Abstract:
A display rack for displaying articles has a support frame with two walls extending at an angle from a narrow strip at the rear corner of the frame. A tubular reinforcing structure extends along the forward free edge of each wall, and aligned openings are in the strip and the reinforcing structures. A plurality of shelves having front and rear corners and opposite side corners are supported on the frame between the walls, with the rear corners engaged in respective openings in the strip and the side corners engaged in respective openings in the reinforcing structures. A forward portion of the shelves projects forwardly of the frame for greater visibility of and access to articles supported on the shelves. A reinforcing brace extends diagonally in each shelf from the rear corner to the front corner, whereby the shelves are essentially cantilevered from the frame.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to a display rack for supporting and displaying articles, and more particularly to a multi-shelf display rack made of corrugated paper, wherein a plurality of shelves are mounted on a support frame having only two walls extending at an angle to one another with the shelves mounted between them so that two sides of the shelves are exposed for enhanced visibility of and access to articles on the shelves. 
     BACKGROUND OF THE INVENTION 
     A large variety of display stands and racks with multiple shelves are known in the prior art for supporting and displaying articles, and especially for displaying articles at a point of sale. Many of these display racks are made of corrugated material, but they typically have a back wall and two side walls, so that only one edge of the shelves is exposed. Other display stands or racks are made of wood or metal and some of these have only two angularly disposed support walls so that a substantial edge portion of the shelves is exposed. Other display racks commonly used are made of metal and have only one support wall, with hooks or other support structure mounted to the wall for supporting articles for display. 
     The following patents are exemplary of prior art systems. U.S. Pat. No. 1,852,471 discloses a display rack system made of paperboard in which the ends of shelves are engaged in openings in the support frame, but only one edge of the shelves is exposed and they are not cantilevered. U.S. Pat. No. 3,656,611 discloses a cabinet-like display rack wherein portions of the corners of the frame are turned inwardly to provide an abutment on which four corners of the shelves are supported. U.S. Pat. No. 3,860,305 discloses a cabinet-like display rack wherein portions of the corners of the frame are turned inwardly to define guides for vertical rods that support four corners of shelves having only one edge exposed. U.S. Pat. No. 4,763,579 discloses a shelf system for mounting in a corner, wherein the shelves are cantilevered from a combination of horizontal and vertical supports at three of the corners, and two edges of the shelves are exposed. U.S. Pat. No. 5,669,683 discloses a corrugated display shelf assembly in which tabs on the back edge and ends of the shelves are engaged in slots in the support frame. Only one edge of the shelves is exposed. U.S. Pat. No. 6,135,033 discloses corrugated paper shelves folded to have triangular reinforcing structure along opposite edges. U.S. Pat. No. 7,252,200 discloses a display system with portions made of corrugated paper and wherein tabs on the display shelf trays engage in slots in the support frame. The shelf trays are made of injected plastic and are supported at three edges, with only one edge exposed. U.S. Pat. No. 3,766,864 discloses a display system in which two edges of the shelves are exposed but they are supported along all four edges and the support is accordion-folded to define a plurality of adjacent spaces in which shelves are supported. 
     None of the display racks or stands known to applicant is made of corrugated paper material wherein the support has only two walls joined at an angle and has openings therein for receiving three corners of reinforced shelves so that the shelves are cantilevered from the support with two edges exposed. 
     Accordingly, it would be desirable to provide a display rack made fully of recyclable corrugated paper material wherein the support has only two walls joined at an angle and has openings therein for receiving three corners of reinforced shelves so that the shelves are cantilevered from the support with two edges exposed. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a display rack comprising a support frame with a plurality of shelves supported thereon, wherein the rack is made of fully recyclable corrugated paper material. The support frame has only two walls, said walls extending at an angle to one another from a narrow strip at the rear corner of the frame and having forward free edges with tubular reinforcing structure extending along their length. A plurality of shelves is supported on the support frame between the two walls so that a forward portion of the shelves projects beyond the walls to provide greater visibility of and access to articles supported on the shelves. The display rack is free standing and may be used alone or in combination with other like racks. For example, multiple racks may be placed back-to-back in combinations of two, three or four racks. 
     More specifically, the walls extend perpendicular to one another and the shelves are rectangular in shape with front, back and opposite side corners. A reinforcing brace is integrated in each shelf and extends diagonally from the shelf rear corner to the shelf front corner. Back and opposite side corners, respectively, of the shelves are engaged in openings in the strip and in the reinforcing structures, respectively, to support the shelves on the support frame. Adhesive or double face tape or other suitable fastening means preferably is engaged between the shelves and adjacent parts of the support to help secure the parts together. 
     Optional graphics panels may be applied to the shelves and/or to the support frame, and in the embodiment shown in  FIGS. 2-4  the graphics panels applied to the shelves assist in supporting the shelves from the support frame. 
     Accordingly, one aspect of the present invention is directed to a display rack for supporting and displaying articles. The display rack comprises a support frame having two walls extending at an angle to one another from a narrow strip at a rear corner of the frame and each having a forward free edge with a tubular reinforcing structure along its length. A plurality of shelves is supported on the support frame between the walls. The shelves each having first support means is engaging the strip and second support means is engaging a respective reinforcing structure so that a forward portion of the shelves projects forwardly of the support frame for greater visibility of and access to articles supported on the shelves. 
     Another aspect of the present invention is directed to a display rack for supporting and displaying articles that comprises a support frame having two side walls extending at an angle to one another from a narrow strip at a rear corner of the support frame. Each side wall has a forward free edge along its length and the narrow strip and the forward free edges each have a plurality of openings spaced along their length. A plurality of shelves is supported on the support frame side walls, wherein each of the shelves is rectangular in shape and has a rear corner, a front corner, opposite side corners, spaced apart parallel top and bottom walls, first and second side edges extending perpendicular to one another from the shelf rear corner and defining shelf rearward side edges. Third and fourth side edges joined to respective first and second side edges and extending perpendicular to one another from the shelf front corner and defining shelf forward side edges. A reinforcing brace between the top and bottom walls extend diagonally from the rear corner of the shelf to the front corner thereof. The rear corners of the shelves is engaged in the respective openings in the strip and the side corners of the shelves is engaged in the respective openings in the forward free edges of the support frame so that the shelves are cantilevered from the support frame with the forward side edges thereof projecting forwardly of the forward free edges of the support frame side walls. 
     A further aspect of the invention is directed a display rack to a display rack for supporting and displaying articles that comprises a support frame made of paper material and having only two walls. The walls extend at an angle to one another from a narrow strip at a rear corner of the frame and each having a forward free edge. A plurality of openings is spaced along the narrow strip and the forward free edges. A plurality of shelves made of paper material is supported on the support frame between the walls. The shelves are rectangular in shape with rearward side edges, forward side edges, a rear corner, a front corner, and opposite side corners. The rearward side edges lying against the walls of the support frame wherein the rear corner of each of the shelf extends into a respective opening in the narrow strip and the side corners of each of the shelf extend into a the respective opening in the forward free edges of the support frame, so that the forward side edges of the shelves project forwardly of the forward free edges of the support frame for greater visibility of and access to articles supported on the shelves. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein: 
         FIG. 1  is a front isometric view of a first embodiment of display rack according to the invention, shown without graphic panels. 
         FIG. 2  is a front isometric view of the first embodiment of display rack with graphic panels applied to the shelves. 
         FIG. 3  is a side view of the embodiment of display rack shown in  FIG. 2 . 
         FIG. 4  is an enlarged fragmentary view of the rack of  FIG. 2 , looking at a slight angle from the back toward the outside of one corner of the rack. 
         FIG. 5  is an enlarged fragmentary view of the rack  FIGS. 1 and 2  looking at a slight angle toward the outside of the back corner of the rack, showing how the rear corner of the shelves extend through the opening in the narrow strip at the back corner of the support frame. 
         FIG. 6  is a plan view of a blank for making the reinforcing brace used in the shelves of the invention. 
         FIGS. 7-10  depict various steps in erecting the reinforcing brace. 
         FIG. 11  is a plan view of a blank for making the wrap that is folded around the brace of  FIGS. 6-10  to make the reinforced shelves of the invention. 
         FIGS. 12-16  depict the various steps in erecting a shelf according to the invention. 
         FIG. 17  is an isometric view looking toward the bottom of a completed shelf. 
         FIG. 18  is a slightly enlarged fragmentary view of the bottom of one corner of the shelf of the invention, showing tabs projecting from two adjacent edges. 
         FIG. 19  is a top plan view of the shelf of  FIG. 18 , showing the tabs projecting coplanar with the top surface of the shelf. 
         FIG. 20A  is a plan view of a blank for making the support frame of the invention. 
         FIG. 20B  is an isometric view looking from the top end of an assembled support frame of the invention, prior to attachment of shelves. 
         FIG. 21  is an enlarged fragmentary view of one corner of the blank of  FIG. 18 . 
         FIGS. 22-25  depict steps in assembling the display rack of the invention. 
         FIG. 26  is a view from the front of an optional embodiment of the invention wherein a graphics display header is attached to the top of the rack. 
         FIG. 27  is an isometric exploded view of a further embodiment wherein a fifth shelf extension is provided for insertion between the top of the display rack of  FIG. 2  and the graphics header of  FIG. 26 . 
         FIG. 28  is a bottom isometric view of one form of graphics shelf skirt that may be applied to the shelves. 
         FIG. 29  is a slightly enlarged fragmentary end view looking toward the top of the display rack, showing the slots for receiving tabs on the graphics header or fifth shelf extension to attach the extension to the rack. 
         FIG. 30  shows the extension being assembled to the stand. 
         FIG. 31  shows the graphics header of  FIG. 27  being applied to the extension. 
         FIGS. 32-34  depict the steps in assembling the graphics skirt to a shelf. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A first form of the invention, devoid of separate graphics panels, is indicated generally at  10  in  FIGS. 1 and 5-25 . This form of the invention comprises a support frame  11  having two walls or panels  12  and  13  joined along one edge to a narrow corner strip  14  at the back corner of the frame and diverging outwardly from the strip perpendicular to one another. The outer edge of each panel is folded to define a tubular reinforced edge  15  and  16 , respectively, having a triangular shape in transverse cross section. As seen best in  FIGS. 18-21 , a plurality of openings  17  are formed through the corner strip spaced along its length, and a corresponding number of openings  18  are formed in the inwardly facing surfaces of the reinforced edges  15  and  16 . Rectangularly shaped shelves  20  have a rear corner engaged in respective openings  17  in the corner strip, and opposite side corners engaged in respective openings  18  in the reinforced edges. As shown in the drawings, double face tape  21  (see  FIGS. 18-23 ) is strategically placed between the shelves and support frame to secure the parts together. Alternatively, a suitable adhesive or other fastening means, not shown, could be used. 
     Adhesive, for example, could be applied in generally the same places as the double face tape shown in the drawings. A base member B preferably is attached to the underside of the bottom shelf, as seen best in  FIGS. 24 and 25 . 
     The shelves  20  are a reinforced two-part construction comprising a diagonally extending center brace  30  and an outer wrap  40 , each made of a single piece of corrugated paper folded as described hereinafter. 
     The construction of the brace is shown in  FIGS. 6-10  and comprises a top panel  31  shaped with converging angled end edges  32   a  and  32   b  defining opposite pointed ends  32   c  and  32   d , first narrow side panels  33   a  and  33   b  foldably joined along opposite sides of the top panel  31 , bottom panels  34   a  and  34   b  foldably joined to respective side panels  33   a  and  33   b  and having outwardly divergent end edges  35   a  and  35   b  angled oppositely to the end edges  32   a  and  32   b  on the top panel  31 , and insert flanges  36   a  and  36   b  foldably joined to respective bottom panels  34   a  and  34   b . Transverse first slots  37   a  and  37   b  are formed across the bottom panels  34   a  and  34   b  and part way into the side panels and insert flanges, and second slots  38  are formed adjacent and parallel to opposite end edges of each of the bottom panels, both for a purpose described hereinafter. Cuts are made across the juncture between the bottom panels and insert flanges approximately midway between the slots  37   a ,  37   b  and the opposite end edges of the insert flanges, defining openings  39   a  and locking tabs  39   b , also for a purpose described hereinafter. 
     The wrap  40  comprises a rectangular top wall  41  having narrow side walls  42   a ,  42   b ,  42   c  and  42   d  foldably joined to its respective edges, first and second triangularly shaped bottom wall panels  43   a  and  43   b  foldably joined to respective opposite side walls  42   a  and  42   c , narrow insert flanges  44   a  and  44   b  foldably joined to the hypotenuse (angled edges) of the respective first and second triangularly shaped bottom wall panels, elongate narrow tabs  45   a ,  45   b ,  45   c  and  45   d  foldably joined to opposite ends of respective side walls  42   a - 42   d , and first and second bottom flaps  46   a  and  46   b  foldably joined to side walls  42   b  and  42   d , respectively. Third slots  47  are formed in the triangular bottom wall panels  43   a  and  43   b  near their folded connection with the side walls  42   a  and  42   c , and fourth slots  48  are formed in the bottom flaps  46   a  and  46   b  near their folded connection with side walls  42   b  and  42   d , respectively. Fifth slots  49  are formed in each triangular bottom wall panel  43   a ,  43   b  near their edge that extends perpendicular to the top wall  41 , and sixth slots  50  are formed in each bottom flap  46   a  and  46   b  near their opposite side edges. The third, fourth and sixth slots define first graphics attaching slots, as described hereinafter. Seventh slots or cuts  51  defining narrow tabs  52  are formed in two adjacent side walls  42   c  and  42   d  adjacent their folded connection with the top wall  41 , and three spaced notches  53  are formed in the free edge of each insert flange  44   a  and  44   b . Locating marks  41 A and  41 B preferably are provided on the top wall panel  41  to aid in proper positioning of the brace  30 . 
     It is preferred that the brace  30  is folded and glued by the manufacturer, but it could be folded into operative condition by a retailer or other user. The steps of erecting the brace into its usable condition are shown in  FIGS. 7-10 . Initial steps in folding the blank for making the brace are seen in  FIG. 7 , wherein one of the bottom panels  34   b  is shown partly folded upwardly and inwardly toward the top panel  31 .  FIG. 8  shows both bottom panels  34   a  and  34   b  folded upwardly and inwardly toward one another over the top panel  31 , and  FIG. 9  shows the bottom panels folded fully inwardly with the insert flanges  36   a  and  36   b  folded downwardly into parallel contiguous relationship with one another. As shown in  FIG. 10 , the locking tabs  39   b  on one insert flange are pressed through the openings  39   a  in the opposite insert flange to hold the brace in the assembled condition shown, with the bottom panels  34   a  and  34   b  forming a bottom spaced from and parallel to the top panel  31 , wherein said top panel, bottom, and side panels form a tubular structure. If the brace is assembled by the manufacturer, adhesive (not shown) could be used in lieu of the openings  39   a  and locking tabs  39   b.    
     It is preferred that the shelves be folded and glued by the manufacturer and shipped to a point of sale or other destination in condition ready to use with the support frame  11  which is shipped flat as shown in  FIG. 20 , but the steps of assembling a shelf according to the invention are shown in  FIGS. 11-17 . If desired, all of the components could be shipped flat to a user who would then erect the components and assemble the display rack. 
     As shown in  FIG. 12 , the brace  30  is placed on the top wall  41  of the wrap, with its sides parallel to the angled edges of the bottom wall panels  43   a  and  43   b  and its opposite pointed ends lying in opposite corners of the top wall. The bottom wall panels are then folded inwardly as shown in  FIGS. 13 and 14 , with the notched insert flanges  44   a  and  44   b  on the angled edges of the bottom wall panels inserted into the slots  37   a  and  37   b  in the bottom of the brace. The notches  52  in the free edge of each insert flange on the wrap receive the upper edges of the brace side panels and insert flanges located below the slots  37   a ,  37   b  in the erected brace as shown in  FIG. 10 . The narrow tabs  45   a ,  45   b ,  45   c  and  45   d  are then folded inwardly to extend across the open ends of the brace, followed by inward folding of the first and second bottom flaps  46   a  and  46   b  as shown in  FIGS. 15 and 16 , to form the finished shelf  20  as shown in  FIG. 17 . 
     As seen in  FIGS. 18 and 19 , the narrow tabs  52  defined by cuts  51  in two adjacent side walls  42   c  and  42   d  project outwardly from adjacent side edges of the shelf for cooperation with slots in the support frame  11  as described hereinafter. 
     As previously briefly described above, the support frame  11 , which is shipped to the user in the flattened condition shown in  FIG. 20B , has two side walls or panels  12  and  13  joined along one edge to a narrow strip  14 , with the outer edges of the side walls folded to define tubular reinforced edges  15  and  16 , respectively, having a triangular shape in transverse cross section. As seen best in  FIG. 20A , the side walls  12  and  13  have a double thickness formed by back panels  12 B and  13 B, respectively, folded and glued behind associated front panels  12 A and  13 A, respectively. A flap  94  on the top edge of panel  12 B is folded over and glued to the front of panel  12 A, and a flap  93  on the top edge of panel  13 B is folded over and glued to the front of panel  13 A. Slots  83  and  84  at the folded juncture of the flaps  94  and  93  with their associated panels  13 B and  12 B, and notches  84 ′ and  83 ′ are formed in respective top edges of walls  12  and  13  to receive tabs on a header panel as described hereinafter. A plurality of openings  17  are formed through the strip  14  spaced along its length, and a corresponding number of openings  18  are formed in the inwardly facing surfaces of the reinforced edges  15  and  16  in transverse alignment with the openings  17 . Shelf attaching slots  60  are made through each side panel  12 ,  13  adjacent each side edge thereof in transverse alignment with the top edges of the openings  17  and  18 , and double face tape  21  is placed on each side panel adjacent and in alignment with the openings  18  in the reinforced edges  15 ,  16 . 
     To assemble the shelves  20  to the support frame  11 , as shown in  FIGS. 22-25 , typically accomplished by the end user, the frame  11  is placed on its back on a support surface and the shelves are positioned edgewise on the frame with one corner of each shelf in registry with a respective opening  17  in the corner strip  14  and an opposite corner engaged in an opening  18  in the adjacent reinforced edge  15  (or  16 , depending on which side of the frame the shelves are first placed). The narrow tabs  52  projecting outwardly from one side edge of each shelf extend into respective shelf attaching slots  60  in the side panel  12  or  13  on which the shelf has been placed. The opposite side panel  12  (or  13 ) is then folded upwardly around the shelves so that the corner of each shelf adjacent the narrow corner strip  14  extends into a respective opening  17  in the corner strip and the corner adjacent the upwardly folded side panel  12  (or  13 ) extends into a respective opening  18  in the reinforced edge  15  (or  16 ). The tabs  52  on the other side edge of each shelf extend into the slots  60  in the upwardly folded side panel  12  (or  13 ). The protective paper is peeled off the double face tape  21  prior to placement of the shelves on the frame so that the tape in combination with the tabs and slots holds the shelf and frame assembly together. 
     As seen best in  FIGS. 24 and 25 , the base member B is attached to the underside of the bottom shelf. The base member rests on the surface on which the display rack is supported. 
     An optional alternate embodiment is indicated generally at  70  in  FIG. 26 . In this embodiment, a graphics header  71  is attached to the top of the support frame  11 , and graphics skirts  72  are attached to the exposed edges of the shelves. Details of the skirts  72  are seen best in  FIG. 28 , wherein the skirt is shown inverted. The skirts  72  each comprise side panels  73  that are oriented vertically when in use and may have a shaped top edge  74 . Narrow bottom flanges  75  and  76  are on the bottom edges of the side panels and shaped locking tabs  77  are on the free edges of the flanges. Double face tape  21  is placed on extended ends  78  of the side panels. To install the skirts, the panels  73  are placed against the exposed edges of a shelf  20 , the flanges  75  and  76  bent rearwardly beneath the shelf, and the tabs  77  inserted upwardly through the slots  50  and into slots  47  or  48  in the bottom of the shelf. The extended ends  78  of the skirts are attached to the sides of the frame by use of the double face tape  21 . 
     Alternatively, as shown in  FIGS. 3 and 4 , the extended ends  78  wrap around the corners of the support frame  11  and tuck into slots on the back of the frame. 
       FIG. 27  shows a further optional embodiment  80  in which an extension piece  81  and fifth shelf  20  are assembled to the top of the support frame  11 , and a graphics wrap  82  is attached to the back of the support frame. When the extension piece is used, the graphics header  71  is attached to the extension piece in the same way it would be attached to the support frame  11 . In this regard, reference is made to  FIGS. 29-31 . 
       FIG. 29  is an end view of the support frame  11  and shows second graphics attaching slots  83  and  84  in the upper end of the support frame for receiving tabs  85  and  86  on the bottom edge of the graphics header  71  or, as depicted in  FIG. 30 , the tabs  87  and  88  on the bottom of the extension piece  81 . The extension piece has corresponding third graphics attaching slots  89   a  and  89   b  for receiving the tabs on the graphics header, as depicted in  FIG. 31 . In the example shown and described herein, and with particular reference to  FIGS. 29-31 , flaps  93  and  94  on the upper end of the support frame are folded over and glued to the walls  12  and  13 , defining a space between the flaps and walls. The slots  83  and  84  open into this space, which provides room for insertion of the tabs  85  and  86  on the lower end of the graphics header  71  or the tabs  87  and  88  on the lower end of the extension piece. Similarly, flaps  95  and  96  are folded and glued on the upper end of the extension piece  81  to provide space for insertion of the tabs  85  and  86  on the lower end of the graphics header  71 . 
     One method of assembly of the graphics skirts  72  to the shelves  20  is shown in  FIGS. 32-34 . In the method shown in these figures the skirt is attached to the shelf by the use of double face tape  21  and insertion of tabs  73  on the free edge of skirt bottom flanges  74  and  75  through the slots  48  and  50  in adjacent edges of the bottom flaps  46   a  and  46   b  and into the aligned slots  47  (not seen in these figures) in the underlying triangular bottom wall panels  43   a  and  43   b.    
     When the shelves are made by the manufacturer, the skirts are glued to the shelves and an extended rearward end  90  on each skirt is wrapped around the corner of the support frame and a tab  91  on end  90  is inserted into a respective slot  92  in the adjacent side panels  12  and  13 , respectively, of the support frame  11 .  FIGS. 2-4  depict this arrangement. 
     The display rack of the invention is economical to make and use and is fully recyclable. The structure allows for additional product visibility and additional shopper interest, both core criteria in measuring a display&#39;s in-store effectiveness. The cantilevered mounting of the shelves provides an exceptionally strong structure, wherein each shelf is easily capable of supporting over 45 lbs of product without appreciable sagging or distress. This strength comes from the insertion of three corners of each shelf into an extended wedge in the vertical wall and the provision of a brace extending in the shelf from the rear corner to the front corner. In this regard, it is noted that the rearward ends of the braces extend into the openings  17 , whereby the brace acts as a cantilevered beam. 
     While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made in the invention without departing from the spirit and intent of the invention as defined by the appended claims.