U.S. patent application number 11/135684 was filed with the patent office on 2006-11-30 for recyclable package.
Invention is credited to Steve R. Young.
Application Number | 20060266672 11/135684 |
Document ID | / |
Family ID | 37462036 |
Filed Date | 2006-11-30 |
United States Patent
Application |
20060266672 |
Kind Code |
A1 |
Young; Steve R. |
November 30, 2006 |
Recyclable package
Abstract
A fully recyclable, tamper resistant package having a folded
inner box comprising a recess for receiving a product, the recess
having a depth slightly less than the thickness of the product, the
inner box being insertable into a transparent plastic outer box
that is permanently sealed with a destruction bond seal following
insertion of the inner box. A thermoformed plastic tray is
preferably used to seat and stabilize the product inside the recess
in the inner box.
Inventors: |
Young; Steve R.; (Plano,
TX) |
Correspondence
Address: |
LOCKE LIDDELL & SAPP LLP;ATTN: STACIE COX
2200 ROSS AVENUE
SUITE 2200
DALLAS
TX
75201-6776
US
|
Family ID: |
37462036 |
Appl. No.: |
11/135684 |
Filed: |
May 24, 2005 |
Current U.S.
Class: |
206/776 |
Current CPC
Class: |
B65D 77/0433
20130101 |
Class at
Publication: |
206/776 |
International
Class: |
B65D 25/54 20060101
B65D025/54 |
Claims
1. A package for a product having a thickness, the package
comprising an inner box having a major surface containing a window,
a substantially transparent polymeric tray member receivable into
the window, the tray member defining a recess having a maximum
depth approximating the thickness of the product when placed in the
tray member, and a substantially transparent polymeric outer box
into which the inner box is slidably insertable, the outer box
having foldable closures that are permanently sealable with a
destruction bond adhesive.
2. The package of claim 1 wherein the destruction bond adhesive is
a polyurethane reactive adhesive.
3. The package of claim 1 wherein the inner box is made of a
cellulosic material or plastic.
4. The package of claim 3 wherein the inner box is made of a
material selected from the group consisting of paper board, bleach
board, clay coated newsback, and corrugated board.
5. The package of claim 1 wherein the tray member is made of a
polymeric material selected from the group of low-density
polyethylene and polyethylene terephthalate.
6. The package of claim 5 wherein the tray member is made of
low-density polyethylene.
7. The package of claim 1 wherein the outer box is made of a
polymeric material selected from the group consisting of
polypropylene and polyethylene terephthalate.
8. The package of claim 7 wherein the outer box is made of
polypropylene.
9. The package of claim 1 wherein the inner box comprises first and
second opposed major surfaces, with a first window disposed in the
first major surface and a second window disposed in the second
major surface.
10. The package of claim 9 wherein the first and second windows are
aligned.
11. The package of claim 1 wherein the tray member comprises a
bottom, a sidewall, and a flange projecting outwardly from the top
of the sidewall.
12. The package of claim 11 wherein the flange supports the tray
member inside the window.
13. The package of claim 11 wherein the flange stabilizes the tray
member inside the window.
14. The package of claim 1 wherein the tray member comprises a
plurality of recesses and at least one divider separating each
recess from each other recess.
15. The package of claim 1 wherein at least two sides of the
product are visible when the product is disposed inside the
package.
16. The package of claim 9 wherein both the top and bottom of the
product are visible when the product is disposed inside the
package.
17. The package of claim 1 wherein the entire package is recyclable
after removal of the product.
18. The package of claim 1 wherein the inner box further comprises
a plurality of foldable flaps hinged to the window.
19. The package of claim 1 wherein the outer box further comprises
a foot support member.
20. The package of claim 1 wherein the inner box and the outer box
further comprise aligned apertures facilitating display of the
package on a pegboard.
21. The package of claim 1 wherein the inner box comprises an end
wall having an aperture having a diameter large enough to receive a
fingertip.
22. The package of claim 11 wherein the bottom of the tray member
comprises at least one slot disposed adjacent to a sidewall,
wherein a header card attached to the product is insertable through
the slot.
23. The package of claim 18 wherein the inner box has a bottom wall
and the flaps have a bottom edge that contacts the bottom wall of
the inner box.
24. The package of claim 18 wherein the inner box has a bottom wall
and the flaps have a lower section that is rolled under and forms a
flange contacting the bottom wall of the inner box.
25. The package of claim 18 wherein the inner box has an end wall
and a sidewall and a bottom wall, wherein the flaps have a lower
section that is rolled under and the lower section contacts one of
the end wall and the sidewall.
26. A package for a product having a shape and a thickness, the
package comprising an inner box having a major surface containing a
window conforming substantially to the shape of the product and a
plurality of foldable flaps hinged to the window to define a recess
having a depth sufficient to receive substantially all the
thickness of the product, and a substantially transparent polymeric
outer box into which the inner box member is slidably insertable,
the outer box having foldable closures that are permanently
sealable with a destruction bond adhesive.
27. The package of claim 26 wherein the destruction bond adhesive
is a polyurethane reactive adhesive.
28. The package of claim 26 wherein the inner box is made of a
cellulosic material.
29. The package of claim 28 wherein the inner box is made of a
material selected from the group consisting of bleach board and
clay coated newsback.
30. The package of claim 26 wherein the outer box is made of a
polymeric material selected from the group consisting of
polypropylene and polyethylene terephthalate.
31. The package of claim 30 wherein the outer box is made of
polypropylene.
32. The package of claim 26 wherein the entire package is
recyclable after removal of the product.
33. The package of claim 26 wherein the inner box further comprises
a plurality of foldable flaps hinged to the window.
34. The package of claim 26 wherein the outer box further comprises
a foot support member.
35. The package of claim 26 wherein the inner box and the outer box
further comprise aligned apertures facilitating display of the
package on a pegboard.
36. The package of claim 26 wherein the inner box comprises an end
wall having an aperture having a diameter large enough to receive a
fingertip.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to fully recyclable packaging for a
product, the packaging having a transparent outer box with a
destruction bond seal, and more particularly, to a tamper resistant
package in which the product is disposed inside a full-thickness
recess in a folded inner box that is insertable into a
substantially transparent, plastic outer box, which outer box is
then sealed. The invention also relates to use of a transparent
thermoformed tray to support the product within a recess in the
inner box.
[0003] 2. Description of Related Art
[0004] In recent years, tamper resistant clamshell display packages
have become widely used in the retail marketing of consumer goods.
So-called "big box" retailers favor use of the packages because
they facilitate display in tray-packs or case-packs and
significantly reduce shrinkage attributable to shoplifting,
pilfering and employee theft. Conventional clamshell packages are
typically thermoformed from transparent PVC resin and have two
halves that are hinged and can be folded together and sealed after
inserting one or more products into recesses formed in one or both
sides of the clamshell. Display cards with appropriate graphics or
instructions are typically inserted into the packages before they
are sealed. Because the PVC is tough and durable, and because the
edge closures are typically bonded together by an RF seal,
clamshell packages are extremely difficult to open without
destroying the package.
[0005] Disadvantages of the conventional clamshell packages to
manufacturers include the facts that they are expensive to make,
are relatively heavy, are not recyclable, and making the RF seal
needed to produce the "destruction bond" consumes time and energy.
Consumers, particularly children and senior citizens, are
frustrated by conventional clamshell packages because they are
extremely difficult, if not impossible, to open following purchase,
invite injury from accidental use of sharp or pointed tools needed
to access the products, present a disposal problem in that they are
neither easily handled nor recyclable. Because clamshell packages
typically have irregular thicknesses and tend to have relatively
sharp edges, they are also difficult to gift-wrap when the subject
products are purchased as gifts.
[0006] An alternative package is therefore needed that is similarly
transparent, durable and tamper resistant, but is also less
expensive, is recyclable and does not require an RF seal. Such a
package is disclosed herein.
SUMMARY OF THE INVENTION
[0007] Unlike conventional PVC clamshell packages, the package of
the invention can be characterized as tamper resistant, durable,
lighter in weight, and totally recyclable, with a rectangular shape
and substantially uniform thickness that facilitate assembly,
handling, storage, shipping, display and gift-wrapping. The subject
package provides excellent product visibility on the front, sides
and back, provides ample space for printed text and graphics, and
can be made faster and at less expensively than comparable
clamshell packages. Perhaps most significantly, consumers
purchasing products disposed inside the packages of the invention
will be able to access those products more safely and then dispose
of the package so as to permit recycling.
[0008] According to one embodiment of the invention, a package is
provided that preferably comprises a foldable, folded, or pop-up
inner box made of paper board, clay coated newsback, corrugated
board, plastic, or another similarly effective material, having a
window in at least one major surface of the box. Most preferably, a
transparent polymeric tray is receivable into the window, the tray
defining a recess having sufficient depth to receive a product
having a thickness not substantially greater than the thickness of
the box. The package further comprises a substantially transparent
polymeric outer box member into which the inner box member is
slidably insertable, the outer box member having foldable end
closures that are permanently sealable with a destruction bond
adhesive, most preferably a transparent, polyurethane reactive
adhesive. One or more die-cut slots can optionally be provided in
the bottom wall of the tray member adjacent to a side or end wall
of the tray member to receive a header card of a prepackaged
product.
[0009] According to one particularly preferred embodiment of the
invention, a package is made as described above, with the tray
member having a sidewall and an outwardly extending flange disposed
at the top of the sidewall to provide abutting contact against a
portion of the major surface of the inner box and thereby stabilize
the position of the tray member relative to the window in the major
surface.
[0010] According to another particularly preferred embodiment of
the invention, a package is made as described above but also
comprising a window in a second major surface of the inner box, the
first and second windows being aligned to provide visibility with
respect to both the top and bottom surfaces of the product disposed
inside the tray member.
[0011] According to another embodiment of the invention, a package
is made as described above, with the tray member further comprising
sidewalls disposed away from the corresponding sidewalls of the
product, and positioning elements disposed inside the tray member
to maintain a desired spacing between the tray member and product
sidewalls, to provide visibility with respect to the product
sidewalls.
[0012] According to another embodiment of the invention, a package
is made as described above, with the window of the inner box
further comprising foldable flaps defining a plurality of flexible
sidewalls hinged to edges of the window. Depending upon the
material selected for use in making the inner box, the side and end
walls of the window in the inner box can be rolled or folded in any
of several different configurations to lend additional strength and
rigidity to the resultant package.
[0013] According to another embodiment of the invention, a package
is provided that does not comprise a tray member and preferably
comprises a foldable, folded or pop-up inner box having at least
one window disposed in a major surface of the inner box and a
plurality of rolled or folded flaps defining a plurality of
sidewalls to the window, the window and sidewalls defining a recess
having sufficient depth to receive a product having a thickness not
substantially greater than the thickness of the inner box, and a
substantially transparent polymeric outer box into which the box is
slidably insertable, the sleeve having foldable end closures that
are permanently sealable with a polyurethane reactive adhesive. As
used herein, the term "permanently sealable" means the end closures
cannot subsequently be reopened by the application of manual force
alone without the use of a hand-held tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The apparatus of the invention is further described and
explained in relation to the following drawings wherein:
[0015] FIG. 1 is an exploded top perspective view of preferred
embodiments of the inner box and tray members of the invention,
showing in phantom outline a representative product receivable into
the tray and inner box;
[0016] FIG. 2 is a top perspective view showing the elements of
FIG. 1 assembled prior to insertion into the transparent outer box
member to form one preferred embodiment of the invention;
[0017] FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 2;
[0018] FIG. 4 is a detail view of a preferred embodiment of a foot
support member suitable for use in the package of the
invention;
[0019] FIG. 5 is an enlarged top perspective view, partially broken
away, of the closed end of the outer box member of FIG. 2,
illustrating a preferred placement of the foot support members on
one side of the package of the invention;
[0020] FIG. 6 is a partially exploded top perspective view of the
inner box member of a second embodiment of the invention, showing
in phantom outline one representative product already inserted into
a first window of the inner box member and another representative
product ready for insertion into a second window of the inner box
member;
[0021] FIG. 7 is a top perspective view showing the elements of
FIG. 6 assembled prior to insertion into the transparent outer box
member to form the second embodiment of the invention;
[0022] FIG. 8 is a top perspective view of another preferred
embodiment of the tray member of the invention;
[0023] FIG. 9 is a an enlarged top perspective view, partially
broken away, of the closed end of the outer box member as described
above in relation to FIG. 5, and further illustrating the manner in
which a hand-held cutting tool can be inserted into a slit adjacent
to a support foot to facilitate safely opening the package;
[0024] FIG. 10 is an exploded top perspective view of another
preferred embodiment of the inner box and tray members of the
invention, showing in phantom outline representative pre-packaged
products receivable into the tray and inner box;
[0025] FIG. 11 is a top perspective view showing the elements of
FIG. 10 assembled prior to insertion into the transparent outer box
member to form another preferred embodiment of the invention
wherein header cards of the pre-packaged products are conveniently
accommodated within the package;
[0026] FIG. 12 is a cross-sectional view taken along line 12-12 of
FIG. 1 1;
[0027] FIGS. 13a, 13b and 13c are cross-sectional views taken along
line 13-13 of FIG. 10 that depict alternative embodiments for the
structure of the inner box;
[0028] FIG. 14 is a top perspective view depicting an alternative
inner box wherein the window is circular rather than rectangular to
illustrate how products having outside configurations other than
rectangular can be received and displayed in the packages of the
invention; and
[0029] FIG. 15 is a detail cross-sectional view that is
illustrative of a die-cut, foldable brace member that can
optionally be created in an end wall or sidewall of the inner box
of the invention to provide greater strength and support to the
inner box.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] A first preferred embodiment of the invention is described
herein in relation to FIGS. 1-5, a second embodiment of the
invention is described in relation to FIGS. 6 and 7, and other
preferred embodiments of the invention are described in relation to
FIGS. 8-15. In general terms, referring first to FIG. 2, recyclable
package 10 preferably comprises inner box 12 having tray member 14
disposed inside a window that is die cut into upwardly facing major
surface 18. A product 16 is depicted in phantom outline as being
disposed inside one of two distinct recesses inside tray member 14,
as will be further described below. For purposes of illustration,
the other recess is depicted as empty, although it should be
understood that in practice another product 16 would be similarly
disposed inside the empty recess if the tray is made as shown. Once
products 16 are placed inside tray member 14, inner box 12 is
slidably inserted into the open end of outer box 64, after which
outer box 64 is sealed with any adhesive suitable for producing a
permanent seal, sometimes also referred to as a "destruction bond."
Once permanently sealed, outer box 64 cannot be opened manually
without the use of tools or without destroying the integrity and
appearance of the package.
[0031] Although package 10 is depicted without graphics in the
accompanying drawings, it should be appreciated that any or all
surfaces of inner box 12 or outer box 64 can have text and graphics
printed on them or otherwise applied to them using any available
printing technology known to those of skill in the art. For
example, and without limitation, inner box 12 can be printed or
label laminated prior to assembly and insertion of tray member 14,
or the plastic sheet used in making outer box 64 can be inside or
outside printed as desired. Text and graphics printed on the
outwardly facing surfaces of inner box 12 will desirably remain
visible through outer box 64 after inner box 12 is sealed inside
the outer box to complete recyclable package 10. It should also be
appreciated that the number and shape of tray members 14 and the
number and shape of product recesses inside each tray member 14 can
vary within the scope of the invention.
[0032] Inner box 12 is preferably made of any suitable recyclable,
cellulosic or plastic material. Bleach board, clay coated newsback,
corrugated board, label-laminated corrugated, whiteface corrugated,
or other similarly effective materials, are particularly preferred
for use in the invention. It is also preferred that the material
used to fabricate inner box 12 be relatively inexpensive, foldable
or easily erectable, and have printable outwardly facing surfaces.
The material used to make inner box 12 will desirably be rigid
enough to maintain its shape when a sheet of the material is die
cut and folded to produce inner box 12, and when inner box 12 is
subsequently inserted into outer box 64. When corrugated material
is used to make inner box 12, inner box 12 can be preassembled as a
"pop-up" box, then stored flat and erected into its use position
just prior to insertion of the product(s). Inner box 12 is
typically opaque, although for some applications, a translucent or
transparent, recyclable polymeric material can also be used in
making inner box 12. Tray member 14 is preferably made of a
substantially transparent, recyclable, thermoformable polymeric
material, with low density polyethylene or polyethylene
terephthalate ("PET") being particularly preferred. Outer box 64 is
preferably made of a durable, substantially transparent, recyclable
polymeric sheet material such as clear polypropylene. PET is also
clear and recyclable, and can likewise be used in making package
10, but is more likely to shatter, particularly at low
temperatures.
[0033] The component parts of package 10 are now further described
in relation to all of FIGS. 1-5. Depending upon the substrate
material and the intended use, inner box 12 can be a "sealed-end,"
"tuck-flap" or "pop-up" box, all of which are known to those of
skill in the art, which has been pre-printed with appropriate text
and graphics. Inner box 12 further comprises top and bottom walls
18, 20, each having major outwardly facing surfaces, side walls 26,
28, end walls 30, 32, and upper and lower windows 22, 24 that are
desirably aligned to render both the top and bottom of product 16
visible in assembled package 10. Flaps 34, 36, and other flaps
similarly positioned on the two inside portions of window 22 that
are not visible in FIG. 1, are preferably hinged to the edges of
window 22. When the flaps are folded down into the interior of
inner box 12 as shown in FIG. 1, they lend support to top wall 18
and assist in positioning and stabilizing tray 14, which is
insertable into the window. Alternatively, as discussed in greater
detail below in relation to FIGS. 13a-13c, the sidewalls of the
inner box that form the recess can be rolled or folded under, and
sometimes glued, to provide additional rigidity and support to the
product.
[0034] An aperture such as finger hole 38 is desirably provided in
end wall 36 to assist assembly personnel in inserting inner box 12
into outer box 64 and to assist consumers in removing inner box 12
from outer box 64 following purchase of package 10. Apertures 38
also facilitate the pass-through of air out of or into the sealed
end of outer box 64 as inner box 12 is inserted or removed,
respectively.
[0035] Referring to FIGS. 1 and 3, tray member 14 is preferably
substantially transparent, and is most preferably thermoformed from
a polymeric sheet of substantially transparent low density
polyethylene or PET. The use of a transparent material for tray
member 14 permits the underside of product 16 to be viewed through
window 24 on the bottom of inner box 12 when tray member 14 is
disposed inside top window 22 as shown in FIG. 2. Tray member 14
further comprises side walls 42, 44, 46, 48 surrounding divided
bottom sections 60, 62. Thermoformed positioning blocks 56, 58 and
inclined surfaces 42, 54 are desirably provided to position
products 16 inside the two recesses in such manner that they do not
abut against each other or against sidewalls 42, 44. If desired, a
continuous divider can be provided as shown between positioning
blocks 58 of tray member 14 in FIGS. 1 and 2, or positioning blocks
58 can be completely separate, as shown for tray member 14' in FIG.
8. When tray member 14 is constructed as shown in FIGS. 1 and 2 or
as shown in FIG. 8, both sides of product 16 are visible even when
package 10 of FIG. 2 is fully assembled and sealed. Outwardly
facing flange 50 is desirably provided around the top of at least
part of the sidewalls to provide additional structural rigidity to
tray member 14 and to position and stabilize tray member 14
relative to window 22 of inner box 12.
[0036] Referring to FIG. 3, it is seen that inwardly folded
sidewalls 26, 28 of inner box 12 cooperate with the sidewalls,
bottom sections 60, 62 and flange 50 of tray member 14 to produce a
stable unit capable of supporting product 16 prior to the insertion
of inner box 12 into outer box 64 as shown in FIG. 2 to complete
package 10. Although the end flap construction of inner box 12 is
not visible in the drawings, such construction is typical of that
of many commercially available, lightweight paper boxes, sometimes
called "tuck-flap" boxes, as are well known to those of skill in
the art. The respective gauges or wall thicknesses of inner box 12
and tray member 14 can vary as desired.
[0037] The height or thickness of tray member 14 and inner box 12,
as distinguished from their respective gauges or wall thicknesses,
are preferably such that the thickest part of product 16 as
positioned inside tray member 14 will not extend more than about
one-eighth inch (0.125'') above the top of flange 50 when product
16 is fully seated inside tray member 14 and tray member 14 is
fully seated inside inner box 12. Most preferably, product 16 will
extend about one-sixteenth inch above flange 50 to exert slight
pressure against outer box 64 after insertion, and to facilitate
grasping of product 16 by the consumer for removal from tray member
14 following purchase.
[0038] Although product 16 is depicted as a rectangular solid in
the drawings, it should be appreciated that the products sealed in
package 10 of the invention may or may not themselves be
pre-packaged inside another box or container as shown in the
drawings. Tray member 14 may have one or a plurality of recesses,
and one or a plurality of products may be placed in a single
recess. Similarly, products having irregular or non-polygonal
shapes can likewise be disposed inside tray member 14, provided
that tray member 14 is at least as deep as the tallest or thickest
portion of the product or products as positioned inside tray member
14.
[0039] The construction of outer box 64 is further described and
explained in relation to FIGS. 2, 4 and 5. As shown, outer box 64
is also formed by folding and sealing a die-cut, substantially
transparent, recyclable polymeric sheet, most preferably comprising
clear polypropylene. Although outer box 64 is preferably preformed
with an open end to await insertion of inner box 12, it will be
appreciated that, if desired, outer box 64 can also be formed
around inner box 12 if inner box 12 is properly positioned on a
die-cut (and possibly scored) blank suitable for use in making
outer box 64. As shown, outer box 64 comprises top and bottom walls
92, 94, closed end wall 66, open end 68 having side flaps 74, 76,
top and bottom flaps 70, 72, sidewall 102, and a second sidewall
made by closing and sealing flaps 78, 80. Adhesive seals 82, 84 are
provided to permanently seal the side and ends of outer box 64. A
preferred adhesive for this use is a transparent polyurethane
reactive ("PUR") adhesive well known to those of skill in the
art.
[0040] If desired, sombrero-shaped apertures 97, 99 and 96, 98, or
functional equivalents, can be provided in inner box 12 and outer
box 64, respectively, to render the packages "peggable," and
die-cut support feet 88, 90, 100 can be included for use in
standing package 10 upright on one end for display purposes.
Referring to FIGS. 4 and 5, support foot 88 can be formed by
die-cutting circular apertures 104, 106 along fold line 110 between
top 92 and end wall 66, and by die-cutting an offset slot 108
between the apertures to form an outwardly extending tab that
serves as support foot 88 when end wall 66 is sealed. Referring to
FIG. 9, the slot disposed beneath support foot 88 provides a
convenient point of entry so that, following purchase, a hand-held
cutting tool 146 can be inserted by the consumer and the blade can
be guided around the perimeter of the package while resting on top
of the inner box and beneath top 92 of outer box 64.
[0041] Referring to FIGS. 6 and 7, another recyclable, tamper
resistant package 116 is disclosed that comprises inner box 112
made as previously described for box 12, and outer box 114 made as
previously described for outer box 64, but does not comprise a tray
member as disclosed above. Inner box 112 comprises top and bottom
walls 118, 120, sidewalls 122, 124 and end walls such as wall 126,
which further comprises aperture 136. Products 138, 140 are
preferably nested inside windows such as window 130 in top wall
118, which is surrounded by inwardly folded flaps 132, 134. Inner
box 112 is insertable into the open end of outer box 114, after
which end flaps 142, 144 and their opposed counterparts are folded
and permanently sealed to form tamper resistant package 116. Here
again, although shown in relation to an embodiment where products
138, 140 are square or rectangular, it will be appreciated that
products having other shapes can also be packaged using the present
invention. FIG. 14, for example, depicts an inner box 224 having a
circular recess 226 suitable for use with a product having a
circular perimeter. Package 116 differs from package 10 in that it
lacks the bottom or side product visibility that is provided by
package 10.
[0042] Alternatively, various types of cavities or ledges known to
those of skill in the art of package design may be used in inner
box 112 to provide additional bottom support to products 138, 140,
particularly where products 138, 140 are relatively heavy. For
example, FIG. 15 depicts one such preferred support for use in a
corrugated box, wherein unitary brace member 230 is folded inwardly
from the backside of inner box 150 to provide additional structural
support to the inner box and to the product displayed in it.
[0043] FIGS. 10-12 illustrate another preferred embodiment of the
invention comprising an inner box 150 that is preferably a
preassembled "pop-up" box made of a heavier gauge, corrugated
substrate, and optionally utilizing a transparent, thermoformed
tray 152 having at least one slot that is die-cut or otherwise
created in the bottom wall of the tray adjacent to an end or side
wall to receive the header card of a prepackaged product to be
displayed inside the tray. Referring to FIG. 10, inner box 150
comprises top 156 and bottom 158 comprising product-viewing windows
160, 162, respectively. Hinged, foldable flaps 164, 166, which are
matched by flaps that are not visible on the opposed sides, are
provided as described above in relation to FIG. 1. Aperture 172 is
provided in end wall 168 to facilitate insertion into an outer box
64' as shown in FIG. 11.
[0044] Form tray member 152 is made as previously described for
tray 14, and comprises bottom wall 202, side walls 204, 206, end
walls 208, 210, and positioning blocks 214, 216 adapted to provide
spacing at the sides and corners, respectively, between product 154
and the end and side walls of the tray. Tray member 152 differs
from tray member 14 in that slots 213, 212 are provided in bottom
wall 202 closely adjacent to the bottom of end walls 208, 210,
respectively, to allow a header card of a prepackaged product to
extend beyond the tray walls, but remain inside the walls of outer
box 64' as shown in FIG. 11. Such slots are desirably positioned
where they can be die cut or otherwise formed in the bottom wall of
tray member 150, and the position of the slots will depend upon how
header card 155 of prepackaged product 154 is oriented in tray
member 150 or another tray. As shown in FIGS. 10-12,
side-positioning blocks 214 are desirably configured to receive the
header card of one prepackaged product 154 between them, while the
header card of the other product extends through slot 213 and into
the interior space behind the associated wall of window 160.
Recesses 220, 222 in FIG. 1 correspond to the underside of the
thermoformed side and end positioning blocks 214, 216,
respectively.
[0045] Once tray member 152 is installed in inner box 150 and
products 154 are installed in tray member 14, package 151 is
assembled by sliding inner box 150 into outer box 64' and
thereafter sealing and previously described in relation to the
embodiment of FIGS. 1-5.
[0046] FIGS. 13a, 13b and 13c depict alternate embodiments for the
construction of inner box 150 of FIGS. 10-12. These alternate
embodiments provide greater structural support and rigidity than do
the hinged flaps shown in FIG. 10. In FIG. 13a, the free edge of
folded section 174 contacts bottom wall 176 near the edge of window
178. In FIG. 13b, folded section 180 terminates in a folded flange
181 that can be glued or otherwise sealed to bottom wall 182 near
window 184. In FIG. 13c, folded section 186 is joined to another
folded section 187 that is turned under and contacts the inside of
wall 188 while lying on bottom wall 190 outwardly of window 200.
The use of window wall configurations such as these is particularly
preferred for use with relatively heavy products.
[0047] The packages of the invention are made of totally recyclable
materials, are tamper resistant, and are characterized by their
uniform shape, low cost, and, when made in accordance with FIGS.
1-5 and 10-12, by enhanced product visibility. The subject packages
are also easily packed and displayed because of their regular
shapes. Package 10 is substantially lighter than conventional PVC
clamshell packages and does not require the use of an RF seal.
Because polypropylene, the preferred material for use in making the
outer box, is more flexible than PVC, the outer box of the package
disclosed herein will not crack or shatter like PVC clamshells, and
does not require the use of expensive equipment that is needed to
manufacture conventional PVC clamshell packages.
[0048] Other alterations and modifications of the invention will
likewise become apparent to those of ordinary skill in the art upon
reading this specification in view of the accompanying drawings,
and it is intended that the scope of the invention disclosed herein
be limited only by the broadest interpretation of the appended
claims to which the inventor is legally entitled.
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