PRODUCT DISPLAY TRAY AND METHOD

A tray for the display of products is described. The tray comprises a base and product display members formed from interconnected panels formed from a continuous substrate. The tray is formed from recyclable material and requires no external components during assembly, while still providing an attractive product display. The tray may be placed in an external container.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the invention is a display and storage container for artificial eyelashes. In one embodiment, the storage container comprises a display box made from a single sheet of material such as paper or cardboard.

2. Background of the Invention

Storage of beauty accessories is a problem for both retailers and end-users. For the retailer, the product should be displayed in an attractive display case that entices customers to buy the item, prevents theft, and clearly shows the purchased product to avoid mistaken purchases that would result in merchandise returns. The product display and storage container should be easy to open for the end-user, and the product should be readily retrievable from the container.

The problem is particularly pronounced for small items, such as artificial eyelashes.

A standard solution is to place the product in a hard plastic case. Such a display case can be manufactured to be transparent but is not easy to open. When the hard plastic shell is opened, sharp edges can be created, resulting in a risk of injury. Further, product containers made out of hard plastic are difficult to recycle.

A need exists in the art for a product display package that is easy to assemble, avoids unnecessary plastic components, and is easy to use. A need also exists for a method of manufacturing such a product display case and container.

SUMMARY OF INVENTION

An object of the invention is to create a product container and display tray that overcomes drawbacks in the prior art. A feature of the invention is that the product display tray includes protrusions to display the product on a stable base. An advantage of the invention is that the contained product is raised from a display base and can readily be accessed by the end customer. An additional advantage of the invention is that the end-user can easily see the features of the product within the container as the product is prominently displayed within the container.

A further object of the invention is to provide a product tray that can be made with no assembly. A feature of the invention is that the product display tray is made from a single substrate. An advantage of the invention is that the display tray does not require any assembly during manufacturing.

Another object of the invention is to create a product display tray that minimizes the use of plastic. A feature of the invention is that, in one embodiment, the main components of the display tray comprise a reinforced paper or cardboard. An advantage of the invention is that after use, the materials can be reused or recycled.

Yet another object of the invention is to provide a system for the display of a product that can be shipped in a flattened shape. A feature of the invention is that the container is formed by folding a substrate in specific locations, and the substrate can be shipped in a flattened state before assembly. An advantage of the invention is that the product container can be shipped as a single flat sheet prior to assembly and that the assembly does not require any additional components.

Another object of the invention is to provide a product display tray that can accommodate a variety of products and a variable quantity of products. A feature of the invention is that the display tray includes an interior chamber that can store multiple parts other than those on display.

Another object of the invention is to provide a display tray for a product that displays items with an adhesive element. A feature of the invention is that one surface of the display tray includes treatment for components with an adhesive layer, such as eyelashes. An advantage of the invention is that it can be used to dispense elements with an adhesive layer.

The invention provides an artificial eyelash display tray having a base and product display components formed by folding a single substrate of reinforced paper.

Also provided is a method for manufacturing a display tray, including cutting a substrate to the required shape, applying several creases, and cutting several slits.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing summary, as well as the following detailed description of specific embodiments of the present invention, will be better understood when read in conjunction with the appended drawings.

Turning to the figures,FIG.1A, depicted therein is a display tray embodiment10, showing one embodiment of the product display device or display tray. The display tray embodiment10comprises the display tray16. The display tray receives a product to be displayed, such as artificial eyelashes shown inFIG.1A. The artificial eyelashes include a lash strip12with at least one side, including an adhesive, in one embodiment. Lash filaments14extend from the lash strip12. The adhesive on the lash strip12is pre-applied, in one embodiment, such as the artificial eyelashes described in the applicant's co-pending patent application Ser. No. 17/409,705, entitled “Ready-to-Use Eyelash Extensions,” the contents of which are hereby incorporated by reference. In other embodiments, the adhesive is applied separately.

A display platform removably receives the product. In the depicted embodiment, the display platform comprises curved members18. In one embodiment, the product side20of the members18includes a coating. The coating allows for the product to be retained by the product display side but does not bond to the product adhesive fully, making the product removable. The coating results in the product side20becoming a laminated product display side. For example, for the lash strip12shown inFIG.1A, the product side20includes a coating to allow for later removal of the lash strips12from the product side20. As discussed below, the curved members18comprise a paper substrate, in one embodiment with the slick coating on the product side20.

The curved members18protrude above the plane formed by the tray base22. The display tray16can be oriented such that the tray base22is substantially vertical (as shown inFIG.1A) or substantially horizontal. The details of the curved member18shown as area e inFIG.1Aare shown inFIG.1E, described below.

FIG.1Bdepicts the lash strips12being removably attached to the product side20of the curved members18. The artificial eyelashes are removed from the members18by applying a force, such as pulling on the lash strips in the general direction depicted by the arrow denoted as f. The configuration, as shown inFIG.1B, in one embodiment, is the configuration encountered by the end customer when viewing the product in a store, except that the display tray16is inserted in a secondary package, one embodiment of which is shown inFIG.1Cand another embodiment is shown inFIG.1D.

FIG.1Cshows one embodiment of an external container30, the interior of which holds the display tray (not visible inFIG.1C). The external container30comprises multiple panels, including a front panel32which includes a clear viewing window34. In one embodiment, the clear viewing window comprises a plastic film. The front panel also includes areas for marking, such as areas to receive the product brand name, the lot and serial number, as well as instructional markings. An aperture adapted to receive a display rod36is also defined in the front panel32. A similar aperture is defined in the back panel (not shown), and therefore, the external container30may hang from a display rod at the point of sale. The panels, such as the front panel32are defined in the cardboard comprising the box30by a series of box fold lines38,39. One fold line38terminates the front panel32, while another fold line39defines the boundary of the adjacent top panel. In this way, in at least one embodiment, the tray comprises a single sheet of cardboard.

As can be appreciated fromFIG.1C, each panel of the container30need not be the same size. In fact, the container30features an irregular shape with a top panel that is much narrower than the corresponding base panel. In the embodiment shown, the top panel is approximately one-third the size of the base panel.

FIG.1Dshows an additional embodiment of a tray container, which comprises an external box31. The box31can also hold the display tray (not visible inFIG.1D). The external box31has six walls adapted to receive the display tray with the curved members protruding from the tray base. The external box, in one embodiment, comprises a paper material, except for a front panel33, which includes a clear plastic window35. In this embodiment, the product attached to the curved members can be readily seen by the end purchaser at the time of purchase. The external box31has a more rectangular shape, with the sizes of the panels corresponding to each other.

Curved Member Detail

FIG.1Eshows a detailed view of the curved member18, first shown inFIG.1A. The curved member18is defined by four edges. A first edge18aincludes a notched area21, as shown inFIG.1E. The notched area21results in the first edge18anarrowing the main body of the curved member18at one end of the curved member18. An opposing second edge18bis a mirror image of the first edge18a, including a corresponding notch. The curved member18also has a display edge18cwhich defines the part of the curved member18which is adapted to display the end-product, as seen inFIG.1A. On an opposite side from the display edge18cis the base edge18d, which includes a portion of material that acts as the connection point19with the rest of the tray16(only a small part of the tray16is visible inFIG.1E). In one embodiment, the connection point19includes a scored line in the cardboard which is adapted to allow the curve member18to bend away from the tray16when folded.

The shape of the curved member18is particularly advantageous, as will be appreciated from the remainder of the description. The presence of notch21on the shorter edge18aallows for easy assembly of the tray while preventing the tray from unintentional disassembly.

Tray Details

Turning toFIG.2A, the figure shows a disassembled display tray16per the embodiment shown inFIGS.1A and1Bin their assembled state. The display tray16includes a tray main body40. The tray main body40comprises one continuous substrate, in the embodiment shown inFIG.2A. In other embodiments, each sub-part described below is attached through appropriate means, such as glue, hook-and-loop fastener, stapling, riveting, and other attachment means.

The main body40comprises a substrate reinforced paper material in one embodiment. In other embodiments, the main body40comprises a cardboard material or a multi-layer paper product. As was discussed above, some parts of the main body40may have the added coating, such as the curved members18. The main body40comprises a substrate based on plant-fibers, such as a cardboard substrate. In this way, the main body40is readily recyclable, or otherwise biodegradable.

In some embodiments, the product is sourced from a single material such as cardboard and can be recycled.

The main body is divided into panels in one embodiment. For embodiments where the main body40comprises a continuous substrate, the panels are defined using folds. In one embodiment, the folds are made by first scoring the substrate. The scoring process results in adding scored lines to the substrate.

In the embodiment shown inFIG.2A, one of the panels is the tray base. Another panel, having approximately the same size, is the pedestal panel42, and it is connected to the base22by a first side panel44. The display panel46is also in communication with the tray base via the second side panel48. In the embodiment shown inFIG.2A, the panel46has a height h1, which is less than the height h2of the pedestal panel42. In other embodiments, the heights are substantially equal.

While multiple side panels are shown in the embodiment depicted in the figures, in some embodiments, the tray device comprises only one side panel.

The first side panel44and the second side panel48have different dimensions in the depicted embodiment, to form the assembled tray shown inFIG.1Athat has an angled display surface. The first side panel44and the second side panel48include folding wings43, which are adapted to assist in the assembly of the paper tray16.

As shown inFIG.2A, the base has two narrower sides defined by narrow folds50that connect the base to the third side panel52and the fourth side panel54. The third side panel52is then connected to a first flap56, and the fourth side panel54is connected to a second flap58. In some embodiments, each flap includes one surface that contains an adhesive layer so that when assembled, the flaps will remain in place. In other embodiments, the first flap56and the second flap58do not include any adhesive. In one embodiment, the side panels52,54have different shapes, and the corresponding flaps are smaller than the depicted flaps56,58.

The third side panel52and the fourth side panel54are substantially the same sizes in the depicted embodiment. Further, the width of the third side panel52and the height of the first side panel44are substantially the same sizes in the depicted embodiment. Therefore, when assembled, as shown inFIG.1A, orFIG.1B, the panels form a substantially rectangular shape.

InFIG.2A, the two curved members18are shown as attached to a longer edge of the display panel46. However, in some embodiments, the curved members are attached to the longer edge of the pedestal panel42. In yet other embodiments, one curved member18is attached to the display panel46, while the other is attached to the pedestal panel42.

The tray base22also includes several slits60. The slits correspond in size to the thickness of the curved members18. In this embodiment, a requirement, therefore, is that the height h1of the display panel46allows the curved members18to reach the slits60when the display panel is bent back in the assembled configuration described below. In the embodiment shown, the several slits60comprise two slits. In other embodiments, only one silt is used. In yet other embodiments, more than two slits are formed. In the depicted embodiment, each slit includes at least one aperture62at each end of the slit to assist in the assembly of the display tray16. In some embodiments, the apertures62are substantially circular and have a diameter that is ten to twenty percent larger than the width of each slit60. The slit60comprises a cut, in one embodiment, a perforated line in another embodiment, or a combination of both. The slits length and width correspond to the product display member's outside contour such that the product display member may pass through the slit.

While the panels depicted inFIG.2Aare substantially rectangular, the panels may take on any number of shapes in other embodiments, which will result in a different shape for the assembled display tray. In some embodiments, at least several of the panels are substantially square. In other embodiments, at least some of the panels comprise a parallelogram, a trapezoid, a rhombus, or even an irregular polygonal shape, and combinations thereof.

Alternative Trays

An alternative embodiment of the tray17is shown inFIG.2B. In the alternative embodiment, the tray base22comprises two panels and the display members. The tray main body panel40includes one or more slits60. Two distinct slits60are shown in the embodiment shown inFIG.2B, but in other embodiment, the shape represented by the slits60is created by one continuous large opening.

The tray base22comprises the same materials in the embodiment17ofFIG.2Bas in the embodiment16ofFIG.2A.

At least some of the slits60include the slit apertures62, as shown inFIG.2B.

The boundary between the display panel46and the main body panel40comprises a fold line61, in the embodiment ofFIG.2B. In some embodiments, the fold line61is scored, in other embodiments it is formed simply as a fold line in the substrate.

Further, while the embodiment shown inFIG.2Bis adapted to display a pair of eyelashes, in other embodiments, the tray includes multiple curved members18and slits60. For example, in one embodiment, the tray is used to display a set of five artificial nails and so five curved members18and five slits60are defined in the tray base22.

In some embodiments, the display panel46is fixed in place by the addition of tape (not shown).

An alternative embodiment of the tray27is shown inFIGS.2C and2D. Depicted inFIGS.2C and2Dis a tray base45and two product display members47. The product display members47are folded out from the tray base45such that the product display members47protrude from the base45. The product display members47, and the tray base comprise a single substrate. In one embodiment, the product display members47are separated from the base45except for the fold lines49. In some embodiments, the separation occurs with cutting50; in other embodiments, the cuts are replaced by perforations50. The cut or perforated lines50define the product display members' contour. Once the product display members47are defined in the base45, force f2is applied, folding them back along the fold line49so as to stand at an angle c with respect to the base45. As can be appreciated fromFIG.2C, the angle c is more than 90 degrees in the depicted embodiment. However, the angle c can be any angle at which the display members remain upright, including 90 degrees, less than 90 degrees, and more than 90 degrees. In some embodiments, the fold lines49are curved, while in other embodiments they are straight. Also, in some embodiments, the fold lines49are not cut or perforated along their entire lengths, while in other embodiments some portion of each edge of the fold lines49may be cut so that the product display member47may be curved more easily. The curvature of the display member47is particularly advantageous when the display member is used to showcase flexible products that are curved, such as flexible strips of artificial eyelashes.

Upon folding of the display members47, openings51are created in the base45. In some embodiments, an adhesive substrate is added to at least one of the openings51so that the tray embodiment27can be secured to an external box, such as ones described herein.

Assembly Steps

FIGS.3A-Ddepict several stages of the assembly process. From the configuration of the display tray16shown inFIGS.2A and2B, inFIG.3A, first, the curved members18are bent back to be substantially perpendicular to the display panel46. The pedestal panel42is also bent back, away from the tray base22.

As shown inFIG.3B, the side panels are bent back in the next phase of the assembly process. The third side panel52is shown in its final position, forming a 90-degree angle with the plane of the tray base22. The first side panel44is not yet in the final position so that the pedestal panel42does not obscure access to slits60.

FIG.3Cdepicts the tray16from the reverse side at approximately the same time, as shown inFIG.3B. The curved members18are in substantial alignment with the slits60in the tray base22. The pedestal panel42does not obscure the display panel46and allows the curved members18to pass through the slits60.

As shown inFIG.3C, a chamber63is formed from the intersection of the panels42and46. This internal chamber can be used to store additional product pieces, a security device, an RFID tag, or other items not visible unless the tray is opened.

FIG.3Ddepicts the state of the tray16once the curved members18have traversed the slits60. Only the first side panel44needs to be bent to its final position, and the pedestal panel42needs to be configured to be substantially parallel with the tray base22. The remaining side panels are substantially in their respective final configurations.

In one embodiment, the pedestal panel42includes an adhesive strip to attach it to the display panel46. In another embodiment, no adhesive is used, but instead, the resilience of the material comprising the tray16is sufficient to maintain the configuration of each panel.

Following the folding of all the panels, the tray16reaches the assembled configuration shown inFIGS.1A and1B. In some embodiments that start from a single flat substrate, once assembled, the substrate becomes a folded substrate.

The various panels can be made with considerable tolerances in variation in size due to the use of a cardboard or paper material, which is resilient but also pliable. The folds which form the various panels can be adjusted in thickness to accommodate variances in the sizes of the panels. Further, the slits are made more extensive than necessary to accommodate the curved members to make the assembly process more comfortable.

In most embodiments, the various panels are kept in place using frictional engagement with little to no adhesive. The limited use of adhesive ensures that the display tray can be made simply by cutting the desired shape in a substrate (such as cardboard) and applying adhesive strips in only a few locations. In some embodiments, no adhesive strips are added.

A benefit of the embodiment shown above is that the packaging can include tamper-evident features, such as seals, on the external box30shown inFIG.1C. The tray itself can be made from a homogenous material and require no added elements.

Manufacturing Overview

An overview of the manufacturing process70is shown in the flowchart inFIG.4. The process begins with providing a substrate72, such as a sufficiently large sheet of cardboard. In other embodiments, the provision of substrate72involves providing multiple segments of a substrate. In some embodiments of the process, the substrate is provided as a sheet. In other embodiments of the process, the substrate is sufficiently pliable so that it is provided from a roll.

Next, the general shape of the tray is cut74into the substrate. For example, in the embodiment shown inFIG.2Aor the embodiment ofFIG.2B, the cut of the substrate will create the external outline of the folded-out display tray.

After the general shape is cut into the substrate, the various bends lines are scored76into the substrate to provide boundaries for the various panels discussed above and to allow the panels to be bent back during the subsequent manufacturing and assembly steps.

Next, the various features of the tray are added78. For example, the slits discussed above are cut into the middle of the base panel. Secondly, additional cuts are made around the curved members to facilitate the curvature. Any adhesive is also added to a limited number of locations in one embodiment of the system.

Following the addition step78, the tray is substantially in the configuration shown inFIG.2A or2B, as discussed above. Optionally, the substantially flat trays are then delivered80to an assembly location. As the trays are substantially flat, delivery can be space and cost-efficient.

Once the trays arrive at the desired location, the trays are assembled82, as was discussed in conjunction withFIGS.3A-Ddiscussed above. The various panels are bent back, and the curved members traverse the slits to form the assembled configuration shown inFIGS.1A and1B. The product that will be sold using the trays is added to the tray by attaching the product to the curved members.

Finally, the assembled trays are placed84in a final package, such as the box shown inFIG.1C. The manufacturing process then ends.

It can be appreciated that the various steps use standard tools and techniques known in the manufacturing and cutting fields. The steps outlined above can readily be automated using a computer-controlled cutting device with interchangeable cutting tools. In some embodiments, the substrate includes a marker to help an automated system locate a corner of the shape to be cut during the cutting steps.

While the flowchart depicted inFIG.4shows the steps in sequential order, many of the steps can be accomplished in different orders, and some steps can be combined. For example, the cutting step and the step of adding features, such as cutting the slits, can be combined in some embodiments.