U.S. patent application number 15/649463 was filed with the patent office on 2019-01-17 for easy tear boxes.
The applicant listed for this patent is Amazon Technologies, Inc.. Invention is credited to Vishal Bansal, Rohan Sujitkumar Dey.
Application Number | 20190016499 15/649463 |
Document ID | / |
Family ID | 63273036 |
Filed Date | 2019-01-17 |
United States Patent
Application |
20190016499 |
Kind Code |
A1 |
Dey; Rohan Sujitkumar ; et
al. |
January 17, 2019 |
EASY TEAR BOXES
Abstract
A cardboard container includes a removable top tear panel that
when removed enables picking of items from the container and a
removable front tear panel that when removed enables picking of
items from the container. Either or both the top tear panel and the
front tear panel may be removed. The front panel includes an
un-removable, U-shaped lip for inhibiting items from accidental
removal from the container.
Inventors: |
Dey; Rohan Sujitkumar;
(London, GB) ; Bansal; Vishal; (Hertfordshire,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amazon Technologies, Inc. |
Seattle |
WA |
US |
|
|
Family ID: |
63273036 |
Appl. No.: |
15/649463 |
Filed: |
July 13, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/4266 20130101;
B65D 5/6602 20130101; B65D 5/001 20130101; B65D 5/16 20130101; B65D
5/541 20130101; B65D 5/4212 20130101 |
International
Class: |
B65D 5/16 20060101
B65D005/16; B65D 5/00 20060101 B65D005/00; B65D 5/42 20060101
B65D005/42; B65D 5/54 20060101 B65D005/54; B65D 5/66 20060101
B65D005/66 |
Claims
1. A container for shipping and then stowing and picking items, the
container having a cuboid structure and comprising: a removable top
tear panel that when removed enables picking of items from the
container; a removable front tear panel that when removed enables
picking of items from the container, the front panel including an
un-removable, U-shaped lip for inhibiting items from accidental
removal from the container; wherein in a shipping configuration the
container is an enclosed carton and in a picking configuration (i)
containers may be stacked such that a top container in the stack
has the top tear panel and front tear panel removed and such that
lower containers in the stack have only the front tear panel
removed, or (ii) containers may be placed on a shelf where either
or both of the front tear panel and rear tear panel is removed.
2. A container for shipping and then stowing and picking items, the
container having a cuboid structure and comprising: a base wall, a
top wall opposite the base wall, a front wall, and a rear wall
opposite the front wall, an upstanding left sidewall, and an
opposing upstanding right sidewall, the sidewalls (i) spanning
vertically between edges of the base wall and the top wall and (ii)
spanning horizontally between edges of the front wall and the rear
wall; the front wall including a front tear panel and a lip below
the tear panel; the front tear panel bounded by side perforations,
lower perforations that join the front tear panel to the lip, and
upper perforations; the top wall including a top tear panel bounded
by side perforations, rear perforations, and front perforations;
the container being configured such that (i) the top tear panel is
removable by tearing the top panel perforations independent of the
front tear panel, (ii) the front tear panel is removable by tearing
the front panel perforations independent of the top tear panel and
the lip, (ii) the top tear panel and front tear panel are removable
together by tearing at least some of the top panel perforations and
front panel perforations, wherein removal of the top tear panel
and/or front tear panel enables picking items from the
container.
3. The container of claim 2 wherein the lip is U-shaped and
includes (i) a lower edge that merges into the bottom wall and (ii)
opposing side edges that merge into corresponding sidewalls.
4. The container of claim 3 wherein the top tear panel includes
layers, each one of the layers is attached one to one of the rear
wall, left sidewall, right sidewall, and front sidewall at a crease
and perforations.
5. The container of claim 3 wherein the top wall layers include a
left top flap joined to the left sidewall by a crease and top left
flap perforation, and a top right flap joined to the right sidewall
by a crease and a right flap perforation, a top rear flap joined to
the rear wall by a crease and a top rear perforation, and a top
front flap joined to the front wall by a crease and a top front
perforation, whereby the top panel is removable by rupturing the
top left perforation, the top right perforation, the top rear
perforation, and the top front perforation.
6. The container of claim 5 wherein the bottom wall is formed by a
left bottom flap, a right bottom flap, a front bottom flap, and a
rear bottom flap; the left bottom flap is attached to the left
sidewall at an unperforated crease, the right bottom flap is
attached to the right sidewall at an unperforated crease, the front
bottom flap is attached to the front wall at an unperforated
crease, and a rear bottom flap is attached to the rear wall at an
unperforated crease.
7. The container of claim 6 wherein the container is formed from an
unbranded, un-laminated cardboard.
8. The container of claim 7 wherein the container includes a
scan-able label.
9. A method for containing and enabling picking of items in a
container comprising the steps of: in a cuboid, cardboard container
that a pair of sidewalls, a bottom wall, a removable top tear
panel, a rear wall, and a front wall that includes a removable
front tear panel and an un-removable, U-shaped lip; grasping a
bottom of the front tear panel and pulling the bottom of the front
tear panel outwardly to rupture perforations defining the front
tear panel, thereby separating the front tear panel from the top
wall, sidewalls, and lip to form a front opening; and picking items
from the container through the front opening.
10. The method of claim 9 further comprising the step of grasping a
front of the top tear panel and lifting the top tear panel upwardly
to rupture perforations defining the top tear panel, thereby
separating the top tear panel from the sidewalls and the rear wall
to create a top opening that is continuous with the front
opening.
11. The method of claim 9 further comprising the step of stacking
another one of the containers on top of a first one of the
containers.
12. The method of claim 9 wherein the lip is U-shaped and includes
(i) a lower wall that merges into the bottom wall and (ii) opposing
side legs that merge into corresponding sidewalls.
13. The method of claim 12 wherein the step of grasping a bottom of
the front tear panel includes engaging a finger aperture defined
between the front tear panel and the lip lower wall.
14. The method of claim 10 wherein the top wall includes layers,
each one of the layers is attached one to one of the rear wall,
left sidewall, right sidewall, and front sidewall at a crease and
perforations and the step of lifting the top tear panel includes
rupturing the crease and the perforations at the rear wall, left
sidewall, right sidewall, and front sidewall.
15. The method of claim 14 wherein the top wall layers include a
left top flap joined to the left sidewall by a crease and top left
flap perforation, and a top right flap joined to the right sidewall
by a crease and a right flap perforation, a top rear flap joined to
the rear wall by a crease and a top rear perforation, and a top
front flap joined to the front wall by a crease and a top front
perforation, and the step of lifting the top tear panel includes
rupturing the top left perforation, the top right perforation, the
top rear perforation, and the top front perforation.
16. The method of claim 15 wherein the step of grasping a front of
the top tear panel includes engaging a finger aperture in the rear
panel and separating the layers of the top wall at the top left
perforation, the top right perforation, the top rear perforation,
and the top front perforation.
17. The method of claim 9 further comprising the step of scanning a
label on the container.
Description
BACKGROUND
[0001] Containers, such as cardboard boxes, are used in vast
quantities for delivering and storing items. For example, a
cardboard box is often used to hold and transport several products
for shipping to a retailer, which products themselves are housed in
a box. The inner boxes holding the products sometimes are
laminated, branded boxes that are intended for displaying the
product on a shelf in a retail setting. For example, the branded
boxes of some candy products include a perforated front panel and
top panel that can be removed from its base and sidewalls such that
an end purchaser can grasp the product and remove it from the box.
Typically, the removable front panel and top panel together form a
unitary combination. Alternatively, in some configurations only the
top portion of the retail box is removable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a front perspective view of a container
illustrating aspects of the present invention;
[0003] FIG. 2 is rear perspective view of the container of FIG.
1;
[0004] FIG. 3 is top view of a die cut sheet used for forming the
container of FIG. 1;
[0005] FIG. 4 is a perspective view of the container of FIG. 1
illustrating the opening process for a front tear panel; and
[0006] FIG. 5 is a perspective view of the container of FIG. 4
illustrating the opening process for a top tear panel.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0007] A container disclosed herein is versatile, as it has a
configuration in which it is a cuboid carton and additional
configurations to enable it to stow items for picking. In this
regard, container has a configuration in which its top wall is
removed, another configuration in which its front wall is removed,
and yet another configuration in which both its top wall and its
front wall are removed. The removability of the top wall and/or
front wall enables the items within the box to be stowed and picked
by a human or robotic arm. The front wall includes a lip that
restrains or inhibits items from falling out or being inadvertently
knocked out of the open front wall.
[0008] Thus, the container may include: a removable top tear panel
that when removed enables picking of items from the container and a
removable front tear panel that when removed enables picking of
items from the container. The front panel includes an un-removable,
U-shaped lip for inhibiting items from accidental removal from the
container. Thus, in a shipping configuration the container is an
enclosed carton and in a picking configuration (i) containers may
be stacked such that a top container in the stack has the top tear
panel and front tear panel removed and such that lower containers
in the stack have only the front tear panel removed, or (ii)
containers may be placed on a shelf where either or both of the
front tear panel and rear tear panel is removed.
[0009] According to another aspect, the container includes: a base
wall, a top wall opposite the base wall, a front wall, and a rear
wall opposite the front wall, an upstanding left sidewall, and an
opposing upstanding right sidewall. The sidewalls (i) span
vertically between edges of the base wall and the top wall and (ii)
span horizontally between edges of the front wall and the rear
wall. The front wall includes a front tear panel and a lip below
the tear panel. The front tear panel is bounded by side
perforations, lower perforations that join the front tear panel to
the lip, and upper perforations. The top wall including a top tear
panel bounded by side perforations, rear perforations, and front
perforations. The container is configured such that (i) the top
tear panel is removable by tearing the top panel perforations
independent of the front tear panel, (ii) the front tear panel is
removable by tearing the front panel perforations independent of
the top tear panel and the lip, (ii) the top tear panel and front
tear panel are removable together by tearing at least some of the
top panel perforations and front panel perforations. Thus, removal
of the top panel and/or side panel enables picking items from the
container.
[0010] FIGS. 1 and 2 illustrate a preferred embodiment of a
container 10. FIG. 3 illustrates the die cut sheet 10' of cardboard
for forming container 10. Preferably, container 10 is formed on a
conventional cardboard, such as EB flute, such that container 10 is
suitable for transporting products up to 5 kg, and in some
circumstances up to 10 kg.
[0011] Container 10 includes a bottom wall 12, a top wall 14, a
front wall 20, a rear wall 50, and left and right sidewalls 80L and
80R. The orientations top, bottom, left, and right are referred to
according to viewing front wall 20 while container 10 is in its
as-used state, with bottom wall 12 resting on a surface.
[0012] As best shown in FIG. 3, top wall 14 in the embodiment shown
in the figures is formed by a top front flap 22, a top rear flap
52, and top left and top right flaps 82 L and 82R. Top front flap
22 is joined to front sidewall 20 at a top front crease 24. Top
rear flap 52 is joined to rear wall 50 at top rear crease 54. Top
left and right flaps 82L and 82R are joined to sidewalls 80L and
80R by top left and top right creases 84L and 84R. Thus, flaps 22
and 52 are folded at creases 24 and 54 such that distal edges of
flaps 22 and 52 are closely spaced apart by a few millimeters such
that flaps 22 and 52 form a layer of top wall 14. And flaps 82L and
84R are folded at creases 84L and 84R such that the distal edges of
flaps 82L and 84R are spaced apart by a few millimeters and such
that flaps 82L and 82R form another layer of top wall 14.
[0013] Bottom wall 12 in the embodiment shown in the figures is
formed by a bottom front flap 46, a bottom rear flap 76, and bottom
left and bottom right flaps 86L and 86R. Bottom front flap 46 is
joined to front sidewall 20 at a bottom front crease 48. Bottom
rear flap 76 is joined to rear wall 50 at bottom rear crease 78.
Bottom left and right flaps 86L and 86R are joined to sidewalls 80L
and 80R by bottom left and bottom right creases 88L and 88R. Thus,
flaps 46 and 76 are folded at creases 48 and 78 such that distal
edges of flaps 46 and 76 are closely spaced apart by a few
millimeters and such that flaps 46 and 76 form a layer of bottom
wall 12. And flaps 86L and 86R are folded at creases 88L and 88R
such that the distal edges of flaps 86L and 86R are spaced apart by
a few millimeters and such that flaps 86L and 86R form another
layer of bottom wall 14. All flaps are separated by cuts 92.
[0014] Preferably, front wall 20, rear wall 50, and sidewalls 80L
and 80R are single sheets of cardboard. The present invention is
not limited to the particular configuration of the sheets described
herein, as a person familiar with carton technology will understand
that several configurations are understood in the field.
[0015] Four vertical creases 90 connect front wall 20, sidewalls
80L and 80R, and rear wall 50 together. In this regard, a glue tab
94 extends from one of the walls (the rear wall 50 as oriented in
the figures) to provide a gluing surface to join the box together.
The present invention is not limited to the particular means for
joining the box, and the present invention encompasses any types of
adhesive, tape, or other means.
[0016] Several perforations and cutouts provide functionality to
container 10. A top front perforation 25 is located coextensive
with or near top front crease 24. Preferably top front perforation
25 is discontinuous, as explained more fully below. A top rear
perforation 55 is located coextensive with or near top rear crease
54. Top rear perforation is interrupted near its center by a rear
tab 68, as explained more fully below. And top side perforations
85L and 85R are located coextensive with or near top left and top
right creases 84L and 84R. Perforations 25, 55, and 85L and 85R
preferably are in or near the corresponding creases to maximize the
open area when the top tear panel is removed. The term
"perforation" is broadly used herein to refer to intermittent
partial or though-cuts or scoring or like features to facilitate
tearing along the line.
[0017] Front wall 20 includes a lip 28 and a tear panel 30. Lip 28
is a U-shaped, un-removable portion of front wall 20 (that is,
there are no perforations that facilitate lip 28 to be removed from
the container.). Lip 28 includes a horizontal portion 32 that
extends laterally between creases 90 that merge into sidewalls 80L
and 80R and a pair of opposing lift and right sides or legs 34L and
34R. Legs 34L and 34R terminate at upper lips or ends 36L and 36R,
and the outboard sides of legs 34L and 34R terminate at vertical
creases 90 that merge into sidewalls 80L and 80R.
[0018] Tear panel 30 is separated from lower portion 32 of lip 28
by a bottom tear panel perforation 40a, is separated from legs 34L
and 34R by a pair of opposing perforations 40b, and is separated
from tear panel upper lips 36L and 36R by upper lip perforations
40c. A pair of opposing perforations 40e extend from the outboard
ends of top front perforation 25 to the outboard ends of lip
perforations 40c. The upper boundary of tear panel 30 is formed by
top front perforation 25 and a tab perforation 96. An upper tab 38
is formed by tab perforation 96 and is by a portion of top front
crease 24. A lower perforation 40d, which may also be a cutout,
forms a finger access 42.
[0019] Rear tab 68 preferably is formed by a rear tab perforation
70, and tab 68 is joined to top rear flap 82 by top rear crease 55
such that tab 68 is free from rear wall 50 upon rupturing of
perforation 70.
[0020] Top panel 60 is formed by top rear perforation 55, top side
perforations 85L and 85R, top front perforation 25 and rear tab
perforation 70. In this regard, when desired to remove to panel 60,
a user may insert his finger into a finger hole 98 which aides in
pulling upwardly on rear tab 68 to rupture rear tab perforation 70,
as illustrated in FIG. 5. Additional upward pulling propagates the
rupture through top rear perforation 55. A user may continue to
rupture top side perforations 85L and 85R and top front perforation
25 until the top of container 10 is open and the items within
container 10 are accessible from above.
[0021] When desired to remove front panel 30, a user may insert a
finger into aperture 42 and pull upwardly on tear panel 30 to
rupture perforations 40a, 40b, 40c, 40e, 25, and 96 to free front
tear panel 30 from the remainder of container 10, as best shown in
FIG. 4.
[0022] In circumstances in which containers 10 are stacked, it is
preferable that only the front tear panels 30 of the containers in
the stack are removed to provide vertical stacking strength to the
containers, if needed. The top container 10 in the stack, of
course, may have either or both its tear panels 30 and 60 removed,
as there is no top load on the uppermost container 10. In
circumstances in which a container is placed on a shelf, it is
preferably that front tear panel 30 is removed and top tear panel
60 may optionally be removed if desired by the particular
application.
[0023] During the process of removing items from container 10. Lip
28 inhibits articles from inadvertently falling or being knocked
out of container 10. In this regard, leg width D1, bottom lip
height D2, and dimension D3 (which is the distance that lip ends
36L and 36R are spaced apart from top flap 22, and therefore
determines the height of legs 34L and 34R) may be chosen depending
on the other box dimensions and based on the sizes of items desired
to be inducted into the and picked out of the box. Dimensions D4
and D5 of finger aperture 42 and dimensions of finger aperture 98
(not called out in the figures) and rear tab dimensions D6 and D7,
which preferably are similar to front tab dimensions (not called
out in the figures for clarity) may be chosen according to
conventional ergonomic principles, as will be understood by persons
familiar with carton technology. The dimensions of lip 38 and lip
surface 32 may be chosen such that taping for holding the box
together has a surface on which to grip.
[0024] Container 10 is suited for shipping items, and then stowing
the items after receipt of container 10 while container 10 is its
open configuration--that is, while either or both of tear panels 30
and 60 are removed--to enable picking of items from container 10 by
either a human or a robot. Container 10 thus preferably is not
laminated or branded but conventional single ply or double ply
corrugated paperboard or cardboard with a one dimensional or two
dimensional code or other identifying, machine-readable indicia.
The term "cardboard" is used herein broadly to refer to any type of
corrugated paperboard, fiberboard, and like carton material.
[0025] The dimensions of carton 10 are reflected in FIG. 3 as
overall length L1 and height H2. Length L1 is the sum of wall
widths L2, L3, L4, and L5. As box is rectangular, lengths L2 and L4
of the front and rear walls should be the same, and lengths L3 and
L5 of the sidewalls should be the same, except for minor variations
to accommodate folding if needed. Upper and lower flap heights H3
and H4 should sum to approximately the smallest of L2, L3, L4, and
L5 (allowing for a few millimeters clearance when folded) such that
when flaps 22, 52, 82L and 82R are folded, they can be glued,
taped, or otherwise joined effectively. The specific dimensions of
the dimensions, lengths, and widths can be determined according to
the desired characteristics of the box and the items contained. For
merely one example, L1 may be 1693 mm, L2 and L4 may be 393 mm, L3
may be 442 mm, L5 may be 439 mm, H1 may be 699 mm, H2 may be 307
mm, H3 and H4 may be 196 mm, D1 may be 45 mm, D2 may be 50 mm, D3
may be 234 mm (making leg height 73 mm), D4 may be 25 mm, D5 may be
50 mm, D6 may be 55 mm, and D7 may be 60 mm.
[0026] The present invention has been described using one
particular example of a container. The present invention is not
intended to be limited to any structure described above, such as
but not limited to the shapes or sizes of the tear panels, the
configuration and orientation of the flaps and walls, specific
materials, the shapes and sizes of the overall box, and the like,
unless specifically set out in the claims.
* * * * *