US20060266672A1 - Recyclable package - Google Patents
Recyclable package Download PDFInfo
- Publication number
- US20060266672A1 US20060266672A1 US11/135,684 US13568405A US2006266672A1 US 20060266672 A1 US20060266672 A1 US 20060266672A1 US 13568405 A US13568405 A US 13568405A US 2006266672 A1 US2006266672 A1 US 2006266672A1
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- United States
- Prior art keywords
- package
- inner box
- product
- window
- tray member
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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- 229920003023 plastic Polymers 0.000 claims abstract description 6
- 239000004033 plastic Substances 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 21
- -1 polyethylene terephthalate Polymers 0.000 claims description 11
- 239000000853 adhesive Substances 0.000 claims description 9
- 230000001070 adhesive effect Effects 0.000 claims description 9
- 239000004743 Polypropylene Substances 0.000 claims description 7
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 7
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 7
- 229920001155 polypropylene Polymers 0.000 claims description 7
- 239000004814 polyurethane Substances 0.000 claims description 6
- 229920002635 polyurethane Polymers 0.000 claims description 5
- 239000004823 Reactive adhesive Substances 0.000 claims description 4
- 239000004927 clay Substances 0.000 claims description 4
- 229920001684 low density polyethylene Polymers 0.000 claims description 4
- 239000004702 low-density polyethylene Substances 0.000 claims description 4
- 239000007844 bleaching agent Substances 0.000 claims description 3
- 239000011087 paperboard Substances 0.000 claims description 2
- 238000003780 insertion Methods 0.000 abstract description 11
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- 239000000047 product Substances 0.000 description 59
- 238000010276 construction Methods 0.000 description 4
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D77/00—Packages formed by enclosing articles or materials in preformed containers, e.g. boxes, cartons, sacks or bags
- B65D77/04—Articles or materials enclosed in two or more containers disposed one within another
- B65D77/0413—Articles or materials enclosed in two or more containers disposed one within another the inner and outer containers being rigid or semi-rigid and the outer container being of polygonal cross-section formed by folding or erecting one or more blanks, e.g. carton
- B65D77/0433—Articles or materials enclosed in two or more containers disposed one within another the inner and outer containers being rigid or semi-rigid and the outer container being of polygonal cross-section formed by folding or erecting one or more blanks, e.g. carton the inner container being a tray or like shallow container, not formed by folding or erecting one or more blanks
Definitions
- 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.
- 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.
- 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.
- 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.
- a package 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- a package 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.
- 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.
- 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;
- 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
- FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 2 ;
- FIG. 4 is a detail view of a preferred embodiment of a foot support member suitable for use in the package of the invention
- 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
- 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;
- 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
- FIG. 8 is a top perspective view of another preferred embodiment of the tray member of the invention.
- 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;
- 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;
- 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;
- FIG. 12 is a cross-sectional view taken along line 12 - 12 of FIG. 1 1 ;
- FIGS. 13 a, 13 b and 13 c are cross-sectional views taken along line 13 - 13 of FIG. 10 that depict alternative embodiments for the structure of the inner box;
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 .
- 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.
- 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 .
- inner box 12 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.
- PET polyethylene terephthalate
- 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.
- 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 .
- the flaps 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.
- 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.
- 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.
- tray member 14 is preferably substantially transparent, and is most preferably thermoformed from a polymeric sheet of substantially transparent low density polyethylene or PET.
- 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 .
- 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 .
- 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 .
- 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 .
- 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.
- tray member 14 and inner box 12 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 .
- 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.
- 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.
- 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 .
- outer box 64 is further described and explained in relation to FIGS. 2, 4 and 5 .
- outer box 64 is also formed by folding and sealing a die-cut, substantially transparent, recyclable polymeric sheet, most preferably comprising clear polypropylene.
- 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 .
- 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.
- 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.
- 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.
- 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 .
- 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 .
- FIG. 14 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 .
- 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.
- 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.
- 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 .
- 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.
- 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.
- 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 .
- FIGS. 13 a, 13 b and 13 c 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 .
- the free edge of folded section 174 contacts bottom wall 176 near the edge of window 178 .
- folded section 180 terminates in a folded flange 181 that can be glued or otherwise sealed to bottom wall 182 near window 184 .
- 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.
- 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.
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Abstract
Description
- 1. Field of the Invention
- 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.
- 2. Description of Related Art
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- The apparatus of the invention is further described and explained in relation to the following drawings wherein:
-
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; -
FIG. 2 is a top perspective view showing the elements ofFIG. 1 assembled prior to insertion into the transparent outer box member to form one preferred embodiment of the invention; -
FIG. 3 is a cross-sectional view taken along line 3-3 ofFIG. 2 ; -
FIG. 4 is a detail view of a preferred embodiment of a foot support member suitable for use in the package of the invention; -
FIG. 5 is an enlarged top perspective view, partially broken away, of the closed end of the outer box member ofFIG. 2 , illustrating a preferred placement of the foot support members on one side of the package of the invention; -
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; -
FIG. 7 is a top perspective view showing the elements ofFIG. 6 assembled prior to insertion into the transparent outer box member to form the second embodiment of the invention; -
FIG. 8 is a top perspective view of another preferred embodiment of the tray member of the invention; -
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 toFIG. 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; -
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; -
FIG. 11 is a top perspective view showing the elements ofFIG. 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; -
FIG. 12 is a cross-sectional view taken along line 12-12 ofFIG. 1 1; -
FIGS. 13 a, 13 b and 13 c are cross-sectional views taken along line 13-13 ofFIG. 10 that depict alternative embodiments for the structure of the inner box; -
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 -
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. - 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 toFIGS. 6 and 7 , and other preferred embodiments of the invention are described in relation toFIGS. 8-15 . In general terms, referring first toFIG. 2 ,recyclable package 10 preferably comprisesinner box 12 havingtray member 14 disposed inside a window that is die cut into upwardly facingmajor surface 18. Aproduct 16 is depicted in phantom outline as being disposed inside one of two distinct recesses insidetray 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 anotherproduct 16 would be similarly disposed inside the empty recess if the tray is made as shown. Onceproducts 16 are placed insidetray member 14,inner box 12 is slidably inserted into the open end ofouter box 64, after whichouter 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. - Although
package 10 is depicted without graphics in the accompanying drawings, it should be appreciated that any or all surfaces ofinner box 12 orouter 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 oftray member 14, or the plastic sheet used in makingouter box 64 can be inside or outside printed as desired. Text and graphics printed on the outwardly facing surfaces ofinner box 12 will desirably remain visible throughouter box 64 afterinner box 12 is sealed inside the outer box to completerecyclable package 10. It should also be appreciated that the number and shape oftray members 14 and the number and shape of product recesses inside eachtray member 14 can vary within the scope of the invention. -
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 fabricateinner box 12 be relatively inexpensive, foldable or easily erectable, and have printable outwardly facing surfaces. The material used to makeinner box 12 will desirably be rigid enough to maintain its shape when a sheet of the material is die cut and folded to produceinner box 12, and wheninner box 12 is subsequently inserted intoouter box 64. When corrugated material is used to makeinner 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 makinginner 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 makingpackage 10, but is more likely to shatter, particularly at low temperatures. - The component parts of
package 10 are now further described in relation to all ofFIGS. 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 18, 20, each having major outwardly facing surfaces,bottom walls 26, 28,side walls 30, 32, and upper andend walls 22, 24 that are desirably aligned to render both the top and bottom oflower windows product 16 visible in assembledpackage 10. 34, 36, and other flaps similarly positioned on the two inside portions ofFlaps window 22 that are not visible inFIG. 1 , are preferably hinged to the edges ofwindow 22. When the flaps are folded down into the interior ofinner box 12 as shown inFIG. 1 , they lend support totop wall 18 and assist in positioning and stabilizingtray 14, which is insertable into the window. Alternatively, as discussed in greater detail below in relation toFIGS. 13 a-13 c, 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. - An aperture such as
finger hole 38 is desirably provided inend wall 36 to assist assembly personnel in insertinginner box 12 intoouter box 64 and to assist consumers in removinginner box 12 fromouter box 64 following purchase ofpackage 10.Apertures 38 also facilitate the pass-through of air out of or into the sealed end ofouter box 64 asinner box 12 is inserted or removed, respectively. - 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 fortray member 14 permits the underside ofproduct 16 to be viewed throughwindow 24 on the bottom ofinner box 12 whentray member 14 is disposed insidetop window 22 as shown inFIG. 2 .Tray member 14 further comprises 42, 44, 46, 48 surrounding dividedside walls 60, 62. Thermoformed positioning blocks 56, 58 andbottom sections 42, 54 are desirably provided to positioninclined surfaces products 16 inside the two recesses in such manner that they do not abut against each other or against 42, 44. If desired, a continuous divider can be provided as shown between positioning blocks 58 ofsidewalls tray member 14 inFIGS. 1 and 2 , or positioning blocks 58 can be completely separate, as shown fortray member 14′ inFIG. 8 . Whentray member 14 is constructed as shown inFIGS. 1 and 2 or as shown inFIG. 8 , both sides ofproduct 16 are visible even whenpackage 10 ofFIG. 2 is fully assembled and sealed. Outwardly facingflange 50 is desirably provided around the top of at least part of the sidewalls to provide additional structural rigidity totray member 14 and to position and stabilizetray member 14 relative towindow 22 ofinner box 12. - Referring to
FIG. 3 , it is seen that inwardly folded sidewalls 26, 28 ofinner box 12 cooperate with the sidewalls, 60, 62 andbottom sections flange 50 oftray member 14 to produce a stable unit capable of supportingproduct 16 prior to the insertion ofinner box 12 intoouter box 64 as shown inFIG. 2 to completepackage 10. Although the end flap construction ofinner 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 ofinner box 12 andtray member 14 can vary as desired. - The height or thickness of
tray member 14 andinner box 12, as distinguished from their respective gauges or wall thicknesses, are preferably such that the thickest part ofproduct 16 as positioned insidetray member 14 will not extend more than about one-eighth inch (0.125″) above the top offlange 50 whenproduct 16 is fully seated insidetray member 14 andtray member 14 is fully seated insideinner box 12. Most preferably,product 16 will extend about one-sixteenth inch aboveflange 50 to exert slight pressure againstouter box 64 after insertion, and to facilitate grasping ofproduct 16 by the consumer for removal fromtray member 14 following purchase. - Although
product 16 is depicted as a rectangular solid in the drawings, it should be appreciated that the products sealed inpackage 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 insidetray member 14, provided thattray member 14 is at least as deep as the tallest or thickest portion of the product or products as positioned insidetray member 14. - The construction of
outer box 64 is further described and explained in relation toFIGS. 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. Althoughouter box 64 is preferably preformed with an open end to await insertion ofinner box 12, it will be appreciated that, if desired,outer box 64 can also be formed aroundinner box 12 ifinner box 12 is properly positioned on a die-cut (and possibly scored) blank suitable for use in makingouter box 64. As shown,outer box 64 comprises top and 92, 94,bottom walls closed end wall 66,open end 68 having side flaps 74, 76, top and 70, 72,bottom flaps sidewall 102, and a second sidewall made by closing and sealing 78, 80. Adhesive seals 82, 84 are provided to permanently seal the side and ends offlaps 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. - If desired, sombrero-shaped
97, 99 and 96, 98, or functional equivalents, can be provided inapertures inner box 12 andouter box 64, respectively, to render the packages “peggable,” and die- 88, 90, 100 can be included for use in standingcut support feet package 10 upright on one end for display purposes. Referring toFIGS. 4 and 5 ,support foot 88 can be formed by die-cutting 104, 106 alongcircular apertures fold line 110 between top 92 andend wall 66, and by die-cutting an offsetslot 108 between the apertures to form an outwardly extending tab that serves assupport foot 88 whenend wall 66 is sealed. Referring toFIG. 9 , the slot disposed beneathsupport foot 88 provides a convenient point of entry so that, following purchase, a hand-heldcutting 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 beneathtop 92 ofouter box 64. - Referring to
FIGS. 6 and 7 , another recyclable, tamperresistant package 116 is disclosed that comprisesinner box 112 made as previously described forbox 12, andouter box 114 made as previously described forouter box 64, but does not comprise a tray member as disclosed above.Inner box 112 comprises top and 118, 120,bottom walls 122, 124 and end walls such assidewalls wall 126, which further comprisesaperture 136. 138, 140 are preferably nested inside windows such asProducts window 130 intop wall 118, which is surrounded by inwardly folded 132, 134.flaps Inner box 112 is insertable into the open end ofouter box 114, after which end flaps 142, 144 and their opposed counterparts are folded and permanently sealed to form tamperresistant package 116. Here again, although shown in relation to an embodiment where 138, 140 are square or rectangular, it will be appreciated that products having other shapes can also be packaged using the present invention.products FIG. 14 , for example, depicts aninner box 224 having acircular recess 226 suitable for use with a product having a circular perimeter.Package 116 differs frompackage 10 in that it lacks the bottom or side product visibility that is provided bypackage 10. - 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 138, 140, particularly whereproducts 138, 140 are relatively heavy. For example,products FIG. 15 depicts one such preferred support for use in a corrugated box, whereinunitary brace member 230 is folded inwardly from the backside ofinner box 150 to provide additional structural support to the inner box and to the product displayed in it. -
FIGS. 10-12 illustrate another preferred embodiment of the invention comprising aninner 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 toFIG. 10 ,inner box 150 comprises top 156 and bottom 158 comprising product-viewing 160, 162, respectively. Hinged,windows 164, 166, which are matched by flaps that are not visible on the opposed sides, are provided as described above in relation tofoldable flaps FIG. 1 .Aperture 172 is provided inend wall 168 to facilitate insertion into anouter box 64′ as shown inFIG. 11 . -
Form tray member 152 is made as previously described fortray 14, and comprisesbottom wall 202, 204, 206, endside walls 208, 210, and positioning blocks 214, 216 adapted to provide spacing at the sides and corners, respectively, betweenwalls product 154 and the end and side walls of the tray.Tray member 152 differs fromtray member 14 in that 213, 212 are provided inslots bottom wall 202 closely adjacent to the bottom of 208, 210, respectively, to allow a header card of a prepackaged product to extend beyond the tray walls, but remain inside the walls ofend walls outer box 64′ as shown inFIG. 11 . Such slots are desirably positioned where they can be die cut or otherwise formed in the bottom wall oftray member 150, and the position of the slots will depend upon howheader card 155 ofprepackaged product 154 is oriented intray member 150 or another tray. As shown inFIGS. 10-12 , side-positioning blocks 214 are desirably configured to receive the header card of oneprepackaged product 154 between them, while the header card of the other product extends throughslot 213 and into the interior space behind the associated wall ofwindow 160. 220, 222 inRecesses FIG. 1 correspond to the underside of the thermoformed side and end positioning blocks 214, 216, respectively. - Once
tray member 152 is installed ininner box 150 andproducts 154 are installed intray member 14,package 151 is assembled by slidinginner box 150 intoouter box 64′ and thereafter sealing and previously described in relation to the embodiment ofFIGS. 1-5 . -
FIGS. 13 a, 13 b and 13 c depict alternate embodiments for the construction ofinner box 150 ofFIGS. 10-12 . These alternate embodiments provide greater structural support and rigidity than do the hinged flaps shown inFIG. 10 . InFIG. 13 a, the free edge of foldedsection 174 contactsbottom wall 176 near the edge of window 178. InFIG. 13 b, foldedsection 180 terminates in a foldedflange 181 that can be glued or otherwise sealed tobottom wall 182 near window 184. InFIG. 13 c, foldedsection 186 is joined to another foldedsection 187 that is turned under and contacts the inside ofwall 188 while lying onbottom wall 190 outwardly of window 200. The use of window wall configurations such as these is particularly preferred for use with relatively heavy products. - 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. - 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.
Claims (36)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/135,684 US20060266672A1 (en) | 2005-05-24 | 2005-05-24 | Recyclable package |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/135,684 US20060266672A1 (en) | 2005-05-24 | 2005-05-24 | Recyclable package |
Publications (1)
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|---|---|
| US20060266672A1 true US20060266672A1 (en) | 2006-11-30 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US11/135,684 Abandoned US20060266672A1 (en) | 2005-05-24 | 2005-05-24 | Recyclable package |
Country Status (1)
| Country | Link |
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| US (1) | US20060266672A1 (en) |
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