Patent Publication Number: US-9415893-B2

Title: Shelf ready display with dual dispensing features

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a National Stage Application under 35 U.S.C. §371 of International Application No. PCT/US2012/059674, filed Oct. 11, 2012, which claims the benefit of U.S. Provisional Application No. 61/545,806, filed Oct. 11, 2011, entitled “Shelf Ready Display With Dual Dispensing Features” and claims the benefit of U.S. Provisional Application No. 61/586,904, filed Jan. 16, 2012, entitled “Shelf Ready Display with Dual Dispensing Features.” 
    
    
     FIELD OF THE INVENTION 
     One or more embodiments of the present invention relate to a shelf ready display package with a dual dispensing feature that can be either a dispensing bin when the display package is placed in a standing position or a shelf opening carton when the dispensing bin is removed and the display package is laid flat. 
     BACKGROUND OF THE INVENTION 
     Display cartons with dispensing bin features have been known to be used for specialized off-shelf retail spaces such as counter tops near cash registers or in hanging configurations on shelving units either within a retail shop aisle or on the aisle end caps. However, this can leave the retailer with left over product if the off-shelf specialized retail space needs change before the product sells out. 
     Automated display carton assembly can include a traditional “minor-major” flap folding sequence that involves first folding the two minor flaps followed by folding an inner major flap, applying glue to the inner major flap and finally folding an outer major flap to seal and close the container. Display cartons with dispensing bin features have the added complexity of bin side panels that must remain movable. Thus, display cartons with dispensing bin features have been known to be formed with an “alternate” folding sequence that involves folding the bin side panel and then folding an inner major flap, followed by folding the minor flaps, applying glue and then folding the remaining major flap to seal and close the display container. The complexity of the bin side panels makes these display cartons expensive to form. 
     BRIEF SUMMARY OF THE INVENTION 
     One or more of the embodiments of the present invention provide a dispenser carton including a removable bin dispenser that forms part of the exterior surface of the carton. The carton has a dual dispensing feature in that the carton may either be displayed with the removable bin dispenser positioned on the carton to form a counter top dispenser configuration or a hanging configuration or the carton may be displayed with the removable bin dispenser simply removed to form a shelf-loaded carton configuration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an automatic sleeve bin-fold dispenser carton according to one embodiment of the present invention. 
         FIG. 2  illustrates the fully assembled carton of  FIG. 1 . 
         FIG. 3  illustrates the fully assembled carton of  FIG. 1  wherein the bottom perforation has been separated from the rest of the carton. 
         FIG. 4  illustrates the carton of  FIG. 1  with the bottom perforation separated and the removable dispenser beginning to be slid out of the carton. 
         FIG. 5  illustrates the carton of  FIG. 1  with the removable dispenser removed from the carton. 
         FIG. 6  illustrates a standard shelf-loaded carton configuration of the carton. 
         FIG. 7  illustrates a counter top dispenser configuration of the carton. 
         FIG. 8  illustrates the hanging configuration of the carton. 
         FIG. 9  illustrates a first step in a folding sequence for assembling the carton. 
         FIG. 10  illustrates a second step in a folding sequence for assembling the carton. 
         FIG. 11  illustrates a third step in a folding sequence for assembling the carton. 
         FIG. 12  illustrates an alternative embodiment of the carton of  FIG. 1  including cutouts and slots. 
         FIG. 13  illustrates an alternative embodiment of the carton of  FIG. 1  including extended removable bin flaps. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The shelf ready display with dual dispensing features is a unique approach for the assembly of a dispensing carton using a standard sleeve-style design with the traditional “minor-major” flap folding sequence. 
     Current dispenser designs (for candy or some similar consumer product) are often built using an “alternate” fold sequence of the minor and major flaps which are glued together. This technique preferably results in a carton which remains intact even after the dispenser feature is activated. 
     While this design approach has been proven a strong performer, the problem is that it may be difficult to produce in certain packaging and/or manufacturing plants, depending on plant configuration and capability. If the packaging is not able to be produced in the plant, the manufacturer may have to send the goods to an external packager, such as a packager with offsite co-pack resources. This may increase the cost of goods sold (COGs), add complexity, and may hamper the manufacturer&#39;s ability to improve their speed to market. 
     The new shelf ready display with dual dispensing features carton resolves this by using a modified major flap shape that includes a cut out area on the inside major flap which is positionable so that the outside major flap can be adhered to the minor flap covering the removable bin dispenser flap and the inside major flap without adhering to the removable bin dispenser flap. The modified major flap shape allows use of the traditional folding sequence and a specific glue application as further described below. This makes the implementation more efficient in that it fits within the functional operations of automated carton equipment. In some embodiments, the cut out area is on one end of the inside major flap while in other embodiments, both ends of the inside major flap have cut out areas. In some embodiments the shape and size of the cut out area can be sized to provide a desired glue application or a desired adhesive strength. For example, in some embodiments, the size of the cut out area allows for an increased amount of glue application to provide an increased adhesive strength. In some embodiments, the glue application can be performed in a single step while in other embodiments glue can be applied in two or more steps. When the glue is applied in two or more steps, one of the steps can be a glue application to the minor flap in the region of the inside major flap cut out area and another step can be a glue application to the inside major flap in the region where the outside major flap will be adhered to the inside major flap. 
     One advantage is that by using a traditional flap fold sequence, the equipment required to run this design is less complex in that there is one less folding station needed. As a result, the actual length of the machine will also tend to be shorter thereby reducing the footprint required on the production floor. 
     Dispenser type carton designs have been used successfully for over a decade, in the highly competitive arena of off-shelf merchandising for immediate consumption products. The implementation of this dispenser design help manufacturers to further optimize the total cost of the effected items by enabling certain items to be made online, in the Plants, thus saving substantial cost and adding efficiency to production. Additionally, by providing the option of converting the dispensing bin into a shelf opening carton, retailers can move the carton from an off-shelf location to a shelf when the need arises. Other packages that place the shelf opening feature on a face opposite to the bin dispensing opening force the retailer to choose a retailing space prior to opening the display. The shelf ready display with dual dispensing features gives the retailer the flexibility of first using the bin dispensing feature and then removing that feature to place the display on a standard shelf. 
       FIG. 1  illustrates an automatic sleeve bin-fold dispenser carton  100  according to one embodiment of the present invention. The carton  100  includes a removable dispenser  110 , a first cut out area  120 , a second cut out area  122 , a top inside major flap  130 , a bottom inside major flap  132 , a top outside major flap  140 , a bottom outside major flap  142 , a top minor flap  150 , a bottom minor flap  152 , a top removable bin dispenser flap  160 , a bottom removable bin dispenser flap  162 , a top secondary minor flap  170 , and a bottom secondary minor flap  172 . 
     As shown in  FIG. 1 , the carton is preferably composed of a single piece of carton material such as paperboard or stiffened paper. For additional structural stability, the carton material can include a fluted intermediate layer. The carton material may be folded to form a container and the flaps on the top and bottom of  FIG. 1  may be glued together. 
     As mentioned above, the carton  100  also includes a removable bin dispenser  110 . The removable bin dispenser is preferably attached to the rest of the carton material in a detachable fashion, such as by using perforations or partial cutting of the carton material. As shown in the Figures below, the removable dispenser  110  may be removed from the carton  100  to allow the carton  100  to display its contents. 
     The carton  100  also includes a first cut out area  120  in the top inside major flap  130  and a second cut out area  122  in the bottom inside major flap  132 . The cut out areas are preferably positioned so that the outside major flaps  140 ,  142  can be adhered to the minor flaps  150 ,  152  covering the removable bin dispenser flaps  160 ,  162  and the inside major flaps  130 ,  132  without adhering to the removable bin dispenser flap  160 ,  162 . 
     In some embodiments, the depth of the carton and thus the height of the side panels is increased or maximized to allow for bin side panels that are as large as possible. Increasing the side panel height and corresponding bin side panel size enables the bin dispenser to open at are larger angle thus creating a larger open area for product dispensing. However, the side panel height may be restricted by the height of shelf where the shelf pack may be shelved. In some embodiments, the side panel has a height of from about 3.5 in. to about 4.0 in. In some embodiments, the bin dispenser opens to an angle of from about 35 degrees to about 55 degrees. 
       FIG. 2  illustrates the fully assembled carton  100  of  FIG. 1 . As shown in  FIG. 2 , an described above, the carton  100  is preferably filled with product and assembled by gluing or adhering the flaps together.  FIG. 2  also shows the removable dispenser  110 , but it has not yet been removed from the carton  100 . The removable dispenser  110  is preferably attached to the carton  100  along a bottom perforation  210 . The removable bin dispenser flaps  160 ,  162  are folded under the outside major flaps  140 ,  142 . 
       FIG. 3  illustrates the fully assembled carton  100  of  FIG. 1  wherein the bottom perforation  210  has been separated from the rest of the carton. Separating the bottom perforation  210  from the rest of the carton  100  is the first step in removing the removable dispenser  110 . 
       FIG. 4  illustrates the carton  100  of  FIG. 1  with the bottom perforation separated and the removable dispenser  110  beginning to be slid out of the carton  100 . In one embodiment, the removable dispenser  110  is not attached to the carton  100  at the sides and may be simply slid out of the carton  100  after the bottom perforation  210  has been separated. In another embodiment, the removable dispenser is attached to the carton  100  at the sides with side perforations that are separated as the removable dispenser  110  is removed from the carton  100 . Additionally, the removable dispenser  110  may be configured so that the top part of the removable dispenser merely rests in place against the surface of the carton  100 . Alternatively, top part of the removable dispenser  110  may be attached to the carton  100  using a top perforation. The top perforation may be at the extreme end of the removable dispenser, or an additional surface may be positioned under the extreme end of the removable dispenser in perforated attachment with the carton  100 . 
       FIG. 5  illustrates the carton  100  of  FIG. 1  with the removable dispenser  110  removed from the carton  100 . The removable dispenser  110  includes a plurality of notches  510  that may engage the carton  100  when the removable dispenser  110  is in an open position and prevent the removable dispenser from becoming disengaged from the carton which could cause the product inside the container to spill out. 
       FIG. 6  illustrates a standard shelf-loaded carton configuration of the carton  100 . In the standard shelf-loaded carton configuration, the removable dispenser  110  is simply discarded. To facilitate use of the carton as a lay-down shelf display, the removable dispenser  110  has been configured so that when it is removed it leaves an aperture  610  in the carton  100  sufficient to allow access to the product when the carton  100  is positioned on a shelf. 
       FIG. 7  illustrates a counter top dispenser configuration of the carton  100 . As shown in  FIG. 7 , the removable dispenser  110  is in an open configuration relative to the interior of the carton  100 . Additionally, the front tab of the removable dispenser  110  has been folded down to provide a power wing  710 . The power wing  710  both allows for additional advertising display and assists in providing structural strength to the front edge of the removable dispenser  110 . 
       FIG. 8  illustrates the hanging configuration of the carton  100 . The hanging configuration is similar to the counter top dispenser configuration of  FIG. 7  with regard to the installation and positioning of the removable dispenser. However, instead of the bottom of the carton  100  being supported by a counter, the carton  100  is instead hung from a shelf or rack. Many methodologies of hanging such cartons from shelves or racks are known in the art. To facilitate hanging the dispensing carton, a slot on the back facing of the carton can be included. 
     Thus, as shown in  FIGS. 2-8 , a displayer such as a retailer may first use the dispensing carton as a counter top or hanging unit and then remove the removable dispenser  110  from the remainder of the carton  100 , and display the carton as a lay-down shelf unit. 
     Additionally, as mentioned above, in the hanging and counter top displays, a tab or power wing  710  hangs downward from the front of the removable dispenser  110 . The power wing  710  adds strength to the removable dispenser and may thus prevent deformation of the removable dispenser when employed as a bin dispenser. Also, the power wing  710  facilitates opening the removable dispenser and may be used to provide additional communication. In some embodiments, the power wing  710  may be displayed or removed. Additionally the power wing may be referred to as a display flap. 
       FIG. 9  illustrates a first step in a folding sequence for assembling the carton  100 . As shown in  FIG. 9 , the removable bin dispenser flap  160  is folded down. The inside major flap  130 , outside major flap  140 , minor flap  150 , and secondary minor flap  170  remain unfolded. 
       FIG. 10  illustrates a second step in a folding sequence for assembling the carton  100 . As shown in  FIG. 10 , minor flap  150  is now folded over the removable bin dispenser flap  160 . Additionally, the secondary minor flap  170  is also folded down. The inside major flap  130  and outside major flap  140  remain unfolded. 
       FIG. 11  illustrates a third step in a folding sequence for assembling the carton  100 . As shown in  FIG. 11 , the inside major flap  130  is folded up. The inside major flap  130  includes a cutout area  120  positioned over the left minor flap. Additionally, an adhesive  1180  such as glue is applied to the exterior surface of the insider major flap  130 . The adhesive is preferably applied to both the minor flap  150  and along the bottom of the inside major flap  130  to allow the outside major flap  140  to adhere to both the minor flap  150  and the inside major flap  130  once the outside major flap  140  is folded down. Once the outside major flap  140  is thus adhered, the carton  100  has been formed. It is preferred to glue the bottom and top flaps of the carton to the left flap (minor flap  150 ) rather than the removable bin dispenser flap to allow the removable bin dispenser to be easily from the carton without adversely impacting the carton&#39;s structural integrity. 
       FIG. 12  illustrates an alternative embodiment of the carton  100  of  FIG. 1  including slots  1220 . As shown in  FIG. 12 , slots  1220  are positioned in the top outside major flap  1240  and/or the bottom outside major flap  1242 . This embodiment may provide an advantage in performing the fold sequence. More specifically, in one embodiment the fold sequence requires folding down the removable bin flaps  1260 ,  1262  as the first step, but the outside major flaps  1240 ,  1242  may somewhat block access to the bin fold flaps. This may make it difficult to start the fold sequence. Consequently, this embodiment provides a plurality of access slots to allow the carton  100  to be more conveniently folded. For example, the carton folding machine or apparatus may include an arm or other mechanical contact that may extend through access slots  1220  to assist in folding the bin flaps  1260 ,  1262  down. 
     Stated another way, as shown in  FIG. 12 , one or more of the outside major flaps may include an access slot positioned so that a folding arm may access said removable bin dispenser flap to initiate folding the removable bin dispenser flap. 
       FIG. 13  illustrates an alternative embodiment of the carton  100  of  FIG. 1  including extended removable bin flaps  1360 ,  1362  and access cut outs  1361 . More specifically, the top extended removable bin flap  1360  and/or the bottom extended removable bin flap  1362  may be configured so that the portion of the bin flap that extends toward the remainder of the carton  100  describes an angle closer to vertical than another configuration  1390  of the bin flap. Consequently, when the carton  100  is assembled as shown in  FIG. 9 , the portion of the bin flap nearest the minor flap  150  may fold down in a more nearly vertical configuration and/or nearer to the base of the minor flap  150 . Access cut outs  1361  are positioned in the top outside major flap  1340  and/or the bottom outside major flap  1342 . As with the embodiment of  FIG. 12 , the access cut outs  1361  provide a plurality of access areas to allow the carton  100  to be more conveniently folded. For example, the carton folding machine or apparatus may include an arm or other mechanical contact that may extend through access cut outs  1361  to assist in folding the bin flap down. 
     As with the alternative embodiment of  FIG. 12 , the alternative embodiment of  FIG. 13  may provide an advantage in performing the fold sequence. More specifically, in one embodiment the fold sequence requires folding down the removable bin flap as the first step, but the outside major flaps may somewhat block access to the bin fold flap. This may make it difficult to start the fold sequence. Consequently, this embodiment provides a more accessible angle to the removable bin flap to allow the carton  100  to be more conveniently folded. For example, the carton folding machine or apparatus may include an arm or other mechanical contact that may engaged the extended portion of the removable bin flap. 
     Stated another way, as shown in  FIG. 13 , the removable bin dispenser flap may include an extension that may be called a fold initiation area. Further, one or more of the outside major flaps may include an access cut out positioned over the fold initiation area to initiate folding the removable bin dispenser flap. 
     The alternative embodiments of  FIGS. 12 and 13  may be employed separately or used together. 
     As an alternative description, the carton may be referred to as a pack. The pack is a shelf ready display pack with a dual opening feature that may be a dispensing bin opening and/or a standard shelf opening because both opening features are preferably on the same facing. Providing the retailer with the flexibility of using the display as a special pack with the dispensing bin and then converting it to a standard shelf pack provides the retailer with more confidence in purchasing the pack because the retailer is not limited to using it as a special display. The retailer may initially set the display up as a special pack with the dispensing bin and may then remove the dispensing bin and move it to a standard shelf if the product is not moving fast enough or if retail space needs change. 
     Additionally, the carton is preferably formed by using a standard flap folding sequence (minor flaps followed by inner major flap followed by outer major flap) that allows use of automated carton forming equipment. The standard sequence is possible by first folding the bin side flap and then executing the standard sequence. Individually wrapped confectionery goods are side loaded into the carton. Flexible packs like M&amp;M&#39;s singles bags are shingled upon loading to facilitate dispensing via the bin. In some embodiments, the carton can hold 3-9 lbs. of product while in other embodiments, the carton can hold 5-8 lbs. while in still other embodiments, the carton can hold 7-8 lbs. of product. 
     The use of a fluted intermediate layer in the paperboard material of the carton may provide enough strength to potentially eliminate the tertiary shipper package. In some embodiments, the use of a fluted intermediate creates a bin dispensing display that holds from about 5 lbs. to about 15 lbs. of product. 
     In some embodiments, when the carton is formed, one or more product packs may be placed inside the carton. The carton may be formed around the product packs or the product packs may be inserted into the carton before or during the folding process. 
     In some embodiments, the product packs may be shingled with other product packs. Shingling is often described as the process of aligning or stacking packaged products such that the bottom of an upper packaged product covers the top of a lower packaged product or the other way around (top of a lower packaged product covers the bottom of an upper packaged product) and may be similar in appearance to roof shingles. In some embodiments, the shingled product packs may be oriented in the carton so as to facilitate gravitational flow of the product packs out of the bin dispenser 
     Also as shown in  FIG. 1 , the removable bin flaps include a notch. The notch is usable to position the degree of opening of the bin flap relative to the carton. In one embodiment, the notches of the bin flaps contact an interior edge of the carton and are rotatable by a user to rotate the bin flap into any position from a closed position with the top of the removable dispenser contacting the carton to an open position wherein the top of the removable dispenser is rotated away from the carton by a significant angle such as 45 or 60 degrees, for example. 
     Additionally, as mentioned above, the area of perforation shown in  FIG. 4  provides the ability to remove the bin side flaps to form the shelf opening. Typically, a manufacturer would not form such a structure at this location because the perforation may be viewed as weakening the structural integrity of the carton, which is typically undesirable at the bottom of the bin. Conversely, in one of the present embodiments, a fluted intermediate layer of paperboard material may be placed on the interior side of this area in order to compensate for a potential weakening of structural integrity. 
     Additionally, the adhesive or glue used to join one or more of the flaps may be selected from the group consisting of pressure sensitive adhesive, hot melt adhesive, cold melt adhesive, and combinations thereof. Cold melt adhesive or cold seal adhesive may be preferred because it has the advantage of taking some time to set up which allows some movement of the flaps prior to fixation and then provides a stronger seal. 
     While particular elements, embodiments, and applications of the present invention have been shown and described, it is understood that the invention is not limited thereto because modifications may be made by those skilled in the art, particularly in light of the foregoing teaching. It is therefore contemplated by the appended claims to cover such modifications and incorporate those features which come within the spirit and scope of the invention.