Abstract:
A display assembly apparatus and method of assembly using a folded frame and structurally reinforcing shelf for shipping and displaying products. The display uses a planar sheet for compact shipping which is adapted to be folded into the form of a vertically rising cabinet having a vertical supporting member defining shelf apertures which correspond to extending tabs on a shipping tray that allows for product to be shipped in the tray and then directly installed into the cabinet without the problems normally associated with stock transfer from shipping cartons to display areas.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application hereby claims priority to and is a continuation-in-part of U.S. provisional application Ser. No. 60/466,984, filed on Apr. 30, 2003 which is hereby incorporated by reference. 

   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not Applicable. 
   REFERENCE TO A MICROFICHE APPENDIX 
   Not Applicable. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to the field of display systems in general. In particular, the present invention relates specifically to a folded panel and tray display system. 
   2. Description of the Known Art 
   As will be appreciated by those skilled in the art, a folded corrugated cardboard display may be used to provide a display base for products in a retail or display environment. Details of a typical cardboard display are contained in U.S. Pat. No. U.S. Pat. No. 5,632,390, issued to Podergois on May 27, 1997; U.S. Pat. No. 5,483,779, issued to Crawford, et al. on Jan. 16, 1996; U.S. Pat. No. 4,655,352, issued to Noyes, et al. on Apr. 7, 1987; U.S. Pat. No. 4,428,136, issued to Franklin on Jan. 31, 1984; U.S. Pat. No. 4,319,688, issued to Wahl on Mar. 16, 1982; U.S. Pat. No. 4,068,398 issued to Parisi on Jan. 17, 1978; U.S. Pat. No. 3,987,737 issued to Smith on Oct. 26, 1976; U.S. Pat. No. 3,601,916 issued to Epstein on Aug. 31, 1971; U.S. Pat. No. 3,559,814 issued to Downing on February, 1971; U.S. Pat. No. 3,113,392 issued to Downing on December, 1963; U.S. Pat. No. 2,824,395 issued to Decker et al. on February, 1958; U.S. Pat. No. 2,373,778 issued to Quinby on April, 1945; U.S. Pat. No. 2,049,231 issued to Storch on July, 1936; and U.S. Pat. No. 1,852,471 issued to Nelson on April, 1932. Each of these patents is hereby expressly incorporated by reference in their entirety. 
   These prior art patents are very limited in their teaching and utilization, and an improved display assembly is needed to overcome these limitations. What is needed then is a combined folded frame and structural shelving display assembly. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to improved display assemblies. In accordance with one exemplary embodiment of the present invention, a display assembly is provided for using a folded frame and structural shelf construction. The folded frame is made from corrugated paper and the shelving trays are manufactured from a thin walled plastic. Advantages of the present invention include: a compact shipping configuration; a lightweight shipping configuration; efficient use of materials; easy set up for the display without requiring tools; efficient display assembly; easy restocking of the display; easy change out of display graphics for different products; inexpensive materials for low cost impact on actual product marketing costs; and a structurally sound display for use in retail and other environments. 
   It is an object of the present invention to provide an aesthetic display system. 
   A further object of the present invention is to provide an inexpensive display assembly. 
   A still further object of the present invention is directed to provide a display assembly that provides for an efficient assembly without requiring tools. 
   Yet another object of the present invention is to provide a display assembly that is structurally sound without requiring adhesives or additional fasteners or connectors. 
   A still further object of the present invention is to provide a lightweight compact display assembly. 
   Yet a further object of the present invention is to provide free standing display assembly. 
   These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent by reviewing the following detailed description of the invention. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views: 
       FIG. 1  is an isometric view of a first exemplary embodiment of the present invention. 
       FIG. 2  is an exploded view of the embodiment of  FIG. 1 . 
       FIG. 3  is an isometric view of an unfolded panel used to assemble the embodiment of  FIG. 1 . 
       FIG. 4  is an isometric view of an unfolded panel showing some of the folds used to assemble the embodiment of  FIG. 1 . 
       FIG. 5  is an isometric view of an unfolded panel showing additional folds used to assemble the embodiment of  FIG. 1 . 
       FIG. 6  is an isometric view of an unfolded panel showing still further folds used to assemble the embodiment of  FIG. 1 . 
       FIG. 7  is an isometric view of an unfolded panel showing yet another fold used to assemble the embodiment of  FIG. 1 . 
       FIG. 8  is an isometric view of the initial insertion of a tray into a folded panel used to assemble the embodiment of  FIG. 1 . 
       FIG. 9  is an isometric view of the final insertion of a tray into a folded panel used to assemble the embodiment of  FIG. 1 . 
       FIG. 10  is an isometric view of a second exemplary embodiment of the present invention. 
       FIG. 11  is an exploded view of the embodiment of  FIG. 10 . 
       FIG. 12  is an isometric view of a third exemplary embodiment of the present invention. 
       FIG. 13  is an exploded view of the embodiment of  FIG. 12 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1 ,  10 , and  12  of the drawings show completed versions of various forms of the display assemblies  100 ,  349 ,  801  with graphics on the outer walls of the display assembly  100 ,  349 ,  801  for showing products  10 .  FIGS. 2 ,  11 , and  13  show an exploded view of the various display assemblies  100 ,  100 ,  349 ,  801  showing the components of a display top  200 , a display shelf support cabinet  300 , a display shelf tray  400 , and a display base  500 . 
   As shown in  FIG. 1  of the drawings, one exemplary embodiment of the present invention is generally shown as a front and back display assembly  100  with a display hat  650 .  FIG. 2  shows an exploded view of the front and back display assembly  100  showing the components of a display top  200 , a vertically rising display shelf support cabinet  300 , a display shelf tray  400 , and a display base  500 . 
   As shown in  FIG. 2 , the display top  200  is a planar sheet  202  having locking tabs  204  at each of the corners. The locking tabs  204  are adapted to fit into a top tab slot  206  formed by the cabinet sides  304 ,  306  of the display cabinet  300 . This engagement allows the display top  200  to hold multiple display cabinets  300  together as is illustrated in  FIG. 1 . 
     FIGS. 1 and 2  show a vertically rising display shelf support cabinet  300  in its assembled form.  FIGS. 3 through 9  show the folding assembly of the cabinet  300  from the initial planar sheet  202 . The folded cabinet  300  includes cabinet top  302 , left cabinet side  304 , right cabinet side  306 , cabinet back  308  and cabinet bottom  309 . 
     FIG. 3  shows the unfolded form of the corrugated cardboard planar sheet  202  used for the cabinet  300 . 
   As shown in  FIG. 4 , the bottom bracing panels  309  shown as the left side foot  310 , right side foot  312 , and back foot  314  are folded in. These will form the bottom bracing panels  309  that are angled in a perpendicular arrangement to provide support. Next, the top lip  316  is folded back and the left top support  318  and right top support  320  are folded in. Finally, the left side top tab  322  and the right side top tab  324  are also folded back. 
     FIG. 5  shows how the top external panel  326  and both the left side external panel  328  and right side external panel  330  are folded in. 
     FIG. 6  shows the folding of the left side internal panel  332  and right side internal panel  334  in towards the internal side of the back  308  of the cabinet  300 . The side internal panels  332 ,  334  fold over the left top support  318  and right top support  320  to hold the top external panel  326  in position. The side locking protrusions  335  are positioned to correspond with the protrusion slots  307  on the back  308  to hold the internal side panels in their final position. 
     FIG. 7  then shows the folding in of the top internal panel  336  over the left side top tab  322  and the right side top tab  324  to lock the sides in position. Top internal panel  336  also has protrusions which fit into protrusion slots  307  on the back  308  to hold the top internal panel  336  in its final position. The top lip  316  sits against the back panel  308 . 
     FIG. 8  shows the use of the shelf apertures  337  shown as the left locking slot  338 , the right locking slot  340 , and the back locking slots  342  for accepting the shelf extension tabs  411  so that the apertures provide a place for supporting the tray  400 . Also shown in  FIG. 8  is the positioning of the tab flaps  344  that are flexibly connected to the vertical supporting members  303  above the shelf apertures  337 , the tab flaps  344  adapted to move between a first access position  346  so that the extending tray tabs  411  can be inserted into the apertures  337 . The tab flaps  344  may then be returned to their planar position such that they achieve a second locking position  348  to lock the extending tray tabs  411  in the apertures  337 . 
     FIG. 9  shows the secondary motion for insertion of the tray  400  for the engagement of the tabs  411  shown as left, right, and back tabs  412 ,  414 ,  416  into the apertures  337  shown as left, right, and back slots  338 ,  340 ,  342 . 
     FIGS. 2 ,  8 ,  11 , and  13  show the display shelf tray  400  in a disengaged state. The tray is manufactured from an injected plastic and is used to package the product  10  during shipping. In this manner, the product  10  does not have to be removed from its shipping container to be inserted into the vertical display cabinet. This results in a great cost savings for installation of newly released product  10 . Also, this simplifies restocking of empty shelves due to the simple removal of an empty shelf and the easy installation of full shelf as it was originally shipped. The tray  400  includes a front tray wall  402 , a back tray wall  404 , a left tray wall  406 , a right tray wall  408 , and a tray bottom  410 . The tray bottom is shown with a grid design to reduce material and save weight for the tray. The tray further includes a left locking tab  412 , right locking tab  414 , and at least one back locking tab  416  for engaging the cabinet  300 . 
   As shown in  FIGS. 1 ,  2 ,  10 ,  11 ,  12 , and  13  a display base  500  may be used to support the display cabinet  300 . The display base  500  is formed in the same manner as a box top as is well known. The display base  500  has a front base wall  502 , a back base wall  504 , a left base wall  506 , a right base wall  508 , and a base bottom  510 . The unique aspects of the display base are the base depth  512  and base width  514 . The base depth  512  and base width  514  allow for the tray  400  to provide additional support to the base  500  of the display assembly  100  by using the bottom  410  of the tray  400  between the front base wall  502  and the cabinet back  308  and between the left base wall  506 , left cabinet side  304  and the right base wall  508 , right cabinet side  306  to wedge in the cabinet sides  304 ,  306  and back  308  within the base  500  and also lock in the feet  310 ,  312 ,  314  of the cabinet sides  304 ,  306  and back  308 . Further improvements may be seen by the use of the base  500  to prevent toppling of the display assembly  100 . 
     FIGS. 10 ,  11 ,  12 , and  13  also show how supplemental graphic panels  600  may be utilized to change graphics for the display assembly  100 . The graphic panels  600  are inserted into the base  500  and may be attached by a folded tab, adhesive, or a hook and loop type system. Also shown in these embodiments are the use of a display hat  650  which may be a box form or a simple vertical graphic panel  700  attached to extend upward from the top  200  of the display assembly. The use of a secondary base  800  may provide a baseboard or molding effect to the bottom of the display assembly  100 . 
     FIGS. 10 and 11  show the construction of the front and side shipping display. As may be seen in the exploded view of  FIG. 11 , the same type of planar sheet construction may be used to that the planar sheet is folded into the form of a vertically rising cabinet. Here, the planar sheet defines a main cabinet  350 , a second auxiliary cabinet  352 , and a third auxiliary cabinet  352  from the same sheet. The planar sheet has been folded in order across the sheet to define a first main internal side panel  354 , a main back  358 , and a second main internal side panel  360 , each of the auxiliary cabinets is similarly constructed with the second cabinet shown as a first auxiliary external side panel  362 , a first auxiliary internal side panel  364 , a first auxiliary back  366 , a second auxiliary external side panel  368 , and a second auxiliary internal side panel  370 . The first main internal side panel  354 , main back  358 , second main internal side panel  360 , first auxiliary internal side panel  362 , auxiliary back  366 , and second auxiliary internal side panel  370  define shelf apertures  337  for supporting the shipping tray. A top panel  200  is also used for support and an alternative construction for the display hat  650  is shown 
     FIGS. 12 and 13  shows the construction of a multisided compacted shipping display. This embodiment uses four planar sheets where each planar sheet is folded like the first embodiment to form the four vertically rising cabinets  802 ,  804 ,  806 , and  808 . Each main cabinet is placed on the side of a square with the shelf area pointing outward to form the four sides of the display. The top panel uses multiple side tab support which fit between the internal and external side panels of the various cabinets to hold the top of the vertically rising cabinets in position and the display base contains the bottom or feet of the different vertical supporting members  303  to limit movement of the vertically rising cabinets. Also shown in the use of a central wedge to hold the cabinets against rising sides of the base so that the cabinets cannot be forced inward on the base. 
   Numbers used to reference items in the drawings are provided as follows:
         Product, item  10     Shipping display  100     display top  200     planar sheet  202     locking side tab supports  204     top tab slot  206     vertically rising display shelf support cabinet  300     cabinet top panel  302     vertical supporting member  303     left cabinet side  304     right cabinet side  306     back slots  307     cabinet back panel  308     bottom bracing panel  309     left side foot  310     right side foot  312     back foot  314     top lip  316     left top support  318     right top support  320     left side top tab  322     right side top tab  324     top external panel  326     left side external panel  328     right side external panel  330     left side internal panel  332     right side internal panel  334     protrusion  335     top internal panel  336     Shelf aperture  337     left locking slot  338     right locking slot  340     back locking slots  342     tab flaps  344     a first access position  346     a second locking position  348     front and side display  349     a main cabinet  350     an auxiliary cabinet  352     a first main internal side panel  354     a first main external side panel  356     a main back  358     a second main internal side panel  360     a first auxiliary external side panel  362     a first auxiliary internal side panel  364     an auxiliary back  366     a second auxiliary external side panel  368     a second auxiliary internal side panel  370     shipping display shelf tray  400     front tray wall  402     back tray wall  404     left tray wall  406     right tray wall  408     tray bottom  410     tabs  411     left extending locking tab  412     right extending locking tab  414     back extending locking tab  416     display base  500     front base wall  502     back base wall  504     left base wall  506     right base wall  508     base bottom  510     base depth  512     base width  514     supplemental graphic panels  600     a display hat  650     vertical graphic panel  700     secondary base  800     four sided display  801     first vertically rising cabinet  802     second vertically rising cabinet  804     third vertically rising cabinet  806     fourth vertically rising cabinet  808         

   From the foregoing, it will be seen that this invention well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure. It will also be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Many possible embodiments may be made of the invention without departing from the scope thereof. Therefore, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.