LOAD RESISTANT PRODUCT DISPLAY CONTAINER FOR STORAGE, TRANSPORT, AND MERCHANDISING

Abstract

A product display container having a plurality of panels operatively connected to define an internal space operable to receive one or more packable product items therein and a plurality of corners in the internal space, and a plurality of reinforcement structures positioned in the internal space at the corners to provide resistance of the product display container to internal and/or external loads.

Description

This application claims priority to U.S. Provisional Application No. 63/392,739, which was filed on Jul. 27, 2022, and is herein incorporated by reference.

TECHNICAL FIELD

Embodiments relate to a strengthened-reinforced product display container for the storage, transport, and sale of merchandisable packable product items. More particularly, the display container uses one or more reinforcement members that facilitate the organization and protection of packable product items placed therein. The one or more reinforcement members also provide enhanced structural strength to the product display container, particularly when the product display container is exposed to internal and/or external loads.

BACKGROUND

Since ancient times, storage and display of goods has been of paramount concern for merchants.

Conventional times necessitate a need to produce packaging that not only stores saleable items (e.g., product items), but also facilitates its safe transport to a point-of-sale (POS) and its ultimate display and merchandising thereof. Packaging that suitably allows for storage, transport and the ready sale of merchantable goods is unique and must, in all three phases, solve problems specific to each phase. Moreover, automation in merchandising has become critical for effective commerce; in both product creation and product packaging. Without such automation, commerce would grind to a halt. Such automation also provides for speed of production, safety in mass production, production efficiencies, product consistency, high volume production, safe and reliable transport and much more.

Outer cases, such as cartons composed of cardboard, paperboard, or similar materials, are well known and used for transporting and storing various types of product items, including retail product items and the like.

Stackable or otherwise shelf-ready packaging is used to package a plurality of packable product items in outer cases for display. Such display may occur, for example, on a supermarket shelf or aisle, directly from the outer case without first having to remove the packable product items from the outer case. The individual packable product items contained within the packaging can be individual packets, cans, bottles, bags, boxes, and the like. Typically, the packaging has a removable element formed by a line of weakness (i.e., a plurality of perforations) in the outer-case, which can be easily or readily removed. Once the removable element is removed, the product items contained within the packaging are displayed to the consumer and facilitates removal of one or more displayed packable product items by the consumer.

Stackable, shelf-ready packaging avoids the time-consuming effort associated with removing packable product items from the outer case and placing the product items onto shelves. Store owners are constantly seeking to identify additional ways to reduce costs for stacking packable product items, while ensuring that the article remains presentable to consumers. Such packaging is typically placed adjacent to other like packaging, e.g., on a shelf, a pallet, or the floor, and the removable element removed in order to display the packable product items contained therein.

Since the packable product items will be displayed in the display package, the outer surfaces thereof are often decorated with images and wording that is relevant for the product packable product items contained therein. The outer surfaces of the display package are often decorated such that the overall impression from a stack or row of the shelf ready packages is improved.

Stacked packages in transport or in storage are subject to jostling that is either mild or intense, depending upon the forces or loads applied thereto and/or within such packages in either singular or stacked configuration (i.e., a stacked structure) of more than one package. Often, packages contain rigid items like plastic or glass bottles that are weighty due to the substances that they contain or because of the makeup of the rigid items themselves. Such weight can cause internal stress and even failure to the packages carrying them given the motion of items housed within the packages. Such display packages may also contain frangible food items easily broken by outside forces applied thereto during storage or transport.

When rigid packable product items within display packages are jostled, internal damage to the packages or the packable product items themselves can occur. Particularly, when such packages contain lines of weakness, the lines of weakness can be prematurely broken due to applied loads, thereby causing the contents of a package to fall out, potentially causing full package failure and damage to the packable product items within. If such packages fail while in a transportable, stacked configuration, an entire transportable unit can be compromised, thereby destroying more packages and damaging product contained therein. In a worst-case scenario, full transport failure could occur due to package failure.

FIG. 1 illustrates a related art stacked configuration 90 of product display containers in either storage or for transport. Because each respective product display container is not reinforced against exposure to internal and/or external loads during display and/or transport, they are subject to collapse due to a lack of structural integrity, particularly when each product display container is filled with packable product items.

SUMMARY

What is required, therefore, is a product display container having a structure that is operable to be stored, transported, and displayed in a stacked configuration in manner that the product packaging: a) protects the one or more packable product items stored therein, b) is highly self-protective especially within a stack for storage and/or transport, and c) resists deformation of all such packages when stacked on a shelf or on the floor of a POS in an endcap display configuration. One or more embodiments described and/or illustrated herein provide technical solutions to pre-existing problems identified hereinabove.

In accordance with one or more embodiments, provided herein are one or more one or more example fully automated strengthened-reinforced product display containers. Such product display containers are operable for use and display at a POS by consumers within the POS.

One on example embodiment, a product display container comprises one or more of the following: a top panel; a bottom panel spatially opposed to the top panel; a front panel operatively connected to the top panel and to the bottom panel; and a back panel spatially opposed to the front panel and operatively connected to the top panel and the bottom panel.

The example product display container also comprises a right panel operatively connected to the top panel and the bottom panel; a left panel, spatially opposed to the right panel, that is operatively connected to the top panel and to the bottom panel; a first corner formed between the left panel and the front panel; a second corner formed between the front panel and the right panel; a third corner formed between the back panel and the right panel; and a fourth corner formed between the back panel and the left panel.

The example product display container also comprises a first reinforcement structure or bumper member that is spatially positioned at the first corner and extends from the bottom panel to the top panel. The first reinforcement structure has a suitably high rigidity that enhances the resistance of the product display container to internal and/or external loads. A second reinforcement structure or second bumper member is positioned at the second corner of the product display container and extends from the bottom panel to the top panel. The second reinforcement structure has a suitably high rigidity that enhances the resistance of the product display container to internal and/or external loads.

Structurally, the first reinforcement structure is spatially positioned adjacent to the top panel, the bottom panel, the left panel, and the front panel. The first reinforcement structure, in accordance with one or more embodiments, is attached to the left panel and front panel while extending to engage both the top panel and the bottom panel. In that way, the first reinforcement structure provides reinforced strengthening to that region of the product display container.

Similarly, the second reinforcement structure is spatially positioned adjacent to the top panel, the bottom panel, the right panel, and the front panel. The second reinforcement structure, in accordance with one or more embodiments, is attached to the right panel and the front panel while extending to engage both the top panel and the bottom panel. In that way, the second reinforcement structure provides reinforced strengthening to that region of the product display container. Such reinforced strengthening by the first reinforcement structure and the second reinforcement structure serve to aid in the load resistance of the product display container when exposed to internal and/or external loads.

Placement of the first reinforcement structure and the second reinforcement structure within the product display container also creates zones of strengthening (ZOS) for the entire structure, and particularly, at the top panel. Such ZOS also strengthen and/or reinforce perforations provided in the corners formed by the panels of the product display container. The ZOS, by reinforcing the perforations, limits or reduces premature failure of the perforations, e.g., by premature disjoining, especially during times of stacked storage or transport. As used herein, the term “premature disjoining” means an unintentional tearing apart (e.g., due to applied internal and/or external loads on the product display container) of perforations on the product display container.

The product display container is configured to receive and store one or more items for transport and sale. For example, when fully constructed, the product display container defines a space having a volumetric capacity to receive one or more packable product items. An automated device or machine is operable to partially or fully fill the volumetric capacity of the product display container by with the packable product items. Once placed within the product display container, the packable product items are arranged in a stacked configuration that maximizes use of the space while also strengthening each individual packable item in a stacked set.

Because of the overall structural configuration of the product display container, and particularly, the first reinforcement structure and the second reinforcement structure, a plurality of product display containers may be arranged in a stacked configuration.

The top panel of the product display container is at least partially removable, which is important for display of the packable product items in the product display container. Though the top panel of the product display container is at least partially removable, and in another example embodiment, fully removable, a plurality of product display containers may still be arranged in a stacked configuration for merchandising at a POS. This also facilitates consumer accessibility to the packable product items and maximally accessible stacked display structures to be formed in a POS.

In accordance with one or more embodiments, the first reinforcement structure and the second reinforcement structure facilitate enhanced load resistance of the product display container. Meaning, use of the first reinforcement structure and the second reinforcement structure in the product display container facilitate resistance to structural deformation, especially when exposed to internal and/or external loads. The first reinforcement structure and the second reinforcement structure prevent at least 10% structural deformation of the total surface area of the product display container when exposed to internal and/or external loads.

In accordance with one or more embodiments, in a stacked configuration, each product display container in the stack provides no more than 5% structural deformation of the total surface area of the product display container when exposed to internal and/or external loads.

In accordance with one or more embodiments, the product display container comprises a third reinforcement structure or third bumper member positioned at the third corner of the product display container. Like the first reinforcement structure and the second reinforcement structure herein, the third reinforcement structure extends from the bottom panel to the top panel. The product display container may also comprise a fourth reinforcement structure or fourth bumper member that is positioned at the fourth corner and extends from the bottom panel to the top panel.

Similarly to the first reinforcement structure and the second reinforcement structure, the third reinforcement structure and the fourth reinforcement structure respectively facilitate a ZOS for the entire structure, and particularly, the top panel. Such zones of strengthening also strengthen and/or reinforce perforations resident on the top panel of the product display container. The ZOS, by reinforcing the perforations, makes their unintended failure, e.g., by premature disjoining, les likely especially during times of stacked storage or transport.

Similarly to the first reinforcement structure and the second reinforcement structure, the third reinforcement structure and the fourth reinforcement structure respectively facilitate enhanced resistance of the product display container to internal and/or external loads. The third reinforcement structure and the fourth reinforcement structure prevent at least 5% structural deformation of the total surface area of the product display container when exposed to internal and/or external loads. In a stacked configuration, each product display container in the stack provides no more than 2.5% structural deformation of the total surface area of the product display container when exposed to internal and/or external loads.

The product display container described and/or illustrated herein is a feature in a fully automated process for packing one or more product display containers with product, the entirety of the process itself being fully automated.

In accordance with one or more embodiments, a process of forming and packing a product display container with product from a single blank. The product display container has the same structural configuration disclosed herein, including a top panel; a bottom panel spatially opposed to the top panel; a front panel operatively connected to the top panel and to the bottom panel; and a back panel spatially opposed to the front panel and operatively connected to the top panel and the bottom panel

Once constructed, the product display container is then automatically filled with one or more packable product items from an automated device that holds and then places a product item into the product display container at a predetermined process block or step. After execution of a filling sequence of the one or more packable product items, the product display container is then automatically enclosed, moved, and stored for later transport and merchantability at a POS.

BRIEF DESCRIPTION OF DRAWINGS

The various advantages of the one or more embodiments will become apparent to one skilled in the art by reading the following specification and appended claims, and by referencing the following drawings, in which:

FIG. 1 illustrates a stacked configuration of product display containers in the related art;

FIG. 2 illustrates a stacked configuration of product display containers in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIG. 3 illustrates a perspective view of a product display container that includes a first reinforcement structure and a second reinforcement structure, in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIG. 4 illustrates a perspective view of a product display container that includes a first reinforcement structure, a second reinforcement structure, a third reinforcement structure, and a fourth reinforcement structure, in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIG. 5 illustrates a perspective view of a product display container that includes a removeable portion, in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIG. 6 illustrates a perspective view of a stacked configuration of product display containers at a POS, in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIG. 7 illustrates a planar view of a stacked configuration of product display containers on a pallet for transport, in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIGS. 8 through 10 respectively illustrate a method of manufacturing a product display container, in accordance with one or more embodiments set forth, described, and/or illustrated herein;

FIGS. 11A and 11B respectively illustrate a partial view of a unitary blank of a product display container having a reinforced minor flap and a product display container having a reinforced minor flap with a bumper.

DESCRIPTION

The following disclosure is presented to provide an illustration of the general principles of one or more embodiments and is not intended to limit, in any way, the concepts contained herein. Moreover, the particular technical features described herein can be used in combination with the other described technical features in each of the one or more embodiments disclosed herein.

All terms defined herein should be afforded their broadest possible interpretation, including any implied meanings as dictated by a reading of the specification as well as any words that a person having skill in the art and/or a dictionary, treatise, or similar authority would assign particular meaning. Further, it should be noted that, as recited in the specification and in the claims appended hereto, the singular forms “a,” “an,” and “the” include the plural referents unless otherwise stated. Additionally, when used herein, the terms “comprise,” “comprises,” and “comprising” specify that certain technical features are present in that embodiment, but should not be interpreted to preclude the presence or addition of additional technical features, components, operations, and/or groups thereof.

The following disclosure is intended to be read in connection with the accompanying drawings which are to be considered part of the entire written description of the disclosure. The drawing figures are not necessarily to scale, and certain technical features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.

As used herein, terms such as “horizontal,” “vertical,” “up,” “down,” “top,” “bottom,” and derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or illustrated herein. These terms are for convenience of description and normally are not intended to require a particular orientation.

As used herein, terms such as “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship in which structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable or rigid attachments or relationships, unless expressly described otherwise, and includes terms such as “directly” coupled, secured, etc. The term “operatively coupled” is such an attachment, coupling, or connection that allows the pertinent structures to operate as intended by virtue of that relationship.

As used herein, the term “fully automated product display container” is a display container which is: a) constructed by one or more automated processes and/or systems, and b) automatically loaded with one or more packable product items for storage, transport, and sale the product display container by one or more automated processes and/or systems.

As used herein, terms such as “fail” or “product display container fail” or “fail of product display container” is a condition in which two or more product display container in a stacked configuration exhibit structural failure from internal and/or external loads while in storage, transport, or at a POS.

As used herein, the terms “adhered” or “affixed” (and other formatives of these terms) means that one surface is attached to another using an adhesive, such as glue, tape, cement, or paste. The adhesive may be placed on either one or both of the surfaces being adhered. Adhesive materials are represented in the drawings as an “X” or striped tape.

As used herein, the term “blank” means a planar piece of material that has been cut into a shape that is then used to create a container.

As used herein, a “unitary blank” means a blank that comprises a single sheet of material, for example, corrugated fiberboard, at the start of an assembly process. In the case of a multi-layer container (such as those disclosed herein), all of the layers are included in the unitary blank and none of the layers that form part of the finished container are separated from each other before being positioned and affixed to each other.

As used herein, the terms “cut” and “cut line” each mean a continuous incision in the material which penetrates the entire thickness of the material.

As used herein, the term “perforation” means an alternating pattern of cuts and connected portions in the material. Perforations are characterized by alternating connected and cut portions which are much more proportional in size (typically a width difference of no more than two to three times between connected portions and cut portions).

As used herein, the term “nick” means a portion of material, such as, for example, between 1/32 and ⅛ inch in width, which connects two adjacent portions of a material and is located along a line along which the two pieces of material are cut apart. A “nick” is distinguished from a perforation in that each nick is located along a line or curve in which the materials are separated by cut portions on either side of the nick and the cut portions are for example, at least five times or at least ten times the width of each nick. A nick can be formed by grinding away a small portion of the cutting die knife rule.

As used herein, the terms “score” and “score line” mean a crease or shallow cut that does not fully penetrate the entire thickness of the material which serves to make folding the material easier along the score line than along an unscored line. The score acts as a joint in the material, along which portions of the material may be more easily folded.

As used herein, the term “separation line” means a line or curve formed of any combination of cut, nicked, and perforated portions that defines a border between two adjacent, connected elements. The weakened connection provided by the separation line enables the elements adjacent to the separation line to be more easily and predictably separated along the separation line than if the separation line were not present.

As used herein, the term “corrugated” means a material comprising primary of a fluted corrugated sheet and at least one flat linerboard.

As used herein, the term “zone of strengthening” or “zones of strengthening” means areas on the product display container, particularly, the top panel (or any load bearing surface thereof) that are strengthened due to the use of the reinforcement bumper members discussed and disclosed herein.

As used herein, the term “stacked storage” is meant as a stacked array of product display containers positioned thusly for storage.

In accordance with one or more embodiments, a fully automated packed product display container (i.e., “product display container”) is provided for use and display at a POS. The product display container is particularly suited for the storage, transport, and display of prepacked food items, and especially confectionary food items that are often brittle though solid or semi-solid (e.g., a chocolate bar, hardened candy, and the like).

The product display container in accordance with one or more embodiments comprises a top panel; a bottom panel spatially opposed to the top panel; a front panel operatively connected to the top panel and to the bottom panel; and a back panel spatially opposed to the front panel and operatively connected to the top panel and the bottom panel.

At construction of the product display container, the back panel is connected to the top panel and the bottom panel. A right panel is connected to the top panel and the bottom panel. A left panel is positioned oppositely to the right panel. The left panel is connected to the top panel and the bottom panel. A first corner is formed between the front panel and the left panel. A second corner is formed between the front panel and the right panel. A third corner is formed between the back panel and the right panel. A fourth corner is formed between the back panel and the left panel.

The constructed product display container also provides a first reinforcement structure that is positioned at the first corner thereof and extends from the bottom panel to the top panel. The first reinforcement structure has a suitably high rigidity that provides the product display container with resistance to internal and/or external loads. Structurally, the first reinforcement structure is positioned adjacent to the top panel, the bottom panel, the left panel, and the front panel. The first reinforcement structure is attached to the left panel and front panel while extending to engage both the top panel and the bottom panel. Thus, the first reinforcement structure provides reinforced strengthening to that region of the product display container.

A second reinforcement structure is positioned at the second corner of the product display container and extends from the bottom panel to the top panel. The second reinforcement structure has a suitably high rigidity that also provides the product display container with resistance to internal and/or external loads. The second reinforcement structure is positioned adjacent to the top panel, the bottom panel, the right panel, and the front panel. The second reinforcement structure is attached to the right panel and the front panel while extending to engage both the top panel and the bottom panel. Thus, the second reinforcement structure provides reinforced strengthening to that region of the product display container. Such reinforced strengthening by the first reinforcement structure and the second reinforcement structures serve provides enhanced resistance to internal and/or external loads, especially when the product display container is in a stacked configuration with other product display containers.

The product display container in accordance with one or more embodiments is operable to receive and packable product items for transport and sale. For example, the product display container defines an internal space having a volumetric capacity for receipt of packable product items. The packable product items are fully or partially filled in the internal space of the product display container by an automated device or machine. Once placed within the product display container, the packable product items are placed in a stacked configuration that maximizes use of the space and strengthens each individual packable item in a stacked set.

Due to the overall structural configuration of the product display container, and particularly, the one or more reinforcement structures therein, the product display container is stackable with other like product display containers.

In accordance with one or more embodiments, the top panel of the product display container is at least partially removable. Such removability of the top panel is important for display of the packable product items housed within it. Although the top panel of the product display container is at least partially removable, and in another embodiment, fully removable, the product display containers are still stackable with one another for merchandising at a POS. Such stackability of at least partially opened product display containers enables accessibility of consumers to stacked packable product items therein and for maximally accessible stacked display structures to be formed in a POS.

In accordance with one or more embodiments, the top panel and a portion of the front panel comprise a continuous perforated line having a rectangular shape or a square shape when the top panel and the front panel are flattened and held adjacent to one another. The perforations provide a continuous link of weakness by which a portion of the front panel and a portion of the top panel may be excised from the product display container, thereby revealing or otherwise exposing its contents of packable product items and facilitating the sale thereof at a POS.

In accordance with one or more embodiments, the first reinforcement structure and the second reinforcement structure provide enhanced load resistance to the product display container. Meaning, incorporation of the first reinforcement structure and the second reinforcement structure in the product display container provides resistance to structural deformation, especially when placed under internal and/or external loads, and does so by preventing at least 10% structural deformation of the total surface area of the product display container when under internal and/or external loads. Preferably, each product display container provides no more than 5% structural deformation of the total surface area thereof when under internal and/or external loads, particularly when arranged in a stacked configuration with at least one other such product display container.

In accordance with one or more embodiments, the product display container may comprise a plurality of reinforcement structures that include a first reinforcement structure, a second reinforcement structure, a third reinforcement structure, and a fourth reinforcement structure. The third reinforcement structure is positioned at the third corner of the product display container, and like the first reinforcement structure and the second reinforcement structure, extends from the bottom panel to the top panel. The fourth reinforcement structure is positioned at the fourth corner, and extends from the bottom panel to the top panel.

Accordingly, the first reinforcement structure, second reinforcement structure, third reinforcement structure, and fourth reinforcement structure individually and collectively provide the product display container with enhanced resistance to internal and/or external loads. For instance, incorporation of the third reinforcement structure and the fourth reinforcement structure serves to prevent at least 5% structural deformation of the product display container when exposed to internal and/or external loads. Preferably, each product display container provides no more than 2.5% structural deformation thereof when exposed to internal and/or external loads, particularly when arranged in a stacked configuration with at least one other such product display container.

The product display container is a key feature of a fully automated process for packing a product display container with product, the entirety of the process itself being fully automated.

The product display container described and/or illustrated herein is a feature in a fully automated process for packing one or more product display containers with product, the entirety of the process itself being fully automated.

In accordance with one or more embodiments, a process of forming and packing a product display container with product from a single blank. The product display container has the same structural configuration disclosed herein, including a top panel; a bottom panel spatially opposed to the top panel; a front panel operatively connected to the top panel and to the bottom panel; and a back panel spatially opposed to the front panel and operatively connected to the top panel and the bottom panel

Once constructed, the product display container is then automatically filled with one or more packable product items from an automated device that holds and then places a product item into the product display container at a predetermined process block or step. After execution of a filling sequence of the one or more packable product items, the product display container is then automatically enclosed, moved, and stored for later transport and merchantability at a POS.

FIG. 2 illustrates a planar view of a product display container 10 in a stacked configuration 100 with other product display containers 10. The product display containers are constructed to resist deformation when exposed to internal and/or external loads (e.g., loads from other like product display containers 10 in the stack). The stacked configuration 100 of product display containers 10 are operable to sit upon a pallet for transport and storage, and can be expected to remain substantially undeformed when in transport, storage, and display at a POS.

FIG. 3 illustrates a perspective view of the product display container 10 having a first reinforcement structure 50 and a second reinforcement structure 55 that are operable to protect packable product items stored within the product display container 10 and the overall structural integrity of the product display container 10. The first reinforcement structure 50 and the second reinforcement structure 55 are positioned in corners of the internal space defined by the outer structural members of the product display container 10. More specifically, the first reinforcement structure 50 is adjacent to first corner 40 and the second reinforcement structure 55 is adjacent to second corner 42. The overall resistance by the package display container 10 to internal and/or external loads is enhanced by arrangement of the first reinforcement structure 50 and the second reinforcement structure 55. The first reinforcement structure 50 and the second reinforcement structure 55 are positioned within the internal space of the product display container 10 such that they each extend from the bottom panel 20 to the top panel 15. The first reinforcement structure 50 and the second reinforcement structure 55, respectively, do not just extend from the bottom panel 20 to the top panel 15, but also provide direct structural support to every other region of the product display container 10 that is engaged by the first reinforcement structure 50 and the second reinforcement structure 55.

FIG. 4 provides a perspective view of the product display container 10 of FIG. 3, but includes two additional reinforcement structures, namely, a third reinforcement structure 70 and a fourth reinforcement structure 75. The first reinforcement structure 50, the second reinforcement structure 55, the third reinforcement structure 70, and the fourth reinforcement structure 75 are respectively positioned in corners of the internal space defined by the outer structural members of the product display container 10. More specifically, the first reinforcement structure 50 is adjacent to first corner 40, the second reinforcement structure 55 is adjacent to second corner 42, the third reinforcement structure 70 is adjacent to third corner 44, and the fourth reinforcement structure 75 is adjacent to fourth corner 46. The overall resistance by the package display container 10 to internal and/or external loads is enhanced by arrangement of the first reinforcement structure 50, the second reinforcement structure 55, the third reinforcement structure 70, and the fourth reinforcement structure 75. The first reinforcement structure 50, the second reinforcement structure 55, the third reinforcement structure 70, and the fourth reinforcement structure 75 are positioned within the internal space of the product display container 10 such that they each extend from the bottom panel 20 to the top panel 15. The first reinforcement structure 50, the second reinforcement structure 55, the third reinforcement structure 70, and the fourth reinforcement structure 75, respectively, do not just extend from the bottom panel 20 to the top panel 15, but also provide direct structural support to every other region of the product display container 10 that is engaged by the first reinforcement structure 50, the second reinforcement structure 55, the third reinforcement structure 70, and the fourth reinforcement structure 75.

FIG. 5 illustrates the product display container 10 of FIG. 1, but with a removable panel 60 applied thereto. The removable panel 60 is attached to the product display container 10, but can be manually manipulated by a user to be torn therefrom along a perforated edge 62. The perforated edge 62 is applied to the product display container 10 when it is first formed from one unitary blank. As is standard manufacturing practice, the perforated edge 62 is applied by an automated machine.

In accordance with one or more embodiments, the removable panel 60 is removed at the POS of the packable product items stored within the product display container 10. Importantly, a plurality of product display containers 10 may be delivered to a POS in a stacked configuration. Once delivered and positioned within a desirable locale of a POS, the removable panel 60 can be removed by a user from each product display container 10 in the stack, thereby displaying the packable product items provided within each product display container 10.

Display of a plurality of product display containers 10 that are in an opened state by removal of the removable panel 60 is possible because of the structural configuration of the product display container 10. Without a structural configuration that includes one or more reinforcement structures 50, 55, 70, 75, the product display containers 10 would be expected to fail due to exposure to internal and/or external loads. The strategic placement and location of one or more reinforcement structures 50, 55, 70, within the internal space of each product display container 10 provides structural integrity which prevents structural deformation or collapse of the product display containers 10 due to exposure to internal and/or external loads. For example, such external loads include, but are not limited to, forces common to handling, stacking, and storing each product display container 10 in a stacked or an un-stacked configuration, transporting each product display container 10 in a stacked or an un-stacked configuration, displaying stacked arrangement of the product display containers 10 at a POS in a stacked configuration or un-stacked configuration, on a store shelf, and the like. Such external loads are ones common to the handling, storage, transport, and display of product display container 10 herein, however, this disclosure also contemplates uncommon forces due to accident, vandalism, theft, reckless transport, and/or storage.

FIG. 6 illustrates a perspective view of a stacked configuration 200 of a plurality of product display containers 10 at a POS display. At the POS display, the stacked configuration 200 of product display containers 10 are in an opened state. Note that the POS display can provide for product display containers 10 therein to be opened while still conferring the benefits of load resistance to each product display container 10 in the stack. Because each product display container 10 in the POS display 200 is in an opened state, consumers may retrieve undamaged packable product items from any product display container 10 in the stack due to the one or more reinforcement structures 55, 70, 75 that provide structural integrity which prevents structural deformation or collapse of the product display containers 10 due to exposure to internal and/or external loads.

FIG. 7 illustrates a planar view of the stacked configuration 200 of a plurality of product display containers 10 positioned on a pallet 250. This provides one example for the stacking, storage, transport, and possible display of product display containers 10.

In the illustrated examples of FIGS. 8, 9, and 10, a flowchart of methods 800, 900, and 1000 of manufacturing a product display container is provided. In one or more examples, the flowchart of the method methods 800, 900, and 1000 may be implemented manually and/or by one or more processors of a control module that comprises a computing device. In particular, the methods 800, 900, and 1000 may be implemented as one or more modules in a set of logic instructions stored in a non-transitory machine- or computer-readable storage medium such as random access memory (RAM), read only memory (ROM), programmable ROM (PROM), firmware, flash memory, etc., in configurable logic such as, for example, programmable logic arrays (PLAs), field programmable gate arrays (FPGAs), complex programmable logic devices (CPLDs), in fixed-functionality hardware logic using circuit technology such as, for example, application specific integrated circuit (ASIC), complementary metal oxide semiconductor (CMOS) or transistor-transistor logic (TTL) technology, or any combination thereof.

In one or more examples, software executed by the control module provides functionality described or illustrated herein. In particular, software executed by the one or more processors of the control module is configured to perform one or more processing blocks of the methods 800, 900, and 1000 set forth, described, and/or illustrated herein, or provides functionality set forth, described, and/or illustrated herein. In one or more example embodiments of the methods 800, 900, and 1000, the control module is to cause a robotic device to perform one or more process blocks in an automated manner. Such a robotic device may comprise one or more robotic arms that performs the one or more process blocks.

In the illustrated example embodiment of FIG. 8, illustrated process block 802 includes forming, from a single blank of material, a plurality of panels operatively connected to define an internal space operable to receive one or more packable product items therein and a plurality of corners in the internal space.

The method 800 may then proceed to illustrated process block 804, which includes positioning a plurality of reinforcement structures in the internal space at the corners to provide resistance of the product display container to internal and/or external loads.

In accordance with illustrated process block 804, positioning the plurality of reinforcement structures comprises positioning one or more of: a first reinforcement structure in the internal space at a first corner formed by the plurality of panels; a second reinforcement structure in the internal space at a second corner formed by the plurality of panels; a third reinforcement structure in the internal space at a third corner formed by the plurality of panels; and a fourth reinforcement structure in the internal space at a fourth corner formed by the plurality of panels.

The method 800 can terminate or end after completion of illustrated process block 804.

In the illustrated example embodiment of FIG. 9, illustrated process block 902 includes forming, from a single blank of material, a plurality of panels operatively connected to define an internal space operable to receive one or more packable product items therein and a plurality of corners in the internal space.

The method 900 may then proceed to illustrated process block 904, which includes positioning a plurality of reinforcement structures in the internal space at the corners to provide resistance of the product display container to internal and/or external loads.

In accordance with illustrated process block 904, positioning the plurality of reinforcement structures comprises positioning one or more of: a first reinforcement structure in the internal space at a first corner formed by the plurality of panels; a second reinforcement structure in the internal space at a second corner formed by the plurality of panels; a third reinforcement structure in the internal space at a third corner formed by the plurality of panels; and a fourth reinforcement structure in the internal space at a fourth corner formed by the plurality of panels.

The method 900 may then proceed to illustrated process block 906, which includes at least partially filling the internal space with packable product items.

The method 900 can terminate or end after completion of illustrated process block 906.

In the illustrated example embodiment of FIG. 10, illustrated process block 1002 includes forming, from a single blank of material, a plurality of panels operatively connected to define an internal space operable to receive one or more packable product items therein and a plurality of corners in the internal space.

The method 1000 may then proceed to illustrated process block 1004, which includes positioning a plurality of reinforcement structures in the internal space at the corners to provide resistance of the product display container to internal and/or external loads.

In accordance with illustrated process block 1004, positioning the plurality of reinforcement structures comprises positioning one or more of: a first reinforcement structure in the internal space at a first corner formed by the plurality of panels; a second reinforcement structure in the internal space at a second corner formed by the plurality of panels; a third reinforcement structure in the internal space at a third corner formed by the plurality of panels; and a fourth reinforcement structure in the internal space at a fourth corner formed by the plurality of panels.

The method 1000 may then proceed to illustrated process block 1006, which includes forming a removable panel at a top panel and a front panel of the plurality of panels, the removable panel being moveable from an unopened state to an opened state which exposes the internal space and facilitates removal of one or more packable product items by a user.

In accordance with illustrated process block 1006, forming the removable panel comprises forming a plurality of perforations in the top panel and the front panel that define a continuous link of weakness by which a portion of the front panel and a portion of the top panel may be excised from the product display container.

The method 1000 can terminate or end after completion of illustrated process block 1006.

As illustrated in FIGS. 11A and 11B, a partial view of a unitary material blank 200 of a product display container having a reinforced minor flap and a unitary material blank 300 of a product display container having one or more reinforced minor flaps with a reinforcement structure or bumper. One or more minor flaps may be formed that are either normal, reinforced (FIG. 11A), or reinforced with a reinforcement structure or bumper (FIG. 11B), or a combination thereof.

For example, using a unitary material blank in accordance with one or more embodiments, a product display container may be formed having one or more of a top/upper reinforcement structure or bumper (via the minor flap) and/or a bottom/lower minor flap. Moreover, the bottom/lower minor flaps may be folded, scored, and connected (e.g., via an adhesive) to form a double-wall minor flap. The unitary material blank may be, either manually and/or via machine, formed into a product display container by manipulating (e.g., folding) the unitary blank fold and using an adhesive to form the unitary material blank into a final configuration. When folding and using an adhesive to connect the minor flaps, bumpers may be selectively formed in a plurality of different structural configurations, such as, for example, on both the top and bottom of the product display container, or on the bottom only, or on the top only. The unitary material blank may be reversed (opposite direction than normal), which facilitates packing the product display container from the top (using existing equipment) and then manipulating the product display container on a side thereof to get the compression strength and window presentation to the customer.

Meaning, knock down flats (KDF's) are provided with the extended minor flaps adhered in place. The corrugated flute direction is ‘reversed’ (horizontal vs vertical highlighted in yellow). When run on standard RSC erecting equipment, the minor flap folds, creating the bumper (horizontally across the width panel and top or bottom panel). This configuration can be done on any combination of one or all the minor flaps. The container may then be packed through the top thereof. The container is then sealed upon filling (e.g., via an adhesive), and then rotated 90 degrees (from the length and bottom panel) onto the length and height panel. This causes the horizontally-oriented reinforcement structures/bumpers to now be oriented in a vertical direction (e.g., length and height panel on the pallet). The case is palletized and shipped with the reinforcement structures/bumpers oriented in the vertical direction. At retail, the shoppable window may be manually removed, thereby exposing (at least partially) the merchandise inside the container as either a display ready case (DRC) or in a modular display (Mod), with the reinforcement structures/bumpers remaining oriented in the vertical orientation.

The terms “coupled,” “attached,” or “connected” may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical, or other connections. Additionally, the terms “first,” “second,” etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless otherwise indicated. The terms “cause” or “causing” means to make, force, compel, direct, command, instruct, and/or enable an event or action to occur or at least be in a state where such event or action may occur, either in a direct or indirect manner.

Those skilled in the art will appreciate from the foregoing description that the broad techniques of the embodiments may be implemented in a variety of forms. Therefore, while the embodiments have been described in connection with particular examples thereof, the true scope of the embodiments should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

Claims

1. A product display container, comprising:

a single, unitary blank of material that includes: a plurality of panels operatively connected to define an internal space to receive one or more packable product items therein, the panels including a top panel, a bottom panel spatially opposed to the top pane, a front panel operatively connected to the top panel and to the bottom panel, a back panel spatially opposed to the front panel and operatively connected to the top panel and the bottom panel, a left panel operatively connected to the top panel and the bottom panel, and a right panel that is spatially opposed to the left panel and operatively connected to the top panel and the bottom panel; a plurality of corners formed in the internal space, including a first corner defined by the connection of the top panel, the bottom panel, the front panel, and the left panel, a second corner defined by the connection of the top panel, the bottom panel, the front panel, and the right panel, a third corner defined by the connection of the top panel, the bottom panel, the back panel, and the left panel, and a fourth corner defined by the connection of the top panel, the bottom panel, the back panel, and the right panel; a first reinforcement structure positioned in the internal space at the first corner to facilitate resistance to internal and/or external loads; and a second reinforcement structure positioned in the internal space at the second corner to provide resistance of the product display container to internal and/or external loads.

2. The product display container of claim 1, wherein the single, unitary blank of material further comprises a removable panel formed at the top panel and the front panel, the removable panel being moveable from an unopened state to an opened state which exposes the internal space and facilitates removal of one or more packable product items by a user.

3. The product display container of claim 2, wherein the removable panel is formed by a plurality of perforations in the top panel and the front panel that define a continuous link of weakness by which a portion of the front panel and a portion of the top panel may be excised from the product display container.

4. The product display container of claim 3, wherein the plurality of perforations form a perforated edge in the front panel that is manipulable by a user to place the removable panel in the opened state.

5. The product display container of claim 1, wherein:

the first reinforcement structure creates a first zone of strengthening at the first corner which facilitates the resistance to internal and/or external loads; and

the second reinforcement structure creates a second zone of strengthening at the second corner which facilitates the resistance to internal and/or external loads.

6. The product display container of claim 1, further comprising:

a third reinforcement structure positioned in the internal space at the third corner formed by the plurality of panels; and

a fourth reinforcement structure positioned in the internal space at the fourth corner formed by the plurality of panels.

7. The product display container of claim 6, wherein:

the third reinforcement structure creates a third zone of strengthening at the third corner which facilitates the resistance to internal and/or external loads; and

the fourth reinforcement structure creates a fourth zone of strengthening at the second corner which facilitates the resistance to internal and/or external loads.

8. A product display container, comprising:

a single, unitary blank of material that includes: a plurality of panels operatively connected to define an internal space operable to receive one or more packable product items therein and a plurality of corners in the internal space; and a plurality of reinforcement structures positioned in the internal space at the corners to provide resistance of the product display container to internal and/or external loads.

9. The product display container of claim 8, wherein the plurality of reinforcement structures comprises:

a first reinforcement structure positioned in the internal space at a first corner formed by the plurality of panels;

a second reinforcement structure positioned in the internal space at a second corner formed by the plurality of panels;

a third reinforcement structure positioned in the internal space at a third corner formed by the plurality of panels; and

a fourth reinforcement structure positioned in the internal space at a fourth corner formed by the plurality of panels.

10. The product display container of claim 8, wherein the single, unitary blank of material further comprises a removable panel formed at a top panel and a front panel of the plurality of panels, the removable panel being moveable from an unopened state to an opened state which exposes the internal space and facilitates removal of one or more packable product items by a user.

11. The product display container of claim 10, wherein the removable panel is formed by a plurality of perforations in the top panel and the front panel that define a continuous link of weakness by which a portion of the front panel and a portion of the top panel may be excised from the product display container.

12. The product display container of claim 11, wherein the plurality of perforations form a perforated edge in the front panel that is manipulable by a user to place the removable panel in the opened state.

13. The product display container of claim 9, wherein:

the first reinforcement structure creates a first zone of strengthening at the first corner which facilitates the resistance to internal and/or external loads; and

the second reinforcement structure creates a second zone of strengthening at the second corner which facilitates the resistance to internal and/or external loads.

14. The product display container of claim 13, wherein:

the third reinforcement structure creates a third zone of strengthening at the third corner which facilitates the resistance to internal and/or external loads; and

the fourth reinforcement structure creates a fourth zone of strengthening at the second corner which facilitates the resistance to internal and/or external loads.

15. A method of manufacturing a product display container, the method comprising:

forming, from a single, unitary blank of material, a plurality of panels operatively connected to define an internal space operable to receive one or more packable product items therein and a plurality of corners in the internal space;

positioning a plurality of reinforcement structures in the internal space at the corners to provide resistance of the product display container to internal and/or external loads.

16. The method of claim 15, further comprising at least partially filling the internal space with packable product items.

17. The method of claim 15, wherein positioning the plurality of reinforcement structures in the internal space comprises positioning one or more of:

a first reinforcement structure in the internal space at a first corner formed by the plurality of panels;

a second reinforcement structure in the internal space at a second corner formed by the plurality of panels;

a third reinforcement structure in the internal space at a third corner formed by the plurality of panels; and

a fourth reinforcement structure in the internal space at a fourth corner formed by the plurality of panels.

18. The method of claim 15, further comprising:

forming a removable panel at a top panel and a front panel of the plurality of panels, the removable panel being moveable from an unopened state to an opened state which exposes the internal space and facilitates removal of one or more packable product items by a user.

19. The method of claim 18, wherein forming the removable panel comprises forming a plurality of perforations in the top panel and the front panel that define a continuous link of weakness by which a portion of the front panel and a portion of the top panel may be excised from the product display container.

20. The method of claim 18, further comprising at least partially filling the internal space with packable product items.