Patent Publication Number: US-6712214-B1

Title: Stackable display tray

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a display tray for displaying products, and more particularly to a novel stackable display tray for providing a wide stacking platform for corresponding interlocked trays stacked in a column. 
     2. Related Background Art 
     Display cases are used primarily for product merchandising in retail stores. In order for a manufacturer of consumer products to remain competitive in the marketplace, displays must have design flexibility for multi-location use within the store, so that they are visible to consumers at any location. This requires display trays having the following characteristics: (i) ease of stacking in single and multiple columns; (ii) maximum product visibility; and (iii) structural stability for extended periods of time in a variety of merchandising environments/locations. 
     SUMMARY OF THE INVENTION 
     The present invention addresses the above concerns and presents a new and novel stackable display system. 
     In one aspect of the present invention, a stackable display tray includes a shell having a plurality of sides defined by an equal number of corners (i.e., the number of corners is equal to the number of sides), a substantially closed bottom having bottom corners corresponding with the corners of the shell, and a top having top corners corresponding with the corners of said shell. The top includes at least two first openings each adjacent to an independent top corner, and the bottom includes at least two second openings each adjacent to an independent bottom corner. The display tray also includes a side panel member having at least two angular panels positioned within the shell. Each angular panel is adjacent a corner. At least two of the angular panels include a tab projecting from the top. At least two of the first openings each receive the tab of one of the angular panels positioned within the shell and at least two of the second openings are each adapted to receive a tab of an angular panel of a side panel member which projects out from a top of an adjacent display tray positioned below the bottom. 
     In yet another aspect of the present invention, a stackable display system includes a plurality of display trays, each having a shell and a side panel member as described in the previous aspect, stacked on top of one another. 
     In another aspect of the present invention, a side panel member for a shell of a display tray includes a first panel and at least two angular support panels integral with the first panel, each including a tab projecting from the top of the angular panel for insertion into a corresponding opening within the shell. The side panel member also includes a display panel integral with the first panel, where the display panel is visible in an opening in a side of the shell and the display panel may be removed to access an interior of the display tray. 
     The display panel may include printed information on one or both sides, so that if the display panel is folded down and over the side of the shell of the display tray to access the contents of the tray, product information is still available to the consumer. Such information is generally related to the type, amount, color, flavor, etc., of the product contained within the display tray. 
     The display panel may also be removable from the side panel member by providing a perforated portion along the fold line. The shell and side panel members of the display tray may be made from pre-cut panels that are folded into the respective shapes as described in the previous aspect. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an assembled display tray according to the present invention. 
     FIG. 2 is a schematic, perspective view of a shell for the stackable display tray according to the present invention. 
     FIG. 3 is a schematic, perspective view of a side panel member for the stackable display tray according to the present invention. 
     FIG. 4 is a schematic, top plan view of a flat panel cut-out of the shell of the stackable display tray according to the present invention. 
     FIG. 5 is a schematic, top plan view of a flat panel cut-out of the side panel member of the stackable display tray according to the present invention including a display panel. 
     FIG. 6 is a schematic, top plan view of a flat panel cut-out of the side panel member of the stackable display tray according to the present invention without the display panel. 
     FIG. 7 is a perspective view of a single column of stacked display trays according to the present invention. 
     FIG. 8 is a perspective view a multiple column pallet of stacked display trays according to the present invention. 
     FIG. 9 is a schematic, top plan view of a circular grouped arrangement of display trays according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The shell of the stackable display tray of the present invention must have at least three sides, but preferably is four sided and rectangular in shape. As used herein, rectangular means any shell having sides that meet at substantially right angles. It will be apparent that a three sided shell will be triangular. Other exemplary shapes that the shell of this invention may take include pentagons and hexagons. 
     The top of the shell must have at least two first openings or slots, with each first opening being adjacent to an independent top corner. Most preferably, the top will have a first opening adjacent each independent top corner, i.e., a triangular display tray would preferably have a top with three first openings and a rectangular display tray would preferably have a top with four first openings. The bottom of the display must have at least two second openings with each second opening being adjacent to an independent bottom corner. The bottom also preferably will have a second opening adjacent each independent bottom corner. 
     The display tray also includes one or more side panel members positioned within the shell. The side panel will include at least two angular panels. Each angular panel is positioned adjacent an independent corner. Projecting from the top of at least two of the angular panels is a tab. Each tab is received by an independent first opening in the top of the shell. Preferably, the display tray having a rectangular shape includes two side panels each having two angular panels with each angular panel having a tab that is received by one of four independent first openings. 
     It should be noted that at least two of the second openings of the bottom of the shell are adapted to each receive a tab of an angular panel of a side panel member projecting from the tops of an adjacent display tray. While this is preferably accomplished by positioning the second openings of the bottom in a manner corresponding, i.e., vertically aligned, to the first openings in the top, this is not always required. For example, a rectangular shell having four equivalent sides, i.e., a square shell, may have first openings with projecting tabs at two corners which are caddy corner to each other and second openings in the bottom of the shell at the other two corners of the square shell. Such a display tray would simply be rotated ninety degrees in order to stack the trays so that each second opening received a tab projecting from the top of the bottom box. It should also be noted that the number of second openings in the bottom of the shell must be equivalent to or greater than the number of tabs projecting from the top of a corresponding stackable display tray. Most preferably, second openings are equivalent to the number of tabs projecting from the stackable display tray. 
     FIGS. 1-9 illustrate the preferred embodiments of a rectangular stackable display tray  1 , formed by assembling an outer shell  4  and at least one inner side panel  38  positioned within the shell. Each panel  38  helps provide structural stability when several display trays are stacked on top of one another. 
     Both components may be manufactured from corrugated paperboard components, or the like, produced with cutting dies and printing plates according to processes well know to those of ordinary skill in the art. With such processes, sheets of material are cut into flat panels which are folded and affixed together to form the shell and the side panels. 
     The shell  4  is formed by folding the respective die-cut panel in the following manner. Starting on a flat surface, panel sides  10  of first panels  6  are folded in toward the centers of panels  6  along fold  12  so that the first panels  6  may be folded up along fold  14  into what will be the interior of the tray. 
     While retaining the first panels  6  in an upright position (with front and rear side panels  10  being maintained in a folded condition on the interior of the shell), second panels  24  are folded in the direction of the interior along folds  22 . 
     Before placing the panels in their final positions, an adhesive is applied to the outer surface of side panels  10 , so that they may be adhered to the inside of second panels  24 . It is also possible to place side panels  10  on the exterior of second panels  24 . This alternative placement, however, results in an exterior seam and this is not preferable. 
     A variety of adhesives may be used which are sufficient for adhering paperboard or an equivalent material to itself. It is preferable, however, that a quick-setting adhesive be used since the folded portions of the shell are under stress, tending to unfold when placed in the folded position and released. 
     An example of such a quick setting adhesive is a heat sensitive adhesive, applied when the adhesive is in a melted condition. When adhering two surfaces together, melted adhesive is applied to the first surface, then the second surface is placed in immediate contact with the first surface. The melted adhesive quickly solidifies shortly after the two surfaces are brought together since the ambient temperature of the surfaces cool the adhesive almost immediately after joining. Preferably, the panels to be adhered together are held under compression for a period of time until the adhesive has set. 
     As one of ordinary skill in the art will appreciate, the panels may also be joined by including interlocking portions on the panels. For example, one surface may include a cut-out or slot for receiving a corresponding locking member from another surface to connect thereto. Moreover, additional panels may be included, which, when folded over, keep an enclosed panel secure. 
     The assembled shell includes a closed bottom and a top which can be either an open top  5 , a partially closed top, or a substantially closed top. Openings  8  may be employed for displaying product, or if the top is partially or substantially closed it may include readily removable portions which may be pulled back and/or ripped off to expose product from the top. As shown in FIGS. 1 and 2, the top, in a preferred embodiment, includes a large center opening  5 , as well as the opening portions  8  adjacent panels  28 . 
     In a preferred embodiment of the present invention, a separate slip-off, corrugated cover may be provided that is slipped over a filled display tray having an open top, in order to keep dust and particles off the contents of the tray. Such a cover may have one or more sides integral with a side(s) of the shell. For example, with one side of the cover integral with a back side of the display tray, i.e. the hinged side, a consumer can lift the side of the cover opposite the hinged side, and fold the cover back along the backside of the tray, or torn off if the hinged side of the cover is removably attached (perforated) to the shell. Alternatively, a four-sided cover may be fitted over a corresponding four-sided tray, so that the cover can be simply lifted off to access the product. 
     After the majority of the shell has been formed and the adhesive set, at least one, preferably two, side panel members  38  are positioned within the shell. As shown in FIG. 5, each side panel member is initially a flat panel having foldable structure including a first panel  40  having angular corner panels  52  positioned on either side. At the end of each corner panel are end panels  62 , with folds  58  and  60  flanking the corner panel next to the first panel  40  and the end panel  62 , respectively. 
     Each corner panel includes a top tab  54  and a bottom recess  56 . Each tab  54  is received by an opening  36  positioned on panel  28 , when top panels  28  are folded down around the sides of the box, preferably, after the display tray has been filled with product. Each tab  54  passes through the respective opening  36  and protrudes above the top surface of the display to be received by a bottom opening  20  in another display tray stacked on the existing tray. The interlocking of the tabs  54  in the respective openings substantially eliminate relative linear movement between adjacent display trays. 
     Each corner panel  52  of a side panel member is folded along a respective fold  58 , so that it creates a first angle between about 30-60° with the first panel  40 , and more preferably about 45°. End panels  62  are folded along fold  60  to from an angle of approximately 90° to the first panel  40 . A second angle between the end panel  62  and the corner panel  52  varies depending upon the angle that exists between the corner panel  52  and the first panel  40 , and is complimentary to the first angle—adding the first angle to the second angle yields approximately 90°. 
     The angular corner panel  52  may be individual panels, a pair (as illustrated and described herein), or even a single perimeter board folded to form all four angular panels. Moreover, one of ordinary skill in the art would also appreciate that the panels may be formed so that they may be placed outside the shell, surrounding each corner. 
     In a preferred embodiment, the side panel members may also be formed with an additional panel  44 , which includes a fold  44   a , formed substantially in the center as shown in the figures. Panel  44  is hinged to panel  40  along fold  50 , and may include a tab  46  which is received in a corresponding slot  16  positioned on the bottom of the first panels  6  of the shell  4 . 
     When the side panel members  38  are installed, the panel  44  is kept in the closed position to protect the contents of the display. When a consumer wishes to access the contents, the panel  44  may be folded over along fold  50  and tab  46  is inserted into slot  16 . Fold  44   a  is provided to form a base portion of the panel when it is folded over the side of the shell. Alternatively, panel  44  may be shorter in height so that fold  44   a  is not required. Given that the panel  44  of the side panel is usually adjacent the first panel  6  of the shell  4 , panel  44  may include an opening  41  corresponding in position and size to slot  16 , so that tab  46  may also be received therein. 
     The solid panel  44  may also be used as a marketing display panel for displaying additional information about the product contained in the display, or for creating an ornamental design that adds aesthetic appeal to the display tray. This feature also enables the present invention to be used as a universal shell, with little or no product information printed thereon, for packaging with any product. Pertinent information regarding the display trays content may then be included on the solid panel  44 . Thus, one would be able to tell what product is contained in the shell by looking at the printed matter on the panel  44 . 
     Thus, one shell may be created with multiple side panel inserts for each designated product to go into the shell. Accordingly, multiple printed shells may be eliminated resulting in cost savings on printing and storage. 
     Such use of a marketing panel may be used on one or all sides of a perspective display tray. Furthermore, product information may be printed on both sides so that when the panel is folded down and over the bottom of the first panel  6  of the shell, product information can still be visible. 
     It will be appreciated that it is not necessary to use an adhesive to keep the side panel members  38  in position within the shell  4 , although one may be used to insure positioning of the panel within the shell. An alternative or additional form of securing the positioning of the side panel members is to size them to frictionally fit within the shell. Specifically, the side panel members may be sized so that they are slightly larger than the distance between the inner surface of the folded over top panel  28 , and the bottom panel  18  of the shell  4 . The locking of tab  54  within an opening  36  also aids in the keeping the side panel members in place. Preferably, however, an adhesive is used as an added measure to secure the panels within the shell of the display tray. 
     After the side panel members are placed in their respective positions within the display tray, the display tray is filled with product. Thereafter, top panels  28  are folded over along fold  26 , top side panels  32  are folded over fold  34  and then affixed by a quick-set adhesive to the sides of the first panels  6 . 
     The display tray is complete after the adhesive used to affix the top side panels  32  to the first panels sets. The filled display trays can then be stacked in columns and palletized in multiple columns for shipment to consumer stores. 
     Multiple types of products may be packaged together. For example, when packaging candy, a different flavor may be in each display, so that a consumer may readily obtain any of the display candies. 
     Shell and display tray assembly may also be fully automated using box making equipment familiar to one of ordinary skill in the art. Such equipment automatically applied the adhesive all at once, forms the shell, inserts the side panel members, fills the display with product, and completes the packaging by folding and affixing final panels  28  and  32 . 
     After packaging and final assembly of the display tray, the singular display trays may be stacked in single columns (see FIG. 7) or palletized in multiple columns (see FIG.  8 ). Each display tray of each column may also be covered with the slip on or integral cover for shipping. In addition or alternative to the slip-on cover, the display trays may be covered with a stretch or shrink wrap for shipping, particularly if the product is exposed via opening  5  at the top of the display tray or openings in the first panel  6  and panel  40 . Stretch wrap over a column of display also helps to stabilize a pallet of trays during shipping. 
     FIG. 9 illustrates another embodiment of the present invention, illustrating a stacked and grouped arrangement capable of being palletized. As shown, a four sided polygonal display tray  64  includes two opposite, equal length sides  66  connected to two opposite and unequal length sides  68  and  70 . Such a display tray can be arranged adjacent to other similarly formed display trays to form a circular grouping  72 . Such an arrangement can be palletized and shipped to the retailer to be displayed as is. Many other similar arrangements may be produced by changing the arrangement of the sides of the shell of the tray. 
     Other variations and modifications of this invention will be apparent to those skilled in this art after careful study of this application. This invention is not to be limited except as set forth in the following claims.