Abstract:
A pallet system for displaying products including a plurality of trays (which may be stacked one to a level, two to a level or four to a level), a tie sheet for securing the trays of a level together, one or more graphics panels that display important and useful product information and a pole cover for product display.

Description:
RELATED APPLICATION  
       [0001]     This application claims the benefit of U.S. Provisional Serial Application No. 60/788,263, filed Mar. 31, 2006 and entitled “Improved Pallet System for Product Display,” the entire contents of which are hereby incorporated by this reference. 
     
    
     RELATED FIELDS  
       [0002]     Embodiments of the present invention relate to a pallet system for displaying products.  
       BACKGROUND  
       [0003]     Pallet systems that house and display products in retail stores or the like at the point of sale are well known. Retailers use such systems to reduce the costs of shipping, stocking and displaying products with such costs-savings being passed on to the consumer. Retail pallet systems are generally made of flat paperboard or corrugated board that can be folded or assembled into free standing structures with trays with planar bases and panels. The folding of the panels is made possible through the use of pre-manufactured score lines or separation lines along the paperboard or corrugated board.  
         [0004]     Pallet systems generally have a plurality of planar tiers with a plurality of compartments or dividers. Each planar tier or compartment may hold a plurality of products for display to customers in retail stores or warehouses. In many cases, the planar tiers of the pallet system are only held together by their own weight, glue, or by interlocking notches or slots in the tiers or compartments. Because of the number of panels associated with forming pallets, it is often difficult to form pallets uniformly, making formation very cumbersome. Additionally, many of the available pallet systems are unattractive and may negatively impact consumer purchasing decisions.  
         [0005]     Retailers may also desire that their pallet systems have an appearance that attracts customers to the display, thereby increasing the chances of purchase. For instance, some pallet systems may include graphics panels to indicate to the consumer the nature of the products displayed in the pallet or to attract customers to the displayed product. Typically, these graphics panels have been glued, stapled or otherwise directly affixed to the product trays. In use, the trays may settle or compact somewhat due to the weight of the trays and products. Problematically, as the trays settle or compact, the graphics panel may become bent, distorted, or otherwise damaged.  
         [0006]     Another problem with some pallet systems is that the product trays used with them do not allow for level stacking, which may also cause the display to be less visually attractive. The top edges of a typical pallet tray are not level with one another. For instance, the tray back is often formed by folding the portions of the blank corrugated board forming the back of the tray over portions of the blank board forming the sides. Because the back portions are folded over the sides, the backs of typical trays extend slightly higher on the sides and front of the trays.  
       SUMMARY  
       [0007]     Embodiments of the present invention generally include pallet systems for holding and displaying products. In some embodiments of the invention, the pallet system may include a number of pallet trays (which may be stacked one to a level, two to a level, four to a level, or in other arrangements), a tie sheet for securing the trays of a level together, and one or more graphics panels that display information related to the product held and displayed in the pallet system, or other types of graphics. The pallet system may also have a number of additional features generally intended to give it an attractive appearance at the point of sale and to increase its durability.  
         [0008]     In certain embodiments of the invention, a pallet system tray may include top surfaces that are level with one another. For instance, the tray may include top surfaces of the tray sides and backs that abut one another to define a level surface to stack additional trays on. In some embodiments, these top surfaces may be joined at a miter joint.  
         [0009]     In these or other embodiments, the pallet system may also include a tie sheet to facilitate orderly stacking of the trays and/or prevent the trays from spreading apart from one another after being stacked. In some embodiments, the tie sheet may include tabs and/or slots that interact with tabs and/or slots on the pallet system trays to lock them together.  
         [0010]     In these or other embodiments, the pallet system may also include a graphics panel that may not distort or otherwise become damaged as the pallet trays settle. For instance, in some embodiments, the graphics panel is only secured to the topmost trays of the pallet and can move independently of the lower trays, such that graphics panel will “float” with respect to the other trays and not become distorted as the pallet settles or compresses due to the weight of the displayed items. In some embodiments, the graphics panels may be secured to the topmost trays by the interaction of a tab with a slot. The graphics panel may also include a blade that aligns the graphics panel with respect to the lower trays, yet allows the graphics panel to slide with respect to those trays as they settle or compact. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0011]      FIG. 1  is a top view of a blank for a pallet tray in accordance with some embodiments of the present invention.  
         [0012]      FIG. 2  is a perspective view of a pallet tray assembled from the blank shown in  FIG. 1 .  
         [0013]      FIG. 3  is a top view of a blank for a capture tray in accordance with some embodiments of the present invention.  
         [0014]      FIG. 4  is a perspective view of a capture tray assembled from the blank shown in  FIG. 3 .  
         [0015]      FIG. 5  is a perspective view of a pallet tray of  FIG. 2  being positioned in a capture tray of  FIG. 4 .  
         [0016]      FIG. 6  is a perspective view of several pallet trays of  FIG. 2  positioned in a capture tray of  FIG. 4 .  
         [0017]      FIG. 7  is a top view of a blank for a tie sheet in accordance with some embodiments of the present invention.  
         [0018]      FIG. 8  is a perspective view of the tie sheet of  FIG. 7 , shown with its tabs pushed out.  
         [0019]      FIG. 9  is a perspective view of the tie sheet of  FIG. 7  being assembled with the portion of the pallet system shown in  FIG. 6 .  
         [0020]      FIG. 10  is a perspective view of another pallet tray being added to the pallet system shown in  FIG. 9 .  
         [0021]      FIG. 11  is a perspective view of pallet tray being positioned in a capture tray in accordance with other embodiments of the present invention.  
         [0022]      FIG. 12  is a perspective view of a tie sheet being assembled onto a portion of a pallet system in accordance with some embodiments of the present invention.  
         [0023]      FIG. 13  is a perspective view of an another pallet tray being added to the pallet system shown in  FIG. 12 .  
         [0024]      FIG. 14  is a top view of a blank for a graphics panel in accordance with some embodiments of the present invention.  
         [0025]      FIG. 15  is a perspective view of a graphics panel assembled from the blank shown in  FIG. 14 .  
         [0026]      FIG. 16  is a perspective view of the graphics panel of  FIG. 15  being associated with a pallet system in accordance with some embodiments of the present invention.  
         [0027]      FIG. 17  is a perspective view of the graphics panel of  FIG. 14  associated with the pallet system shown in  FIG. 16 .  
         [0028]      FIG. 18  is a perspective view of a graphics panel being associated with a pallet system in accordance with some embodiments of the present invention.  
         [0029]      FIG. 19  is another perspective view of the graphics panel being associated with a pallet system as shown in  FIG. 18 .  
         [0030]      FIG. 20  is a top view of a blank for a pole cover in accordance with some embodiments of the present invention.  
         [0031]      FIG. 21  is a perspective view of a pole cover assembled from the blank shown in  FIG. 20 .  
         [0032]      FIG. 22  is a top view of a blank for a riser in accordance with some embodiments of the present invention.  
         [0033]      FIG. 23  is a perspective view of a riser formed from the blank shown in  FIG. 22 .  
         [0034]      FIG. 24  is a perspective view of the riser and pole cover of  FIGS. 21 and 23  being assembled to a pallet system in accordance with some embodiments of the present invention.  
         [0035]      FIG. 25  is a perspective view after the riser and pole cover have been assembled to the pallet system of  FIG. 24 .  
         [0036]      FIG. 26  is a perspective view of a riser being assembled to a pallet system in accordance with some embodiments of the present invention.  
         [0037]      FIG. 27  is a perspective view after the riser has been assembled to the pallet system of  FIG. 26 .  
     
    
     DETAILED DESCRIPTION  
       [0038]      FIG. 1  shows a blank  10  for a pallet tray  30  in accordance with some embodiments of the present invention. The blank  10  may be formed by cutting a sheet of material, such as corrugated board, solid fiberboard, heavy paperboard, heavy plastic sheet, or other materials, and also perforating the blank with score lines  31 . The blank  10  shown in  FIG. 1  includes a planar base  32 , a back panel  38 , a top back panel  40 , opposing inner side panels  44 , L-shaped top dust panels  50 , opposing outer side panels  54 , top side panels  46 , side top flap panels  58 , front panel  60 , and opposing front dust flaps  62 . Blanks for pallet trays having other configurations are also possible and within the scope of the present invention.  
         [0039]     The pallet tray  30  shown in  FIG. 2  may be assembled from the blank  10  shown in  FIG. 1  by vertically folding the top back panel  40  of the blank  10  along its associated score lines  31  and inserting tabs  42  into slots  34 . Next, the opposing inner side panels  44  may be inwardly folded along their associated score lines  31  and the L-shaped dust panels  50  may be inwardly folded along their score lines  31 . Back panel  38  may then be folded into an upright position along the score line  31  separating it from planar base  32 .  
         [0040]     Subsequently, the outer side panels  54  may be folded into an upright position along the score lines  31  separating them from the planar base  32  and the top flaps  46  may be folded over the inner side panels  44 . The tabs  42  on the top flap  46  may be inserted into the slots  34  on the inner side panels  44  to secure the top flaps  46  to the inner side panels  44 . Next, the side dust panels  62  may be folded inwardly and the side top flap panels may be folded down with their associated tabs  42  tucked into slots  34 .  
         [0041]     Subsequently, the front panel  60  may be folded upright over the side dust panels  62  with the left and right sides of the front panel flexing as they are folded over the score lines  31 . The front panel  60  may be secured by inserting its associated tabs  42  into the slots  34 . Finally, the tabs  36  on the base  32  may be pushed downward so that they extend beneath the base  32 .  
         [0042]     Other methods may also be employed to assemble pallet trays in accordance with the present invention.  
         [0043]     The pallet tray  30  shown in  FIG. 2  includes top surfaces  200  that are level with one another to facilitate stacking additional pallet trays on top in a stable manner. In the embodiment shown in  FIG. 2 , the top surfaces  200  are joined at mitered corners  33 , i.e., beveled at a 45-degree angle to form a 90-degree corners. In other embodiments, it is not necessary for the pallet tray  30  to include mitered corners or other level top surfaces.  
         [0044]     In some embodiments, such as the embodiment shown in  FIG. 2 , the pallet tray  30  includes apertures  56  to assist in lifting and moving the pallet tray.  
         [0045]      FIG. 3  shows a blank  11  used to form the capture tray  64  shown in  FIG. 4 . Like the blank  10  for the pallet tray  30 , blank  11  may be formed by cutting a sheet of material and perforating it with score lines  31 . The blank  11  shown includes a planar base, four side panels  68 , and four dust panels  70 . Capture tray  64  may be formed from blank  11  by folding the dust flaps inwardly and folding side panels  68  upright to insert tabs  42  into slots  34 . In some embodiments, once capture tray  64  is formed, it may be centered and secured on a pallet (not shown) with a pneumatic staple gun, glue, nails, rivets or in some other manner. Blanks for forming capture trays having other configurations are also possible and within the scope of the present invention.  
         [0046]      FIG. 6  shows one way to position a level of pallet trays  30  into a capture tray  64 . In this embodiment, the pallet trays  30  are shown in one type of X 4  configuration (e.g., a configuration that includes 4 pallet trays per level), although other X 4  configurations may also be possible and within the scope of the present invention.  FIG. 6  also shows that dividers  72  may optionally be positioned inside of pallet trays  30 .  
         [0047]      FIG. 7  shows a blank  12  used to form the tie sheet  80  shown in  FIG. 8 . Blank  12  may be made in similar manners and from similar materials as blanks  10  and  11 , although in other embodiments, the blanks  10 ,  11 , and  12  may be made from different materials. The blank  12  shown in  FIG. 7  includes a pole opening  82 , rectangular shaped notches  84 , and perimeter and interior tabs  42 . Pushing the tabs outwardly (as shown in  FIG. 8 ) forms additional slots in the tie sheet  80 . Blanks for forming tie sheets of other configurations are also possible and within the scope of the present invention.  
         [0048]     As illustrated in  FIG. 9 , tie sheet  80  may be placed on top of the pallet trays  30  and the tabs  42  may be inserted into corresponding slots  34  in the trays  30  to secure the tie sheet  80  in place and fix the positions of the pallet trays  30  with respect to one another.  FIG. 10  shows how additional levels of pallet trays  30  may be placed onto the tie sheet  80  with the tabs  42  fitting through slots or notches in the tie sheet (or around the edge of the tie sheet) and into the slots  34  of the lower level of pallet trays  30 . Thus, in some embodiments, including the embodiments shown in  FIGS. 9 and 10 , the slots  34  in the lower level of pallet trays  30  are sized to receive both the tabs  42  of the tie sheet  80  and the tabs  42  of the upper level of pallet trays  30 . In other embodiments, however, the tie sheet and/or pallet trays may be secured to the lower level of pallet trays in another manner.  
         [0049]      FIGS. 11-13  illustrate the use of a tie sheet  80  in conjunction with a pallet system having a X 2  configuration.(e.g. a pallet system that includes two pallet trays per level).  
         [0050]      FIG. 14  shows a blank  13  used to form the graphics panel  90  shown in  FIG. 15 . Blank  13  may be made in similar manners and from similar materials as blanks  10 ,  11 , and  12 , although in other embodiments, the blanks  10 - 13  may be made from different materials. Blank  13  includes a central panel  92 , two side opposing panels  94 , dust panels  96 , locking tabs  98 , top side panel  100  and top tab  102 . The graphics panel  90  may be formed by folding the various portions of blank  13  over score lines  31 .  
         [0051]      FIGS. 16-17  show a graphics panel  90  being associated with a pallet system in accordance with some embodiments of the present invention. The graphics panel  90  may be secured to a topmost pallet tray  30  by inserting the tab  42  of the graphics panel  90  into a slot  34  of the pallet tray. The blade  102  of the graphics panel  90  may be inserted into a gap between the sides and backs of the pallet trays  30  such that the graphics panel will slide with respect to the pallet trays  30  that are not the topmost pallet tray. A lower portion of the graphics panel  90  may be inserted into the capture tray  64  to help further retain the graphics panel  90 .  FIGS. 18-19  show an alternative method for associating graphics panels  90  with a pallet system that does not involve a graphics panel blade  102  like the one shown in  FIG. 15 . Rather, the graphics panel  90  shown in  FIGS. 18-19  fits over the edges of the pallet trays  30 . Graphics panels  90  may also be associated with pallet systems in other manners that are within the scope of the present invention.  
         [0052]      FIG. 20  shows a blank  14  used to form the pole cover  110  shown in  FIG. 21 . The blank  14  shown in  FIG. 20  may be formed from similar, or different, materials, and in similar, or different, manners as the blanks discussed above. Like the blanks discussed above, blank  14  may be folded along score lines  31  to form the pole cover shown in  FIG. 21 . The blank  14  includes a planar base  112  with two opposing sectional tubes  114  with square openings (shown in  FIG. 21 ), two opposing side panels  116  with notches  118 , pole opening  120 , and rectangular slots  122 . On formation, the two opposing sectional tubes  114  are racked up to a square position and secured in place by tabs  42 , and the opposing side panels  116  are folded down. In some embodiments of the present invention, other pole cover configurations may be used, or, in still other embodiments, no pole cover is necessary.  
         [0053]      FIGS. 22 and 23  show a blank  15  and the riser  130  that may be formed from it, which may optionally be used in conjunction with some pallet systems of the present invention. As shown in  FIGS. 24 and 25 , the riser  130  may be secured to the pole cover  110 , which may positioned near or at the top of the pallet display. In other embodiments, a sign on a pole may be associated with the pole cover  110 . As shown in  FIGS. 26 and 27 , the riser may be directly associated with the rest of the pallet display in some embodiments, and pole cover  110  is not always necessary.  
         [0054]     Changes, modifications, substitutions, additions and deletions may be made to the structures, methods and concepts described above without departing from the scope or spirit of the present invention.