Shelf ready package having structural integrity and processes for making them

Abstract

A shelf ready package and method of manufacturing a shelf ready package, including an outer case and a strengthening element. The shelf ready package including at least a first blank and a second blank where the first blank is formed into the outer case and the second blank is formed into the strengthening element.

What is claimed is: 
     
         1 . A shelf ready package comprising at least a first blank and a second blank, the first blank is formed into an outer case and the second blank is formed into a strengthening element, wherein the outer case comprises a non-removable element and an at least partially removable element, formed by a first line of weakness, such that the at least partially removable element can be at least partially or fully removed along the first line of weakness, wherein the strengthening element is inside the outer case, wherein the strengthening element is positioned against at least one wall of the outer case so as to cover at least a part of the first line of weakness, wherein the strengthening element comprises a second line of weakness and wherein the second line of weakness follows along at least a part of the first line of weakness covered by the strengthening element. 
     
     
         2 . A shelf ready package according to  claim 1 , wherein the first blank is formed into an outer case comprising:
 a) a front wall;   b) a back wall opposing said front wall;   c) two opposing side walls;   d) upper portions which collectively form a top wall; and   e) lower portions which collectively form a bottom wall.   
     
     
         3 . A shelf ready package according to  claim 1 , wherein the strengthening element comprises at least two faces. 
     
     
         4 . A shelf ready package according to  claim 1 , wherein the strengthening element is attached to at least one wall of the outer case. 
     
     
         5 . A shelf ready package according to  claim 1 , wherein the strengthening element is attached to only one wall of the outer case. 
     
     
         6 . A shelf ready package according to  claim 1 , wherein at least a section of the strengthening element has a similar height as one of the wall of the outer case. 
     
     
         7 . A shelf ready package according to  claim 1 , wherein the strengthening element is positioned against at least one of the walls of the outer case, selected from the side walls, the front wall, the back wall and combination thereof. 
     
     
         8 . A shelf ready package according to  claim 1 , wherein the strengthening element is attached to the non-removable element of the outer case, the at least partially removable element of the outer case, or both the non-removable element and the removable element. 
     
     
         9 . A shelf ready package according to  claim 1 , wherein the strengthening element is positioned in a corner of the outer case. 
     
     
         10 . A shelf ready package according to  claim 8 , wherein the strengthening element is positioned in a corner of the outer case and comprises two faces connected together by a spanning element. 
     
     
         11 . A shelf ready package according to  claim 1 , wherein the strengthening element is structured and arranged such that the strengthening element does not prevent the first blank and the second blank from folding and being manipulated to form the shelf ready package. 
     
     
         12 . A shelf ready package according to  claim 1 , wherein at least a section of the strengthening element has a similar height as one of the wall of the outer case, wherein the strengthening element is positioned against the front wall and one side wall, in a corner of the outer case, comprises two faces connected together by a spanning element and is a layer of corrugate. 
     
     
         13 . A process for making the shelf ready package according to  claim 1 , comprising the steps of:
 (a) creating the first blank of the outer case and the second blank of the strengthening element;   (b) perforating the first blank and the second blank to create the first line of weakness and the second line of weakness respectively; and   (c) assembling the first blank and the second blank together by positioning and optionally attaching the second blank inside the first blank in order to form a resulting blank.   
     
     
         14 . A process for making a shelf ready package according to  claim 13 , further comprising the steps of:
 (a) folding the resulting blank and attaching together the left-most part and right-most part of said resulting blank;   (b) bonding the front lower portion and back lower portion together, preferably using glue, tape, or combinations thereof, to form the bottom wall;   (c) placing articles inside the outer case; and   (d) bonding the front upper portion and back upper portion together, preferably using glue, tape, and combinations thereof, to form a upper wall.