Abstract:
A stackable display case for protecting products which are unable to support a compressive load. Such display case provides improved protection of products during shipping and sale. Such display cases are loaded with products, stacked three or more cases high, two per layer, on a pallet at a production facility before being shipped to warehouse style and other retail outlets. Such display cases allow products to be sold directly from pallets and require a minimal amount of manual labor compared to prior art shipping displays. Such display case provides visibility and accessibility from four sides of pallets, and from at least three sides of each display case. Such a display case requires substantially less manual labor at a manufacturing and shipping facility, and almost no manual labor at the point of sale.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates generally to a stackable display case for sale of retail products. More specifically, the invention relates to stackable one-piece open top display cases which may be filled, stacked on pallets, and wrapped before shipping them to warehouse retail outlets. Such display cases provide visibility and accessibility from four sides of pallets. 
   2. Description of Related Art 
   Millions of dollars are spent each year in packaging products for transportation from manufacturers to retail outlets. Rather than require these products to be removed from containers and individually placed on shelves in a store front, it has long been desirable to ship and sell products directly from pallets. Member-only warehouse clubs provide the buying public, including private individuals and businesses, price savings by selling goods directly from pallets. Club stores often display their goods as delivered from suppliers on shipping pallets and thus reduce their costs by eliminating the labor of unpacking goods from pallets and displaying them for purchasers. Club stores often prefer to deal with suppliers who ship their goods on pallets. 
   Costs are also reduced by modifying the types and amounts of packaging associated with retail products. However, some products do not easily survive undamaged while being shipped on pallets to retail establishments, especially products which cannot bear compressive loads such as plants, gift baskets, lamps, buckets of cut flowers, stuffed animals, and bags of snack products. These products routinely require special packaging and significant manual labor for retail sale even if sold from pallets. Many packing schemes and packages have been invented to solve the problems associated with getting such products undamaged to consumers while still allowing consumers to easily view and select products. 
   One solution to this frequent problem has been to ship products in stackable trays or cartons, each comprising several components.  FIG. 1  shows an overhead view of a composite of various features and components of trays according to the prior art. With reference to  FIG. 1 , a prior art tray or carton  102  may have a vertical stacking tab or cleat  104  rising above the top plane of each tray or carton  102 . Such tab  104  locks into a corresponding opening (not shown) in the tray  102  stacked above it. Alternatively, a prior art tray  102  may have a foldable glued flap  106  which overlays each corner and is secured to the tray&#39;s side by glue, adhesive or other means. Such flaps  106  provide increased strength and support for a compressive load of stacked trays and further protect the goods inside each tray  102 . Such foldable flaps  106  may be overly complex to assemble, may not be suitable for trays containing certain products, or may require excessive manual labor. 
   Another existing alternative is to fold a flap  108  at a corner and lock it onto a tab  110  of a separate strengthening insert  114 . A receiving opening  112  in the bottom surface near each corner accepts an insert&#39;s tab  110  which protrudes from the top plane of each tray  102 . When each insert&#39;s tab  110  is interlocked into a receiving opening  112 , each tray  102  is less likely to move horizontally relative to another tray  102  and damage the contents of the tray below it. Additional inserts  114  require additional manual labor at assembly. 
   Yet another existing strengthening means is to insert a top-mounted removable foldable corner insert  118  into each corner of a tray  102 . Such removable corner insert  118  may fold over the outside of a tray  102 , or may reside completely within a tray  102 . One style of free corner insert  120  has a single fold and sits squarely inside each corner. Such a free corner insert  120  may provide some additional strength against compressive loads to a tray, but does not contribute to a container which is substantially open for displaying the contained goods. 
   In general, assembly, shipping, displaying, and sale of certain products from stackable trays or cartons is complex, and may require substantial manual labor at the point of sale for proper display of such goods, especially where such goods are sold from pallets. With reference to  FIG. 1 , many trays and cartons have foldable sides  116  which form openings for easily viewing of enclosed goods. Some foldable sides  116  are secured in place by inserting tabs  122  in corresponding openings along side creases  124 . Many trays also have openings which serve as carrying handles  126  for convenience. Such openings  126  do not provide sufficient visibility of enclosed goods. 
   Several patents disclose other improvements to cartons, crates and trays for bundling, shipping, and selling products which cannot support a compressive load. For example, U.S. Pat. No. 2,152,079 issued to Mott on Mar. 28, 1939 discloses a combination shipping and display carton. After shipping, a perforated section of the package may be removed for display and sale of individual packaged units within the carton. Even though this invention provides a means to stack bundles of individual units, this invention requires manual labor to modify each container to allow for sale of individual units contained within the packages. 
   U.S. Pat. No. 3,315,875 issued to Praetorius on Apr. 25, 1967 discloses a similar concept in that a side panel may be removed exposing individual units for sale. Likewise, U.S. Pat. No. 4,000,811 issued to Hardison et al., and U.S. Pat. No. 5,826,728 to Sheffer disclose a convertible carton which provides protection for its contents during shipping, and which subsequently may be transformed into an aesthetically pleasing display carton. These inventions may solve alignment and shipping problems, but require substantial manual labor prior to final display and sale of goods even though such packages may be stacked and shipped on pallets. These cartons are not folded from a single blank. 
   U.S. Pat. No. 5,052,615 issued to Ott et al. on Oct. 1, 1991 discloses a stackable carton or tray for a single layer of tomatoes. This invention requires separate reinforcing members inserted into tray corners so as to bear the load of other trays; these trays are not formed from a single folded paperboard blank. 
   U.S. Pat. No. 6,712,214 issued to Wintermute et al. on Mar. 30, 2004 discloses a stackable display tray which is similarly formed from a blank and multiple additional inserts. Portions of the blank are folded up to create sides and reinforced corners for a multi-sided tray or shell. Angular panels are positioned inside the tray to provide increased stability and support. 
   U.S. Pat. No. 6,270,007 and U.S. Pat. No. 6,488,200 issued to Jensen, Jr., and International Patent Application PCT/US01/26610 disclose an improved crate for stacking and shipping plants. It discloses a crate system consisting of a bottom cap, crate walls, and a top cap. The bottom and top caps are the same size and shape, and are interchangeable. Goods inside the crate are protected from compressive loads, and the crates can be stacked several crates deep. In this invention, the corners and bottom sections are not formed from the same blank. It would be more ideal to have a shipping container comprised of just a bottom and support walls thus eliminating the need for a top piece for every container, tray or carton. 
   Published International Patent Application PCT/US02/19025 entitled “Stackable Display Container” by Holdsworth, et al., discloses a stackable display container which may be formed from a single blank, shipped flat and assembled without adhesive. Such container has stacking shoulders and reinforced corners. This invention is only open on two sides wherein the other two sides are designed for handles. 
   None of these inventions adequately solves the problems associated with transporting and selling goods which are sensitive to compressive loads, these goods being sold directly from pallets. Consequently, a need exists for a carton, tray, or display which is easily stackable, and which remains stacked on a pallet in columns during shipping. A need exists for a shipping display which can be easily assembled at a production facility, and which can be used for the sale of goods as initially shipped and displayed on a pallet. A further need exists for a display which can be easily assembled from a single display blank and which has few or no additional parts required for shipping. A further need exists for a tray which may be stacked in columns and shipped on pallets, which allows the contents of the carton or tray to be seen, and which requires little or no additional manual labor for the goods to be sold from pallets. The present invention fills these and other needs as detailed more fully below. 
   SUMMARY OF THE INVENTION 
   A stackable display case allows products which are unable to support a compressive load to reach consumers for retail purchase substantially unharmed. Such display cases are loaded with products, stacked several layers deep, two per layer, on a pallet at a manufacturing facility before being shipped to warehouse style retail outlets. Such display cases allow products to be sold directly from pallets and require a minimal amount of manual labor compared to prior art shipping packages. Such display cases provide visibility and accessibility from four sides of pallets, and from three or four sides of each display case. Such a display case requires substantially less manual labor at a manufacturing and shipping facility, and almost no manual labor at the point of sale. 
   The invention accordingly comprises the features described more fully below, and the scope of the invention will be indicated in the claims. Further objects of the present invention will become apparent in the following detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The novel features characteristic of the invention are set forth in the appended claims. The invention as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: 
       FIG. 1  shows a perspective view of a tray having a variety of prior art elements which serve to strengthen the tray against compression loads; 
       FIG. 2A  shows a perspective view of a flat corrugated display blank according to the present invention prior to being assembled into a hybrid shoppable pallet display; 
       FIG. 2B  shows a perspective view of a corrugated display according to the present invention after front posts have been assembled; 
       FIG. 2C  shows a perspective view of a corrugated display according to the present invention after the front roll-over panel has been assembled the support stays of the front posts, front and rear sides have been uprighted, and side wings have been folded into proper position; 
       FIG. 2D  shows a perspective view of a nearly assembled corrugated display according to the present invention after the side panel roll-overs have been assembled over the side wings; 
       FIG. 3A  shows a side perspective view of four layers of hybrid shoppable pallet displays according to the present invention assembled on a pallet and ready for shipment to a retail outlet, such assembly having protective corner coverings, a protective lid and shrink-wrapped plastic which stabilizes the product inside the pallet assembly; and, 
       FIG. 3B  shows an overhead view of one hybrid shoppable pallet display wherein strengthening inserts have been added to provide additional strength against compression loads according to one embodiment of the present invention. 
   

   REFERENCE NUMERALS 
   
       
         102  product tray 
         104  vertical stacking tab or cleat 
         106  foldable glued flap 
         108  corner flap with opening for stacking tab 
         110  vertical tab of strengthening insert 
         112  receiving opening for stacking tab 
         114  strengthening insert 
         116  foldable side flap 
         118  top-mounted removable foldable corner insert 
         120  free corner insert 
         122  tab on foldable side flap 
         124  side crease 
         126  carrying handle 
         202  bottom panel 
         204  back panel 
         206  post panel tab 
         208  side panel attached to back panel 
         210  front panel flap 
         212  panel flap slot 
         214  panel flap tab 
         216  front panel 
         218  crease line 
         220  first post panel 
         222  second post panel 
         224  third post panel 
         226  interlocking top tab 
         228  three dimensional vertical support post 
         230  side panel flap 
         232  top tab receiving opening 
         236  lower side panel 
         238  short side support post width 
         240  long side support post width 
         242  side or front panel height 
         302  bag or product package 
         304  positioning insert 
         306  protective corner piece 
         310  protective shipping lid 
         312  side opening 
         314  front opening 
         316  first tier of hybrid shoppable pallet displays 
         318  second tier of hybrid shoppable pallet displays 
         320  pallet 
     
  
   DETAILED DESCRIPTION 
   While the invention is described below with respect to a preferred embodiment, other embodiments are possible. The concepts disclosed herein apply equally to other stackable product display cases for selling products from pallets and other containers, especially those display cases with substantially vertical sides and an open top for protection and display of products which alone cannot support a compression load. The invention is described below with reference to the accompanying figures. 
   According to a preferred embodiment,  FIG. 2A  through  FIG. 2D  show perspective views of a hybrid shoppable pallet display in various stages of assembly.  FIG. 2D  shows a nearly assembled hybrid shoppable pallet display which is formed from a single flat display blank such as the one shown in  FIG. 2A . With a minimal number of steps, a finished display may be assembled quickly and easily prior to use. In one embodiment, no adhesive is required for complete assembly of such display. The one piece design provides increased efficiency and higher production rates at the point of packaging than previously possible. 
   With reference to  FIG. 2A , the first step for assembly is to form three dimensional vertical support posts  228 . For each post, a first post panel  220  is folded along a crease line  218  over a third post panel  224  whereby a first post panel tab  206  is lying flat against a front panel  216 , and whereby a second post panel  222  and an attached second post panel tab  206  lie substantially perpendicular to the plane of the flat unassembled display blank. The result of this first step is shown in  FIG. 2B . 
   With reference to  FIG. 2B , the next step is to fold one front panel flap  210  over the front panel  216 . A panel flap  210  and a panel  216  together may be considered a rollover panel. Each front panel flap  210  may have one or more flap tabs  214 . Front panel flap tabs  214  are formed in the display blank so as to fit snuggly in slots  212  which are formed in corresponding and appropriate places along a folding crease  218  along the base of the front panel  216 . Folding creases  218  may be perforated to assist in assembly, opening or destruction of displays. The front panel flap  210  is folded over and secures the post panel tabs  206  of the vertical posts  228 . These post panel tabs  206  so secured help provide the necessary stability, strength, and shape of the vertical posts  228 . At the top of each support post  228 , there is at least one interlocking top tab  226 . In a preferred embodiment, an interlocking top tab  226  is formed at a crease line between a second panel  222  and a third panel  224  such that upon forming a support post  228 , parts of each interlocking top tab  226  are perpendicular to each other. Such V-shaped interlocking top tab  226  fits adroitly within a top tab receiving opening  232  formed in the bottom of each support post  228  due to the contouring of each lower side panel  236  and side panel flap  230 . 
   With reference to  FIG. 2C , there is a top tab receiving opening  232  in each of the corners of the bottom panel  202  of the display. The next step of the assembly process is to fold the back panel  204  and front panel  216  to a vertical or perpendicular position relative to a bottom panel  202 . Support posts  228  form part of a front panel  216 . Subsequently, side panel flaps  230  are folded over the top of a second set of panel tabs  206  attached to or forming part of the support posts  228 . This second set of panel tabs  206  lie parallel to the sides of the pallet display. The side panel flaps  230  are simultaneously folded over panel tabs  206  which form part of side panels  208 , the side panels  208  being hingedly attached to the back panel  204 . The side panel flaps  230  are likewise secured by flap tabs  214  inserted snuggly into slots  212 . The panel tabs  206  so secured provide the necessary support, strength and stability to the back panel  204  and support posts  228 . The back panel  204  and support posts  228  are designed to bear vertical compression loads. Such compression loads include, but are not limited to, several hybrid shoppable pallet displays loaded with products stacked one above another in columns on a pallet. In an alternative embodiment, front panel crease lines  218  and side panel crease lines  218  may be comprised of two narrowly separated perforated crease lines so as to adroitly facilitate the folding of panel flaps  210 ,  230  over panel tabs  206 . 
   A nearly assembled hybrid shoppable pallet display is shown in  FIG. 2D . The vertical posts  228  provide support for compressive loads while simultaneously allowing substantial visibility of products within the display. A front side width  240  and short side width  238  of each vertical support post  228  are selected so as to provide an optimal amount of strength to each vertical support post  228  even when another display or other large item is stacked on top of it. The size of each front side width  240  and each short side width  238  of each post  228  is a compromise between providing maximum visibility (large open sides) of the interior of the display and providing adequate strength to support compressive loads associated with stacking identical or similar displays on top of one another on a pallet. The height  242  of the lower side panels  236  and front panels  216  is likewise a compromise between providing maximum visibility to products within the display and providing sufficient strength to the display and protection to the products. The height  242  of the side panels  236  is not required to be the same as the height  242  of the front panels  216 . 
     FIG. 3A  shows in a perspective view three layers  316 ,  318 ,  322  of hybrid shoppable pallet displays stacked back to back on a pallet  320  according to one embodiment of the invention. Other numbers of layers are possible. At the top of a completed pallet  320  there is a protective shipping lid  310  which may be removed at the point of sale. Protective corner pieces  306  also may be placed on the corners of pallet displays before wrapping the loaded pallet  320  with plastic as is common in the industry for shipping purposes. 
   A completed pallet is formed by manually stacking each display on top of one another after each display is loaded with products  302 . Each interlocking top tab  226  of each support post  228  and back panel  204  is fit into a corresponding top tab receiving opening (not shown) which is aligned directly above each tab  226 . Such interlocking provides support and stability against horizontal forces during shipping and handling which tend to misalign columns of prior stacked displays, cartons or boxes. 
   Since the backs  204  of the hybrid shoppable pallet displays are in the center of the pallet, the remaining open three sides of each hybrid shoppable pallet display provide access and visibility to products  302  from four sides of a pallet  320 . Specifically, side openings  312  and front openings  314  allow consumers to view, select and remove products  302 . The maximum visibility provided by the hybrid shoppable displays allows consumers to see as much of the printing of the product packaging as possible.  FIG. 3A  shows products  302  facing one direction: toward a long side opening  314 . However, some products  302  may alternatively be faced toward a short side opening  312 . In this way, the front of products  302  may be visible from four sides of a loaded pallet  320 . Providing such high visibility of products  302  is desirable for marketing purposes. The front panels  216 , lower side panels  236 , back panels  204 , and support posts  228  may be printed with marketing or other designs or information. 
   As products  302  are depleted from a top layer  322 , empty hybrid shoppable pallet displays may be removed thus providing increased visibility to products  302  in the next lower layer  318 . This process may be repeated until the remaining layers  316  and  318  end are depleted. 
   Optionally, positioning inserts  304  may be placed between rows of products  302  within each display. Such positioning inserts  304  laterally support and align products  302  and protect products from moving excessively within a shoppable display. The corners of positioning inserts  304  may be rounded so as to increase the likelihood that positioning inserts remain properly placed and oriented. Additionally, positioning inserts  304  may provide, but are not required for, support against vertical compression loads. With reference to  FIG. 3B , in one embodiment, positioning inserts  304  may be formed with a single crease in an “L” shape. Other shapes and orientations are possible. 
   In one embodiment, a hybrid shoppable pallet display is designed to fit onto half of a standard shipping pallet of size 48 inches by 40 inches (122 cm by 102 cm). Such pallet size corresponds to a hybrid shoppable pallet display of size 40 inches (102 cm) along the front by 23 and ¾ inches (60 cm) along its short side. In a preferred embodiment, the height of a hybrid shoppable pallet display is from 15 inches (38 cm) to 18 inches (46 cm) in height. Other heights are possible where such display height conforms to the height of products within the display. The height  242  of the lower side panels  236  and front panels  216  is preferably about three and one half inches (9 cm) but other heights greater or smaller are possible. 
   In shipping tests with hybrid shoppable pallet displays having three open sides, there were zero refused shipments due to damaged products. In an alternative embodiment, a hybrid shoppable pallet display is build with at least four vertical support posts  228 . In such an embodiment, a hybrid shoppable pallet display has openings in all four sides. With reference to  FIG. 2B , in such embodiment, in place of a back panel  204 , two additional vertical support posts  228  are formed along the back portion of the display blank. In such embodiment, products are visible from all four sides. 
   Those skilled in the art recognize that other variations and configurations of the components of a hybrid shoppable pallet display are possible. For example, in an alternative embodiment, a hybrid shoppable pallet display only uses a single post panel tab  206  for each vertical support post  228 . In a further alternative embodiment, there may be four or more vertical support posts  228  per hybrid shoppable pallet display. In a further alternative embodiment, there may be multiple interlocking top tabs  226  for each vertical support post  228 . In yet a further alternative embodiment, portions of a hybrid shoppable pallet display may be detached or separated from the paperboard blank before complete assembly of the hybrid shoppable pallet display. In another alternative embodiment, a positioning insert may be folded from the paperboard blank used to create the hybrid shoppable pallet display. 
   The foregoing discussion of the invention has been presented for purposes of illustration and description. One of ordinary skill in the art will recognize that one can modify the dimensions and particulars of the display, as well as the specific design of the crease lines, and other display features, without straying from the inventive concepts. The description is not intended to limit the invention to the forms disclosed herein. Consequently, variation and modification commensurate with the above teachings, within the skill and knowledge of the relevant art, are within the scope of the present invention. A preferred embodiment described herein is further intended to explain the best mode presently known of practicing the invention and to enable others skilled in the art to utilize the invention. It is intended that the appended claims be construed to include alternate embodiments to the extent permitted.