Patent Publication Number: US-11033120-B2

Title: Display hutch

Description:
REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 62/684,780 filed on Jun. 14, 2018, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present disclosure relates to displays, and more particularly to retail merchandising displays. 
     2. Description of Related Art 
     In the retail environment, various containers are provided for shipping or for display of a product, such as pop-up displays. The pre-assemblies for conventional pop-up displays usually require costly hand finishing and special machine gluing to be made prior to shipping to their retail location. Moreover, in-store set-up time for conventional pop-up displays can be time consuming. 
     The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved pop-up displays. This disclosure provides a solution for this need. 
     SUMMARY OF THE INVENTION 
     A container includes a plurality of panels connected together at fold lines configured for extending at least partially around an interior space. The panels include a front panel, a first side panel, a back panel and a second side panel. The back panel includes a first back portion and a second back portion. At least one of the first back portion or the second back portion is free from openings. A shelf panel is foldably connected to the front panel. The first back portion is adhered to the shelf panel. 
     The first side panel can be connected to the front panel along a respective one of the fold lines. The second side panel can be connected to the front panel along a respective one of the fold lines opposite from the first side panel. The container can include an adhesion flap foldably connected to the second side panel along a fold line. The adhesion flap can overlap the second back portion of the back panel. The adhesion flap can be adhered to an exterior surface of the second back portion of the back panel. The second back portion is foldably connected to the first side panel along a fold line. 
     The first back portion can be slidable with respect to the second back portion. The first back portion can have a length in the longitudinal direction of the container and the second back portion can have a length in the longitudinal direction. The length of the first back portion can be less than the length of the second back portion. The first back portion can be configured to slide between a first position and a second position thereby folding the shelf panel along a fold line between the shelf panel and the front panel. 
     The shelf panel includes a shelf adhesion flap foldably connected to the shelf panel. An interior surface of the shelf adhesion flap can be adhered to an interior surface of the first back portion. A top edge of the first back portion can be flush with a top edge of the shelf adhesion flap. The container can include a plurality of end flaps. Each end flap can be foldably connected to a respective one of the plurality of panels. 
     In accordance with another aspect, a blank for a container includes a plurality of panels connected together along respective fold lines configured to be folded at least partially around an interior space. The panels include a front panel, a first side panel, a back panel and a second side panel. The back panel includes a first back portion and a second back portion. The first back portion can be connected to the second back portion along a break line. 
     The first side panel can be connected to the front panel along a fold line. The second side panel can be connected to the front panel along a fold line. The blank can include an adhesion flap connected to the second side panel along a fold line. The back panel can be connected to the first side panel along a fold line. The blank can include a shelf panel at least partially connected to the front panel along a fold line. The break line can be weakened to facilitate breaking the second back portion from the first back portion by at least one of a knife cut and/or perforations. The break line can be a first break line. The first back portion can be connected to the second back portion along the first break line and a second break line. The blank can include a cut portion between the first and second break lines. 
     In accordance with another aspect, a method of forming a container includes folding a plurality of panels of a blank connected together at fold lines at least partially around an interior space. The panels include a front panel, a first side panel, a back panel and a second side panel. The back panel includes a first back portion and a second back portion. The method includes adhering the first back portion to a shelf panel. The method includes separating the first back portion from the second back portion along a break line. 
     Folding the plurality of panels can include folding the back panel along a fold line between the back panel and the first side panel and folding the second side panel along a fold line between the second back portion and the front panel. The method can include adhering an interior surface of an adhesion flap to an exterior surface of the second back portion. The method can include sliding the first back portion downward and folding the shelf panel along a fold line between the shelf panel and the front panel. 
     These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein: 
         FIG. 1  is a plan view of an exemplary embodiment of a blank for a container constructed in accordance with the present disclosure, showing a back panel foldably connected to a side panel; 
         FIG. 2  is a perspective view the blank of  FIG. 1 , showing the back panel having first and second back panel portions; 
         FIG. 3  is a perspective view of the blank of  FIG. 1 , showing the back panel being folded over onto the side and front panels; 
         FIG. 4  is a perspective view of the blank of  FIG. 1 , showing the back panel folded onto the side and front panels; 
         FIG. 5  is a perspective view of the blank of  FIG. 1 , showing the side panel and the adhesion flap being folded over onto the back panel; 
         FIG. 6A  is a perspective view of the blank of  FIG. 1  formed into a container, showing the container from its back side in a flattened position; 
         FIG. 6B  is a perspective view of the blank of  FIG. 1  formed into a container, showing the container from its front side in a flattened position; 
         FIG. 7  is a perspective view of the container of  FIGS. 6A and 6B  from a bottom end, showing the panels of the container being folded along respective fold lines to enclose an interior space and erect the container; 
         FIG. 8  is a perspective view of the container of  FIGS. 6A and 6B  from a bottom end, showing the panels of the container folded along respective fold lines to enclose an interior space and showing respective end flaps of the panels folded inward into the interior space; 
         FIG. 9  is an upright front perspective view of the container of  FIGS. 6A and 6B , with the first back portion and shelf panels partially slid down relative to the second back panel portion; and 
         FIG. 10  is an upright front perspective view of the container of  FIGS. 6A and 6B , with the first back portion and shelf panels fully slid down with respect to the second back panel portion. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a container in accordance with the disclosure is shown in  FIG. 1  and is designated generally by reference character  100 . Other embodiments of containers in accordance with the disclosure, or aspects thereof, are provided in  FIGS. 2-10 , as will be described. The systems and methods described herein can be used to store product and can also be converted to display product such as in a retail setting. 
     As shown in  FIG. 1 , a blank  100  for a container  102  (shown in  FIGS. 6A-10 ) includes a plurality of panels  104 ,  106 ,  108 ,  110 , and  112  connected together at fold lines  116 ,  118 ,  120 , and  122  configured to be folded at least partially around an interior space  119  (labeled in  FIG. 8 ). The panels include a front panel  104 , a first side panel  106 , a back panel  108  and a second side panel  110 . A plurality of end flaps  134   a - 134   e , is included, each end flap  134   a - 134   e  is foldably connected to a respective one of the plurality of panels at respective fold lines  136   a - 136   e . End flaps  134   a - 134   e  are configured to be folded along their respective fold lines  136   a - 136   e  to at least partially enclose a first end of the interior space  119 . Blank  100  forms a hutch-style container  102  that can be used for merchandising displays at a retail location. Embodiments of blank  100  and container  102  provide for a quick set-up and do not necessarily require hand finishing. 
     With continued reference to  FIG. 1 , back panel  108  includes a first back portion  108   a  and a second back portion  108   b . The first back portion  108   a  is connected to the second back portion  108   b  along a break line, e.g. a perforation line  148   a . In the embodiment of  FIG. 1 , two break lines, e.g. perforation lines  148   a  and  148   b , are between first back portion  108   a  and second back portion  108   b . A cut  150  is positioned between the perforation lines  148   a  and  148   b . Those skilled in the art will readily appreciate that any suitable number of perforation/break lines or arrangements thereof can be used. The break lines, e.g. perforation lines  148   a  and  148   b , are weakened to facilitate breaking second back portion  108   b  from first back portion  108   a  by at least one of a knife cut and/or perforations. In the embodiment of  FIG. 1 , first back portion  108   a  and second back portion  108   b  are free from openings, such that each back portion  108   a ′ and  108   b , on its own, is a solid panel without openings such as apertures or cuts. 
     With continued reference to  FIGS. 1 and 2 , first side panel  106  is connected to the front panel  104  along a fold line  116 .  FIGS. 1 and 2  show an interior facing surface  105   a  of front panel  104 , exterior facing surface  105   b  is shown in  FIGS. 8-10 . Front panel  104 , as described throughout the description below, is inclusive of an upper portion  104 ′. Second side panel  110  is connected to front panel  104  along a fold line  118  opposite from first side panel  106 . Fold line  118  between front panel  104  and second side panel  110  similarly extends between upper portion  104 ′ and fold line  116  similarly extends between upper portion  104 ′ and first side panel  106 . Blank  100  includes an adhesion flap  112  foldably connected to second side panel  110  along a fold line  120 . Second back portion  108   b  of back panel  108  is foldably connected to first side panel  106  along a fold line  122 . 
     As shown in  FIGS. 1 and 2 , blank  100  includes shelf panels  114   a  and  114   b  that are foldably connected to front panel  104 . Shelf panels  114   a  and  114   b  include respective shelf adhesion flaps  126   a  and  126   b  foldably connected to their respective shelf panel  114   a  and  114   b . Shelf adhesion flap  126   a  is connected to shelf panel  114   a  along fold line  142   a . Shelf adhesion flap  126   b  is foldably connected to shelf panel  114   b  along fold line  142   b . A top edge  130  of first back portion  108   a  is flush with a top edge  132  of shelf adhesion flap  126   a.    
     With continued reference to  FIGS. 1 and 2 , shelf panel  114   a  includes shelf side flaps  138   a  and  138   b  and shelf panel  114   b  includes shelf side flaps  140   a  and  140   b . Shelf side flaps  138   a  and  138   b  are foldably connected to shelf panel  114   a  along respective fold lines  144   a  and  144   b . Shelf side flaps  140   a  and  140   b  are foldably connected to shelf panel  114   b  along respective fold lines  146   a  and  146   b . Shelf panel  114   a  (and its associated flaps described above) is separated from side panels  106  and  110  by way of respective cuts  115   a  and  115   b . Shelf panel  114   b  (and its associated flaps described above) is separated from side panels  106  and  110  and front panel  114  by way of cut  113 . Shelf adhesion flaps  126   a  and  126   b  include respective interior surfaces  128   a  and  128   b . Adhesion materials, such as glue, are applied to the interior surfaces  128   a  and  128   b . Glue can be applied in the form of glue dots shown schematically by solid dots on surfaces  128   a  and  128   b  in  FIG. 2 . 
     As shown in  FIG. 3-4 , after back panel  108  is folded about fold line  122 , an exterior surface  107   b  of first back portion  108   a  is adhered to interior surfaces  128   a  and  128   b  of shelf adhesion flaps  126   a  and  126   b . First back portion  108   a  includes an interior surface  107   a  that faces an interior surface  111   a  of second back portion  108   b  and adhesion flap  112  when assembled. First back portion  108   a  has a length L 1  in the longitudinal direction of the container and second back portion  108   b  has a length L 2  in the longitudinal direction. Length L 1  of first back portion  108   a  is less than the length L 2  of second back portion  108   b.    
     As shown in  FIG. 5-6B , second side panel  110  is folded along fold line  118  and adhesion flap  112  overlaps second back portion  108   b  of the back panel  108 . Adhesion flap  112  is adhered to an exterior surface  111   b  of second back portion  108   b  of back panel  108  along a adhesion line, e.g. a glue line. This glue line can include one or more glue dots  121  between an interior surface of adhesion flap  112  and exterior surface  111   b  of second back portion, as indicated schematically by the solid dots of  FIGS. 2-5  on an interior surface  117   a  of an adhesion flap  112 . It is contemplated that glue dots  121  on flap  112  and flaps  126   a  and  126   b  can be applied to the surfaces as shown at the same time, and then the folds at  122  and  118  can take place. It is also contemplated that other suitable adhesion techniques and materials can be used. The glue on adhesion flap  112  and shelf adhesion flaps  126   a  and  126   b  and can be applied by way of a straight line gluing, as opposed to requiring special machine gluing. 
     As shown in  FIGS. 9-10 , first back portion  108   a  is slidable with respect to second back portion  108   b . First back portion  108   a  is configured to slide between a first position (e.g. where a top edge of first back portion  108   a  is approximately at the same position as a top edge of second back portion  108   b ), and a second position (e.g. where a bottom edge of first back portion  108   a  is approximately at the same position as a bottom edge of front panel  104 . The sliding of first back portion  108   a  can be achieved by folding the shelf panels  114   a  and/or  114   b  along respective fold lines  124   a  and  124   b  toward back panel  108 , by pushing first back portion  108   a  downward, or both. This folding/pushing also folds shelf side flaps  140   a  and  140   b  along their respective fold lines  146   a  and  146   b  with respect to shelf panel  114   b  and folds shelf side flaps  138   a  and  138   b  along their respective fold lines  144   a  and  144   b . When container  102  is erected, respective interior surfaces  141   a  and  141   b  of shelf side flaps  140   a  and  140   b  abut interior surfaces of second and first side panels  110  and  106 , respectively. Respective interior surfaces  143   a  and  143   b  of shelf side flaps  138   a  and  138   b  abut interior surfaces of second and first side panels  110  and  106 , respectively. 
     With reference now to  FIGS. 3-10 , a method of forming a container includes securing first back portion  108   a  to at least one of the shelf panels  114   a  and  114   b , e.g. by folding back panel  108  about fold line  122 , shown in  FIG. 3 . Securing the panels can be done by adhering exterior surface  107   b  of first back portion  108   a  to one or more of shelf panels  114   a  and  114   b . The method includes separating first back portion  108   a  from second back portion  108   b  along the break line, e.g. first and second perforations  148   a  and  148   b . The method includes folding second side panel  110  along fold line  118  between the second back portion  108   b  and the front panel  104 , as shown in  FIG. 5 . Those skilled in the art will readily appreciate that separating first back portion  108   a  from second back portion  108   b  can be done before or after folding second side panel along fold line  118 . 
     The method includes adhering an interior surface  117   a  of an adhesion flap  112  to an exterior surface  111   b  of second back portion  108   b . Exterior surface  117   b  of adhesion flap  112  is shown in  FIG. 6A . The combined container  102 , shown in  FIGS. 6A-6B , can then be erected at a retail location, or in another suitable location. As shown in  FIGS. 7-8 , erecting container  102  includes folding front panel  104  with respect to first side panel  106  about fold line  116  and folding adhesion flap  112  with respect to second side panel  110  along fold line  120  to form a generally rectangular shape about interior space  119 .  FIG. 7  shows a partially popped-up/erected container and  FIG. 8  shows the container fully popped-up with end flaps  134   a - 134   e  folded inward and shelves  114   a  and  114   b  folded and slid down into place (sliding described in more detail with respect to  FIGS. 9-10 , below). 
     With reference now to  FIGS. 9-10 , once erected (or concurrently therewith) the method includes sliding first back portion  108   a  downward and folding the shelf panel  114   a  along a fold line between the shelf panel  114   a  and the front panel  104 , this sliding is indicated schematically by the downward pointing arrows of  108   b . As shown in  FIG. 10 , once first back portion  108   a  is slid down to abut interior surfaces  135   a  and  135   e  of end flaps  134   a  and  134   e , respectively, shelves  114   a  and  114   b  can be stacked with product as desired. While shown and described in the exemplary context of a hutch-style display container, those skilled in the art will readily appreciation that any other suitable container style can be formed without departing from the scope of this disclosure. Blanks and containers as disclosed herein can be constructed of any suitable material such as corrugated paper board. 
     The methods and systems of the present disclosure, as described above and shown in the drawings, provide for containers with superior properties including ease of manufacturing due to the capability for straight line gluing, and quick pop-up at a retail location. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.