Abstract:
A display pack is provided that includes a planar support panel of corrugated paper having a front surface and a rear surface. A plastic product shell is disposed adjacent to the front surface of the support panel. The shell defines a product portion sized to receive a product and a planar portion circumscribing the product portion. A planar overlay sheet is disposed over the product shell, defining an opening such that the product portion of the product shell protrudes therethrough. The overlay sheet is configured to extend beyond a peripheral edge of the product shell and couple to the front surface of the support panel, capturing the shell in place.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates generally to a display pack and, more particularly, a display pack configured to hold one or more products within a transparent chamber.  
         [0002]     Traditionally, products have been shipped in bulk from a manufacturer to a retailer in cartons containing protective packing material. The container and packing material were configured to provide sufficient structural strength to enable palletizing and shipping in bulk. Once at the retailer, individual products were then removed from the cartons to be individually placed on a shelf or rack for display. For small, expensive, and easily stolen products, the shelf or rack might be located within a secured display case to minimize the risk of theft. All of this was costly and time consuming.  
         [0003]     More recently, small products have been packaged in comparatively large containers to deter theft. Some manufacturers have used smaller packaging captured in a transparent display pack, typically significantly larger than the small packaging, to provide for increased deterrence of theft. For example, certain display packs have been made from two vacuum-formed sheets of clear plastic, sealed around the edges, forming a chamber for holding the product.  
         [0004]     Although such display packs have been particularly effective in many applications, shortfalls exist. Oftentimes, the entire periphery of such display packs have been sealed, to provide added theft deterrence, which makes access difficult for the ultimate purchaser. Since such display packs typically are formed of durable plastic, access even via scissors can be difficult. Once cut open, portions of the display card typically remain captured within portions of plastic, which can hamper recycling of packaging materials.  
         [0005]     Manufacturers expend considerable effort in designing products and related materials to be visually appealing to the consumer. Product packaging can play an important role in attracting consumers. Thus, it is desirable to optimize the visual appeal of display packs, to promote the consumers interest in the product.  
         [0006]     It should, therefore, be appreciated that there remains need for a display pack that addresses these issues. The present invention fulfills this and other needs.  
       SUMMARY OF THE INVENTION  
       [0007]     Briefly, and in general terms, the invention provides a display pack for securing a product. The display pack is configured to withstand the rigors of transport, particularly in palletized assemblies, without requiring excess plastic structure. The display pack includes a support panel, an overlay sheet, a transparent product shell captured between the support panel and the overlay sheet. The support panel is formed of corrugated paper of sufficient strength to aid in load distribution when in a palletized assembly. Once the product is purchased by the consumer, the product shell can be removed relatively easily for recycling.  
         [0008]     More specifically, by way of example and not limitation, the display pack includes a planar support panel of corrugated paper having a front surface and a rear surface. A plastic product shell is disposed adjacent to the front surface of the support panel. The shell defines a product portion size to receive a product and a planar portion circumscribing the product portion. A planar overlay sheet is disposed over the product shell, defining an opening such that the product portion of the product shell protrudes therethrough. The support panel can also define an opening such that the product can be viewable from the back. The overlay sheet is configured to extend beyond a peripheral edge of the product shell and couple to the front surface of the support panel, capturing the shell in place.  
         [0009]     In an exemplary embodiment, the support panel is formed of E-flute or F-flute corrugated paper, and the overlay sheet is formed of blister-board paper. Adhesive is disposed between the overlay sheet and the support panel, preferably confined to a peripheral region of the overlay sheet. The front surface of the support panel is formed of treated paper to encourage adhesion.  
         [0010]     In detailed aspect of an exemplary embodiment, the overlay sheet is formed of paper material having a thickness between about 8 points and about 24 points, and more preferably, between about 21 points and about 24 points.  
         [0011]     In another detailed aspect of an exemplary embodiment, the product shell is formed of material selected from a list including PVC, PET, PETE, PETG, APET, styrene, and PPE.  
         [0012]     The invention also resides in a packaging assembly for shipping and displaying a plurality of display packs. The packaging assembly includes a display stand having a rectangular base panel and four sidewalls extending normal to the base panel. The display stand defines a plurality of slots to receive the plurality of display packs.  
         [0013]     In an exemplary embodiment of the invention, two of the side wall oppose each other and define a plurality of paired slots. Each of the paired slots configured to receive at least one of the display packs.  
         [0014]     In another exemplary embodiment of the invention, the base panel defines a plurality of slots, each slot configured to receive at least one of the display packs.  
         [0015]     For purposes of summarizing the invention and the advantages achieved over the prior art, certain advantages of the invention have been described herein. Of course, it is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.  
         [0016]     All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment disclosed. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     Embodiments of the present invention will now be described, by way of example only, with reference to the following drawings, in which:  
         [0018]      FIG. 1  is a front elevational view of a first embodiment of a display pack in accordance with the present invention, depicting a support panel, an overlay sheet, and a transparent product shell captured between the support panel and the overlay sheet, for securing a product in place.  
         [0019]      FIG. 2  is an exploded perspective view of the display pack of  FIG. 1 .  
         [0020]      FIG. 3  is a rear elevational view of the overlay sheet of the display pack of  FIG. 1 .  
         [0021]      FIG. 4  is a cross-sectional view of the display pack of  FIG. 1 , taken along line  4 - 4  of  FIG. 1 .  
         [0022]      FIG. 5  is a cross-sectional view (similar to  FIG. 4 ) of a second embodiment of a display pack in accordance with the present invention.  
         [0023]      FIG. 6  is an exploded perspective view of a third embodiment of a display pack in accordance with the present invention.  
         [0024]      FIG. 7  is a cross-sectional view (similar to  FIG. 4 ) of the display pack of  FIG. 6 .  
         [0025]      FIG. 8  is a perspective view of a display stand housing several display packs of  FIG. 1 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0026]     With reference now to the drawings, and particularly to  FIGS. 1 and 2 , there is shown a display pack  10  for securing a product  12 . The display pack is configured to withstand the rigors of transport, particularly in palletized assemblies, without requiring excess plastic structure. The display pack has a three-piece configuration, including a support panel  14 , an overlay sheet  16 , a transparent product shell  18  captured between the support panel and the overlay sheet. The support panel is formed of corrugated paper of sufficient strength to aid in load distribution when in a palletized assembly (e.g.,  FIG. 8 ). Once the product is purchased by the consumer, the product shell can be removed relatively easily for recycling.  
         [0027]     With reference to  FIG. 4 , the support panel  14  is formed of E-flute or F-flute corrugated paper, including a first sheet  20 , intermediate sheet  22 , and a second sheet  24 . The first sheet is configured to provide secure adhesion of the support panel to the overlay sheet  16 . In the exemplary embodiment, the first sheet  20  is formed of white paper (e.g., white no. 1 or white no. 3). It has been found that adhesion between the overlay sheet and the support panel is improved if white paper is used as opposed to raw paper. In other embodiments, effective adhesion can be achieved using various other materials, such as pre-coated corrugated paper. For example, clay-coated corrugated paper can be used to promote adhesion. Primarily for cost considerations, the intermediate sheet  22  and the second sheet  24  are formed of the raw paper.  
         [0028]     The overlay sheet  16  extends beyond a peripheral edge  26  of the product shell  18  and couples to the first sheet  20  of the support panel  14 , thereby capturing the shell in place. The overlay sheet  16  defines a cut-out  28  about a product region  30  of the product shell. The display pack  10  prominently displays the product  12  and packaging artwork  32 , while on retail display. Artwork is printed on the overlay sheet  16 , providing an enticing presence. Artwork also can be printed on the back surface of the support panel  14 . In other embodiments, artwork can be provided by other means known in the art, such as litho-labels.  
         [0029]     Referring to  FIG. 5 , a display pack  10 ′ is shown that further includes a rear panel  33  (e.g., card stock, blister board and so on) disposed to the rear surface of the support panel  14 ′, which can be used to depict artwork. In this embodiment, the rear panel and the overlay sheet  16 ′ extend beyond the peripheral edge of the support panel  14 ′ to cover the corrugated folds and inhibit debris from entering therebetween.  
         [0030]     Preferably, the overlay sheet  16  is formed of blister board paper having a paperweight between about 8 points and 24 points, and, more preferably, between about 21 and 24 points, measured as known in the art. In the exemplary embodiment, the overlay sheet is formed of blister board paper having paperweight about 21 points. In other embodiments, various other types of materials can be used for the overlay sheet, such as, card stock, corrugated paper, board stock, and adhesive labels. Various issues can be considered in selecting the paperweight, such as cost, product size, product weight, and desired packaging artwork, to name just a few.  
         [0031]     Adhesive material  38  is provided between the overlay sheet  16  and the support panel  14 . In the exemplary embodiment, a solvent-based adhesive is pre-coated on the backside of the overlay sheet  16 . As shown in  FIG. 3 , adhesive is limited to a peripheral region  34  of the overlay sheet. The peripheral region substantially borders the periphery of the product shell  18 ; this minimizes material adhering directly to the product shell. Once the product  12  is purchased by the consumer, the product shell can be removed relatively easily for recycling. In this manner, the plastic material of the product shell can be recycled without need of removing extraneous adhesive and paper material.  
         [0032]     In other embodiments, adhesive can be pre-coated on the support panel  14 . Alternatively, adhesive can be applied during assembly to either or both the overlay sheet  16  and support panel  14 . Although in the exemplary embodiment solvent-based adhesive is used, various other adhesive materials can be used, such as latex-based or water-based materials.  
         [0033]     The product shell  18  includes a peripheral planar portion  36  about the product region  30 . The planar portion abuts the support panel  14 . The product region conforms to the shape of the product  12 . In the exemplary embodiment, the product shell is configured to capture one product; however, in other embodiments, the product shell can define multiple regions for capturing multiple products. Also, multiple, separate product chambers can be provided in a single product display, as needed. The product shell  18  is formed of molded PVC plastic. In other embodiments, other plastics such as PVC, PET, PETE, PETG, APET, styrene, PPE, and corn-based (e.g., PLA), can be used in other embodiments. In selecting the material for the product shell, a number of factors can be considered, e.g., durability, recyclability, visual appeal, and other concerns.  
         [0034]     During assembly, the product  12  is positioned in the product region  30  of the product shell  18 , and the support panel  14  is disposed against the product shell, capturing the product. The overlay sheet is disposed atop the product shell such that the product region extends through the cut out  28 . Adhesive  38  on the backside of the overlay sheet contacts the corresponding surface of the support panel, securing the overlay sheet and product shell to the support panel. Once assembled, the display pack can be loaded for transport.  
         [0035]     With reference now to  FIGS. 6 and 7 , a display pack  50  is shown, having a product  12  disposed between two product shells  52 ,  54 , each defining a product chamber  56 ,  58 , respectively. The product shells include peripheral regions  57 ,  59  that circumscribe the product chamber. Both product shells are secured in place by an overlay sheet  60  and a support panel  62 , in a similar manner as discuss above. The overlay sheet and the support panel both define cut-outs  64 ,  66  aligned with the respective product chambers of the product shells, allowing the product chambers to extend out the cut-outs. As best seen in  FIG. 5 , the product is viewable from both sides of the display pack, providing a prominent and versatile display presence. In a variation, the product shells can be attached along a common edge, e.g., forming a hinge about which the shell can be folded to capture the product.  
         [0036]     As shown in  FIG. 8 , display packs can be conveniently transported in a palletized assembly  70 . A prescribed number of display packs are housed in display stands  72 . For ease of reference, the combination of a display stand housing at least one display pack is referred to as a packaging assembly  74 . In various embodiments, the packaging assembly can further include a shipping cover (not shown) sized to enclose the display packs within the packaging assembly.  
         [0037]     Each display stand  72  includes a rectangular base panel  76  and four side walls (front  78 , left  80 , right  82 , and rear  84 ), extending normal to the plane of the base panel. The stand provides a plurality of slots  86  for receiving the display packs. In the exemplary embodiment, the slots are provided by the left and the right side walls, in corresponding pairs spaced and prescribed intervals along the display stand. In other embodiments, the display stand can further include slots provided along the base panel. Alternatively, slots can also be limited exclusively to the base panel.  
         [0038]     In the exemplary embodiment, the four side walls ( 78 ,  80 ,  82 ,  84 ) have a common maximum height that substantially less than the height of the display packs loaded in the stand  70 . In other embodiments, the height of the side walls can vary from one another, and all or selected walls can extend above the display pack. For example, a stadium-type tray can be used in which the rear wall defines a maximum height of the display stand, the front wall defines a minimum height of the display stand, and the left and right wall increase in height from the front to the rear wall. In yet another embodiment, the side walls can provide corner posts to aid in load distribution.  
         [0039]     The packaging assemblies  74  are stacked in layers  78  on a pallet  90 . Each level can further include dividers (not shown) disposed between the packaging assemblies. For example, dividers can be about the same height as the packaging assemblies to aid in supporting the load of the other levels. Interlocking corrugated sheets can be used to for the dividers. In certain applications, the divider can extend above the packaging assemblies to serve as the primary load support.  
         [0040]     The palletized assembly can further include planar support (not shown) between the levels to provide a stable base for the level directly above and facilitates even load distribution. For example, sheet of corrugated paper can be disposed between the levels.  
         [0041]     Although the invention has been described in detail with reference only to the exemplary embodiments, those skilled in the art will appreciate that various other embodiments can be provided without departing from the scope of the invention. Accordingly, the invention is defined only by the claims set forth below.