U.S. patent application number 14/158361 was filed with the patent office on 2014-09-18 for multi-part product shipping box and display tray.
This patent application is currently assigned to Technology Container Corporation. The applicant listed for this patent is Technology Container Corporation. Invention is credited to Fred Dowd.
Application Number | 20140263305 14/158361 |
Document ID | / |
Family ID | 51522938 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140263305 |
Kind Code |
A1 |
Dowd; Fred |
September 18, 2014 |
Multi-Part Product Shipping Box and Display Tray
Abstract
A reusable combined multi-part product shipping box and display
tray. In one arrangement, the box includes two generally
rectangular trays, each defining four sides, with four barrier
portions projecting upward from each tray proximate its edges, one
barrier portion at about the center of each of the sides, and four
corner posts, one projecting up from each corner of the tray. The
box includes a generally rectangular sleeve defining four sides and
four corners, and open ends that are about the same size and shape
as the trays, the sleeve adapted to engage with the trays to close
its open ends and form a shipping container, the sleeve adapted to
sit on the tray inside of and up against the barrier portions, with
each corner of the sleeve located outside of and against a corner
post, such that the sleeve is tightly engaged with the trays.
Inventors: |
Dowd; Fred; (Princeton,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Technology Container Corporation |
Worcester |
MA |
US |
|
|
Assignee: |
Technology Container
Corporation
Worcester
MA
|
Family ID: |
51522938 |
Appl. No.: |
14/158361 |
Filed: |
January 17, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12640246 |
Dec 17, 2009 |
8631956 |
|
|
14158361 |
|
|
|
|
61138220 |
Dec 17, 2008 |
|
|
|
Current U.S.
Class: |
220/4.28 ;
206/509; 220/6; 220/676 |
Current CPC
Class: |
B65D 25/00 20130101;
B65D 11/1846 20130101; B65D 25/54 20130101; B65D 81/263 20130101;
Y02W 30/807 20150501; Y02W 30/80 20150501; B65D 25/30 20130101;
B65D 85/34 20130101; B65D 2301/20 20130101 |
Class at
Publication: |
220/4.28 ; 220/6;
206/509; 220/676 |
International
Class: |
B65D 6/18 20060101
B65D006/18; B65D 21/02 20060101 B65D021/02; B65D 25/30 20060101
B65D025/30 |
Claims
1. A box assembly, comprising: (i) at least one tray, comprising:
(a) a generally planar portion having four sides that define
corresponding edges of the planar portion, each of the four sides
defining a corresponding center; (b) a set of projecting walls
extending from the surface of the generally planar portion, each
projecting wall of the set of projecting walls disposed at a
corresponding edge of each corresponding side of the four sides of
the planar portion; (d) a corner post disposed at a corresponding
corner of a set of four corners of the tray, each corner post
spaced inwardly from a first edge and a second edge that define the
corresponding corner of the tray; and (ii) a generally rectangular
sleeve having a set of four walls that define four corners, a first
opening at a first end of the sleeve and a second, opposed opening
at a second end of the sleeve, the set of four walls of the first
end of the sleeve configured to engage the at least one tray to
close the first opening of the sleeve and form a shipping
container, the first end of the sleeve configured to be disposed on
the at least one tray, the set of four walls of the first end of
the sleeve configured to be disposed between the set of projecting
walls and the set of corner posts such that an outer surface of
each wall is configured to be disposed against each corresponding
projecting wall and an inner surface of each corner of the sleeve
is configured to be disposed against a corner post of the at least
one tray to secure the first end of the sleeve to the at least one
tray.
2. The box assembly of claim 1, wherein each wall of the set of
four walls of the sleeve is captured between one projecting wall of
the set of projecting walls and two opposing corner posts of the
set of corner posts.
3. The box assembly of claim 1, wherein the sleeve comprises a
corrugated material.
4. The box assembly of claim 3, wherein the corrugated material
comprises: a first linerboard and a second linerboard spaced apart
from the first linerboard; and a corrugated sheet disposed between
the first linerboard and the second linerboard, the corrugated
sheet defining a set of sealed flutes having a longitudinal axis
extending between the first end of the sleeve and the second end of
the sleeve, each sealed flute of the set of sealed flutes
configured to contain a volume of air.
5. The box assembly of claim 4, wherein the corrugated material
comprises a corrugated plastic material.
6. The box assembly of claim 3, wherein the sleeve is configured to
be folded into a flat form.
7. The box assembly of claim 1, wherein at least a portion of each
corner post of the set of corner posts are tapered from top to
bottom.
8. The box assembly of claim 7, wherein each post comprises two
substantially vertical portions that meet at right angles, each
vertical portion defining a taper toward a top end of the
corresponding vertical portion, the top end opposing the surface,
the taper of each vertical portion defined by an outer surface that
is angled inwardly from the vertical reference such that the top
end of each vertical portion is more narrow than a base of each
vertical portion.
9. The box assembly of claim 1, wherein each post defines an
opening configured to accept an identical post of another tray to
allow nesting of the trays.
10. The box assembly of claim 9, wherein the sleeve defines a
plurality of holes in a first wall of the sleeve and in a second
wall of the sleeve, the first wall opposing the second wall.
11. The box assembly of claim 10, wherein the sleeve defines a
first handle cutout in the first wall of the sleeve and a second
handle cutout in the second wall of the sleeve, the first handle
cutout and the second handle cutout being spaced and
vertically-aligned.
12. The reusable combined multi-part product shipping box and
display tray of claim 11, wherein each tray has an opening in about
a center of, and through, the generally planar portion.
13. The reusable combined multi-part product shipping box and
display tray of claim 1, wherein each wall of the set of four walls
of the sleeve is captured between one projecting wall of the set of
projecting walls and two opposing corner posts of the set of corner
posts.
Description
RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of U.S.
patent application Ser. No. 12/640,246, entitled "Reusable,
Combined Multi-Part Product Shipping Box and Display Tray," filed
on Dec. 17, 2009 which claims priority to U.S. Provisional Patent
Application Ser. No. 61/138,220, entitled "Reusable, Combined
Multi-Part Product Shipping Box and Display Tray," filed on Dec.
17, 2008. The entire contents of the priority applications are
hereby incorporated by reference in their entirety.
BACKGROUND
[0002] Bananas currently and historically have been shipped in a
corrugated paper box consisting of a double wall Half Slotted
Container (HSC) body covered by a single wall HSC full depth
telescoping cover. These paper boxes are typically fabricated local
to the banana plantations where they are assembled on a box-forming
machine or by hand at the packing sheds on the banana plantations.
The double wall bottom of the box is formed, in a secondary
operation, and then packed with the bananas inverted or crown up to
minimize transportation damage. Another box-making machine or
individual forms the single wall top of the box which is then slid
over the bottom of the box to the full depth of the container. When
completed, the bananas are protected by the combined wall
thicknesses in a paper box that has triple thick sidewalls, double
wall bottom flaps and single wall top flaps.
[0003] The finished box is relatively expensive, typically over
$1.25 per box and gets thrown out at the store level. It is a
one-time use shipping container that generates about 2.5 pounds of
waste for each 40 pound box of bananas.
[0004] After packing in boxes, the bananas are loaded into
refrigerated containers and shipped to market. Another mode of
transport to market is when the boxes of bananas are loaded into
the hold of a ship without the container, just packed on pallets.
With either method, upon arrival at port the bananas are shipped to
ripening companies in various markets where they are ripened by a
gas process. After the bananas are ripened, they are shipped to the
stores.
[0005] At the store level, store personnel have to manually unpack
each box of bananas and put them on display on store shelves, crown
down, for customers to view and purchase. Accordingly, either the
ripening supplier or the store personnel have to invert the cases
or bunches of bananas by hand prior to lifting each bunch out and
putting them on a display stand. Bananas are a high volume retail
item. The unpacking and handling of bananas at the store level is
very time consuming and labor intensive, costing the supermarkets
labor and wasted time.
SUMMARY
[0006] By contrast to conventional packing boxes, embodiments of
the present innovation relate to a reusable combined multi-part
product shipping box and display tray. In one arrangement, the box
or container can be used to ship bananas, other produce, or other
goods, multiple times. The box, thus reduces the environmental
impact of shipping millions of cases of bananas to market. The
innovation reduces solid waste, energy consumption and greenhouse
gases by approximately 60% when compared to the disposable paper
box system described above.
[0007] The container also greatly reduces the costs associated with
shipping. The paper box described above currently costs over $1.25
per unit. The container of the present innovation can decrease the
cost per shipping cycle to approximately $0.20.
[0008] The three-part shipping container can minimize or eliminate
the in-store labor associated with unloading each case of bananas
by hand. This allows the supplier to invert each case of bananas
prior to sending them to the store. Alternatively, the store
personnel can invert an entire case at a time, place the case in
the display area, remove the straps and lift the top tray and
sleeve off the case, and the bananas are ready for display on the
lower tray. This allows an entire tray of bananas to be displayed
for sale with no further handling. A huge reduction of labor is
thus achieved.
[0009] The container can be used for almost any other merchandise
such as floral products that require lightweight, flexible display
shippers. The size, strength and structure of the container can be
readily modified as desired to suite the product being shipped. It
can be customized to each specific item.
[0010] In one arrangement, embodiments of the innovation relate to
a reusable combined multi-part product shipping box and display
tray. There are two generally rectangular trays, each defining four
sides, with four barrier portions projecting upward from each tray
proximate its edges, one barrier portion at about the center of
each of the sides, and four corner posts, one projecting up from
each corner of the tray. There is also a generally rectangular
sleeve defining four sides and four corners, and open ends that are
about the same size and shape as the trays, the sleeve adapted to
engage with the trays to close its open ends and form a shipping
container, the sleeve adapted to sit on the tray inside of and up
against the barrier portions, with each corner of the sleeve
located outside of and against a corner post, such that the sleeve
is tightly engaged with the trays.
[0011] In one arrangement, the trays are made of plastic and define
an opening just inside of each post and that is sized and shaped to
accept an identical post of another tray, to allow nesting of the
trays. In one arrangement, the sleeve is manufactured of corrugated
plastic and foldable into a flat form. In one arrangement, the
posts are tapered from top to bottom where the bottom of the posts
defines a wall portion that is essentially perpendicular to the top
of the tray. The posts can include two sections at essentially
ninety degrees to one another to form an "L" shaped configuration,
one such section located on each of the two adjacent sides of the
tray, so that each post engages with the two sides of the sleeve
that meet at a corner of the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing and other objects, features and advantages
will be apparent from the following description of particular
embodiments of the innovation, as illustrated in the accompanying
drawings in which like reference characters refer to the same parts
throughout the different views. The drawings are not necessarily to
scale, emphasis instead being placed upon illustrating the
principles of various embodiments of the innovation.
[0013] FIG. 1 is a top perspective view of an embodiment of a tray
for a box assembly.
[0014] FIG. 2 is an exploded view of a sleeve for the box assembly
in the process of being placed on the tray of FIG. 1.
[0015] FIG. 3 is an assembled view of the sleeve and tray of FIG.
2, illustrating the partially-assembled box ready to be filled with
merchandise (such as bananas) that will be shipped in the box.
[0016] FIG. 4 shows the box assembly of FIGS. 1-3 fully assembled,
with a second tray covering the open top of the assembly of FIG. 3;
the Figure does not shown the removable bands or other devices used
to hold the trays and sleeve together after the box has been
filled.
[0017] FIG. 5 is an enlarged side view of one corner of the tray of
FIG. 1, showing the post and barrier detail.
[0018] FIG. 6 is a top view of the die-cut blank used to make the
sleeve shown in FIG. 2-4.
[0019] FIG. 7 is an enlarged view of the undersides of one corner
of two of the trays shown in FIGS. 1-5, detailing the manner in
which such trays nest for storage and shipment.
[0020] FIG. 8 illustrates an arrangement of a sleeve for the box
assembly, according to one arrangement.
[0021] FIG. 9 illustrates an example of a schematic view of sleeve
wall prior to sealing of the ends of the wall, according to one
arrangement.
[0022] FIG. 10 illustrates an example of a schematic view of sleeve
wall following the sealing of the ends of the wall, according to
one arrangement.
DETAILED DESCRIPTION
[0023] As illustrated in FIGS. 1-4, a container or box assembly 10
consists of two substantially identical, injected molded tray, and
one corrugated plastic sleeve that folds flat to minimize the
storage and shipping space required once the box is broken down
into its three parts.
[0024] The trays are relatively lightweight and strong. The trays
are configured to be nested with each other for condensed return
freight efficiencies. Also, each tray includes corner posts that
help to align the corrugated plastic sleeve and locate the sleeve
snugly on the tray. The corner posts include a tapered entry which
transitions to a vertical 90-degree wall, which helps to lock the
sleeve into position and pulls the sleeve sidewalls into a tight,
rigid position for improved sleeve (container sidewall) stacking
strength.
[0025] The trays further include vertical projections or barriers
projecting upward from each of the four edges of the tray. These
barriers limit or inhibit the sidewalls of the sleeve from
expanding beyond the external perimeter of the tray. In one
arrangement, the barriers are located centered on each of the four
sides of the tray, at or close to the edges of the tray. The sleeve
sits inside these barriers and rests up against them by the weight
of the product pushing against the sleeve sidewalls.
[0026] The trays define ventilation holes in the center to provide
weight reduction and top provide cooling and gas applications when
pallets are shipped in the holds of ships, for example. The cooling
gases come up from the floor of the pallet. Also, the trays can
define various additional holes and cutouts in the tray for weight
reduction. Weight control of the combined two trays and sleeve is
important since a full truckload of bananas approaches the legal
limit of weight a truck can safely carry.
[0027] The sleeve can be manufactured from a variety of materials.
For example, the sleeve can be manufactured from corrugated
polypropylene (i.e., plastic), such as 5 mm corrugated
polypropylene, or any malleable material such as corrugated paper,
injection molded plastic or corrugated polyethylene. When
configured from corrugated plastic, the sleeves are relatively
strong, lightweight, and unaffected by moisture or humidity.
Additionally, when made from corrugated plastic, the sleeves can be
machined on specialized machinery at a relatively low cost.
Corrugated plastic can be mass produced at low cost to meet the
volume requirements of a vast market. However, the sleeve could be
made from any other material that has similar properties.
[0028] The sleeve, in one arrangement, has a desired quantity and
size of ventilation holes cut out of the appropriate panels to
provide airflow for cooling and ripening purposes in desired
locations of the assembled box. The sleeve can also include two
handholds at each end. The purpose of having two handholds is that
the box is packed with the bananas crown up and stacked at the
plantation with the bananas oriented in this position, meaning that
they are shipped in this position. When the bananas leave the
ripening rooms, many times the cases are inverted either
individually or entire pallets at a time so the bananas are
orientated crown down for consumer display; this prevents the need
for supermarket personnel to invert each bunch of bananas. Having a
mirror image handhold allows the box of bananas to be conveniently
carried at both the plantation and at the store level.
[0029] The radius on the cut out portion of the handhold can be
included, as it helps reduce tearing associated with having a cut
end on a vertical flute line. Relief may be cut into the length
panel that marries to the glue flap so the sleeve can be put over
the corner posts on the tray. The size of the sleeve and trays can
be easily modified to accommodate different case counts, products
and other desirable variables.
[0030] With reference to FIG. 4, the box assembly or container 10
is made up of two of trays 12, and one sleeve 80. In one
arrangement, the trays 12 are injection molded from a plastic
material having the requisite strength and weight, but could be
made of other materials such as metal. As shown in FIG. 1, tray 12
defines sides 38-41. Projecting corner posts 14 are located
slightly inside of each corner on the top side 50, at a distance
from the edges that is approximately equal to the thickness of
sleeve 80. As further shown in FIGS. 1 and 5, each post 14 defines
integral sections 16 and 18, one located parallel to each of the
edges, and having a length that is approximately related to the
length of the side on which it resides; thus section 16 is longer
than section 18. Both of sections 16 and 18 have an upper tapered
wall portion 20 and a lower vertical wall portion 22. Openings 70
are located just inside of posts 14 and define an open area that is
about the size of the area circumscribed by a post, so that the
trays can be nested for storage and shipment, as shown in FIG. 7.
Trays 12 further comprise four projecting walls or barrier portions
42, one located at about the center of each side of the tray, at
the edge.
[0031] In one embodiment, tray 12 is about 16 by 20 inches, and
posts 14 are about 0.50 inches high. Lower wall portion 22 has a
height of about 0.13 inches. Upper wall portion 20 has a height of
about 0.37 inches, and is tapered inward at a shallow angle.
Barrier portions 42 are about 0.38 inches high and about 4 inches
long. Central opening 62 is about 4 by 6 inches. The outer rim of
the trays has a thickness of about 0.31 inches, and feet 64 and 65
project below the rim by about 0.19 inches. These dimensions are
not critical but are illustrative of a tray that can be used as
part of a box for shipping and displaying bananas, as further
explained herein.
[0032] In one arrangement, the sleeve 80 is die cut from 5 mm thick
corrugated polypropylene material, and defines handle cutouts 92
and openings 94, both located on the short sides of the assembled
sleeve and shown in FIG. 2; more or fewer openings and/or openings
on other of the sleeve sidewalls can be used as desired. In one
arrangement, there are two sets of handle cutouts 92 at each short
side of the assembled sleeve. These mirror-image handle cutouts
allow the assembled box to be easily handled regardless of the
orientation of the box. When used for bananas, for example, the
mirror-image handle cutouts allow the box to be easily handled
whether the product is in the "crown up" or "crown down" positions.
Assembly is accomplished by gluing the end flaps together to create
a joint area. As shown in FIG. 6, the assembled sleeve can be
folded flat along score lines 96-99, as desired. When expanded,
sleeve 80 defines open ends 82 and 83 that are sized and shaped to
fit a tray 12. When box 10 is assembled, trays 12 comprise the
bottom and top, and sleeve 80 defines the box sidewalls 84, 85, 86,
87. One or more strong removable straps of a type known in the art
(not shown in the drawings) are used to keep box 10 fully
assembled, once the product to be shipped and displayed has been
placed into the box.
[0033] Box 10 is used as follows. As shown in FIG. 1, a tray 10 is
placed on a surface with top 50 facing up. As shown in FIGS. 2 and
3, sleeve 80 is placed edge down on tray 12 such that the sleeve
corners are located just outside of posts 14, and the sleeve
sidewalls are located just inside of barriers 42. Upper tapered
post portions 20 help to guide sleeve 80 into place as it is
slipped over the posts, while lower vertical portions 22 help to
hold sleeve 80 squared tightly in place. Barriers 42 help to
prevent the sleeve sidewalls from bowing outward appreciably when
product is placed into the open-top box.
[0034] When sleeve 80 is properly located on tray 12, bananas or
other product being shipped are placed into the container through
open end 82 of sleeve 80, which is the open top of the container.
Bananas are placed in the normal shipping position--crown up. When
the container is sufficiently filled (typically with about 40
pounds of bananas), a second tray 12 is placed upside down on the
open top, with its bottom side 60 facing out, as shown in FIG. 4.
One or more straps or other releasable devices that hold the
assembly together are then placed, and box 10 is ready to be
shipped. Openings 62 and 94 allow for flow of cooling and ripening
gases.
[0035] For retail display, box 10 is flipped over and placed on a
display shelf. The straps are removed. Upper tray 12 and sleeve 80
are removed. This leaves lower tray 12 with product (e.g., bananas)
sitting thereon. Store personnel do not need to lift the bananas
from the box or turn them upward (crown down) for display. In fact,
personnel do not need to handle the bananas in any way.
[0036] Once all of the bananas are sold, the empty trays can be
stacked and placed on pallets for shipment back to the packing
location. Likewise, the sleeves can be folded flat, palletized, and
returned for re-use.
[0037] As indicated above, the sleeve 80 can be manufactured from a
corrugated material, such as a corrugated plastic material. In one
arrangement, as indicated in FIG. 2, the sidewalls 84-87 are
configured with corrugations 91 that extend from a first end 81 to
a second end 83 of the sleeve 80. In such an arrangement, the ends
81, 83 of the sleeve 80 are open to the environment to allow air
and fluid to pass there through. In another arrangement, as
illustrated in FIG. 8, the walls 84-87 at the first end 81 and the
second end 83 of a sleeve 180 are sealed together, to define a set
of sealed flutes 126 within the sleeve 80. Each of the sealed
flutes 126 includes a longitudinal axis extending between the first
end 81 of the sleeve 180 and the second end 83 of the sleeve
80.
[0038] For example with reference to FIG. 9, a wall 84 of the
sleeve 180 includes a first linerboard 120 and a second linerboard
122 spaced apart from the first linerboard 120. The wall 84 further
includes a corrugated sheet 124 disposed between the first and
second linerboards 120, 122. During a manufacturing process, a
manufacturer compresses the linerboards 120, 122 together at both
ends 81, 83 of the sleeve 180 and secures the linerboards 120, 122
to each other at these ends 81, 83. For example, in the case where
the linerboards 120, 122 and corrugated sheet 124 are formed from a
plastic material, the manufacturer can pinch the linerboards 120,
122 together at respective ends 81, 81 and secure the linerboards
120, 122 together using a mechanical coupling, an adhesive, heat,
or an ultrasonic welding process. As indicated in FIG. 10, the
manufacturing process creates a set of sealed flutes 126 within the
wall 84 where each sealed flute 126 contains a volume of air.
[0039] With such a configuration, because the sealed flutes 126
trap air within the wall 84, the sleeve 180 can be manufactured
using less material (e.g., plastic) and can be manufactured with a
greater stacking strength than conventional sleeves. Additionally,
the seal at either end 81, 83 minimizes the introduction of vermin
(e.g., insects) and dirt between the linerboards 120, 122
[0040] While various embodiments of the innovation have been
particularly shown and described, it will be understood by those
skilled in the art that various changes in form and details may be
made therein without departing from the spirit and scope of the
innovation as defined by the appended claims.
* * * * *