US20070295639A1 - Packaging assembly - Google Patents

Abstract

The present invention provides a packaging assembly for displaying and shipping a packaged product, the packaging assembly comprising a display pack having one or more product chambers for containing the packaged product and a box that houses the display pack, the box including a front panel having a product window disposed therein for revealing the packaged products contained within the display pack, wherein the front panel includes a lip around a perimeter of the product window that prevents the display pack from being removed from the box through the product window.

Description

FIELD OF THE INVENTION
• The present invention relates generally to bulk packaging for shipping and display and, more particularly, to a packaging assembly for economically and safely shipping and displaying one or more products.
BACKGROUND OF THE INVENTION
• Traditionally, products have been shipped in bulk from a manufacturer to a retailer in cartons containing protective packing material. Individual products were then removed from the cartons to be individually placed on a shelf or rack for display. For small, expensive and easily stolen products, the shelf or rack might be located within a secured display case to minimize the risk of theft.
• This system of shipping and display is both costly and time consuming. The manufacturer must often pay relatively expensive initial packaging costs, particularly for items that are easily damaged by rough handling. The retailer must pay employees to individually place each product item on display in a manner that is both appearing to the customer and safe for the product. Furthermore, for small, expensive and easily stolen products, which are kept in secured display cases, the retailer must pay a sales person to attend to each customer wishing to inspect the products. These costs are typically passed along to the consumer, who receives little benefit from them other than to receive a product that has safely survived the rigors of shipping. Accordingly, there is a continuing need for more economical means of safely and efficiently shipping and displaying products for sale.
• It is known that small products may be packaged in comparatively large containers to deter theft. However, these containers require the use of large amounts of retail space, and the containers must be decorated and otherwise configured to appeal to consumers, adding to the total product packaging cost. Therefore, some manufacturers have used smaller packaging, with an optional, transparent display pack, such as a blister pack, available at a retailer's request.
• The display pack, which contains the product within its smaller packaging, typically is significantly larger than the small packaging, providing for increased deterrence of theft. Typically, display packs are configured with an appealing appearance to the customer, and provide added safety in shipping. Display packs are usually made from two vacuum-formed sheets of clear plastic, sealed around the edges, forming a chamber for holding the product. Such display packs are relatively inexpensive, and benefit from the appealing appearance of the small packaging, which is visible through the display packs. U.S. Design Pat. No. D 353,092, to Green, entitled “Blister Pack” discloses a transparent display pack assembly having several cavities for containing products.
• Warehouse shopping clubs such as Sam's Club and Costco require manufacturers to ship products according to strict guidelines that ensure the products are adequately protected during shipment and ready to be displayed on the warehouse floor. A challenge for manufacturers is in striking an appropriate balance between adequately protecting the products and minimizing the amount of handling necessary to display the products on the store floor. Internal plastic packaging is preferred because it allows the product to be viewed by consumers. However, such packaging is more susceptible to damage during shipment and is difficult to display in bulk form. Consequently, warehouse clubs and manufacturers have a long felt need for external packaging that is sufficiently strong to protect the internal plastic packaging, yet that permits easy handling and display of the packaged products on the store floor.
• It should, therefore, be appreciated that there exists a need for a packaging assembly that overcomes the drawbacks of prior packaging assemblies, as described above, and that includes a box and a product display pack housed within the box, wherein the box is sufficiently strong to protect the product display pack, yet permits easy handling and display of the packaged product. The present invention fulfills this need and provides further related advantages.
SUMMARY OF THE INVENTION
• In view of the foregoing, it is an object of the present invention to provide a packaging assembly including a box and a product display pack housed within the box, wherein the box includes a front panel having a lip that prevents the display pack from being removed through a product window in the front panel, thereby discouraging theft of the product.
• The present invention provides a packaging assembly for shipping and displaying a plurality of products. It provides for economy and safety by protecting the products from shipping damage, providing for fast and efficient display, and offering significant protection against theft without requiring the attention of a salesperson.
• One aspect of the present invention involves a packaging assembly for displaying and shipping a packaged product, the packaging assembly comprising a display pack having one or more product chambers for containing the packaged product and a box that houses the display pack, the box including a front panel having a product window disposed therein for revealing the packaged products contained within the display pack, wherein the front panel includes a lip around a perimeter of the product window that prevents the display pack from being removed from the box through the product window. In the preferred embodiment of the invention, the display pack comprises a transparent, two-part blister pack assembly carried within the box, but visible through the product window in the front panel. Each product chamber of the display pack comprises a convex portion that protrudes from the packaging assembly such that the convex portion is disposed substantially in front of the front panel of the box. Additionally, each product chamber of the display pack further comprises a concave portion disposed substantially within the box, wherein the convex and concave portions are mated to form the one or more product chambers.
• According to the invention, the display pack comprises a front portion containing one or more convex portions of the one or more product chambers, and a rear portion containing one or more concave portions of the one or more product chambers. The front portion of the display pack comprises a substantially planar sheet of transparent plastic having the convex portions projecting therefrom, and a side wall around a perimeter of the front portion that is disposed substantially normal to the planar sheet. In addition, the rear portion comprises a substantially planar sheet of transparent plastic having the concave portions forming recesses therein, and a side wall around a perimeter of the rear portion that is disposed substantially normal to the planar sheet. The front and rear portions of the display pack are adjoined such that the convex and concave portions align to create the one or more product chambers.
• According to some embodiments of the invention the packaging assembly may further comprise a substantially planar product display card disposed between the front and rear portions of the display pack such that the display card is visible through the product window in the front panel of the box. The display card preferably includes one or more cutouts that correspond with dimensions and locations of the one or more product chambers. According to additional embodiments, the packaging assembly may further comprise a product insert area disposed within the cardboard box, the product insert area containing packaged product parts that are not displayed through the product window. According to further embodiments, a rear panel of the box may comprise one or more concave recesses dimensioned to receive one or more convex portions of a display pack of another packaging assembly.
• Another aspect of the present invention involves a multi-layer stack of packaging assemblies for displaying and shipping packaged products, the stack comprising a first layer of packaging assemblies and a second layer of packaging assemblies disposed on top of the first layer of packaging assemblies, wherein each packaging assembly comprises a display pack having one or more product chambers for containing the packaged product and a box that houses the display pack. The box includes a front panel having a product window disposed therein for revealing the packaged products contained within the display pack, wherein the front panel includes a lip around a perimeter of the product window that prevents the display pack from being removed from the box through the product window. In addition, a rear panel of the box comprises one or more concave recesses dimensioned to receive one or more convex portions of a display pack of another packaging assembly.
• Other features and advantages of the present invention should become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
• Embodiments of the present invention will now be described, by way of example only, with reference to the following drawings, in which:
• FIG. 1 a is a side view of a preferred packaging assembly, in accordance with the principles of the present invention;
• FIG. 1bis a bottom view of the preferred packaging assembly ofFIG. 1a;
• FIG. 2ais a bottom view of the display pack of the preferred packaging assembly, in accordance with the principles of the present invention;
• FIG. 2bis an exploded view of the display pack ofFIG. 2a;
• FIG. 3ais a top view of the preferred packaging assembly ofFIG. 1a,wherein the cardboard box is provided with concave recesses dimensioned to receive the convex portions of another packaging assembly; and
• FIG. 3bis a top view of a layer of packaging assemblies formed by positioning a plurality of the packaging assemblies ofFIG. 3ain a side-by-side orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
• The present invention is directed to a packaging assembly for displaying and shipping one or more packaged products. In particular, the packaging assembly includes a box having a front panel with an opening or product window for revealing a packaged product disposed within the box. The packaging assembly further comprises a two-part, transparent plastic display pack carried within the box, but visible through the product window in the front panel. The box includes a lip around an edge of the product window that prevents the two-part plastic display pack from being removed from the box. The preferred packaging assembly of the invention includes a box made of corrugated cardboard to provide adequate strength for shipping and handling. It should be understood to those of ordinary skill in the art that the box may comprise any number of materials having a high strength to weight ratio without departing from the scope of the invention.
• Referring toFIGS. 1aand1b,a preferredpackaging assembly100 for displaying and shipping one or more packaged products in accordance with the principles of the invention will now be described. Specifically, thepackaging assembly100 comprises acardboard box110 that houses adisplay pack140 having one ormore product chambers145 for containing the packaged product. Thecardboard box110 comprises afront panel115, arear panel118, atop panel120, abottom panel124, aleft side panel126, and aright side panel128, wherein thefront panel115 includes aproduct window130 comprising an opening or cutout in thefront panel115 for revealing one or more packaged products disposed within thedisplay pack140. In accordance with the principles of the invention, thefront panel115 of thecardboard box110 includes alip150 around aperimeter155 of theproduct window130, such that theperimeter155 of the product window is smaller than a perimeter of thedisplay pack140. In other words, thelip150 is the portion of thefront panel115 that fits over thedisplay pack140 and prevents thedisplay pack140 from being removed from thecardboard box110 through theproduct window130. Thepackaging assembly100 may further comprise aproduct insert area135 disposed within thecardboard box110. Particularly, theproduct insert area135 may contain additional product parts, accessories, instructions and other materials related to the product that are not displayed through theproduct window130.
• Thedisplay pack140 of thepreferred packaging assembly100 of the invention may comprise a transparent, two-part blister pack assembly carried within thecardboard box110, but visible through theproduct window130 in thefront panel115. As illustrated inFIG. 1b,eachproduct chamber145 of thedisplay pack140 includes aconvex portion146 that protrudes from thepackaging assembly100 such that it is disposed substantially in front of thefront panel115. Additionally, eachproduct chamber145 further includes aconcave portion148 disposed substantially within thecardboard box110. Theconvex portions146 andconcave portions148 are mated to form theproduct chambers145 for the packaged products. In the illustrated embodiment, theproduct window130 comprises a single opening that is large enough to receive all of theproduct chambers145. According to other embodiments, thefront panel115 may comprise a plurality of product windows, each product window dimensioned to receive a single product chamber. According to some embodiments of the invention, thedisplay pack140 may be vacuum sealed around its periphery.
• With further reference toFIGS. 1aand1b,thebottom panel124 of thecardboard box110 preferably includes a surface area that is sufficiently large to allow thepackaging assembly100 to stand on its own while being transported or displayed. In addition, thecardboard box110 should be strong enough to support a significant amount of weight placed on top of thepackaging assembly100 in the form of additional stacked packaging assemblies. In this regard, thepreferred packaging assembly100 of the invention includes abox110 made of corrugated cardboard to provide adequate strength for stacking layers of packaging assemblies on too of one another.
• Referring toFIGS. 2aand2b,the two-part display pack140 of the invention is depicted after being removed from thecardboard box110. Specifically, thedisplay pack140 comprises afront portion160 containing theconvex portions146 of theproduct chambers145 and arear portion165 containing theconcave portions148 of theproduct chambers145. More particularly, thefront portion160 of thedisplay pack140 comprises a substantiallyplanar sheet180 of transparent plastic having theconvex portions146 projecting therefrom, and aside wall185 around the perimeter of theplanar sheet180 that is disposed substantially normal to theplanar sheet180. Similarly, therear portion165 comprises a substantiallyplanar sheet190 of transparent plastic having theconcave portions148 forming recesses therein, and aside wall195 around the perimeter of theplanar sheet190 that is disposed substantially normal to theplanar sheet190. Theplanar sheet180 of thefront portion160 preferably is slightly larger in length and width than theplanar sheet190 of therear portion165 such that theside wall185 of thefirst portion160 may be slipped into place over theside wall195 of the rear portion, as depicted inFIG. 2a.
• When the front andrear portions160,165 are adjoined, the convex andconcave portions146,148 align to create theproduct chambers145. Eachproduct chamber145 is configured to hold a packaged product (or a portion of a packaged product), and is dimensioned to conform to the shape of the packaged product to accommodate both display and shipping requirements. Since the front andrear portions160,165 are formed using a transparent material, theproduct chambers145 allow the one or more packaged products to be visible to potential buyers. As depicted inFIG. 2b,a substantially planarproduct display card170 may be disposed between the front andrear portions160,165 of thedisplay pack140 such that thedisplay card170 is visible through theproduct window130 in thefront panel115 of thecardboard box110. Thedisplay card170 preferably includescutouts175 that correspond with the dimensions and locations of theproduct chambers145, so as to accommodate the one or more packaged products within theproduct chambers145.
• With farther reference toFIGS. 2aand2b,in the illustrated embodiment the front andrear portions160,165 are readily separable from each other. According to some embodiments of the invention, the front andrear portions160,165 may be provided with interlocking indents such that an interference or friction fit is established therebetween. Alternatively, the front andrear portions160,165 may be sealed together by fusing theside wall185 of thefront portion160 to theside wall195 of therear portion165. In this manner, the display pack may be vacuum sealed around its periphery.
• In thepackaging assembly100, the packaged products are suspended in theproduct chambers145, thereby protecting the packaged products from damage during shipping and handling. Thedisplay pack140 internally provides vertical and lateral support to the rest of thepackaging assembly100. Thedisplay pack140, while having an appealing shape, and optionally having adisplay card170 to augment its appearance, displays the packaged products in full view, allowing the aesthetics of the packaged products and information on thedisplay card170 to encourage consumers to purchase the products. In this regard, the outer periphery of theentire cardboard box110 may be employed to display printing such as text and/or images associated with the packaged products. Thelip150 of thefront panel115 provides further surface area for displaying additional printing such as text and/or images associated with the packaged products.
• According to the invention, thepackaging assembly100 described herein acts as a theft deterrent because thecardboard box110 makes the overall assembly too large to easily conceal, for example underneath an article of clothing. Additionally, thecardboard box110 gives thepackaging assembly100 added strength to avoid being crushed during shipping and handling, especially when layers, or tiers, of packaging assemblies are stacked on top of one another, as described below. Unlike conventional blister packs that require a slotted display stand for proper support, thepackaging assembly100 of the invention is self-supporting and may be employed to transport and display much larger products.
• Thedisplay pack140 preferably is sized to extend fully from thebottom panel124 to thetop panel120 of thecardboard box110. The display pack, thereby, can assist the cardboard box in supporting the weight of any overlaying layers, or tiers, ofpackaging assemblies100. This supplemental support optionally allows the cardboard box to be formed of panels that are thinner, and thus less costly, than would be required if the overlaying tiers were to be supported by the cardboard boxes, alone.
• FIG. 3ais a top view of thepackaging assembly100 ofFIG. 1, wherein therear panel118 of thecardboard box110 comprises one or moreconcave recesses200 dimensioned to receive theconvex portions146 of thedisplay pack140 of anotherpackaging assembly100. As illustrated inFIG. 3b,alayer210 of packaging assemblies may be formed by positioning a plurality ofpackaging assemblies100,100′,100″ side-by-side such that theconvex portions146″ of therearmost packaging assembly100″ nest within the correspondingconcave recesses200′ of thepackaging assembly100′ that is immediately in front of therearmost packaging assembly100″. Similarly, theconvex portions146′ ofpackaging assembly100′ nest within the correspondingconcave recesses200 of the leadingpackaging assembly100 disposed immediately in front ofpackaging assembly100′. Although the illustrated embodiment depicts alayer210 having three side-by-side packaging assemblies100,100′,100″, it should be understood by those of ordinary skill in the art that any number of packaging assemblies may be employed to form a layer without departing from the scope of the invention.
• With further reference toFIGS. 3aand3b,additional layers210 ofpackaging assemblies100 may be stacked on top of each other to form a multi-layer stack ofpackaging assemblies100. In particular, by nesting theconvex portions146 of apackaging assembly100 within the correspondingconcave recesses200 of anadjacent packaging assembly100, the resultant formation includes enhanced structural rigidity that allows layers ofpackaging assemblies100 to be stacked on top of one another without crushing the bottom layer. In addition, the cargo space necessary for shipping a multi-layer stack ofpackaging assemblies100 is significantly reduced when thepackaging assemblies100 are nested in this manner. The multi-layer stack ofpackaging assemblies100 may be wrapped in shrink-wrap or otherwise contained during shipment. After shipment, the stack is then unwrapped such that thepackaging assemblies100 may be displayed for sale on the store floor.
• The present invention has been described above in terms of presently preferred embodiments so that an understanding of the present invention can be conveyed. However, there are other embodiments not specifically described herein for which the present invention is applicable. Therefore, the present invention should not to be seen as limited to the forms shown, which is to be considered illustrative rather than restrictive.

Claims (20)

1. A packaging assembly for displaying and shipping a packaged product, the packaging assembly comprising:

a display pack having one or more product chambers for containing the packaged product; and

a box that houses the display pack, the box including a front panel having a product window disposed therein for revealing the packaged products contained within the display pack;

wherein the front panel includes a lip around a perimeter of the product window that prevents the display pack from being removed from the box through the product window.

2. The packaging assembly ofclaim 1, wherein the display pack comprises a transparent, two-part blister pack assembly carried within the box, but visible through the product window in the front panel.

3. The packaging assembly ofclaim 1, wherein each product chamber of the display pack comprises a convex portion that protrudes from the packaging assembly such that the convex portion is disposed substantially in front of the front panel of the box.

4. The packaging assembly ofclaim 3, wherein each product chamber of the display pack further comprises a concave portion disposed substantially within the box.

5. The packaging assembly ofclaim 4, wherein the convex and concave portions are mated to form the one or more product chambers.

6. The packaging assembly ofclaim 1, wherein the product window comprises a single opening that is large enough to receive each of the one or more product chambers.

7. The packaging assembly ofclaim 1, wherein the product window comprises a plurality of openings, each opening dimensioned to receive a single product chamber.

8. The packaging assembly ofclaim 1, wherein the display pack comprises a front portion containing one or more convex portions of the one or more product chambers, and a rear portion containing one or more concave portions of the one or more product chambers.

9. The packaging assembly ofclaim 8, wherein the front portion of the display pack comprises a substantially planar sheet of transparent plastic having the convex portions projecting therefrom, and a side wall around a perimeter of the front portion that is disposed substantially normal to the planar sheet.

10. The packaging assembly ofclaim 9, wherein the rear portion comprises a substantially planar sheet of transparent plastic having the concave portions forming recesses therein, and a side wall around a perimeter of the rear portion that is disposed substantially normal to the planar sheet.

11. The packaging assembly ofclaim 8, wherein the front and rear portions of the display pack are adjoined such that the convex and concave portions align to create the one or more product chambers.

12. The packaging assembly ofclaim 8, further comprising a substantially planar product display card disposed between the front and rear portions of the display pack such that the display card is visible through the product window in the front panel of the box.

13. The packaging assembly ofclaim 12, wherein the display card includes one or more cutouts that correspond with dimensions and locations of the one or more product chambers.

14. The packaging assembly ofclaim 1, wherein the perimeter of the product window is smaller than a perimeter of the display pack.

15. The packaging assembly ofclaim 1, further comprising a product insert area disposed within the cardboard box, the product insert area containing packaged product parts that are not displayed through the product window.

16. The packaging assembly ofclaim 1, wherein a rear panel of the box comprises one or more concave recesses dimensioned to receive one or more convex portions of a display pack of another packaging assembly.

17. A multi-layer stack of packaging assemblies for displaying and shipping packaged products, the stack comprising:

a first layer of packaging assemblies; and

a second layer of packaging assemblies disposed on top of the first layer of packaging assemblies;

wherein each packaging assembly comprises:

a display pack having one or more product chambers for containing the packaged product, and

a box that houses the display pack, the box including a front panel having a product window disposed therein for revealing the packaged products contained within the display pack, wherein the front panel includes a lip around a perimeter of the product window that prevents the display pack from being removed from the box through the product window, wherein a rear panel of the box comprises one or more concave recesses dimensioned to receive one or more convex portions of a display pack of another packaging assembly.

18. The multi-layer stack of packaging assemblies ofclaim 17, wherein the display pack comprises a transparent, two-part blister pack assembly carried within the box, but visible through the product window in the front panel.

19. The multi-layer stack of packaging assemblies ofclaim 17, wherein each product chamber of the display pack comprises:

a convex portion that protrudes from the packaging assembly such that the convex portion is disposed substantially in front of the front panel of the box; and

a concave portion disposed substantially within the box;

wherein the convex and concave portions are mated to form the one or more product chambers.

20. The multi-layer stack of packaging assemblies ofclaim 17, wherein:

the display pack comprises a front portion containing one or more convex portions of the one or more product chambers, and a rear portion containing one or more concave portions of the one or more product chambers;

the front portion of the display pack comprises a substantially planar sheet of transparent plastic having the convex portions projecting therefrom, and a side wall around a perimeter of the front portion that is disposed substantially normal to the planar sheet; and

wherein the rear portion comprises a substantially planar sheet of transparent plastic having the concave portions forming recesses therein, and a side wall around a perimeter of the rear portion that is disposed substantially normal to the planar sheet.

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