Abstract:
A display assembly constructed primarily of fluted plastic material comprising two triangular vertical end columns, a center wall between the columns, and a header extending between the tops of the two end columns to provide lateral stability and additional display area. If desired, one or more middle columns may be added to widen the display area. The display is manufactured to be delivered to the user in a flat knocked-down folded condition. The display is designed to be easily assembled by the user at the point of use without any tools or connectors other than those that are a part of and integral to the fluted plastic panels which are assembled to form the display. Fabric may or may not be laminated to the vertical end and/or middle columns; if not, use of translucent plastic materials for such columns permits internal backlights to be used. Optional extension columns may also be attached to the end columns to widen the display area.

Description:
FIELD OF THE INVENTION 
     The invention relates generally to foldable display assemblies and more particularly to lightweight portable display assemblies constructed of a fluted plastic product. 
     BACKGROUND 
     Trade shows are an increasingly used means for vendors of products to advertise their goods and services to the trade. These shows are held worldwide and attract vendors, buyers, and resellers from far flung geographic areas. Large sums of money are spent by vendors to display their products in an eye catching manner. Generally, the vendor either purchases or makes a display assembly and ships it to the trade show where it is assembled. After the show the display is disassembled and shipped back to the vendor&#39;s place of business where it is stored until the next trade show. It is not uncommon for a vendor to attend multiple trade shows annually. 
     The display assemblies commonly available are expensive to purchase or construct, ship, assemble, disassemble, and store. The expense associated with them is due to their weight and large unwieldy size, and the materials from which they are constructed. Generally, displays are constructed of heavy hard to work materials such as wood and metal. They are fastened together with common fasteners such as screws staples, pins, and metal rods. The displays are knocked down for shipment to the trade show location and often require skilled labor to assemble. Some trade show displays may be knocked down for shipment as luggage, but they generally must be shipped in multiple packages due to the fact that they consist of a sheet material and a separate frame structure. The bulky frame structure alone may require shipment in multiple packages. 
     SUMMARY OF THE INVENTION 
     The invention provides an improvement in currently available display assemblies. It comprises two triangular shaped end columns which support a center wall centrally disposed between the end columns. If it is desired to widen the display area, one or more middle columns, similar in construction to the end columns, may be added. The center wall is engaged along its vertical edges with each of the end and/or middle columns by tabs extending from each vertical edge of the center wall and inserted into corresponding slots on the end and/or middle columns in a locking arrangement. The locking slot and tab arrangement provide a butted joint between the columns and the center wall, which provide a strong and rigid interlock between the center wall and the columns as well as providing vertical stability of the entire display assembly. 
     Further locking engagement of the center wall between the columns is provided by a header member that extends between two adjacent columns. The header locks into each column by the engagement of a slot on the header with the top of a vertical wall of each column. 
     The display is constructed of fluted plastic with or without fabric laminated to it. The fluted plastic material allows the display to be made light weight and to be of modular construction. It also allows the parts of the display to be folded and packed flat in a small easily portable point of sale container. The point of sale container may be inexpensively shipped and stored. The material has the advantage of being inexpensively die cut and creased. A particular advantage of the material is that it is a one piece material that may nonetheless be cut almost entirely through its thickness to form a “cut hinge.” 
     The interconnection of the parts of the display is accomplished entirely by insertion of die cut tabs and slots. No other fasteners are required. Strength and rigidity of the display is also entirely a function of the folding and interlocking of the parts of the display. No other materials are used to accomplish this purpose. Creasing of the fluted material to form fold lines during manufacture of the display parts allows for straight and properly aligned folds during assembly. 
     Triangular or rectangular construction of the columns, and overlapping of the fluted material with mating tabs and slots, provides strength and stability. The center wall is additionally strengthened by horizontal and vertical ribs formed by folding the center wall section along preformed fold lines. Added rigidity and an aesthetic look is provided by a header attached horizontally from the top of a first end column extending to the top of a second end column. If fabric is not used on the columns, the translucent nature of the fluted plastic material permits installation of lights within the columns, thus providing backlighting to whatever images may be applied to the exterior of the columns. 
     The front of the display is similarly laminated with fabric to provide a professional appearance. The entire display may also be impregnated during manufacture with a fire retardant additive. 
     The entire display assembly is packed in a point of sale container in a knocked down flat condition. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a perspective view of the front of one embodiment of the display assembly. 
     FIG. 2 is a perspective view of the back of the display assembly of FIG.  1 . 
     FIG. 3A is a plan view of an unfolded end column without laminated fabric. 
     FIG. 3B is a plan view of an unfolded end column with laminated fabric. 
     FIG. 4A is perspective view of the back of a center wall section. 
     FIG. 4B is a perspective view of the center wall section of FIG. 4A as fully assembled. 
     FIG. 5 is a perspective view of the back of the header. 
     FIGS. 6A through 6D are perspective views of a display in various stages of assembly. 
     FIGS. 7A,  7 B, and  7 C are perspective views. FIG. 7A shows an end column without fabric partially unfolded after taking it out of the point of sale container. FIGS. 7B and 7C show two stages of assembly of the end column of FIG.  7 A. 
     FIG. 8 is a perspective view of two assembled end columns showing their position relative to one another in a fully assembled display. 
     FIG. 9 is a plan view of two assembled end columns showing their position relative to one another in a fully assembled display. 
     FIG. 10 is an partial cutout elevation view showing a locking door and center wall slot in an end column. 
     FIG. 11 is a perspective view of the front of the embodiment of FIG. 1, including optional extension columns. 
     FIG. 12 is a plan view of an unfolded extension column. 
     FIGS. 13A-13D are perspective views of the process of assembling an extension column. 
     FIG. 14 is a perspective view from the back of the display assembly showing assembly of the four center wall sections to an end column. 
     FIG. 15 is a cross sectional view of the fluted material used in the invention. 
     FIG. 16 is a perspective view of the material of FIG. 15 arranged to illustrate the cut hinge aspect of the invention. 
     FIG. 17 is a plan view of an unfolded center wall section with laminated fabric. 
     FIG. 18 is a perspective view showing the first stage of assembly of the header to the end columns. 
     FIG. 19 is a perspective view showing the second stage of assembly of the header to the end columns. 
     FIGS. 20A through 20E are perspective views showing various stages of refolding an end column for placement in the point of sale container. 
     FIG. 21 is a sequence of perspective views showing various stages of assembly of an alternative embodiment of the invention. 
     FIG. 22 is a plan view of an unfolded extension column. 
     FIG. 23 illustrates the sequence of folding together the extension column of FIG.  22 . 
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, FIG. 1 depicts the front of my fully assembled portable knock-down display assembly ready to provide a background display at sales meetings, conventions, trade shows, and the like. The display assembly is constructed in accordance with the principles of the invention and is generally designated by the numeral  11 . Display assembly  11  comprises upstanding, laterally spaced apart, triangular first end column and second end column  14  and  15 . The end columns stabilize the display assembly  11  and support between them a center wall  22  with a front face, as shown in FIG. 1, which may optionally be attractively laminated with fabric to give the display a professional look associated with more expensive displays. The center wall is the primary viewing area for displayed materials. The front facing side, which is disposed at an angle to the center wall  22 , of the end columns  14  and  15  also serves as a display area. This area is viewable as the display is approached from the side such is often the case at trade shows where displays are arranged in rows. Also supported between the end columns  14  and  15  is a header  19 , providing further lateral support as well as a viewing area for displayed materials. Both the center wall  22  and the header  19  form the front viewing surface of the display  11 . The end columns and center sections could be laminated with a fabric or left alone. 
     If a fabric is used, it is preferably laminated in place by adhering it to the fluted plastic material with an adhesive. Equivalent techniques include thermal bonding, ultrasonic welding, and the like. It may be necessary, and in any event is preferred, to sew down the ends of the fabric to prevent fraying. Again, other equivalent techniques, such as thermally sealing the fabric ends, are within the scope of the invention but not preferred. 
     Signs or other items to be displayed may be mounted on the display assembly with any traditional method, such as two way tape, hook-and-loop fasteners, pins, or adhesive. 
     FIG. 2 shows the back of the display assembly  11  illustrating, among other features of the display assembly, the center wall horizontal reinforcing ribs  25  and vertical ribs  26 , respectively. Horizontal reinforcing ribs  25  are formed by folding the center wall section panels along integral “cut hinges,” as will be described in more detail below. Vertical reinforcing ribs  26  are a separate material attached to the back of the center wall. The preferred material is aluminum, but any material having sufficient stiffness and strength to support the center wall is within the scope of the invention. Furthermore, incorporating a material into the wall itself is equivalent to attaching a separate material to the back of the wall, but it is not the preferred embodiment. 
     As previously stated, each of the end columns  14  and  15 , the center wall sections  23 , and the header  19  are die cut from heavy duty fluted plastic, thereby providing strength to the assembled display  11 . FIG. 15 is a cross sectional view of this material, which is available from many vendors. Corrugated plastic material  54  comprises top layer  55 , flutes  56 , and bottom layer  57 . As shown in FIG. 16, it is possible to cut through either (but not both) the top layer  55  or bottom layer  57  and flutes  56 , leaving the other layer intact, to create a “cut hinge” in the material. 
     FIG. 3A illustrates an end column in an unfolded flat condition as it is after being die cut. FIG. 3B shows an end column having the optional fabric  29  described above. Each end column is a unitary construction having three major segments connected by integral “cut hinges,” as will be described in more detail below. Each end column segment  34   a ,  34   b , and  34   c  has integrally connected tabs  13  for mating engagement with corresponding column slots  31 . Each end column  14  and  15  has locking slots  28  each adjacent and in communication with its respective locking door  70 . The number and location of tabs  13  and locking slots  28  are not critical to the scope of the invention. Hand holds  30  are cutout in each end column  14  and  15 , for ease of assembly and carrying. The optional but preferred hand holds  30  are hidden from the viewer by the center wall  22  when the display  11  is fully assembled. 
     Locking door  70  is shown in detail in FIG.  10 . The preferred embodiment of the locking door  70  includes a generally elongated (as shown, rectangular) opening in the fluted plastic end column. An angled tab portion  71  separates the wider portion of the opening from its respective locking slot  28 . The hinge  72  of the locking door  70  preferably includes a cutout portion  73  that increases the ability of tab portion  71  to easily fold into the center of the end column. Due to the nature of the fluted plastic material, the tab portion  71  springs back to its original flush position with the wall of the end column  14  and  15  when the force depressing it inward is released. Thus, during assembly of the display  11  by the user, the center section end tabs  52  may be inserted into the wider portion of the opening, pushed past tab portion  71  into the narrower locking slots  28 , and then tab portion  71  will spring back into place and lock center section end tab  52  in place within locking slot  28 . Assembly of the display  11  will be more fully described in the text to follow. 
     FIGS. 7A,  7 B, and  7 C illustrate the assembly steps of an end column  14  or  15 . Beginning with FIG. 7A, a folded end column  14  or  15  is taken from its point of sale container  12 , shown in FIG. 6A, and unfolded on a clean floor with the finish side, or exterior side, of the end column  14  or  15  towards the floor. In FIG. 7B, slotted panels  17  are rolled over along longitudinal fold lines and tucked under tabbed panels  20 . Tabs  13  are inserted into slots  31  to form a rigid column, as shown in FIG.  7 C. 
     FIGS. 7A, B, and C each illustrate cut hinges  32  between adjacent end column segments  34   a ,  34   b , and  34   c . Each end column is folded as shown in FIGS. 20A through 20E for shipment in its point of sale container  12 . FIG. 20A shows an end column  14  or  15  on the floor with the finish side up. The end column is folded beginning with FIG.  20 B and ending with FIG.  20 E. 
     FIGS. 4A and 4B show center wall section panels  23 . FIG. 4A shows an unfolded center section  23 . FIG. 4B illustrates a folded center section  23  as viewed from the back. Each center section has elongated notches  41  that engage with locking slots  28  on the end columns  14  and  15  when the display is assembled. To ensure a snug fit, the width of elongated notch  41  is slightly less than the thickness of the fluted plastic material out of which the display  11  is constructed. FIG. 17 shows a variation on FIG. 4A, specifically a center section  23  having lamintated fabric  58  as described above. 
     The header  1   9 , as shown in FIG. 5 from the back in assemble d form, serves as a part of the display area and as a lateral support member. The display area on the front of the header  19  is especially adaptable for placement of a banner indicating the name of the trade show participant. Each end of header  19  has header slots  51 , which will be explained below in connection with the instructions for assembly of the display  11 . To ensure a snug fit, the width of header slot  51  is slightly less than the thickness of the fluted plastic material out of which the end columns  14  and  15  are constructed. Header  19  need not be fluted plastic material, and thus the preferred material is a lightweight foam such as those manufactured from polyvinylchloride (PVC). A joint support piece  40  helps the assembled header  19  remain flat over its entire length. A preferred material for joint support piece  40  a is plastic three-sided, rectangular channel that fits snugly to the thickness of header  19 . A support piece may be used at either the top of bottom of header  19 , or both (as illustrated). 
     The overall process of assembling the display assembly  11  is now described and is shown generally in FIG. 6A through 6D. Assembly starts with opening the point of sale container  12 , unfolding the various fluted plastic sections contained in the box, and assembling the two end columns  14  and  15 , the four center sections  23 , and the header  19 . These steps have previously been described. The next step is to place the two end columns  14  and  15  on end as shown in FIG. 8, which is a view of the end columns  14  and  15  from their back side. One of the end columns is placed with its locking doors  70  pointing upward and the other with its locking doors  70  facing downward as shown in FIG.  8 . FIG. 9 is a plan view of the end columns placed as shown in FIG.  8 . 
     The next step consists of inserting all the center sections  23  into both end columns  14  as shown in FIG. 14, which is a view of the display  11  from its back side. For convenience of illustration, only a single end column  14  is shown, but the process is the same for each end column  14 . Insertion of the center sections  23  is accomplished by first depressing the locking doors  70  towards the center of the end column  14  or  15  and then inserting the center section end tabs  52  as shown in FIG. 14 into the locking door  70  opening and the locking slots  28 . The center section  23  is then slid forward, engaging the end column  14  wall in the center sect ion end tabs  52 , flush with the locking door  70  opening, thereby allowing the locking door  70  to swing back to its original closed position to lock the center wall  22  in place. 
     The unfolded header  19  is attached to the end columns  14  and  15  as shown in FIGS. 18 and 19. The header slots  51  are slid onto the end columns  14  and  15  and header slots  51  mate with the wall of the end columns  14  and  15 . The header  19  is then pulled forward on the end columns  14  and  15  as far as possible. One or both of the end columns  14  or  15  is rotated toward the center to pinch the header  19  in place. A joint support piece  40  on the top or bottom (or both) of header  19  may be slid over the center crease. 
     The display assembly  11  may be used as described above, or an extension column  60  may be added to either or both end columns, as illustrated in FIG.  11 . Extension columns  60  are useful for increasing the display area of the invention. For example, in a preferred but not mandatory embodiment, two extension columns  60  can be used to increase the total width of display assembly from eight feet to nine and one-half feet. In general, extension columns  60  are upstanding and triangular in cross section, similar to first end column  14  and second end column  15 . Extension columns  60  also help stabilize the display assembly  11 , and are arranged to extend the area viewable as the display is approached from the side. 
     FIG. 12 illustrates an extension column  60  in an unfolded flat condition as it is after being die cut, and the sequence of assembling the flat material into an assembled column. Each extension column is a unitary construction having three major sections  61 ,  62 ,  63 , connected by two integral cut hinges  32 . FIGS. 13A-13D illustrate the process of assembling extension column  60 . Extension column  60  is taken from its point of sale container and unfolded on a clean floor (or, in the preferred embodiment, a drop cloth  64  provided with the point of sale container to keep the finish side surface clean). The finish side, or exterior side, of the extension column faces downward. The larger panel is folded until it reaches a crease of the smaller panel on the opposite side. Each panel is bent along each of two scores formed in the material during manufacture. Once each small panel is folded to meet the larger panel, hook-and-loop fasteners (commonly sold under the trade name “Velcro”) are used to hold column  60  in its assembled shape. The number and exact location of fasteners is not critical to the scope of the invention. To attach extension column  60  to an end column, another set of loop-and-pile fasteners  65  is used. In the preferred embodiment, there are three such pairs, but this is only an example. Each pair comprises a hinged portion of material that has the loop and the pile facing each other within the hinged portion. Thus, by opening the hinge, the individual surfaces may be exposed so that they may mate with corresponding surfaces located on end columns  14  and  15 , thus holding extension column  60  in place. 
     FIGS. 21 through 23 illustrate an alternative embodiment of the invention. Many components and features of this embodiment are the same or very similar to the embodiment described above, and therefore the following discussion will focus only on specific differences between the embodiments. 
     As illustrated in FIG. 21, an extended display assembly  81  comprises first and second end columns  14 ,  15  as before, but additionally includes at least one middle column  80 . As illustrated, two such middle columns  80  are shown, but this is only an example. The number of middle columns  80  is selected as needed to extend the overall size of extended display assembly  81  to the desired amount. As in the previous embodiment, center wall sections  23  are located between the end columns  14 ,  15  and middle columns  80 , and headers  19  are then added t o each respective center section. 
     FIG. 22 is a plan view of an unfolded middle column  80  analogous to the unfolded end column  14 ,  15  shown in FIG.  3 A. As with end columns  14  and  15 , middle column  80  may or may not employ laminated fabric, and thus while FIG. 22 illustrates an embodiment without such fabric, it should be understood that an embodiment using such fabric is within the scope of the invention. However, as FIG. 21 illustrates, the preferred rectangular cross section of middle column  80  (described below) is such that only a narrow width is visible after display assembly  81  is fully assembled. Illuminating the interior of middle column  80 , which is possible when the fabric is not employed, would produce a striped appearance that might detract from the visual appeal of display assembly  81  Use of fabric, by contrast, helps present a large and uniformly appearing background that complements the extended size of extended display assembly  81 . 
     Middle column  80  is a unitary construction having three major segments connected by integral cut hinges  32  as described above. Each middle column segment  82   a ,  82   b , and  82   c  has integrally connected alignment tabs  83  for mating insertion into corresponding alignment slots  84 , and engagement tabs  113  for mating engagement with corresponding engagement slots  131 . Each middle column  80  has locking slots  28  as described above. By contrast to end columns  14  and  15 , there are two opposing sets of locking slots  28  in each middle column  80 . Referring again to FIG. 21, middle column  80  must attach to center wall sections  23  on each of its two opposed side faces, as opposed to end columns  14 ,  15  which attach to center wall sections  23  on only one of their three faces. Otherwise, the number and location of all tabs and slots are not critical to the scope of the invention. Optional hand holds (not shown) may be cutout in the middle column  80  for ease of assembly and carrying. 
     FIG. 23 illustrates the assembly steps of an middle column  80 . As before, a folded middle column  80  is taken from its point of sale container (not shown) and unfolded on a clean floor with the finish side, or exterior side, of the middle column  80  towards the floor. The cut hinges  32  are employed to fold the various sections together as shown. As indicated by the bold arrows, alignment tabs  83  are inserted into alignment slots  84 . Engagement tabs  113  are inserted into engagement slots  131  to form a rigid middle column  80 . The preferred cross section of middle column  80  is rectangular, but this is only a preference and not a limitation on the scope of the invention. 
     All references to fluted plastic material should be understood to include either extruded or corrugated plastic materials, the latter of which would be preferred manufacturing in large volumes. 
     The invention may be embodied in other specific forms. The preferred embodiment shown in the Figures and described above is only an example of the invention, which is fully defined by the following claims.