Technical Field of the Invention

The present invention relates to packaging and in particular to packaging for the storage, transportation and display of products.

5 Background to the Invention

There are known package assemblies which may be used to transport products located within the package assembly which can also be used to display the products. Such package assemblies are often transported in a first configuration and are subsequently assembled to form a merchandising display unit when required. In known 10 packaging, assembly of the display unit can be complex and take a substantial amount

of time. In some situations this may result in the display unit being assembled incorrectly or in some cases not at all.

It is also known to provide packaging wherein the package assembly is retained in a display configuration using a series of spring based mechanisms. The inclusion of 15 spring based mechanisms in packaging of this type increases the complexity of package

assembly and also the cost. Furthermore, the springs used may lose elasticity over time leading to a malfunctioning display unit.

It is an aim of embodiments of the present invention to provide a package assembly which may be used for both the transportation and display of products located 20 within the package assembly which is quickly and easily moved between a

storage/transportation configuration and a display configuration. It is a further aim of the present invention to provide a package assembly which does not require the use of springs or other complex mechanisms to retain the package assembly in a display configuration.

It is also an aim of the present invention to provide improved methods of using such a packaging assembly.

Summary of the Invention

According to a first aspect of the invention there is provided a package assembly for the storage, transportation and display of products comprising:

an outer container;

an inner container received within the outer container for holding products, the inner container being movable relative to the outer container between a storage position for the storage and transportation of products and a display position in which the inner container at least partly projects from the outer container for the display of products; and a support structure for retaining the inner container in the display position relative to the outer container;

wherein the support structure comprises at least one support flap formed integrally with at least one edge of the outer container, the or each support flap being operable to automatically engage the inner container to hold the inner container in its display position relative to the outer container upon movement of the inner container from the storage position to the display position.

The package assembly may be configured to form a floor standing merchandising unit for displaying said products when in said display position. The package assembly may be configured to hold and display a plurality of packaged products.

In some embodiments the outer container comprises an open lower end comprising at least one edge wherein the or each support flap is formed integrally with at least one edge forming the open lower end.

The or each support flap may be located within the volume enclosed by the outer container, in use. The or each support flap may be located substantially between an inner surface of the outer container and an outer surface of the inner container when the inner container is in the storage position relative to the outer container. The or each support flap may be located such that at least a portion of the or each support flap is in contact with a portion of a surface of the inner container when the inner container is in the display position relative to the outer container. The surface may be the lowermost surface of the inner container.

The or each support flap may be configured such that the or each support flap is operable to move between a position wherein it is located substantially between an inner surface of the outer container and an outer surface of the inner container, and a position wherein at least a portion of the or each support flap is in contact with the lowermost surface of the inner container when the inner container moves from the storage position to the display position relative to the outer container. The or each support flap may be inherently resiliently biased away from the inner surface of the outer container but be held in the position wherein it is located between the inner surface of the outer container and the outer surface of the inner container due to the presence of the inner container. The bias may be such that when the lowermost surface of the inner container is moved above the uppermost end of the or each support flap, the or each support flap falls inwardly. In such embodiments the or each support flap may fall inwardly until prevented from doing so by coming into contact with a further element of the package assembly. The element may comprise a further surface of the outer container, a further surface of the inner container, or in embodiments wherein there is provided more than one support flap, the or each support flap may be prevented from falling further by coming into contact with at least one other support flap forming the support structure.

The or each support flap may comprise a substantially rectangular form. In some embodiments the or each support flap is tapered such that its width varies along its length. The or each support flap may comprise a first end integrally connected to the outer container and a free end and the or each support flap may be tapered such that the or each support flap is wider at the first end than at the free end.

The position of the support structure, and hence the position of the inner container relative to the outer container when the inner container is in the display position, may be chosen by varying the size and/or shape of the flaps forming the support structure.

In embodiments wherein there is provided at least two support flaps, the arrangement may be configured such that each support flap falls inwardly until it contacts and is supported by at least one other support flap to form the support structure.

In some embodiments the inner container may be moved relative to the outer container through an upper opening from the storage position to the display position.

In some embodiments, prior to opening the package assembly, the inner container comprises a closed lower end and the upper end of the outer container is closed, such that the inner and outer containers form a complete enclosure for products located in the inner container when the inner container is in the storage position relative to the outer container.

The outer container may comprise an openable upper end closure arrangement which may be opened to form an upper opening in the outer container. After opening the upper end closure arrangement of the outer container, the inner container may be moved relative to the outer container through the upper opening in the outer container.

In such embodiments the outer container may further comprise a series of perforations, die-cuts, or a combination thereof spaced below the upper end of the outer container to assist in the opening of the upper end closure arrangement.

There may be provided a fold line within at least one surface of the outer container such that the reclosable upper end closure is hingedly connected to at least a portion of the outer container and forming a reclosable closure in the form of a flip top lid, rotatable between a closed position and an open position. The openable upper end closure arrangement of the outer container may be reclosable.

The upper opening of the outer container may be configured such that the inner container can be fully removed from the outer container through the upper opening.

The outer container may be a carton formed from a blank of cartonboard or the like.

The inner container may be a carton formed from a blank of cartonboard or the like. According to a second aspect of the invention there is provided a blank for the manufacture of the outer container of a package assembly according to the first aspect of the present invention comprising: a front wall panel, a rear wall panel and a pair of side wall panels, the wall panels being separated by a series of fold lines; and one or more support flaps each formed integrally with at least a portion of a lower edge of one of the wall panels; wherein the length of the or each support flap is greater than the width of the narrowest wall panel.

The or each support flap may have a tapered form such that its width varies along its length.

According to a third aspect of the present invention there is provided a method of manufacture of the package assembly according to the first aspect of the present invention, using the blank according to the second aspect of the present invention, comprising the steps of:

a) forming the outer container from the blank by folding the or each support flap towards the inner face of its respective wall panel; folding the blank along the fold lines which separate the wall panels in a constant direction so as to form a sleeve comprising a polygonal cross section enclosing a volume containing the or each support flaps; and securing in position; and

b) inserting the inner container into the formed outer container.

The method may further comprise locating a product within the inner container before performing step b). Securing the wall panels in position may comprise attaching at least one securing tab located along the edge of one of the rear wall panel or a side wall panel to an outer face of the other of the rear wall panel or the side wall panel.

According to a fourth aspect of the present invention there is provided a method of storing and/or transporting products using a package assembly in accordance with the first aspect of the present invention comprising the steps of:

a) locating products within the inner container; and

b) locating the inner container within the outer container such that the inner container is in the storage position relative to the outer container.

Step b) may comprise inserting the inner container through the open lower end of the outer container.

The products may be packaged products.

According to a fifth aspect of the present invention there is provided a method of displaying products using a package assembly according to the first aspect of the present invention comprising the steps of:

a) providing the inner container in the storage position relative to the outer container;

b) moving the inner container relative to the outer container; to the display position and

c) retaining the inner container in the display position relative to the outer container using the support structure of the package assembly.

Step b) may comprise moving the inner container through the upper opening in the outer container. The method may further comprise opening the upper end closure arrangement of the outer container before performing step b).

The products may be packaged products. The method may comprise placing a lower end of the outer container on a floor or other generally horizontal surface with the inner container extending upwardly through the upper end of the outer container in the display position to form a merchandising display unit for the packaged products. Detailed Description of the Invention

In order that the invention may be more clearly understood an embodiment thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

Figure 1 is an exploded perspective view of an embodiment of a package assembly of the present invention.

Figure 2 is a plan view of an embodiment of a blank of the present invention which may be used to form an embodiment of the outer container of the package assembly of the present invention.

Figure 3 is a perspective view of a preferred embodiment of the outer container of the package assembly of the present invention.

Figure 4 is a perspective view of a preferred embodiment of the package assembly of the present invention.

Figures 5A-5C are perspective views of a preferred embodiment of the package assembly of the present invention illustrating the operational use of the package assembly. An embodiment of a package assembly 2 in accordance with an aspect of the present invention is shown in the accompanying drawings. Relative directional terms such as upper and lower as used herein, including in the claims, refer to the package assembly when positioned upright on its base as shown in Figures 4 and 5 A to 5 C and should be construed according. When applied to component parts of the package assembly, such terms refer to the orientation of the parts when used in the package assembly in its upright position. It will be appreciated, however, that the package assembly and its parts could be used in other orientations, especially for storage and transportation purposes. The package assembly 2 includes an inner container 4 and an outer container 6.

The package assembly 2 has a storage configuration wherein the inner container 4 is located within the usually closed outer container 6 as illustrated in Figure 4, and a display configuration wherein the inner container 4 is projected telescopically from within the outer container 6 after opening, as illustrated in Figure 5C. Inner container 4 is automatically retained in the projected display position by a support structure 7 formed integrally with the outer container 6. The package assembly 2 may be used to store, transport and display a plurality of packaged products and may form a self supporting, floor standing merchandising unit for the display of the packaged products when in the display position.

Inner container 4 has a front wall 8, a rear wall 8\ and opposed side walls 10,

1(T interconnecting the front and rear walls to define an interior volume of substantially rectangular cross-sectional profile. The inner container 4 also has a lower end closure 12 so that a product or products may be retained inside the interior volume. In the present embodiment, the upper end 14 of the inner container is open and may be profiled with a lower front edge so that product held in the inner container can be seen when the package assembly is in the display configuration. In alternative embodiments, the upper end of the inner container 4 may be provided with an openable and/or removable closure.

The outer container 6 also has a front wall 16, a rear wall 16' and opposed side walls 18, 18' interconnecting the front and rear walls so as to define an interior volume with a substantially rectangular cross-sectional profile. The outer container 6 includes an upper end closure 20. The lower end 21 of the outer container 6 is not closed. The support structure 7 includes extended support flaps 22, 22' 24, 24' that are each hingedly connected with a lower edge of a respective wall 16, 16\ 18, 18' of the outer container. The support flaps 22, 22 ^Λ 24, 24' are folded inwardly and each extends upwardly adjacent the inner surface of its respective wall of the outer container, at least when the package assembly 2 is in the storage configuration. The upper end of the outer container 6 includes an initially sealed but openable flip top lid portion 26. The lid portion 26 is defined by means of a fold line 28 extending across the width of rear wall 16' parallel to but spaced below the upper end of the rear wall and a line of weakness 30 extending about the front and side walls of the outer container parallel to and in the same plane as the fold line. The line of weakness 30 may comprise a line of perforations.

In a preferred embodiment, the inner and outer containers 4, 6 of the package assembly 2 are each formed from a blank of foldable material such as cartonboard, cardboard, paperboard or the like. The choice of material is not limited however to materials of this type. Rather, the inner container 4 and the outer container 6 may be constructed from a metal or plastics material, for example, or indeed a combination of two or more different types of material. The inner container 4 and outer container 6 may be formed from the same materials or from different materials, or different combinations of materials.

An embodiment of a blank 100 used to form the outer container 6 of the present invention is shown in Figure 2. The blank 100 comprises in order from left to right as shown: a first side wall panel 118', front wall panel 116, a second wall panel 118 and a rear wall panel 116', with adjacent wall panels being separated by respective vertical fold lines 120, 120\ 120".

Joined to the lower edge of each of the front panel 116, rear panel 116' and side panels 118, 118' by a respective horizontal fold line 122, 122\ 124, 124' is a respective support flap 22, 22', 24, 24\ The support flaps 22, 22', 24, 24' are each of a generally rectangular form but are tapered such That the width of each flap varies along its length, with the flaps being wider at the edge joined to the respective wall of the outer container than at the free end. The support flaps 22, 22\ 24, 24' have a length which is preferably not less than the narrowest dimension of the outer container (i.e. not less than the width of the narrowest wall panels, which in this case are the side wall panels). Typically each flap has a length which is greater than the width of the outer container 6 but less than the length of the outer container. When the outer container is erected, the support flaps 22, 22', 24, 24" are inherently resiliently biased away from their respective wall of the outer container due to the nature of the material from which the outer container is made. However, the support flaps 22, 22', 24, 24' are dimensioned so that they cannot fall flat within the outer container but rather will contact one another so as to form a frusto- pyramid like support structure 7 to hold the inner container in a raised display position as illustrated in Figure 5C. The length of the support flaps determines the height at which the inner container 4 is supported in the display position and is selected accordingly.

Joined to the upper edge of each of the front panel 116, rear panel 116' and side panels 118, 118' by a respective fold line 136, 136', 138, 138' is an upper end closure tab 102, 102', 104, 104'. The upper end closure tabs are dimensioned and configured so as to be folded over to form a substantially planar upper end closure 20 of the outer container 6 in a conventional manner. Accordingly, the tabs 102, 102' have a length from the respective fold lines 136, 136' which is not greater than the width of each side panel 118, 118' and the length of tabs 104, 104' from respective fold lines 138, 138' is not greater than the width of either the front panel 116 or rear panel 116' so that the tabs can be folded flat to form the upper end closure 20.

Formed in the front wall panel 116 and side wall panels 118, 118' are respective lines of weakness 30, 30', 30" which span the entire width of their respective panels 116, 118, 118'. In addition, rear wall panel 116' further comprises fold line 28. Lines of weakness 30 and fold line 28 form a line which divides panels 116, 116', 118, 118' into an upper portion 110 and a lower portion 112. The upper portion 110 defines the flip-top lid 26 in the erected outer container 6.

Rear panel 116' further comprises securing tabs 114, 114' located along the free side edge of the panel 116'. During erection of the blank to form the outer container 6 as described below, the securing tabs 114, 114' are adhered to the outer surface of the first side wall panel 118'. However, it will be appreciated that the securing tabs 114, 114' could be provided on the free edge of the first side wall panel for connection with the outer surface of the rear wall panel instead. Referring to Figures 2 to 4, a method of erecting the outer container 6 from blank 100 is now described.

Support flaps 22, 22', 24, 24' are folded to overlie the inner faces of their respective panels 116, 116", 118, 118' along respective fold lines 122, 122", 124, 124\ The blank 100 is then folded along vertical fold lines 120, 120", 120" in a constant direction so as to form a sleeve comprising a rectangular cross section with the support flaps 22, 22', 24, 24' on the inside. Securing tabs 114, 114' are subsequently joined to outside side panel 118" using a suitable adhesive to hold the wall panels in position with the panels 116, 116', 118, 118" forming respective outer container walls 16, 16", 18, 18". At this stage the sleeve is open at both its lower and upper ends 21, 202. The partially erected blank 100 can be folded flat at this stage for later completion of the erection process if desired.

In the present embodiment, the securing tabs 114, 114' are attached to the outer surface of the first side panel 118' rather than to the inner surface so as not to impede movement of the inner container 4 or the locking flaps. However, in other embodiments it may be possible to secure the tabs 114, 114' internally.

To complete erection of the outer container 6, the upper end closure 20 is formed by folding the upper tabs 102, 102", 104, 104" inwards along respective fold lines 122, 122", 124, 124". Each upper tab is secured to at least one further upper tab such that upper tabs 102, 102", 104, 104" form the substantially planar upper end closure 20 of the outer container 6. Each upper tab 102, 102", 104, 104" may be secured to at least one further upper tab using a suitable tape or adhesive or by any other suitable means.

The inner container 4 may be formed in a similar manner from a corresponding blank of foldable material. The erected inner and outer containers 4, 6 are of complementary shape and size so that the inner container 4 is a close sliding fit within the outer container 6, with the support flaps 22, 22' 24, 24' each being received between its respective wall of the outer container 6 and the corresponding wall of the inner container when the package assembly 2 is in the storage/transport configuration. In the present embodiment, both the outer and inner containers 4, 6 have a rectangular cross-section but it will be appreciated that they could be other shapes such as square, triangular or indeed circular in cross-section.

In use, the inner container 4 is loaded with product and is inserted into the partially closed outer container 6 through the open lower end 21 so that the support flaps 22, 22", 24, 24' are located between their respective wall of the outer container 6 and the corresponding wall of the inner container 4. With the inner container 4 fully inserted, the package assembly 2 forms a fully enclosed receptacle for the products which are securely held between the lower end closure 12 of the inner container 4 and the upper end closure 20 of the outer container 6. In this configuration, the package assembly 2 can be used in a conventional way for storage and transportation of the enclosed product. Once at a point of sale or other display location, the package assembly 2 can be placed with the outer container 6 upright on the floor or other suitable surface and the upper end of the outer container 6 opened by tearing the material in the front and side walls of the outer container along the line of weakness 30 and the pivoting lid portion 26 backwards about the fold line 28 as illustrated in Figure 5 A.

Opening the lid portion 26 reveals an upper end portion of the inner container as shown in Figure 5 A so that product held in the inner container can be seen. This also allows access to inner container 4 from outside of the outer container 6. If desired, the inner container 4 can be raised relative to the outer container 6 by sliding it upwardly through the open upper end of the outer container 6 to a display position as illustrated in Figures 5B and 5C. The inner container 4 is raised until its lower end 12 moves above the uppermost end of the support flaps 22, 22', 24, 24\ At this point, the flaps 22, 22', 24, 24 ^' fall inwards due to their natural bias as previously described to a position wherein each flap 22, 22', 24, 24' contacts and is supported by at least one other flap forming a stable support structure 7. Inner container 4 is then lowered so that its closed lower end 12 rests on the support structure 7. This holds the inner container in the raised display portion.

As already discussed, the height at which the inner container 4 is supported in the display position is determined by the length of the flaps 22, 22', 24, 24" which are configured accordingly. Preferably, the inner container 4 should be supported a position where a sufficient portion of the inner container 4 is still located in the outer container 6 so that the arrangement is stable.

If it is desired to reclose the package assembly 2, the inner container 4 can be fully removed through the upper end of the outer container 6 and re-inserted through the lower end. The flip-top lid 26 can be reclosed to retain and remaining product in the inner container.

Whilst the present embodiment the outer container 6 has four support flaps 22, 22 \ 24, 24 \ one on each wall, fewer support flaps could be used provided the inner container 4 can be stably supported in the display configuration. It is envisaged, for example, that the support structure 7 may be formed in some embodiments using only one pair of opposed flaps 22, 22" or 24, 24' for example. Rather than having a flip-top lid 26, an upper end region 110 of the outer container 6 may be fully removable. For example, the line of weakness 30 could be extended across the rear wall 16' as well as the front and side walls

The inner container 4 may further comprise a handle or grip portion in the upper section 14 which aids in the movement of the inner container 4 with respect to the outer container 6, in use. The inner container 4 could also comprise an inner divider or shelf on which product is located or may itself hold a further container in which product is held.

The package assembly 2 will typically be used to store, transport and display a plurality of packaged product units. In its storage position, it can be used as a conventional packaging carton to store and transport the packaged products to a retail outlet or the like. At the retail outlet, the assembly is moved to its display position as described to form a self-supporting, floor standing merchandising unit in which the packaged products are displayed in the raised inner container, the outer container forming a base or plinth for the display. Depending on its location, potential customers may be able to remove packaged products from the assembly for purchase. The package assembly 2 therefore provides a versatile packaging carton that can be formed into a self supporting, telescopic merchandising unit. Product information and display graphics can be printed on the exposed surfaces of the inner and outer containers to form an attractive merchandising display unit.

The above embodiment is described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.