Abstract:
A method is provided, including providing a first packaging support having a predetermined first count of first platforms, each first platform being defined by a predetermined width; providing a second packaging support having a predetermined second count of second platforms, each second platform being defined by a predetermined width; inserting the first and second packaging supports into an outer carton; inserting a predetermined third count of products into the outer carton, wherein the first and second packaging supports provide for stable positioning of the predetermined third count of products during shipment to and display at a retailer&#39;s establishment.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to product packaging and product display, and more particularly to methods and devices for providing low cost product retainment during shipping and enhanced display characteristics at retailer. 
       BACKGROUND 
       [0002]    Retailing or shopping as a concept extends at least as far back as ancient Greece, where the agora served as a marketplace for merchants to sell their goods. In ancient Rome a similar marketplace known as the forum existed. Throughout history fairs and markets have a long history that started when humans felt the desire to exchange goods and services where people would shop. Such markets are frequently weekly whilst fairs were typically less frequent. Subsequently, shops began to be permanently established when market traders stayed in one location and were traditionally specialized, e.g. a bakery, a butchery, a grocer, where the customer would be served by the shopkeeper, who would retrieve all the goods on their shopping list. Shops would often deliver the goods to the customers&#39; homes. 
         [0003]    Then in the 1930s supermarkets appeared in the United States during the Great Depression as customers became price sensitive in a manner never seen before. In supermarkets, and their larger cousins the hypermarkets, customers select goods, retrieve them off the shelves using self-service, and may even scan the items to generate their bill and pack their own goods. Customers deliver their own goods. Subsequently, online retailing has been added to the options for customers via the Internet where after selection and purchase the goods are delivered to their homes. 
         [0004]    Within each of these different retailing models, be it individual retailers, supermarkets, or online retailing operations, there exists another retailing concept, business-to-business (B2B) retailing wherein one business acts as the customer to another business. For example, a supermarket, such as Krogers, Safeway, Wal-Mart etc, sources the products it sells either directly from multiple producers such as PepsiCo, Nestlé, Unilever, Kraft, and General Mills or from food distributors such as Sysco Corporation who purchase and manage logistics for the retailer. 
         [0005]    Since the Industrial Revolution products have been shipped in bulk from a manufacturer to a retailer in a variety of packaging display vehicles. The package display vehicles need to be attractive, stand up to the rigors of shipment, requiring minimal handling at the retail level and provide easy access to the product. They also need to be cost effective. With the recent drastic changes in the retail environment over the past few years with low cost supermarkets/hypermarkets and big box retailers these retailers no longer want to even cut cases for display or unpack goods onto the shelves. Excess protective packaging such as increase board strength, using double wall versus single wall, dividers, corner boards, slip sheets, layer pads or trays between layers of packages, all add additional material, labor and freight costs to the manufacturer, retailer and the consumer. These cost variables can frequently be overlooked but can add to significant excess costs. The constant competitive pressure to drive costs down on the manufacturing and retail sides, while, at a minimum, maintaining profitability present challenges which the embodiments of the invention address. 
         [0006]    At the same time retailers demand packaging that facilitates high sales turnover within the allocated space in the shortest amount of time. They demand that the products be ready to shop once the pallet hits the retail floor and any perimeter protective packaging is removed. The next time they want to touch the packaging display vehicle is to recycle it once empty. To compound matters, many of the large retailers and warehouse clubs, have varying requirements for special promotions, graphics, packages, sizes, and counts etc. which make long production runs less feasible. Adding to these factors, there is constant pressure to reduce the costs to retailers and as the life cycles of a product package size, structure, quantity, graphics, merchandising, etc. become shorter then these reduce the feasibility for long term packaging machinery expenditures by the manufacturer. In many instances, the retailer does not want to do anything more than remove part of the packaging the products are shipped in to yield the product display the customer interacts with. 
         [0007]    At the same time retailers and customers alike do not want products that have been damaged in transit, storage or on display as well as ensuring other problems are overcome to avoid deleterious effects on the product that, in turn, might impair its marketability. Likewise, retailers and manufacturers alike do not want the costs associated with returns where the product has been damaged even if the packaging appears unaffected. This has tended to result in increased packaging around the product in order to attain the necessary strength and rigidity. Of the packaging display vehicles used for such packaging, it has heretofore been necessary, in many instances, for them to be formed of heavy gauge costly material and/or to utilize special reinforcing inserts to be positioned within the packaging display vehicle. Numerous multiple 90 and 180 degree folds are required to lock reinforcement features in place adding additional labor costs, production displays and additional opportunities for repetitive stress injuries to occur. 
         [0008]    Further, the weight and current designs of the superimposed stacked arrangement of product packaging in storage, display, shipment, etc. certain external packaging is subjected to substantial compressive forces leading to use of thicker cardboard etc. in packaging in order to avoid the collapse or distortion of the lower packaging sometimes nesting inside the container it was supposed to be superimposed and stacked on, resulting in sidewall deflection, tearing of adjoining interlocking supports and panels, accidental exposure of product and in some cases, pallet loads collapsing. To overcome this, some packaging designs use display trays with smaller footprints and a smaller number of products per display in order to minimize twisting, torque and other disfigurement resulting from excessive stress when extra products are added. This results in an increased unit cost per package as the cost of the display and assembly is prorated over fewer pieces. 
         [0009]    Most prior art packaging efforts focus on getting the product safely from the plant, to the retailers&#39; distribution center and ultimately to the retail floor. In some cases, minimal effort seems to be placed on designing a package that will withstand the rigors of how it is actually shopped on to the retail floor. At this stage, the removal of product(s) from the packaging should leave the remainder intact and presenting an appealing image to the customer. The retailer does not want to pay employees to individually reposition each product item on display in a manner that is both appealing to the customer and safe for the product nor do customers want to rummage through a product display to ascertain the product in front of them or find one that appeals to them. Accordingly, many products are packaged in packaging formats that provide a stable base but result in increased packaging volume and therefore reduced product count per package. Embodiments of the invention address these issues. 
         [0010]    At the same time, lead times are continuing to shrink such that varying product packaging requires manufacturers can mix-and-match a small number of elements to provide the desired flexibility in packaging options and desired response time of retailers Embodiments of the invention address these issues. 
         [0011]    Within the prior art there are a large number of patents that address different aspects of product packaging but none address all of the issues identified above nor do any of these prior art packaging approaches provide an adequate solution to retailers evolving demands. Further, most of these prior art approaches tend to address products that are small, lightweight, and approximately constant in their three dimensions. Solutions for high aspect ratio products are far less common. 
         [0012]    Accordingly, there is a need for a packaging solution that allows a common package footprint to handle multiple different products. 
         [0013]    There is further a need in the art for a container with improved strength characteristics to withstand the collapsing or lateral deflection of vertical container walls which may result when forces are applied to such containers without requiring complex assembly or design. 
         [0014]    There is further a need for a container that is optimally adapted for pallet-type marketing, namely retail sale of products displayed in bulk in the containers in which they are shipped in bulk. 
         [0015]    There is a further a need for a container which is easy to manipulate and easy to assemble. 
         [0016]    Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. 
       SUMMARY 
       [0017]    It is an object of the present invention to mitigate limitations within the prior art relating to product packaging and product display, and more particularly to methods and devices for providing low cost product retainment during shipping and enhanced display characteristics at retailer. 
         [0018]    In accordance with an embodiment of the invention there is provided a method comprising;
   providing a first packaging support comprising a predetermined first count of first platforms, each first platform being defined by a predetermined width;   providing a second packaging support comprising a predetermined second count of second platforms, each second platform being defined by a predetermined width;   inserting the first and second packaging supports into an outer carton;   inserting a predetermined third count of products into the outer carton, wherein   the first and second packaging supports provide for stable positioning of the predetermined third count of products during shipment to and display at a retailer&#39;s establishment.
 
In accordance with an embodiment of the invention there is provided a method comprising;
   receiving a product of a plurality of products at a location for display within a shipment carton, the shipment carton comprising:
       a first packaging support comprising a predetermined first count of first platforms, each first platform being defined by a predetermined width;   a second packaging support comprising a predetermined second count of second platforms, each second platform being defined by a predetermined width;   an outer shell;   
       displaying the product of the plurality of products at the location within a display carton, wherein   the product of the plurality of products are inserted within the outer shell and are restrained by the first and second packaging supports and the first and second packaging supports provide for stable positioning of the product of the plurality of products during shipment and display.   
 
         [0030]    Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0031]    Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein: 
           [0032]      FIGS. 1 and 2  depict a prior art approach to product packaging according to U.S. Pat. No. 6,386,366; 
           [0033]      FIG. 3  depicts a prior art approach to product packaging according to U.S. Pat. No. 7,004,379; 
           [0034]      FIGS. 4A and 4B  depict typical packaging formats within the prior art; 
           [0035]      FIG. 4C  depicts a typical retailer shelf for products with high aspect ratio, 
           [0036]      FIG. 5  depicts a packaging methodology according to an embodiment of the invention; 
           [0037]      FIG. 6  depicts a packaging methodology according to an embodiment of the invention; 
           [0038]      FIGS. 7A and 7B  depict packaging methodologies according to embodiments of the invention; 
           [0039]      FIG. 8  depicts packaging methodologies according to embodiments of the invention; 
           [0040]      FIG. 9  depicts packaging methodologies according to embodiments of the invention; 
           [0041]      FIG. 10  depicts packaging methodologies according to embodiments of the invention; 
           [0042]      FIG. 11  depicts packaging methodologies according to embodiments of the invention; and 
           [0043]      FIG. 12  depicts packaging methodologies according to embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0044]    The present invention is directed to product packaging and product display, and more particularly to methods and devices for providing low cost product retainment during shipping and enhanced display characteristics at retailer. 
         [0045]    The ensuing description provides exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims. 
         [0046]    A “package,” “box,” “container,” or “carton” as used herein and throughout this disclosure, refers to an outer packaging employed in the packaging, shipment, storage, and display of products which are packaged or unpackaged within. 
         [0047]    Referring to  FIG. 1  there is depicted a prior art packaging approach as disclosed within U.S. Pat. No. 6,386,366. As depicted a container  101  which is currently used to transport and store several individually packaged products P is depicted. The container  101  includes a body  102  having a bottom panel  103  and two side panels  104  extending upward from opposite sides of the bottom panel  103 . Openings  105  are provided in opposite sides of the body  102  and permit limited viewing of one face of the packaged products P. The container  101  also includes a removable lid  106 . In order to display the packaged products P loaded within the container  101 , the lid  106  is removed. Thereafter, each individually packaged product P must be removed from the body  102  and properly positioned in a display location. This, however, is a labor-intensive process, as previously described. 
         [0048]    Alternatively, after the lid  106  is removed, the body  102 , with the packaged products P loaded therein, can be positioned in a display location. In order to permit access to the packaged products P by a consumer, a bottom flap  107  and side flaps  108  of the body  102  must also be opened. In this state, however, the body  102 , appears unkempt and only permits limited viewing of one face of the packaged products P. In addition, when the bottom flap  107  and the side flaps  108  are opened, the body  102  no longer provides adequate support for the packaged products P. For example, if the packaged products P are packaged as individual bags or soft-side packages, the side flaps  108  and, especially, the bottom flap  107  no longer provide vertical or lateral support for the packaged products P. The packaged products P, therefore, can easily fall through one of the openings  105 . Consequently, positioning of the body  102  in a display location, with the packaged products P loaded therein, results in a product display which is generally unappealing and unattractive to a consumer. 
         [0049]    An embodiment of a prior art shipping and display container  100  according to the prior art packaging approach according to embodiments of the invention as disclosed within U.S. Pat. No. 6,386,366 are depicted in  FIG. 2 . As shown in  FIG. 2 , the tray  100  of the shipping and display container includes a bottom panel  110 , a back panel  120  extending upward from the bottom panel  110  along a back edge thereof, a front panel  130  extending upward from the bottom panel  110  along a front edge thereof, and a pair of bottom side flaps  112  extending from opposite sides of the bottom panel  110 . The back panel  120  and the front panel  130  are each preferably oriented generally perpendicular to the bottom panel  110 . The bottom side flaps  112  extend upward from the bottom panel  110  and are also preferably oriented generally perpendicular to the bottom panel  110 . As such, the tray  100  is generally L-shaped. 
         [0050]    Further, as shown in  FIG. 2 , an upper edge  114  of the respective bottom side flaps  112  is preferably linear, extending generally parallel with a lower edge  116 , such that the bottom side flaps  112  are relatively uniform in height. Alternatively, however, the upper edge  114  can assume other configurations, either linear or non-linear, such that the bottom side flaps  112  can have shapes, either regular or irregular, other than that shown in  FIG. 2 . The tray  100  also includes a pair of back side flaps  122  extending from opposite sides of the back panel  120  and a pair of front side flaps  132  extending from opposite sides of the front panel  130 . The back side flaps  122  extend forward from the back panel  120  and are preferably oriented generally perpendicular to the back panel  120 . The front side flaps  132  extend rearward from the front panel  130  and are preferably oriented generally perpendicular to the front panel  130 . As such, each of the bottom side flaps  112  are secured to an adjacent one of the back side flaps  122  and the front side flaps  132 . The bottom side flaps  112  can be secured to the back side flaps  122  and the front side flaps  132  by, for example, adhesive, tape, or staples. 
         [0051]    The front panel  130  includes a back face (not shown) facing toward the back panel  120  and a front face  134  facing away from the back panel  120  opposite the back face. As shown in  FIG. 5 , the front face  134  provides a display area adapted to receive indicia  136  thereon. The indicia  136  generally includes information identifying the packaged products P positioned on the tray  100  and can be, for example, printed directly on the front face  134  or a label affixed to the front face  134 . Also as shown in  FIG. 2 , the cover  200  includes a top panel  210  and a front panel  220  extending downward from the top panel  210  along a front edge thereof. The front panel  220  is preferably oriented generally perpendicular to the top panel  210 . As such, the cover  200  is also generally L-shaped. 
         [0052]    The cover  200  also includes a pair of top side flaps  212  extending from opposite sides of the top panel  210 , a back flap  214  extending from a back edge of the top panel  210 , and a pair of front side flaps  222  extending from opposite sides of the front panel  220 . The top side flaps  212  extend downward from the top panel  210  and are preferably oriented generally perpendicular to the top panel  210 . The back flap  214  is configured to extend generally downward from the top panel  210  and is pivotable relative to the top panel  210  about the back edge thereof. The front side flaps  222  extend rearward from the front panel  220  and are preferably oriented generally perpendicular to the front panel  220 . As such, each of the top side flaps  212  are secured to an adjacent one of the front side flaps  222  by, for example, adhesive, tape, or staples. 
         [0053]    Referring to  FIG. 3  there is depicted a prior art approach to product packaging according to U.S. Pat. No. 7,004,379 wherein the folded and glued preform after the automatic folding and gluing steps and prior to shipment are depicted by assemblies  310  as well as prior to folding and gluing with preform  320 . The preform  320  employs multiple panels that form the corner posts which are folded over each other about fold lines in order to form a corner comprised of two layers of sheet material. The fold line, however, extends from the top of the corner to approximately three-quarters of the way down the corner and is then cut to form a foot. Thus, when the panel is folded over to overlay another panel, the foot remains extending outward. Also when the panel is folded over so as to overlie the other panel, a smaller panel at the free end of the corner panels overlies the edge of the inner surface of the side wall and is glued thereto to form a side corner wall and the main portion of panel overlying the other panel forms a front corner wall. Each of the other corners is formed in the identical manner. Shoulder forming panels and positioning tabs are pre-cut and formed at the uppermost part of the panel forming the side walls and include old lines and die-cut sections. At the manufacturer, the top end of the panel forming the side wall is folded over along a fold line and the inner surface of the panel is glued to the inner surface of the side wall. Once assembled the assembly  310  allows for robust stacking of assemblies  310  for shipment etc but poor display options to the customer as the assemblies  310  must be displayed transversely for ease of access. 
         [0054]    However, both prior art packaging solutions as depicted in  FIGS. 1 through 3  are typical of those within the prior art and address the provisioning of packaging shells within which discrete product packages are presented to the customer, where as depicted in  FIG. 4A , such prior art packaging options exploit packages for each individual product that are inherently stable due to their exploitation of packaging dimensions that are approximately constant in each axis and have large bases upon which each individual product package sits. Referring to  FIG. 4B  a prior art packaging technique is depicted wherein the outer shell of the packaging incorporates a series of slots within which the cardboard back sheet of the product packaging are inserted. However, as evident, the manufacturer does not exploit this for all of their products and a typical display of products without large product package bases is depicted in area  430  with product packages lying down. Each display package is designed specifically to the product displayed and accordingly first display package  410  for 3 packs of halogen lights is different to second display package  420  for single pack incandescent lights. Similarly,  FIG. 4C  shows a typical display within a big box retailer for decorative floor registers for air conditioning vents wherein each display package simply has the floor registers leaning against the back wall of the display package initially until customers remove one or more wherein they may lean forward, slide down, etc. 
         [0055]    Accordingly, referring to  FIG. 5 , there is depicted a packaging methodology according to an embodiment of the invention for products wherein a standard box  520  when assembled has product unit  510  inserted within it which is then sealed to yield shipment box  530 . At the retailer, the first to fourth flaps  520 A to  520 D may be removed leaving carton  520 E with product unit  510  visible, allowing the customer to remove each product  510 A. Once all product  510 A is removed, the carton  520 E and Packaging Supports  510 B may be disposed off. Optionally, Packaging Supports  510 B may be recycled along with carton  520 E as they are both based upon similar materials, e.g. paper based or plastic, or they may be recycled separately as they are formed from different materials, e.g. a cardboard box for carton  520 E and plastic Packaging Supports  510 B. Alternatively, the manufacturer may work with the retailer to recover the Packaging Supports  510 B by collecting these at the next delivery of further products. Now referring to  FIG. 6  there is depicted a product unit  510  in expanded view with first and second Packaging Supports  610 A and  610 B at two ends of a set of products  620 . Whilst  FIGS. 5 and 6  depict a packaging methodology according to an embodiment of the invention for shipment and retail display it would be evident that the concept may also be used solely for shipment with the retailer removing products from the packaging prior to display or cutting off the front of the box  520  and merely removing the four flaps  520 A to  520 D and Packaging Support  610 A for display. 
         [0056]    Referring to  FIGS. 7A and 7B  there are depicted packaging methodologies according to embodiments of the invention. As depicted in  FIG. 7A  a perspective view of Packaging Support  700  is shown comprising a base plate  730  with a plurality of platforms  720  which define between them a plurality of zones  710  which are dimensioned to fit one end of a product to be packaged for shipment and retail display.  FIG. 7B  depicts plan and front elevation views of Packaging Support  700 . As depicted, the number of platforms  720  may be varied for a given base plate  730  to suit the product being packaged. In this manner, the manufacturer may standardize the carton within which the Packaging Supports  700  and products are assembled such that all aspects of palletization, shipments, display are consistent irrespective of whether the product being shipped is for example a thin vent grill or a deep floor register. 
         [0057]    This being evident in  FIG. 8  wherein first and second Packaging Supports  800 A and  800 B according to embodiments of the invention are depicted. First Packaging Support  800 A comprising M platforms of width W 1  with zones G 1  between them. Second Packaging Support  800 B comprising N platforms of width W 2  with zones G 2  between them. As depicted in  FIG. 9 , first and second Packaging Supports  900 A and  900 B are depicted in cross-section showing that the platforms may be solid or formed from a sheet so that the platforms are hollow. Beneficially, the second Packaging Support  900 B allows a large number of Packaging Supports to be stacked and shipped to the manufacturer for use from their supplier. As discussed supra, a Packaging Support may be formed from a variety of materials including, but not limited to, stamped cardboard, cut-and-folded cardboard, molded paper pulp, molded fiber, expanded polystyrene, vacuum formed polyethylene terephthalate (PET) and polyvinyl chloride (PVC), polyethylene, polypropylene, as well as molded and/or shaped foams. In some embodiments of the invention the Packaging Supports may be metal should the product warrant it through considerations such as cost, weight, etc. Cardboard and molded pulp variants may be made waterproof through the spray application of a wax, for example. In other embodiments of the invention the Packaging Support may be machined, laser cut etc from a pre-form. 
         [0058]    Now referring to  FIG. 10 , there are depicted packaging methodologies according to embodiments of the invention with first to third Packaging Supports  1000 A to  1000 C. As depicted with first and second Packaging Supports  1000 A and  1000 B respectively, the platforms may be offset at a predetermined angle to an axis of the first and second Packaging Supports  1000 A and  1000 B respectively. Accordingly, upon the retailer shelving the first and second Packaging Supports,  1000 A and  1000 B respectively provide for the products  1110  to sit against the rear of the carton  1120  such as depicted in first retailer cross-section  1100 A in  FIG. 11  or the bottom of the carton  1120  and be sloped slightly such as depicted in second retailer cross-section  1100 B in  FIG. 11 . Alternatively, when displaying products vertically no angle may be employed. 
         [0059]    Third Packaging Support  1000 C in contrast is designed to engage with large products within a carton, e.g. air filters which are large surface area but thin, large area grills, and other products. As depicted in  FIG. 12  with first and second cross-sections  1200 A and  1200 B respectively, a Packaging Support  1210  may be employed with thin product  1220  and thick product  1230 . If the spacing of the platforms within the Packaging Support  1210  is greater than the thickness of the product then each zone between the platforms may be employed to hold a product. In other embodiments of the invention only a portion of the zones between the platforms may be employed such that for example the same Packaging Support  1210  is employed with a range of products for packaging, shipment and display. 
         [0060]    Within the foregoing descriptions of embodiments of the invention in respect of  FIGS. 5 through 12  it may have been assumed by the reader that the Packaging Supports at either end are identical. However, they may be different in order to accommodate the particular product packaging. It would also be evident that multiple sets of Packaging Supports may be employed within a single container or carton with or without additional flat sheet or shaped dividers. Similarly, a Packaging Support may according to the requirements of the manufacturer or retailer have platforms of different dimensions within a single Packaging Support. For example, a product may require 2 elements, e.g. a floor register and air filter which have different dimensions. Rather than these being disposed in adjacent cartons with, for example 20 registers in a first carton and 80 filters in a second carton the display packaging may comprise 16 registers with 16 filters alternating within the same carton. Accordingly, this may provide for reduced waste and/or eased inventory management at the retailer. In other embodiments a product may exploit two or more zones within a Packaging Support at one side of the product and a different number of zones in a Packaging Support at the other side of the product. 
         [0061]    Within embodiments of the invention the Packaging Supports have been described as separate to the box within which the products are shipped and/or displayed. However, it would be evident that within other embodiments of the invention the Packaging Supports may be integral to the box either through attachment prior to insertion of the products, e.g. by glue, tape, staples, etc, or integrally formed within the box at its manufacture. 
         [0062]    The foregoing disclosure of the exemplary embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents. 
         [0063]    Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.