Cross-Reference to Related Applications

[0001] The present application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 62/737,158, which was filed on September 27, 2018 in the names of Fred Dowd et a!., the disclosure of which is incorporated herein by reference.

Field of the Invention

[0002] The present invention relates generally to shipping containers and, more particularly, to containers designed principally for use in the shipment and display of food products.

Background of the Invention

[0003] Containers constructed from corrugated paper boxes are commonly utilized to package and transport food products from a supplier to a retailer where the product is offered for sale. As can be appreciated, the construction of such containers is of particular significance in not only transporting the food product with adequate physical protection but also ensuring proper ventilation in order to maintain product freshness and quality.

[0004] in particular, the shipment of bananas and tropical fruit has been found to be particularly sensitive to physical damage and freshness quality during transport from the plantation where the bananas are grown to the retail store where the bananas are ultimately sold. Most typically, bananas are shipped in a corrugated paper box comprised of a five-sided box body which is selectively enclosed with a telescoping cover.

[0005] Although well known in the art, conventional paper boxes used in the shipment of bananas and tropical fruit have been found to suffer from a number of notable shortcomings. Most notably, paper boxes (i) are relatively expensive, single-use containers, which significantly increase overall shipment costs, (ii) require the packing and unpacking of the products through a relatively laborious and time-consuming process, and (iii) are limited in structural rigidity and thereby render the product susceptible to physical damage.

[0006] In response to the aforementioned drawbacks identified with traditional paper boxes, food shipment containers have been recently modified in design to protect the food product throughout its shipment and, in turn, facilitate the labor required to unpack and display the product at its ultimate point-of-sale.

[0007] Most notably, in U.S. Patent No. 8,631,956 to F. Dowd, the disclosure of which is incorporated herein by reference, there is disclosed a multi-part product shipping box and display tray. In the '956 patent, the shipping box, or container, is designed for multiple uses and is preferably constructed of a rigid and durable material, such as plastic.

[0008] Furthermore, the container disclosed in the '956 patent utilizes a three-piece construction to facilitate the packaging and display of food products therein. Specifically, the box comprises a four-sided, collapsible sleeve, generally rectangular in cross-section, that is selectively enclosed by opposing, generally planar, trays. To facilitate assembly, each tray includes a tabular projection, or barrier portion, at the approximate midpoint of each of its sides. Additionally, each tray includes an L-shaped post spaced slightly in from each of its corners. Based on the relative positions of the barrier portions and L-shaped posts, as well as the thickness of the sleeve, assembly of the container is achieved by fittingly disposing either open end of the sleeve between the barrier portions and L-shaped posts.

[0009] In this manner, the container disclosed in the '956 patent can be used to package and subsequently display food products in a relatively simple and unlaborious process. Specifically, the food product is simply disposed on the inner surface of one of the trays. Thereafter, the sleeve is slid down into engagement with the tray so as to circumscribe the product. Lastly, the opposing tray is mounted onto the open end of the sleeve to enclose the product. Straps or additional fastening elements may be used to prevent inadvertent disassociation of the shipping container.

[0010] The unloading and subsequent display of the product retained within the container of the '956 patent can be similarly achieved in a simple and unlaborious process. Notably, the container is disposed, right-side-up, at the desired point-of-sale. Then, by simply removing the straps and lifting the top tray and sleeve, the product is rendered on display on the lower tray. As such, no direct lifting (i.e. removal) of the product is required, which is highly desirable.

? Summary of the invention

[0011] It is an object of the present invention to provide a new and improved container for use in the shipment and display of a product.

[0012] It is another object of the present invention to provide a container of the type as described above which is designed to adequately protect the product shipped therein.

[0013] It is yet another object of the present invention to provide a container of the type as described above which is properly ventilated to ensure the freshness and quality of the product shipped therein.

[0014] It is still another object of the present invention to provide a container of the type as described above which is reusable.

[0015] It is yet still another object of the present invention to provide a container of the type as described above which allows for the packing and unpacking of a product retained therein in a simple, efficient and uniaborious process.

[0016] It is another object of the present invention to provide a container of the type as described above which has a limited number of parts, is inexpensive to manufacture and is easy to assemble.

[0017] Accordingly, as one feature of the present invention, there is provided a container for the shipment and display of a product, the container comprising (a) a sleeve having an open top end and an open bottom end, and (b) a pair of opposing trays reieasably mounted on the top and bottom ends of the sleeve, each of the pair of opposing trays comprising an inner surface, an outer surface, and a peripheral edge, each of the pair of opposing trays additionally comprising a continuous outer flange formed on the inner surface along the entirety of the peripheral edge and a continuous inner flange formed on the inner surface spaced at a fixed distance inward from the continuous outer flange, (c) wherein the inner surface, the outer flange and the inner flange on each of the pair of opposing trays together define a continuous, peripheral groove which is dimensioned to fittingly receive either of the open top end and the open bottom end of the sleeve.

[0018] Various other features and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawings which form a part thereof, and in which is shown by way of illustration, an embodiment for practicing the invention.

The embodiment will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. The following detailed description is therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.

Brief Description of the Drawings

[0019] In the drawings, wherein like reference numerals represent like parts:

[0020] Fig. 1 is a top perspective view of a container for the shipment and display of a product, the container being constructed according to the teachings of the present invention;

[0021] Fig. 2(a) is a top perspective view of the bottom tray shown in Fig. 1;

[0022] Fig. 2(b) is a top plan view of the bottom tray shown in Fig. 2(a);

[0023] Fig. 2(c) is a section view of the bottom tray shown in Fig. 2(b), taken along lines 2(c)-2(c); and

[0024] Fig. 2(d) is a bottom plan view of the bottom tray shown in Fig. 2(a).

Detailed Description of the Invention

[0025] Referring now to Fig. 1, there is shown a top perspective view of a container for use in the shipment and display of a product, the container being constructed according to the teachings of the present invention and identified generally by reference numeral 11. As will be explained in detail below, container 11 is specifically designed to enable a product shipped therein to be displayed through a simple and easy conversion process.

[0026] In the description that follows, container 11 is described in connection with the shipment and display of a food product, such as bananas or pineapples. However, it should be noted that container 11 is not limited to use with food products. Rather, it is to be understood that container 11 could be alternatively utilized for the shipment and display of other types of products, such as floral products, without departing from the spirit of the present invention.

[0027] Container 11 is similar in construction to the container disclosed in U.S. Patent No. 8,631,956 to F. Dowd (hereinafter the '956 patent). Specifically, container 11 comprises a four-sided sleeve 13 that is selectively enclosed by a pair of opposing trays 15-1 and 15-2. As can be appreciated, the three-piece construction of container 11 serves to facilitate the packaging and display of products retained therein, which is a principal object of the present invention.

[0028] Sleeve 13 is similar to the sleeve disclosed in the '956 patent in that sleeve 13 is constructed as a unitary, four-sided, member which can be collapsed into a flattened, generally planar configuration prior to use (i.e. for ease of storage and shipment). Preferably, sleeve 13 is constructed out of a corrugated plastic, corrugated paper or any other suitable malleable material. The four-sided construction of sleeve 13 yields an open top end 17-1 and an open bottom end 17-2 that are selectively enclosed by top and bottom trays 15-1 and 15-2, respectively, upon assembly.

[0029] Sleeve 13 is provided with handle-shaped cutouts 19 in selected sidewalls as well as a plurality of generally circular thru-holes, or openings, 21. As can be appreciated, openings 21 allow for the proper ventilation and cooling of food products retained in container 11. As can be seen, openings 21 are preferably aligned in each sidewall of sleeve 13 in order to promote laminar air flow through container 11.

[0030] Each tray 15 is similar to the trays disclosed in the '956 patent in that each tray 15 is constructed as a unitary, generally rectangular, plastic member that is appropriately dimensioned to enclose open ends 17 of sleeve 13, with each tray 15 being represented herein as being approximately 20 inches in length and approximately 16 inches in width. Additionally, each tray 15 is provided with a central, rectangular opening, or window, 22.

[0031] The principal difference between container 11 and the container in the '956 patent is that each tray 15 is designed with a novel interface 23 for fittingly receiving an open end 17 of sleeve 13. Specifically, referring now to Figs. 2(a}-(d), a single tray 15 is shown in isolation that shows in detail the novel interface 23 for receiving sleeve 13.

[0032] As can be seen, each tray 15 is identical in construction and therefore can be used as either a top or bottom enclosing element for sleeve 13, thereby rendering the assembly process simpler and more efficient. Each tray 15 is constructed as a generally planar member that includes an inner surface 31, an outer surface 33 and an outer peripheral edge 35. A continuous outer flange, or rim, 37 is formed on inner surface 31 along the entirety of outer peripheral edge 35 and projects orthogonally out therefrom at a height of approximately 0.38 inches.

[0033] Additionally, a continuous inner flange, or rim, 39 is formed on inner surface 31 spaced slightly inward from outer flange 37 and projects orthogonally upward from inner surface 31 at a height of approximately 0.38 inches. Preferably, inner flange 39 is spaced in from outer flange 37 a fixed width of approximately 0.31 inches. In this manner, a continuous peripheral groove, or recess, 41 is formed on inner surface 31 of tray 15 that is uniform in cross- section for nearly the entirety of its length.

[0034] As can be appreciated, the continuous, peripheral design of recess 41 greatly facilitates the alignment and reception of an open end 17 of sleeve 13 therein. Notably, the continuous nature of recess 41 simplifies the orientation requirements between sleeve 13 and each tray 15, whereas traditional containers with trays that utilize a unique selection of orientation posts (e.g. of the type disclosed in the '956 patent) have more restrictive orientation requirements. As such, it has been found that container 11 is considerably easier to assemble than the container described in the '956 patent.

[0035] Additionally, the continuous nature and considerable depth of recess 41 (approximately 0.31 inches) serves to strengthen the retention of sleeve 13 therein. In particular, the continuous nature of recess 41 serves to more evenly distribute the load applied to sleeve 13 by a product packed tightly therein and thereby prevent sleeve 13 from bulging or otherwise distorting, which is a condition commonly experienced with traditional containers that rely upon spaced apart orientation posts and tabs for assembly (e.g. of the type disclosed in the '956 patent). [0036] As another feature of the invention, outer flange 37 is shaped to define a pair of vertically-extending indentations 45 along a set of opposing exterior sides of tray 15, as seen most dearly in Figs. 2(a), 2(13) and 2(d). As can be appreciated, indentations 45 are provided to receive straps (not shown) which are used to encircle container 11 when in its assembled and product-loaded state. As a result, indentations 45 serve to not only prevent straps from sliding axially off of container 11 but also create a largely flush region of contact between the strap and the container around which it is enclosed, thereby minimizing the risk of bulging or inadvertent disassociation. In this capacity, it is also envisioned that straps could be used to assist in the handling of an assembled container 11 during shipment.

[0037] As yet another feature of the invention, bottom surface 33 of each tray 15 is provided with a plurality of feet 47 and 49 which enable a large quantity of trays 15 to be arranged and shipped as a tightly nested stack. More specifically, as seen most clearly in Figs. 1 and 2(d), a single pair of feet 47 and 49 is located directly inside each corner of interface 23 and projects orthogonally out from bottom surface 33 at a fixed height. Accordingly, with trays 15 stacked in a front-to-back relationship, feet 47 and 49 align within the interior corners defined by the inner flange 39 of the adjacent tray 15, thereby helping to retain the plurality of trays 15 in a stacked arrangement.

[0038] For illustrative purposes only, foot 47 is represented as having a cross-type shape in transverse cross-section and foot 49 is represented as having a circular shape in transverse cross-section. However, it is to be understood that the shape of feet 47 and 49 could be modified without departing from the spirit of the present invention.

[0039] As still another feature of the invention, it should be noted that the thickness of sleeve 13 is selected to be relatively thin (approximately 0.31 inches). Therefore, when multiple filled containers 11 are arranged side-by-side with thru-holes 21 in direct alignment with one another, the thin nature of sleeve 13 serves to promote laminar air flow through the collection of containers 11 during transportation as well as when maintained in ripening rooms.

[0040] In use, container 11 is designed to ship and display a product in the following manner. Sleeve 13 is mounted on bottom tray 15-2 with open bottom end 17-2 of sleeve 13 fittingly inserted into its recess 41. Due to the continuous nature of recess 41 in bottom tray 15-2, the aforementioned orientation and registration process is greatly simplified as compared to traditional multi-piece containers.

[0041] With sleeve 13 mounted on botom tray 15-2, the desired product is preferably loaded onto inner surface 31 of bottom tray 15-2 within the cavity formed by sleeve 13. Once completed, top tray 15-1 Is mounted onto sleeve 13 such that open top end 17-1 of sleeve 13 fittingly protrudes into recess 41 in top tray 15-1. Assembled as such, container 11 serves to adequately protect the food product retained therein. To prevent inadvertent disassociation of the three principal components of container 11, straps or similar types of fastening elements may be tightly wrapped around container 11, as needed, with the straps preferably aligning within indentations 45 in trays 15.

[0042] Once shipped to the intended destination, container 11 can be partially disassembled and used to display the product. Namely, container 11 is disposed, right-side-up, at the desired point-of-sale. Then, by simply removing any straps and lifting top tray 15-1 and sleeve 13, the product is left on display on bottom tray 15-2. As such, store personnel can effectively display a shipped product without having to remove (i.e. lift) the product from its shipment packaging, thereby greatly simplifying the entire product unpacking and display process.