US20060054676A1 - Easy open container - Google Patents

Abstract

There is provided a shipping container and methods of manufacturing a shipping container that may be opened using a tear strip to sever a cover portion of the container from a tray portion of the container. The container is preferably formed from corrugated cardboard that includes an outer layer, an inner liner, and a corrugated medium disposed between the outer layer and the inner liner. The tear strip is preferably located on the inside of the inner liner, beginning at the glue flap. The outer layer, but not the corrugated medium or the inner liner, has a division to facilitate pulling the tear strip through the container to separate the cover from the tray portion. During manufacture, the inner liner and the corrugated medium are adhered to one another, and the outer layer is provided in two separate pieces that are adhered to the corrugated material, leaving a slit or a space between the two separate portions. The tear strip is then adhered to the inside area of the inner liner adjacent to or above the area where the slit is provided.

Description

• This application claims the benefit of U.S. Provisional Application No. 60/601,269, filed Aug. 13, 2004, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
• The present invention relates to shipping containers and methods of manufacturing shipping containers that may easily be converted to display containers. The containers are provided with a tear strip that does not rip the outermost layer of the container, allowing graphics to remain intact, preventing a ragged edge, and allowing the container to be easily opened while still protecting the contents during shipping.
BACKGROUND
• It is often desirable for shipping containers to be converted to display trays at a retail point of sale, avoiding the need to unpack the product from a shipping container and restack it in a separate display tray. Often, display/shipping containers are opened by removing a tear strip that is embedded in (or provided on the inside layer of) the shipping container upon arrival of the container at the retail point of sale, allowing a portion of the container to be removed and display the remaining product in a portion of the container.
• For example, the top (or cover) of the container may be removed while the product sits in the bottom (or lower tray) on a store shelf or display unit. These containers have a removable tear strip of cardboard that encircles a portion of the container. Removal of the strip releases the top portion of the container.
• Such tear strips are problematic, however, because the cardboard does not always tear evenly, or rips off before being fully removed, requiring the use of a knife to finish opening the container. If a knife is used, the product in the container may be damaged during opening if the knife inadvertently penetrates the packaged product during opening, rendering the damaged product useless. The use of knives may also result in cutting an uneven edge on the display container, causing the display to look sloppy and undesirable.
• The use of typical tear strips is also problematic because the removal of the tear strip often causes the outermost portion of the resulting display tray to be torn or otherwise damaged. Again, this results in an unattractive display tray that is not suitable for displaying product at a retail point of sale. This may result in the need to remove and re-arrange the contents of the container, occupying valuable employee time, negating the benefits of using the tear strip in the first place, and requiring additional storage units for the product (e.g., if the product is not being restocked onto a shelf but onto a separate display unit).
• Another problem with typical tear strips is that a relatively large amount of effort may be required to remove them because the tear strip is applied to the inside of the container. The tear strips are typically embedded between multiple layers of corrugated material and other outer and inner box layers, requiring the user to use a substantial amount to force to remove the strip. This force may cause the tear strip itself to rip off before the container is actually opened. Tear strips can also be difficult to predict and may tear a substantial portion of the display tray, particularly the outer layer, which is typically the portion that displays graphics and preferably presents a pleasing, finished edge,
• Some manufacturers have attempted to solve these problems by forming the corrugated material and then perforating the outer layer, presumably to make the container easier to open. This attempted solution has actually presented a number of additional problems. First, a perforated outer layer does not provide a clean edge when the tear strip is removed. Graphics are still damaged and run the risk of being delaminated. Second, the act of perforating the outer layer necessarily causes damage to the corrugated flutes underneath the layer. For example, the flutes can be crushed from the pressure of the cutting machine or they may be nicked or cut themselves during the cutting process. Damage to the corrugated flutes causes the structural integrity of the container to weaken. Accordingly, these solutions are not sufficient.
• Other manufacturers have sought to develop containers that have two portions that can be separated, but without using tear strips at all, in an attempt to prevent some of these problems. For example, one option has been to use an adhesive to attach two separable halves of a container. Another option has been to use a piece of wide tape with an embedded filament that holds the two halves together. Removing the filament separates the two halves, allowing the container to be opened to display product. However, removal of the filament requires tearing through the wide tape, which may result in the display tray having an unattractive appearance due to the edges of the torn wide tape that remain on the tray and are visible. Such unattractive display trays are not suitable for displaying product at a retail point of sale.
• As discussed, many systems for opening boxes have been developed that use tear strings, adhesive, and other securing mechanisms. In corrugated boxes, the string must tear through the paper liners and corrugated medium. This often results in a ragged edge being left and the de-lamination of the outside liner. With the introduction of new paper to meet the ECT standards, the tear quality has become even worse. If an adhesive is used, there exists some concern about the securing and integrity of the container prior to its being opened. Consequently, there exists a need for a tearing system that will tear cleanly, maintain most of the box strength, and yet be economical to manufacture. It is important to retailers that a shipping container can be easily opened, without requiring a knife or other tools, but that it also attractively displays a product at a retail point of sale once opened. It is also important to be able to include, and protect, graphics, such as advertisements, on the display portion of the tray. Various embodiments and aspects according to the present invention provide one or more, and sometimes combinations, of these aspects.
SUMMARY
• There is provided a shipping container and methods of manufacturing a shipping container that may be opened using a tear strip to sever a cover portion of the container from a tray portion of the container. The container is preferably formed from corrugated cardboard that includes an outer layer, an inner liner, and a corrugated medium disposed between the outer layer and the inner liner. The tear strip is preferably located on the inside of the inner liner, beginning at the glue flap. In certain embodiments, the glue flap has a die cut portion that may be used as a pull tab. Additionally, the one of the body panels (and preferably the last body panel) of the container has another die cut portion that covers the pull tab and tear strip. The outer layer, but not the corrugated medium or the inner liner, is provided in at least two separate pieces (for example, from two different rolls, in two different materials, or from a single sheet that is severed) such that the outer layer has a division to facilitate pulling the tear strip through the outer layer to separate the cover from the tray portion.
• In order to manufacture a container having such a divided or severed outer layer and tear strip, the inner liner and the corrugated medium are adhered to one another, and then the outer layer is applied separately to the corrugated material, leaving a slit or a space between the two separate outer layer portions. A tear strip is then adhered to the inside area of the inner liner adjacent to or above the area where the slit is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1A shows a side perspective view of a container according to one embodiment of this invention.
• FIG. 1B shows a side perspective view of another embodiment of a container having a pull tab and a flap separated from the body of the container.
• FIG. 2A shows a top view of a blank that may be used to manufacture containers according to certain embodiments of this invention.
• FIG. 2B shows the opposite side of the blank ofFIG. 1.
• FIG. 3 shows a cross-sectional view of one embodiment of the material used to make a container according to certain embodiments of this invention.
• FIG. 4 shows a tray of a container in use.
• FIG. 5 shows a container according to certain embodiments of the invention being opened.
• FIG. 6 shows a container according to certain embodiments of the invention after being opened.
• FIG. 7 shows a container according to alternate embodiments of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
• Various embodiments of aspects of this invention provide ashipping container10 that may easily be converted to a display container with minimal effort, while also providing an attractive display unit without ragged and rough edges. As shown inFIG. 1,container10 includes abody portion12 with alower tray14 and acover16. Thelower tray14 and cover16 are separated by adivision18 and atear strip20.
• Generally, certain embodiments include a container10 (or corrugated box) having aninner liner32, a corrugated (or fluted) middle material ormedium36, and anouter layer34. (Although single walled corrugated material will be described throughout this application, it should be understood that various aspects of the invention may be used with materials having multiple layers of corrugated material separated by inner liners, such as double and triple walled corrugated material, each having more than one layer of corrugated material separated by inner liners.)
• Attached to the inside of theinner liner32 is atear strip20. Theoutside layer34 is provided in at least two separate pieces (for example, from two different rolls, in two different materials, or from a single sheet that is severed). This dividedouter layer34 provides anupper portion70 of the outer layer that forms acover16 of thecontainer10 and alower portion72 of the outer layer that forms atray14 once thetear strip20 is removed.
• As shown inFIGS. 2A and 2B, thebody portion12 is made up of a series of panels, such aswall panels26,end flap panels28, and aglue flap38. (Note that the glue flap need not have upper and lower flaps, although it may, if desired.) Thewall panels26 form thesides40 of container10 (as shown inFIG. 5), and theend flap panels28 fold over one another to form the top42 and bottom44 of thecontainer10, also shown inFIG. 5.
• As shown inFIG. 3,container10 is preferably formed from corrugated cardboard that includes anouter layer34, aninner liner32, and acorrugated material36 disposed between the outer and inner liners. More specifically,FIG. 3 shows a portion of a container that is formed from corrugated cardboard. As shown, theouter layer34 is provided in at least two separate pieces. (Only two portions are shown, because most shipping units only need to be divided into a tray and a cover, but if additional divisions are desired, it is possible to provide more than two portions ofouter layer34.) The pieces may be referred to as upper and lower portions, and they may be formed in any number of ways.
• For example, the material that formsouter layer34 may be fed from rolls on two different machines to form two separate layers and adhered to theinner liner32 andcorrugated material36 so that the separate layers lie adjacent to one another. The completed blank may then be cut to the desired form. (Note that the materials may be cut to the desired form before being adhered to the inner liner andcorrugated material36, if desired.) In this embodiment, theouter layer34 may be formed from two different types of material. For example, thelower portion72 may be made out of a sturdy plastic (since it will form theultimate tray14 and may need more structure) andupper portion72 may be made out of paperboard. This combination may be reversed, or the same type of materials may be used, or any other types of material may be used.
• It is also possible to prepare theouter layer34 by using a single piece of material and severing before it is applied to theinner liner32 andcorrugated material36. In other words,outer layer34 may be pre-cut prior to application. One way to provide such a pre-cut is by a knife cut or any other device that can sever the outer layer into twoseparate portions70 and72. For example, during the manufacturing process, the inner liner32 (shown inFIG. 2B) and thecorrugated material36 may be adhered to one another. As shown inFIG. 2A, theouter layer34 may be cut into two separate portions—anupper portion70 and alower portion72—by a knife or other cutting device (non-limiting examples of which include a water jet, a laser, or scissor rollers) along the desired location.
• Any appropriate method of cutting, dividing, or using separate pieces of material forouter layer34 will be referred to throughout this document as providing a dividedouter layer34 or adivision18. In short, whereas previous containers were made out of three continuous layers, the present container comprises three layers, but the third layer is provided in two separate pieces. This severing or dividing ofouter layer34 facilitates pulling thetear strip20 through thecontainer10 to separate thecover16 from thetray portion14, which will be described in more detail below.
• Referring generally toFIGS. 1A, 1B, and2A, adivision18 is formed along an outer portion ofcontainer10.Division18 may be created to provide anupper portion70 and alower portion72 using any of the above-described methods. The upper andlower portions70,72 are then adhered to thecorrugated material36, leaving a slit or adivision18 between the twoportions70 and72. Although some manufacturers may prefer a small and barely noticeable slit between theportions70 and72, there may be some instances when a larger space is desired. Accordingly, it is possible to adhere upper andlower portions70 and72 in positions that are further apart from one another, for example, a few centimeters apart to a few inches apart or even wider, if desired.
• Manufacturing thecontainer10 by providing separate pieces ofouter layer34 or by separately cutting theouter layer34 and then attaching it to the container to create adivision18 helps protect the structural integrity of the container. Other containers that are manufactured by scoring the outer liner once it has already been attached to the corrugated material crush and damage the corrugated flutes, deforming the material and compromising its strength. By contrast, the present invention maintains the box strength and provides enhanced structural integrity to thecontainer10. With theouter layer34 completely separated from thecorrugated material36 during the cutting process, no tearing of theouter layer34 takes place when thecontainer10 is opened. During use, the completely severed or divided outer layer prevents delamination and tearing of the graphics that typically occurs without the use of the present invention. This is because thetear strip20 does not ever have to actually tear through any part of theouter layer34 since it is already divided from itself alongdivision18.
• In certain embodiments, thedivision18 is preferably a relatively thin cut, e.g., a knife cut as shown inFIGS. 1A and 1B. This sever occurs before the outer layer is adhered to the corrugated material, which protects the corrugated material from the knife cut, prevents it from being nicked during manufacture, and prevents thecorrugated material36 from being easily cut or crushed during shipping, helping to maintain the strength of the box. In other embodiments, thedivision18 may be wider than a knife cut. Likewise, by providing upper andlower portions70 and72 out of two different rolls of material that are pre-cut or that are cut immediately before being applied toinner liner32 andcorrugated material36, there is no need to cutouter layer34 while it is applied to thecorrugated material36, preventing the risk of damaging the flutes of thematerial36.
• Although not shown, it is also possible to provide more than one division18 (for example, if it is desired to protect the cover from being delaminated and torn, providing two severed portions, or a division between two separate pieces of material may help prevent tearing of the cover as well.)Thedivision18 may be in a relatively straight line, to provide alower tray14 and cover16 of similar shape, (for example, the rectangular shape as shown inFIG. 5), or it may be diagonal across body to provide atray14 and cover16 having different shapes (such as those shown inFIG. 6), or it may travel in any other desired direction.
• It is particularly preferred that the division extend entirely around the periphery of the container and provide twodistinct portions70 and72. It is also particularly preferred that thedivision18 be located at a lower portion of the container, such that ashallow tray14 is formed, as shown inFIG. 4.
• However, as shown inFIG. 7, it is also possible to use to present invention to create stadium-type trays, with high sides and a low front. In these embodiments, thedivision18 is preferably provided at anupper area80 of container so that the upper lid82 (or cover) is removed, leavinghigh sides84.High sides84 form the sides oftray14. There is aremovable section86 at the front portion92 of the container that can be removed to provide anopening88 and alow front90 for the stadium-tray, making it easier for a consumer to access a product contained therein. Theremovable section86 may be provided by perforations, another tear strip (for example, using thesame division18 concept) or any other method that is appropriate for removing material.
• Again, using thedivision18 on this type of tray helps stabilize the strength of the container during shipping and allows thelid82 to be removed without ruining or delaminating the graphics of the container. If adivision18 is used to create theremovable area86, it can provide for increased strength of that area and again, can help protect the graphics that could otherwise be disturbed during removal ofremovable section86.
• As shown inFIG. 2B, atear strip20 is applied along the inside of thewall panels26 on theinner liner32. Thetear strip20 is adhered to theliner32 such that it runs substantially parallel to thedivision18 that is located on the outside of the container. Tearstrip20 may be formed from the same material as the inner liner and outer layer, such as paperboard or plastic or any other desired material, or it may be formed from a different material, such as wire, plastic ribbon, or any other type of material that is strong enough to cut through corrugated material but malleable enough to be adhered to the inside of a container. Tearstrip20 may be applied using glue or any other appropriate securing mechanism. It is particularly preferred that thetear strip20 be located on the inside ofcontainer10 about even or parallel to the area where thedivision18 is located on the outside of container10 (as shown inFIG. 2A), or slightly above it. In other words, the tear strip on the inside of the container runs about parallel to thedivision18 on the outside of the container. Thetear strip20 has atop edge60 and abottom edge62, and thebottom edge62 is preferably aligned with or slightly above thedivision18 of the outer layer.
• When the tear strip is pulled, it tears through the inside liner or liner/s and the corrugated medium/s, and then pulls through thedivision18, which avoids the tearing of the outside liner. As described above, thedivision18 is slit in such a way that only the outside liner has been cut and no weakening to any other part of the substrate occurs. This allows the tearing to be clean, preventing delamination of the graphics on thetray14 and preventing the formation of ragged edges.
• In order to fully understand the cooperation betweentear strip20, thedivision18, and thetray14 andcover16, it is useful to refer to blank30 prior to assembly ofcontainer10, shown inFIGS. 2A and 2B.FIG. 2A shows theouter layer34 of blank30 andFIG. 2B shows theinner layer32 of blank30. Both figures show wall panels,end flap panels28 andglue flap38 prior to assembly.
• Theglue flap38 is used to secure thewall panels26 together and is shown in phantom lines inFIG. 5 (to illustrate thatglue flap38 is preferably on the inside of the last body panel, although it may also be adhered to the outside of the body.)Glue flap38 has one or more die cuts46 (which are shown as forming a triangular shaped tab) that form apull tab24, which is connected to an end of thetear strip20. A user accesses the die cuts46 to pull out thepull tab24.
• Once thecontainer10 has been assembled, there is a need to protect the die cutpull tab24 andtear strip20 in order to prevent the tear strip from being torn before the container should be opened, for example, during shipping or storage. Accordingly, it is preferred forpull tab24 to be protected by anoptional cover flap48 formed in one of the body panels, and preferably thelast body panel50.
• As shown inFIG. 2A,cover flap48 may be die cut out of one of the body panels, and is preferably die cut out of thelast body panel50. Thecover flap48 may be cut out of the end edge of thepanel50 or it may be cut out from anywhere on the panel. It is preferred that the die cut be made around thecover flap48, leaving a small portion54 wherecover flap48 remains attached to panel once separated around the remaining die cut area. This small portion54 that remains attached to thepanel50 allows thecover flap48 to be placed back into alignment with the panel to complete thetray14. It is also possible for thecover flap48 to be completely removable.
• As shown inFIG. 1B, once the diecut cover flap48 is pulled back from thecontainer10, it presents the die cutportion46 andopening66. (Opening66 is formed at the end ofglue panel38, which is shown in phantom onFIG. 1B.)Opening66 provides an area for the user's finger to grasp underneath thedie cut member46 and release it fromglue flap38, thus providing apull tab24. The use then grasps the pull tab, to whichtear strip20 is attached, and opens thecontainer10. It is also possible for the user to access thetear strip20 directly, oncecover flap48 is pulled back.
• In another embodiment, thetear strip20 is connected directly to coverflap48. The user grasps thecover flap48 and by pulling on it, rips thetear strip20 across the container and through thedivision18 to open thecontainer10. Although the die cuts46 andpull tab24 are preferably formed on theglue flap38 and although thecover flap48 is preferably formed on thelast body panel50, it should be understood that thedie cut member46,pull tab24, and/orcover flap48 may be formed on any ofwall panels26.
• In other embodiments, thetear strip20 need not be covered by a flap, but is secured in place and covered by a removable section, such as piece of tape or so forth, that helps prevent thetear strip20 from being torn during shipping or any time prior to when separation of thetray14 and cover16 is desired.
• Although a preferred embodiment of a diecut pull tab24 has been described as formed directly from the blank30 (and thus, is comprised of the same material as container), it should also be understood the pull tab may be formed from a separate structure that is connected to the tear strip or it just may be an end of tear strip, that is, for example, enlarged. In still other embodiments, the tear strip may protrude from the box and be formed into a loop to facilitate pulling the tear strip to open the box. If provided outside the container, there may be a piece of adhesive or tape the prevents it from being pulled before disassembly of the container is desired.
• In other embodiments, thetear strip20 need not be covered by a flap, but is secured in place and covered by a removable section, such as piece of tape or so forth, that helps prevent thetear strip20 from being torn during shipping or any time prior to when separation of thetray14 and cover16 is desired.
• Once the upper andlower portions70 and72 of theouter layer34 have been adhered to theinner liner32 and thecorrugated material36, thecontainer10 may be assembled by folding thepanels26 to createsides40 and adhering theglue flap38 to the inside of thelast body panel50.End flap panels28 on one side are folded over one another to form a bottom44. Thecontainer10 may then be filled with the desired product. Once ready for closure, theend flap panels28 on the other side are folded over one another to form a top42. (Note that the blank30 may be manufactured and shipped in a flattened position to a distributor who assembles and packs the container for shipping to the ultimate retailer.)
• Once thecontainer10 arrives at its desired location, a user may separatecover flap48 that is formed in one of the body panels (and preferably from the last body panel50) to reveal die cutarea46 andopening66, as shown inFIG. 1B. The user lifts the die cutportion46, which forms apull tab24. The user grasps and pulls thetab24 to activate thetear strip20 to tearstrip20 tears through theinner liner32 and thecorrugated material36. Thetear strip20 does not cut through theouter layer34 because, as discussed, theouter layer34 features thedivision18 that allowstear strip20 to pass without roughing up the edges or ruining the graphics onouter layer34. In other words, theinner liner32 andcorrugated material36 remain intact while theouter layer34 has separate upper70 and lower72 portions. This division or separation makes separating thetray14 and cover16 easier than current methods because there is less resistance. This feature also allows the container to be torn open without ruining the graphic image and the structural integrity of the remaining tray.
• Changes and modifications, additions and deletions may be made to the structures and methods recited above and shown in the drawings without departing from the scope or spirit of the invention and the following claims.

Claims (15)

1. A container having a tray portion and a cover portion, comprising:

a body comprising an inner liner and an outer layer with a corrugated material disposed between the inner liner and the outer layer;

the outer layer provided in separate upper and lower portions, the upper and lower portions separately applied to the corrugated material to provide a division between the upper and lower portions and to prevent the corrugated material from being deformed from pressure of cutting of the outer layer once applied, the division of the outer layer extending around the body to define the tray portion and the cover portion; and

a tear strip adhered to the inner liner such that the tear strip is substantially parallel to the division of the outer layer.

2. The container ofclaim 1, further comprising a glue flap and a series of wall panels, the glue flap forming a pull tab attached to the tear strip.

3. The container ofclaim 2, wherein one of the wall panels forms a cover flap that is adapted to cover the pull tab of the glue flap, wherein pulling back the cover flap reveals the pull tab, and wherein pulling the pull tab separates the tray portion from the cover portion.

4. The container ofclaim 2, wherein the tear strip has an end that originates at the pull tab.

5. The container ofclaim 1, wherein the tear strip has a bottom edge that is in line or slightly above the severed lower portion of the outer layer.

6. The container ofclaim 1, wherein when the tear strip is pulled, it tears through the inner liner and the corrugated material, but avoids tearing the outer layer because the severed outer layer is already completely separated from itself along the tear strip line.

7. The container ofclaim 1, wherein the division is angled on one or more portions of the body.

8. The container ofclaim 1, wherein the upper and lower portions of the outer layer are provided from different types of material.

9. The container ofclaim 1, wherein the division is provided at an upper area of the container and further comprising a removable section at a front portion of the container to provide a container with high walls and a low front.

10. A method of manufacturing an easy open container, comprising:

(a) providing an inner liner, an outer layer, a corrugated material, and a tear strip;

(b) cutting the inner liner, the outer layer, and the corrugated material in the form of a box-shaped blank having wall panels and end flaps, with the outer layer divided into an upper and a lower portion;

(c) adhering the inner liner and the corrugated material to one another;

(d) adhering the upper portion and the lower portion of the outer layer to the corrugated material such that a slit is left between the upper and lower portions; and

(e) adhering the tear strip to the inner liner, the tear strip aligned with the slit of the outer layer.

11. The method ofclaim 10, further comprising:

(f) cutting a glue flap at the end of box-shaped blank;

(g) cutting a pull tab shaped member in the glue flap; and

(h) aligning the tear strip so that it is attached to the pull tab.

12. The method ofclaim 11, further comprising cutting a cover flap in a wall panel at an end of the blank opposite the glue flap, such that the cover flap covers the glue flap upon assembly.

13. The method ofclaim 10, further comprising assembling the wall panels and end flaps to form a box-shaped container having a tray and a cover that are connected to one another but separated at their outermost portions by the division in the outer layer.

14. The method ofclaim 10, wherein the outer layer is provided from two different types of material.

15. The method ofclaim 10, wherein the container is provided with a series of wall panels and cutting at least one of the wall panels to provide a removable section.

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