DISPLAY CONTAINER HAVING INTEGRAL DISPLAY PANEL AND METHOD FOR CONSTRUCTING THE SAME

Abstract

A container for packaging and displaying a product is provided. The container includes a continuous blank of sheet material having a first surface and an opposing second surface. The blank also includes a front panel, a first side panel, an opposing second side panel, a rear panel, a first bottom panel coupled between the front panel and the rear panel, and a second bottom panel extending from the front panel. At least one of the front panel, the first side panel, the second side panel and the rear panel includes a print screen on the first surface thereof. The blank forms the container having a front wall, a first side wall, an opposing second side wall, a bottom, and a display wall defining a compartment. The front panel first surface forms an exterior surface of the front wall, the first side panel first surface forms an exterior surface of the first side wall, the second side panel first surface forms an exterior surface of the second side wall and the rear panel first surface forms an interior surface of the display wall.

Description

BACKGROUND OF THE INVENTION

This invention relates generally to containers and, more particularly, to a container having an integral display panel and a method for constructing the container.

Containers are often used to store, display and/or dispense products, such as confectionary products, bulk products, food condiments or other products. The container is usually constructed and/or filled with the product, and closed for transportation to a home, restaurant or retail store. At least some known containers are bulky and non-collapsible such that the known containers require a significant amount of space to store and to transport. Additionally, at least some known containers are difficult and time-consuming to manufacture. Accordingly, such containers are costly to manufacture and require human attention in the forming of the container, as well as a more sophisticated forming machine. Moreover, because of the increased costs, at least some containers are simply designed in an effort to reduce costs, manufacturing time and labor, which oftentimes results in reduced functionality of the container.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a container for packaging and displaying a product is provided. The container includes a continuous blank of sheet material having a first surface and an opposing second surface. The blank also includes a front panel, a first side panel, an opposing second side panel, a rear panel, a first bottom panel coupled between the front panel and the rear panel, and a second bottom panel extending from the front panel. At least one of the front panel, the first side panel, the second side panel and the rear panel includes a print screen on the first surface thereof. The blank forms the container having a front wall, a first side wall, an opposing second side wall, a bottom, and a display wall defining a compartment. The front panel first surface forms an exterior surface of the front wall, the first side panel first surface forms an exterior surface of the first side wall, the second side panel first surface forms an exterior surface of the second side wall and the rear panel first surface forms an interior surface of the display wall.

In a further aspect, a container for packaging and displaying a product is provided. The container includes a continuous blank of sheet material having a first surface and an opposing second surface. The first surface includes a plurality of print screens thereon. The blank is foldable along a plurality of fold lines to form the container having a front wall, a first side wall, an opposing second side wall, a bottom and a display wall defining a compartment. Each of an exterior surface of the front wall, an exterior surface of the first side wall, an exterior surface of the second side wall and an interior surface of the display wall each includes one print screen of the plurality of print screens.

In a further aspect, a method for constructing a container is provided. The method includes providing a continuous blank of sheet material having a first surface and an opposing second surface, the blank including a front panel, a first side panel, an opposing second side panel, a rear panel, a first bottom panel coupled between the front panel and the rear panel, and a second bottom panel extending from the front panel, wherein at least one of the front panel, the first side panel, the second side panel and the rear panel including a print screen on the first surface thereof. The method further includes forming the container by folding the blank along a plurality of fold lines, the container having a front wall, a first side wall, an opposing second side wall, a bottom and a display wall defining a compartment, the front panel first surface forming an exterior surface of the front wall, the first side panel first surface forming an exterior surface of the first side wall, the second side panel first surface forming an exterior surface of the second side wall and the rear panel first surface forming an interior surface of the display wall. The method also includes coupling each of the first side wall and the second side wall to the bottom.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a blank of sheet material for constructing a container according to one embodiment;

FIG. 2 is a perspective view of a container partially constructed from the blank shown in FIG. 1;

FIG. 3 is a perspective view of a container partially constructed from the blank shown in FIG. 1;

FIG. 4 is a perspective view of a container constructed from the blank shown in FIG. 1;

FIG. 5 is a perspective view of a container including an insert constructed from the blank shown in FIG. 1; and

FIG. 6 is a perspective view of a container in a shipping configuration constructed from the blank shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is described below in reference to its application in connection with and operation of a container including an integral display panel. However, it will be apparent to those skilled in the art and guided by the teachings herein provided that the invention is likewise applicable to any suitable storage and/or display container including, without limitation, a carton, a tray or a box.

In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the teachings herein provided. The container may have any suitable size, shape and/or configuration, i.e. number of sides, whether such sizes, shapes and/or configurations are described and/or illustrated herein. For example, in one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates transporting the container and/or a shape that facilitates stacking and/or arrangement of a plurality of containers.

FIGS. 1-6 illustrate the construction of one embodiment of a container. Specifically, FIG. 1 illustrates a top plan view of one embodiment of a blank of sheet material designated in its entirety by element reference number 8. FIGS. 2 and 3 are perspective views of a container partially designated in its entirety by element reference number 10 constructed from blank 8 shown in FIG. 1. FIG. 4 is a perspective view of container 10 in a constructed configuration. FIG. 5 is a perspective view of container 10 in the constructed configuration including an insert. FIG. 6 is a perspective view of container 10 in a shipping configuration.

Referring to FIG. 1, blank 8 includes a first surface 11 and an opposing second surface 12. In one embodiment, blank 8 is made of paperboard. In an alternative embodiment, blank 8 is made of cardboard, corrugated board, plastic and/or any suitable material.

In one embodiment, first surface 11 includes a plurality of print screens thereon, and second surface 12 is blank or void of any marking, such as a graphic and/or other printing. Print screens 13 include any suitable markings including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. For example, the markings may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. In one embodiment, the markings are printed within at least one print screen on only one side of blank 8 for facilitating reducing manufacturing costs and/or time. In a particular embodiment, the print screens are positioned within one or more panels (as described in greater detail below) on first surface 11 of blank 8 and correspond to a visible surface, such as an exterior surface or a display surface, of constructed container 10.

Blank 8 includes rear panel 14, a first bottom panel 16, a front panel 18, a second bottom panel 20, and a first side panel 22 and opposing second side panel 24. Rear panel 14 is hingeably coupled to first bottom panel 16 along a fold line 26. In one embodiment, fold line 26 includes a hinge line and/or a line of separation, such as a die cut, defined along a portion of fold line 26. It is apparent to those skilled in the art and guided by the teachings herein provided that fold line 26, as well as other fold lines described herein, may include any suitable line or lines of weakening.

Rear panel 14 includes a first rear flap 30, a second rear flap 32, and a third rear flap 34. In this embodiment, rear flaps 30, 32, and 34 each include at least one angled side wall. First rear flap 30 and third rear flap 34 extend outwardly from rear panel 14 and are coupled to rear panel by preformed, substantially parallel, fold line 36 and fold line 38, respectively. Second rear flap 32 extends outwardly from rear panel 14 and is coupled to rear panel 14 along a second fold line 40 that is substantially perpendicular to fold lines 36, 38. In this particular embodiment, rear flaps 32, 34, 36 each fold along respective fold lines 36, 40, 38 approximately 180 degrees towards first surface 11 or second surface 12.

First bottom panel 16 extends from rear panel 14 along fold line 26. First bottom panel 16 also extends laterally between side edge 41 and opposing side edge 42. First bottom panel 16 is coupled to front panel 18 by a fold line 43. Front panel 18 includes a first portion 44, a second portion 46, and a third portion 48. First portion 44 extends from first bottom panel 16 along fold line 43. Second portion 46 is coupled to first portion 44 along a preformed fold line 50, and third portion 48 is coupled to second portion 46 along a preformed fold line 52. Second bottom panel 20 extends outwardly from front panel 18 such that second bottom panel 20 is coupled to third portion 48 along a preformed fold line 53. In this embodiment, preformed fold lines 43, 50, 52, and 53 are substantially parallel.

Additionally, second bottom panel 20 extends laterally between substantially parallel opposing side edges 54, 55, and includes a bottom edge 56. Bottom edge 56 is substantially perpendicular to opposing side edges 54, 55. In one embodiment, second bottom panel 20 includes at least one tab extending outwardly from second bottom panel 20 along a bottom fold line. In a particular embodiment, second bottom panel 20 includes tab 57 and tab 58 such that each tab 57, 58 extends outwardly along bottom fold line 59. Tabs 57, 58 form or define slot 60 and slot 62, respectively. Second bottom panel 20 also includes at least one slot defined therein. In this embodiment, second bottom panel 20 includes slot 64 and slot 66. Slots 64, 66 are positioned within second bottom panel 20 at a distance 68 with respect to side edges 54, 55, respectively.

Side panel 22 generally extends laterally outwardly from front panel 18. In one embodiment, side panel 22 extends laterally outwardly from front panel third portion 48 along a fold line 69. Side panel 22 includes a first side portion 71, a second side portion 74, a third side portion 78 and a fourth side portion 82 defining a fastener. In a particular embodiment, first side portion 71 is coupled to second side portion 74 along a fold line 90, second side portion 74 is coupled to third side portion 78 along a fold line 92, and third side portion 78 is coupled to fourth side portion 82 along a fold line 94. In this embodiment, preformed fold lines 90, 92, 94 are substantially parallel.

In one embodiment, first side portion 71 includes a projection 91 that extends from first side portion 71. Projection 91 is configured to be positioned within slot 64. First side portion 71 also includes a projection 96, which extends outwardly from a top surface of the first side wall formed by first side panel 22, as described in greater detail below. In this embodiment, projection 96 is generally hook-shaped and at least partially defined by a slot 98 that forms a retaining surface for facilitating maintaining a display panel of container 10 in a display position. As described above, fourth side portion 82 defines a fastener 100. In this embodiment, fastener 100 is generally hook-shaped and defines a slot 102.

Side panel 24 generally extends laterally outwardly from front panel third portion 48 along a fold line 70. Side panel 24 includes a first side portion 72, a second side portion 76, a third side portion 80, and a fourth side portion 84 defining a fastener. In this embodiment, first side portion 72 is coupled to second side portion 76 along a fold line 104, second side portion 76 is coupled to third side portion 80 along a fold line 106, and third side portion 80 is coupled to fourth side portion 84 along a fold line 108. In this embodiment, preformed fold lines 104, 106, and 108 are substantially parallel.

Additionally, first side portion 72 includes a projection 109 extending from first side portion 72. Projection 109 is configured to be positioned within slot 66. First side portion 72 also includes a projection 110, which extends outwardly from a top surface of the first side wall formed by second side panel 24, as described in greater detail below. In this embodiment, projection 110 is generally hook-shaped and at least partially defined by a slot 112 that forms a retaining surface for facilitating maintaining the display panel of container 10 in a display position. As described above, fourth side portion 84 includes a fastener 114. In this embodiment, fastener 114 is generally hook-shaped and defines a slot 116.

As shown in FIG. 1, fold lines 50, 90, 104 are collinear, fold lines 52, 92, 106 are collinear, and fold lines 53, 94, 108 are collinear. Further, fold lines 69 and 70 are substantially perpendicular to fold line 53.

Referring to FIG. 4, container 10 further includes a display wall 200, a bottom 210, a front wall 220, a first side wall 230, and an opposing second side wall 240. Display wall 200, bottom 210, front wall 220, first side wall 230 and second side wall 240 include an exterior or display surface 250 and an interior or back surface 260. Each exterior surface 250 of display wall 200, front wall 220, first side wall 230 and second side wall 240 includes print screens (not shown). As described above, in one embodiment the print screens include any suitable markings including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. For example, the markings may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. In this embodiment, the markings are printed within at least one print screen on first surface 11 of blank 8 for facilitating reducing manufacturing costs and/or time. Further, the print screens are positioned within a panel (as described in greater detail below) on first surface 11 of blank 8 and correspond to a visible exterior or display surface of the corresponding wall or panel of container 10, with container 10 in the constructed configuration.

Each wall is formed from a corresponding panel or corresponding panels. Display wall 200 corresponds to rear panel 14 and is formed by folding rear flaps 30, 32, 38 along fold lines 36, 40, 34, respectively, and coupling rear flaps 30, 32, 38 to back surface 260 of display wall 200. Front wall 220 corresponds to portions 44, 46, 48 of front panel 18. Specifically, first portion 44 forms an internal surface 261 of front wall 220 coupled to bottom 210 along fold line 43, second portion 46 forms a top surface 262 that is coupled to internal surface 261 along fold line 50, third portion 48 forms an external surface 263 coupled to top surface 262 along fold line 52, and external surface 263 is coupled to bottom 210 along fold line 53. Internal surface 261 is substantially perpendicular to bottom 210. Top surface 262 is substantially parallel to bottom 210. External surface 263 is substantially parallel to internal surface 261.

Bottom 210 is constructed of first bottom panel 16 and second bottom panel 20. As shown in FIG. 2, after forming front wall 220, bottom 210 is formed by folding second bottom panel 20 along fold line 53 towards second surface 12 and coupling second bottom panel 20 to second surface 12 of first bottom panel 16.

Additionally, first side wall 230 corresponds to portions 71, 74, 78, 82. Specifically, first side wall 230 is coupled to third portion 48 along fold line 50, first side portion 71 forms an internal surface 264 of first side wall 230, second side portion 74 forms a top surface 265 that is coupled to internal surface 264 along fold line 92, third side portion 78 forms an external surface 266 coupled to top surface 265 along fold line 92, and external surface 266 is coupled to fourth side portion 82 along fold line 94. Fourth side portion 82 extends outwardly from external surface 266 along fold line 94. Internal surface 264 is substantially perpendicular to bottom 210. Top surface 265 is substantially parallel to bottom 210. External surface 266 is substantially parallel to internal surface 264.

Additionally, second side wall 240 corresponds to portions 72, 76, 80, 84. Specifically, second side wall 240 is coupled to third portion 48 along fold line 70, first side portion 72 forms an internal surface 267 of second side wall 240, second side portion 76 forms a top surface 268 that is coupled to internal surface 267 along fold line 104, third side portion 80 forms an external surface 269 coupled to top surface 268 along fold line 106, and external surface 269 is coupled to fourth side portion 84 along fold line 108. Fourth side portion 84 extends outwardly from external surface 269 along fold line 108 such that fourth side portion 84 is folded towards interior surface 260. Internal surface 267 is substantially perpendicular to bottom 210. Top surface 268 is substantially parallel to bottom 210. External surface 269 is substantially parallel to internal surface 267.

As shown in FIG. 3, container 10 is in partially constructed configuration 272. As shown in FIG. 4, container 10 is in a constructed display configuration 280. In further forming container 10, first side wall 230 is folded along fold line 69 towards bottom 210. Similarly, second side wall 240 is folded along fold line 70 towards bottom 210. Generally, projections and fasteners are configured to facilitate maintaining container 10 in display configuration 280. More specifically, projections 91, 109 are positioned within slots 64, 66, respectively, such that side walls 230, 240 are coupled to bottom 210 along edges 41, 42, respectively. As shown in FIG. 4, tabs 57, 58 are configured to couple to fasteners 100, 114, respectively. More specifically, in this embodiment, fastener 100 cooperates with tab 57 wherein a portion of fastener 100 is positioned within slot 60 to couple first side wall 230 to bottom 210. Similarly, fastener 114 cooperates with tab 58 wherein a portion of fastener 114 is positioned within slot 116 to couple second side wall 240 to bottom 210. Additionally, in this embodiment, projections 96, 110 engage a bottom portion 270, 274, respectively, of display wall 200 such that projections 96 and 110 are configured to facilitate maintaining display wall 200 in a display configuration 280. When container 10 is in display configuration 280 or shipping configuration 290, graphics are displayed on display or exterior surfaces 250 of display wall 200, front wall 220, first side wall 230, and second side wall 240.

As shown in FIG. 5, container 10 further includes an insert 282 wherein display wall 200, bottom 210, front wall 220, first side wall 230, and/or second side wall 240 are configured to cooperate with one another to retain insert 282 within a compartment. In the exemplary embodiment, insert 282 includes at least one receptacle 284 to hold suitable products.

As shown in FIG. 6, display wall 200 is movable about fold line 26 for facilitating converting container 10 from display configuration 280 to a shipping configuration 290. In shipping configuration 290, display wall 200 is rotated approximately 270 degrees towards bottom 210. Rotating display wall 200 about fold line 26 provides a stackable container with an integral display. Stacking containers provide ease in shipping, and requires less volume than shipping formed containers. Additionally, a container formed from a single blank reduces costs and prevents confusion of forming a container that includes multiple elements.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims

1. A container for packaging and displaying a product, the container comprising:

a continuous blank of sheet material having a first surface and an opposing second surface, the blank comprising a front panel, a first side panel, an opposing second side panel, a rear panel, a first bottom panel coupled between the front panel and the rear panel, and a second bottom panel extending from the front panel, wherein at least one of the front panel, the first side panel, the second side panel and the rear panel comprising a print screen on the first surface thereof, the blank forming the container having a front wall, a first side wall, an opposing second side wall, a bottom, and a display wall defining a compartment, wherein the front panel first surface forming an exterior surface of the front wall, the first side panel first surface forming an exterior surface of the first side wall, the second side panel first surface forming an exterior surface of the second side wall and the rear panel first surface forming an interior surface of the display wall.

2. A container in accordance with claim 1 wherein, with the container formed, the display wall is movable between a first position generally parallel to the bottom and a second position generally perpendicular to the bottom.

3. A container in accordance with claim 1 wherein the second bottom panel further comprises at least one tab formed within the second bottom panel, a fastener extending from the first side panel cooperating with the tab for facilitating coupling the first side wall to the bottom.

4. A container in accordance with claim 3 wherein the second bottom panel defines a slot, a projection formed on the first side panel positioned within the slot for facilitating forming the first side wall.

5. A container in accordance with claim 3 wherein the first side wall forms a projection extending with respect to a top surface of the first side wall and configured for facilitating maintaining the display wall in a display position.

6. A container in accordance with claim 3 wherein the at least one tab defines a slot, a portion of the fastener positioned with the slot.

7. A container in accordance with claim 1 wherein the display wall further comprises:

a first flap coupled to the second surface of the rear panel along a first edge of the display wall;

a second flap coupled to the second surface of the rear panel along a second edge of the display wall; and

a third flap coupled to the second surface of the rear panel along a third edge of the display wall.

8. A container in accordance with claim 1 wherein the front panel further comprises:

a first portion coupled to the first bottom panel along a first fold line;

a second portion coupled to the first portion along a second fold line substantially parallel to the first fold line; and

a third portion coupled to the second portion along a third fold line substantially parallel to the second fold line and coupled to the second bottom panel along a fourth fold line substantially parallel to the third fold line, the first portion, the second portion and the third portion folded along respective fold lines to form the front wall.

9. A container in accordance with claim 8 wherein the first portion forms an interior surface of the first side wall, the second portion forms a top surface of the first side wall and the third portion forms an exterior surface of the first side wall.

10. A container in accordance with claim 8 wherein the first side panel is coupled to a first side edge of the third portion along a fifth fold line substantially perpendicular to the fourth fold line, and a second side panel is coupled to an opposing second side edge of the third portion along a sixth fold line substantially perpendicular to the fourth fold line.

11. A container in accordance with claim 1 wherein the first side panel further comprises:

a first portion coupled to a first side edge of the front panel along a first fold line;

a second portion coupled to a first lateral edge of the first portion along a second fold line substantially perpendicular to the first fold line;

a third portion coupled to the second portion along a third fold line substantially parallel to the second fold line; and

a fastener extending from a second lateral edge of the first portion along a fourth fold line opposing the first lateral edge, the first portion, the second portion and the third portion folded along respective fold lines to form the first side wall, the fastener configured for facilitating coupling the first side wall to the bottom.

12. A container in accordance with claim 11 wherein the first portion forms an interior surface of the first side wall, the second portion forms a top surface of the first side wall and the third portion forms an exterior surface of the first side wall.

13. A container in accordance with claim 12 further comprising a projection extending from the top surface of the first side wall, the projection configured for facilitating maintaining the display panel in a displayed position.

14. A container in accordance with claim 11 wherein the first portion further comprises a projection extending from the first portion, the projection positioned within a slot defined within the second bottom panel.

15. A container for packaging and displaying a product, the container comprising:

a continuous blank of sheet material having a first surface and an opposing second surface, the first surface including a plurality of print screens thereon, the blank foldable along a plurality of fold lines to form the container having a front wall, a first side wall, an opposing second side wall, a bottom and a display wall defining a compartment, each of an exterior surface of the front wall, an exterior surface of the first side wall, an exterior surface of the second side wall and an interior surface of the display wall each including at least one print screen of the plurality of print screens.

16. A container in accordance with claim 15 wherein each of the first side wall and the second side wall includes a fastener cooperating with a corresponding tab formed in the second bottom panel for facilitating coupling the first side wall to the bottom.

17. A container in accordance with claim 16 wherein the tab defines a slot, a portion of the fastener positioned with the slot for facilitating coupling the first side wall and the second side wall to the bottom.

18. A container in accordance with claim 15 wherein each of the first side wall and the second side wall further comprises a projection extending from a top surface for facilitating maintaining the display wall in a display position.

19. A container in accordance with claim 15 wherein each of the first side wall and the second side wall forms a projection positioned within a corresponding slot defined within the second bottom panel for facilitating forming the first side wall and the second side wall.

20. A container in accordance with claim 15 wherein the display wall is movable with respect to the bottom between a first position generally parallel to the bottom and a second position generally perpendicular to the bottom.

21. A container in accordance with claim 15 further comprising an insert positioned within the compartment.

22. A container in accordance with claim 21 wherein the insert defines a plurality of receptacles for displaying a product.

23. A method for constructing a container, the method comprising:

providing a continuous blank of sheet material having a first surface and an opposing second surface, the blank comprising a front panel, a first side panel, an opposing second side panel, a rear panel, a first bottom panel coupled between the front panel and the rear panel, and a second bottom panel extending from the front panel, wherein at least one of the front panel, the first side panel, the second side panel and the rear panel comprising a print screen on the first surface thereof;

forming the container by folding the blank along a plurality of fold lines, the container having a front wall, a first side wall, an opposing second side wall, a bottom and a display wall defining a compartment, the front panel first surface forming an exterior surface of the front wall, the first side panel first surface forming an exterior surface of the first side wall, the second side panel first surface forming an exterior surface of the second side wall and the rear panel first surface forming an interior surface of the display wall; and

coupling each of the first side wall and the second side wall to the bottom.

24. A method in accordance with claim 23 wherein coupling each of the first side wall and the second side wall to the bottom further comprises coupling a fastener extending from each of the first side wall and the second side wall to a corresponding tab formed within the bottom.

25. A method in accordance with claim 23 further comprising coupling the display panel to each of the first side wall and the second side wall.

26. A method in accordance with claim 25 wherein coupling the display panel to each of the first side wall and the second side wall further comprises moving the display panel with respect to each of the first side wall and the second side wall such that a projection extends from a top surface of each of the first side wall and the second side wall interferes with the display panel for facilitating maintaining the display panel in a display position.

27. A method in accordance with claim 25 further comprising positioning an insert within the compartment.