Rapid Assembly Display Pack

Abstract

A display pack includes first and second sheet members arranged in a stacked configuration, with first and second cutouts in general axial alignment such that the smaller cutout provides an inner flange around the larger cutout. The display pack includes at least one container having a flat insertion portion and a chamber portion. The flat insertion portion is sandwiched between the two sheet members and the chamber portion protrudes from a plane of the sheet members via the larger cutout. Enclosing the product in the chamber portion is a lid member with a main body portion positioned over the chamber portion and an outer flange, wherein the inner flange covers the outer flange to secure the lid member to the display pack. A method of packaging includes providing a partially preassembled display pack as described above, placing a product in the container, placing the lid member on the display pack with the main portion extending into the opening through at least the smaller cutout and pressing the lid member into the opening until the outer flange passes through at least the smaller cutout and is covered by the first sheet member.

Description

FIELD OF INVENTION

[0001] This invention relates to product packaging, and in particular, it relates to packaging for products suitable for store merchandising.

BACKGROUND OF INVENTION

[0002] Packaging serves different purposes by providing solutions to product protection, security and marketing. While packaging should be functional, it can also be ordinary or unique, practical or amusing. As consumer products have expanded and diversified, so have packaging designs in order to accommodate the growing and changing needs of manufacturers, packagers, shippers, retailers and even the consuming public. Packaging should preferably facilitate shipping, handling and marketing while minimizing costs of production and assembly. Moreover, as landfills are filled to capacity and suspicion of global warming turns to reality, recycling has become mainstream and there is growing preference by manufacturers and consumers alike for packaging with less carbon footprint.

[0003] With advances in technology, packagers are put to the challenge of meeting different needs. On the one hand, many products, especially in the field of electronics and computer, are shrinking in size, thus requiring less packaging. However, the value and often fragile nature of such products require sturdier packaging against damage, theft and tampering. Packaging should also promote efficient storage and display yet also provide an aesthetically pleasing appearance to catch the eye of the consumer. Such goals are often at odds with each other, posing many challenges in the improvement of packaging designs.

[0004] Shipping wrappers or packages using paper and cardboard are known. For example, U.S. Pat. No. 6,085,904 (Perdue Jr.) disclosed a single face corrugated paperboard package for containing an article. The package includes a pair of paperboard sheets each having an interior surface and an exterior surface. A cohesive coating is applied over substantially the entire interior surface of each of the paperboard sheets. A tear strip is disposed on the interior surface of at least one of the paperboard sheets. The tear strip includes an uncoated portion. The uncoated portion has two opposed longitudinal sides defined by a pair of spaced apart lines of intermittent impressions. Optionally, the tear strip may also include a tape disposed between the pair of spaced apart lines of intermittent impressions. The pair of paperboard sheets may be formed from a single paperboard sheet. The invention also includes the method of making the same.

[0005] U.S. Pat. No. 6,736,267 (Schamante) disclosed a product display package for retaining product is provided with a display card having a reinforced hanger hole that is resistant to tear. The display card includes a main body including a front surface, a rear surface and an upper edge. The display card has a closed loop hanger hole formed in the main body that is adapted to receive a hanger to hang the display card for display. A container having a housing defining a compartment to house product is supported by the display card. The display card has a tape reinforcement layer adhered to the main body in a region adjacent to the hanger hole to enhance the strength of the display card between the hanger hole and the upper edge of the main body of the display card.

[0006] U.S. Pat. No. 4,657,611 (Guines) disclosed a package having discrete article enclosures, such as a blister card for medicaments or the like in capsule, lozenge, or pill form, by means of a first strip having a plurality of blister-like protrusions therein outward from one face and leaving corresponding hollows and openings thereinto at the opposite face thereof, a relatively rupturable second strip adherent to the latter face of the first strip and sealing the openings therein, a supporting card therefor overlying the second strip over the openings and having an openable access tab opposite each opening.

[0007] U.S. Pat. No. 7,726,480 (Nazari), the entire content of which is hereby incorporated by reference, disclosed prior and improved packaging using corrugated cardboard sheets and a plastic container. Prior packaging discussed therein included those using two sheets of corrugated cardboard or one sheet of corrugated cardboard and one sheet of paper, and at least one clear plastic container having a flat insertion portion and a chamber portion, wherein the insertion portion is sandwiched between the two sheets and the chamber portion protrudes from the plane of the sheets via a cut (opening) on one cardboard sheet. The two sheets are adhered together around the periphery with an adhesive. A commonly used adhesive is a hot melt glue. Improvements on such packaging described in the aforementioned patent included crushing at least a selected area, for example, a periphery area, of the corrugated cardboard sheet(s) to provide a better seal and greater structural strength for larger packages and/or heavier items.

[0008] All of the above packaging are typically processed at a single location in a single duration. That is, the components of the packaging are typically located at a process plant where the components are assembled with the consumer product packaged therein. This process ties elements of product and packaging logistics to each other and can therefore limit options for the packager, shipper, manufacturer and retailer both geographically and temporally. It is therefore desirable to provide packaging that can be rapidly and readily assembled with greater flexibility in terms of time and place by enabling assembly in discrete stages where such stages can occur at different times and locations.

SUMMARY OF THE INVENTION

[0009] Accordingly, the present invention is directed to a display pack or packaging ("pack" and "packaging" used interchangeably herein) and packaging method that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.

[0010] Additional features and advantages of the invention will be set forth in the description below and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed in the written description and claims thereof as well as the appended drawings.

[0011] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and described, the present invention in one embodiment provides a display pack for a product, including a first and a second sheet members that are arranged in a stacked configuration. The first member has a smaller cutout and the second member has a larger cutout. The first and second cutouts are in general axial alignment with each other such that the smaller cutout provides an inner flange around the larger cutout. Adhesive material is applied to at least one selected area between the two sheet members to adhere the two sheet members together. The display pack includes at least one container having a flat insertion portion and a chamber portion adapted to hold the product. The flat insertion portion is sandwiched between the two sheet members and the chamber portion protrudes from a plane of the sheet members via the larger cutout. The chamber portion defines an opening and an interior volume to hold the product. Enclosing the product in the chamber portion is a lid member with a main body portion positioned in the opening and an outer flange around the main body portion, wherein the inner flange of the first sheet member covers the outer flange of the lid member to secure the lid member to the display pack.

[0012] The present invention includes a partially pre-assembled display pack that can remain in a stable condition suitable for receiving the product and final assembly at another time or location. In fact, final assembly can be accomplished rapidly and with ease, including by manual manipulation without any tools or machinery by merely placing the product in the chamber portion and snapping down a lid member into the display pack. In one embodiment, the partially pre-assembled display pack includes a first and a second sheet members that are arranged in a stacked configuration. The first member has a smaller cutout and the second member has a larger cutout. The first and second cutouts are in general axial alignment with each other such that the smaller cutout provides an inner flange around the larger cutout. Adhesive material is applied to at least one selected area between the two sheet members to adhere the two sheet members together. The display pack includes at least one container having a flat insertion portion and a chamber portion adapted to hold the product. The flat insertion portion is sandwiched between the two sheet members and the chamber portion protrudes from a plane of the sheet members via the larger cutout. The chamber portion defines an opening and an interior volume to hold the product. Advantageously, the partially pre-assembled display pack can be handled and transported with ease without disassembling. Moreover, multiple partially pre-assembled display packs can be closely stacked on each other to occupy minimal space during storage or shipping.

[0013] The present invention is further directed to a method of packaging that includes at least two discrete stages of packaging: partial pre-assembly, and final assembly. In one embodiment, a method of packaging includes providing a partially preassembled display pack as described above, placing a product in the container, placing the lid member on the display pack with the main portion extending into the opening through at least the smaller cutout and pressing the lid member into the opening until the outer flange passes through at least the smaller cutout and is covered by the first sheet member. The display pack is advantageously designed to facilitate installation of a lid member by a one-step manual manipulation. The method may also include crushing at least one peripheral section of the display pack for greater structural strength, improved heat conduction therethrough for activating heat-sensitive adhesive, and/or a better seal on the display pack between the sheet members.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0015] FIG. 1a. is a perspective view of an embodiment of a display pack of the present invention.

[0016] FIG. 1b is a perspective view of an alternate embodiment of a display pack of the present invention.

[0017] FIG. 2 is an exploded perspective view of the display pack of FIG. 1a.

[0018] FIG. 3 is an end cross-sectional view of the display pack of FIG. 1a, taken along line 3-3.

[0019] FIG. 4 is an end cross-sectional view of the display pack of FIG. 1b, taken along line 4-4.

[0020] FIG. 5 is an exploded perspective view of yet another embodiment of the display pack of the present invention.

[0021] FIG. 6 is an exploded perspective view of yet another embodiment of the display pack of the present invention.

[0022] FIG. 7 is perspective view of a lid member of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

[0023] FIGS. 1a, 2, 3 and 4 illustrate an embodiment of a display pack 10 that provides more options in the handling, transport, storage and display of consumer merchandise. The display pack has a first and a second overlaying members 12a and 12b that are affixed to each other to securely hold at least one container 16 adapted to house at least one item 18, e.g., a consumer product such as a DVD in its protective case. Although the first and second member need not be identical or a mirror image of each other, it is preferred that the first and second members have generally matching structure in terms of their overall size, thickness, shape and/or underlying construction material so that they match and the display pack 10 presents a clean and appealing appearance with even and flushed outer edges 20 when the first and second members are in a stacked configuration.

[0024] Each of the first and second members 12a, 12b has a cutout or through-opening 22a, 22b that is surrounded in its entirety by the construction material of the members such that they can be generally axially aligned with each other so that there is communication therethrough from opposite sides of the stacked configuration to define a cutout 22 for the display pack 10 as a whole. Both cutouts 22a, 22b are of a generally common shape and size that corresponds with the shape and size of the container 16. However in accordance with a feature of the present invention, the cutout 22a of the first member 12a is of a slightly different size than the cutout 22b of the second member 12b. For example, one cutout 22 can be slightly smaller than the other cutout. In the disclosed embodiment of FIGS. 1-4, the cutouts 22a, 22b are both rectangular with the cutout 22a being is slightly smaller than the cutout 22b such that a lip or inner flange 49 is formed around the inner edge 24a of the first member 12a surrounding the inner edge 24b of the second member 12b. The width of the inner flange depends in part of the size of the display pack and/or the cutouts. In one embodiment, the width ranges between about 1/8 inch and 0.5 in, and more preferably, about 0.25 in. Thus, when the first member 12a is placed over the second member 12b, only the inner edge 24a of the first member is visible in the top plan view of FIG. 1a, as the inner edge 24b surrounding the cutout 22b (shown in solid lines) of the second member 12b is hidden and recessed relative to inner edge 24a (shown in broken lines).

[0025] Due to the structure of the first and second members 12a, 12b and the construction of the display pack 10, it is understood that the wording "cutout" as used herein may refer as appropriate within the context of the discussion to the cutout of each of the first and second members and/or to the cutout of the display pack that is formed when the first and second members are in a stacked configuration. In that regard, it is further understood that wording for other structures and regions, e.g., inner edges, outer edges, rim portion, etc., that are present in the first and second members individually and/or in the display pack when the members are in a stacked configuration may refer to either and/or both as appropriate within the context of the discussion.

[0026] Spanning between the inner edges 24 and the outer edges 22 of the first and second members is a surrounding area 28 of the display pack that frames the container 16. The first and second members are affixed to each other by means of an adhesive material 26, such as heat-sensitive adhesive material, that is applied to at least selected areas of inner surfaces 13 of the members 12a, 12b. The first and second members may also be sealed together about their periphery via crushing, as discussed further below, although crushing is not required to practice the invention. In the illustrated embodiment of FIGS. 1-4, the surrounding area 28 comprises a plurality of opposing areas 30, including two parallel pairs of straight opposing areas 30', 30'' for a total of four straight areas of different widths, where each area of an opposing pair has about the same width. In a disclosed embodiment, the smaller width is about 1.0 inch and the larger width is about 2.0 inches.

[0027] The surrounding area 28 includes a peripheral section 32 that extends between the outer edge 20 and a continuous step or boundary 34 that extends around the cutout 22 and delineates between a thinner crushed peripheral edge portion 36 and a thicker inner uncrushed portion 38. The widths of the surrounding area 28 and of the crushed and the uncrushed portions 36, 38 thereof can vary depending on the size, weight and/or shape of the consumer product 18. The widths can also depend on the container 16, in particular, the width of its flat insertion portion 48, as discussed further below. In the disclosed embodiment, the width of the thinner crushed peripheral edge portion 36 is about 0.5 inch.

[0028] An alternate embodiment of the present invention is shown in FIG. 1b. Display pack 10' has a similar structure with similar features and components. One difference is that the boundary 34 is discontinuous and segmented such that the surrounding area 28 has a plurality of crushed portions 36 separated by the uncrushed portion 38 (including uncrushed subportions thereof). Moreover, the peripheral crushed portions 36 can be straight or curved around corners of the display pack 10'.

[0029] In the disclosed embodiments, the first and second overlaying members 12a, 12b are flat, planar sheet members such that when they are in a stacked configuration the display pack 10 generally defines a plane with the container 16 protruding from at least one side of the plane. In one embodiment, the first and second overlaying members are corrugated cardboard sheets, wherein each sheet has an original thickness defined by at least three layers, including two outer paper sheets 40 and a corrugated member 42 (FIGS. 3 and 4). The corrugated member therebetween provides corrugations and air gaps 43 (for example, in the form of elongated, generally parallel air channels between the two outer paper sheets 40). In these figures, the air gaps or spaces between the various layers 40 and 42 are exaggerated to illustrate the relationship among the various layers. Suitable cardboard sheets include 200 lb test E-flute cardboard, and microflute cardboard sheets. Accordingly, where the first and second members include sheet members such as corrugated cardboard sheets, the aforementioned crushed portions 36 have generally crushed corrugations where the air gaps 43 are substantially eliminated between the two outer paper sheets 40. In one embodiment, the crushed portions 36 are crushed to up to approximately 50% of their original thickness. And, where the crushed portions include inner edges 20 and/or outer edges 24 of the first and second members 12a, 12b, crushing of the cardboard sheets compresses the edges such that there is minimal visual distinction and separation between the three layers of the corrugated cardboard sheets in the crushed portions when viewed from the side. The three layers together thus effectively form a sealed outer edge 21 (continuous as shown in FIG. 1a, or discontinuous as shown in FIG. 1b) of the display pack that resists peeling, fraying, tearing and/or separation. Crushing of corrugated cardboard sheets is described in U.S. Pat. No. 7,726,480, the entire disclosure of which is hereby incorporated by reference.

[0030] In the disclosed embodiment, the first and second members 12a, 12b each have a rectangular shape such that the display pack 10 has a rectangular shape. In another embodiment, the two sheet members are formed from a single larger sheet member folded over, for example, along a midline that is creased and/or perforated.

[0031] With the members 12a, 12b arranged in the stacked configuration to foam the display pack, the inner surfaces 13a, 13b face each other leaving outer surfaces 14 exposed. The outer surfaces 14a, 14b can be printed with or otherwise display product information and other information useful to the consumer. As mentioned, the adhesive material 26 is applied to at least selected areas of the inner surfaces to adhere the members 12a, 12b to each other so that the container 16 is secured to the display pack 10.

[0032] The container 16 encasing the consumer product 18 has a main body 44 and a separate lid member 46. Both the main body and the lid member can be made from any suitable material, including a clear plastic material such as PET. The main body 44 has a peripheral flat insertion portion 48 that surrounds an opening 50 of a protruding chamber portion 52. The chamber portion defines an interior volume suited for occupation by the consumer product 18. The peripheral flat insertion portion 48 is configured to be coplanar with the display pack 10 so as to lie flat between a rim portion 23 (FIGS. 3 and 4) of the first and second members 12a, 12b that immediately surrounds the inner edges 24 defining the cutout 22 of the display pack 10. The chamber portion 52 protrudes from one side of the plane of the display pack and has a size and shape generally corresponding to the size and shape of the consumer product 18.

[0033] Because the first and second members 12a, 12b are affixed to each other, the flat insertion portion 48 of the container 16 sandwiched in the rim portion 23 secures the container 16 to the display pack and prevents the container from falling through the cutout 22. The maximum width of the flat insertion portion 48 should be no greater than the width of the surrounding area 28 and the minimum width should be no less than about 0.25 inches. In one embodiment, the width is between about 0.5 inches and about 1.0 inch. In the latter regard however, it is understood that the minimum width also depends on the size and/or weight of the consumer product 18 held in the container 16 and the width of the surrounding area 28.

[0034] Best seen in FIG. 2, the flat insertion portion 48 of the container 16 can be continuous around the opening 50 with a generally uniform width to better resist detachment of the container from the display pack and tampering in general. In the illustrated embodiment, the flat insertion portion 48 has a rectangular shape with four straight insertion portions, where each of four straight insertion portions has about the same width. In one embodiment, the width is about 0.5 inch.

[0035] The chamber portion 52 extends from the opening 50 of the container 16. In the illustrated embodiment of FIG. 2, the chamber portion 52 has a surrounding side wall 54 that extends outwardly from the plane of the display pack at an angle from the insertion portion 48, and a bottom wall 56 that is generally parallel with the flat insertion portion 48. It is understood that the shape and relative size of the side wall and the bottom wall depend on the shape and size of the consumer product 18. In the illustrated embodiment, the chamber portion 52 has a rectangular shape and thus there are four straight side wall portions 54 with a generally flat bottom wall 56.

[0036] Best seen in FIG. 3, the side wall 54 extends at an angle theta relative to the flat insertion portion 48, with theta ranging between about 90 and 135 degrees. In the embodiment of FIG. 2, angle theta is about 120 degrees. The chamber portion 52 has a depth D that is greater than a depth d of the consumer product 18 so a gap of space G is provided between a plane defined by the opening 50 and an upper or adjacent surface 19 of the consumer product 18. The gap G can range between about 0.25 and 1.0 in. In one embodiment, the gap is about 0.5 inches.

[0037] On an outer surface of the side wall 54 are detents that form raised formations 60 on an inner surface of the side wall. The formations function as stops for the lid member 46 and they also keep the lid member 46 centered in the opening 50 by minimizing lateral movement, especially where the opening 50 spans greater than the spacing between the lid side wall 68. An upper portion of each raised formation provides an inwardly projected surface 62 that can be curved. The surfaces 62 sit immediately below the plane of the opening 50 in supporting the lid member at or near the opening 50. The surfaces are intended to prevent a thief from being able to depress the lid member into the interior volume so as to pry it loose from the display pack, especially in the instance where the main body portion of the lid member is not abutting the upper surface 19 of the consumer product 18. A lower portion 63 of each raised formation is in general contact with the consumer product 18 to cushion and/or wedge in the consumer product from shifting about in the container 16. It is understood that words describing direction or orientation herein, such as top, bottom, above, below and the like, are used herein merely for the ease of reference with respect to the drawings and do not in any manner limit the scope of the present invention, including manner of its construction or use.

[0038] In the illustrated embodiment, each raised formation 60 has a generally triangular cross section (best seen in FIG. 4) such that the degree (or width) of projection of the formation into the interior volume of the chamber portion 52 relative to the side wall 54 decreases with increasing depth. There can be any plurality of raised formations 60 on the side wall 54. In the illustrated embodiment where the container 16 is rectangular, there is one raised formation on each of the shorter side wall 54 of the container and two raised formations on each of the longer side wall 54 of the container.

[0039] The lid member 46 has a main cover portion 64 that is indented relative to an outer flange 70 by means of a lid side wall 68 surrounding the main cover portion 64. The indented main cover portion 64 and the outer flange 70 are generally parallel to each other (and to the flat insertion portion 48 of the container 16) but indented by the lid side wall 68 extending between them so that the cover portion 64 sits deeper in the chamber portion 52 than the outer flange 70. The lid side wall 68 also extends at the angle theta relative to the outer flange 70, where theta ranges between about 90 and 135, more preferably about 120 degrees, to correspond with the aforementioned angle theta of the container 16. The width of the lid side wall 68 is no greater than the depth of the gap G and should be less than the distance between an upper surface 19 of the consumer product and the upper surface 62 of the raised formation 60. In one embodiment, the main cover portion 64 is about 5.25 inches by 6.75 inches, the side wall 68 has a width about 0.25 inch and the outer flange 70 has a width about 1/8 inch.

[0040] As illustrated, the main cover portion 64 and the cutout 22a of the first support member 12a have a nearly identical shape and size. As mentioned, the cutout 22b has a similar shape and size to that of the cutout 22a with the exception that the latter is smaller. The opening 50 of the container 16 also has as a similar shape but its size is slightly larger than the lid member. Precise relative sizing of the various components and structure of the display pack, including the cutouts 22a, 22b, the opening 50, the formations 60 and/or the lid member 46, enables the lid member to be snapped into the opening 50 via the cutout 22a. In accordance with a feature of the present invention, the outer flange 70 is adapted to initially catch and rest on the inner edge 24a of the first support member 12a suspending the lid member 46 (in broken lines in FIGS. 3 and 4) at or near the opening 50 in preparation for the lid member to be snapped down (in solid lines in FIGS. 3 and 4) into the opening 50 and locked in the display pack by a downwardly force F, as described further below. Once snapped in place, the lid member 46 is securely situated on the container 16 enclosing the product in the chamber portion 52 and generally immobilized from lateral motion by the raised formations 60 and from upwardly/downwardly motion by the inner flange 49 of the first member 12a and the surface 62 of the raised formations 60. Notably, where the shape of the cutout 22 and the opening 50 of the container 16 is polygonal with corners, such as rectangular with four corners in the illustrated embodiment of FIG. 2, the corners 72 of the outer flange 70 of the lid member are rounded such that its width is reduced significantly or altogether absent in the corners to allow more flexibility in the lid member 46 to so that it can be pushed through the cutout 22a of the first support member 12 and snapped into the display pack.

[0041] An alternate embodiment of the present invention is illustrated in FIG. 5, where similar numbers denote similar features. Display pack 110 has first and second members 112a and 112b that are triangular sheet members, for example, triangular corrugated cardboard sheets, each with a circular cutout 122 that are adhered to each other by an adhesive material (not shown). Container 116 has a generally spherical shape with a circular cross section and at least two raised formations 160 in the interior volume. A continuous flat insertion portion 148 surrounds opening 150 of the container. A raised, e.g., dome-shaped, main cover portion 164 is indented by means of lid side wall 168 and a flat connecting wall 169 between the lid side wall 168 and the cover portion 164. Lid member 146 is circular and has a main cover portion 164 that is not flat but protrudes upwardly opposite of chamber portion 152 of the container 116 on the other side of the plane defined by the members 112a and 112b. Outer flange 170 of the lid member 146 is continuous with a generally uniform width. A downwardly force can be exerted on the main cover portion 164 and/or the flat connecting wall 169 in pressing and snapping the lid member in the display pack.

[0042] Another alternate embodiment of the present invention is illustrated in FIG. 6, where similar numbers denote similar features. Display pack 210 has a first and second members 212a and 212b that are sheet members of any shape, for example, corrugated cardboard sheets, that are affixed together by adhesive material 226. Extending through a circular cutout 222 of the display pack and an opening 250 of container 216 is consumer product 218 which has a circular cross section. In this embodiment, lid member 246 is without a side wall or connecting wall. A discontinuous outer flange 270, for example, of four discrete flange sections extends directly from a dome-shaped cover portion 264. A downwardly force F may be applied to the cover portion 264 to snap down the lid member 246 into the display pack.

[0043] It is understood that the first and second members and the display packs of the present invention may assume any variety of shapes, including, circular, oval, polygonal and irregular shapes. It is also understood that the containers and lid members may assume any variety of shapes, including circular, oval, polygonal and irregular shapes. Moreover, any structure featured in one embodiment of the present invention may be incorporated in addition to or in place of a similar feature in any other embodiments as needed or desired. It is further understood that the first and second members can be made of any suitable material, for example, corrugated cardboard, regular cardboard, one sheet of paper (sturdy) and one sheet of corrugated cardboard, or even plastic. If of plastic, the container may be integral with one or both of the sheet members.

[0044] In accordance with a feature of the present invention, assembly of any of the present display packs may involve at least two stages: partial pre-assembly (without involving a consumer product and a lid member) and rapid final assembly (involving a consumer product and a lid member). By providing a pre-assembly stage, the display pack may be pre-assembled at a location and/or time different from those of the final assembly stage where the consumer product is placed and secured in the display pack with the lid member snapped in. With display packs that are pre-assembled, products and items may be packaged rapidly in the display packs with minimal time and effort. This feature should greatly increase flexibility and efficiency in supply chain and logistics management for a wide variety of consumer products by providing manufacturers, packagers, shippers and retailers with more options in what, when, where and how consumer products are processed, packaged, transported, displayed and stored at various stages from production to sale.

[0045] Accordingly, the present invention includes a method of assembling a display pack. To partially pre-assemble the display pack 10 (or any of the display packs disclosed herein) in preparation for final assembly with the consumer product 18, the container 16 is stacked on the second support member 12b such that the chamber portion 52 sits in the cutout 22b and protrudes out of the plane of the second member from the outer surface 14b. The container is suspended by the flat insertion portion 48 which catches on the inner surface 13b of the rim portion 23 of the second support member 12b. The adhesive material 16 is applied to one or both of the inner surfaces 13a, 13b of the first and second support members in at least the peripheral section 32 of the two members, which is also the location where pressure and/or heat can be applied for crushing and sealing the crushed portions 36 especially where the support members are corrugated cardboard sheets. The adhesive material may also be applied as desired to the inner surfaces of the remaining surrounding area (in its entirety, or in certain interior areas for "spot sealing"). However, the rim portion 23 of the inner surfaces 13a, 13b where the flat insertion portion 48 is sandwiched should be kept free of the adhesive material if it is desirable that the container 16 be easily removable from the display pack for recycling. In addition, the container may be made as a re-usable container, and easy removal may facilitate re-use.

[0046] After application of the adhesive material, the first support member 12a is placed on the second member 12b with the cutouts 22a, 22b aligned such that flat insertion portion 48 of the container 16 is sandwiched in the rim portion 23 between the first and second members. Where crushing is desired, the peripheral section 32 of FIG. 1a (or discontinuous peripheral sections 32 of FIG. 1b) of the two support members is subjected to a sufficient amount of pressure for crushing and sealing. Where the first and second members are corrugated cardboard sheets, the corrugations inside the cardboard sheets are crushed and flattened. Heat is applied, either simultaneously with or subsequent to the application of pressure, to the outer surface of either one or both cardboard sheets in the peripheral section. Because the corrugations inside the cardboard sheets are crushed and the air gaps are substantially eliminated, the crushed cardboard sheets become a better heat conductor. Sufficient heat can be conducted from the outer surfaces to the inner surfaces where the heat-sensitive adhesive has been applied to activate the adhesive and seal the pack. Any inner and/or outer edges 20, 24 that are crushed in this process present an aesthetically pleasing view because the crushed corrugations are less visible thereby providing the edges with a refined and finished appearance. Many types of sealer machines that may be used to carry out the crushing and sealing process are disclosed in the aforementioned U.S. Pat. No. 7,726,480.

[0047] Once pre-assembled, the display pack is prepared to receive the consumer product 18 and the lid member 46 at a different time and/or place. For example, the pre-assembled pack with the lid member detached can be transported to a remote location where the consumer product is being manufactured or warehoused awaiting packaging. For final assembly, the consumer product 18 is placed in the chamber portion 52. In the embodiment of FIGS. 1-4, the chamber portion has a sufficient depth such that the entirety of the consumer product sits below the surface 62 of the raised formation 60. The lid member 46 is placed over the opening 50 and suspended by the outer flange 70 catching on the inner edge 24a of the first support member 12a. The cover portion 64 sits in the cutouts 12a, 12b and the opening 50 for stability. As illustrated in FIG. 4, a space gap S exists between the cover portion 64 and an adjacent surface of the consumer product such that a downwardly force F can be readily applied to the cover portion (manually or by machine) to snap down the lid member 46 into the opening 50. In particular, the outer flange 70 is pushed past the inner edge 24a and comes to rest on the surface 62 of the raised formations 60. Because the cutout 22a is smaller than the lid member 46, the inner flange 49 is effectively provided around the inner edge 24a of the first support member 12a relative to the inner edge 24b of the second support member 12b. By covering the outer flange 70, the inner flange 49 prevents the lid member from dislodging and falling back out of the cutout 22a. The outer flange 70 is thus securely wedged against the inner flange. The indented configuration of the lid member facilitates this snap-down action as it stabilizes the lid member which may otherwise have a tendency to shift about as the downwardly force is being applied. The snap-down action is also facilitated by the absence of corners in the outer flange which allows sufficient flexibility and deformation in the outer flange 70 and side wall 68 for the outer flange to fit through the cutout 22 of the first support member 14a.

[0048] After the lid member 46 is snapped in, it sits over the chamber portion 52, at or slightly below the opening 50 blocking the opening 50, with the outer flange 70 generally in contact with the surfaces 62 of the raised formations 60. The raised formations 60 and the indented cover portion 64 ensure that the consumer product 18 is generally wedged inside the chamber portion 52 from shifting about during handling and transport of the display pack. And, because the outer flange 70 has been snapped below the first support member 12a and rests below and behind the inner edge 24a, the outer flange 70 is hidden and generally inaccessible through the cutouts 22a, 22b rendering the lid member tamper-resistant. With the first and second support members 12a, 12b adhered to each other and crushed and sealed in the peripheral section 32, the lid member 46 and the chamber portion 52 are securely sandwiched between the members 12a, 12b and locked in the display pack such that removal of the consumer product 18 is generally limited to cutting of the members 12a, 12b or the container 16 by means of a sharp instrument such as a blade, knife, scissors or the like.

[0049] In the embodiment of FIG. 5, the first and second members 112a, 112b and the container 116 are partially pre-assembled in the same manner. However, a portion of the consumer product (not shown) placed in the container can sit above opening 150 as accommodated by lid member 146. The lid member has an outer flange 170, and a dome-shaped cover portion 146 that extends oppositely of chamber portion 152, without a connecting side wall. The lid member is placed over the cutout 122a and centered above the product 18 with the outer flange 170 surrounding the inner edge 24a of the first support member. A gap exists between the cover portion 146 and the product such that a downwardly force can be applied to the cover portion to snap down the lid member into the display pack. The outer flange 170 is pushed past the inner edge 24a and comes to rest on the surface 62 of the raised formations 60. The portion of the product protruding above the opening can help stabilize the lid member as the downwardly force is being applied. The outer flange may be continuous (FIG. 5) or discontinuous (FIG. 7) around the lid member, as needed to provide sufficient flexibility and deformation so that the outer flange can fit through the cutout of the first support member. Fully assembled, the display packs of FIGS. 5 and 6 are similarly tamperproof by means of the outer flange being generally hidden and inaccessible under the first support member.

[0050] The preceding description has been presented with reference to certain exemplary embodiments of the invention. The drawings shown wherein are not necessarily to scale, some portions having been enlarged to show details. The display pack may include more than one cutout and/or container and each container may contain more than one consumer product. It is understood that any of the actions and steps taken to assemble the display pack of the present invention can be performed manually or by machine. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes to the described structure may be practiced without meaningfully departing from the principal, spirit and scope of this invention. It is understood that the drawings are not necessarily to scale. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and illustrated in the accompanying drawings. Rather, it should be read as consistent with and as support for the following claims which are to have their fullest and fairest scope.

Claims

1. A display pack assembly for a product, comprising: a first and a second sheet members, the two sheet members being arranged in a stacked configuration, the first member having a smaller cutout and the second member having a larger cutout, the first and second cutouts being in general axial alignment with each other such that the smaller cutout provides an inner flange around the larger cutout; an adhesive material in at least one selected area between the two sheet members to adhere the two sheet members together; at least one container having a flat insertion portion and a chamber portion adapted to hold the product, the flat insertion portion being sandwiched between the two sheet members and the chamber portion protruding from a plane of the sheet members via the larger cutout, the chamber portion defining an opening and an interior volume adapted to receive the product; a lid member enclosing the product in the chamber portion, the lid member having a main body portion positioned in the opening and an outer flange around the main body portion, wherein the inner flange covers the outer flange to secure the lid member to the display pack, wherein the lid member is larger than the smaller cutout but configured flexibly to pass through the smaller cutout.

2. A display pack assembly of claim 1, wherein the lid member has an indented configuration.

3. A display pack assembly of claim 1, wherein the lid member has a flat main body portion.

4. A display pack assembly of claim 1, wherein the lid member has a raised body portion.

5. A display pack assembly of claim 1, wherein the lid member has a main body portion that has a size and shape substantially equal to a size and shape of the smaller cutout.

6. A display pack assembly of claim 1, wherein the first and second sheet members include corrugated cardboard sheets.

7. A display pack assembly of claim 6, wherein the stacked configuration has an original thickness and at least one crushed peripheral section with a lesser thickness.

8. A display pack assembly of claim 6, wherein the lesser thickness is at most about 50% of the original thickness.

9. A display pack assembly of claim 6, wherein the at least one crushed peripheral section is substantially free of air gaps.

10. A display pack assembly of claim 6, wherein the adhesive material includes a heat-sensitive adhesive material

11. A display pack assembly of claim 1, wherein the chamber portion has at least one formation having a surface configured as a stop for the outer flange of the lid member.

12. A display pack assembly of claim 1, wherein the container is clear plastic.

13. A display pack assembly of claim 1, wherein the outer flange of the lid member has rounded corners.

14. A display pack assembly adapted for receiving a product and a lid member, comprising: a first and a second sheet members, the two sheet members being arranged in a stacked configuration, the first member having a smaller cutout and the second member having a larger cutout, the first and second cutouts being in general axial alignment with each other such that the smaller cutout provides an inner flange around the larger cutout; an adhesive material in at least one selected area between the two sheet members adhering the two sheet members together; at least one container having a flat insertion portion and a chamber portion adapted to hold the product, the flat insertion portion being sandwiched between the two sheet members and the chamber portion protruding from a plane of the sheet members via the larger cutout, the chamber portion defining an opening and an interior volume adapted to receive the product, the container having at least one stop to support the lid member.

15. A display pack of claim 14, wherein the container is clear plastic.

16. A display pack of claim 14, wherein each of the first and second sheet members comprises a corrugated cardboard sheet.

17. A display pack of claim 14, wherein one of the first and second sheet members comprises a corrugated cardboard sheet and the other of the first and second sheet members comprises a sheet of paper.

18. A method of packaging a product for display, comprising providing a display pack comprising: a first and a second sheet members, the two sheet members being arranged in a stacked configuration, the first member having a smaller cutout and the second member having a larger cutout, the first and second cutouts being in general axial alignment with each other such that the smaller cutout provides an inner flange around the larger cutout; an adhesive material in at least one selected area between the two sheet members adhering the two sheet members together; at least one container having a flat insertion portion and a chamber portion adapted to hold the product, the flat insertion portion being sandwiched between the two sheet members and the chamber portion protruding from a plane of the sheet members via the larger cutout, the chamber portion defining an opening and an interior volume adapted to receive the product; a detached lid member having a main body portion and an outer flange; placing the product in the container; placing the lid member on the display pack with the main portion extending into the opening through at least the smaller cutout; and pressing the lid member into the opening until the outer flange passes through at least the smaller cutout and is covered by the first sheet member.

19. A method of packing a product for display of claim 18, further comprising crushing at least one peripheral section of the display pack.

20. A method of packing a product for display of claim 18, further comprising crushing a plurality of peripheral sections of the display pack.