PAPER BASED PRODUCT PACKAGING ASSEMBLY
A recyclable, paper based product packaging assembly is provided. The packaging assembly can be used to ship an entire endcap's worth of displayable products while reducing the amount of material used. The assembly comprises a pallet, corner posts, product trays and a shroud. The product trays can be lifted directly from the pallet onto store shelves for display.
1. Field of the Invention
This patent relates to a packaging assembly for shipping and displaying products. More particularly, this patent relates to a recyclable, paper based packaging assembly that can be moved with a lift truck, pallet jack or dolly and can carry enough product display trays to fill up a retail store end cap.
2. Description of the Related Art
Retail companies are initiating environmental sustainability programs to reduce the amount of non-recyclable packaging used in their stores. As part of these programs the retail companies are asking their product suppliers to reduce “storebound” materials and to use materials that are readily recyclable.
Current product displays are delivered to stores based on the idea of filling a single shelf with product. Retailers and suppliers are now considering having an entire endcap's worth of products shipped in a single container. This presents a problem for the packaging company because an entire endcap of product can weigh 155 pounds or more, which exceeds OSHA's allowable lifting weight. Consequently, the packaging assembly must be placed on a pallet and moved by lift truck or pallet jack. But placing a packaging assembly on a conventional wood or plastic pallet can create more waste material which is not recycled.
Thus it is an object of the present invention to provide a recyclable, paper based packaging assembly that can be used to ship an entire endcap's worth of displayable products while reducing the amount of material used.
Another object of the invention is to provide a paper based packaging assembly that includes an integral pallet so that the assembly can be moved by fork lift or other mechanical means.
Still another object of the invention is to provide a palletized packaging assembly that can be shipped in groups of four on a conventional 40″ by 48″ pallet.
Another object of the invention is to provide a packaging assembly that can be used to ship irregularly shaped products or soft packaged products yet can still be stacked one packaging assembly on another.
Further and additional objects will appear from the description, accompanying drawings, and appended claims.
SUMMARY OF THE INVENTIONThe present invention is a product packaging assembly for shipping product display trays to a retail location where the trays can be removed and placed on shelves for display. The product packaging assembly comprises a pallet member, at least one tray-like structure for holding product, a shroud surrounding the pallet member on four sides, and one or more load bearing structures.
The pallet member has a top, bottom and four sides, and comprises a load bearing panel and runners foldably connected to the load bearing panel and formed from the same piece of folded material as the load bearing panel. At least one of the runners embraces a support member. The runners include spaces formed therein for receiving opposing ends of lateral support members.
The vertical load bearing structures rest on the pallet member load bearing panel over the runners and are disposed between the tray-like structures and the shroud. The tray-like structures are supported by the pallet member and may comprise a tray and a sleeve that surrounds the product.
The pallet member, support members, tray-like structures, shroud and vertical load bearing structures may be made of paperboard.
In a more particular embodiment, the pallet member is a quarter pallet, the tray-like structures are product display trays, and the vertical load bearing structures are corner posts.
The quarter pallet is formed from a folded blank and comprises a load bearing panel and two longitudinal runners or legs foldably connected to the load bearing surface. The inner facing walls of each leg define two sets of opposed openings for receiving opposing ends of a set of lateral support posts. The longitudinal legs define channels for receiving leg support posts. The leg support posts are perpendicularly oriented to the lateral support posts and when installed are interposed between an upper surface of the lateral support posts and the underside of the load bearing panel.
Product carrying display trays are disposed on the pallet and form a part of the packaging assembly. The assembly may have one or more “layers” of product display trays. A shroud formed from a second folded blank is placed around the quarter pallet and product trays. Corner posts inserted between the shroud and the product trays completes the assembly.
The product packaging assembly is formed almost entirely from paper. The quarter pallet blank and the shroud preferably are formed from folded corrugated board. The lateral support posts, leg support posts and corner posts preferably are formed from convolutely wound paper. The quarter pallet, posts and shroud can be disposed of through normal paper recycling programs.
The shroud may be affixed to the quarter pallet with tape, although it is anticipated that the assembly can be made and used without tape or with a minimum of tape. The corner posts extend from top to bottom and bear any load that is placed on top of the product packaging assembly.
The product packaging assembly is easy to assemble and tear down. Assembly may be done by the product supplier. It is anticipated that four product packaging assemblies can be transported on a single conventional 40″ by 48″ pallet. At the supplier's site and at the retail site each packaging assembly can be moved via fork lift, dolly or other means and the product trays removed and placed on the retail shelves.
While this invention may be embodied in many forms, there is shown in the drawings and will herein be described in detail one or more embodiments with the understanding that this disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the illustrated embodiments.
Turning to the drawings, there is shown in
As shown in
More particularly, the quarter pallet blank 24 comprises a top or load bearing panel 48 defined by front and rear edges 50 and opposing fold lines 52. Additional parallel fold lines 54, 56, 58 help define the outer side panels 60, bottom panels 62 and inner side panels 64 of the pallet's two longitudinal legs 49. Fold lines 58 and outer edges 61 help define reinforcing panels 66, 68. When the quarter pallet blank 24 is folded into its final shape as shown in
As shown in
As shown in
Preferably, the corner posts 14, lateral support posts 22 and leg support posts 28 are hollow, convolutely wound paper tubes such as those manufactured and marketed by Sonoco Products Company of Hartsville, S.C. and described in U.S. Pat. Nos. 4,482,054; 5,593,039; 6,059,104 and 6,186,329, incorporated herein by reference. In the embodiment illustrated in the figures and as shown in
As best shown in
The bottom shroud 20 is made from a blank (not shown) and comprises front and rear panels 41 and two side panels. 43 and is configured to fit snugly over the quarter pallet 12 as shown in
Where, as in the embodiment illustrated in
Preferably the entire packaging assembly 10 is made from paper or paper based materials. The corner posts 14, support posts 22 and leg posts 28 preferably are made from wound paper formed into desired shapes as already noted. The pallet 12, bottom shroud 20 and top cap 18 may be made from folded corrugated.
The product packaging assembly 10 may be assembled in the following manner. The quarter pallet 12 is assembled by folding the quarter pallet blank 24 of
Next, the assembled bottom shroud 20 is placed over the quarter pallet 12 as shown in
As shown in
The first four product display trays 16 define a first “layer.” Additional “layers” of product display trays 16 may be placed on top of the first layer as shown in
As shown in
Four packaging assemblies 10 can fit on a single 40″ by 48″ conventional wood pallet 34 as shown in
In the illustrated embodiment the packaging assembly 10 consists of three layers of product trays, each layer consisting of four product display trays 16, each product display tray 16 holding 12 a dozen product containers 76. The entire illustrated product packaging assembly 10 holds forty-eight product containers 76 per layer, or one hundred forty-four total product containers 76.
Instead of a separate top cap 18 and bottom shroud 20 as shown in
Thus there has been described a packaging assembly made from recyclable paper materials that is strong enough to withstand stacking and simple enough to be assembled at the product vendor site. The packaging assembly has a built in pallet and so can be moved by forklift truck or dolly. The assembly can contain an entire endcap's worth of product display trays in a tight, secure, protected package.
Other modifications and alternative embodiments of the invention are contemplated which do not depart from the scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications that fall within their scope.
Claims
1. A product packaging assembly comprising:
- a pallet member having a top, bottom and four sides, the pallet member comprising a load bearing panel and runners connected to the load bearing panel and formed from the same piece of folded material as the load bearing panel, at least one runner embracing a support member, and the runners comprising spaces formed therein for receiving opposing ends of lateral support members.
2. The product packaging assembly of claim 1 further comprising:
- at least one tray-like structure for holding product, at least one the tray-like structure being supported by the pallet member.
3. The product packaging assembly of claim 2 further comprising:
- a shroud surrounding the pallet member on its four sides.
4. The product packaging assembly of claim 3 further comprising:
- one or more vertical load bearing structures resting on the load bearing panel over the runners and disposed between the at least one tray-like structure and the shroud.
5. The product packaging assembly of claim 4 wherein the pallet member, support members, at least one tray-like structure, shroud and vertical load bearing structures are made of paperboard.
6. A product packaging assembly comprising:
- a quarter pallet made from a first folded blank and having a load bearing panel formed from folded material and substantially parallel first and second legs disposed under the load bearing panel and being formed from the same folded material as the load bearing panel, each leg comprising an outer side panel folded downwardly from the load bearing panel, a bottom panel folded inwardly from the outer side panel, and an inner side panel folded upwardly from the bottom panel, said inner side panels having a plurality of opposed, aligned openings for receiving opposing ends of lateral support posts, said legs defining hollow, parallel channels for receiving leg support posts perpendicularly disposed with respect to the lateral support posts, said opposing ends of said leg support posts being interposed between the leg support posts and the load bearing panel.
7. The product packaging assembly of claim 6 further comprising:
- at least one set of product display trays disposed on the pallet, each set of product display trays defining a layer.
8. The product packaging assembly of claim 7 further comprising:
- a bottom shroud formed from a second folded blank and having front and rear panels and two side panels and having a rectilinear cylindrical shape for sliding over the quarter pallet.
9. The product packaging assembly of claim 8 further comprising:
- corner posts resting on and extending vertically upward from the load bearing panel and interposed between the shroud and the product display trays.
10. The product packaging assembly of claim 9 wherein the bottom shroud extends upward less than the full height of the packaging assembly, and wherein the packaging assembly further comprises a top cap disposed over the corner posts and product tray layers, the top cap having a bottom edge adjacent the top edge of the shroud, the top cap having flaps for enclosing the top of the packaging assembly.
11. The product packaging assembly of claim 9 wherein the bottom shroud extends the full height of the packaging assembly, and the bottom shroud further comprises flaps for enclosing the top of the packaging assembly.
12. The product packaging assembly of claim 9 wherein the bottom shroud front and rear panels each define an opening large enough to accommodate the forks of a fork lift truck.
13. The product packaging assembly of claim 9 wherein the first and second folded blanks are formed from corrugated board and the lateral support posts, leg support posts and corner posts are made of convolutely wound paper.
14. The product packaging assembly of claim 9 wherein the bottom shroud is affixed to the pallet with tape.
Type: Application
Filed: Jul 24, 2007
Publication Date: Jul 31, 2008
Inventors: Patrick Abel (Florence, KY), Mark Heuer (Florence, KY)
Application Number: 11/782,048
International Classification: B65D 88/00 (20060101); B65D 19/02 (20060101); B65D 19/00 (20060101);