CONTAINER ASSEMBLY INCLUDING A POP-UP POCKET COMPONENT

The invention relates to containers that include a pop-up pocket and a pocket support that is attached to container and tilts the pock-up pocket when the container is opened.

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Description
FIELD OF THE INVENTION

The present teachings relate generally to containers, and more specifically to container assemblies that includes one or more pop-up pockets. Preferably the container assembly includes a cover component and the pock-up pocket is directly or indirectly attached to the cover component, such as by the use of one or more pocket supports. The pop-up pocket may provide improved visual appearance of the contents of the pocket and/or improved access to the contents of the pocket.

BACKGROUND OF THE INVENTION

When a container is opened, the contents of the container are generally in the same orientation as when the container was closed. This may make it difficult to see portions of the contents of the container, may be unaesthetic, and/or may make it difficult to remove the contents from the container. As such, there is a need for containers that provide improved access to the contents of the container. There is also a need for containers that provide improved appearance of the contents of the container. There is a additionally a need for containers having a pocket for storing articles. There is also a need for improved structures of containers and/or improved aesthetic features of containers.

SUMMARY OF THE INVENTION

The container assemblies according to the teachings herein solve one or more of, or even all of the aforementioned needs by employing a pop-up pocket component that tilts one or more articles in the container when the container is opened. This may result in an improved aesthetic appearance of the opened container, an improved ability to remove an object from the container, an improved ability to see an object in the container (e.g., a surface of an object that is oriented vertically in the closed container), an improved structure of the container (e.g., a stronger container that better protects an object in the container), or any combination thereof.

One aspect of the invention is direct to a container assembly comprising a lower tray component, a covering component, and one or more pop-up pocket components. The lower tray component preferably includes a base and a plurality of upright walls including a back wall. Each of the upright walls of the lower tray component preferably has an edge facing in a generally upward direction. The covering component includes or consists essentially of a base. The covering component may be an upper tray component. Preferred upper tray components include a base and a plurality of upright walls including a back wall. The back wall of the lower tray component preferably is hingedly attached to the covering component. For example, the back walls of the lower tray component and the upper tray component may be hingedly attached. When the container assembly is a closed configuration, each upright wall of the upper tray component preferably has an edge that faces in a generally downward direction when the container is in a closed position. Preferred pop-up pocket components include a pocket suitable for holding one or more articles. The pop-up pocket component preferably is capable of fitting within a space between the covering component and the lower tray component. The pop-up pocket component preferably includes at least one pocket supports suitable for providing an attachment to both the pocket and to the covering component. For example, the pocket support may be attached to the back wall of the upper tray component and to the base of the pocket (e.g., on the bottom surface of the base). Preferably, the pocket has a base with a bottom surface that faces the base of the lower tray component. The base of the pocket has a back edge that lies towards the back wall of the lower tray component. The pocket support preferably is attached to the pocket on the base of the pocket at a position sufficiently away from the back wall of the lower tray component so that when the covering component (e.g. the upper tray component) is hingedly lifted away from the lower tray component, the pop-up pocket is tilted. The tilt of the pocket may be defined by the tilt angle between the base of the pocket and the base of the lower tray component. When the container assembly is fully open, the tilt angle preferably is about 1° or more.

Another aspect of the invention is directed at a container assembly including a lower tray component, and covering component, and a pock-up pocket component that includes a pocket, wherein the pocket is hingedly attached to the covering component and the covering component is hingedly attached to the lower tray component, so that as the container assembly is opened, the pocket is continuously tilted.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an illustrative container assembly in a closed orientation.

FIG. 2 is a perspective view of an illustrative container assembly including a lower tray component and an upper tray component that are hingedly connected.

FIG. 3 is a perspective view of an illustrative container assembly including a lower tray component and a covering component that are hingedly connected.

FIG. 4 is a perspective view of an illustrative container assembly including a lower tray component and an overlapping upper tray component that are hingedly connected.

FIG. 5 is a cross-sectional view of the container assembly of FIG. 1 taken parallel to the side walls, showing only the lower tray component, the covering component, and the hinge attaching the two components.

FIG. 6 is a cross-sectional view of the container assembly of FIG. 4 taken parallel to the side walls, showing only the lower tray component, the covering component, and the hinge attaching the two components.

FIG. 7 is a perspective view of an illustrative container assembly according to the teachings herein.

FIG. 8 is an enlarged view of FIG. 7 showing an illustrative pocket support connected to a pocket and to a covering component.

FIG. 9 is an illustrative exploded view of the container assembly of FIG. 7 with one side wall removed from the covering component, the insert component, and the lower tray component.

FIGS. 10, 11, 12 and 13 are side views with one side wall removed from the covering component, the insert component, and the lower tray component to show an illustrative container assembly including a pop-up pocket component. In FIG. 10, the container assembly is in a closed position. In FIG. 11, the angle 67 between the back wall 32 of the lower tray component 6 and the back wall 52 of the upper tray component is greater than 90° and less than 180°. In FIG. 12, the angle between the back wall 32 of the lower tray component 6 and the back wall 52 of the upper tray component is about 90°. In FIG. 13, the angle 67 between the back wall 32 of the lower tray component 6 and the back wall 52 of the upper tray component is about 0°.

FIG. 14 is an illustrative blank for a pocket, such as the pocket 12 of FIG. 7.

FIG. 15 is an illustrative exploded view of a container assembly that does not contain an insert component. One side wall is removed from the covering component and the lower tray component.

FIG. 16 is an illustrative cross-sectional view of the container of FIG. 3 showing a portion of a container assembly where a container lid is hingedly connected to a lower tray component.

 DETAILED DESCRIPTION

The container assembly includes a lower tray component and a covering component. The container assembly is suitable for holding one or more articles and preferably includes additional components such as a pop-up pocket component. The covering component preferably is hingedly attached to the lower tray component. As such, the covering component may rotate about the axis of a hinge. A rear portion of the covering component may be generally fixed relative to the lower tray component, and a front portion of the covering component may pivot about the fixed rear portion. When in a closed position, the covering component preferably closes the container assembly and creates a compartment (e.g. a cavity). When the covering component is opened, it may be possible to see some of, or all of the compartment.

The container assembly includes a front region and an opposing back region, a top region and an opposing bottom region, two opposing side regions, and a central compartment region. The container assembly includes a lower tray component that is located in the bottom region and has walls extending into the back, front and side regions. The container assembly includes a covering component that is located at least in the top region. The covering component and the lower tray component preferably are hingedly attached at the back region or proximate the back region. The covering component has a portion at or near the front region of the container assembly that can be lifted and rotated away from the lower tray component (e.g., away from the portion of the lower tray component that is located in the front region of the container assembly).

The container assembly preferably includes one or more pop-up components capable of fitting within the compartment of the container assembly. The pop-up component includes a pocket suitable for at least partially containing one or more articles. The pocket-up compartment preferably includes a pocket support. The pocket support may be attached to both the pocket and the covering component. As such, the pocket support may provide a lever for lifting the pocket (e.g. the back portion of the pocket) when the front of the covering component is lifted. For example, the pocket may become tilted, with the tilt angle increasing as the front of the covering component is lifted for opening the container assembly.

The teachings herein contemplate the structures and features depicted in the accompanying drawings. Variations to the structures and features are also contemplated within the teachings. For example, any dimensions, angles, tolerances and/or proportions shown in the drawings are part of the teachings herein. Departures from the dimensions, angles, tolerances and/or relative proportions shown in the drawings are part of the teachings herein to the extent that such variations do not materially affect the intended operation or functionality of the depicted structures and features. For example, variations in an amount of less than 50%, 30% or 10% are envisioned; variations in an amount of more than 50%, 30% or 10% are also envisioned.

Unless otherwise stated or reasonably apparent from the context of the teachings, geometries may vary from those depicted in the drawings. Sharp corners at free ends of the structures may be rounded. Rounded corners at free ends of structures may be sharp.

The creases and/or scores depicted in the drawings may include perforations, or may be free of perforations. These may be located as depicted in the drawings or moved. Additional scores, creases and perforations may be may be added. Perforations may be omitted, or may be located intermittently or substantially entirely along a crease. For example, perforations may be located along only a portion of a crease (e.g., a total length of slit material being about 90% or less, about 60% or less, about 40% or less, about 20% or less, or about 10% or less).

Any of the various components of the container assembly may be formed from a single continuous sheet, or from one or more sheets. For example, a covering component, an insert component or a tray component may be formed of a first sheet that provides a structure to the component and a second sheet that covers some or all of the first sheet. As such, a second sheet may provide an aesthetic appearance to the component. A component of the container assembly may include sufficient support features, such as side wall connection features so that one or more of the side walls are maintained in a generally orthogonal orientation relative to the base portion, so that adjacent side walls are maintained in a generally orthogonal orientation relative to each other, or both. For example the container may include a sufficient number of support features so that the base portion and any pair of adjacent side walls are generally mutually orthogonal.

Preferred upper and lower tray components include a base and four side walls. Each side wall may be connected to a peripheral edge of the base portion. Each side wall may have two lateral peripheral edges. The lateral peripheral edges of a side wall may be located at opposing edges of the side wall. The lateral peripheral edges of the side walls may be generally orthogonal to the peripheral edge of the base portion. Adjacent side walls may be connected along their lateral side wall edges. The tray may have four corners defined by the intersection of a lateral side wall edge and a peripheral edge of the base portion.

The single continuous sheet may be formed of any material capable of being folded to form various features and/or multiple layers of the container components, such as multiple walls, multiple layers of a wall, multiple layers of the base, or any combination thereof.

The single continuous sheet has a first face and an opposing second face. The thickness of the single continuous sheet (i.e., the distance between the two opposing faces) may be uniform or may vary. Preferably the single continuous sheet has a thickness that is sufficiently uniform so that it can be made from stock materials (e.g., card stock, sheet stock) or other material having generally uniform thickness. As used herein, a sheet having uniform thickness has a thickness with a standard deviation of about 20% or less, about 10% or less, about 5% or less, or about 1% or less. For example, the standard deviation of the thickness may be about 0%.

One or both of the faces of the sheet may be adapted for printing directly on its surface. Preferably at least one of the faces is adapted for printing directly on its surface. For example, the sheet may include one face that is a show surface and an opposing face that is a hidden surface. When folded into a container, one or more portions of the show surface may be visible. When folded into a container, preferably none of the hidden surface is visible. Nevertheless, it may be advantageous to have printing on a hidden surface so that instructions or other features may be provided on that surface. It is also possible to fold a sheet and/or employ openings in a sheet so that portions of both faces are visible.

A component of the container may include any number of layers (e.g., base layers, wall layers, or both). For example, the base may include a plurality of base layers, one or more side walls (e.g., each side wall) may include a plurality of base layers, or both. Depending on the materials selected, a single layer may generally have insufficient strength to support the component of the container. By using a plurality of stacked layers, a component having sufficient strength may be achieved. The number of base layers that form the base may be about 1 or more, about 2 or more or about 3 or more. The number of side wall layers that form a side wall may be about 1 or more, about 2 or more or about 3 or more. Each side wall of a component may have the same number of side wall layers or may differ in the number of side wall layers. Preferably, each side wall of a component has the same number of side wall layers. It will be appreciated that the number of layers of a feature (e.g. a base and/or a wall) may depend on the thickness of the material employed for a layer and/or the strength of the material.

A base layer preferably extends over a majority of, a substantial portion of, or even the entirety of the base (e.g., the tray base, the insert base, or the pocket base). For example a base layer may span about 50% or more, about 70% or more, about 90% or more, about 95% or more, or about 99% or more of the base, as defined by the ratio of the area of the base layer to the area of the base.

The base may have any shape, and preferably has a polygonal shape. More preferably the base portion has a generally rectangular shape which may be a square shape. The base may have a first pair of peripheral edges along opposing sides of a polygonal (e.g., rectangular) base. The base may have a second pair of peripheral edges along different opposing sides of a polygonal base. For example the base may have four sides and the two pairs of peripheral edges may define the circumference of the base portion.

A sheet (i.e., a blank) for a component or element of the container may be formed by die cutting a sheet stock material. As such, the single continuous sheet may be a die cut preform for a container component. Any material suitable for folding, die cutting, or both may be employed. The sheet material may be a single layered material or may have multiple layers. For example the sheet may include a layer of a polymer, a layer of a paper, or both. A particularly preferred material is a paperboard. Any paperboard may be employed. The sheet material preferably has a thickness that is sufficiently low so that the sheet can be easily folded, die cut, or both. The thickness of the sheet material preferably is about 2 mm or less, more preferably about 1.5 mm or less, even more preferably about 1.2 mm or less, even more preferably about 1.0 mm or less and most preferably about 0.8 mm or less. The thickness of the sheet material preferably is sufficiently high so that the container can be assembled without having to fold an excessive number of layer (e.g., for forming a base). The thickness of the sheet material preferably is about 0.1 mm or more, more preferably about 0.2 mm or more, even more preferably about 0.25 mm or more, even more preferably about 0.30 mm or more, and most preferably about 0.35 mm or more. For example, the sheet material may be a paperboard characterized as about 8 point, 10 point, about 12 point, about 14 point, about 16 point, about 18 point, about 20 point, about 22 point, about 24 point, or about 26 point, about 28 point, about 30 point, or about 32 point.

The blank for a container may include regions having creases, regions having slits, regions having perforations, or any combination thereof. Creases preferably are employed in areas that provide a structural feature, such as a connection between two adjacent side walls. Creases are also preferably employed to allow easy folding, defined folding, or both in regions that will be visible in the assembled container. Preferably, the assembled container is free of visible slits or perforations. Perforations and/or slits preferably are employed for folding in regions that are not visible in the assembled container and may not be required to provide a structure between the areas on either side of the fold.

The lower tray component includes a base. The base is preferably located at the bottom region of the container assembly. The lower tray component includes upright walls that extend from the base. The lower tray may contain one or any combination of the following, and preferably all of the following: a front wall (e.g., located in the front region of the container assembly), a back wall (e.g., located in the back of the container assembly), or two opposing side walls (e.g., located in the opposing side regions of the container assembly). Two adjacent upright walls of the lower tray component may have the same height or may have different heights. Preferably two adjacent upright walls of the container have the same height and/or have heights that differ by less than about 30% (e.g., less than about 10%). The two opposing side walls of the lower tray component may have the same height or may have different heights. Preferably two opposing side walls of the container have the same height and/or have heights that differ by less than about 30% (e.g., less than about 10%). The front and back walls of the lower tray component may have the same height or may have different heights. Preferably the front and back walls of the lower tray component have the same height and/or have heights that differ by less than about 30% (e.g., less than about 10%). The base of the lower tray component has a length defined by the distance in the direction from the front wall to the back wall. The base of the lower tray component has a width defined by the distance in the direction between the two side walls.

As discussed herein, the covering component preferably is hingedly attached to the lower tray component at or near the back region of the container assembly. The covering component includes at least a base that preferably is located in the top region of the container assembly. The base of the covering component has a length defined by the distance in the direction from the front to the back regions of the container assembly. The base of the covering component has a width defined by the distance in the direction from one side region to the other side region. The bases of the lower tray component and the covering component may have lengths that are the same or different. Preferably the length of the base of the covering component is about equal to or greater than the length of the base of the lower tray component. More preferably, the length of the base of the covering component is equal to the length of the base of the lower tray component. The bases of the lower tray component and the covering component may have widths that are the same or different. Preferably the width of the base of the covering component is about equal to or greater than the width of the base of the lower tray component. More preferably, the width of the base of the covering component is equal to the width of the base of the lower tray component. The covering component may be an upper tray component including one or more walls projecting downward from the base of the covering component. The upper tray component may contain one or any combination of the following, and preferably all of the following: a front wall (e.g., located in the front region of the container assembly), a back wall (e.g., located in the back of the container assembly), or two opposing side walls (e.g., located in the opposing side regions of the container assembly). If employed, the walls of the upper tray component may have one or any combination of the features described for the lower tray component (e.g., relative heights of adjacent and/or opposing walls).

The pop-up pocket component includes a pocket suitable for holding or at least partially holding one or more articles. The pocket may have any shape or size. The pocket preferably has a front wall, opposing side walls, a base, and a top wall opposing the base. The pocket preferably does not have a back wall. The pocket preferably is sized so that it fits within the compartment of the container assembly when the container assembly is in a closed configuration (i.e., with the covering component in a closed position). The pocket preferably has a closed end (e.g., proximate to the front region of the container assembly) that tilts downward when the container assembly is opened. The pocket preferably has a closed end (e.g., proximate the back region of the container assembly) that tilts upward when the container assembly is opened. The pocket may have one or more features that facilitates the removal of an article from the pocket or facilitates the viewing of the article in the pocket. For example, the pocket may have a top wall having a length that is sufficiently short so that the article can be easily viewed and or easily removed from the pocket. For example, the ratio of the length of the top wall of the pocket to the length of the base of the lower tray component preferably is about 0.95 or less, about 0.90 or less, about 0.85 or less, about 0.80 or less, or about 0.75 or less. The length of the top wall of the pocket should be sufficiently long so that the articles in the pocket are orderly maintained in the pocket and/or so that a portion of the article is hidden from view when the container assembly is opened. The ratio of the length of the top wall of the pocket to the length of the base of the lower tray component preferably is about 0.10 or more, about 0.20 or more, about 0.30 or more, about 0.40 or more, or about 0.50 or more. The side walls of the pocket may be similarly reduced in length. The top walls and side walls may be rectangular or one or more of these walls may have a non-rectangular shape. For example the length of a side wall may vary (e.g., become reduced) going from the base to the top wall. The ratio of the surface area of the top wall of the pocket to the surface area of the base of the lower tray component preferably is about 0.9 or less, more preferably about 0.8 or less, even more preferably about 0.7 or less, and most preferably about 0.6 or less

The pop-up pocket component includes a pocket support. The pocket and the pocket support may be integrated (e.g., made from a single blank) or may be provided as separate sub-components (e.g., made from separate blanks). The pocket support generally functions as a lever for lifting some of, or all of the pocket. For example, the pocket support may function as a lever for lifting a portion of the pocket near the back of the container assembly so that the pocket becomes tilted. The pocket support preferably includes a first portion for connecting with the covering component. The pocket support preferably includes a second portion for providing a lever. The pocket support preferably includes a third portion for connecting with the pocket. For example, the third portion of the pocket support may be connected with the bottom surface of the base of the pocket. The pocket support may include one or more hinges. For example, the pocket support may include a hinge between the first and second portions, between the second and third portions, or both.

Insert Component

The container assembly may include an insert component. It will be appreciated according to the teachings herein that the container assembly may be free of an insert component. Preferred insert components are trays having a base, a front wall and two side walls. The insert component preferably is free of a back wall. If the insert component includes a back wall, it preferably is sufficiently short so that the pocket support can attach to the back wall of an upper tray component. The front wall of the insert component preferably contacts the inside surface of the front wall of the lower tray component. The front wall of the insert component preferably extends above the height of the front wall of the lower tray component. The side walls of the insert component preferably each contact the inside surface of one of the side walls of the lower tray component. The side walls preferably have a height that extends above the height of the of the corresponding side walls of the lower tray component. One or more of the walls of the insert component may be a supporting wall. A supporting wall may contact the base of the covering component when the container is closed. One or more of the walls of the insert component may be a reinforcing wall. A reinforcing wall may reinforce the structure provided by the walls of the lower tray component and or the upper tray component. One or more walls of the insert component may function as a guide wall for guiding the covering component into position when closing the container assembly.

As used herein, a tray component (e.g., an upper tray component, a lower tray component, or a tray of an insert component) preferably is free of a top wall (i.e., a ceiling).

The container assembly preferably includes a hinge component that hingedly connects the lower tray component and the covering component. The hinge component may be any mechanical means of allowing the covering component to rotate about an axis defined by or parallel to the distal edge (i.e., the top edge) of the back wall of the lower tray component. When covering component includes a back wall 52, the rotation may be defined by the angle, α, between the planes of the two back walls 32, 52. When the container is closed and the two back walls are parallel and/or coplanar, the angle α is preferably about 180°. As the container is opened, the angle α decreases. The container preferably may be opened to an angle α of about 110° or less, preferably about 80° or less, even more preferably, about 45° or less, and most preferably about 20° or less. For example it may be possible to rotate the back wall of the upper tray component to about 0° (e.g. so that the two back wall contact each other). A preferred hinge component is a tape, such as a tape having an adhesive layer on one surface.

An illustrative container assembly 2 having features according to the teachings herein is shown in FIG. 1. A container assembly may have one or any combination of the features shown in FIG. 1. In FIG. 1, a container assembly is shown in a closed configuration. With reference to FIG. 1, the container assembly 2 may include a bottom tray component 6 and a covering component 7. The bottom tray component 6 includes a base 30 (not shown) and a plurality of generally upright walls 32, 34 (not shown), 36 extending from the outer perimeter of the base 30. The covering component 7 has at least a base 50. The walls 32, 34, 36 of the bottom tray component 6 preferably extend from the outer perimeter of the base 30 of the bottom tray component 6 in directions that are generally perpendicular to the plane of the base 30. By way of example, the covering component may be an upper tray component 8, such as illustrated in FIG. 1, having one or more walls 52, 54 (not shown in FIG. 1), 56. The walls 52, 54, 56 of the covering component 7 preferably extend from the outer perimeter of the base 50 in directions that are generally perpendicular to the plane of the base 50. The bottom tray component 6 and the covering component 7 are hingedly attached. With reference to FIG. 1, the bottom tray component may have a back wall 32 and the top tray component may have a back wall 52, and the two back walls may be hingedly attached using a hinge 60. The hinge 60 may be on the outside of the back walls (such as illustrated in FIG. 1). Preferably, the hinge 60 is inside the container assembly, or otherwise hidden from view when the container assembly is in a closed configuration. When the container assembly is in a closed configuration, preferably the back walls 32, 52 are oriented at about an 180° angle and/or the base 30 of the bottom tray component 6 is about parallel with the base 50 of the covering component 7. The base 50 of the covering component 7 may have a length measured in the direction from the back wall 52 towards the opposing front wall 54 (not shown). The base 50 of the covering component 7 may have a width as measured in the direction between the two side walls 56. The base 30 of the bottom tray component 6 may have a length and width similarly measured in the front to back directions and side to side directions. Preferably, the base 30 of the bottom tray component and the base 50 of the covering component 7 have about the same length, have about the same width, or both. As illustrated in FIG. 1, one or more of the walls (e.g., each of the upright walls) of the upper tray component 8 may be parallel with and preferably coplanar with a corresponding wall of the lower tray component 6 when the container assembly 2 is in the closed configuration.

When in the container assembly 2 is in the closed configuration, other components such as the pocket component and/or the insert component preferably are position within a compartment (i.e., a cavity) formed by the lower tray component 6 and the covering component 7.

The walls 52, 54, 56 of the upper tray component 8 may each have the same height, or one or more of the walls may have a different height (e.g., a different height relative to an adjacent wall, a different height relative to an opposing wall, or both). Preferably, the walls 52, 54, 56 have about the same height, such as illustrated in FIG. 1. The walls 32, 34, 36 of the lower tray component 6 may each have the same height, or one or more of the walls may a different height (e.g., a different height relative to an adjacent wall, a different height relative to an opposing wall, or both). The walls 32, 34, 36 of the upper tray component 8 preferably have about the same height, such as illustrated in FIG. 1.

The height of the walls of the upper tray component 8 may be greater than, the same as, or less than the height of a corresponding wall of the lower tray component 6. For example, in FIG. 1, the walls of the upper tray component 8 have about the same height as the walls of the lower tray component. With reference to FIG. 2, the container assembly 2′ may include walls of the upper tray component 8′ that shorter than the walls of the lower tray component 6′.

With reference to FIG. 3, a container assembly 2″ may have a covering component 7″ that is not a tray. For example, the covering component 7″ may be a lid that consists essentially of a base 50″. As such, the hinge 60 may be attached to the base 50″ of the covering component 7″. Although the hinge 60 is shown on the outside of the covering component 7″ and the lower tray component 6″″, the hinge preferably is positioned on the inside of the container assembly 2′″ or is otherwise hidden from view.

With reference to FIG. 4, the covering component 7′″ may have a base 50′″ that is larger than the base 30′″ of the lower tray component 6. Here, one or more of the walls of the upper tray component 8′″ is parallel to but not coplanar with a corresponding wall of the lower tray component. For example, only the rear walls 32′″, 52′″ may be coplanar when the container assembly 2′″ is in a closed configuration.

FIG. 5 is a cross-sectional view of the container assembly 2 shown in FIG. 1 taken in a plane parallel to the side walls and dissecting the base 50 of the covering component 7. Only the bottom tray component 6, the upper tray component 8 and the hinge 60 are shown. Here, the base 30 of the lower tray component 6 and the base 50 of the upper tray component 8 have about the same length. The front wall 34 of the lower tray component 6 is coplanar with the front wall 54 of the upper tray component 8. The back wall 32 of the lower tray component 6 is coplanar with the back wall 52 of the upper tray component 8. When in the closed configuration, the upper and lower tray components 6, 8 create a compartment 28 (i.e. a cavity) that holds one or more of the other components of the container assembly 2 according to the teachings herein.

With reference to FIG. 5, the closing of the container assembly 2 may be limited by the contact of two or more walls. For example, the distal edges of the front walls 34, 54 may contact each other when the container assembly is closed.

FIG. 6 is a cross-sectional view of the container assembly 2′″ shown in FIG. 4 taken in a plane parallel to the side walls and dissecting the base 50 of the covering component 7′″. Only the bottom tray component 6′″, the upper tray component 8′″ and the hinge 60 are shown. Here, the base 30 of the lower tray component 6′″ is shorter than the base 50 of the upper tray 8′″. The front wall 34′″ of the lower tray component 6′″ is parallel to, but not coplanar with the front wall 54′″ of the upper tray component 8′″. The back wall 32′″ of the lower tray component 6′″ is coplanar with the back wall 52′″ of the upper tray component 8′″. When in the closed configuration, the upper and lower tray components 6, 8 create a compartment 28 (i.e. a cavity) that holds one or more of the other components of the container assembly 2 according to the teachings herein. With reference to FIG. 5, the closing of the container assembly 2 may be limited by the contact of two or more walls. For example, the distal edges of the front walls 34, 54 may contact each other when the container assembly is closed. As illustrated in FIG. 6, the back wall 32″″ of the lower tray component may have a height that is shorter than the height of the front wall 34″. For example, the front wall 34′″ and side walls 36′″ may have about the same height and the back wall 32′″ may have a shorter height.

With reference to FIG. 6, the closing of the container assembly 2′″ may be limited by the contact of a wall with a base. For example, the distal edge of the front wall 34′″ of the lower tray component 6′″ may contact a surface of the base 50′″ of the upper tray component when the container assembly is closed. It will be appreciated that an insert component (not shown) may provide a closing limit function similar to that shown in FIG. 6.

FIG. 7 is a perspective view of the container assembly 2 shown in FIG. 1 when the back walls of the upper and lower tray components are arranged at a relative angle of about 90°. FIG. 8 is an enlarged view of a region of FIG. 7. FIG. 9 is an exploded view of FIG. 7 with side walls removed from one side of each of the upper tray component, the lower tray component, and the insert component. With reference to FIG. 7, the container assembly 2 generally includes a pop-up pocket component 4 and optionally may include an insert component 10. The pop-up pocket component 4 includes a pocket 12 and a pocket support 14. The pocket has an open compartment 27 (e.g., an open space) suitable for holding one or more articles. The pocket 12 has a base 15. The weight of the articles in the pocket 12 may generally rest upon the base 15. As such, the base 15 of the pocket 12 should be made of a material sufficiently strong and/or sufficiently thick so that the base 15 generally maintains its shape when the articles are carried in the pocket. As illustrated in FIG. 7, when the container assembly 2 is in an opened configuration, the base 15 of the pocket 12 becomes generally inclined relative to the base 30 of the lower tray component 6. For example, when the container assembly 2 is opened, a portion of the base 15 of the pocket 12 may be lifted (e.g., to a level above the height of the container assembly when in a closed configuration). With reference to FIGS. 7 and 9. The pocket may include opposing side walls 14, a top wall 16, and a front wall 17. The base 15 of the pocket 12 may include an fee edge 18 that does not include a wall (e.g. does not include an upright wall). The pop-up pocket component preferably includes a pocket support 14 configured and arranged so that it raises one end of the pocket 12 simultaneous with the opening of the container assembly 2.

The container assembly may include an insert component 10, such as illustrated in FIG. 7 and FIG. 9. With reference to FIGS. 7 and 9, the insert component 10 preferably includes a base 40, a front wall 44, and optionally one or more side walls 46. For example, the insert component may include a base 40, a front wall 44, and two side wall 46. Preferably, the insert component 10 is substantially free of or entirely free of a back wall. If the insert component 10 includes a back wall, the back wall preferably does not project above the back wall 32 of the lower tray component 6. One or more of the walls 44, 46 of the insert 10 may be a supporting wall 45. As used herein, a supporting wall 45 is a wall that contacts and/or supports at least a portion of the base 50 of the covering component 7 when the container assembly 2 is in a closed configuration. For example, a wall edge 48 of the insert 10 may contact the base 50 of the covering component when the covering component is closed. If a wall 44, 46 of the insert 10 does not contact the base 50 of the covering component 7, it may be provide secondary support for the base 50 and/or reinforce a wall 34, 36 of the lower tray component that supports the covering component 7. The insert 10 generally has a base 40 that is smaller in length and width relative to the base 30 of the lower tray component 6 so that the base 40 of the insert can fit in the space defined by the base and walls of the lower tray component 6. Preferably a surface of the base 40 of the insert 10 and a base 30 of the lower tray component 6 are in direct contact (e.g., over the entire surface of the base 40) and/or parallel. Preferably, the insert 10 does not easily remove from the lower tray component. As such, when the container assembly 2 is open and held upside down (i.e., with the lower tray component 6 on the top) the insert 10 preferably does not slide out of the lower tray component 6. For example, the insert 10 may be inserted into the lower tray component 6 using a frictional fit with one or more walls 44, 46 of the insert contacting a corresponding wall 34, 36 of the lower tray component 6. Preferably the fitting (e.g., fiction fitting or otherwise) of the insert 10 into the lower tray component 6 includes contacting the front wall 44, and two side walls 46 of the inert 10 each with a corresponding wall of the lower tray component 6. The insert 10 may optionally be attached to the lower tray component 6. Any suitable means of attachment may be employed. For example, the attachment may employ one or more fasteners, an adhesive, a tape, a bonding agent, or any combination thereof. If a fastener is employed it may be a separate component and/or integrated into either or both of the insert 10 and lower tray component 6. For example a securing feature may include a slit or slot in one component and a tab in the other component where the two components become when the tab is inserted into the slit. The attachment of the insert 10 to the lower tray component 6 may employ an adhesive, tape, and/or bonding agent 49 such as illustrated in FIG. 9. The adhesive, tape and/or bonding agent 49 may be deposited on a surface of the lower tray component, to a surface of the insert component, or both. The adhesive, tape, and/or bonding agent 49 may be deposited on a surface of a wall, a surface of a base, or any combination thereof. If a tape is employed, it preferably is a tape having an adhesive layer on one or both faces, and more preferably on both faces.

With reference to FIGS. 8 and 9, the pocket support 14 may include one or more portions. Preferably the pocket support includes a first portion 20 suitable for attaching to the covering component. Preferably the pocket support 14 includes a second portion 22 suitable for providing a rigid support between the covering component and the base 15 of the pocket. Preferably the pocket support includes a third portion 24 suitable for attaching to the base 15 of the pocket 12. One or more of the portions may be provided as a separate element. Preferably, the first portion 20, the second portion 22, and the third portion 24 are formed from a single blank. For example, the portions may be separated by folds or creases in a blank. The first and second portions 20, 22 of the pocket support preferably are hingedly connected. Preferably the first portion and the second portion are connected by a crease or fold that functions as a hinge. The second and third portions 22, 24 of the pocket support preferably are hingedly connect. Preferably, the second portion 22 and the third portion 24 of the pocket support are connected by a crease or fold that functions as a hinge. The hinge between the first and second portions and the hinge between the second and third portion preferably are in different directions (e.g., when the container assembly is open to an angle of about 90° as shown in FIG. 9. As such, the pocket support may including a multiple of folds and or creases. The profile of the pocket support including the multiple of folds and or creases may be generally “Z” shaped (e.g., and not “C” or “U” shaped). Preferably, the first portion 20 is generally free of creases, perforations, or folds that would reduce the stiffness of the first portion. The pocket support 14 may be integrated into the pocket 12 or may be attached to the pocket, such as illustrated in FIGS. 7 and 9. Any suitable means of attachment may be employed. For example, the attachment may employ one or more fasteners, an adhesive, a tape, a bonding agent, or any combination thereof. If a fastener is employed it may be a separate component and/or integrated into either or both of the pocket 12 and the pocket support 14. The attachment of the pocket 12 (e.g., the third portion 24 of the pocket support) and the pocket support 14 may employ an adhesive, tape, and/or bonding agent 49 such as illustrated in FIG. 9. The adhesive, tape and/or bonding agent 49 may be deposited on a surface (e.g., an inside surface) of the lower tray component, to a surface (e.g., an outer surface) of the insert component, or both. The adhesive, tape, and/or bonding agent 49 may be deposited on a surface of a wall, a surface of a base, or any combination thereof. If a tape is employed, it preferably is a tape having an adhesive layer on one or both faces, and more preferably on both faces.

The first portion 20 of the pocket support 14 may be attached to a surface of the covering component 7. Preferably, the first portion 20 of the pocket support 14 is attached directly or indirectly to a the back wall 52 or the base 50 of the covering component 7. More preferably the first portion 20 of the pocket support 14 is attached directly or indirectly to the back wall 52 of an upper tray component 8. Any suitable means of attachment may be employed. For example, the attachment may employ one or more fasteners, an adhesive, a bonding agent, a tape, or any combination thereof. If a fastener is employed it may be a separate component and/or integrated into either or both of the first portion of the pocket support 14 or the covering component 7. The attachment of the third portion 24 of the pocket support 14 and the covering component 7 may employ an adhesive, a tape, and/or a bonding agent 49 such as illustrated in FIG. 9. The adhesive, tape, and/or bonding agent 49 may be deposited on a surface of the upper tray component, on a surface of the first portion 20 of the insert support 14, or both. The adhesive, tape, and/or bonding agent 49 may be deposited on a surface (e.g., preferably an inside surface) of a wall, a surface (e.g., preferably an inside surface) of a base, or any combination thereof. If a tape is employed, it preferably is a tape having an adhesive layer on one or both faces, and more preferably on both faces.

With reference to FIG. 11, the attachment between the third portion 24 of the pocket support 14 and the base 15 of the pocket, preferably is arranged so that the resulting hinge 23 between the second and third portions 20, 22 is generally parallel to the intersection of the back wall 32 and base 30 of the lower tray component 6. The location of the 23 is preferably on the rearward half (i.e., the half that is towards the back walls) of the base 15 of the pocket. The ratio of the distance from the hinge 23 and the back wall 32 of the of the lower tray component 6 preferably to the length of the base 15 of the pocket 12 preferably is about 0.5 or more, more preferably about 0.6 or more, even more preferably about 0.7 or more, even more preferably about 0.75 or more, and most preferably about 0.80 or more. The ratio of the distance from the hinge 23 and the back wall 32 of the of the lower tray component 6 preferably to the length of the base 15 of the pocket 12 preferably is about 0.99 or less, more preferably about 0.98 or less, even more preferably about 0.97 or less, even more preferably about 0.94 or less, and most preferably about 0.95 or less. The distance between the hinge 23 and the back wall 32 of the lower tray component may be about the same as the length of the second portion 22 of the pocket support 14.

FIGS. 10, 11, 12 and 13 are side views of the container assembly 2 of FIG. 7, with one side wall removed from each of the covering component, the insert component, and the lower tray component. In FIG. 10, the container assembly is in a closed position, and FIGS. 11, 12, and 13 shown the container assembly 2 in various open positions. In the closed position (FIG. 10), the angle between the back walls 32, 52 of the lower and upper tray components 6, 8 is about 180°. In FIG. 11, the angle 67 between the back wall 32 of the lower tray component 6 and the back wall 52 of the upper tray component is greater than 90° and less than 180°. In FIG. 12, the angle between the back wall 32 of the lower tray component 6 and the back wall 52 of the upper tray component is about 90°. In FIG. 13, the angle 67 between the back wall 32 of the lower tray component 6 and the back wall 52 of the upper tray component is about 0°. When in an open position and weighted by one or more articles, it will be appreciated that at least one edge the pocket 12 will generally contact a base layer (e.g., the base 40 of the insert component or the base 30 of the lower tray component).

With reference to FIG. 10, the base 15 of the pocket 12 may be generally parallel to the base 30 of the lower tray component 6 when the container assembly is closed. Here, the second portion 22 and/or the third portion 24 of the pocket support 14 may be generally parallel to the base 30 of the lower tray component 6. For example, some or all of the second portion 22 and/or the third portion 24 of the pocket support may be sandwiched between the base 15 of the pocket 14 and the base 30 of the lower tray component 6.

With reference to FIGS. 10 and 11, when the container assembly is in the closed configuration (FIG. 10), a peripheral edge 38 of the front wall 34 of the lower tray component 6 may contact a peripheral edge 58 of the front wall 54 of the upper tray component 8. Similarly corresponding peripheral edges of the side walls of the lower tray component 6 and upper tray component 8 may also contact each other.

The lower tray component may have walls (e.g., front walls, side wall, and back wall) having the same height. The upper tray component may have walls (e.g., front wall, side walls, and back wall) having the same height. The insert may have walls (e.g., front wall, side walls) having the same height. The pocket may have walls (e.g., front wall, side walls) having the same height.

The first portion 20 of the pocket 14 preferably is sufficiently long so that the first portion 20 can extend from the inside intersection of the base 30 and back wall 32 of the lower tray component to a position on the upper tray component. The length of the first portion 20 of the pocket support 14 preferably is greater than the inside height (i.e., measured from the inside of the tray) 71 of the back wall 32 of the lower tray component 6, such as illustrated in FIGS. 10 and 11. The first portion 20 of the pocket support 14 preferably has a length that is short enough so that the first portion 20 of the pocket support can be generally aligned with the back walls 32, 52 of the upper and lower tray components, when the container assembly 2 is in a closed orientation. The length of the first portion 20 of the pocket support 14 preferably is less than or equal to the combined height of the back wall 32 of the lower tray component 6 and the height of the back wall 52 of the upper tray component 8.

The side walls 13 of the pocket 12 may have any shape, and may be the same or different. Preferably the size and shape of the side wall 13 of the pocket 12 is selected to facilitate removing one or more articles from the pocket and/or to facilitate viewing an article in the pocket. Preferably the side wall 13 of the pocket 12 does not extend the length of the base 15 of the pocket and/or the side wall 13 has a length that is reduced near the top wall 16 compared with the length of the side wall 13 near the base 15 of the pocket 12. For example, the side wail 13 of the pocket 12 may have a generally trapezoidal shape, such as illustrated in FIG. 10. The top wall 15 of the pocket 12 preferably has a shape and/or size that facilitates removing and/or viewing an article in the pocket. The top wall 16 of the pocket 12 preferably has one or more dimensions different from the base 15 of the pocket 12. For example, the top wall 16 may have a length that is less than the length of the base 15 of the pocket 12. Preferably, the width of the top wall 16 (e.g., the distance in the direction between the two opposing side walls 13 of the pocket) is about the same as the width of the base 15 of the pocket 12.

When the container assembly includes an insert component, the height of the walls of the insert component may be equal to, greater than, or less than the combined inside heights of the corresponding walls of the upper and lower tray components. Preferably, the height of the walls of the insert component are equal to or less than the combined inside heights of the corresponding inside walls of the upper and lower tray components. More preferably, the heights of the walls of the insert component are less than the combined inside heights of the corresponding inside walls of the upper and lower tray components. For example, as illustrated in FIGS. 10 and 11, the height 69 of the insert component may be greater than combined inside heights of the front wall 34 of the lower tray component 6 and the front wall 54 of the upper tray component.

With reference to FIGS. 10-13, as the container assembly 2 is opened, the hinge angle 62 between the first and second portions 20, 22 of the pocket support 14 may increase. For example, the hinge angle may increase from an initial angle of about 90° (in the closed position) to an angle greater than 90°. The hinge angle 62 may increase towards or even increase to about 180°. For example, when the angle between the back walls 32, 52 of the upper and lower tray components has an angle 67 of about 0°, the hinge angle 62 may be about 180°. The hinge angle 64 between the second and third portions 22, 24 of the pocket support generally decreases as the container assembly 2 is opened. As the container assembly 2 is opened, one edge 18 of the pocket 12 is lifted and the incline angle 66 of the base of the pocket 12 increases. It will be appreciated that the incline angle 66 of the base 15 of the pocket 12 preferably is maintained at less than 90°, and more preferably at less than 45°. The incline angle 66 of the base 15 of the pocket 12 is illustrated in FIG. 9.

The pocket support 14 may be attached to the base 50 of the covering component 7, such as illustrated in FIG. 16. It will be appreciated that this arrangement may be particularly useful when the covering component does not include a back wall, such as illustrated in FIG. 3 and FIG. 16. For example, the bottom surface of the base of the covering component may be attached to the pocket support 14, and preferably to the first portion 20 of the pocket support. The pocket support 14, preferably is also attached to the pocket 15. For example the third portion 24 of the pocket support 14 may be attached to a bottom surface of the base 15 of the pocket 12. of As such, the pocket support 14 (e.g., the second portion 22 of the pocket support) may function as a lever for lifting and/or tilting the pocket. The pocket support here may have a profile that is generally “C” with hinges 62 and 64 connecting the second 22 and third portions 24 and the first 20 and second portions 22 respectively.

The pocket may be formed from one or more blanks. An exemplary blank 70 that may be used to form a pocket is illustrated in FIG. 14. A pocket may include one or any combination of the features shown in FIG. 14. In FIG. 14, the numbers in parentheses refer to the corresponding features of the pocket when the blank is folded. It will be appreciated that the elements of a pocket blank may be provided by a plurality of blanks, for example by attaching two or more blanks together. Preferably, the pocket is provided by a single blank, such as illustrated in FIG. 14. The dotted lines in FIG. 14 illustrated locations where the blank may be folded. At such locations, the blank may include one or more fold facilitating features in the folding of the blank. Example of fold facilitating features include one or more perforations, one or more scores, one or more creases, one or more slits, or any combination thereof. The blank 70 may include a base layer 72. The base layer 72 of the blank may be used as part or all of the base 15 of a pocket 12. The blank may include a reinforcing base layer 74 projecting from one edge of the base layer 72. When this edge is folded over by 180°, the reinforcing base layer 74 may lie above the base layer 72 and/or contact the base layer 72. As such, the base 15 of the pocket 12 may include two or more layers including the base layer 72 and the reinforcing base layer 74 of a blank 70. The blank 70 may include a top wall layer 76. The top wall layer 76 of the blank may be used as part of, or all of the top wall 16 of a pocket 12. The blank may include a reinforcing top wall layer 78 projecting from one edge of the top wall layer 76. When this edge is folded over by 180°, the reinforcing top wall layer 78 may lie below the top wall and/or contact a surface of top wall layer 76. As such, the top wall 16 of the pocket 12 may include two or more layers including the top wall layer 76 and the reinforcing top wall layer 78 of a blank 70. The blank may include two or more side wall layers, including a first side wall layer 84, and a second side wall layer 84′. Each side wall layer preferably projects from an edge of the base layer 72 and/or an edge of the top wall layer 76. With reference to FIG. 14, one side wall 84′ may project from both an edge of the base layer 72 and an edge of the top wall layer 76. In other words, a side wall layer 84′ may have opposing edges with a base layer 72 projecting from one edge and the top wall layer 76 projecting from the opposing edge. When these opposing edges of the side wall layer 76′ are each folded by an angle of about 90°, the base layer 72 and the top wall layer 76 becomes spaced apart and preferably parallel. Each of the side wall layers 84, 84′, 84″ may become part of a side wall 13 of a pocket 12. It will be appreciated that a side wall 13 of a pocket 12 may include one or more of the side wall layers 84, 84′, 84″ of the blank 70. For example, side wall layers 84, 84″ may be oriented so that there surfaces are adjacent. When assembling the pocket, two side wall layers (e.g., side wall layers 84, 84″) of the blank 70 may be attached together. The blank may include a front wall layer 80 and optionally a reinforcing front wall layer 82. Preferably, one of the front wall layer 80 and the reinforcing front wall layer 82 projects from a base layer 72, and the other may projects from a top wall layer 76. The blank 70 may be folded so that the front wall layer 80 and the reinforcing front wall layer are parallel and/or in contact. The blank 70 may include connector tabs 86, 86′. A connector tab may become part of a front wall layer. For example, a connector tab may project from a side wall and provide a connection between the side wall and the front wall.

The blank may include one or more front-to-base connector tabs 88 that provides a connection between the base 15 of the pocket 12 and the front wall 17 of the pocket 12. The front-to base connector tab 88 may project from an edge of a front wall layer 80 or a reinforcing front wall layer 82. The front-to base connector tab 88 may be folded and arranged to be positioned below the base layer 72. When folded as such, the front-to-base connector tab 88 may function to raise the forward portion of the pocket 12. As such, when the container assembly 2 is closed, the front-to base connector tab may function to make the base 15 of the pocket 12 more level. Preferably, the thickness of the front-to-base connector tab 88 is about the same thickness as the pocket support 14 (e.g., the second and/or third portions 22, 24 of the pocket support 14) so that the pocket 12 rests generally level when the covering component is in a closed position. As such, when the covering component 7 is closed, the base 15 of the 12 pocket may be parallel to the base 30 of the lower tray component 6.

The container assemblies according to the teachings herein may be configured to receive one or more items for retail packaging purposes, for displaying purposes, for storage purposes, for transportation purposes, or any combination thereof. For example the container may be configured for receiving an electronic device (such as a consumer electronic device), a cosmetic, a perfume, a bonus gift, a key chain, jewelry, a kit, an article of clothing, a houseware item, an automotive accessory, paper goods, a food item, or any combination thereof.

The container assemblies according to the teachings herein may be used for a single-use packaging, or a multiple-use packaging. Preferably the packaging is a multiple use packaging.

Though not necessarily drawn to scale, geometries, relative proportions and dimensions shown in the drawings are also part of the teachings herein, even if not explicitly recited. However, unless otherwise stated, nothing shall limit the teachings herein to the geometries, relative proportions and dimensions shown in the drawing.

Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.

The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

LIST OF FEATURES

    • 2 Container assembly
    • 4 Pop-up pocket component
    • 6 Lower tray component
    • 7 Covering component
    • 8 Upper tray component
    • 10 Insert component
    • 12 Pocket
    • 13 Side wall of pocket
    • 14 Pocket support
    • 15 Base of pocket
    • 16 Top wall of pocket
    • 17 Front wall of pocket
    • 18 Edge of base of pocket that does not have an upright wall
    • 20 First portion of pocket support
    • 21 Hinge between first and second portion of the pocket support
    • 22 Second portion of pocket support
    • 23 Hinge between second and third portion of the pocket support
    • 24 Third portion of pocket support
    • 26 Cavity of container
    • 27 Space and/or cavity inside the pocket
    • 28 Adhesive and/or attachment means between the third portion of the pocket support and the pocket. Optionally mechanical fastener.
    • 30 Base of lower tray
    • 32 Back wall of lower tray
    • 34 Front wall of lower tray
    • 36 Side wall of lower tray
    • 38 Edge of wall of lower tray
    • 40 Base of insert
    • 44 Front wall of insert
    • 45 Supporting wall
    • 46 Side wall of insert
    • 48 Edge of wall of insert
    • 49 Adhesive and/or attachment means between insert ad lower tray Optionally mechanical fastener.
    • 50 Base of upper tray
    • 52 Back wall of upper tray
    • 54 Front wall of upper tray
    • 56 Side wall of upper tray
    • 58 Edge of wall of upper tray
    • 59 Adhesive and/or attachment means between the first portion of the pocket insert and the upper tray back wall. Optionally mechanical fastener.
    • 60 Hinge
    • 62 Hinge between the first and second portions of the pocket support
    • 64 Hinge between the second and third portions of the pocket support
    • 66 Incline angle of the pocket
    • 67 Hinge angle between lower tray and the upper tray
    • 68 Height of back wall of the lower tray
    • 69 Height of the insert
    • 70 Blank for a pocket
    • 71 Inside wall height of front wall of the lower tray
    • 72 Base layer
    • 74 Reinforcing base layer
    • 76 Top wall layer
    • 78 Reinforcing top wall layer
    • 80 Front wall layer
    • 82 Reinforcing front wall layer
    • 84 Side wall layers
    • 86 Connector tab from side wall for reinforcing the front wall
    • 88 Front-to-base connector tab
    • 90 Bend or crease or score

Claims

1. A container assembly comprising:

i. a lower tray component having a base and a plurality of upright walls including a back wall, wherein each upright wall has an edge facing in a generally upward direction;
ii. a covering component having at least a base, wherein the back wall of the lower tray is hingedly attached to the covering component;
iii. one or more pop-up pocket components, wherein each pop-up pocket component includes a. a pocket suitable for holding one or more articles and fitting within a space between the covering component and the lower tray component, and b. at least one pocket supports suitable for providing an attachment to both the pocket and the back wall of the upper tray;
wherein the pocket has a base with a bottom surface that faces the base of the lower tray component, and the base of the pocket has a back edge that lies towards the back wall of the lower tray component, and the pocket support is attached to the pocket on the base of the pocket at a position sufficiently away from the back wall of the lower tray component so that when the covering component is hingedly lifted away from the lower tray component, the pop-up pocket is tilted to a tilt angle between the base of the pocket and the lower compartment of about 1° or more.

3. The container assembly of claim 1, wherein the covering component is an upper tray component having a plurality of upright walls including a back wall, wherein the back wall of the lower tray is hingedly attached to the back wall of the upper tray component.

3. The container assembly of claim 2, wherein the container further contains an insert component having a base and one or more upright walls including at least one support walls, wherein each support wall is sufficiently high so that the base of the upper tray component rests on the support wall when the upper tray is hingedly placed over the lower tray component, and wherein at least one support walls includes at least one front wall or side wall.

4. The container assembly of claim 3, wherein the insert component is free of a back wall having a height longer than the height of the back wall of the lower tray component and/or wherein the insert component is free of a back wall.

5. The container assembly of claim 2, wherein the lower tray component and upper tray component each have four upright walls including a front wall, a back wall, and two opposing side walls, and wherein the insert component includes three upright walls include a front wall and two opposing side walls.

6. The container assembly of claim 3, wherein the insert component is pressure fit into the lower tray component, wherein one or more walls of the insert component contact corresponding walls of the lower tray component.

7. The container assembly of claim 2, wherein the base of the upper tray component and the base of the lower tray component have the same dimensions.

8. The container assembly of claim 7, wherein the edge of each upright wall of the upper tray component lies above and faces a corresponding edge of an upright wall of the lower tray component when the container assembly is in a closed position.

9. The container assembly of claim 1, wherein the pocket support has three or more portions, including a first portion, a second portion and a third portion,

wherein when the container assembly is in a closed position, the first portion is generally upright, is attached to an inside surface of the back wall of the upper tray component, and extends along the back wall of the lower tray component, the second portion is hingedly connected to the first component, is generally coplanar with and rests above the base of the lower tray component, and extends forward from the back edge of the base of the lower tray component towards the third portion, and the third portion is attached to a region of the bottom surface of the base of the insert component and is hingedly attached to the second portion.

10. The container assembly of claim 1, wherein the second portion of the insert component has a length in the direction between the first portion and the third portion, wherein the length of the second portion is greater than the height of the back wall of the lower tray component.

11. The container assembly of claim 1, wherein the pocket has side walls that extend only a portion of the length of length of the side walls.

12. The container assembly of claim 1, wherein the pocket includes a top that lies generally parallel to the base of the pocket wherein the length of the side wall along the base of the pocket is greater than the length of the side wall along the top of the pocket.

13. The container assembly of claim 1, wherein the top of the pocket has a surface area and the base of the lower tray component has a surface area, wherein the ratio of the surface area of the top of the pocket to the surface area of the base of the lower tray component is about 0.9 or less.

14. The container assembly of claim 1, wherein the top of the pocket has a surface area and the base of the insert component has a surface area, wherein the ratio of the surface area of the top of the pocket to the surface area of the base of the insert component is about 0.9 or less.

15. The container assembly of claim 1, wherein the length of the second portion of the pocket support is sufficiently long so that the when the container assembly is fully open, the base of the pocket is tilted at a tilt angle relative to the base of the lower tray component, wherein the tilt angle is about 2° or more.

16. The container assembly of claim 1, wherein the pocket has a base that includes two or more layers, the pocket has a top that includes two or more layers, or both.

17. The container assembly of claim 1, wherein the hinge between the upper tray component and the lower tray component extends substantially along the length of the back walls of the two components.

18. The container assembly of claim 1, wherein the pocket support is a contiguous sheet of material and wherein the one or more hinge between two adjacent portions of the pocket support includes a score and/or a crease in the material.

19. The container assembly of claim 1, wherein the container assembly is free of an insert component.

20. The container assembly of claim 1, wherein the pocket support only connects directly to the upper tray component and to the pocket.

Patent History
Publication number: 20140262932
Type: Application
Filed: Mar 15, 2013
Publication Date: Sep 18, 2014
Inventor: Gary Lenkeit (Croton on Hudson, NY)
Application Number: 13/835,896
Classifications
Current U.S. Class: Through Pivotal Link (e.g., Hinge Or Fold Line) (206/755)
International Classification: A47F 5/00 (20060101);