SHIPPING CONTAINER FOR CARDED PACKAGES

Abstract

Specially designed shipping containers and a method of packing the containers are disclosed which orient carded packages having a bottom portion substantially larger than a top portion in alignment to facilitate efficient packing with reduced empty space in the containers for shipping of the carded packages and facilitate easy removal of the carded packages from the shipping container for display. The shipping containers use less packing material per carded package the resulting lighter smaller containers require less fuel to ship and producing less waste resulting in a “Green” shipping container. A method of packing such shipping containers is disclosed.

Description

FIELD OF THE INVENTION

This invention relates to a shipping container which orients display card packages in alignment to facilitate efficient, space saving packing for shipping of the packages and facilitates easy removal of the carded packages from the shipping container for display such as in a retail outlet. Specially designed shipping containers are used to orient display card packages in alignment to facilitate efficient packing with reduced empty space in the shipping containers for storage and transport of the carded packages. The shipping containers use less packing material per carded package the resulting lighter smaller containers require less fuel to ship and result in less waste resulting in a “Green” shipping container. The shipping container further prevents damage or bending of the carded package, thus reducing scrap or waste. A method of packing such shipping containers is disclosed.

BACKGROUND OF THE INVENTION

In retail stores such as grocery stores, drug stores, convenience stores and “outlet” stores, smaller items can be packaged in sealed plastic or other display card packaging for display and ultimate purchase by the consumer. Non-limiting examples of such display card packaging include items such as batteries and household items such as bowl cleaning tablets, detergents and small parts and the like are often packaged in carded display packs. Products packaged in this way are often displayed in paper trays which allow for easy shelf restocking. Once the supply of packages is exhausted, the stock can be resupplied by placing additional trays containing display card packages onto the shelf. The trays may also be stacked on shelves.

Since the margins for these types of retail stores are razor-thin, operators of such stores are constantly looking for ways to decrease their cost of operating the stores. One cost is the labor needed to move retail items from storage and place them onto the display case for consumers to purchase. It is typically time consuming for a stock person to remove the items from a shipping container and to place them on a display case. This is especially difficult when handling large numbers of packages that need to be placed on a shelf or in a display case. The stock person must align the packages on the shelf or in the display case. Thus, the stockperson typically places packages on the shelf one at a time or only a few at a time. This is inefficient and time consuming. This problem is exacerbated when the need arises to rotate stock, such as the case with items having an expiration date. Rotation of the stock involves moving the older items to the front of the shelf to ensure those items are sold first and placing the newer stock along the rear of the shelf. To accomplish this, the stock person needs to remove all of the old stock from the shelf, place the new stock on the shelf and then return the old stock to the front of the shelf in front of the new stock. This can become quite a time consuming chore if the packages are placed on the shelf one at a time or only a few at a time.

Existing shipping containers such as those disclosed in U.S. Pat. Nos. 7,549,542; 5,730,296 and 6,953,118 provide for efficient removal and display of carded packages, however, these container can waste 50 percent or more of the internal volume of the container as a result of inefficient packing of the carded packages. There has not been a shipping container that would provide for an efficient method for packing and removing such tray packed carded packages from a shipping container and placing them on shelf. An efficient container will reduce shipping and packaging costs. The present invention to provides a shipping container and method to facilitate the efficient space saving packing, shipping and quick and efficient transfer of packaged items from a shipping container to a shelf or a display case in a retail store or other outlet.

SUMMARY OF THE INVENTION

Specially designed shipping containers have been developed to ship and orient display carded packages in alignment to facilitate efficient packing with reduced empty space in the shipping containers and facilitate easy removal of the carded packages from the shipping container for display. The shipping containers use less packing material per carded package the resulting lighter smaller containers require less fuel to ship and result in less waste resulting in a “Green” shipping container. The shipping container further prevents damage or bending of the carded package, thus reducing scrap or waste. Carded packages referred to herein have a bottom portion of each carded package substantially thicker than the top portion,

To facilitate the transfer of packages from the shipping container, the packages to be shipped should be oriented in the shipping container so the carded end. This alignment allows the stock person to easily thread the rod of the transfer tool through the openings of a number of packages for transfer to the peg of the display board. The shipping containers, or cartons, of this invention are designed to allow the packages to be placed in the containers lying down yet opened in such a way that the packages are oriented vertically with the openings, adjacent to the upper portion thereof, substantially aligned. This facilitates the placement of the transfer tool through the openings in the packages. One embodiment of the shipping container includes a divider that keeps the rows of packages separate and helps to maintain proper orientation and alignment of the packages.

A method of this invention comprises, removing tear strips from the side walls of a packed and sealed shipping container thereby dividing the container into two parts and with the aid of dividers placed in the container at the time of packing, dividing the oriented and pushed together carded display packages such that each shipping container portion contains one tray of carded display packages ready to be placed on a shelf.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present invention are illustrated in the appended drawings in which like reference numbers refer to like elements and in which:

FIG. 1 is a plan view of a first embodiment of a blank for the shipping container;

FIG. 2 is a plan view of a second embodiment of a blank for the shipping container;

FIG. 3 is a perspective view of a partially erected shipping container made from the first embodiment of the blank of FIG. 1;

FIG. 4A is a perspective view of a tray containing carded packages;

FIG. 4B is a perspective view of a tray containing carded packages;

FIG. 5 is a plan view of a tray;

FIG. 6 is a perspective view of two opposing trays containing carded packages with one tray rotated 180 degrees pushed together;

FIG. 7A is a perspective view of a two opposing separators;

FIG. 7B is a plan view of a single unit separator;

FIG. 8 is a perspective view of a shipping container containing two opposing trays and two separators;

FIG. 9 is a perspective view of a shipping container containing two opposing trays and two separators positioned for closure of the shipping container;

FIG. 10 is a perspective view of a shipping container containing two opposing trays and two separators about to be closed;

FIG. 11 is a perspective view of a shipping container containing two opposing trays filled with carded display packages after the shipping container has been opened.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a plan view of a paperboard blank 100, that can be used to make a shipping container that is particularly useful in combination with carded blister or carded box packs. This blank includes a pair of tear strips that facilitate opening the container after it has been shipped to a retail outlet or other final destination. Referring to FIG. 1, paperboard blank 100 incorporates an adhesive tab 105 and four main panels 110, 120, 130 and 140. Adhesive tab 105 is connected along its right edge to the left edge of first main panel 110 along score line 111. First main panel 110 is connected along its right edge to the left edge of second main panel 120 along score line 121. Second main panel 120 is connected along its right edge to the left edge of third main panel 130 along score line 131. Third main panel 130 is connected along its right edge to the left edge of fourth main panel 140 along score line and 141. Each main panel 110, 120, 130, and 140 adjoins a top flap and a bottom flap, wherein the main panels are separated from the top flaps by a top score line 150 extending across the entire blank and the main panels are separated from the bottom flaps by a bottom score line 160 extending across the entire blank.

Above first main panel 110 is first top flap 115A. Above second main panel 120 is second split top flap 125A1 and 125A2. Above third main panel 130 is third top flap 135A. Above fourth main panel 140 is fourth split top flap 145A1 and 145A2.

Below first main panel 110 is first bottom flap 115B. Below second main panel 120 is second split bottom flap 125B1 and 125B2. Below third main panel 130 is third bottom flap 135B. Below fourth main panel 140 is fourth split bottom flap 145B1 and 145B2.

A first vertical perforation 126 extends from the top right edge of bottom flap 125B1 through second main panel 120 to the bottom right edge of top flap 125A1. A second vertical perforation 128 extends from the top left edge of bottom flap 125B2 through second main panel 120 to the bottom left edge of top flap 125A2. The two vertical perforations 126 and 128 define a tear strip 127.

A third vertical perforation 146 extends from the top right edge of bottom flap 145B1 through second main panel 140 to the bottom right edge of top flap 145A1. A fourth vertical perforation 148 extends from the top left edge of bottom flap 145B2 through second main panel 140 to the bottom left edge of top flap 145A2. The two vertical perforations 146 and 148 define a tear strip 147.

FIG. 2 is a plan view of a paperboard blank 200, that can be used to make a shipping container that is particularly useful in combination with carded blister or carded box packs. The container formed by paperboard blank 200 has top and bottom flaps 225A1; 225A2 and 245A1; 245A2 and 225B1; 225B2 and 245B1; 245B2 respectively that are not initially split resulting a tighter sealed and stronger container when such properties are desired. This blank includes a pair of tear strips that facilitate opening the container after it has been shipped to a retail outlet or other final destination. Referring to FIG. 2, paperboard blank 200 incorporates an adhesive tab 205 and four main panels 210, 220, 230 and 240. Adhesive tab 205 is connected along its right edge to the left edge of first main panel 210 along score line 211. First main panel 210 is connected along its right edge to the left edge of second main panel 220 along score line 221. Second main panel 220 is connected along its right edge to the left edge of third main panel 230 along score line 231. Third main panel 230 is connected along its right edge to the left edge of fourth main panel 240 along score line and 241. Each main panel 210, 220, 230, and 240 adjoins a top flap and a bottom flap, wherein the main panels are separated from the top flaps by a top score line 250 extending across the entire blank and the main panels are separated from the bottom flaps by a bottom score line 260 extending across the entire blank.

Above first main panel 210 is first top flap 215A. Above second main panel 220 is top flap 225A which is divided by tear strip 227 into 225A1 and 225A2. Above third main panel 230 is top flap 235A. Above fourth main panel 240 is top flap 240A which is divided by tear strip 247 into 245A1 and 245A2.

Below first main panel 210 is first bottom flap 215B. Below second main panel 220 is top flap 225B which is divided by tear strip 227 into 225B1 and 225B2. Below third main panel 230 is bottom flap 235B. Below fourth main panel 240 is bottom flap 240B which is divided by tear strip 247 into 245B1 and 245B2.

A first vertical perforation 226 extends from the bottom right edge of bottom flap 225B1 through second main panel 220 to the top right edge of top flap 225A1. A second vertical perforation 228 extends from the bottom left edge of bottom flap 225B2 through second main panel 220 to the top left edge of top flap 225A2. The two vertical perforations 226 and 228 define a tear strip 227.

A third vertical perforation 246 extends from the bottom right edge of bottom flap 245B1 through second main panel 240 to the top right edge of top flap 245A1. A fourth vertical perforation 248 extends from the bottom left edge of bottom flap 245B2 through second main panel 240 to the top left edge of top flap 245A2. The two vertical perforations 246 and 248 define a tear strip 247.

Tear strips 127; 147 and 227; 247 can be formed by standard packaging techniques. For example, this can be done by employing parallel cut lines that define both sides of the tear strips so as to form the outer boundary of the tear strips. Alternatively, the cut lines may be obliquely arranged like legs extending into the center portion of the tear strips and where the legs diverge in the direction of the tear of the tear strip. In addition, a tab may be formed at one end of any of the tear strips. Tabs may be easily grasped by the user to pull off tear strips 127; 147 and 227; 247 respectively to thereby open the container formed from blank 100 or blank 200.

The tear strips may be strengthened with tape, ribbon, cord, plastic, wire and the like. It is preferred that the strengthening material be located on the inside of container on the inside facing surface of the tear strip. Alternately, the strengthening material may be embedded between multiple layers of corrugated material and other outer and inner box layers.

To form a container from blanks 100 or 200, adhesive tab 105, 205 is folded about score line 111, 211 so adhesive tab 105, 205 is generally perpendicular to first main panel 110, 210, which is folded about score line 121, 221 so first main panel 110, 210 is generally perpendicular to second main panel 120, 220, which is folded about score line 131, 231, so second main panel 120, 220 is generally perpendicular to third main panel 130, 230, which is folded about score line 141, 241 so third main panel 130, 230 is generally perpendicular to fourth main panel 140, 240. This results in adhesive tab 105, 205 being adjacent to the right edge of fourth main panel 140, 240. Adhesive tab 105, 205 can be adhered to the right portion of fourth main panel 140, 240 by glue or other mechanical or adhesive means, such as staples or hot melt adhesives to provide the general configuration for the desired container. The joint formed between adhesive tabs 105, 205 with the right portion of main panel 140, 240 is known in the art as a lap joint. Bottom flaps 115B, 215B, 125B1 and 125B2, 225B1 and 225B2, 135B, 235B and 145B1 and 145B2, 245B1 and 245B2 are folded inwardly toward each other and adhered to each other by standard means, such as by glue or other mechanical or adhesive means to form a bottom for the desired container. Preferably, bottom flaps 125B1, 125B2, and 145B1, 145B2, are the inner flaps of the bottom of the box 100. Preferably, bottom flaps 225B1, 225B2, and 245B1, 245B2, are the outer flaps of the bottom of the box 200.

The configuration of such a container 100, at this stage of erection is shown in FIG. 3.

After paperboard blank 100 or 200 is folded as discussed above, it is filled with carded packages 400 preferably contained in tray 500 to be shipped, for example to a retail outlet. There can be two rows of packages or multiples of two rows located in shipping container 100 or 200. The number of rows is not critical as long as there are an even number of rows and there are a number of carded packages 400 in each row and each of the packages is oriented in each row so that card portions 410 of the packages are substantially aligned upward as shown in FIGS. 4A and 4B. The carded packages 400 are shown in optional tray 500.

The tray of the present invention may be any tray suited for holding carded packages. The sides of the tray may be of uniform height as illustrated in FIGS. 4A and 4B, 5 and 6 or with slanted sides or with sides containing various shapes and figures.

Tray Nesting with Fingers and Insertion into the Shipping Container:

Lay 2 loaded trays opposing one another on their sides, with one tray rotated 180 degrees so it is inverted with respect to the other tray. Thereby aligning the carded side 410, FIG. 4A, with the box (package) side 420 FIG. 4B of the carded packages in the opposing tray. Merge the two trays partially together such that a portion of the carded portion of each carded package is pushed between the package portion and carded portion of two adjacent carded packages in the opposing tray. The two trays are aligned such that if the were pushed tightly together the two trays would fit together as illustrated in FIG. 6.

Once the carded packages are partially pushed together, insert 2 finger separators, 700 in FIG. 7A, fingers down as illustrated in FIGS. 8 and 9, then completely push the trays together. with the un-die-cut flat surface over the carded packages in the tray. Preferably, the carded packages are about 75% pushed together before inserting the 2 finger separators 700 in FIG. 7A, fingers down as illustrated in FIG. 8, then completely push the trays together. with the un-die-cut flat surface folded over the carded packages in the tray. The width of fingers 720 is up to about 95% of the width of package portion 420 of the carded packages. The space between fingers 720 is not less than the thickness of two cards 410. Separator fingers 720 are connected to separator panel 710 along score line 740.

A blank for forming a separator of FIG. 7A comprises a paperboard blank having a first portion of a plurality of parallel extensions and a second portion of a panel; wherein adjacent fingers are separated from one another by parallel spaces; and wherein the plurality of extensions are connected on one end to a second portion of the separator, a panel portion and are not connected on the opposing end, the first portion of the separator adjoining the second portion of the separator along a score line extending substantially perpendicular to the parallel fingers;

An alternative finger separator formed of a single blank, FIG. 7B, may be used to separate the carded packages upon opening of the container. Separator 800 is folded along score line 735 thereby forming fingers 720. Once the carded packages are partially pushed together, insert the finger separator 800 fingers down as illustrated in FIGS. 8 and 9, then completely push the trays together, with the un-die-cut flat surfaces 710 folded at score line 740 to lie flat over the carded packages in the tray. Preferably, the carded packages are about 75% pushed together before inserting the finger separator, 800 in FIG. 7B, fingers down as illustrated in FIG. 8, then completely push the trays together, with the un-die-cut flat surfaces folded over the carded packages in the tray. The width of fingers 720 is up to about 95% of the width of package portion 420 of the carded packages. The space between fingers 720 is not less than the thickness of two cards 410. Separator fingers 720 are connected to separator panel 710 along score line 740.

A method of packing a shipping container without using optional trays comprises; forming an open shipping container for carded display packages from a container blank; comprising; forming two rows of carded display packages;

positioning the two rows on their side; rotating one row such that it is inverted with respect to the other row; aligning the carded side of carded packages in one row with the package side of the carded packages in the other row; merging the two rows partially together; inserting the fingers of one or two finger separators into the space between the two partially merged rows of carded packages; merging the two rows completely together; placing the merged rows and one or two separators into the shipping container; and closing the shipping container.

A blank for forming a separator of FIG. 7B comprises a paperboard blank having a central portion and two end portions separated by the central portion, wherein the central portion comprises a plurality of parallel cut outs of about the same length and width positioned at about the same distance from the outer blank edge of the end portions, said central portion forming fingers when folded along a center score line perpendicular to the cut outs at about the center of the blank the end portions of the separator adjoining the central portion of the separator along a score line extending substantially perpendicular to the parallel cut outs at the ends of the cutouts ends which ends are aligned along the perpendicular score lines.

For a container from blank 100, put the tray-finger assembly in to the box. Fold the 4 small flaps, 145A1, 145A2, 125A1 and 125A2, inward, then while applying hot melt adhesive to the two large flaps 115A and 135A, or the two top surfaces of the small flaps, fold and seal the 2 large flaps to the top surface of the small flaps. FIG. 10 illustrates the shipping container about to be sealed. The container flaps may be sealed with conventional adhesives, staples and tapes known in the art and used for this purpose.

For a container from blank 200, put the tray-finger assembly in to the box. Fold the 2 top flaps, 245A1, 245A2, and 225A1; 225A2, inward, then while applying hot melt adhesive to the two flaps 215A and 235A, or the two top surfaces of the top flaps, 245A1, 245A2, and 225A1; 225A2, fold and seal the 2 flaps 215A and 235A, to the top surface of the flaps, 245A1, 245A2, and 225A1; 225A2. The container flaps may be sealed with conventional adhesives, staples and tapes known in the art and used for this purpose.

Shipping container 100 can be easily opened by pulling the end of tear strips 127 and 147 to remove tear strips 127 and 147 respectively. Shipping container 200 can be easily opened by pulling the end of tear strips 227 and 247 to remove tear strips 227 and 247 respectively. With any embodiment of the shipping container, opening the shipping container as set forth above will allow the shipping container to be separated into two portions. A method for opening a shipping container of the present invention comprises locating the two tear strips; pulling the two tear strips wherein the two tear strips are completely removed from the container; separating the container at the two finger dividers and pulling apart the container resulting into two separate containers, FIG. 11; and lifting the tray containing carded packages out of the shipping container.

Thus, as seen in FIGS. 10 and 11, when the shipping container is placed on a horizontal surface and the tear strips removed, the shipping container separates into two portions not connected to each other, that is two separate partial containers. The display card packages in each portion are separated from each other by the finger separators which provide for easy separating of the oriented carded display packages 400 in trays 500. The trays containing the carded packages are easily removed from the divided shipping container for easy placement on a shelf. The flaps of the shipping container partial portions may be pulled to separate them from the inner flaps thereby giving greater access to the contents of the container. Optionally, the shipping container may be packed with display card packages that are not contained in a tray.

This application claims priority of U.S. Provisional Patent Application Ser. No. 61/540,746, entitled “SHIPPING CONTAINER FOR CARDED PACKAGES,” filed on Sep. 29, 2011, which is incorporated by reference herein.

The description of illustrative and preferred embodiments of the present invention is not intended to limit the scope of the invention. Various modifications, alternative constructions and equivalents may be employed without departing from the true spirit and scope of the appended claims.

Claims

1. A shipping container for carded display packages comprising:

first and second opposing side panels, each side panel including a front edge,

a back edge,

a top edge and

a bottom edge;

a back panel joined along opposite sides to the side panels, the back panel defining a first edge and a second edge, each of the first edge of the back panel and the second edge of the back panel adjoining one of the pair of opposing side panels along a back edge thereof;

a front panel joined along opposite sides to the side panels, the front panel defining a first edge and a second edge, each of the first edge of the front panel and the second edge of the front panel adjoining one of the pair of opposing side panels along a front edge thereof;

split first and split second top flaps adjoining each of the first and second side panels respectively along the top edges thereof;

split first and split second bottom flaps adjoining each of the first and second side panels along the bottom edges thereof;

two, finger separators having a first portion of a plurality of parallel extensions and a second portion of a panel; wherein adjacent fingers are separated from one another by parallel spaces;

wherein the plurality of extensions are connected on one end to a second portion a panel and are not connected on the opposing end, the first portion of the separator adjoining the second portion of the separator along a score line extending substantially perpendicular to the parallel fingers;

a first tear strip extending through the first side panel and a second tear strip extending through the second side panel; wherein removal of the tear strips splits the container into two portions each portion capable of holding a plurality of carded display packages aligned for display.

2. A blank for forming a shipping container, comprising: a tab having a right edge a left edge a top edge and a bottom edge; a first main panel having a right edge, a left edge, a top edge and a bottom edge; a second main panel having a right edge, a left edge, a top edge and a bottom edge, the first main panel connected along its right edge to the left edge of the second main panel; a third main panel having a right edge, a left edge, a top edge and a bottom edge, the second main panel connected along its right edge to the left edge of the third main panel; a fourth main panel having a right edge, a left edge, a top edge and a bottom edge, the third main panel connected along its right edge to the left edge of the fourth main panel; a first top flap adjoining the top edge of the first main panel; a second split top flap adjoining the top edge of the second main panel; a third top flap adjoining the top edge of the third main panel; a fourth split top flap adjoining the top edge of the fourth main panel; a first bottom flap adjoining the bottom edge of the first main panel; a second split bottom flap adjoining the bottom edge of the second main panel; a third bottom flap adjoining the bottom edge of the third main panel; a fourth bottom split flap adjoining the bottom edge of the fourth main panel; a first tear strip extending through the second main panel and a second tear strip extending through the third main panel.

3. The blank of claim 2, wherein the first tear strip is located at about the midpoint of the width of the second main panel and the second split top flap.

4. The blank of claim 2, wherein the second tear strip is located at about the midpoint of the width of the fourth main panel and the fourth split top flap.

5. The blank of claim 2, wherein the first and second tear strips are formed by parallel cut lines that define both sides of the tear strips such that the parallel form the outer boundry of the tear strips.

6. The blank of claim 5, wherein the parallel cut lines that define both sides of the tear strips are arranged obliquely.

7. The blank of claim 2, wherein the first and second tear strips are strengthened.

8. A blank for forming a shipping container, comprising: a tab having a right edge a left edge a top edge and a bottom edge; a first main panel having a right edge, a left edge, a top edge and a bottom edge; a second main panel having a right edge, a left edge, a top edge and a bottom edge, the first main panel connected along its right edge to the left edge of the second main panel; a third main panel having a right edge, a left edge, a top edge and a bottom edge, the second main panel connected along its right edge to the left edge of the third main panel; a fourth main panel having a right edge, a left edge, a top edge and a bottom edge, the third main panel connected along its right edge to the left edge of the fourth main panel; a first top flap adjoining the top edge of the first main panel; a second top flap adjoining the top edge of the second main panel; a third top flap adjoining the top edge of the third main panel; a fourth top flap adjoining the top edge of the fourth main panel; a first bottom flap adjoining the bottom edge of the first main panel; a second bottom flap adjoining the bottom edge of the second main panel; a third bottom flap adjoining the bottom edge of the third main panel; a fourth bottom flap adjoining the bottom edge of the fourth main panel; a first tear strip extending through the second top flap, the second main panel and the second bottom flap and a second tear strip extending through the fourth top flap, the fourth main panel and the fourth bottom flap.

9. The blank of claim 8, wherein the first tear strip is located at about the midpoint of the width second top flap, the second main panel and the second bottom flap.

10. The blank of claim 8, wherein the second tear strip is located at about the midpoint of the width of the fourth top flap, the fourth main panel and the fourth bottom flap.

11. The blank of claim 8, wherein the first and second tear strips are formed by parallel cut lines that define both sides of the tear strips such that the parallel form the outer boundary of the tear strips.

12. The blank of claim 11, wherein the parallel cut lines that define both sides of the tear strips are arranged obliquely.

13. The blank of claim 8, wherein the first and second tear strips are strengthened.

14. A blank for forming a separator comprising a paperboard blank having a first portion of a plurality of parallel extensions and a second portion of a panel; wherein adjacent fingers are separated from one another by parallel spaces; and wherein the plurality of extensions are connected on one end to a second portion of the separator, a panel portion and are not connected on the opposing end, the first portion of the separator adjoining the second portion of the separator along a score line extending substantially perpendicular to the parallel fingers;

15. A blank for forming a separator comprising a paperboard blank having a central portion and two end portions separated by the central portion, wherein the central portion comprises a plurality of parallel cut outs of about the same length and width positioned at about the same distance from the outer blank edge of the end portions, said central portion forming fingers when folded along a center score line perpendicular to the cut outs at about the center of the blank the end portions of the separator adjoining the central portion of the separator along a score line extending substantially perpendicular to the parallel cut outs at the ends of the cutouts ends which ends are aligned along the perpendicular score lines.

16. A method of packing a shipping container comprising;

forming an open shipping container for carded display packages from a container blank;

comprising:

loading two trays with carded display packages;

positioning the two trays on their side;

rotating one tray such that it is inverted with respect to the other tray;

aligning the carded side of carded packages in one tray with the package side of the carded packages in the other tray;

merging the two trays partially together;

inserting the fingers of one or two finger separators into the space between the two partially merged trays of carded packages;

merging the two trays completely together;

placing the merged trays and one or two separators into the shipping container; and

closing the shipping container.

17. A method of packing a shipping container comprising;

forming an open shipping container for carded display packages from a container blank;

comprising:

forming two rows of carded display packages;

positioning the two rows on their side;

rotating one row such that it is inverted with respect to the other row;

aligning the carded side of carded packages in one row with the package side of the carded packages in the other row;

merging the two rows partially together;

inserting the fingers of one or two finger separators into the space between the two partially merged rows of carded packages;

merging the two rows completely together;

placing the merged rows and one or two separators into the shipping container; and

closing the shipping container.