U.S. patent application number 10/427504 was filed with the patent office on 2004-06-03 for large-capacity shipment and display bin.
This patent application is currently assigned to Weyerhaeuser Company. Invention is credited to Remaks, William J..
Application Number | 20040104138 10/427504 |
Document ID | / |
Family ID | 32393899 |
Filed Date | 2004-06-03 |
United States Patent
Application |
20040104138 |
Kind Code |
A1 |
Remaks, William J. |
June 3, 2004 |
Large-capacity shipment and display bin
Abstract
The container 10 comprises a bottom cover 12, a plurality of
stackable trays 14 for holding produce, a sleeve 18, and a top
cover 20. Each tray 14 is filled with produce and placed within the
bottom cover 12. After the trays 14 are stacked, a film may be
wrapped around the trays 14 to stabilize the produce. The sleeve 18
is then lowered over the trays 14 and the container 10 is capped
with the top cover 20. When assembled, the container 10 may be
secured by securement members, such as straps 64, and placed on a
base member 22 for supporting the container and facilitating the
shipping of the container. At the point of sale, the top cover 20
and sleeve 18 may be removed, exposing the produce, thereby forming
a display bin capable of displaying the shipped produce to
customers for purchase.
Inventors: |
Remaks, William J.;
(Louisville, KY) |
Correspondence
Address: |
WEYERHAEUSER COMPANY
INTELLECTUAL PROPERTY DEPT., CH 1J27
P.O. BOX 9777
FEDERAL WAY
WA
98063
US
|
Assignee: |
Weyerhaeuser Company
|
Family ID: |
32393899 |
Appl. No.: |
10/427504 |
Filed: |
April 30, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10427504 |
Apr 30, 2003 |
|
|
|
09898862 |
Jul 3, 2001 |
|
|
|
Current U.S.
Class: |
206/386 ;
206/499 |
Current CPC
Class: |
B65D 2519/00597
20130101; B65D 2519/00273 20130101; B65D 71/70 20130101; B65D
2519/00711 20130101; B65D 2519/00194 20130101; B65D 2519/00497
20130101; B65D 71/066 20130101; B65D 2519/00044 20130101; B65D
2519/00019 20130101; B65D 2519/00099 20130101; B65D 71/0088
20130101; B65D 2519/00104 20130101; B65D 2519/00174 20130101; B65D
2519/00333 20130101; B65D 2519/00069 20130101; B65D 2519/00323
20130101; B65D 2519/00641 20130101; B65D 2519/0091 20130101; B65D
19/20 20130101; B65D 2519/00064 20130101; B65D 2519/00029 20130101;
B65D 2519/00034 20130101; B65D 2519/00159 20130101 |
Class at
Publication: |
206/386 ;
206/499 |
International
Class: |
B65D 019/00 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A container for shipping and displaying produce, comprising: a
bottom cover having a bottom wall and upwardly extending sidewalls
substantially transverse to said bottom wall defining a
pre-selected shape and forming an interior cavity; a plurality of
produce trays stacked in overlying relationship to said bottom wall
of said bottom cover, a portion of said plurality of produce trays
disposed within said interior cavity of said bottom cover; a sleeve
having sidewalls defining said pre-selected shape and defining an
interior cavity, said sleeve disposed around said plurality of
produce trays so that said plurality of produce trays are
positioned within said interior cavity of said sleeve, a lower
portion of said sidewalls positioned within said sidewalls of said
bottom cover; and a top cover having a top wall and downwardly
depending sidewalls substantially transverse to said top wall
defining said pre-selected shape and forming an interior cavity,
said top cover overlaying a top portion of said plurality of trays,
an upper portion of the sidewalls of said sleeve positioned within
the sidewalls of said top cover.
2. The container of claim 1, further comprising a stretchable film
wrapped around the perimeter of said plurality of produce
trays.
3. The container of claim 1, further comprising a plurality of
straps, said plurality of straps being wrapped around said top
cover and said bottom cover for securing said assembly together
during shipping.
4. The container of claim 1, further comprising a base member
having a top surface; said bottom wall of said bottom cover
disposed adjacent to said top surface of said base member.
5. The container of claim 1, wherein said pre-selected shape is
rectangular.
6. The container of claim 1, wherein said sidewalls of said sleeve
has a plurality of apertures in the sidewalls thereof.
7. The container of claim 1, wherein said bottom cover and said top
cover are constructed from a single wall material.
8. The container of claim 1, wherein said sleeve is constructed
from a triple wall material.
9. The container of claim 1, wherein said top wall of said top
cover is substantially parallel with said bottom wall of said
bottom cover.
10. The container of claim 1, wherein a plurality of said container
assemblies are stacked to form a shipping container.
11. The container of claim 1, further comprising a spacer disposed
between said top cover and said plurality of trays.
12. The container of claim 3, further comprising edge members, said
edge members disposed around said top cover to reinforce said
assembly where said straps are applied.
13. The container of claim 1, wherein said sidewalls of said bottom
cover being downwardly foldable to cover said base member.
14. The container of claim 1, wherein said base member is a
pallet.
15. The container of claim 1, wherein said base member is a slip
sheet.
16. A method of assembling a container for shipping and displaying
produce, comprising: providing a base member having a top surface;
placing a bottom cover upon said top surface, said bottom cover
having a bottom wall and upwardly extending sidewalls which define
an interior cavity; stacking a plurality of produce trays in
overlying relationship to said bottom wall, a portion of said
plurality of produce trays disposed within said interior cavity of
said bottom cover; placing a sleeve having sidewalls that form an
interior cavity over said plurality of produce trays and into
engagement with a portion of said bottom cover; and placing a top
cover upon and in engagement with a top portion of said sleeve.
17. The method of claim 16, further comprising wrapping a
stretchable film around said plurality of produce trays.
18. The method of claim 16 further comprising securing said top
cover to said bottom cover with a plurality of straps.
Description
RELATED APPLICATION
[0001] This application claims priority to U.S. application Ser.
No. 09/898,862 filed Jul. 03, 2001, the benefit of which is hereby
claimed under 35 U.S.C. .sctn.120.
FIELD OF THE INVENTION
[0002] The present invention relates to a multi-component packaging
system, and more particularly to a large-capacity shipment and
display bin for shipping and displaying produce.
BACKGROUND OF THE INVENTION
[0003] For many years, produce, especially tree fruit such as
apples, peaches, nectarines, pears and the like, have been packed
and shipped in individual corrugated cartons or wooden lug boxes.
These containers receive a single stack of molded pulp or plastic
trays typically five to ten layers high, each tray cradling and
protecting a layer of fruit. This proven method of placing and
shipping tree fruit has been widely accepted by retail
merchandisers.
[0004] With the advent of larger, higher volume retail grocery
stores, a much greater turnover of tree fruit inventory occurs, and
store merchandisers are hard pressed to keep enough tree fruit
displayed to satisfy the demand. Present individual cartons and lug
boxes suffer from many deficiencies that are amplified by these
type of merchandisers. For example, individual cartons and lug
boxes require the produce merchandisers to unpack and hand stack on
counters for display and sale the individual trays, taking one at a
time out of the carton or lug box. Additionally, in the larger
supermarkets and club stores, these tray packed fruit displays take
on a massive aspect, requiring an extensive number of man hours to
develop and maintain. Furthermore, the large number of individual
cartons and lug boxes required to stack such a display are
expensive in aggregate, typically are not reusable, and must be
disposed of as solid waste.
SUMMARY OF THE INVENTION
[0005] The present invention overcomes the deficiencies of the
prior art as discussed above by presenting a large-capacity
container utilized for shipping and displaying produce. The present
invention combines the protective qualities of molded pulp or
plastic trays in conjunction with a pallet-sized container or bulk
bin. After the container has arrived at the store, the container
can be transformed into a display bin capable of displaying the
shipped produce to customers for purchase.
[0006] In accordance with an aspect of the present invention, a
container for shipping and displaying produce is presented
including a bottom cover having a bottom wall and upwardly
extending sidewalls substantially transverse to the bottom wall.
The bottom cover defines a pre-selected shape and an interior
cavity. The container also includes a plurality of trays for
receiving produce, which is stackable in overlying relationship to
the bottom wall of the bottom cover. A portion of the trays is
disposed within the interior cavity of the bottom cover. A sleeve
is further included having sidewalls defining the pre-selected
shape and defining an interior cavity. The sleeve is disposed
around the plurality of trays so that the trays are positioned
within the interior cavity of the sleeve, and the lower portion of
the sidewalls are positioned within the sidewalls of the bottom
cover. The container further includes a top cover having a top wall
and downwardly depending sidewalls substantially transverse to the
top wall. The top wall defines the pre-selected shape and an
interior cavity. The top cover overlays a top portion of the
plurality of trays, and the upper portion of the sidewalls of the
sleeve is positioned within the sidewalls of the top cover.
[0007] In one embodiment, a film is wrapped around the perimeter of
the trays. In another embodiment, the container is placed on a base
member to be shipped.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and many of the attendant advantages
of this invention will become more readily appreciated as the same
become better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
[0009] FIG. 1 illustrates a perspective view of a large-capacity
shipment and display container constructed in accordance with
aspects of the present invention;
[0010] FIG. 2 illustrates a perspective assembly view of the
container shown in FIG. 1;
[0011] FIG. 3 illustrates a perspective view of multiple containers
in a stacked configuration for shipping;
[0012] FIG. 4 illustrates the container transformed into a display
bin at a point of purchase; and
[0013] FIG. 5 illustrates a perspective view of the bottom cover of
the container shown in FIG. 1 having its bottom walls folded
downwardly to conceal the base member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The present invention will now be described with reference
to the accompanying drawings where like numerals correspond to like
elements. One suitable embodiment of a large-capacity shipment and
display container, generally designated 10, for shipping and
displaying produce constructed in accordance with aspects of the
present invention is illustrated in FIGS. 1-5. A plurality of
containers 10 may be aggregated in a stacked configuration to
facilitate shipping in large carriers, such as refrigerated trucks,
as best shown in FIG. 3. Referring now to FIG. 1, the container 10
comprises a bottom cover 12, a plurality of stackable trays 14 for
holding produce 38, a sleeve 18, and a top cover 20. When
assembled, the container 10 may be secured by securement members,
such as straps 64, and placed on a base member 22 that supports the
container and facilitates the shipment of the container. At the
point of sale, the top cover 20 and sleeve 18 may be removed,
exposing the produce 38, thereby forming a display bin capable of
displaying the shipped produce to customers for purchase.
[0015] Referring now to FIG. 2, the container 10 includes a bottom
cover 12 having a bottom wall 30 and upwardly extending sidewalls
32 substantially transverse to the bottom wall 30, which define a
preselected shape and an interior cavity. In the embodiment shown,
the pre-selected shape is a parallelepiped, such as a rectangle.
However, it should be readily evident that other shapes may be
used. The bottom cover is the bottom member of the container and
may be placed upon a base member 22, such as a standard wooden or
plastic "grocery" pallet or slip sheet. The base member 22 is of
standard size, approximately forty inches (40") by forty-eight
inches (48") in size, and facilitates in the handling and shipping
of the container. The bottom cover 12 is preferably constructed
from a blank of single wall corrugated paperboard, which is cut,
scored, folded, and fastened in the traditional fashion known in
the art to form a bottom cover 12 having the dimensions of a
standard large capacity container or bulk-bin. In one embodiment,
the dimensions of the bottom wall are approximately forty inches
(40") by forty-eight inches (48"). With this configuration, the
bottom cover 12 can be cut and folded downwardly to cover the
pallet 22 for improved appearance and safety, as illustrated in
FIG. 5.
[0016] Returning to FIG. 2, the container 10 also includes trays
14, commonly referred to in the art as "apple trays", stackable in
an overlying relationship to the bottom wall 30 of the bottom cover
12. Each tray 14 includes a plurality of produce receiving portions
(not shown) that supports the produce, protecting the produce, such
as tree fruit, in a cradle-like hold. The structure and design of
the trays 14 are well known in the art and will not be described in
detail here. The trays are preferably made of molded pulp and are
configured to hold a plurality of produce, such as one disclosed in
U.S. Pat. No. 3,695,479 to Crabtree, which is hereby expressly
incorporated by reference. Alternatively, the trays may be
constructed of a molded plastic. In either case, the trays 14 are
of a standard size so that the trays may be placed side-by-side on
the bottom wall 30 of the bottom cover 12, filled with produce 38,
and then stacked ten to twenty layers high. Alternatively, the tray
may be of a suitable size such that a single tray can fill the
entire bottom wall of the bottom cover. It will be appreciated by
those skilled in the art that the number of stackable trays will
vary depending on the produce type, size, and pack configuration,
and that less than ten and more than twenty trays are possible.
After each tray is filled with produce 38 and stacked one tray on
top of another, stretch film 16, preferably ventilated, is snugly
wrapped around the stacked trays 14 several times, to firmly bind
together the trays 14 of produce in order to stabilize the produce
during transit.
[0017] Referring still to FIG. 2, the container 10 further includes
a sleeve 18, commonly referred to in the art as a tube, which is
placed over the stackable trays 14 when assembled. The sleeve 18
has sidewalls 44 that are integrally connected, and an open bottom
and top that define the pre-selected shape of the bottom cover 12.
The sleeve 18 is suitably dimensioned so that its bottom portion
fits inside the bottom cover in a overlapping relation, engaging
the bottom wall. The sleeve 18 is further dimensioned such that
when the container is assembled, the sleeve 18 envelops the
stackable trays 14. The sleeve 18 is preferably constructed from a
material having high compression strength, such as corrugated or
solid paperboard, or plastic, to provide the necessary rigidity and
stacking strength necessary to withstand the rigors of stacking and
shipping.
[0018] In one embodiment, the sleeve 18 is constructed from a
triple wall corrugated paperboard blank having a plurality of
panels that form the sidewalls 44. Score lines are provided between
the panels and a flap is connected to the outside edge of one of
the outer panels so that the panels may be joined to form the
sleeve 18. With this configuration, the sleeve 18 can be stored and
shipped in a "knocked down" condition, i.e., the sleeve is folded
onto itself along diametrically opposed corners so that the sleeve
lays flat, and may be easily reusable after shipment. The sleeve 18
further includes a plurality of apertures 46 positioned in the
sidewalls 44. In the embodiment shown, the plurality of apertures
46 are vertically disposed slots; however, other apertures of
suitable dimensions and orientation may be used.
[0019] The container 10 further includes a top cover 20,
essentially a duplicate of the bottom cover 12, which is placed
over the top portion of the sleeve 18 in overlapping relation to
close the container. The top cover 20 includes a top wall 50 and
downwardly depending sidewalls 52 substantially transverse to the
top wall 50 defining the pre-selected shape of the bottom cover 12,
and the sleeve 18, and defining an interior cavity. Similar to the
bottom cover 12, the top cover 20 is preferably constructed from a
single wall corrugated paperboard blank that is cut, scored,
folded, and fastened to form the top cover 20. To protect the
produce in transit, a headspace filler 60 such as foam, bubblepack,
or some other suitable material may be placed within the interior
cavity of the sleeve 18, on top of the stackable trays 14 and below
the top cover 20.
[0020] As best shown in FIG. 1, after the container in fully
assembled, securement members, such as steel or plastic straps 64,
may be wrapped in a known fashion around the major and/or minor
axes of the container, securing the top cover 20 and the bottom
cover 12 for shipping. To reinforce the bottom and top covers 12
and 20, various edge protectors, not shown but well known in the
art, constructed from a suitable material may be placed over the
edges of the top and bottom covers, under the straps 64. Once the
container 10 is shipped to the merchandisers, such as grocery
stores, supermarkets, and club stores, the straps 64 may be
removed, and the top cover 20 and sleeve 18 may be slipped off.
After the sleeve 18 is removed, the produce 38 is exposed,
transforming the container from a shipping container to a display
bin 70, as illustrated best in FIG. 4. It should be appreciated by
those skilled in the art that the container should be in the
desired location on the merchandisers' floor before disassembling
part of the container. The container 10, now usable as a display
bin, allows purchasers to select the produce from the top trays,
and allows the merchandiser to remove the trays and the film one or
more layers at a time, once the produce of the top layer is
empty.
[0021] Assembling the exemplary embodiment of the container in
accordance with the aspects of the present invention will now be
described with reference to FIGS. 1-5. A bottom cover 12 of a
desired, pre-selected dimension, is obtained and placed on a base
member 22, such as a pallet or slip sheet. A tray 14 having
recesses for holding produce is placed within the bottom cover 12
and loaded with produce 38, such as tree fruit. Once the tray 14 is
full, another tray 14 is stacked on top of the last filled tray,
until the desired capacity is reached. Then, a film 16 may be
wrapped around the stacked trays 14 of produce to stabilize the
produce for transit. Next, a sleeve 18 is lowered over the stacked
trays 14 of produce to envelop the trays 14. Once the sleeve 18 is
in place, resting inside the bottom cover 12, a top cover 20 of
identical dimensions as the bottom cover 12 is placed on top of the
sleeve 18. Securement straps 64 are then wrapped around the
container 10 to secure the container together, which then may be
stacked on top of one another and placed within a refrigerated
transportation carrier. After arriving at the retail location, the
containers 10 are removed from the transportation carrier and
placed in the storage room, with one container 10 placed in the
store for display. Once in place on the sales floor, the top cover
20 and sleeve 18 are removed, transforming the container 10 into a
display bin 70 capable of displaying the shipped produce to
customers for purchase.
[0022] While the container 10 constructed in accordance with
aspects of the present invention has be described above and
illustrated herein as a parallelepiped and having the dimensions of
a large-capacity container or bin, it will be readily evident that
other shapes and sizes may be used to form the container 10.
[0023] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention.
* * * * *