U.S. patent application number 12/165948 was filed with the patent office on 2009-02-05 for stackable pallet system including v-shaped corner supports.
This patent application is currently assigned to GREAT NORTHERN CORPORATION. Invention is credited to Kerianne Bernstein, Kevin Corrigan, Bill Glassen, Patrick Graf, Kevin Kostos, Scott McFarland.
Application Number | 20090032432 12/165948 |
Document ID | / |
Family ID | 40337113 |
Filed Date | 2009-02-05 |
United States Patent
Application |
20090032432 |
Kind Code |
A1 |
Kostos; Kevin ; et
al. |
February 5, 2009 |
STACKABLE PALLET SYSTEM INCLUDING V-SHAPED CORNER SUPPORTS
Abstract
A modular packaging and display system for shipping and
displaying products. The modular packaging and display system
includes multiple display trays supported by a series of V-shaped
spacers. The modular packaging and display system includes a
plurality of V-shaped support members positioned near the corners
of each display tray to stabilize the packaging system. The spacers
and the support members are preferably formed from paperboard. The
modular packaging and display system is strong enough to support
the weight of the products and the trays and withstand the weight
of one or more units stacked thereupon.
Inventors: |
Kostos; Kevin; (Racine,
WI) ; Glassen; Bill; (Racine, WI) ; Corrigan;
Kevin; (Racine, WI) ; McFarland; Scott;
(Racine, WI) ; Graf; Patrick; (Highland Park,
IL) ; Bernstein; Kerianne; (Oshkosh, WI) |
Correspondence
Address: |
ANDRUS, SCEALES, STARKE & SAWALL, LLP
100 EAST WISCONSIN AVENUE, SUITE 1100
MILWAUKEE
WI
53202
US
|
Assignee: |
GREAT NORTHERN CORPORATION
Appleton
WI
|
Family ID: |
40337113 |
Appl. No.: |
12/165948 |
Filed: |
July 1, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60947531 |
Jul 2, 2007 |
|
|
|
Current U.S.
Class: |
206/600 |
Current CPC
Class: |
B65D 71/0096 20130101;
B65D 2571/00049 20130101; B65D 5/0065 20130101; B65D 21/0215
20130101; B65D 2571/00086 20130101; B65D 5/006 20130101; B65D
2571/00012 20130101; B65D 2571/00055 20130101 |
Class at
Publication: |
206/600 |
International
Class: |
B65D 19/00 20060101
B65D019/00 |
Claims
1. A modular packaging and display system, comprising: a bottom
support tray having a rectangular floor and a plurality of
sidewalls projecting above the floor; at least a first display tray
and a second display tray, each display tray having a rectangular
floor and four corners defined by a plurality of sidewalls
projecting above the floor, each of the first and second display
trays including at least four access openings each positioned near
one of the four corners; a plurality of V-shaped support members
each having a first end in contact with the floor of the bottom
support tray and extending upward through the access openings
formed in the first and second display trays; and a plurality of
V-shaped spacers each positioned between one of the plurality of
V-shaped support members and the corner of one of the bottom
support tray and the first display tray, wherein the V-shaped
spacers support the first display tray above the bottom support
tray and support the second display tray above the first display
tray when the packaging and display system is in an assembled
condition.
2. The modular packaging and display system of claim 1 wherein each
of the V-shaped support members includes a first leg and a second
leg joined at an apex, and wherein each of the V-shaped spacers
includes a first leg and a second leg joined at an apex.
3. The modular packaging and display system of claim 2 wherein each
of the V-shaped spacers are positioned between one of the V-shaped
support members and the sidewalls of one of the first intermediate
display tray and the bottom support tray.
4. The modular packaging and display system of claim 3 wherein each
of the first and second display trays include a plurality of
support tabs projecting below the floor from the sidewalls, wherein
the support tabs contact an outer surface of the V-shaped spacer
positioned therebelow to restrict movement of the V-shaped spacers
when the modular packaging and display system is in the assembled
condition.
5. The modular packaging and display system of claim 2 wherein the
V-shaped support members and the V-shaped spacers are each formed
from paperboard.
6. The modular packaging and display system of claim 2 wherein the
V-shaped support members are positioned such that the apex of the
V-shaped support member is in contact with the apex of the V-shaped
spacer.
7. The modular packaging and display system of claim 2 wherein the
V-shaped support members are positioned such that the first leg of
the V-shaped support member is perpendicular to the first leg of
the V-shaped spacer and the second leg of the V-shaped support
member is perpendicular to the second leg of the V-shaped
spacer.
8. The modular packaging and display system of claim 4 wherein each
corner of the first and second display trays include a pair of
support tabs each extending from one of the sidewalls that define
the corner, wherein each of the support tabs restricts the movement
of the V-shaped spacer positioned therebelow away from the
corresponding V-shaped support member when the display system is in
the assembled condition.
9. The modular packaging and display system of claim 1 further
comprising at least a first center support resting on the floor of
the support tray and in contact with the first display tray and a
second center support resting on the floor of the first display
tray and in contact with the second display tray.
10. A modular packaging and display system, comprising: a bottom
support tray having a rectangular floor and a plurality of
sidewalls projecting above the floor; at least a first display tray
and a second display tray each having four corners defined by a
plurality of sidewalls projecting above the floor, each of the
first and second display trays having a plurality of support tabs
projecting from the sidewalls below a bottom surface of the floor
at each of the corners; a plurality of V-shaped support members
each having a first end in contact with the floor of the bottom
support tray and extending upward through the floor of each of the
first and second display trays; a plurality of V-shaped spacers
that support the first display tray above the bottom support tray
and support the second display tray above the first display tray,
wherein each of the V-shaped spacers contacts the bottom surface of
the first display tray or the second display tray when the display
system is in an assembled condition, wherein each of the support
tabs contacts an outer surface of one of the spacers to restrict
the movement of the spacer.
11. The modular packaging and display system of claim 10 wherein
the floor of each of the first and second display tray includes a
plurality of access openings that each receive one of the V-shaped
support members.
12. The modular packaging and display system of claim 10 wherein
each of the spacers is positioned between one of the V-shaped
support members and two sidewalls of one of the first and second
display trays such that the sidewalls and the support members
restrict the movement of the V-shaped spacers.
13. The modular packaging and display system of claim 12 wherein
each of the V-shaped support members includes a first leg and a
second leg joined at an apex, and wherein each of the V-shaped
spacers includes a first leg and a second leg joined at an
apex.
14. The modular packaging and display system of claim 13 wherein
each of the V-shaped spacers are positioned between one of the
V-shaped support members and the sidewalls of one of the first
intermediate display tray and the bottom support tray.
15. The modular packaging and display system of claim 10 wherein
the V-shaped support members and the V-shaped spacers are each
formed from paperboard.
16. The modular packaging and display system of claim 13 wherein
the V-shaped support members are positioned such that the apex of
the V-shaped support member is in contact with the apex of the
V-shaped spacer.
17. The modular packaging and display system of claim 13 wherein
the V-shaped support members are positioned such that the first leg
of the V-shaped support member is perpendicular to the first leg of
the V-shaped spacer and the second leg of the V-shaped support
member is perpendicular to the second leg of the V-shaped spacer.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is based on and claims priority to
U.S. Provisional Patent Application Ser. No. 60/947,531 filed on
Jul. 2, 2007.
BACKGROUND OF THE INVENTION
[0002] The present disclosure generally relates to a modular
packaging and display system. More specifically, the present
disclosure relates to a system for packaging multiple products,
including irregularly-shaped products, on a pallet to be shipped to
a retailer, who then may display the products in the packaging in
which they are shipped.
[0003] Mass merchandising retailers, such as "club stores" often
display their products on the pallet on which the products were
shipped from the vendors. The products in their primary packages
are arranged in multiple layers using a secondary packaging and
display system. The primary purpose of the secondary packaging
system is to contain and organize subgroups of the primary
packaging, as well as to improve the stacking strength of the
palletized unit. In some types of packaging systems, multiple trays
are supported by the products themselves, while there are other
packaging systems in which the trays are supported by spacing
elements.
[0004] One example of such system is shown in U.S. Pat. No.
7,066,342. In this packaging system, a tubular support post is
positioned in each corner of the packaging system. Each tubular
support post extends from the bottom to the top of the packaging
and display system. A series of hollow, tubular spacer sleeves are
positioned over each of the support posts to provide the required
spacing between the different display levels. Each of the spacer
sleeves is a hollow, tubular member that slides over the support
post such that the support post prevents the spacer sleeve from
moving relative to the display tray.
[0005] Although the packaging system of the '342 patent provides a
display system that allows products to be displayed in the same
manner in which they are shipped, the manufacturing process
required to create the tubular support posts and tubular spacer
sleeves increases the cost of the packaging system. Therefore, a
need exists for a pallet display system that utilizes less
expensive structural components while providing the advantages of a
modular system that can be used to display products that is also
used for shipping purposes.
SUMMARY OF THE INVENTION
[0006] The present disclosure is a modular packaging system for
shipping and displaying palletized products. The system comprises
multiple vertically stacked trays for holding the products,
V-shaped spacers that provide the required spacing between
different levels of the display system, and V-shaped support
members positioned adjacent to the spacers and extending through
access openings formed in the display trays to stabilize the entire
display system. The bottom support tray is designed to rest on a
standard pallet and the entire assembly may be wrapped in a
transparent plastic film to protect the products from dust and
damage.
[0007] The pallet display system is strong enough not only to
support the weight of the products on the trays and withstand the
vibration and impact forces that can occur during shipping, but is
strong enough to withstand the weight of one or more units stacked
on the top of the loaded display system. The system is particularly
suited for shipping and displaying irregularly shaped items where
the items cannot withstand vertical stacking forces, such as soft
packaged goods, since the system itself can bear the entire
stacking load.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings illustrate the best mode presently contemplated
of carrying out the invention. In the drawings:
[0009] FIG. 1 is a perspective view of the pallet packaging and
display system loaded with a series of products;
[0010] FIG. 2 is a perspective view of the pallet display system
with the series of products removed;
[0011] FIG. 3 is a perspective, exploded view of the pallet display
system showing the individual components required to create the
display system;
[0012] FIG. 4 is a section view taken along line 4-4 of FIG. 2;
[0013] FIG. 5 is a section view similar to FIG. 4 illustrating an
alternate configuration of the pallet display system;
[0014] FIG. 6 is a magnified view of the interaction between the
support tab formed on the display tray and a pair of the spacer
elements; and
[0015] FIG. 7 is a top view of one of the display trays
illustrating the cutout openings formed in each of the corners.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 illustrates a modular pallet display system 10 for
shipping and displaying a series of retail products 12 in a mass
merchandising environment. The packaging system 10 includes a
plurality of display trays 14a-c for holding the products 12. As
illustrated in FIG. 1, the display trays 14 are spaced from each
other by an adequate height to allow the individual retail products
12 to be positioned in a desired orientation, such as the upright
orientation shown in FIG. 1. As illustrated in FIG. 1, the entire
pallet display system 10 is supported on a shipping pallet 16 that
allows the pallet display system 10 filled with products 12 to be
shipped in a known manner. As an example, the entire pallet display
system 10 can be wrapped in an outer wrap to maintain the integrity
of the pallet display system 10 and to protect the products 12 from
dust and damage during shipment.
[0017] Alternatively, the pallet display system 10 can be shipped
in a broken down condition and assembled at a retailer for use in
displaying the series of products 12. In such an embodiment, the
products 12 would be shipped in a conventional manner and loaded
onto the pallet display system 10 once the product 12 and display
system 10 arrive at the retailer. However, it is contemplated that
the preferred embodiment of the pallet display system 10 would
allow the product manufacturer to load the pallet display system 10
prior to shipment, such that the retailer could simply remove the
outer packaging and position the entire pallet display system at a
desired position in the retail outlet for product display and
purchase.
[0018] Referring now to FIGS. 2 and 3, the pallet display system 10
includes a bottom support tray 14a that serves as the base of the
pallet display system 10. The support tray 14a receives a series of
support members 18. As shown in FIG. 4, in the embodiment of the
invention shown in the Figures, each of the support members 18 is a
V-shaped, laminated paperboard edge protector, such as the
VBOARD.RTM. product available from the Great Northern Corporation.
Referring back to FIG. 3, each of the V-shaped support members 18
is positioned near one of the four corners of the support tray 14a
and extends from the support tray 14a through the first display
tray 14b and the second display tray 14c. As illustrated in FIG. 7,
both the first display tray 14b and the second display tray 14c
include access openings 60 that allow the support members 18 to
pass through a floor 20 of the respective display tray. As
illustrated in FIG. 7, each of the access openings 60 has a
generally V-shape that corresponds to the cross-sectional shape of
the support member 18.
[0019] As shown in FIG. 3, each of the support members 18 has a
length that extends from a first end that contacts the tray floor
20 of the bottom support tray 14a and extends through the access
openings formed in each of the intermediate display trays 14b, 14c.
The support members 18 each terminate at a second end 22 that
extends above the second display tray 14c (FIG. 2).
[0020] Referring now to FIG. 3, in addition to the series of
support members 18, the pallet display system 10 includes a series
of spacers 24 that provide the required spacing and support for
each of the first and second display trays 14b, 14c. Each of the
spacers 24 is positioned in one of the corners of the respective
display tray and provides the required support and spacing for the
first display tray 14b above the bottom support tray 14a. As
illustrated in FIG. 3, the first end 26 of each spacer 24 contacts
the top surface 27 of the tray floor 20 below the spacer 24 while
the second end 28 contacts the bottom surface of the tray floor 20
above the spacer 24. In this manner, the series of spacers 24
provide the required support for the second display tray 14c above
the first display tray 14b and for the first display tray 14b above
the bottom support tray 14a. Although the embodiment shown in FIG.
3 includes only three product levels, it should be understood that
the pallet display system 10 could have fewer or greater numbers of
levels depending upon the size of the product and the shipping
requirements.
[0021] In addition to the series of spacers 24, the pallet display
system 10 includes a series of center supports 30 that provide
additional support and spacing between the different levels of the
display system. In the embodiment shown, each of the center
supports 30 are U-shaped members formed from corrugated cardboard
or laminated paperboard. Each of the center supports 30 includes a
pair of support legs 32 joined to a center web 34. The center
support 30 rests upon the top surface 27 of the tray floor 20 and
contacts the bottom surface of the tray floor 20 of the display
tray 14 positioned immediately thereabove. Although the pallet
display system 10 is shown including the center supports 30, it is
contemplated that the display system 10 could be constructed
without using the center support 30. In such an embodiment, the
series of spacers 24 would provide the required strength and
spacing between the different tray levels.
[0022] Referring now to FIG. 2, each of the first and second
display trays 14b and 14c, as well as the bottom support tray 14a,
includes the generally planar tray floor 20 and outer sidewalls 36
that extends upward from the tray floor 30. As illustrated in FIG.
2, each of the display trays 14 has a generally rectangular shape
and the outer sidewalls 36 extend around the entire outer periphery
of the tray floor 20. The outer sidewalls 36 provide a retaining
wall for retaining product within the display tray, as illustrated
in FIG. 1.
[0023] Referring back to FIG. 2, the outer sidewall of each display
tray 14 includes an upper edge 38 and a lower edge 40, where the
lower edge 40 is generally coplanar with the bottom surface of the
tray floor 20. As best shown in FIG. 6, each corner of the display
tray 14 includes a pair of support tabs 42 that project downward
beneath the lower edge 40 and the bottom surface of the tray floor
20. The support tabs 42 contact an outer face surface 44 of the
spacer 24 to reduce the tendency of the spacer 24 to tip outward
away from the center of the pallet display system 10. As
illustrated in FIG. 6, the second end 28 of the spacer 24 is
positioned above the lowermost edge 46 of the support tab 42 such
that the spacer 24 is prevented from tipping outward.
[0024] As can be further seen in FIG. 6, the first end 26 of an
upper spacer 24 rests upon the tray floor 20 and is prevented from
moving outward by the height of the outer sidewall 36. Thus, the
combination of the outer sidewall 36 and the support tab 42 prevent
the upper and lower spacers 24 shown in FIG. 6 from moving outward.
As can be understood in FIG. 3, the support members 18 are
positioned inward of the spacers 24 to prevent the spacers 24 from
moving inward relative to the pallet display system. Thus, the
combination of the support members 18, the outer sidewalls 36 and
the support tabs 42 restrict the lateral movement of the spacers 24
when the packaging and display system 10 is in the assembled
condition.
[0025] Referring now to FIG. 4, thereshown is a section view taken
through one corner of the pallet display system when the pallet
display system is assembled without product. As illustrated in FIG.
4, the spacer 24 is generally V-shaped and includes a first leg 48
and a second leg 50 joined to each other at an apex 52. In the
preferred embodiment, the spacer 24 is formed from laminated
paperboard, such as the V-BOARD.RTM. edge protector available from
Great Northern. In the embodiment shown in FIG. 4, each of the legs
48, 50 has a length of approximately two inches, although other
lengths are contemplated as being within the scope of the present
disclosure.
[0026] In the embodiment of FIG. 4, the support member 18 also
includes a first leg 54 and a second leg 56 joined to each other at
an apex 58. Like the spacer 24, the support member 28 is formed
from a laminated paperboard product, such as V-BOARD.RTM. available
from the Great Northern Corporation. In the embodiment shown, each
of the first and second legs 54, 56 of the support member 18 has a
length of approximately one inch, although other lengths are
contemplated as being within the scope of the present
disclosure.
[0027] In the embodiment shown in FIG. 4, the apex 58 of the
support member 18 is positioned adjacent to the apex 52 of the
spacer 24. In this configuration, the first leg 54 of the support
member 18 is positioned in contact with the first leg 48 of the
spacer 24. At the same time, the second leg 56 of the support
member 18 is in contact with the second leg 50 of the spacer 24. In
such configuration, the spacer 24 is entrapped between the sidewall
36 and the support member 18.
[0028] Referring now to FIG. 5, the support member 18 is shown
positioned in an alternate configuration in which the apex 58 of
the support member 18 is spaced from the apex 52 of the spacer 24.
In the embodiment of FIG. 5, the first wall 54 of the support
member 18 is positioned perpendicular to the first wall 48 of the
spacer 24. Likewise, the second wall 56 is positioned perpendicular
to the second wall 50. As illustrated, this configuration of the
spacer 24 and the support member 18 creates an open space 59
between the support member 18 and the spacer 24. It is contemplated
that either embodiment shown in FIGS. 4 and 5 could be utilized
while operating within the scope of the present disclosure.
[0029] Construction of the pallet display system 10 of the present
invention will now be described with reference to the drawing
Figures. Initially, the bottom support tray 14a is positioned on
the top surface of the shipping pallet 16, as shown in FIG. 3.
Preferably, the support tray 14a does not include any precut access
openings and includes a continuous tray floor 20. In the embodiment
shown, the support tray 14a also does not include the support tabs
42 that are included on the first and second display trays 14b and
14c.
[0030] Once the bottom support tray 14a is placed on the shipping
pallet 16, a spacer 24 is placed in each corner such that the outer
surface of the spacer 24 contacts the inner surface of the outer
sidewall 36.
[0031] Once the spacers 24 have been positioned as shown in FIG. 3,
the series of support members 18 are nested into the apex of the
spacer 24, as illustrated in FIG. 3. Since the tray floor 20 of the
bottom support tray 14a does not include any access openings, the
bottom end of each support member 18 rests on the top surface 27 of
the tray floor 20.
[0032] Once the spacers 24 and support members 18 are positioned as
shown, the center support 30 is positioned on the tray floor. After
the spacers 24 and center support 30 are positioned, the first
display tray 14b is aligned with the support members 18 such that
the support members 18 pass through the access openings 60 formed
near each corner of the display tray 14b, as shown in FIG. 7. Once
each of the support members 18 is aligned with the corresponding
access opening 60, the first display tray 14b is slid downward
until the bottom surface of the tray floor 20 contacts the spacers
24 and the center support 30. The first display tray 14b is shown
in such a supported position.
[0033] Once the first level display tray 14b is positioned, the
next level of spacers 24 and center supports 30 is positioned on
the tray floor 20. Once positioned, the second display tray 14c is
slid downward along the support members 18 until the bottom surface
of the tray floor contacts the center support 30 and the spacers
24.
[0034] In the embodiment shown in FIGS. 1-3, a final set of spacers
24 and center supports 30 is positioned on the top display tray 14c
to provide adequate support for the pallet display system 10 when
the display system is packaged and shipped. However, the top layer
of spacers 24 and the center support 30 is not required in all
embodiments. Additionally, the length of the support members 18 can
be modified to extend a lesser distance above the second display
tray 14c.
[0035] Once the pallet display system 10 has been constructed,
individual products can be loaded onto the display system as shown
in FIG. 1. It is contemplated that the individual products 12 could
be loaded onto the display system either as each level is
constructed or once the entire display system 10 has been
constructed. It is contemplated that the product manufacturer would
assemble the display system 10 and load products onto the display
system 10 prior to shipment. In such an embodiment, the entire
display system would be wrapped with an outer wrap of plastic
material or cardboard to prevent the individual products from
falling out of the display system 10.
[0036] As also previously described, it is contemplated that the
pallet display system 10 could also be assembled at a retailer for
displaying the products for sale. In such an embodiment, the entire
pallet display system 10 would be shipped in a disassembled
condition and assembled by the retailer prior to product
display.
[0037] Once the pallet display system 10 has been unloaded at a
retail outlet, product from the top level 62 (FIG. 1) can be sold
to consumers. Once the entire top level 62 has been sold, the
spacers 24 and center support 30 are discarded and the second
display tray 14c is removed. This process continues until all of
the product 12 has been sold from the pallet display system 10. In
this manner, the size of the pallet display system can decrease as
product is sold from the display system.
[0038] As can be understood in the previous description and the
drawing Figures, the series of spacers 24 evenly space the display
trays 14 and provide a platform on which additional trays may be
placed. The height of the spacers 24 is determined by the height of
the product 12 and their primary packaging or, more particularly,
the desired height between the display trays 14.
[0039] As described in the foregoing description, both the spacers
24 and the support members 18 are formed from V-shaped laminated
paperboard edge protectors, such as V-BOARD available from Great
Northern Corporation. Both the spacers 24 and support members 18
are V-shaped and include a pair of legs joined at an apex. The
V-shaped edge protectors that form the spacer 24 and support member
18 provide adequate longitudinal strength to allow products having
a substantial weight to be stacked onto each other. Further, since
the support member 18 extends from the bottom display tray 14a to
the top of the packaging system, the support member 18 provides
additional stacking strength for the display system when it is
assembled, as shown in FIG. 1.
* * * * *