DISPLAY HUTCH AND METHODS OF ASSEMBLING THE SAME
A display hutch includes a hutch blank and a plurality of shelf blanks The hutch blank includes a back wall and at least two side walls. The back wall includes a plurality of back-wall slots. The at least two side walls include a plurality of side-wall slots. The plurality of shelf blanks includes a plurality of side tabs and one or more back tabs. Each of the side tabs is inserted into a respective side-wall slot and attached to the hutch blank. The plurality of shelf blanks and the hutch blank are configured to lay K.D. flat with the plurality of shelf blanks attached to the hutch blank. Each of the one or more back tabs is configured to be inserted into a respective one of the plurality of back-wall slots to form a plurality of shelves. The plurality of shelves is configured to support product for display.
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/906,719, filed Nov. 20, 2013, and entitled “Display Hutch,” which is incorporated herein in its entirety.
FIELD OF THE INVENTIONThe present invention relates generally to containers for displaying products. In particular, the present invention relates to a display hutch providing more efficient shipping and assembly.
BACKGROUNDDisplay hutches have been utilized to display products to customers at retail locations. Conventional display hutches, which employ a system of clips for attaching shelves, require excessive manual labor to assemble and necessitate additional components. This makes such display hutches inefficient to manufacture, assemble, and ship.
SUMMARY OF THE INVENTIONAccording to some aspects of the present disclosure, a display hutch includes a hutch blank and a plurality of shelf blanks The hutch blank includes a back wall and at least two side walls. The back wall includes a plurality of back-wall slots. The at least two side walls include a plurality of side-wall slots. The plurality of shelf blanks includes a plurality of side tabs and one or more back tabs. Each of the plurality of side tabs is inserted into a respective side-wall slot and attached to the hutch blank. The plurality of shelf blanks and the hutch blank are configured to lay K.D. flat with the plurality of shelf blanks attached to the hutch blank. Each of the one or more back tabs is configured to be inserted into a respective one of the plurality of back-wall slots to form a plurality of shelves. The plurality of shelves is configured to support product for display.
According to additional aspects of the present disclosure, a method of assembling a display hutch includes providing a hutch blank. The hutch blank has a back wall and at least two side walls extending from the back wall. The side walls include a plurality of side-wall slots. The method also includes providing a plurality of shelf blanks Each of the plurality of shelf blanks includes a plurality of side tabs. The method further includes inserting each of the plurality of side tabs into respective side-wall slots, folding each of the plurality of side tabs toward the side wall having the respective side-wall slot in which the side tab is inserted, attaching each of the plurality of side tabs to the respective side wall, and folding the hutch blank and the attached plurality of shelf blanks to be K.D. flat.
The above summary is not intended to represent each embodiment or every aspect of the present invention. Additional features and benefits of the present invention are apparent from the detailed description and figures set forth below.
Other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTIONThe side-wall slots 18a-f are paired. For example, the side-wall slot 18a is paired with the side-wall slot 18d to assist in securing one shelf. Similarly, the plurality of support-bar openings 20a-d is also paired. For example, the support-bar opening 20a is paired with support-bar opening 20d to assist in securing a support bar. The first and second side walls 14a,b are shown as having a contoured profile. It is contemplated that the first and second side walls may be more of a generally polygonal shape, such as a rectangle. It is contemplated that a hutch blank may include more than two side walls.
FIGS. 2A,B illustrate a sequence of interim blanks before forming a shelf blank of
As shown in
The length of the shelving L1 (see
It is contemplated that the shelving may be of different shapes and sizes than depicted in
One non limiting example of a display hutch is shown in
The display hutch 300 in
In one embodiment of a display hutch, each of the shelf blanks will be of the same size and shape. The number of shelves can vary, but are typically between 2 and 10 shelves and, more specifically from 3 to 5 shelves in each display hutch. It is contemplated that different sizes and shapes of the shelves may be used in forming a display hutch.
Referring now to
A plurality of the shelf blanks is attached to the hutch blank via side tabs and side-wall slots at block 114 of
The side tabs 72a,b are then folded towards and attached to a respective one of the first side wall 14a and the second side wall 14b of the hutch blank 10. In one non-limiting example, the side tabs 72a,b are attached to the hutch blank 10 via fasteners such as a plurality of staples 75a-c as shown in
Optional graphic panel blanks may be attached to an exterior surface of the side walls in block 116 of
The display hutch is configured to lay knockdown (K.D.) flat with the plurality of shelf blanks being attached to the hutch blank for shipping at shown in blocks 118, 120 of
After the display hutch is ready for use, it can be unfolded with the shelf blanks attached in block 122 of
The shelf blanks are folded towards the back wall of the hutch display and the back tabs of the shelf blanks are inserted into the back-wall slots of the hutch blank to form a plurality of shelves as recited in blocks 126 and 128 of
The display hutch and method of assembling the same provide a number of significant advantages over conventional display hutches. In particular, conventional display hutches often employ a system of clips for attaching the shelves to the hutch blank. Such clips require an inefficient and extensive manual labor to embed each clip into the corrugated material of each shelf and the side walls. By contrast, the system of slots and tabs employed in the display hutch of the present disclosure can be assembled rapidly and efficiently. Moreover, the system of slots and tabs does not require extra components such as the clips of the conventional display hutches. Additionally, unlike conventional display hutches utilizing a system of clips, the display hutch of the present disclosure can be shipped in a K.D. flat configuration pre-assembled with the shelf blanks already attached to the hutch blank. Thus, after shipping, assembly of the display hutch of the present disclosure can be completed in a much more efficient manner. Indeed, a user need only unfold the side walls and back wall and form the shelves (e.g., fold the shelf blanks and insert the back tabs in the back slots). A user may also secure the optional support bars, if used.
Still further, while conventional display hutches that employ a system of clips can only attach the shelves at an inset position with respect to a front of the display hutch, it is contemplated that the display hutch of the present disclosure can attach the shelves at an inset position and/or at a position that is at the furthest point in the front of the display hutch.
The display hutches or containers of the embodiments described herein are typically manufactured using corrugated paperboard, preferably with the corrugations running in a vertical direction for increased strength. As non-limiting examples, the container is manufactured from C-flute, EB-flute, E-flute or B-flute corrugated paperboard. It is to be understood that the principles of this invention could be applied to containers comprising other materials, such as non-corrugated paperboard, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, polymeric materials, and other foldable materials.
While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims.
Claims
1. A display hutch comprising:
- a hutch blank including a back wall and at least two side walls, the back wall including a plurality of back-wall slots, the at least two side walls including a plurality of side-wall slots; and
- a plurality of shelf blanks including a plurality of side tabs and one or more back tabs, each of the plurality of side tabs being inserted into a respective side-wall slot and attached to the hutch blank, the plurality of shelf blanks and the hutch blank being configured to lay K.D. flat with the plurality of shelf blanks attached to the hutch blank, each of the one or more back tabs being configured to be inserted into a respective one of the plurality of back-wall slots to form a plurality of shelves, the plurality of shelves being configured to support product for display.
2. The display hutch of claim 1, further comprising one or more support bars for supporting one or more of the plurality of shelves.
3. The display hutch of claim 1, further comprising at least two graphics panel blanks each attached to an exterior surface of a respective one of the at least two side walls.
4. The display hutch of claim 3, wherein the at least two graphics panels cover areas of attachment between the side tabs and the hutch blank.
5. The display hutch of claim 1, further comprising a bottom-shelf blank that is attached to the hutch blank without being inserted into any of the plurality of side-wall slots.
6. The display hutch of claim 1, wherein the hutch blank and the plurality of shelf blanks are configured to be shipped with the plurality of side tabs attached to the hutch blank and in a K.D. flat configuration.
7. The display hutch of claim 1, wherein the at least two side walls have a contoured profile.
8. The display hutch of claim 1, wherein the display hutch comprises corrugated paperboard.
9. The display hutch of claim 1, wherein the display hutch comprises non-corrugated paperboard, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, or polymeric materials.
10. A method of assembling a display hutch for shipping, comprising:
- providing a hutch blank, the hutch blank including a back wall and at least two side walls extending from the back wall, the at least two side walls including a plurality of side-wall slots;
- providing a plurality of shelf blanks, each of the plurality of shelf blanks including a plurality of side tabs;
- inserting each of the plurality of side tabs into respective side-wall slots;
- folding each of the plurality of side tabs toward the side wall having the respective side-wall slot in which the side tab is inserted;
- attaching each of the plurality of side tabs to the respective side wall; and
- folding the hutch blank and the attached plurality of shelf blanks to be K.D. flat.
11. The method of claim 10, further comprising providing a bottom-shelf blank having a plurality of bottom-shelf tabs and attaching the plurality of bottom-shelf tabs of the bottom-shelf blank to the hutch blank without inserting the bottom-shelf tabs into any of the side-wall slots.
12. The method of claim 10, further comprising attaching at least one graphic panel to each of the at least two side walls.
13. The method of claim 10, wherein the attaching each side tab to the respective side wall includes fastening each side tab to the respective side wall.
14. The method of claim 10, wherein the attaching each side tab to the respective side wall includes gluing each side tab to the respective side wall.
15. The method of claim 10, wherein the back wall of the hutch blank includes a plurality of back-wall slots and the plurality of shelf blanks includes at least one back tab, and the method further comprises folding each shelf blank and inserting the at least one back tab on each of the shelf blanks into a respective one of the back-wall slots to form a plurality of shelves.
16. The method of claim 15, further comprising attaching at least one support bar configured to provide support to one or more of the plurality of shelves.
17. The method of claim 10 further comprising shipping the folded hutch blank and the attached plurality of shelf blanks while in a K.D. flat configuration.
18. The method of claim 10, wherein the display hutch comprises corrugated paperboard.
19. The method of claim 10, wherein the display hutch comprises non-corrugated paperboard, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, or polymeric materials.
Type: Application
Filed: Nov 17, 2014
Publication Date: May 21, 2015
Inventor: Scott M. Miller (Trenton, OH)
Application Number: 14/543,279
International Classification: A47F 5/11 (20060101); A47B 43/02 (20060101); A47B 47/00 (20060101); A47F 5/00 (20060101); A47F 5/10 (20060101);