Abstract:
A container that can function both as a shipper and as a retail display is provided. The container comprises a tray and a lid. Upon delivery to the retail site, the lid can be removed and used as a display base. The tray is mounted to the lid and secured thereto with locking tabs.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Field of the Invention 
         [0002]    This disclosure relates to packaging. More particularly, this disclosure relates to a two piece container comprising a base and a tray that can function both as shipper and as a retail display in which the tray is mounted to the base. 
         [0003]    Description of the Related Art 
         [0004]    Containers that function as both shippers and retail displays are known. For example, U.S. Pat. No. 7,066,342, owned by Sonoco Development, Inc., discloses a modular packaging system comprising posts and trays that can be used to both ship and display retails goods. 
         [0005]    U.S. Pat. No. 4,411,382 discloses an erectable display comprising a floor base and a display tray. The base is collapsible and fits inside the tray during shipping. 
         [0006]    U.S. Pat. No. 6,942,102 discloses a shipper comprising a base and a lid. After the lid is removed the base functions as a display. 
         [0007]    U.S. Pat. No. 7,066,333 discloses a shipping container comprising a base and a lid. After the lid is removed the base can be used as a retail display. 
         [0008]    A need exists for a container comprising a tray and a lid, wherein the container can function both as a shipper and as a retail display in which the lid can function as a base and the tray can be mounted to and elevated by the lid/base. The container described herein is designed to meet this need. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    The present disclosure relates to a container that can function both as a shipper and also as a retail display. The container comprises a tray and a lid. The lid also functions as a display base. Upon delivery to the retail site, this lid is removed and the tray can be mounted to and elevated by the lid/base. 
         [0010]    In one embodiment the tray comprises a bottom panel, two side panels, a front panel, a back panel and at least one locking tab. The lid comprises a top  40 , two side panels, a front panel and a rear panel. The top defines at least one slot. The container can be reconfigured from a box-like shipper configuration in which the lid covers the tray side panels, the tray front panel and the tray back panel but not the tray bottom panel, to a retail display configuration in which the tray rests on the lid and in which the locking tab(s) is/are inserted into the slot(s) to secure the tray to the lid. In the display configuration, the tray bottom panel rests on the lid top and is coextensive therewith. 
         [0011]    The container may also comprise a foldable header affixed to the back panel along a back panel top edge. The header extends from the back panel to a free edge. The header may be folded over so that its free edge can be inserted into a die cut located in the tray back panel. 
         [0012]    In one refinement the lid top defines a side slot adjacent each of its side edges and the tray comprises two side locking tabs. Each side locking tab is configured to fit through a corresponding side slot in the lid top when the container is in the display configuration. 
         [0013]    In another refinement the top defines a front slot adjacent a front edge and the tray front panel comprises a front locking tab hingedly attached to an inner front panel and configured to fit through the front slot when the container is in the display configuration. 
         [0014]    In another aspect the disclosure relates to a blank used to make a tray such as the tray described above. The blank comprises a bottom panel, a back panel, a first header panel, a second header panel, two inner side panels, two outer side panels, two middle side panels, an outer front panel, an inner front panel and side locking tabs. 
         [0015]    The bottom panel has a rectangular perimeter comprising a front edge, opposing side edges and a rear edge. The bottom panel defines a front slot adjacent the front edge and a pair of slide slots adjacent the side edges. 
         [0016]    The back panel is hingedly attached to the bottom panel along the bottom panel rear edge. The back panel has a top edge and opposing side edges and includes an upwardly facing tab defined by a die cut. 
         [0017]    Each side outer panel is hingedly attached to the bottom panel along one of the bottom panel side edges. Each side outer panel has a perimeter comprising a bottom edge coinciding with a bottom panel side edge, a rear edge, a slanted top edge and a front edge. 
         [0018]    Each side inner panel is hingedly attached to a corresponding side outer panel along the slanted top edge. Each side inner panel has a perimeter comprising the slanted top edge, a free bottom edge, a rear edge and a front edge parallel to but shorter than the rear edge. 
         [0019]    Each side middle panel is hingedly attached to the back panel along a back panel side edge. Each side middle panel has a perimeter comprising the back panel side edge, a front edge parallel to but shorter than the back panel side edge, and a bottom edge. 
         [0020]    The outer front panel is connected to the bottom panel along a front fold line. The inner front panel is connected to the outer front panel along a front panel fold line. 
         [0021]    Each side locking tab is hingedly attached to an inner side panel free bottom edge. 
         [0022]    The front locking tab is hingedly attached to the inner front panel. 
         [0023]    In a refinement a header is hingedly attached to and extends from the back panel along the back panel top edge. 
         [0024]    In another aspect the disclosure relates to a method of assembling a retail display from a shipping container such as the one described above. The method comprises the steps of: 
         [0025]    lifting the lid off of the tray and standing the lid on a flat surface with the top facing up; 
         [0026]    placing the tray onto the top of the lid; and 
         [0027]    inserting the locking tab(s) into the corresponding slot(s). 
         [0028]    In a refinement the method comprises the additional step of: 
         [0029]    raising the header into position and inserting the free edge of the header into the curved die cut located in the tray rear wall. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]      FIG. 1  is perspective view of a shipping container comprising a tray and base according to the disclosure. 
           [0031]      FIG. 2  is perspective view of the container of  FIG. 1  after the base has been removed and used as a pedestal for the tray. 
           [0032]      FIG. 3  is a plan view of a blank used to make the tray of  FIG. 2 . 
           [0033]      FIG. 4  is a plan view of a blank used to make the base of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0034]    While the invention described herein may be embodied in many forms, there is shown in the drawings and will herein be described in detail one or more embodiments with the understanding that this disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the disclosure to the illustrated embodiments. Aspects of the different embodiments can be combined with or substituted for one another. 
         [0035]    As will be appreciated, terms such as “above” and “below”, “upper” and “lower”, “top” and “bottom,” “front” and “back,” (etc.), used as nouns, adjectives or adverbs refer in this description to the orientation of the structure of the container as it is illustrated in the various figures. For example, “upward” generally refers to the direction towards the top of the page in  FIG. 2  and “forward” generally refers to the direction towards the viewer in  FIG. 2 . Such terms are not intended to limit the invention to a particular orientation. 
         [0036]    Turning to the drawings, where like numerals indicate like elements, there is shown one embodiment of a container  10  that can function as a shipper and can be reconfigured to also function as a retail display. 
         [0037]      FIG. 1  is perspective view of the container  10 . Although the container comprises a tray  12  and a lid/base  14 , only the lid  14  can be seen in this view. The tray  12  is covered by the lid  14 . The lid  14  covers and protects the tray  12  during shipping. 
         [0038]    The lid/base  14  can be any suitable dimensions, and generally is slightly larger than the tray so that the lid  14  slides easily over the tray  12 . 
         [0039]    The lid  14  comprises a top  40 , two side panels  42 , a front panel  44  and a rear panel  46  (obscured in  FIG. 1 ). The top  40  may be formed from multiple top flaps  102 ,  104 ,  106  and  108  folded inwardly as explained in reference to  FIG. 4  below. The lid  14  has a bottom rim  126  upon which it can rest when used as part of a display. 
         [0040]      FIG. 2  is perspective view of the container  10  of  FIG. 1  after the lid  14  has been lifted from the tray  12  and used as a base  14  for the tray  12 . The tray  12  is mounted to the base  14  as explained below. The tray  12  comprises a rectangular bottom panel  16 , double or triple wall thickness side panels  18 , a front panel  20 , a back panel  22  and a header  24  that extends upwardly from and is affixed to the back panel  22 . 
         [0041]    Each side panel  18  has a trapezoidal shape and extends from a front edge  86  to a relatively longer rear edge  82  and from a bottom edge  68  to a slanted top edge  84 . Each side panel  18  comprises a side middle panel  58  (obscured in  FIG. 2 ) sandwiched between a side outer panel  56  and a side inner panel  54 . 
         [0042]    The front panel  20  has an elongated rectangular shape and extends upwardly from a front edge  66  to a top edge or fold line  63  and laterally from one side panel front edge  86  to an opposite side panel front edge  86 . The front panel  20  comprises an outer front panel  61  connected to the tray bottom panel  16  along a front fold line  66  and an inner front panel  62  (obscured in  FIG. 2 ) connected to the outer front panel  61  along a front panel fold line  63 . The side panels  18  have locking tabs  64  that extend laterally inward from each side outer panel  56  and are secured between the outer and inner front panels  61 ,  62 . 
         [0043]    In the illustrated embodiment the back panel  22  is rectangular extends upwardly from a rear edge  52  of the tray bottom panel  16  to a back panel top edge  74  (obscured by the second header panel  32  in  FIG. 2 ) and laterally from one side edge  76  to an opposite side edge  76 . The back panel  22  includes an upwardly facing tab  26  defined by a curved die cut  28 . The side middle panels  58  referred to above are attached to the back panel  22  along vertical fold lines  76  coinciding with the back panel side edges  76 . 
         [0044]    The header  24  comprises a first header panel  30  and a second header panel  32  hingedly connected by a fold line  34  so that the second header panel  32  can be folded over in front of the first header panel  30  until a free edge  36  of the second header panel  32  is secured under the tab  26 . The first header panel  30  is best shown in  FIG. 3 , and extends from the back panel top edge  74  to the fold line  34  and laterally from one side edge  78  to an opposite side edge  78 . The first header panel  30  may comprise a horizontal fold line  79  located parallel to and between the back panel top edge  74  and the header fold line  34 . This fold line  79  helps facilitate construction of the header  24  as explained below. 
         [0045]    In the illustrated embodiment the tray  12  includes a side locking tab  38  hingedly attached to each side inner panel  54  and a front locking tab  39  hingedly attached to the inner front panel  62 . These tabs  38 ,  39  are inserted into slots defined by the base  14  to help secure the tray  12  to the base  14 . The tray  12  may hold one or more articles (not shown), such as blister packs, CDs and DVDs. 
         [0046]      FIG. 3  is a plan view of a blank  50  used to make the tray  12  of  FIG. 2 . The blank  50  may be corrugated board, paper board or any suitable material. In the illustrated embodiment, the blank  50  comprises a bottom panel  16 , a back panel  22 , a first header panel  30 , a second header panel  32 , two side inner panels  54 , two side outer panels  56 , two side middle panels  58 , an outer front panel  61 , an inner front panel  62 , side locking tabs  38 , a front locking tab  39  and elongated locking tabs  64 . 
         [0047]    In the illustrated embodiment the bottom panel  16  has a rectangular perimeter comprising a front edge  66 , opposing side edges  68  and a rear edge  52 . The bottom panel  16  defines a front slot  70  adjacent the front edge  66  and a pair of slide slots  72  adjacent the side edges  68 . 
         [0048]    The back panel  22  is hingedly attached to the bottom panel  16  along the bottom panel rear edge  52  and has a top edge  74  and opposing side edges  76 . As noted above the back panel  22  includes an upwardly facing tab  26  defined by a die cut  28 . The die cut  28  may be any suitable shape, including the curved shape shown in the figures. 
         [0049]    The first header panel  30  is hingedly attached to the back panel  22  along the back panel top edge  74  and has a top edge  34  coinciding with the header fold line  34  and free, opposing side edges  78 . In  FIG. 3  the first header panel  30  has a horizontal fold line  79  located parallel to and between the back panel top edge  74  and the header fold line  34 . 
         [0050]    The second header panel  32  is hingedly attached to the first header panel  30  along the header fold line  34  and has a free edge  36  and free, laterally opposing side edges  80 . 
         [0051]    Each side outer panel  56  is hingedly attached to the bottom panel  16  along one of the bottom panel side edges  68 . Each side outer panel  56  has a perimeter comprising a bottom edge  68  coinciding with a bottom panel side edge  68 , a rear edge  82 , a slanted top edge  84  and a front edge  86  parallel to but shorter than the rear edge  82 . An elongated locking tab  64  extends from the front edge  86 . 
         [0052]    Each side inner panel  54  is hingedly attached to a corresponding side outer panel  56  along the slanted top edge  84 . Each side inner panel  54  has a perimeter comprising the slanted top edge  84 , a free bottom edge  88 , a rear edge  90  and a front edge  92  parallel to but shorter than the rear edge  90 . A side locking tab  38  extends from the bottom edge  88 . 
         [0053]    Each side middle panel  58  is hingedly attached to the back panel  22  along a back panel side edge  76 . Each side middle panel  58  has a perimeter comprising the back panel side edge  76 , a slanted top edge  94 , a front edge  96  parallel to but shorter than the back panel side edge  76 , and a bottom edge  98 . 
         [0054]      FIG. 4  is a plan view of a blank  60  used to make the lid/base  14  of  FIGS. 1 and 2 . The blank  60  comprises four major rectangular panels: the front panel  44 , the rear panel  46  and the two side panels  42 . Together these panels  42 ,  44 ,  46  may be thought of as forming the four “sides” of the lid  14 . The illustrated blank  60  further comprises irregularly shaped top flaps  102 ,  104 ,  106  and  108  that fold inwardly and together form the top  40  of the container  10  of  FIG. 1 . The side top flap  102  extends from one of the side panels  42  along a fold line  112 . The other side top flap  106  extends from the other side panel  42  along a fold line  112 . The front top flap  104  extends from the front panel  44  along a fold line  114 . The rear top flap  106  extends from the rear panel  46  along a fold line  116 . An elongated glue flap  110  extends from a vertical edge  120  of a side panel  42  and is used to secure the side panel  42  to the rear panel  46  as explained below. 
       Method of Assembling the Tray and Base 
       [0055]    The tray  12  is assembled from the blank  50  according to the following steps: 
         [0056]    Fold the back panel  22  upward along rear edge  52  until it is vertical and perpendicular to the bottom panel  16 . 
         [0057]    Fold each side middle panel  58  forward along back panel side edge  76  until the side middle panels are perpendicular to the back panel  22 . 
         [0058]    Fold the side panels  56  upward along edges  68  until they are vertical and perpendicular to the bottom panel  16 . The side outer panels  56  should be flush against the side middle panels  58 . 
         [0059]    Fold the side inner panels  54  over the side middle panels  58  and insert the locking tabs  38  into the corresponding side slots  72 , then fold the locking tabs  38  upward so that they are flush against the tray bottom panel  16 . 
         [0060]    Fold the locking tabs  64  toward each other along front edges  86  until they are perpendicular to their respective side outer panel  56 . 
         [0061]    Fold the outer front panel  61  upward along bottom panel front edge  66  until it is vertical and perpendicular to the bottom panel  16 . The outer front panel  61  should be flush against the locking tabs  64 . 
         [0062]    Fold the inner front panel  62  along front panel fold line  63  and over the locking tabs  64  and insert the front locking tab  39  into the corresponding front slot  70 , then fold the locking tab  39  upward so that it is flush against the tray bottom panel  16 . 
         [0063]    Finally, rotate the header panels  30  and  32  forward along horizontal fold line  79  and fold lines  34 ,  74  until the header  24  is secured in a shipping position in which the base  14  can fit easily over the header  24  and the rest of the tray  12 . 
         [0064]    The base  14  is assembled from the blank  60  according to the following steps: 
         [0065]    Fold the glue flap  110  along vertical fold line  120  until it is perpendicular to the side panel  42  to which it is attached. 
         [0066]    Fold the front panel  44 , side panels  42  and rear panels  46  along vertical fold lines  118  and affix the glue flap  110  to rear panel  46  to form a cylindrical structure. 
         [0067]    Fold the top flaps  102 ,  104 ,  106  and  108  inwardly along fold lines  112 ,  144  and  116  and secure the top flaps  102 ,  104 ,  106  and  108  together in a planar configuration to complete the base assembly. Folding the top flaps  102 ,  104 ,  106  and  108  opens a front slot  122  adjacent the front edge  114  and a pair of side slots  124 , each adjacent a side edge  112 . 
         [0068]    Once assembled, the tray  12  can be loaded with products and the base  14  can then be placed over the tray  12  to form the container of  FIG. 1 . 
       Method of Assembling the Display 
       [0069]    Once the container  10  reaches its final destination, such as a retail store, the display can be assembled as follows: 
         [0070]    Lift the base  14  off of the tray  12  and stand the base  14  on a flat surface with the top  40  facing up and the front edge  114  facing forward. This basically is the configuration shown in  FIG. 1 . 
         [0071]    Taking the tray  12  in hand, raise the header  24  into position by lifting the second header panel  32  upward and backward and inserting the free edge  36  into the curved die cut  28  and behind the upwardly facing tab  26 . During this step the first header panel  30  may rotate backwards along horizontal fold line  79  and the second header panel  32  may rotate forward along fold line  34 . 
         [0072]    Place the tray  12  onto the top  40  of the base  14 , being careful to insert the front locking tab  39  into the front slot  122  and the two side locking tabs  38  into the side slots  124  to complete the assembly of the display. The display should look like that shown in  FIG. 2 . 
       INDUSTRIAL APPLICABILITY 
       [0073]    The container  10  can function as shipper and as a retail display in which the tray  12  is mounted to the base  14 . The base  14  can be any height and can elevate the tray  12  for a more appealing and convenient retail display. The tray  12  also can be used alone as a retail display. 
         [0074]    It is understood that the embodiments of the invention described above are only particular examples which serve to illustrate the principles of the invention. Modifications and alternative embodiments of the invention are contemplated which do not depart from the scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications and alternative embodiments that fall within their scope.