FIELD OF THE INVENTION
The present invention relates generally to a system and method for shipping extendable display packages, and, more particularly, to a simple, effective and inexpensive extendable display package shipping system and method where the package and a product mounted in the package automatically extend from a compact shipping configuration to an extended display configuration at a retailer's facility when the package is removed from a shipping carton.
BACKGROUND OF THE INVENTION
Packaging is a well-known field and different packaging systems are disclosed in several earlier patents. By way of example, in 1902, a U.S. Pat. No. 706,330 issued to Menges for a “Package For Water Bottles, Water Bags, &c.” purports to disclose a box for a water bag with a ribbon connecting the top portion of the water bag to the box cover such that when the cover is opened the water bag unfolds. U.S. Pat. No. 1,078,447 for a “Display Case” issued in 1913 to Lines, purports to disclose a case with an internal tray that is linked to a cover such that when the cover is raised the tray follows upward. In 1956, U.S. Pat. No. 2,748,928, issued to Stavis et al., for a “Paperboard Doll Container” and purports to disclose a box having an internal flat insert which allows the doll to be shipped while positioned against the flat insert. At a retail store the insert and the doll are raised to a slanted position although the doll's position relative to the insert does not change. In 1971, U.S. Pat. No. 3,567,014, issued to Feigelman for a “Tray For Shipping And Displaying Merchandise” and purports to disclose a tray with merchandise, such as bottles, which are shipped in a sleeve. When the tray reaches a retailer, the tray is removed from the sleeve for display, an advertising slide is pulled upwards and side flaps are unfolded.
U.S. Pat. No. 3,757,934 issued in 1973 to Taub for a “Telescoping Display Assembly” purports to disclose a container of merchandise having an array of telescoping overlapping panels. The panels are telescoped inward when shipped but are extended to feature a multi-panel display at the point of sale. Two years later, U.S. Pat. No. 3,918,576 issued to Taub for a “Combination Shipping Container And Display Support” and purports to disclose a bin-type display assembly where a shipping carton is used as a bottom support platform for merchandise after the merchandise is removed from the carton that is then inserted into a sleeve to form the support platform for the merchandise. A header type display with artwork and/or printed material is added to extend above the sleeve. The same year U.S. Pat. No. 3,924,734, issued to Gardner and Pilz for an “Expandable Display Tray” and purports to disclose an open top display tray that may be expanded by moving sidewalls away from each other. U.S. Pat. No. 4,191,288 issued in 1980 to Hostad for a “Shipper Display Unit” purports to disclose an assembly where an outer member is removed and made into a base and an inner carton containing merchandise to be displayed is placed above the outer member and a display card is mounted above the carton.
In 2002, U.S. Patent Application Publication 2002/0104777 appeared listing Robley, Jr. as an inventor for a “Display Type Packaging System” and purports to disclose a package with a carton back and a transparent front. Inside a cavity of the carton there are a number of projecting clamps that engage the carton and the product displayed in the package to provide a three-dimensional effect. In 2005, U.S. Patent Application Publication No., 2005/0218036 appeared for a “Box For Toy Packing” listing Sang-Min Ahn as the inventor and purporting to disclose a toy package in the form of a dog house having an open front region which allows the toy to be moved into and out of the house. U.S. Pat. No. 6,837,378 issued in 2005 to Mason and Youngs for a “Transportable Merchandise Display Unit” purports to disclose a unit with an outer container housing an inner display case during shipment. When the unit is delivered to a retailer, the inner display case is pulled upward and an elastic band is used to retain the display case in its upper position.
In 2010 and 2011, U.S. Patents issued to Calendrille Jr., U.S. Pat. No. 7,641,052, and to Calendrille Jr., and others, and U.S. Pat. No. 7,954,641, both entitled “Display Packaging For An Animated Toy.” The Patents purport to disclose an animated toy with a package that not only displays the toy, but also allows the toy to move while connected to the package. In 2011, a U.S. Patent issued to Virvo, U.S. Pat. No. 7,909,168, for a “Slide And Lock Display System” and purports to disclose a display apparatus that includes an inner sleeve containing merchandise and an outer sleeve. During shipment, the inner sleeve is positioned within the outer sleeve. When the apparatus reaches its destination, the inner sleeve is pulled upwards and expandable elements support and lock the inner sleeve in a display position. In 2012, U.S. Patent Application Publication No., 2012/0067772 appeared for a “Display Packaging For Plush Toys” listing Canon as the inventor and purports to disclose a toy package in the form of a chair with bottom, sides and back surfaces for supporting a plush toy but allowing the toy limbs to move when the toy is displayed for sale. In 2012, Calendrille, Jr., was issued another U.S. Pat. No. 8,191,713 for an “Interactive Display Packaging For A Toy Figure” and purports to disclose a package for housing a toy where the package includes a manually manipulated animation mechanism that enables the toy to be repositioned in the package. The package may include a movable segment to which the toy is connected and the mechanism may drive the segment that in turn moves the toy.
These patents and the devices disclosed are of some interest, however, they do not teach a robust and secure system for shipping a product securely, at minimal expense, and still allow the product to be displayed securely in a preferred configuration.
SUMMARY OF THE INVENTION
In accordance with the present invention, an advantageous method and system are described for shipping extendable display product packages where each package and product may be shipped in compact or collapsed configurations to minimize shipping costs, but be displayed in raised or extended configurations to best present the product to the shopping public at the point of sale. Another advantage is that when unloading the product packages from a shipping carton the packages automatically extend from the collapsed configuration so that the package and the product mounted in the package may be placed directly on a retail shelf in the raised configuration. No further action is necessary from the stock person who is unloading product from the shipping carton. Moreover, the system provides that the product is secured against easy removal from the package such that theft is discouraged. The extendable display package system is simply constructed, structurally robust, compact and extendable, and yet relatively inexpensive.
Briefly summarized, the invention relates to an extendable display package shipping system including an extendable display package for receiving a product, the display package including a hand opening to enable the display package to move from a lowered position to a raised position, a shipping carton for containing two display packages back to back, the shipping carton having four side walls and an upper closure, and a shipping carton insert disposed over the two display packages in the shipping carton, the insert being exposed when the upper closure of the shipping carton is opened and the insert having a hand opening in alignment with the hand openings of the two display packages to enable a user to grip the insert and the two display packages simultaneously to move the display packages to the raised positions and remove the display packages from the shipping carton.
The invention also relates to a method for making the extendable display package shipping system including the steps of providing a first blank shaped to form a first tray, providing a second blank shaped to form a first slide wall, providing a third blank shaped to form a first abutment structure, assembling the first blank into the first tray to support a product, assembling the second blank into the first slide wall, mounting the first abutment structure to the first slide wall to enable the first abutment structure to be compressed and expanded, mounting the first slide wall to the first tray to be movable between lowered and raised positions, connecting a first product to the first slide wall to enable the product to move between collapsed and extended configurations when the first slide wall is moved between the lowered and raised positions, compressing the first abutment structure, placing the first slide wall in the lowered position and the first product in the collapsed configuration, providing a fourth blank shaped to form a second tray, providing a fifth blank shaped to form a second slide wall, providing a sixth blank shaped to form a second abutment structure, assembling the fourth blank into the second tray for a second product, assembling the fifth blank into the second slide wall, mounting the second abutment structure to the second slide wall to enable the second abutment structure to be compressed and expanded, mounting the second slide wall to the second tray to be movable between lowered and raised positions, connecting a second product to the second slide wall to enable the second product to move between collapsed and extended configurations when the second slide wall is moved between the lowered and raised positions, compressing the second abutment structure, placing the second slide wall in the lowered position and the second product in the collapsed configuration, providing a seventh blank shaped to form a shipping carton, the shipping carton having an upper closure and a lower closure, providing an eighth blank shaped to form an insert for the shipping carton, assembling the seventh blank into the shipping carton, closing the lower closure of the shipping carton, bending the eighth blank into the insert, placing the first and second extendable display packages into the assembled shipping carton, placing the insert into the assembled shipping carton over the first and second extendable display packages to enable a user to grip the insert and the first and second slide walls simultaneously, and closing the upper closure of the shipping carton.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, the accompanying drawings and detailed description illustrate embodiments thereof, from which the structures, construction and operation, processes, and many related advantages of the embodiment may be readily understood and appreciated.
FIG. 1 is a front isometric view of a preferred extendable display package system in a lowered position with a collapsed toy figure as a mounted product.
FIG. 2 is a front isometric view of the display package system shown in FIG. 1, in a raised position with the toy product extended.
FIG. 3 is a front isometric view of a tray and a slide wall of the display package system shown in FIGS. 1 and 2, in the raised position.
FIG. 4 is a rear isometric view of the tray and the slide wall shown in FIG. 3.
FIG. 5 is a rear isometric view of the display package and product shown in FIG. 2, illustrating a brace in an expanded position in solid lines and in a compressed position in dotted lines.
FIG. 6 is a plan view of flat corrugated blanks that forms the tray, the slide wall, and the brace.
FIG. 7 is an enlarged, partial, front isometric view of the brace taped to a rear panel of the slide wall.
FIG. 8 is an enlarged, partial, rear elevation view of two cords covered with tape attaching the toy product to a front panel of the slide wall.
FIG. 9 is a front isometric view of another embodiment of a display package in a lowered position and a mounted product in a collapsed position.
FIG. 10 is a front isometric view of the display package shown in FIG. 9, in a partially raised position with the toy product partially extended.
FIG. 11 is a front isometric view of the display package shown in FIGS. 9 and 10, in a fully raised position with the toy product fully extended.
FIG. 12 is a plan view of flat corrugated blanks for a tray and a slide wall of the display package shown in FIGS. 9-11.
FIG. 13 is an isometric view of a shipping carton with a top closure in a sealed configuration and graphics indicating the top of the shipping carton.
FIG. 14 is a partial isometric view of the shipping carton with the top closure in an open configuration.
FIG. 15 is a plan view of a flat corrugated blank for the shipping carton.
FIG. 16 is a partial isometric view of the shipping carton with a bottom closure in an open configuration.
FIG. 17 is a partial isometric view of the shipping carton with the bottom closure in a closed configuration.
FIG. 18 is an isometric view of a shipping carton insert.
FIG. 19 is a plan view of a flat corrugated blank for the insert.
FIG. 20 is an isometric view of the insert in the shipping carton over loaded display packages with the top closure of the carton in an open configuration.
FIG. 21 is a side isometric view of the insert disposed over two back-to-back display packages in a cut-away view of a closed shipping carton.
FIG. 22 is an isometric view similar to the view of FIG. 20, but with a user gripping the insert and two display packages simultaneously.
FIG. 23 is an isometric view of the insert lifted partially and the two display packages partially extended.
FIG. 24 is an isometric view of the slide walls of the two display packages fully extended, locked, and partially removed from the shipping carton.
FIGS. 25
a and 25b is a flow diagram for a method of making the extendable display package shipping system.
FIG. 26 is a flow diagram for a method of manufacturing the display package.
DESCRIPTION OF THE EMBODIMENTS
The following description is provided to enable those skilled in the art to make and use the described embodiments set forth. Various modifications, equivalents, variations, and alternatives, however, will remain readily apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and alternatives are intended to fall within the spirit and scope of the present invention defined by the below listed claims.
Referring now to FIGS. 1 and 2, there is shown a preferred embodiment of an extendable display package 10 for a product, the package including a tray 12, the tray having a three part base 14, two part sidewalls 16, 18, and a two part rear wall 20. The display package may mount any collapsible product, such as a toy FIG. 22, here configured as an ELMO™ brand plush toy. Behind the toy figure is a two-part slide wall 24. The slide wall 24 is mounted within the rear wall 20 of the tray and the slide wall is movable between a lowered or compact position for shipment, shown in FIG. 1, and a raised or extended position for retail display, shown in FIGS. 2-5. The slide wall may feature artwork and/or advertising relating to the mounted product displayed. The product 22 is connected to the slide wall 24 such that the product is movable between a lowered or collapsed configuration, shown in FIG. 1, and a raised or display configuration, shown in FIG. 2. A key feature of the display package 10 is that during shipment from a factory to a point of display/sale, when multiple display packages are themselves packaged in a master-shipping carton, volume is minimized when each slide wall is in the compact position, resulting in reduced shipping costs. However, when the shipping carton reaches a retail destination, a stockperson/user is able to remove the individual display packages from their shipping cartons and display the product, such as the toy figure, in the extended configuration so as to enhance customer visibility and make a better presentation of the toy figure, especially with background artwork printed on the slide wall of the package.
An example of an actual tray/slide wall/toy may be about twelve inches wide, about six inches deep and about sixteen inches high when shipped with the slide wall in the lowered compact position. In the presentation or slide wall raised position, the tray/slide wall/toy is about twenty-three inches high. In the alternative, the tray and slide wall may be scaled up or down as a function of the product to be carried and displayed. In the alternative, it is understood that products other than toys may be packaged as described.
In more detail, the tray 12, shown as a flat corrugated blank in FIG. 6, includes a lower base panel 30 and a first or back rear wall panel 32 separated from the lower base panel 30 by a score line 34. (A score line is an indented line made by a sharp tool during fabrication of a corrugated container and facilitates folding of the container. The score lines are usually made during the same manufacturing step when the periphery and any cutouts of the blank are die-cut.) Connected to the back rear wall panel 32 is a second or front rear wall panel 36 separated from the back rear wall panel by a narrow top wall panel 38 located between two score lines 40, 42. The top wall panel 38 includes a first slot 44 contiguous with an opening 46 in the front rear wall panel 36. An upper base panel 48 is separated from the front rear wall panel 36 by a score line 50 and second and third spaced apart slots 52, 54. The front and back rear wall panels 32, 34 along with the top wall panel 38 and the first slot 44 provide a convenient and protective channel for the movable slide wall 24, as will be discussed in detail below.
A triangular left sidewall 60, FIG. 6, is separated from the back rear wall panel 32 by a score line 62 and a fourth slot 64. A triangular left sidewall flap 66 is separated from the left sidewall 60 by a score line 68, the left sidewall flap having a peripheral tab 70 that is to be received by the fourth slot 64 when the tray is folded. (A single dotted score line is used here to indicate a 90° fold and a double dotted score line is used to indicate a 180° fold.) A triangular right sidewall 72 is separated from the back rear wall panel 32 by a score line 74 and a fifth slot 76, and a triangular right sidewall flap 78 is separated from the right sidewall by a score line 80, the right sidewall flap having a peripheral tab 82 that is to be received by the fifth slot 76.
A left base flap 90 and a right base flap 92 are separated from the left and right sidewalls, respectively, by score lines 94, 96, respectively. A first front wall panel 98 is separated from the lower base panel 30 by a score line 100 and a sixth slot 102, and a second front wall panel 104 is separated from the first front wall panel 98 by a score line 106. The second front wall panel 104 includes a peripheral tab 108 that is to be received by the sixth slot 102. The first front wall panel 98 includes left and right tabs 110, 112 separated from the first front wall panel 98 by score lines 114, 116, respectively. The left tab 110 is received between the left sidewall 60 and the left sidewall flap 66 when the tray is folded during assembly and the right tab 112 is tucked between the right sidewall 72 and the right sidewall flap 78 when the tray is folded. In the alternative, the shapes and sizes of the sidewalls, the sidewall flaps and the front wall panels may be different or not used, perhaps as a function of the product to be mounted and/or expense. The second, third, fourth, fifth and sixth slots may be deleted along with the peripheral tabs. The sizes and shapes of the rear wall panels and the top wall panel may also be changed without departing from the invention herein.
The slide wall 24, shown as a flat corrugated blank in FIG. 6, includes a first or front panel 120 separated by a score line 122 from a second or rear panel 124. The front panel 120 includes an oval shaped hand opening or cutout 126, upper side wings 128, 130, four openings 132, 134, 136, 138 to receive cords for attaching the ELMO™ figure to the slide wall. Two opposing lower abutment flanges 140, 142 are near the bottom of the front panel. The abutment flanges engage the top wall panel 38 when the slide wall is pulled sufficiently upward to limit such movement. The rear panel 124 of the slide wall includes an oval shaped hand opening or cutout 144 aligned with the oval shaped opening 126 of the front panel 120, and upper side wings 146, 148. Two opposing lower abutment flanges 150, 152 are near the bottom of the rear panel where the wings and flanges align with identically named elements of the front panel when the slide wall is folded along the score line 122. The rear panel 124 also includes two short slots 160, 162 for receiving end segments of an abutment structure in the form of an accordion folded brace 164, FIG. 6. The folded panels of the slide wall 24 act as a security barrier to prevent consumers from removing fasteners that attach the product to the slide wall. The two panels 32, 36 of the rear wall of the tray enclose the slide wall sufficiently to prevent tampering with the cords or other fasteners used to secure the product to the slide wall. The panels of the slide wall and the rear wall also present a more aesthetic appearance for display. Corrugated fiberboard sheets may be used for the package although other forms of paper (such as non-corrugated paper) or plastic may be used if desired.
The brace 164, shown as a flat blank in FIG. 6, may be a strip of corrugated that has a relatively long center segment 166, a first pair of oppositely disposed score lines 168, 170, a first pair of oppositely disposed short segments 172, 174, a second pair of score lines 176, 178, a second pair of oppositely disposed short segments 180, 182, a third pair of score lines 184, 186, and a third pair of oppositely disposed short segments 190, 192 that fit through the short slots 160, 162. The brace 164 may be held in place with a strip of tape 194, FIG. 7, placed across the third pair of brace segments 190, 192. The accordion folded brace 164 is compressed along the first, second and third pairs of score lines 168, 170, 176, 178, 184, 186 when the slide wall 24 is in the lower position. When the slide wall is in the lower position, shown in FIG. 1, the brace 164 is directly “squeezed” between the rear panel 124 of the slide wall 24 and the back rear wall panel 32 of the rear wall 20, as supported by the remaining structure of the slide wall and the tray, resulting in a force applied to the brace 164 to keep the brace in a compressed accordion fold, as shown in dotted lines in FIG. 5. The dotted lines illustration of the brace in FIG. 5 shows where the brace would be when the slide wall is in the lowered position. When the slide wall 24 is in the raised position, shown in FIGS. 4 and 5, and the brace 164 is lifted beyond the first slot 44 in the top wall panel 38, there is no longer a squeezing force on the brace and the brace, which has a memory once folded, expands as shown in solid lines in FIG. 5. When the slide wall is lifted fully by the user/stockperson and gravity attempts to lower the slide wall there is an abutment between the lower edge 196, FIG. 5, of the now expanded brace and a top edge 198 of the back rear panel 32 of the rear wall to prevent the slide wall from lowering on its own.
Referring now to FIG. 8, two cords 200, 202, made of wire or string, for example, extend from the toy figure (or other product) through the openings 132, 134, 136, 138 in the front panel 120 of the slide wall and are attached and then covered with strips of tape 204, 206. In the alternative, fasteners such as staples or adhesives may be used to connect the brace 164 to the slide wall. Also, the brace may have other shapes, or another device, such as a spring or a tab. Other material besides corrugated may be used, such as heavy paper. Of course, other toy figures besides ELMO™ may be packaged, such as other SESAME STREET MUPPETS™ brand figures, or other dolls or action figures, or other products altogether.
A slightly different embodiment is shown in FIGS. 9-12, where a display package 220 includes a tray 222 that may be identical with the tray 12, with a three-part base 224, two part sidewalls 226, 228, and a two-part rear wall 230. The display package 220 also includes an ELMO™ brand toy figure 232, and a slide wall 234 movable between a lowered position shown in FIG. 9, and a raised position shown in FIG. 11. The toy figure 232 is connected or mounted to the slide wall 234 such that the toy figure is also movable between a lowered or collapsed configuration, shown in FIG. 9, and an extended or display configuration, shown in FIG. 11. The toy figure shown in FIG. 10 is in a partially extended position.
In more detail, the tray 222, shown as a flat corrugated blank in FIG. 12, includes a lower base panel 240, and a first or back rear wall panel 242 separated from the lower base panel 240 by a score line 244. Connected to the back rear wall panel 242 is a second or front rear wall panel 246 separated from the back rear wall panel 242 by a top wall panel 248 located between two score lines 250, 252. The top wall panel 248 includes a first slot 254 contiguous with an opening 256 in the front rear wall panel 246. An upper base panel 258 is separated from the front rear wall panel 246 by a score line 260. A left sidewall 262 is separated from the back rear wall panel 242 by a score line 264 and a second slot 266. A left sidewall flap 268 is separated from the left sidewall 262 by a score line 270, the left sidewall flap having a peripheral tab 272 that is to be received by the second slot 266 when the tray is folded. A right sidewall 274 is separated from the back rear wall panel 242 by a score line 276 and a third slot 278, and a right sidewall flap 280 is separated from the right sidewall 274 by a score line 282, the right sidewall flap 280 having a peripheral tab 284 that is to be received by the third slot 278 when folded.
Score lines 290, 292 separate a left bottom flap 286 and a right bottom flap 288 from the left and right sidewalls 262, 274, respectively.
A first front wall panel 296 is separated from the lower base panel 240 by a score line 298 and a fourth slot 300, and a second front wall panel 302 is separated from the first front wall panel 296 by a score line 304. The second front wall panel 302 has a peripheral tab 306 that is to be received by the fourth slot 300 when folded. The first front wall panel 296 includes left and right tabs 308, 310 separated from the first front wall panel 296 by score lines 312, 314, respectively. The left tab 308 is tucked between the left sidewall 262 and the left sidewall flap 268 when the tray is folded during assembly and the right tab 310 is received between the right sidewall 274 and the right sidewall flap 280 when folded.
The slide wall 234 is somewhat different from the slide wall 24, FIGS. 1-5. The slide wall 234 includes a first or front panel 320 separated by a score line 322 from a second or rear panel 324. The front panel 320 includes an oval shaped opening 326, upper side wings 328, 330, and four openings 332, 334, 336, 338 to receive cords for attaching the ELMO™ figure to the slide wall 234. Two opposing lower abutment flanges 340, 342 are part of the front panel that operate as explained above in relation to the display package 10 to prevent the slide wall from being pulled away from the tray when the slide wall is raised. The rear panel 324 also includes an oval shaped hand opening or cutout 344 aligned with the oval shaped hand opening 326 of the front panel 320, and upper side wings 348, 350. Opposing lower abutment flanges 352, 354 are near the bottom of the rear panel 324 and align with identically named elements of the front panel 320 when the slide wall is folded along the score line 322. The slide wall 234 is different from the slide wall 24 in that the front panel 320 of the slide wall 234 is connected to two abutment structures in the form of side flaps 356, 358 which are separated from the front panel section by score line 360, 362, respectively. The side flaps 356, 358 are unfolded, flattened or compressed against the front panel 320 by the front rear wall panel 246 when the slide wall 234 is in the lowered position as shown in FIG. 9, but when the side flaps 356, 358 clear the top wall panel 248, the side flaps 356, 358, which may have some memory, are able to pivot, fold or expand outward to the positions shown in FIG. 11. When released by the stockperson/user after being pulled upward, the slide wall will tend to lower itself because of gravity; however, the side flaps 356, 358 cause an engagement or abutment between their lower edges 364, 366, FIG. 11, and a top edge 368 of the front wall panel 246 of the rear wall 230. As with the display package 10, the double panel slide wall 234 provides a protected and secure connection for the toy or other product that is not easily reached by someone trying to steal the product by removing it from the package. The double panel rear wall 242, 246 protects and secures the slide wall 234.
It is noted that throughout this description, words such as, “upward”, “downward”, “upper”, and “lower”, “top” and “bottom”, as well as like terms, refer to portions or elements of the display package and shipping carton as they are viewed in the drawings relative to other portions, or as they will typically be handled during use or operation in relationship to the positions of other elements of the system, or as they move based on the configurations illustrated.
In operation, the trays are formed from sheets of corrugated that are cut and scored, and then folded in ways well known to those skilled in the art. The slide wall and abutment brace are also formed from corrugated sheet. The toy figure is attached to the slide wall and the slide wall is inserted between the rear wall panels. The slide wall is placed in the lowered position and the display package is placed into a shipping carton for shipment from an assembly location to a point of display/sale, such as a toy store. When the shipping carton reaches the toy store, a stockperson/user removes two display packages simultaneously, as will be explained in detail below, which automatically places the packages and the mounted products in the display configuration. The user placing his/her fingers in the oval shaped openings in the slide walls to lift the slide walls. This action also accomplishes removal of the packages from the shipping carton and the toy figure to go from the collapsed configuration to the display configuration. The compressed brace or side flaps expands when the slide wall is fully raised and abut the tray to prevent lowering of the slide wall.
The display package described in detail above, features a robust, but simply constructed, tray, slide wall, and abutment structure that allows shipment from a factory to a display location to occur at a reduced volume and, thereby, expense. Nevertheless, the package is able to display to advantage its toy or other product to potential customers.
Referring now to FIGS. 13-17, there is shown a shipping carton 400, in an assembled and sealed configuration with a closed top closure 402 in FIG. 13, with the top closure 402 in an open configuration in FIG. 14, as a flat corrugated fiberboard blank in FIG. 15, with a bottom closure 404 in an open configuration in FIG. 16, and with the bottom closure 404 in a closed configuration in FIG. 17. The shipping carton 400 includes a front panel or wall 406, a back panel or wall 408, a left side panel or wall 410, a right side panel or wall 412, two upper top flaps 414, 416, and two under top flaps 418, 420. The upper and under top flaps 414, 416, 418, 420, form the top closure 402 and is known in the field as a regular slotted carton closure, often called an RSC closure. Four bottom flaps 422, 424, 426, 428 form the bottom closure 404 and together are known in the field as a 1-2-3 snap lock and/or Houghland closure.
The two upper flaps 414, 416 are separated from the front and back panels 406, 408 by two score lines 430432, respectively, and the two under flaps 418, 420 are separated from the left and right side panels 412, 410 by two score line 434, 436, respectively. Two bottom side flaps 422, 424 are separated from the front and right side panels 406, 412 by two score lines 440, 442, respectively, and the other two bottom flaps 426, 428 are separated from the back and left side panels 408, 410 by two score lines 444, 446, respectively. The shipping carton also includes a glue flap 448 separated from the front panel 406 by a score line 450 where the glue flap 448 is adhered to the left side panel 410 when the shipping carton 400 is partially assembled. A carton making company, often called a converter, may deliver the shipping carton to the product producing company already glued.
The RSC top closure is typically sealed by a strip of tape 460 as shown in FIG. 13, and the 1-2-3 bottom closure is typically closed manually from the open position shown in FIG. 16, to the closed position shown in FIG. 17, where the bottom flap 426 is folded down first, the bottom side flaps 424, 428 are then folded down on top of the bottom flap 426 (when the carton is turned upside down), and, finally, the bottom flap 422 is folded down on top of the bottom side flaps 424, 428 and a lip portion 462 of the bottom flap 422 is tucked under the bottom flap 426. Typically, tape is not needed with the 1-2-3 snap lock closure. Graphic arrows, such as the graph arrows 464, 466 and the phrase “THIS SIDE UP” may be printed on one or more of the front, back and side panels 406, 408, 410, 412 to ensure that the shipping carton is opened at the retail store right side up. In the alternative, other types or styles of boxes and box closures may be used, if desired, and other notices may be used to indicate which part of the shipping carton is considered the top and should be opened to unload and extend the display packages. The shipping carton is preferably formed of corrugated fiberboard but may be made of other types of paper or plastic material.
Referring now the FIGS. 18 and 19, an insert 470 is illustrated in a folded configuration in FIG. 18 and in a flat corrugated blank in FIG. 19. The insert 470 includes two central panels 472, 474 separated by two parallel score lines 476, 478 and a narrow panel 479. Each central panel includes a hand sized oval opening or cutout 480, 482. Two large middle panels 484, 486 are separated from the central panels 472, 474 by score lines 488, 490, respectively. Separated from the middle panels 484, 486 by score lines 492, 494, are outer flaps 496, 498, respectively. When the insert is folded as shown in FIGS. 18 and 20, the hand openings 480, 482 in the central panels 472, 474 align with each other, and when placed over two extendable display packages, such as the display packages 500, 502, FIG. 21, the hand openings 480, 482 of the insert 470 align with the hand openings in slide walls 504, 506 of the display packages 500, 502. The slide walls 504, 506 are identical to the slide wall 24, illustrated in FIGS. 3-6, and the hand openings 126, 144. The display packages 500, 502 may be identical to the display package 12, FIGS. 1-6, or to the display package 222, FIGS. 9-12.
As shown in FIG. 21, the two display packages 500, 502 are placed back to back when loaded into the shipping carton 400 such that the hand openings 480, 482 in the insert 470 and the hand openings in the slide walls 504, 506 are aligned and very close together enabling a user's hand 510, FIG. 22, to grip the insert 470 and the slide walls 24 simultaneously. In operation, after the RSC closure 402, FIG. 13, at the top of the shipping carton 400, FIG. 22, is opened, the user's hand 510 is able to grip the insert 470 and the slide walls 504, 506 at the same time such that when the user pulls upward to remove the display packages, initially, only the insert 470 is raised along with both slide walls 504, 506 of the display packages, as shown in FIG. 23. Once the slide walls 504, 506 are fully extended, accordion folded braces 507, 508, FIG. 24, which are identical to the brace 164, FIGS. 4 and 5, extend to lock the slide walls in the raised positions. Continued extraction of the insert 470 and the display packages 500, 502 begin to remove and separate the display packages from the shipping carton. The display packages 500, 502 are shown extended and partially removed from the carton 400 in FIG. 24. After removal of the display packages from the carton the insert may be discarded, and the display packages are ready for display without further effort or attention.
A major advantage of the present invention is achieved in that the single continuing act of unloading the display packages from the shipping carton causes the slide walls of the display packages and the attached products to extend to the display configuration “automatically” in that no additional effort is needed. The result is that the display packages are first extended, then locked in the extended configurations and finally the display packages are separated from the carton immediately ready to be placed on a retailer's shelf. There is no need for the user who unloads the shipping cartons to remember to extend the display packages, or to even learn how to perform the extensions, or to do anything other than placing the extended and locked display packages directly on the retail shelf because the act of removing the packages from the carton also extends and locks the slide walls. Another advantage is that the display package and product may be shipped in a compact configuration to save volume and expense. In addition, the various structures disclosed hereinabove are simply constructed of inexpensive materials but are more than robust for their purpose. Furthermore, the display packages are secured against easy removal of the attached product so that theft is discouraged.
The present invention also includes a method for making the extendable display package shipping system 520, FIGS. 25a and 25b, including the steps of providing a first blank shaped to form a first product mounting tray 522, such as the blank 12, FIG. 6, providing a second blank shaped to form a first slide wall 524, such as the blank 24, FIG. 6, and providing a third blank shaped to form a first abutment structure 526, such as the abutment structures 164, FIG. 6, (or incorporating abutment side flaps 356, 358, FIG. 12, into the second blank). The three blanks 12, 24, 164 may all come from a single sheet of corrugated fiberboard before they are cut and scored into the first, second and third blanks The method continues by assembling the first blank into the first tray 528, assembling the second blank into the first slide wall 530, such as the slide wall 24, FIGS. 3 and 4, mounting the first abutment structure to the first slide wall 532 to enable the first abutment structure to be compressed and expanded as shown in FIG. 5, and mounting the first slide wall to the first tray 534 to be movable between lowered and raised positions.
The method for making the extendable display package shipping system 520 also includes the steps of connecting a first product to the first slide wall 536 to enable the product to move between collapsed and display configurations, such as the movable toy product 22 shown in FIGS. 1 and 2, when the first slide wall is moved between the lowered and raised positions, compressing the first abutment structure 538 to the position shown in dotted lines in FIG. 5, placing the first slide wall in the lowered position 540 and the first product in the collapsed configuration as shown in FIG. 1, providing a fourth blank 542 shaped to form a second tray for mounting a second product, providing a fifth blank 544 shaped to form a second slide wall, providing a sixth blank 546 shaped to form a second abutment structure, assembling the fourth blank into the second tray 548, assembling the fifth blank into the second slide wall 550, mounting the second abutment structure to the second slide wall 552 to enable the second abutment structure to be compressed and expanded, mounting the second slide wall to the second tray 554 to be movable between lowered and raised positions, connecting a second product to the second slide wall 556 to enable the second product to move between collapsed and extended configurations when the second slide wall is moved between the lowered and raised positions, compressing the second abutment structure 558, and placing the second slide wall in the lowered position 560 and the second product in the collapsed configuration.
The method for making the display package shipping system 520 includes the further steps of providing a seventh blank 562 shaped to form a shipping carton, such as the shipping carton 400, FIG. 15, the shipping carton having an top closure and a bottom closure, providing an eighth blank shaped to form an insert 564 for the shipping carton, such as the insert 470, FIG. 18, assembling the seventh blank into a shipping carton 566, such as the shipping carton 400, FIG. 13, closing the bottom closure of the shipping carton 568, such as shown in FIG. 17, bending the eighth blank into an insert 570, such as the insert 470 shown in FIG. 18, placing the first and second extendable display packages into the assembled shipping carton 572 back to back, such as illustrated in FIG. 21, placing the insert into the assembled shipping carton 574 over the first and second extendable display packages to enable a user to grip the insert and the first and second slide walls simultaneously, as shown in FIG. 22, and closing the top closure of the shipping carton 576 as shown in FIG. 13.
The method for making the display package shipping system 520 may also include the steps for forming hand openings 578 in each of the first and second slide walls, such as the openings 126, 144, FIG. 5, forming hand openings 580 in the insert, such as the openings 480, 482, FIG. 19, aligning the openings of the slide walls and the insert 582 when the insert is placed into the assembled shipping carton over the first and second extendable display packages, forming each of the first and second trays with a rear wall having front and rear panels 584, such as the panels 32, 36, FIG. 6, forming each of the first and second slide walls with front and rear panels 586, such as the panels 120, 124, FIG. 6, forming each of the first and second abutment structures with accordion folded end segments 588, as shown in FIG. 6, forming the shipping carton with a regular slotted carton top closure 590, and forming the shipping carton with a 1-2-3 snap lock bottom closure 592.
The present invention may also includes a method 600, FIG. 26, for making the display package comprising the steps of providing a corrugated blank shaped to form a tray 602, forming the tray with a rear wall having front and rear panels 604, providing a corrugated blank shaped to form a slide wall 606, forming the slide wall with front and rear panels 608, providing a blank shaped to form an abutment structure 610, forming the abutment structure with accordion folded end segments 612, assembling the blank into the tray for a product 614, assembling the blank into the slide wall 616, mounting the abutment structure to the slide wall to be compressed and expanded 618, mounting the slide wall in the tray to be movable between lowered and raised positions 620, connecting the product to the slide wall 622, the toy product moving between collapsed and extended position when the slide wall is moved between the lowered and raised positions, compressing the abutment structure 624, placing the slide wall in the lowered position 626, and arranging the slide wall to enable it to be pulled to the raised position 628, such as forming the hand openings.
From the foregoing, it can be seen that there has been provided detailed features for an advantageous system and method for shipping extendable display product packages where each package and product may be shipped in a compact, lowered or collapsed configuration to minimize shipping costs, but be displayed in a raised or extended configuration to best present the product to the shopping public at the point of sale. Another advantage is that when unloading the product packages from a shipping carton, the packages automatically extend from the lowered position to the extended positions so that the packages with the mounted products may be placed directly on a retail shelf in the raised configurations. No further action is necessary from the stockperson/user who is tasked with unloading the shipping carton. Moreover, the system provides that the product is secured against easy removal from the package so as to discourage theft. The extendable display package shipping system is simply constructed, structurally robust, compact and easy to use, and yet, relatively inexpensive. While particular embodiments of the system have been shown and described in detail, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the present invention in its broader aspects. Therefore, the aim is to cover all such changes and modifications as fall within the true spirit and scope of the claimed invention. The matters set forth in the foregoing description and accompanying drawings are offered by way of illustrations only and not as limitations. The actual scope of the invention is to be defined by the subsequent claims when viewed in their proper perspective based on the prior art.
Patent Application
20140097122
