
assemblies are
stacked on one another.
The two immediately adjacent vertical supports 35 shown in FIG. 2 may
be adhesively engaged. Adhesive engagement between the vertical supports may
improve the overall strength, durability, and stability of the assembly 100.
The vertical
supports may be permanently or temporarily engaged to one another by any of a
variety
of adhesive materials, such as removable adhesives, time release adhesives,
biodegradable adhesives, etc.
In at least one embodiment, the adhesive is a hot melt adhesive which
may be applied by applicators. By means of appropriate adhesive dispensing
equipment,
the nature of which will be readily apparent to those familiar with the art,
strips of
adhesive may be placed on the vertical supports. For optimal results, both the
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application temperature and depth of an adhesive strip should be consistent.
In order to form a temporary bond, the hot melt adhesive should have an
open time of approximately 30 to 45 seconds. The open time is defined as the
period
between application of adhesive on a vertical support and solidification of
adhesive.
An example of an adhesive suitable for use with at least one embodiment
of the present invention is commercially available from H. B. Fuller as
Product No. H.L.
7674. Depending upon the type of handling contemplated, however, the specific
open
time may vary. In general, an open time of between about 5 seconds to about 1
minute
is particularly well suited for the present invention.
The specific bonding strength of the adhesive is controlled by varying the
application temperature of the adhesive, and the depth of the adhesive strips
(generally
1/16 to 1/8" depth). A higher application temperature and deeper adhesive
strips will
increase the bonding, and a lower temperature and thinner adhesive strips will
decrease
bonding. In general, the hot melt adhesive is preferably applied within a
temperature
range of 270 degrees Fahrenheit to 340 degrees Fahrenheit.
More information regarding suitable adhesives may be found in U.S.
Patent No. 6,499,596.
As described above, each support member has a trapezoidal shape in side
view. Similarly, the two support members of the assembly 100 also form a
trapezoidal
shape in side view, as best seen in FIG. 4. In addition to providing
structural benefits,
the trapezoidal shape of the inventive assembly reduces packaging material. As
mentioned above, some embodiments of the inventive assembly use approximately
23%
less corrugate (by surface area) than a Bliss style box, about 19% less than
an RSC case,
and about 11% less than a 'short-flap' RSC case. The reduction in packaging
material
reduces the cost of producing an assembly and also conserves material.
Therefore, this
reduction benefits the producer of the assembly because of reduced cost, the
recipient
because of a reduction in waste material that must be recycled or otherwise
disposed of,
and the environment.
Embodiments of the assembly may also include one or more handgrips
60, as shown in FIG. 2. The handgrip 60 may be at least partially defined by
one or both
sides (25, 30), as seen in FIGs. 1 and 2. As seen in the embodiment of the
support
member 10 shown in FIG. 1, the vertical support 35 also defines at least a
portion of the
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handgrip 60. Providing such a cutaway in the vertical support, as best seen in
FIG. 5,
improves the comfort and gripping area of the handgrip 60 of the assembly 100
shown
in FIG. 2.
As mentioned above, package assemblies made in accordance with the
present invention are capable of containing and displaying particularly heavy
and/or
bulky product containers with minimal use of material while providing
excellent
containment and strength characteristics. Referring now to FIG. 3, a preferred
embodiment of the inventive assembly 100 is shown. The assembly of FIG. 3 is
holding
four containers 102, each product container 102 being an approximately 1-
gallon jug of
fluid. As seen, each support member (10, 12) holds two containers in place on
the
bottom member 20. While the preferred embodiment of the assembly holds four
approximately 1-gallon jugs of fluid, other embodiments include eight 1/2
gallon jugs of
fluid. In other embodiments, the assemblies need not hold jugs or jugs of
fluid but may
instead hold bottles, cans, boxes, or any other type of product container 102.
In some
embodiments of the assembly, depending on the number of product containers
ordered
by a customer, it may be desirable to have product containers in only one of
the two
support members (not depicted).
FIG. 5 shows a plan view of a typical unitary blank for making the
support member shown in FIG. 1. FIG. 5 illustrates in detail how the vertical
support 35
is integrally engaged to the top 15, the bottom 20, and the sides (25, 30)
along fold lines
65. The blank comprises three substantially rectangular sections: the top 15,
the bottom
20, and the vertical support 35. The blank further comprises two substantially
trapezoidal sections: the two sides (25, 30). The blank further comprises four
flaps (70,
75, 80, and 85). As seen in FIG. 5, the top and the bottom are foldably
engaged to a first
pair of opposing sides of the vertical support. The sides (25, 30) are
foldably engaged to
a second pair of opposing sides of the vertical support. Flaps 70, 75 are
foldably
engaged to opposing sides of the bottom 20 and are adjacent to the sides (25,
30),
respectively. Similarly, flaps 80, 85 are foldably engaged to opposing sides
of the top
15 and are adjacent sides 25, 30, respectively. Flaps 80, 85 include cutaway
areas 90
that, when the blank is folded, combine with the cutaway areas 95 of the sides
and
vertical support to create the handgrips.
Referring now to FIG. 6, another embodiment of the inventive assembly
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is shown. The assembly 100 shown in FIG. 6 is similar to the assembly in FIG.
3.
However, as seen in FIG. 6, each support member (10, 12) of the assembly 100
further
includes one or more transition regions 105. A transition region 105 extends
between
the top and a side of a support member. In some embodiments, like in FIG. 6,
each
5 support member (10, 12) include two transition regions. As depicted in
FIG. 6, the
transition region 105 may extend at an oblique angle 0 relative to the sides.
One major
benefit of using assemblies with transition regions is the reduction in the
overall profile
of the assembly. This increases the number of assemblies that may be shipped
together,
and the number of assemblies that may be placed near one another on store
shelves.
10 Another benefit is the reduction in packaging material, because the
assembly more
closely conforms to the profile of the product containers it holds.
The sides 25 (and 30, not shown) of the support members (10, 12) have a
trapezoidal shape in side view, like in the embodiments described above. The
trapezoidal shape is created, as before, by providing a top edge 40 that is
shorter than a
bottom edge 50. In the embodiment shown in FIG. 6, the bottom edge 50 extends
such
that the bottom of the containers 102 are substantially fully support by the
bottom 20 of
the support member.
FIGs. 7 and 8 each depict an assembly with transition regions similar to
the assembly depicted in FIG. 6. However, the assemblies 100 shown in FIGs. 7
and 8
differ from the assembly shown in FIG. 6 in that the sides (25, 30) of the
support
members (10, 12) do not have a trapezoidal shape in side view. As seen in
FIGs. 7 and
8, the sides of each support member are substantially rectangular in shape.
The
assembly shown in FIG. 7 depicts the assembly in FIG. 6, with the bottom edges
50
reduced in length to be substantially equal to the length of the top edges 40.
Thus, a
portion of the bottom of each container 102 is not supported by the bottom 20
of the
support members. Such an embodiment allows for a further reduction in assembly
material, while still providing the necessary support to transport and, if
desired, stack
the assemblies.
The assembly shown in FIG. 8 depicts the assembly in FIG. 6, with the
top edges 40 increased in length to be substantially equal to the length of
the bottom
edges 50. Thus, like in FIG. 6, the bottom of the containers 102 is
substantially fully
support by the bottom 20 of the support member. And, because the top edge has
been
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increased in length, the upper portion 110 of the containers is substantially
protected by
the sides (25, 30).
Referring now to FIG. 9, the assembly of FIG. 3 is depicted with a top
pad 115. Once the containers 102 are placed in the assemblies 100 in a desired
arrangement, the top pad 115 is placed on top of the top 15 (as seen in FIG.
3, for
example) of one or both support members (10, 12). The top pad 115 has a
horizontal
pad surface 120, a first portion 121 of which rests on a portion of the top
support surface
117 (as seen in FIG. 3, for example) of support member 10, and a second
portion 122 of
which rests on a portion of the top support surface 117 of support member 12.
The pad
surface 120 is oriented substantially parallel to the top support surface 117.
The pad
surface 120 has an area which extends at least partially over each of the tops
15. The pad
surface 120 of the top pad may be greater than, equal to, or less than the
area of the
combined tops 15 positioned thereunder. Typically, the top pad will have an
area
slightly less than the combined area of the tops 15 over which the top pad
extends. The
top pad acts as a unitizing element within the assembly to further enhance the
overall
strength of the assembly. The top pad 115 also forms a support between stacked
assemblies.
FIG. 10 depicts a support member 10, similar to the one shown in FIG.
11, without a top. In side view, the sides 25, 30 of FIG. 10 are trapezoidal
in shape.
FIG. 11 depicts an assembly made up of two of the support members
shown in FIG. 10. The assembly of FIG. 11 is similar to the assembly shown in
FIG. 2,
except that the support members do not have tops.
FIG. 12 depicts the assembly of FIG. 11 with containers 102 placed
therein. The embodiment shown in FIG. 12 provides many of the structural
benefits of
the assemblies with tops, but reduces packing material. Adding a top pad 115
to the
assembly, such as in FIG. 13, provides additional support to the assemblies if
desired for
stacking the assemblies. In at least one embodiment without a top, as in FIG.
12, it may
be desirable for the top pad to rest on the tops of the product containers. In
such an
embodiment, the height of the vertical supports and sides must be no greater
than the
height of the product containers to prevent distortion of the top pad and
possible
destabilization of stacked assemblies.
Referring now to FIG. 14, the assembly of FIG. 1 is shown partially
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encapsulated by a film 120. The film 120 may be any type of retaining film or
material.
For example the film 120 may be shrink-wrap, stretch wrap, plastic sheeting or
netting,
or any other type of retaining material. The film 120 may encapsulate the
entire
assembly, including a top pad. Alternatively, the film may have one or more
openings
It should be noted that the embodiments of the assembly described herein
not only reduce the amount of packaging material, but also reduce the amount
of film
used because of the reduction in overall profile. This reduction further
decreases
production costs and helps reduce waste and environmental impact.
15 FIG. 15 depicts the assembly 100 of FIG. 14 with a top pad 115. If
stacking is desirable, adding a top pad 115 to the assembly provides
additional support
to the assemblies when stacked. The top pad 115 may further act as a cutting
surface
once the assembly is received. The film 120 may be cut and opened, through
application of a knife or other cutting means. The presence of the top pad 115
prevents
FIG. 16 shows three of the assemblies depicted in FIG. 15 stacked
vertically on top of one another. Generally, four to eight assemblies may be
stacked on
top of one another vertically. In at least one embodiment, five assemblies may
be
stacked on top of one another vertically. However, depending on the strength
of the
Referring now to FIG. 17, another embodiment of the package assembly
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13
100 is depicted. The embodiment depicted in FIG. 17 is similar to the
embodiment
shown in FIG. 3, but is instead capable of holding six approximately 1-gallon
jugs of
fluid. Of course, like all the embodiments described herein, the embodiment
shown in
FIG. 17 need not be limited to holding jugs of fluid, but instead may hold
bottles, cans,
boxes, or any other type of product container 102 that are known by those of
ordinary
skill in art.
FIG. 18 is similar to the embodiment in FIG. 17, with the addition of
protective flaps 130. The protective flaps 130 provide protection to the
containers 102
by shielding the upper portion 110 for example, from the weather while the
assemblies
100 are on the loading dock. The protective flaps 130 also provide a surface
for placing
identifying marks associated with the underlying product that is easily
recognizable even
at an appreciable distance.
It should be noted that embodiments without tops, such as in FIGs. 10 ¨
12 may also be designed to carry more containers, such as shown in FIG. 17 and
described above. Similarly, it should be noted that embodiments with tops,
such as in
FIGs. 1 ¨ 3, and embodiments with tops and transition regions, such as in
FIGs. 6¨ 8,
may also include protective flaps like in FIG. 18.
The above disclosure is intended to be illustrative and not exhaustive.
This description will suggest many variations and alternatives to one of
ordinary skill in
this art. The various elements shown in the individual figures and described
above may
be combined or modified for combination as desired. All these alternatives and
variations are intended to be included within the scope of the claims where
the term
"comprising" means "including, but not limited to".
Further, the particular features presented in the dependent claims can be
combined with each other in other manners within the scope of the invention
such that
the invention should be recognized as also specifically directed to other
embodiments
having any other possible combination of the features of the dependent claims.
For
instance, for purposes of claim publication, any dependent claim which follows
should
be taken as alternatively written in a multiple dependent form from all prior
claims
which possess all antecedents referenced in such dependent claim if such
multiple
dependent format is an accepted format within the jurisdiction (e.g. each
claim
depending directly from claim 1 should be alternatively taken as depending
from all
CA 02652357 2011-11-10
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14
previous claims). In jurisdictions where multiple dependent claim formats are
restricted,
the following dependent claims should each be also taken as alternatively
written in
each singly dependent claim format which creates a dependency from a prior
antecedent-possessing claim other than the specific claim listed in such
dependent claim
below.
Those skilled in the art may recognize other equivalents to the specific
embodiment described herein which equivalents are intended to be encompassed
by the
claims attached hereto.
