U.S. patent application number 10/994661 was filed with the patent office on 2005-03-31 for thermoformed package with insert.
This patent application is currently assigned to See The Shoes LLC. Invention is credited to Cesario, Salvatore.
Application Number | 20050067318 10/994661 |
Document ID | / |
Family ID | 46303360 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050067318 |
Kind Code |
A1 |
Cesario, Salvatore |
March 31, 2005 |
Thermoformed package with insert
Abstract
A container is formed in a blank having two body halves
interconnected by a hinge. The container body is at least partially
clear to allow inspection of an article held in the interior and an
optional insert member is sized to nest within one of the body
halves. The container optionally includes an integrally formed
carrying handle. Empty containers are nested to minimize shipping
space. Each container optionally includes stack-stabilizing
structure so that plural containers may be stacked into stable
stacks, and any selected container may be easily removed from the
stack. The inventive container protects articles held therein
during shipping and storage, and displays the articles both before
and after sale.
Inventors: |
Cesario, Salvatore; (West
Linn, OR) |
Correspondence
Address: |
IPSOLON LLP
805 SW BROADWAY, #2740
PORTLAND
OR
97205
US
|
Assignee: |
See The Shoes LLC
|
Family ID: |
46303360 |
Appl. No.: |
10/994661 |
Filed: |
November 22, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10994661 |
Nov 22, 2004 |
|
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|
10368043 |
Feb 14, 2003 |
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Current U.S.
Class: |
206/524.6 |
Current CPC
Class: |
B65D 75/22 20130101;
B65D 85/187 20130101 |
Class at
Publication: |
206/524.6 |
International
Class: |
B65D 085/84 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 23, 2002 |
WO |
PCT/US02/30075 |
Claims
We claim:
1. A thermoformed container, comprising: a container base; a
container lid, said container lid sized to matingly engage the
container base in a closed position to define an interior space
configured for receiving an article; a hinge interconnecting the
container base to the container lid to allow the lid to be
selectively moved from a closed position in which the lid engages
the base to an open position in which the lid disengages the base;
an insert nested in the container base.
2. The container according to claim 1 in which the container base
is clear and the insert is printed with indicia.
3. The container according to claim 1 wherein an indicia carrying
space is defined between the container base and the insert.
4. The container according to claim 1 wherein the container base
defines bottom and rear panels, the container lid defines top and
front panels, and the hinge interconnects the rear panel of the
base to the top panel of the lid at an upper edge of said rear
panel and a rear edge of said top panel.
5. The container according to claim 4 wherein the top panel defines
a top panel plane, the back panel defines a back panel plane, and
the hinge lies completely within the intersection between said top
and back panel planes.
6. The container according to claim 1 wherein the container base
and container lid are clear and the insert is opaque.
7. The container according to claim 1 including means for retaining
the insert nested in the container base.
8. A thermoformed container, comprising: a first container half; a
second container half, said first and second container halves
cooperatively sized to matingly engage the one another in a closed
position to define an interior space configured for receiving an
article; a hinge interconnecting the first and second container
halves to allow relative selectively movement between the halves to
open and close the container; a removable insert in the first or
second container half and said insert configured to conform to the
said container half.
9. The container according to claim 8 including means for retaining
said insert in said first or second container.
10. The container according to claim 9 wherein said means for
retaining said insert in said first or second container comprises
interlocking tabs and recesses formed on respective mating portions
of said first or second container halves and said insert.
11. The container according to claim 8 wherein said insert is
received in first container half and wherein said first container
half is clear and said insert has indicia printed on a surface
thereof.
12. The container according to claim 11 wherein said insert is
opaque.
13. The container according to claim 8 wherein an indicia carrying
space is defined between said insert and said first or second
container half, and including media having indicia printed thereon
is received in said space.
14. The container according to claim 13 wherein the first container
half defines a base having bottom and rear panels, the second
container half defines a lid having top and front panels, and the
hinge interconnects the rear panel of the base to the top panel of
the lid at an upper edge of said rear panel and a rear edge of said
top panel.
15. The container according to claim 14 wherein the top panel
defines a top panel plane, the back panel defines a back panel
plane, and the hinge lies completely within the intersection
between said top and back panel planes.
16. Method of providing information to consumers about an article
held in a container, comprising the steps of: (a) packaging the
article in a container defined by a clear container base, and a
container lid, said container lid sized to matingly engage the
container base in a closed position to define an interior space
configured for receiving the article, and a hinge interconnecting
the container base to the container lid to allow the lid to be
selectively moved from a closed position in which the lid engages
the base to an open position in which the lid disengages the base;
printing on an insert piece written indicia comprising information
about the article and inserting the insert piece into the container
base, said insert base sized to nest within said container base.
Description
FIELD OF THE INVENTION
[0001] This invention relates to the field of packaging, and more
particularly, to a thermoformed package designed for use with any
variety of goods, but especially for footwear.
BACKGROUND
[0002] Thermoformed containers are used ubiquitously as packaging
for innumerable objects. Generally speaking, containers formed by
thermoforming processes offer economical packaging options for a
variety of consumer goods, and at many different distribution
levels. For example, thermoformed containers may be used as
competitive replacements for paperboard and cardboard-based
packages for many items. The following description of the packaging
industry as it relates to footwear is just one example of the
demands for packaging.
[0003] The market for consumer footwear is notoriously competitive
and there are numerous footwear manufacturers competing for a share
of that market. The intense level of competition in the footwear
industry is found in nearly every market sector, and regardless of
the particular type of shoe. However, the competition is perhaps
most keenly focused in the market sector pertaining to active shoes
and athletic shoes. In this market sector as well as others,
competitors are constantly searching for ways to increase sales and
market shares. Some of the most successful, and thus commonly used
marketing techniques, are very familiar to most consumers. Examples
include rapid introduction of new styles, product endorsements by
famous athletes, intense brand name marketing and promotion, and
advertising directed to specific consumer groups such as consumers
falling into specific targeted demographic groups. These techniques
along with other marketing activities help give footwear
manufacturers a competitive edge in a highly competitive
market.
[0004] Traditional shoeboxes are sometimes utilized for marketing
purposes in addition to their more traditional function. Shoes of
all types are usually packaged in traditional rectangular shoeboxes
manufactured from some kind of paperboard, often cardboard.
However, while such boxes serve an accepted functional role of
storing and protecting the shoes, they do little to promote the
product itself, other than minimal promotional information printed
on the boxes.
[0005] While there are many different styles of shoeboxes, nearly
all of them are variations on a standard theme: a rectangular box
that is usually made of cardboard. Such boxes are useful for many
reasons. From a purely functional point of view, rectangular
shoeboxes provide a reasonably secure internal compartment for
storing the shoes after manufacturing, and all the way from the
factory to the consumer sales outlet. And traditional boxes are
easily stacked, whether for shipping in containers from an offshore
manufacturing location to a warehouse, for storage in a warehouse
or a retail outlet, or for storing product for consumer inspection
at warehouse-type retail outlets. While the internal compartment of
a rectangular box is not custom designed to hold a pair of shoes,
most shoes are held reasonably well in a standard box when the
shoes are nested in the traditional opposed orientation, and
generally with a paper sleeve inserted between the shoes to prevent
them from rubbing together and scuffing.
[0006] But in addition to their functional benefits, traditional
rectangular shoeboxes serve another purpose, and that is as a part
of the marketing plan. Nearly all shoe manufacturers try to use
their product packaging as part of their overall marketing programs
designed to sell the product. Thus, many shoe manufacturers print
graphics and other promotional information on their boxes. Even
though this marketing information may be visible only on the sides
of the boxes since boxes are usually stacked, the space can be used
as advertising space. Moreover, the box may be printed with
information about the shoes--sizes and the like.
[0007] However, there are several problems evident in traditional
shoeboxes. First, the standard rectangular box design necessarily
takes up more space than is needed to contain the shoes. Even when
nested in an opposed orientation, a pair of shoes defines a shape
that is seldom a regular rectangle, and as a result, most standard
shoeboxes have excess materials and take up more space than is
necessary. These factors increase costs of the product. For
example, minimizing the amount of raw material used to make the box
could reduce material costs tied up in the packaging. Likewise,
eliminating excess packaging material that takes up added space can
reduce shipping and storage costs.
[0008] Second, most shoeboxes are made of some form of
paper--usually cardboard or a heavy paperboard. While such
materials tend to make a relatively strong container, the can be
crushed and are subject to moisture absorption and damage. Moisture
damage to cardboard can be a significant problem. And even
broken-down cardboard boxes designed for shoes tend to take up a
significant amount of space. Further, the boxes must be
manufactured in one location as blanks, shipped to another location
where they are set up as boxes. Finally, raw material costs for
cardboard are increasing at a steady rate, making the economics of
using cardboard less and less favorable.
[0009] But perhaps the greatest shortcoming of traditional,
rectangular shoeboxes is their limited ability to enhance product
sales. As noted above, most shoe manufacturers print promotional
information of one kind or another on their shoeboxes, including
trademarks, logos and the like. This is valuable to a degree in
selling the product. But cardboard is inherently opaque, and as
such, a consumer must open the box to look at the shoes contained
inside. Shoe manufacturers want their consumers to look at their
shoes--the appearance of the shoe is an important factor in the
consumer's decision on what to buy. It can be difficult to pull a
box out of a stack of boxes, open it to look at the shoe, and then
replace the shoe in the box in even a relatively neat fashion.
Stated in another way, a large part of the consumer's buying
decision is based upon the appearance of the shoe. As a result,
shoe manufacturers spend a great deal of time and money in making
their shoes look attractive to consumers--the manufacturers want
consumers to see the product. But for all of this, shoes are almost
always hidden in a shoebox.
[0010] As noted, the foregoing is but one example of some
shortcomings of traditional, paper-based packaging. There is a real
need for improved packaging containers.
[0011] The present invention provides a see-through display
container that overcomes the problems in the prior art, and at the
same time provides substantial marketing and product promotion
advantages for whatever product might be held in the container. To
name a few examples of the advantages that the inventive package
provides, the container actually helps promote the product held
within the container and increase sales by presenting the product
in a container that the consumer can see through. The product
includes an integral handle so that the container itself functions
as a carrying case for the enclosed product. This allows retailers
to stop putting traditional boxes in bags, which of course are an
unnecessary and thus wasteful expense. In addition, since the
container is see-through, other consumers will be able to see what
the purchaser has purchased. This is a further promotional
tool.
[0012] The invention illustrated and described herein is a
container that may be used as a package for many different objects.
The structural features of the invention and the manner in which
the inventive package is formed make the container useful in
numerous industries for innumerable goods. Nonetheless, the package
of the present invention is described below with particular
reference to its use as a container for footwear. While the
description of the invention sometimes focuses on a footwear
container, it is to be understood that the principles of the
invention apply to the container used for other purposes, and that
the invention is not limited to use as a footwear container, but is
instead limited only by the appended claims.
[0013] In a preferred embodiment the present invention comprises a
shoe container formed of a clear or translucent plastic that is
formed such that a pair of shoes fits precisely into the interior
of the container and is visible through the container. The
container may be formed in any size to accommodate any sized shoe.
The container of the present invention may be formed to define an
interior space that conforms to the size and dimensions of a
particular style of shoe, or other items. Thus, little space is
wasted on both the interior and exterior and manufacturing,
shipping and storage costs are minimized.
[0014] The containers are preferably thermoformed in a one-piece
clamshell configuration that includes an integral hinge and
carrying handle. The package is formed in a manner that results in
a strong container that protects items contained therein. Moreover,
the package embodies structural features that provide unique
storage and stacking capabilities.
[0015] In one embodiment the containers are manufactured from
transparent polymeric materials that resist cracking and breaking,
and which withstand impact. The containers may be nested so that
storage space is minimized. When the containers are packaged with
shoes, the halves of the clamshell package are closed over the
shoes and are securely latched or interconnected to provide a
secure package. With particular reference to footwear, the shoes
may be oriented within the container in such a manner to ideally
display the shoes to consumers. In a preferred embodiment, the
shoes are oriented in the traditional toe-to-heel orientation.
[0016] The outer dimensions of the containers are configured to
optionally include stack stabilization features so that multiple
containers may be stacked in stable layers. In one preferred
embodiment, the containers include outwardly facing protrusions or
rails that nest into a complimentary and cooperative structure in
the next adjacent container when stacked. This allows a single
container to be easily removed from a large stack of
containers.
[0017] The container may be formed of many different types of
plastics, including plastics containing significant levels of
recycled materials. Many kinds of plastics used to make the
inventive container may be recycled after use. The plastic may be
colored to match the color scheme that the manufacturer has
selected for the shoe, and the color of the container may thus be
combined into a marketing plan. Written indicia such as brand names
and logos may be printed on or formed in the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be better understood and its numerous
objects and advantages will be apparent by reference to the
following detailed description of the invention when taken in
conjunction with the following drawings.
[0019] FIG. 1 is a perspective view of one preferred embodiment of
a container according to the present invention.
[0020] FIG. 2 is right a side elevational view of the container
illustrated in FIG. 1, and showing the container partly opened.
[0021] FIG. 3 is a right side elevational view of the container
illustrated in FIG. 2, in which the container is closed.
[0022] FIG. 4 is perspective, top view of the container shown in
FIG. 1 with the container in a fully open position to expose the
interior space of the container.
[0023] FIG. 5 is a right side elevational view of a stack of two
closed containers of the type illustrated in FIG. 1.
[0024] FIG. 6 is a right side elevational view of the container
illustrated in FIG. 1, but showing the stack stabilization rail in
a different position.
[0025] FIG. 7 is a cross sectional view of the container
illustrated in FIG. 6, taken at approximately the middle of the
longest dimension of container.
[0026] FIG. 8 is a side elevational, schematic view of the a
preferred method of making the container of FIG. 7, showing a blank
of material in dashed lines over a schematic representation of the
forming tool, and showing the blank pulled onto the tool.
[0027] FIG. 9 is a side elevational view of a container similar to
the container shown in FIG. 6, with the stack stabilization
structures removed, and showing the interactions of the main
container panels and the corners thereof.
[0028] FIG. 10 is a perspective, exploded view of a container
similar t the containers shown in FIGS. 1 through 9 and
illustrating an alternative embodiment that includes an insert
piece that snaps into the interior of one half of the
container.
[0029] FIG. 11 is a right side elevational cross sectional view of
the container shown in FIG. 10 in the closed position, in which a
portion of the insert piece is broken away to illustrate structures
lying behind the insert in the view.
[0030] FIG. 12 is a left side elevational cross sectional view
similar to the view of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Preferred embodiments of the container of the present
invention are shown in the FIGS. 1 through 9. The invention is
described at times herein with respect to an exemplary design
intended for use with footwear such as athletic shoes. However, the
invention as defined in the appended claims is not limited to a
container for shoes, and those of ordinary skill in the art will
instead recognize that the invention applies to containers for any
kind of goods.
[0032] With reference to FIG. 1, container 100 is formed in two
body halves, namely a first body half 102 and a second body half
104, which are joined together and integrally interconnected at a
hinge 106. The hinge 106 is fabricated from the same material as
the body halves, as opposed to being fabricated from a different
material or in a different piece, and the hinge is not cut during
formation of the container. The container 100 is preferably formed
in a single piece by thermoforming, as described below. Body halves
102 and 104 are sized to mate with one another when closed about
hinge 106 so that the two halves lock together such that they
define an open interior space configured for receiving an article,
such as a pair of shoes.
[0033] As shown particularly well in FIGS. 2 and 3, a joint 107
extends between the two body halves 102 and 104 when the body
halves are mated together (i.e., when container 100 is closed).
Joint 107 extends diagonally across the lateral end panels of the
container. More specifically, hinge 106 connects the body halves
102 and 104 between an upper edge 108 of rear panel 110 of body
half 104, and the adjacent rear edge 109 of top panel 116 of body
half 102. The joint 107 between the two body halves extends in a
diagonal direction extending from the hinge 106, across the lateral
side panels (one of which is illustrated in FIGS. 2 and 3 and is
given reference number 120) and to the lower edge 112 of front
panel 114 of body half 102. The corresponding lower edge of body
half 104 is given reference number 115.
[0034] The diagonal joint 107 does not obstruct any of the four
main panels of container 100, thereby providing for an unobstructed
view of items such as shoes held in the container through the four
largest sides of the container. Thus, the top panel 116 and front
panel 114 of body half 102, and the bottom panel 118 and rear panel
110 of body half 104 are unobstructed by a hinge or joint of any
kind. Only the lateral side panels 120 and 122, respectively, are
bisected by the joint 107.
[0035] The two-body halves 102 and 104 respectively define a base
unit and a lid that covers the base unit and which closes the
halves together. In the embodiments illustrated in the figures, the
base (e.g. body half 104) and the lid (e.g. body half 102) are
divided diagonally at joint 107, so that each of the base and the
lid contribute approximately the same amount of interior space.
[0036] The body halves 102 and 104 include cooperatively formed
peripheral edges that assist in locating the body halves with
respect to one another when closed together, and to retain the
halves in the closed position. Thus, a flange 117 extends around
the periphery of body half 102 and defines a recessed flange that
cooperatively mates with a flange 115 that extends around the
periphery of body half 104. The two flanges 117 and 115 are
cooperatively formed so that a friction-fit is defined between the
two body halves when they are closed together, as shown in FIGS. 2
and 3.
[0037] Cooperatively formed tabs and tab-receiving recesses may be
formed along the mating edges of flanges 117 and 115 to assist in
maintaining the two body halves in the closed position shown in
FIG. 1. Thus, when the two body halves 102 and 104 are closed--that
is, moving the halves from the position shown in FIG. 2 into the
position shown in FIG. 3--flange 115 mates with and is received
into flange 117, and the flanges thus align to define the joint 107
(FIG. 1). There is a friction fit between flanges 117 and 115,
which contributes to holding the two halves in the closed position
of FIG. 1. Referring now to FIG. 4, the friction fit between the
two halves is aided by tabs 160 formed around the periphery of
flange 115 in body half 104. When the body halves are closed, the
tabs 160 are received into cooperatively formed recesses 162 spaced
around the periphery of flange 117 of body half 102 and located
such that each tab 160 is received into a recess 162 when the body
halves are closed together.
[0038] A carrying handle 126 is integrally formed in one of the
lateral side panels, and in the illustration the handle 126 is
formed in side panel 120. FIG. 1 illustrates how the handle may be
grasped to pull the container. An optional opening 127 is formed in
panel 120 below the lower extent of handle 126. If used, opening
127 provides an alternate way to grasp container 100, and in
particular allows the container to be picked from a stack with a
long rod having a hook on the end. Many stores and warehouses and
the like place inventory on racks that may be quite high. A
specific container that may otherwise be out of reach may be
obtained by inserting a hook rod into opening 127 and pulling the
container out of the stack. Opening 127 also functions as a vent to
allow air to enter and escape from the container 100. Additional
vent holes may be formed in container 100 during the manufacturing
process as vents, if desired.
[0039] With reference now to FIGS. 1 through 3, the specific
construction of handle 126 may be detailed. Thus, handle 126 is
defined by a integral pocket 131 formed into and projecting
outwardly from side panel 120 of body half 102. Flanges 117 and
115, and thus joint 107 extend around the outer periphery of pocket
131. At its lowermost point, pocket 131 extends below joint 107. A
cooperative pocket 133 is formed in side panel 120 of body half 104
in a position to receive the lower portions of pocket 131 when the
two body halves are in the closed position as seen in FIG. 3. A
protrusion 135 formed on flange 115 is received in an opening 137
that is formed in flange 117 during formation of the container. The
combination of protrusion 135 as it fits into opening 137 helps
stabilize the handle, as does the combination of pocket 131 as it
fits into cooperative pocket 133 when the container is closed. As
used herein, relative directional terms such as "inwardly" or
"outwardly" are used to refer to directions relative to the inside
and outside of the container when it the two body halves are
closed. Likewise, "upwardly" and "downwardly" are used in reference
to the ground plane, which for purposes herein is the plane that is
parallel to bottom panel 118 (FIG. 2). It will be appreciated that
protrusion 135 may be used as an alternate way to grasp container
100, and thus allows the container to be picked from a stack with a
long rod having a tip on the end that is capable of fitting into
the protrusion from the lower side of the container. As noted
above, many stores and warehouses place inventory on racks that may
be quite high. A specific container that may otherwise be out of
reach may be obtained by inserting a rod tip into protrusion 135
and pulling the container out of the stack.
[0040] Container 100 also includes optional stack stabilization
structures that allow numerous containers to be stacked atop one
another in a stable stack, yet so that a selected container may
easily be pulled out of the stack without unstacking or upsetting
the stability of the remaining containers in the stack. An
outwardly projecting "foot" in body half 102 is configured to mate
with a cooperatively formed "recess" in the body half 104 of the
next adjacent container 100 when more than one containers 100 are
stacked. The "foot" formed in body half 102 is a rail 128 that in a
side view of the container (e.g. FIG. 2) generally is
semi-cylindrical, and which extends across the entire top panel 116
(FIG. 1) along its longest dimension. The cooperatively formed
"recess" 130 that receives rail 128 on an adjacent, stacked
container, may be seen in FIGS. 2 and 3 and is seen to be a
cooperatively shaped, generally semi-cylindrical recess that
extends across the entire bottom panel 118 along its longest
dimension. Together, rail 128 and recess 130 define a secure
nesting system in which multiple adjacent containers 100 stacked
atop one another are interlocked, as shown in FIG. 5. Although a
stack of containers as shown in FIG. 5 is stable, a selected
container may easily be removed from the stack by pulling on handle
126 such that the selected container slides laterally out of the
stack. If a stack includes many containers 100, even removing one
individual container from the bottom or lower portion of the stack
will not upset the stack. Instead, the containers above the removed
container drop downwardly such that they nest again in a stable
stack with rails 128 interlocking recesses 130.
[0041] Moreover, the position of rail 128 and recess 130 relative
to top panel 116 and bottom panel 118 may be varied. For example,
in FIG. 6 it may be seen that rail 128 and recess 130 are formed in
approximately the center of top panel 116 between corner stabilizer
132, which is described below, and hinge 106, and in a
corresponding position in bottom panel 118 about midway between
corner stabilizer 132 and edge 115. Positioning the rail in the
middle of the panels as shown in FIG. 6 allows one container to be
stacked such that is rotated 180.degree. relative to adjacent
containers. Furthermore, with rail 128 and recess 130 positioned as
in FIG. 6, containers 100 of differing sizes may be stacked atop
one another with the stack stabilization structures (rail 128 and
recess 130) maintaining a stable stack.
[0042] Those of ordinary skill in the art will readily recognize
that there are numerous alternative and equivalent structures that
may be utilized to facilitate stable stacking of multiple
containers, yet allowing easy removal of any particular container
from the stack. For example, the system of a rail 128 extending
across one panel and a cooperatively formed recess in a facing
panel in an adjacent container could be replace with other
equivalent structures, such as a system of posts and receptacles
for the posts.
[0043] Moreover, as noted, the stack stabilization features defined
by rail 128 and recess 130 are optional features, and a container
according to the present invention may be manufactured without the
rail and recesses. With reference to FIG. 9, a container 180 that
is alike container 100 in all other respects is shown without
either a rail 128 or a recess 130. Owing to the manner in which the
containers are formed, as described below, and particularly, the
manner of forming hinge 106, the container 180 may be stacked on
any one of the four main sides--back panel 110, front panel 114,
top panel 116 and bottom panel 118. Thus, the two body halves 102
and 104 are formed such that the geometry of hinge 106 results in a
hinge that lies completely within the intersection of the planes
defined by adjacent main panels. Stated another way, and with
reference to FIG. 9, the hinge 106 does not interrupt or extend
into the planes defined by either the back panel 110 or the top
panel 116, and there are no parts of the container that extend
through the planes defined by these panels. This allows the
container 180 to be stacked stably on any of those panels. In FIG.
9, the planes defined by the main panels 110, 114, 116 and 118 are
shown in dashed lines labeled "P". The main panels define planar
sections that, as illustrated with the dashed lines P, intersect at
right angles. The main panels 110, 114, 116 and 118 in FIG. 9 are
flat surfaces. In some instances, it may be desirable to alter
those surfaces so that they incorporate other structural
components, for example, a series of reinforcing ribs that extend
along the surfaces to strengthen the panels. While the surface of a
panel having such reinforcing ribs would not be planar, the
combined upper portions of the reinforcing ribs would define a
planar surface. Accordingly, it is to be understood that as used
herein, the word "plane" refers to the characteristic of a surface
that extends across the main panels, regardless of whether the
panels are "flat" in section or otherwise.
[0044] Likewise, flanges 117 and 115 are formed so that the joint
107 defined when the body halves are closed does not interrupt or
extend into the planes defined by the bottom panel 118 or the front
panel 114 (dashed lines P). Again, this allows the container 180 to
be stacked stably on either front panel 114 or bottom panel
118.
[0045] It will be appreciated that the hinge and flange
configuration just described allows container 180 to be stacked in
any orientation and on any of the four main body panels relative to
adjacent containers. With respect to a container 100 that includes
a stack stabilization feature (e.g. rail 128 and recess 130), the
container may be stacked on any of the three main panels 110, 118
or 114.
[0046] Container 100 further includes corner stabilization features
that are designed to add dimensional stability to the corners and
minimize damage to the containers that may arise from crushing.
Specifically, a corner stabilizer 132 is formed into each of the
four corners of container 100 that are not bisected by joint 107.
The corner stabilizer 132 defines a strength-inducing radius, which
is produced by an indentation 134 defined when the container is
fabricated. The indentation provides structural rigidity and is
formed when the container is thermoformed from a blank. The flanges
117 and 115 impart additional structural rigidity, both when the
container is open and closed.
[0047] With specific reference now to FIG. 4, the interior of
container 100 defines an article-holding space 124 that is
configured to hold articles such as a pair of shoes without regard
to any particular orientation of the shoes relative to one another.
Continuing with the example of a pair of shoes, the shoes in the
pair may thus be oriented in a toe-to-heel orientation, or any
other orientation to display the shoes to consumers. Recess 130,
which as described above defines a stack stabilization feature,
projects inwardly into interior space 124 and provides a laterally
extending support or ledge on the interior of the container on
which one of the shoes may be placed to facilitate a unique view of
the shoe. For example, and depending upon placement of the shoe in
space 124, the consumer may be able to see the shoe from a
perspective view that allows portions of the sole and the upper to
be easily seen.
[0048] Container 100 is preferably fabricated from a clear material
so that goods held within the container are plainly visible through
the container panels. As used herein, the word "clear" refers to
any transparent or translucent material used to fabricate the
container and through which the interior of the container may be
seen. Many materials may be used to fabricate the container. These
include numerous grades of PET (polyethylene terephthalate), high
density polyethylene (HDPE), low density polyethylene (LDPE), and
vinyls such as various grades of polyvinyl chloride (PVC). Those or
ordinary skill in the art will recognize that the material selected
will depend upon the structural and cosmetic requirements of the
particular package. The polymers used to manufacture container 100
may include modifier compounds such as softeners, impact modifiers
and the like, depending upon the application. In a preferred
embodiment the material selected for manufacturing the container
will include a high percentage of recycled material.
[0049] The material used to form container 100 may be clear,
colored, or and any combination of coloring may be used. Moreover,
portions of the container may be opaque so long as at least some of
the container is clear to display the contents.
[0050] The container of the present invention is preferably formed
using a thermoforming processes whereby a blank of material is
pulled into a tool or mold, for instance with a vacuum, to form the
container. With reference to FIG. 8 it may be seen that container
100 is formed in an inverted position such that a blank of plastic
material 150, illustrated in dashed lines, is positioned over the
forming tool 152, which is shown in section, and schematically.
Tool 152 is the type of tool known in the industry as a "male"
tool. A male tool is preferably used to thermoform container 100
because during the thermoforming process, those portions of
material 150 that are nearest the tool when thermoforming occurs
are the thickest portions of the finished part. Tool 152 comprises
a first male part 156 and a second male part 158, each of which is
roughly triangular in cross section and each of which has an apex
154 that lies closest to the plastic material 150 prior to the
forming process. It will be appreciated that first male part 156
forms body half 104 and that second male part 158 forms body half
102. The two parts 156 and 158 are positioned close together to
define hinge 106 at the junction between the two parts. The hinge
106 formed from the combination of the two parts 156 and 158 is, as
described above, unobtrusive with respect to the main panels of the
container. Additionally, the hinge is formed without the need for
cutting any of the material 150.
[0051] With specific reference to FIG. 8, the thickest portions of
the container formed on tool 152 are those portions of the
container that are formed at apexes 154 as the material 150 is
pulled downwardly into the tool (in the direction of arrows A).
Thus, the corners of the container 100 are strengthened not only by
corner stabilizers 132 described above, but also because the
corners of the container are formed of the thickest material in the
container. As such, the corners are quite strong and resistant to
crushing. On the other hand, the thinnest portions of the finished
part are those portions that are located at the greatest distance
from the initial interface between material 150 and the uppermost
portions of the tool, which in the embodiment shown correspond to
apexes 154. In other words, as material 150 is pulled downwardly
into the tool from its original, planar position (in dashed lines
in FIG. 8), the thickness of material 150 tends to decrease the
further the material is pulled into the tool. As a result, the
thinnest portion of container 100 in FIG. 8 is found at hinge 106
and at lower edge 112 of front panel 114, and lower edge 115 of
bottom panel 118, which is the point furthest from apexes 154. This
increases the flexibility of the hinge 116 and makes it more
readily bendable, and the ability of the flanges 117 and 115 to
mate together when the container halves are closed.
[0052] It will further be noted that the tool 152 is formed such
that there are no "reverse drafts" or "negative drafts" in the
container 100. For example, and with reference to the cross
sectional configuration of rail 128 and recess 130, the rail is
generally cylindrical in shape, but as best seen in FIG. 7, is
non-concentric. Because these portions are not perfectly rounded,
the container is easily separate from tool 152 after container 100
is formed. Moreover, numerous empty containers may be nested within
one another yet easily separated.
[0053] Again with reference to use of container 100 as a container
for shoes, preferably the package is sized such that one container
will fit several different sizes of shoes. Thus, as one example, a
blank container 100 may be designed to hold a specific style of
shoes (such as athletic shoes) in the size range of men's sizes 7
to 9 (in the traditional U.S. sizing system), and also women's
athletic shoes in sizes 9 to 11. And while the container of the
present invention may often be smaller than traditional rectangular
shoeboxes designed for the same sizes of shoes, it is close enough
in size so that it may be used without modification to the existing
shoe distribution, warehousing and sale infrastructure.
[0054] The blank or empty containers 100 are designed so that they
may be nested with other blanks. The container 100 illustrated in
FIG. 4 thus could be stacked and nested with other containers for
ease of shipping and to minimize the space required for shipping
many empty containers. It will be appreciated that with the
illustrated configurations, many blanks may be nested for shipping
to a manufacturing facility in a minimal amount of space, and much
less space than would be occupied by an equal number of paperboard
box blanks. Further, the container of the present invention is
ready for use and does not need to be built or set up by the user.
This saves on both labor and equipment costs.
[0055] Those of skill in the art will further recognize the many
different shapes that can be used to define a container equivalent
to the container described herein. Thus, to name but a few
examples, the container could be formed with more than one handle,
the article-receiving space inside of the container may be designed
to conform more uniquely to a specific article, and as noted
previously, there are numerous methods of facilitating stacking in
stable stacks. Moreover, while numerous different shapes are
envisioned for both the interior space of the container and the
overall container shape, in the preferred embodiment the container
is roughly equivalent in size and shape to a standard shoebox for
holding a pair of shoes of similar size. In this way the container
of the present invention is accommodated easily into existing
footwear manufacturing, distribution and sales infrastructure.
[0056] With reference now to the container 100 illustrated in FIGS.
10 through 13, an insert 200 defined by a member 201 that it
typically a plastic material that may be thermoformed in the manner
described above. Insert 200 is designed to nest snuggly in the
interior of body half 104. The purpose of insert 200 is to define a
universal logo/brand name carrying means for container 100. Thus,
as described above, container 100 is preferably fabricated from a
clear material that allows a consumer to view the articles packaged
in the container.
[0057] The insert 200 may be fabricated from a like material, but
may be colored and may have various information printed on it, such
as brand names, company names, logos, sizes, etc. For example,
insert 200 may be textured, printed, embossed, debossed or a
combination of any of these, so that a standard clear container 100
may be "customized" to contain any brand, size, etc. of shoe
(depending upon what is printed on the insert). In addition, the
insert 200 may be fabricated from paperboard and other similar
materials that are moldable into a desired shape.
[0058] Moreover, as detailed below, when insert 200 is in place
nested in body half 104, a space is defined between the insert and
the body half, and information such as the types just mentioned may
be printed on paper, film, etc and inserted into the space. This
allows a manufacturer to use one container for several different
items.
[0059] Member 201 is essentially identical in shape to body half
104 so that the member nests completely within body half 104 as
indicated in FIG. 10, except that the carrying handle 126 has been
eliminated from the member 201 shown in the figures. Because member
201 has the same three-dimensional configuration as body half 104,
it may be thermoformed in a mold having the same dimensions as the
mold used for body half 104.
[0060] Insert 200 and the corresponding body half 104 include
cooperative structures designed to hold the insert snuggly in place
relative to the body half. Specifically, tabs 161 formed at the
four corners of the body half 104 are sized to engage cooperatively
positioned and shaped tabs 263 on member 201. When member 201 is
pushed into body half 104, the tabs 161 connect to the tabs 263 to
retain the insert in place in the body half. The tabs 161 may be of
similar construction to tabs 160 described above, or may be
modified in order to provide more secure engagement with the tabs
263.
[0061] Insert 200 is shown in place within body half 104 in FIGS.
11, 12 and 13. As may be seen, the insert resides within the body
half such that the surface of member 201 that abuts inner surface
202 of body half 104 rests closely against the inner surface 202,
yet defines a space 204 into which indicia carrying media such as
paper, film, and the like printed with information may be inserted.
Stated another way, since the dimensions of insert 200/member 201
are substantially identical to the dimensions of body half 104, the
insert 200 conforms to body half 104 when the two are mated
together as indicated.
[0062] It will be appreciated that there are numerous structures
that are equivalent to the tabs 161, 263 described above that
facilitate attachment of insert 200 into body half 104. For
example, a friction fit between the insert 200 and body half 104
will suffice. Moreover, it will be apparent that the function of
insert 200 may be accomplished with an insert that nests within
body half 104 but which is smaller in size so that the insert does
not cover the majority of the interior surface of the body half, as
shown in the embodiment illustrated. Also, insert 200 and container
100 may just as well be constructed so that the insert mates with
the first body half 102 rather than the second body half 104 as
shown.
[0063] As described above, the insert 200 may be manufactured from
colored materials and/or may be preprinted etc. with a variety of
indicia. Accordingly, the insert defines a manner of using a single
container 100 to contain a variety of different goods, where a
different insert 200 is used with each different good. Even where
the insert is manufactured so that it is opaque in order to display
written indicia, the goods held in container 100 may be viewed and
inspected by consumers through the remaining portions of the
container, which as described above are clear. Further, the
consumer may removed the insert 200, leaving a completely clear
container for home storage of any shoes, etc.
[0064] While the present invention has been described in terms of a
preferred embodiment, it will be appreciated by one of ordinary
skill that the spirit and scope of the invention is not limited to
those embodiments, but extend to the various modifications and
equivalents as defined in the appended claims.
* * * * *