Structural Strapped Multi-Pack Packaging

Abstract

A composite unitary package for transporting goods in containers includes a wrapper assembly having two side portions extending vertically from a bottom portion and around the outside of a plurality of the containers. Spacers partially or fully extend between certain of the containers, and one or more inelastic tensioned straps extends around the side portions of the wrapper assembly, and compressively binds the side wrapper assembly portions, the spacers and the containers together such that the frictional forces on the combination of wrapper assembly, spacers and containers form a stable, load-bearing package that withstands transportation forces.

Description

This application is a continuation-in-part of U.S. patent application Ser. No. 11/594,187, filed Nov. 8, 2006 which is a continuation-in-part of U.S. patent application Ser. No. 11/082,984, filed Mar. 18, 2005.

BACKGROUND

This invention is directed to strap-reinforced compressed packaging, including paperboard packaging with separation of wares in the packaging, and the integration of the container in the package. Separation spacers, a tensioned strap, and portions of the package wrapper form a tightly-held load-bearing structural unit suited to multi-layer palletizing, the rigors of transportation, storage and shelf display purposes, with significant economic and ecological benefits.

Paperboard packaging is extensively used for the transportation and display of goods. Current packaging practice does not follow structural engineering principles of integrating all the elements of a package contents with those of the packaging, per se. Thus the available intrinsic strengths of the containers forming the package contents are not fully utilized with that of the package elements per se to provide a robust integrated load-bearing package unit.

This failure to optimize package strength is then reflected in potential failure of individual packages in a multi-tiered palletized or transported load, with consequent damage to the integrity of the whole pallet load, under the stresses resulting from the static and dynamic forces of transportation.

Current packaging practice relies in large measure on the structural strength and rigidity of the exterior carton per se for pallet load stability, thus requiring a cardboard box structure of undue strength and rigidity, with correspondingly high paperboard and glue content. The profligate use of materials to construct such large and thick packaging for multi-layer palletizing, transportation and storage is a little-recognized but important factor that contributes to the generation of greenhouse gases and global warming, and to the denuding of forests.

The current modes of packaging frequently permit relative movement and fretting between adjacent containers within a package, which translates, under transportation conditions, into goods and/or containers damaged from mutual impact with containers within the package. Such internal movement of containers within a package can include sliding, pivoting and tilting, and can result in skewing of containers within the package, which renders the package unstable, thus destroying the stability and integrity of the pallet load, with a consequent cascade of further damage to adjoining packages and their contents.

The prior use of strapping has been generally ineffective, and raises problems of pallet-load-bearing stability, having been used primarily in a bundling role, with a failure to recognize the strap's potential contribution in an integrated load bearing structural component. Earlier theoretical packaging work resulted in undependable packages in the load-bearing sense with un-predicted failures. These shortcomings have been and are particularly disadvantageous in the supply/distribution service, where the primary focus is on palletized handling and transportation of packages of wares. Consequently, commercial application of any similar horizontal tensioned strapped package constructs in the supply chain has not been previously achieved.

Strapped packages having rows and/or columns of three or more containers, upon the application of the forces of transportation, face an additional problem. Unless the containers are prevented from lateral movement, horizontally applied outside forces cause the containers in one column or row to shift, or “nest” relative to the containers in adjacent rows or columns. This shifting causes the containers to become loose in the strapped package, and to possibly rotate or skew in the package, such that the package and containers lose their ability to withstand the application of vertical, horizontal or other transportation forces resulting from the dynamic forces applied to the package during transportation, such as impact forces, shear forces and rotary forces.

SUMMARY OF THE INVENTION

The present invention in an embodiment provides a transportation suitable package assembly of significantly reduced packaging material content, based upon the principle of combining the structure and load bearing capability of the goods containers in the package with the structure of the package per se, using inelastic tensioned binding members, such as inelastic straps, to compress the package and its contents of goods containers into an integrated, stable, structural load-bearing unit.

It will be understood that to meet the needs of industry, packages are required to be suited for loading onto pallets, and also to be able to withstand the rigors of long term rugged transportation and potential mishandling. In this context, more than simple vertical load-bearing capability is required, as transverse dynamic (i.e. skewing or pivoting) loading during transportation may be an inescapable reality, so that resistance to skewing loads may be an essential characteristic of the subject packages, which are referred to as “substantially rigid,” to encompass the requisite anti-skewing and anti-pivoting capability.

Separation between individual containers within the package of the present invention is provided by the provision of spacer media, where each spacer media is compressed between adjacent containers by the tensioned binding inelastic strap member, or members, against the walls of the containers in the package, creating a frictional linking element to prevent skewing of the containers in the package, and further integrating the package and its contents into a stable unitary structural load-bearing, substantially rigid unit that can be arranged in layers upon pallets.

Such pallet loads may consist of a single, uniform product, or may consist of mixed, multi-product pallets, for convenient shipping and distribution in the supply chain.

The use of reduced areas of packaging materials, and of discontinuous package surfaces is particularly helpful in affording improved package ventilation, in the changing of packaged product temperature, by heating or by cooling, with concomitant savings in plant and operating costs.

Further advantages of the present system are: the provision of packaging providing pallet loads of enhanced stability; improved capability for palletizing with a mixture of goods packages; faster shelf transfer due to reduced de-packaging requirements; reduction in material return shipment or discard; facilitated package breakdown due to reduced joints and use of low-tension glue, with improved return handling and transportation; and enhanced re-use of packaging.

The rising costs of packaging, in both materials and labor costs for packaging production and for the handling of packaged goods, together with the adverse impact upon the environment from extreme levels of corrugate production presently required, all combine to make commercial application of the present invention both feasible and highly desirable.

Thus, there is provided a package construct having an outer wall structure; a plurality of containers in tightly packed relation, substantially filling at least the lower portion of the outer wall structure; spacers or spacer walls between a portion of each container and adjacent containers, and inelastic tensioned strapping means wrapped about the wall structure compressing the wall structures, the plurality of containers and the spacers together to provide a substantially rigid unitary structural unit well-suited for stacking in self-supporting, multi-layers, including palletization for shipping. A package of the present invention, which may contain rigid or semi-rigid containers having a load bearing capability, and combinations thereof, can be handled as a structural unit, in the manner of a traditional rigid box.

In most instances, the individual containers within a package are substantially identical. Flaps and spacers between containers, or between portions of containers, can provide a protective cushion between the contents of the package, such spacers serving also to cushion and protect adjacent containers. The tensioned strap compresses the spacers against the containers, or portions of containers, to create a frictional holding force between adjacent containers, which force aids in preventing lateral movement of the containers when transportation forces are applied.

The spacers stabilize and integrate the strength of the containers with the package. The use of interposed spacers between the containers also limits or prevents mutual working, fretting and frictional movement between the goods containers during prolonged and rugged shipping and handling.

The claimed package also serves favorably for display purposes as individual package constructs by the simple expedient, in many instances, of removing the strapping from the package. The present packages also lend themselves to pallet, multiple construct displays. The pallet displays include a single, pallet-size container incorporating the principles and physical attributes of the present invention, to provide a belted, rigid construction.

The surfaces of the paperboard packaging material can lend themselves to printed advertising, and for purposes of pallet-contents, determination in warehouses and storerooms.

The subject package system is readily used with a wide range of products, including cans, bottles, jars, and other containers both rigid and semi-rigid.

The simplified packaging of the present invention protects the package contents against damage due to impact with adjoining package units and/or the application of external forces incurred in transporting the packages, and stabilizes the containers in the package against mutual slipping, sliding, skewing and impact. The packaging in combination with the goods containers themselves form structural, load bearing units, which can function in a support role to overlying layers of packages in multi-tier pallet loads.

The use of a binding member such as an inelastic tensioned strap or straps serves to trap, compress and immobilize the intervening spacer members and the containers in the package, in a compressed relation with adjacent product container surfaces. This stabilized contact induces high frictional forces between the compressed surfaces, such that the spacer members are effectively anchored at both ends, so as to serve as effective bracing struts between the package wall or divider and the product container per se. These high frictional forces also oppose skewing or pivoting tendencies of the container under load forces.

In a subject package containing a number of such stabilized product containers, the package, combined with the containers, becomes a structural unit with enhanced stability and load bearing and load sharing capability. In many instances, such as semi-rigid and rigid products per se, the product and the package paperboard serve as rigid components, compressed together and integrated by the classic lateral compressive forces of the tensioned strapping into a substantially rigid, load-bearing package unit capable of withstanding transportation forces.

In an embodiment of the present invention, the positioning of a strap or straps can be defined by the location of strap recess cut-outs in the side wall portions of the wrapper assembly, which recess cut-outs may also form associated spacers by which the strap compresses the spacer into engagement with a portion of the adjoining goods container.

The subject package construct achieves corners of strength and integrity that provide the idealized “sweet-zones” localized surfaces that are highly resistant to deformation and buckling under compressive lateral strapping loads.

Using substantially inelastic tensioned straps in the present packaging embodiments facilitates both manual and machine deconstruction/reconstruction of the subject package. The characteristics of compressively binding the same package components with the inelastic tensioned straps by hand or by machine assures maintenance of the requisite compressive forces and sustains package integrity to be maintained in the manner of a traditional rigid box undergoing transportation forces.

The paperboard typically used in carrying out the present invention is corrugated paperboard, wherein the inherent stiffness and compressive strength of the paperboard in the direction in line with or parallel to the corrugations is utilized where feasible to enhance the strength and rigidity of the ultimate pack. Such corrugate also has the property of laying flat when unpackaged, for facilitated return and re-use, or recycling. Alternatively, other materials such as molded or fabricated members such as trays or support sheets may be used functionally to also serve the purposes normally envisioned for paperboard.

The tensioned securing strap/straps of the present combination package may utilize a variety of strap features to optimize the use of these packages, both in packing and unpacking, or in repackaging. Such inelastic straps are selected from a wide range, including self-adherent straps, pealable straps, friction-welded straps, strapping with interlocking tabbed ends that are separable by transverse sliding disengagement, and knotted strapping having a pull-release free end.

The spacer used in the package is made of materials selected from the group consisting of paper, corrugated paperboard, plastic sheet stock, labels and sleeves, expanded and non-expanded carpet, rubber, fabric, pre-form egg-carton style material, plastic ring carriers, semi-structural and structural wood, cellulose and oil-based products, fiber products and interposed secondary product. The spacer can be an independent sheet or sheets inserted between the containers, which independent sheets may coincide with the container height. The independent sheets can also be less than the container height. The independent sheets are integrated with the package by compression applied by the tensioned strap and need not contact the paperboard base and paperboard walls. The spacer can also be an adhesive bond between containers. The spacer can also be part of the paperboard, such as a D-cut, protrusion, and alternatively, a flap sandwiched between containers. These D-cuts, protrusions, and flaps can extend from the bottom or from the sides of the package and from other spacers. The spacers ultimately become locked in place by the compressive force of the binding tensioned strap member.

In an embodiment that is not shown, the containers are held against movement by use of an adhesive between the bottom of each container and the lower portions of the outer wall structure. In this embodiment, each container is in abutment with all adjacent containers, and the tensioned strap that extends around the outer wall structure compresses the wall structure and containers together, whereby the adhesive acts as a “virtual” spacer preventing relative movement between the containers and the outer wall structure.

A further, major advantage of the subject packaging system is the facilitation of product handling from pallet to shelf, wherein the removal of the strap or straps then enables the package to be used as a magazine, where contents can be slid on to the shelf or the assembly can be directly placed on the shelf, in a readily viewable and hand-accessible condition, without further unpackaging, for significant manpower reduction. This obviates the current practice of carton slashing with a box cutter. The use of high-tensile, low shear adhesive connected between surfaces of the board package can provide additional integration and stability to the package, while facilitating recycling by enabling the ready reduction of glued corner pieces to their original planar (blank) form.

Environmentally, packaging in accordance with the present invention leads to significant and measurable reduction in the mass of cardboard required per unit of goods shipped, and the elimination of one ton of cardboard production has been equated to a one ton reduction of carbon dioxide emissions, so that significant ecological benefits clearly accrue from the present invention.

The present invention comprises a unitary load-bearing package formed from a cardboard or paperboard product having a base portion and side portions extending vertically around the outside of the containers or around a portion of the outside of the containers. A plurality of containers having rigid or semi-rigid side walls are located in each compartment in an embodiment of the invention, and are supported by the base portion.

At least one tensioned inelastic strap extends horizontally around the container-filled package and is in contact with at least one of the containers through a plurality of recesses in the package side walls in which the strap or straps reside. The tensioned inelastic strap applies a tight compressive force to the outer side walls of the package, the container walls, and the spacers to form a unitary load-bearing transportation package, where the walls of the containers in the package, as well as the strap, the spacers and the outer side walls of the package combine to resist the load forces on the package generated under rigorous shipping conditions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a goods container including drop-in spacers in accordance with an embodiment of the present invention;

FIG. 2 is a plan view of a bottom portion of the wrapper assembly of another embodiment of the present invention having a series of incised D-cut spacers formed in the bottom portion and shown in their non-deployed position;

FIG. 3 is a top plan view of a further embodiment of the present invention providing a package with a transparent cover having non-deployed D-cut spacers in the cover of the package, which spacers extend downward and between containers when deployed;

FIG. 4 is a top plan view of another embodiment of the present invention, comprising a container-loaded package, showing a combination of deployed D-cuts and overlap drop-in dividers;

FIG. 5 is a perspective detail view of the divider used in the package of FIGS. 3 and 4;

FIG. 6 is a perspective detail assembly view of another embodiment of the divider used in the package of FIGS. 3 and 4;

FIG. 7 is a top plan view of a subject package loaded with containers of two different sizes with the smaller sized, or secondary, containers interspersed between the larger containers;

FIG. 8 illustrates an example of D-cut spacers shown non-deployed, used in the embodiment of the present invention illustrated in FIG. 7;

FIG. 9 is a perspective assembly view of a further embodiment of a multi-layer package of the present invention showing goods in tubbed containers;

FIG. 10 is a front elevation of the embodiment of FIG. 9;

FIG. 11 is a perspective view of a bottle-loaded, U-sleeve carton embodiment of the present invention, shown prior to strapping;

FIG. 12 is a top plan view of the embodiment of FIG. 11, showing the spacers between the bottle containers;

FIG. 13 is a perspective view of an assembled, empty sleeve carton in accordance with the teachings of the present invention, wherein container-holding apertures are formed in a top portion of the sleeve carton;

FIG. 14 shows a die-cut blank of the sleeve carton of FIG. 13;

FIG. 15 is a perspective view of a loaded, glued and strapped sleeve carton of the embodiment of FIGS. 13 and 14;

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS OF THE INVENTION

FIG. 1 shows a package 10 in accordance with the present invention. The package 10 has side portions 12, 14 that are notched at their corners 16, which notches receive an encircling inelastic tensioned strap or straps 18 to contact and laterally compress the side portions 12, 14 around the outside of the goods containers 20 in the package. The strap 18 also tightly compresses the containers 20 in abutment with all adjacent containers, in abutment with a side portion 12 or 14 and in abutment with panel spacers 22, 24, to further hold the containers immobile and against movement relative to other containers and relative to side portions 12 and 14. Panel spacers 22, 24 and a cruciform-shaped central spacer 26 are drop-in spacers that are inserted between containers to provide separation of the containers 20, without impeding displacement of the containers 20 into mutual frictional engagement with adjacent containers 20.

The cruciform-shaped spacer 26 for use in a package in accordance with the present invention may consist of two rectangles of corrugated board, each having a mid-width slot extending parallel with the flutes of the board for half the length of each board. One board is reversed and turned at right angles to the other, and the slots slide over each other, to interdigitate the boards, and establish the load-bearing cruciform.

Alternatively, two unslotted boards 26 may be formed at right angles along their midline, and glued back-to-back to form the cruciform section, again with the flutes of the corrugations extending vertically to the height of the cruciform. The cruciform spacer 26 height may be selected to coincide with the top of the package 10, so as to form a strong, load bearing prop, in supporting relation with a superimposed stack of packages.

The four laterally extending arms of the cruciform spacer 26 are of sufficient lateral extent to be sandwiched between centrally located adjacent containers 20, serving to separate and frictionally cushion the containers. The vertical orientation of the corrugated flutes enables the cruciform 26 arms to readily conform to both the initial and the compressed ‘strapped’ location of the respective containers, and to exert high friction/tensile stabilization forces on the containers 20, when the package is strapped.

The high frictional forces thus developed by the cruciform spacer 26 under the persistent compression force of the tensioned strap/straps 18 also serve to mutually stabilize the containers 20 along a vertical axis to counter any skewing or pivoting tendencies of the container engendered from loads applied externally to the package, such as experienced during transportation. The package 10 has a bottom portion 28 to support the containers 20 and spacers 22, 24 and 26. Under the compressive forces provided by the strap or straps 18, the spacers 22, 24, 26 are compressed between adjacent containers 20 into high-friction integrating contact, thereby integrating the package into a unitary, load-bearing structural unit with all elements of the package 10 remaining immobile relative to each other upon the application of transportation forces.

Turning to FIG. 2, a package 30 with side walls 32 is used to package cylindrical shaped goods containers 34. The cylindrical shaped containers 34 are placed on the bottom portion or sheet 36. The bottom sheet 36 has a series of D-cuts 38, many being illustrated beneath containers 34 and all of them shown in their initial, un-deformed, as cut and non-deployed condition. The form of D-cuts 38 shown is illustrated with a broken base and fold line 40 which comprises the uncut pivot line about which each D-cut 38 is pivoted upwardly substantially ninety degrees, out of the plane of the bottom sheet 36.

The D-cuts 38 have their base lines 40 located and oriented to be tangential to the bottom of containers 34, such that, when bent upwardly normal to the plane of bottom sheet 36, the laterally inclined, upwardly projecting portion 42 of the D-cut 38 has an angled, ‘wrapping’ component of its length to provide an extended contact area with the surfaces of adjoining adjacent containers 34. The D-cuts 38 now serve as spacers to separate the containers 34 from each other. The portion of each D-cut 38 adjacent the base line 40 abuts and locates the base of the adjoining container 34.

A tensioned inelastic strap or band 44 compresses the side walls 32 of the package 30, and across corner flaps 46 contacts a portion of the containers 34 and compresses the containers 34 into tightly abutted, mutually bracing relation. The respective D-cuts 38 that are in compressed relation with the sides of the containers 34 create a series of high frictional links between the respective individual containers 34, the D-cuts 38 and adjacent containers, while securing the bottoms of containers 34 to package bottom sheet 36.

The tensioned strap 44 holds the corner flaps 46 in place. The tensioned strap 44 compresses the side walls 32 of the package 30, at least a portion of the surface of ‘corner’ goods containers 34, and the D-cut spacers 38, thereby locking the entire compressed assembly of containers 34 and D-cuts 38 in highly frictionally unitary integrated relation with the side walls 32 and bottom sheet 36 of package 30, so as to form a structural, load bearing package 30.

Turning to the embodiment of FIGS. 3 and 4, the illustrated D-cuts 48 are of semi-horseshoe form, being formed in the transparent lid 50 of a package 52, and illustrated in their as-cut, under formed and non-deployed condition. Each D-cut 48 has a pair of spaced-apart, uncut straight baselines 54, about which the D-cut 48 pivots for insertion between mutually abutting adjacent containers 56 (FIG. 4). Additional dividers 58 may be placed so as to extend upwardly from the bottom sheet 60 of the package 52, or inserted downwardly, to provide the desired separation of the containers 56. Concerning the central four containers 62, while sheer impact loads will be substantially dispersed by the adjoining outboard containers, a support/divider in a form such as a cardboard tube (not shown) may be inserted centrally to contact and cushion these four containers 62.

Turning to FIG. 4, the lid of package 52 is removed, showing the details of the bottom sheet 60 D-cuts 38 (FIG. 2) in their upturned position, and with overlap dividers 58 in position. The D-cuts 38 separate the containers 56 from each other as spacers. The dividers 58 hold four containers in the corner of the package 52 stably and in an immovable position relative to the package 52 and the other containers 56 in the package.

In FIG. 5 a modified divider embodiment 66 has end flaps 68 and 70 for gluing attachment to the adjoining wall portion (not shown) of the package 52 of FIG. 3. The outer or x′d surfaces 72 are the gluing surfaces.

In FIG. 6 the modified divider embodiment 74 has projecting insert tab ends 76 which are inserted into recesses 78 that are die-cut into the surfaces of package 52. It will be understood that these attachment modes may be applied to other separators and dividers of the present invention, and that other attachment modes are as known in the art may be used.

Referring to FIG. 7, a package 80 is shown, having larger containers 82 interspaced with secondary smaller containers 84, referred to above as possibly being tequila bottles 82, interspaced by smaller bottles of margarita mix 84. The containers 82, 84 of different sizes are positioned in the package 80 with the pluralities of one size containers 82 interposed between containers of a second size 84. When a tensioned strap (not shown in FIG. 7) is applied laterally to package 80, the adjacent containers of different sizes are compressed into mutual immobilizing positions in the wrapper 86, thus forming a stable load-bearing reinforced structural unit.

FIG. 8 shows a typical arrangement of a portion of the D-cut spacers 88 in bottom sheet 90 (shown beneath containers 92, 94, prior to upward displacement of D-cuts 88 between the containers. Each container 92, 94 is separated from the surrounding containers by the upwardly projecting D-cut spacers 88. The tensioned straps extend laterally around package 96, but have been omitted from FIG. 8 for purposes of clarity. Applying the tensioned straps and compressing the side walls 98 of the package, the containers 92, 94 and the spacers 98 tightly against each other creates a stable load-bearing reinforced structural unit with the containers, package walls and D-cut spacers held in an immobile position relative to each other. It is also feasible to use an upper sheet with D-cut spacers 88 in the same way as illustrated as a cap structure of the package 96.

FIGS. 9 and 10 show a multi-pack package 100 containing four layers of containers in the form of tubs 102, contained within a closed end package in accordance with the present invention. Transverse dividers 104 having inverted L shaped sections that form U shaped dividers separate and enclose the rows of tubs 102. Alternate ones of the L shaped dividers are reversed to overlap an adjoining divider, to which the former divider is spot glued with high shear, low tensile glue. The dividers 104 also form a cap structure to engage the tops of the containers 102. Tensioned straps 108 overlie the outer end of each of the dividers 104 and bind the four end flaps of package 108. The binding force of straps 106 on the package 100 compresses the dividers 104, the containers 102 and the end flaps 108 together to provide a strong and stable package that can withstand transportation forces acting on the package. The end flaps 108 may also be spot-glued.

FIG. 11 illustrates a loaded U-shaped sleeve 110 filled with bottle containers 112, prior to the application of peripheral tensioned strapping (not shown) through the strap cut outs 114. The sleeve 110 is folded to have two side panels 116 and a bottom panel 118. When the tensioned strap is applied, as described above, a compressive force is applied to the containers 112, side panels 116 and spacers or D-cuts 120, to compress all of the containers immobile relative to all adjacent containers and the sleeve 110. FIG. 12 shows D-cuts 120 extending upwardly from the bottom panel 118 of sleeve 110 into their upwardly deployed, interposed, cushioning frictional relation between adjacent ones of the containers 112. The D-cuts 120 prevent lateral movement of containers 112 in sleeve 110.

FIG. 13 discloses an embodiment of the present invention comprising an empty sleeve 122 in its final, closed form, without a showing of goods containers or securing tensioned straps. Referring to the blank 124 of sleeve 122, shown in FIG. 14, the top panel portion 126 forms a cap structure and has a series of apertures 128 to receive the caps of the containers 112, as seen in FIG. 15. The side panel portions 130 have strap cutouts 132 at their edges. An edge gluing panel 134, which forms a part of bottom panel 136 overlaps the opposed side panel 130, to which panel 134 is spot glued, after loading of the goods containers 112 into sleeve 122, and installation of the tensioned straps of the assembly.

In use, as shown in FIG. 15, the goods containers 112 (illustrated as bottles) are loaded on the bottom panel 136 with dividers or spacers 138 inserted between the rows of bottles. The side panel portions 130 and top panel portion 126 are folded over, with the apertures 128 engaging the caps of the bottle containers 112, and the edge gluing panel 134 glued to the side panel portion 130. The apertures 128 and dividers or spacers 138 act in combination to position the bottle containers 112 in their intended places and prevent them from moving when undergoing transportation when stacked. Two tensioned straps 140 are then applied around sleeve 122 and through cutouts 132, in tensioned, securing relation with the package, applying compressive force to the containers 112, side panels 130, and spacers 138, which compressive force in combination with the apertures 128 prevent the bottle containers from moving when the package is transported

Specific embodiments of structural tensioned strapped multi-pack packaging has been described for the purpose of illustrating the manner in which the invention is made and used. It should be understood that the implementation of other variations and modifications of the invention and its various aspects will be apparent to one skilled in the art, and that the invention is not limited by the specific embodiments described. Therefore, it is contemplated to cover the present invention and any and all modifications, variations, or equivalents that fall within the true spirit and scope of the basic underlying principles disclosed and claimed herein.

Claims

1. A composite unitary package for transportation, storage and display, comprising:

an assembly comprising a bottom portion and at least two side portions, said side portions extending vertically around the outside of a plurality of containers, the containers located on the bottom portion;

at least one spacer extending at least partially between and being in contact with certain of said containers;

at least one laterally extending tensioned member compressively binding said side portions, the at least one spacer, and the containers together;

each container being immobile in relation to adjacent containers and said side portions;

the lateral compression establishing a frictional force between the at least one spacer and said certain of said containers in contact with said at least one spacer, the frictional force resisting movement of said certain of said containers relative to said assembly and relative to other of said containers;

the lateral and frictional forces combining to provide a mutual binding, laterally compressive tightly packed package with each container immobilized in relation to other containers, and the lateral and frictional forces frictionally integrating the binding member, the wrapper, the at least one spacer, and the containers, forming a stable load-bearing reinforced structural unit.

2. The composite unitary package as set forth in claim 1, wherein said at least one spacer comprises at least a first flap on said assembly, the flap projecting from said assembly into contact with at least two of said containers.

3. The composite unitary package as set forth in claim 1, wherein said at least one spacer includes a panel portion inserted between two adjacent rows of said certain of said containers.

4. The composite unitary package as set forth in claim 1, wherein the at least one spacer comprises a protective cushion between said certain of said containers.

5. The composite unitary package as set forth in claim 1, wherein said at least one spacer further includes a cap structure engaging at least a part of certain of said containers.

6. The composite unitary package as set forth in claim 5, wherein said cap structure engages with certain of said containers by one of apertures and D-cuts in the cap structure.

7. The composite unitary package as set forth in claim 1, wherein the at least one spacer is fixed to one of said bottom portion and at least one of said side portions.

8. The composite unitary package as set forth in claim 1, wherein said side portions of the assembly have recesses to receive said tensioned member.

9. The composite unitary package as set forth in claim 1, wherein said at least one spacer is made of materials selected from the group consisting of paper, corrugated paperboard, plastic, corrugate, labels and sleeves, expanded and non-expanded carpet, rubber, fabric, pre-form egg-carton style material, adhesive, plastic ring carriers, semi-structural and structural wood, cellulose and oil-based products, fiber products and interposed secondary product.

10. The composite unitary package as set forth in claim 1, wherein said containers comprise material selected from the group consisting of rigid, semi-rigid, and flexible materials.

11. A composite unitary package containing a plurality of substantially identical containers for transportation, storage and display, comprising:

a wrapper having a bottom portion and side portions, said side portions extending laterally around the outside and at least partially in engagement with and receiving said containers;

said containers disposed in multiple layers in said wrapper, and said multiple layers separated and supported by rows of containers;

at least one spacer extending between said containers;

at least one laterally extending tensioned inelastic strap compressing the at least one spacer, the side portions of the wrapper, and at least one layer of said containers into mutual lateral binding frictional compressive relation;

the wrapper, the at least one tensioned strap, the at least one spacer combining to immobilize the positions of the containers and spacer relative to the wrapper and forming a stable load-bearing reinforced structural package unit.

12. The composite unitary package as set forth in claim 11, wherein said at least one spacer comprises an inverted U-shaped section that separates and encloses said rows of containers.

13. The composite unitary package as set forth in claim 12, wherein said at least one spacer is formed from conjoined L-shaped sections that overlap an adjoining L-shaped section to form a cap structure engaging a top of each of said containers.

14. A composite unitary package containing a plurality of containers, said containers being of two different sizes with a plurality of a first size container interposed between a plurality of containers of a second size, comprising:

a wrapper extending at least partially in engagement with and receiving said first size containers;

at least one inelastic tensioned strap compressing the wrapper and the first and second sized containers into mutual lateral compressive relation, the wrapper, the at least one tensioned strap, and the first and second sized containers in compressive contact and immobilizing the positions of the first and second sized containers in the wrapper and forming a stable load-bearing reinforced structural unit.

15. The composite unitary package as set forth in claim 1, wherein said assembly is made of materials selected from the group consisting of cardboard, corrugated paperboard, molded materials and fabricated materials.

16. The composite unitary package as set forth in claim 11, wherein said at least one spacer is independent from said wrapper.

17. The composite unitary package as set forth in claim 1, wherein the side portions have vertically extending flutes providing additional columnar load-bearing strength to said package.

18. The composite unitary package as set forth in claim 1, wherein the binding member is selected from the group consisting of self-adherent strap, pealable strap, friction-welded strap, strapping with interlocking tabbed ends that are separable by transverse sliding disengagement, and knotted strapping having a pull-release free end.

19. The composite unitary package as set forth in claim 1, wherein the bottom portion of the assembly comprises a tray, and said side portions have a first pair of side panels and a second pair of side panels extending vertically around the outside of the plurality of containers.

20. A composite unitary package for transportation, storage and display, comprising:

an assembly comprising a bottom portion and at least two side portions, said side portions extending vertically around the outside of a plurality of containers, the containers extending vertically from the bottom portion;

at least one laterally extending tensioned inelastic strap member compressively binding said side portions and said containers together, each container being immobile in relation to adjacent containers and said side portions;

the lateral compression establishing a frictional force between the containers and said side portions, the frictional force resisting movement of said containers relative to said assembly and relative to other of said containers;

said bottom portion including adhesive disposed in one of: between a portion of each of said containers and between a bottom of the container and the bottom portion of said assembly, said adhesive providing a force restraining movement of said containers relative to said bottom portion of said assembly and relative to other containers;

the lateral, frictional and adhesive forces combining to provide a mutual binding, laterally compressive tightly packed package with each container immobilized in relation to other containers and the side portions, forming a stable load-bearing reinforced structural unit.