Multi-Part Product Shipping Box and Display Tray

Abstract

A reusable combined multi-part product shipping box and display tray. In one arrangement, the box includes two generally rectangular trays, each defining four sides, with four barrier portions projecting upward from each tray proximate its edges, one barrier portion at about the center of each of the sides, and four corner posts, one projecting up from each corner of the tray. The box includes a generally rectangular sleeve defining four sides and four corners, and open ends that are about the same size and shape as the trays, the sleeve adapted to engage with the trays to close its open ends and form a shipping container, the sleeve adapted to sit on the tray inside of and up against the barrier portions, with each corner of the sleeve located outside of and against a corner post, such that the sleeve is tightly engaged with the trays.

What is claimed is: 
     
         1 . A box assembly, comprising:
 (i) at least one tray, comprising:
 (a) a generally planar portion having four sides that define corresponding edges of the planar portion, each of the four sides defining a corresponding center; 
 (b) a set of projecting walls extending from the surface of the generally planar portion, each projecting wall of the set of projecting walls disposed at a corresponding edge of each corresponding side of the four sides of the planar portion; 
 (d) a corner post disposed at a corresponding corner of a set of four corners of the tray, each corner post spaced inwardly from a first edge and a second edge that define the corresponding corner of the tray; and 
   (ii) a generally rectangular sleeve having a set of four walls that define four corners, a first opening at a first end of the sleeve and a second, opposed opening at a second end of the sleeve, the set of four walls of the first end of the sleeve configured to engage the at least one tray to close the first opening of the sleeve and form a shipping container,   the first end of the sleeve configured to be disposed on the at least one tray, the set of four walls of the first end of the sleeve configured to be disposed between the set of projecting walls and the set of corner posts such that an outer surface of each wall is configured to be disposed against each corresponding projecting wall and an inner surface of each corner of the sleeve is configured to be disposed against a corner post of the at least one tray to secure the first end of the sleeve to the at least one tray.   
     
     
         2 . The box assembly of  claim 1 , wherein each wall of the set of four walls of the sleeve is captured between one projecting wall of the set of projecting walls and two opposing corner posts of the set of corner posts. 
     
     
         3 . The box assembly of  claim 1 , wherein the sleeve comprises a corrugated material. 
     
     
         4 . The box assembly of  claim 3 , wherein the corrugated material comprises:
 a first linerboard and a second linerboard spaced apart from the first linerboard; and   a corrugated sheet disposed between the first linerboard and the second linerboard, the corrugated sheet defining a set of sealed flutes having a longitudinal axis extending between the first end of the sleeve and the second end of the sleeve, each sealed flute of the set of sealed flutes configured to contain a volume of air.   
     
     
         5 . The box assembly of  claim 4 , wherein the corrugated material comprises a corrugated plastic material. 
     
     
         6 . The box assembly of  claim 3 , wherein the sleeve is configured to be folded into a flat form. 
     
     
         7 . The box assembly of  claim 1 , wherein at least a portion of each corner post of the set of corner posts are tapered from top to bottom. 
     
     
         8 . The box assembly of  claim 7 , wherein each post comprises two substantially vertical portions that meet at right angles, each vertical portion defining a taper toward a top end of the corresponding vertical portion, the top end opposing the surface, the taper of each vertical portion defined by an outer surface that is angled inwardly from the vertical reference such that the top end of each vertical portion is more narrow than a base of each vertical portion. 
     
     
         9 . The box assembly of  claim 1 , wherein each post defines an opening configured to accept an identical post of another tray to allow nesting of the trays. 
     
     
         10 . The box assembly of  claim 9 , wherein the sleeve defines a plurality of holes in a first wall of the sleeve and in a second wall of the sleeve, the first wall opposing the second wall. 
     
     
         11 . The box assembly of  claim 10 , wherein the sleeve defines a first handle cutout in the first wall of the sleeve and a second handle cutout in the second wall of the sleeve, the first handle cutout and the second handle cutout being spaced and vertically-aligned. 
     
     
         12 . The reusable combined multi-part product shipping box and display tray of  claim 11 , wherein each tray has an opening in about a center of, and through, the generally planar portion. 
     
     
         13 . The reusable combined multi-part product shipping box and display tray of  claim 1 , wherein each wall of the set of four walls of the sleeve is captured between one projecting wall of the set of projecting walls and two opposing corner posts of the set of corner posts.