Portable display containers and methods of making and using the same

Portable display containers with spine and cross supports, methods of making portable display containers with spine and cross supports, and methods of using containers with spine and cross supports. The portable display containers have a plurality of tiers, each tier having a base tray, at least one spine, and two or more cross supports that add strength and rigidity to the display, allowing the portable display containers to be fully loaded with product or items prior to transportation and/or shipment to the display location.

FIELD OF THE INVENTION

The present invention generally relates to the field of display containers and methods of making and using the same. More specifically, embodiments of the present invention pertain to portable display containers having multiple tiers, and spine and cross supports that allow for easy access to the product, yet add strength and rigidity, allowing the portable display containers to be fully loaded with items prior to transportation and/or shipment to the display location. Embodiments of the present invention also relate to methods of making and using portable display containers.

DISCUSSION OF THE BACKGROUND

Most products (e.g., packages of tortillas), after arriving at stores, must be loaded onto store shelving for display to potential consumers, thereby adding significant additional handling costs to the product and exposing the product to damage. Traditional display containers, which may be more effective than store shelving to showcase a product (e.g., because the display container may be more open or eye-catching, the product may be more readily accessed from 3 or 4 sides, the display container may be placed in a prime location in a store apart from the standard store shelving, etc.) are also typically loaded with product after the display container and the product arrive (separately) at the store. This is because such display containers are either heavy and semi-permanent (e.g., those made of steel or aluminum), rendering them inefficient and costly to dispose of after a single use or return to the product vendor for reloading and reuse, or disposable (e.g., those made of cardboard) but lacking the strength and rigidity to protect the product during transportation and/or shipment. Thus, these traditional disposable displays must also be manually loaded with product after the display container arrives at the store.

Consequently, the need exists for containers that are effective for product display (i.e., open with easy access to the product) and are strong and rigid enough to protect the product during shipment and/or transportation to the display location, yet are cost effective and environmentally friendly (e.g., recyclable) as a disposable unit after use, without the traditional need for additional handling to load the product into the display container after arrival at the display destination. Likewise, there is a need for methods of efficiently making and using such display containers.

This “Background” section is provided for background information only. The statements in this “Background” are not an admission that the subject matter disclosed in this “Background” section constitutes prior art to the present disclosure, and no part of this “Background” section may be used as an admission that any part of this application, including this “Background” section, constitutes prior art to the present disclosure.

SUMMARY OF THE INVENTION

The present invention relates to portable display containers (see, e.g. display container100inFIG. 1) having a plurality of display tiers or levels (see, e.g., display tiers101inFIG. 1) that may be stacked vertically on a portable platform (e.g., a pallet), and are strong enough to be shipped fully loaded with product, but cost effective and environmentally friendly as a disposable unit. Each of the tiers of the portable display containers comprises a base tray (see, e.g.,202inFIGS. 2 and 302inFIG. 3A), at least one spine (see, e.g.,203inFIGS. 2 and 303inFIG. 3B), and two or more ribs (see, e.g.,204inFIGS. 2 and 304inFIG. 3C). The base tray, spine(s) and ribs are configured to provide extra strength and rigidity to the display, thereby allowing the plurality of tiers to be stacked, and each tier of the display container to be loaded with product prior to transportation and/or shipment to the product's display destination.

The present invention further provides methods of making and using portable display containers that may be fully loaded with product prior to shipment and/or transportation (e.g., display container100inFIG. 1). The method of making the container generally includes (i) assembling a display tier by (a) forming a base tray, the base tray being formed by folding each of two end panels at an angle of approximately 90° with respect to a bottom panel of a blank for a base tray, folding each end panel extension of two pairs of end panel extensions at an angle of about 90° with respect to the end panel to which the end panel extension is attached, folding each side panel of two side panels at an angle of approximately 90° relative to the bottom panel; and attaching each of the end panel extension to one of the two side panels; (b) forming at least one spine by folding each of two spine flaps at an angle of about 90° relative to spine center portions of a spine blank to form a spine panel, two or more spine slots and a spine top ridge, and folding each spine extension of two pairs of spine extensions at an angle of approximately 90° relative to the spine panel; (c) placing at least one spine into the base tray such that the two pairs of spine extensions contact and/or are attached to the end panels of the base tray; (d) forming at least two cross supports by folding each cross support flap of two cross support flaps at an angle of approximately 90° relative to a cross support center portion of a cross support blank to align cross support cutouts and to form a cross support panel and a cross support top ridge, and folding each cross support extension of two pairs of cross support extensions at an angle of approximately 90° relative to the cross support panel; (e) inserting into and/or mating each of the cross supports with one of the spine slots of the spine(s); (ii) placing the display tier on a portable platform or on a lower tier of the stack of display tiers; and (iii) repeating steps (i) and (ii) for each tier of the portable display container.

In some embodiments, the method further includes applying an adhesive to each of the spine extensions prior to placing the spine(s) into the base tray and/or applying adhesive to each of the cross support extensions prior to inserting into and/or mating the cross support extensions with the spine(s). The base tray, spine(s) and the cross supports provide the extra strength and rigidity necessary to transport the portable display container fully loaded with product.

These and other advantages of the present invention will become readily apparent from the detailed description of various embodiments below.

DETAILED DESCRIPTION

For the sake of convenience and simplicity, the terms “container,” “display,” “container display” and “pallet display” are generally used interchangeably herein and the use of one generally includes the others, unless the context necessarily indicates otherwise, but are generally given their art-recognized meanings. Likewise, the terms “cross support” and “rib” are generally used interchangeably, unless the context indicates otherwise.

Additionally, and although at times the present invention is described with regard to the shipment, transportation and/or display of tortillas, the invention is not so limited and may include any product or item that may be loaded on or into the tiers of the portable display container.

Exemplary Portable Display Containers

Referring to the drawings wherein like reference numbers correspond to like or similar parts throughout the several views, and referring particularly to the exemplary embodiments ofFIG. 1, embodiments of the present invention relate to portable display containers having a plurality of tiers in a stack on a portable platform. Although the portable display container100ofFIG. 1has six tiers101, the portable display container of the present invention may have from two to ten tiers or more. The portable platform105ofFIG. 1comprises a standard pallet. However, any portable platform capable of (i) being easily transported, (ii) supporting the weight of the display tiers and items in the display tiers, and (iii) being cost effectively disposed of and/or recycled may be used.

In addition, the portable display container100ofFIG. 1has an approximately rectangular shape when viewed from the top down, having a width W1and a length L1. However, the portable display container100may also have a shape which is square (i.e., L and W are the same), or the portable display container100may be oriented such that the length L is approximately parallel to the short dimension of the pallet105, and the width W is roughly parallel to the long dimension of the pallet105.

The length L1and the width W1of the portable display100ofFIG. 1may range from about 18″ to 120″ (e.g., 18″, 20½″, 36¾″, 42″, 48″, 66″, 72″, 84″, 104″, etc.) and any value therein. Most typically, the length L1will be approximately 48″ and the width W1will be approximately 40″. In some embodiments, two or more stacks of display tiers may be placed on a single portable platform. For example, two 20″×48″ stacks of display tiers may be placed on a one 40″×48″ pallet. In embodiments of the present invention, the overall height H1of the portable display container100may range from about 24″ to about 72″ (e.g., 24½″, 32″, 40¼″, 56″, etc.), depending on the number of tiers and the type of product displayed. Most typically, the height H1will be about 52″.

In some embodiments, the portable display container100is made from single, double and/or triple wall corrugated pads. In other embodiments, portable display container100may be made from cardboard, paperboard, chipboard, a honeycomb pad, a laminate (e.g., paperboard or corrugated paper laminated with plastic and/or foil), combinations thereof, etc. In various embodiments, the portable display container may include any display container that would benefit from added strength or rigidity.

FIG. 2shows an embodiment of a single tier201of the present invention comprising a base tray202, a spine203, and four cross supports or ribs204. As shown in the embodiment ofFIG. 2and most typically, the height H2of the spine203is approximately equal to the height H3of the cross supports204. The height H2of the spine203and the height H3of the cross supports may range from about 6″ to about 36″ (e.g., 6″, 8¾″, 10″, 17″, 20″, 24½″, 32″, etc.). The height H1of the base tray202may range from about 10% to 40% of the height H2of the spine and/or the height H3of the cross supports (e.g., 10%, 15%, 18%, 22%, 25%, 33%, 40%, etc.). Dimensionally, the height H1of base tray203may range from about 1″ to 9″ (e.g., 1″, 1¾″, 3″ 4¼″, 6″, 7½″, etc.). In a typical portable display container that is 48″×40″, the height of the base tray will be about 3″, and the height of the spine and cross supports will be about 8½″.

In the embodiment ofFIG. 2, a single spine203is approximately centered along the width W of the base tray202having approximately the same length L as the base tray. However, in other embodiments, a single tier may comprise two or more spines, and such spines may be located back-to-back, or parallel to each other with a space or gap between each of the spines so as to increase the support and/or the rigidity of the display, with minimal reduction in the usable space of the portable display container. The display tier ofFIG. 2comprises one spine203approximately centered in the base tray and four cross supports or ribs204, each extending the width W of the display tier201, and configured such that the ribs204intersect the spine at roughly a 90° angle. As shown, the embodiment ofFIG. 2creates 10 sections for product to be displayed. Although the embodiment ofFIG. 2comprises four cross supports, in other embodiments the number of cross supports may range from two to eight (e.g., 2, 3, 4, 5, 6, etc.).

Referring now toFIGS. 3A-3C, therein are shown perspective views of the basic components of the portable display container comprising base tray302(seeFIG. 3A), a spine303(seeFIG. 3B) and a cross support304(seeFIG. 3C). The base tray302comprises (i), a bottom panel310, (ii) two opposing end panels330a,330b, (iii) an exterior side panel320b(the opposing exterior side panel is not shown), and (iv) an interior side flap321a(the opposing interior side flap is not shown). In some embodiments, the base tray may have side panels, not side flaps and the end panels extensions may be glued or otherwise adhered to the side panels. The bottom tray has an approximately rectangular shape when viewed from the top down, and may be constructed of corrugated pads (single, double or triple wall), cardboard, paperboard, chipboard, a honeycomb pad, a laminate (e.g., paperboard or corrugated paper laminated with plastic and/or foil), combinations thereof, etc.

The spine303(seeFIG. 3B) comprises (i) a spine panel340, (ii) spine top ridges350a-350e, (iii) two pairs of spine extensions341a,341band342a(not shown),342b, and (iv) four spine slots351-354. When the spine303is placed into and/or assembled with tray302, the pairs of spine extensions contact and/or engage opposing end panels330a,330bto add stability and/or rigidity to spine303. In the embodiment ofFIG. 3B, each of the four spine cutouts351-354are configured to receive one cross support304such that, when assembled, a total of four cross supports304would be inserted into and/or mated with the spine303.

The cross support304(seeFIG. 3C) comprises (i) a cross support panel360, (ii) cross support top ridge370, (iii) two pairs of cross support extensions361a,361band362a(not shown),362b, and (iv) cross support slot363. When the cross support304is inserted into and/or mated with spine303, the two pairs of cross support extensions361a,361band362a,362bcontact and/or engage interior side flaps321a,321b, respectively, to add stability and/or rigidity to cross support304. To mate cross support304with spine303, the cross support slot363is inserted into and/or through one of the spine slots (e.g.,351) such that the cross support top ridge370is even with and/or in the same plane as the spine top ridges350a-350e. The same procedure is used to insert cross support304into each of the other three spine slots (e.g.,352-354). An assembled tier is more fully described below.

Referring now toFIG. 4, therein is shown an exploded view of an embodiment of one tier of a portable display container. A base tray402, comprising (i) a bottom panel410, (ii) two side panels420a,420b, (iii) two side flaps421a,421b, (iv) two end panels430a,430b, and (v) and two pairs of end panel extensions431a,432aand431b,432b(not shown), forms the bottom of the tier. The two side panels420a,420bare foldably attached to the bottom panel410at an angle of approximately 90° relative to the bottom panel410, and each have a corresponding side flap421a,421bfoldably attached at an angle of approximately 180° relative to the corresponding side panel420a,420b, respectively. In the embodiment shown inFIG. 4, the bottom panel has three pairs of bottom slots411a,411b(not shown),412a,412b(not shown), and413a,413b(not shown). The side flaps421a,421bhave corresponding tabs422a,423a,424a, and422b,423b,424brespectively. The tabs422a-424aare configured to fit into bottom slots411a-413a, and the tabs422b-424bare configured to fit into bottom slots411b-413b(not shown) to lock or otherwise secure the side panels420a,420band side flaps421a,421bto the bottom panel410. The number of bottom slots and tabs to secure each side panel/side flap may vary from one slot/tab to 6 slots/tabs or more.

The two opposing end panels430a,430beach have a corresponding pair of end panel extensions431a,432aand431b,432b(not shown). End panel extensions431a,432aare foldably attached to end panel430aat an angle of 90° relative to end panel430a, and end panel extensions431b,432bare foldably attached to end panel430bat an angle of 90° relative to end panel430b. When base tray410is completely assembled, end panel extensions431a,431bare captured and/or otherwise secured between side panel420aand side flap421a, and end panel extensions432a,432bare captured or otherwise secured between side panel420band side flap421b. In some embodiments, end panel extensions431a,431b,432aand432bmay comprise glue and/or an adhesive on one or both surfaces of end panel extensions431a,431b,432aand432bto further secure end panel extensions431a,431b,432aand432bto the corresponding side panels420a,420band/or the side flaps421a,421b.

In the embodiment ofFIG. 4, the spine403comprises a spine panel440, having spine top ridges450a-450e, a pair of spine extensions441a,441b,442a(not shown), and442b. The pairs of spine extensions441a,441b,442aand442bare configured such that when the spine403is placed or otherwise located within bottom tray402, the spine extensions441a,441bcontact and/or engage end panel430a, and the spine extensions442aand442bcontact and/or engage end panel430bin order to align and/or stabilize spine403within bottom tray402. In some embodiments, the pairs of spine extensions441a,441band442a,442bmay comprise glue and/or an adhesive on the surfaces in contact with end panels430a,430b, to further secure the pairs of spine extensions441a,441band442a,442bto their respective end panels430a,430b.

In the embodiment ofFIG. 4, spine403comprises four spine slots451-454, each having a height of approximately half (50%) of the height of spine403and each configured to receive one of the four cross supports404(see below). Although inFIG. 4, there are four spine slots451-454, spine403may have between two and ten slots (e.g., 2, 3, 4, 5, 7, 9, etc.) and an equal number of cross supports404. In some embodiments, the spine slots451-454are evenly spaced across the length of spine403, while in other embodiments, the distance between cutouts may vary. Most typically, the height of the spine slots451-454will be half of the height of the spine403, but in some embodiments, the height of the spine slots451-454may range between 10% and 90% (and all values therein) of the height of the spine403(e.g., 10%, 12.5%, 17%, 25%, 38%, 45%, 50%, 62%, etc.).

The four cross supports404comprise cross support panel460having a cross support top ridge470, a pair of cross support extensions461a,461band462a,462b(not shown). Each of the cross supports404also comprises a cross support slot463having a height of approximately half (50%) of the height of cross support404and configured such that when one of the cross supports404is inserted into one of the spine slots451-454and/or assembled with spine403, the top of the cross support404aligns with the top of spine403. Most typically, the height of the cross support404will be the same as the height of the spine403, and slot463will be half (50%) of the height of the cross support404. However, in some embodiments, the height of the cross support slot463may range between 10% and 90% (and all values therein) of the height of the cross support404(e.g., 10%, 12.5%, 17%, 25%, 38%, 45%, 50%, 62%, etc.).

When the height of the spine slots451-454are less than 50% of the height of the spine403, the height of each of the cross support slots463will be correspondingly increased so that when one of the cross supports404is inserted into and/or assembled with the spine403, the cross support top ridge470aligns with and/or is in the same plane as the spine top ridges450a-450e. For example, if the height of the spine slots451-454are 35% of the height of the spine403, the height of each of the cross support slots463will be 65% of the height of the cross support404. Similarly, if the height of the spine slots451-454are 22% of the height of the spine403, the height of each of the cross support slots will be 78% of the height of the cross support404.

The pairs of cross support extensions461a,461band462a,462bare configured such that when one of the cross supports404is inserted into and/or assembled with the spine403, and is placed and/or otherwise located within bottom tray402, one pair of cross support extensions461a,461bcontact and/or engage side flap421a, and the other pair of cross support extensions462a,462bcontact and/or engage side flap421b. In some embodiments, the pairs of cross support extensions461a,461band462a,462bmay comprise glue and/or an adhesive on the surfaces in contact with side flaps421a,421b, to further secure the pairs of cross support extensions461a,461band462a,462bto their respective side flaps421a,421b. In embodiments where there are no side flaps, the pairs of cross support extensions may contact, engage and/or be adhered to with glue and/or an adhesive, side panels420a,420b

Exemplary Blanks for Portable Display Containers

FIGS. 5A-5C, show exemplary blanks for the base tray, spine and cross supports, respectively, of a portable display container. In some embodiments, the blanks are made from corrugated paper. In other embodiments, the container blanks shown inFIGS. 5A-5Cmay be made from cardboard, paperboard, a laminate (e.g., paperboard or corrugated paper laminated with plastic and/or foil), combinations thereof, etc.

FIG. 5Ashows a blank502A for a base tray (e.g., the base tray302ofFIG. 3A). The base tray blank502A is generally cut from a single sheet of board stock (e.g., corrugated paper or fiberboard, cardboard, etc., which may be single, double or triple ply, laminated or coated with plastic, wax, adhesive paper, etc.) More than one blank may be cut from a single sheet of board stock.

Base tray blank500A comprises a bottom panel510, two side panels520a,520b, side flaps521a,521b, and two end panels530a,530b. The opposing end panels530a,530bare foldably attached to the bottom panel510at fold lines529a,529b, respectively. The opposing side panels520a,520bare foldably attached to the bottom panel510at fold lines527and528respectively. The side flap521ais foldably attached to the side panel520aat a pair of parallel fold lines525a,526a. Likewise, the side flap521bis foldably attached to side panel520bat a pair of parallel fold lines525b,526b. The pairs of parallel fold lines525a,526aand525b,526ballow for ease of folding the side flap to an angle of approximately 180° in relationship to side panels520a,520b, respectively. In various embodiments, each of the fold lines of a pair525a,526aand525b,526bmay be at a distance of between ⅛″ and ½″ from each other (e.g., ⅛″, 3/16″, ¼″, ⅜″, etc.). Fold lines525a,526a,525b,526b,527,528,529aand529bmay be scored (e.g., pressed and/or partially cut into the material of the blank500A for ease of folding the container) on one, the other, or both sides of the container blank500A.

Each of the end panels530a,530bhas a pair of end panel extensions531a,532aand531b,532b, respectively, which secure each of the end panels530a,530bto the side panels520a,520band/or the side flaps521a,521b. End panel extensions531a,532aare foldably attached to end panel530aat fold lines535a,536a, and end panel extensions531b,532bare foldably attached to end panel530bat fold lines535b,536b. Fold lines535a,536a,535b, and536bmay be scored on one, the other, or both sides of container blank500A.

The side flaps521a,521bhave tabs522a-524aand522b-524b, respectively. The bottom panel510has bottom slots511a-513aand511b-513bat and/or near fold lines527and528, respectively, configured to receive tabs522a-524aand522b-524b. When side panels520a,520bare folded at an angle of approximately 90° relative to bottom panel510, and when side flaps521a,521bare folded at an angle of approximately 180° relative to side panels520a,520brespectively, tabs522a-524aand522b-524balign with and/or may be mated with bottom slots511a-513aand511b-513b, respectively, to secure side panel520a/side flap521aand side panel520b/side flap521bin position relative to the bottom panel510. Although the base tray blank502A has three slots511a-513ato mate with tabs522a-524ato secure side panel520a/side flap521ato bottom panel510, and likewise three slots511b-513bto mate with tabs522b-524bto secure side panel520b/side flap521bto bottom panel510, the number of bottom slots/tabs to secure each side panel/side flap may vary from one slot/tab to 6 slots/tabs or more.

FIG. 5Bshows a blank503B for a spine (e.g., the spine ofFIG. 3B). The spine blank503B is generally cut from a single sheet of board stock (e.g., corrugated paper or fiberboard, cardboard, etc., which may be single, double or triple ply, laminated or coated with plastic, wax, adhesive paper, etc.) More than one blank may be cut from a single sheet of board stock.

The spine blank503B comprises spine flaps540a,540b, spine center portions550a-550e, two pairs of spine extensions541a,542aand541b,542b, and spine cutouts551-554. The spine flaps540a,540bare foldably attached to the spine center portions550a-550eat pairs of parallel fold lines545a/545b,546a/546b,547a/547b,548a/548b, and549a/549b. The pairs of parallel fold lines545a/545b,546a/546b,547a/547b,548a/548b, and549a/549ballow for ease of folding each of the spine flaps540a,550bto an angle of approximately 90° in relationship to the spine center portions550a-550eto form a spine panel (e.g. the spine panel340ofFIG. 3B). In various embodiments, each of the fold lines of a pair545a/545b,546a/546b,547a/547b,548a/548b, and549a/549bmay be at a distance of between ⅛″ and ½″ from each other (e.g., ⅛″, 3/16″, ¼″, ⅜″, etc.). Fold lines545a/545b,546a/546b,547a/547b,548a/548b, and549a/549bmay be scored on one, the other, or both sides of the spine blank503B.

When spine flaps540a,540bare folded at an angle of approximately 90° relative to the spine center portions550a-550e, the spine cutouts551-554form slots (see, e.g., slots351-354ofFIG. 3B), and the spine center portions form spine top ridges (see, e.g., spine top ridges350a-350eofFIG. 3B). Each of the spine slots formed from the spine cutouts are configured to receive and/or mate with a cross support (e.g., the cross support304ofFIG. 3C).

In addition, spine flap540ahas a pair of spine extensions541a,542afoldably attached to spine flap540aat fold lines543a,544a, respectively. Likewise, spine flap540bhas a pair of spine extensions,541b,542bfoldably attached to spine flap540bat fold lines543b,544b, respectively. The fold lines543a,544a,543band544bprovide for ease of folding the spine extensions541a,541b,542aand542bto an angle of approximately 90° relative to the corresponding spine flap540aor540b.

Although spine blank503B comprises four spine cutouts551-554and therefore, five spine center portions, in alternative embodiments, spine blank503B may comprise as few as two spine cutouts (and three spine center portions) or as many as 10 spine cutouts (and 11 spine center portions).

FIG. 5Cshows a blank504C for a cross support (e.g., the cross support ofFIG. 3C). The cross support blank504C is generally cut from a single sheet of board stock (e.g., corrugated paper or fiberboard, cardboard, etc., which may be single, double or triple ply, laminated or coated with plastic, wax, adhesive paper, etc.) More than one blank may be cut from a single sheet of board stock.

The cross support blank comprises cross support flaps560a,560b, cross support center portion570, two pairs of cross support extensions561a,562aand561b,562b, and cross support cutouts563a,563b. The cross support panels560a,560bare foldably attached to the cross support center portion570at parallel fold lines565a,565b. The parallel fold lines565a,565ballow for ease of folding each of the cross support panels to an angle of approximately 90° relative to the cross support center portion to form a cross support panel (e.g., the cross support panel360ofFIG. 3C) having a cross support top ridge (e.g., the cross support top ridge370ofFIG. 3C). In various embodiments, the parallel fold lines565a,565b, may be at a distance of between ⅛″ and ½″ from each other (e.g., ⅛″, 3/16″, ¼″, ⅜″, etc.). Parallel fold lines565a,565bmay be scored on one, the other, or both sides of the cross support blank504C.

When cross support flaps560a,560bare each folded at an angle of approximately 90° relative to the cross support center portion570, the cross support cutouts563a,563balign, essentially forming a single cross support slot (see, e.g., cross support slot363ofFIG. 3C), and the cross support center portion forms a cross support top ridge (see, e.g., cross support top ridge370ofFIG. 3C). The single cross support slot formed from the alignment of cross support cutouts563a,563bare configured to be inserted into and/or mate with one of the spine slots (see, e.g., spine slot351ofFIG. 3B). In some embodiments, each of the cross support flaps560a,560bmay have more than one cross support cutouts such that when folded, the assembled cross support panel may have more than one cross support slot. In such embodiments, the cross support is configured to mate with more than one spine, wherein the spines are approximately parallel to each other (see the discussion related toFIG. 2, above).

In addition, cross support flap560ahas a pair of cross support extensions561a,562afoldably attached to cross support flap560aat fold lines566a,567a, respectively. Likewise, cross support flap560bhas a pair of cross support extensions561b,562bfoldably attached to cross support panel560bat fold lines566b,567b, respectively. The fold lines566a,567a,566band567ballow for ease of folding the cross support extensions561a,561b,562aand562bto an angle of approximately 90° relative to the corresponding cross support flap560aor560b. The fold lines566a,567a,566band567bmay be scored on one, the other, or both sides of the cross support blank504C.

Referring now toFIG. 6, therein is shown a portable display container600having six display tiers601, each display tier601comprising a base tray602, one spine603, four cross supports604and a pallet605. As shown, the portable display container ofFIG. 6also comprises product680loaded onto the display tiers. Although the product shown is packages of tortillas, it should be understood that the invention is not so limited and a wide variety of different types of products (e.g., packages of popcorn, chips, nuts, candies, dried fruit, paper products, cotton products, clothing items, etc.) may be loaded onto the display tiers of the portable display container.

InFIG. 7, there is shown a portable display container700having six display tiers701, each display tier701comprising a base tray702, one spine703, four cross supports704, and a pallet705. As shown, the portable display container ofFIG. 7also comprises product780loaded onto the display tiers, and inside corner posts790. The inside corner posts790may be inserted within the corners of each display tier and may extend from at or near the bottom of base tray702of one display tier701to at or near the bottom of the next display tier701in the stack. In some embodiments, the cross section of the inside corner posts790may be a 90° angle.

Exemplary Methods of Making Multi-Level Portable Display Containers

An exemplary method of forming multi-level portable display containers generally comprises (a) assembling a display tier by: (i) forming a base tray by (A) folding each of two end panels (e.g.,530a,530bofFIG. 5A) along a corresponding fold line (e.g.,529a,529bofFIG. 5A) at an angle of approximately 90° relative to a bottom panel (e.g.,510ofFIG. 5A) of a base tray blank (such as blank502A ofFIG. 5A), (B) folding each end panel extension of two pairs of end panel extensions (e.g.,531a,532aand531b,532bofFIG. 5A) along corresponding fold lines (e.g.,535a-536a,535b-536bofFIG. 5A) at an angle of approximately 90° relative to the end panel to which the end panel extension is attached, (C) folding each side panel of two side panels (e.g.,520a,520bofFIG. 5A) along corresponding fold line (e.g.,527,528ofFIG. 5A) at an angle of approximately 90° relative to the bottom panel, (D) attaching each of the end panel extension to one of the two side panels; (ii) forming at least one spine by (A) folding each of two spine flaps (e.g.540a,540bofFIG. 5B) along corresponding parallel fold lines (e.g.,545a-549a/545b-549bofFIG. 5B) at an angle of approximately 90° relative to spine center portions (e.g.550a-550eofFIG. 5B) of a spine blank (e.g.,503B of5B) to form a spine panel (e.g.,340ofFIG. 3b), two or more spine slots (e.g.,351-354ofFIG. 3B) and a spine top ridge (e.g.,350a-350eofFIG. 3B), and (B) folding two pairs of spine extensions (e.g.,541a-542a,541b-542b) along corresponding fold lines (e.g.,543a-544a,543b-544bofFIG. 5B) at an angle of approximately 90° relative to the spine panel; (iii) placing the at least one spine into the base tray, such that the two pairs of spine extensions contact and/or are attached to the end panels of the base tray; (iv) forming at least two cross supports by (A) folding each cross support flap of two cross support flaps (e.g.,560a,560bofFIG. 5C) along corresponding parallel fold lines (e.g.,565a,565bofFIG. 5C) at an angle of approximately 90° relative to cross support center portion (e.g.,570ofFIG. 5C) of a cross support blank (e.g.,504C ofFIG. 5C) to align cross support cutouts (e.g.,563a,563bofFIG. 5C) and form a cross support panel (e.g.,360ofFIG. 3c) and a cross support top ridge (e.g.,570ofFIG. 3C), and (B) folding each cross support extension of two pairs of cross support extensions (e.g.,561a-562aand561b-562bofFIG. 5C) along corresponding fold lines (e.g.,566a-567aand566b,567bofFIG. 5C) at an angle of approximately 90° relative to the cross support panel; (v) inserting into and/or mating the cross support slot of each of the cross supports with one of the spine slots of the spine(s) such that the spine top ridge and the cross support top ridge are in the same plane and such that the cross support extensions contact the corresponding side panels of the base tray; (b) placing the display tier on a portable platform or on another tier of the stack of display tiers; and (c) repeating steps (a) and (b) for each tier of the portable display container.

The method may also comprise folding each of two side flaps (e.g.,521a,521bofFIG. 5A) along two parallel fold lines (e.g.,525a-526aand525b-526bofFIG. 5A) at an angle of approximately 180° relative to one to the side panel to which the side panel is attached, and placing and/or inserting each end panel extension of the two pairs of end panel extensions in between the side panel and side flap. The method may further comprise inserting each of one or more tabs (e.g.,522a-524a,522b-524bofFIG. 5A) into each of one or more bottom slots (e.g.,511a-513a,511b-513bofFIG. 5A) to secure the side flaps to the bottom panel, and the end panel extensions between the side panels and the side flaps.

In some embodiments, steps of the method may be performed in a different order while still providing for a complete assembly. For example, the step of inserting into and/or mating the cross support slot of each of the cross supports with one of the spine slots of the spine(s) may be performed prior to the step of placing the at least one spine into the base tray. Similarly, the step of folding each end panel extension of two pairs of end panel extensions along corresponding fold lines at an angle of approximately 90° relative to the end panel to which the end panel extension is attached may be performed prior to the step of folding each of two end panels along a corresponding fold line at an angle of approximately 90° relative to a bottom panel of a base tray blank. It should be understood that where practical, the present invention includes performing the steps in a different order other than that order specifically described above.

In some embodiments the method may comprise, for each spine, applying adhesive to the two pairs of spine extensions prior to placing the spine(s) into the base tray and/or for each cross brace, applying an adhesive to the two pairs of cross brace extensions prior to inserting into and/or mating the cross braces with the spine(s).

The display tiers may comprise single, double and/or triple wall corrugated pads. In other embodiments, the display tiers may be made from cardboard, paperboard, chipboard, a honeycomb pad, a laminate (e.g., paperboard or corrugated paper laminated with plastic and/or foil), combinations thereof, etc.

Exemplary Methods of Using Portable Display Containers

An exemplary method of using portable display containers generally comprises: (a) placing a plurality of items in the portable display container described above, (b) placing inside corner posts within the corners of each display tier, wherein the cross section of each of the inside corner posts is a 90° angle and each of the inside corner posts extend from at or near the bottom panel of one base tray of one display tier to at or near the bottom panel of the next display tier above in the stack; (c) wrapping the portable display container with protective material; (d) moving and/or transporting the portable display container to a display location; and (e) removing the protective material.

The method may also include removing the inside corner posts after the portable display container is moved and/or transported to the display location. In some embodiments the method may further comprise placing outside corner posts at the corners of the portable display container, wherein the outside corner posts extend from at or near the portable platform to the top of the top display tier of the stack, and removing the corner posts after the portable display container is moved and/or transported to the display location.

The inside corner posts and outside corner posts may comprise from cardboard (including compressed cardboard), paperboard, chipboard, a honeycomb pad, a laminate (e.g., paperboard or corrugated paper laminated with plastic and/or foil), combinations thereof, etc.

CONCLUSION

Thus, the present invention advantageously provides portable display containers that are effective for product display because of the openness and the ease of access to the product in the containers, yet are strong and rigid enough to protect the product during shipment and/or transportation to the display location, thereby eliminating the need for additional handling to load the product into the display container after the product arrives at the display destination. The portable display containers described herein are also cost effective and environmentally-friendly because they are recyclable after use. The present invention also advantageously provides methods of making and using portable display containers.