One-Piece Bland/Shroud and Display Case

The present invention relates generally to the protection of packages shipped in groups, and more particularly to a blank/shroud and display case using this shroud which is used to protect an array of packages while leaving two opposed sides of the array unenclosed.

When shipping products or packages (hereafter packages) which have little strength, it is necessary to protect the packages with a suitably strong shipping/storage container. Typically, it is desired to use corrugated board for such containers, which is a relatively cheap material and lends itself to automation. However, it may also be desirable to display the package in the container (for ready identification by the user) and to afford easy access to the packages. Various containers have been disclosed in the art for this purpose.

For example, KOOL-AID BURSTS.RTM. (comprising a fruit-flavored beverage in a plastic bottle with a flexible neck and twist-off top) are now shipped in a shrink-wrapped, display case comprising a top and bottom, corrugated, cardboard tray about a 4.times.2 array of six-packs of the KOOL-AID BURSTS.RTM.. A supporting divider is also provided between the array to vertically support the display case as the KOOL-AID BURSTS.RTM. bottles themselves have little vertical strength (as the twist-off tops and necks are flexible). However, the assembly of such display cases is not readily automated and hence is labor intensive.

In accordance with the present invention, a one-piece blank which is foldable to provide a shroud used in conjunction with a bottom tray is provided to enclose an array of packages and to provide vertical support for an assembled display case. The one-piece blank or shroud formed thereby includes a central top panel which is rectangular shaped so as to overlay a top of the array of packages. The top panel defines a pair of opposed first sides extending parallel to an x-axis and a pair of opposed second sides extending parallel to a y-axis. The blank or shroud also includes a pair of side panels, each side panel including a respective first hinge line parallel to the x-axis attaching the side panel to a respective first side so that when the side panels are bent along the first hinge lines to form the shroud the side panels are located adjacent respective opposed side faces of the array of packages. The blank or shroud further includes a pair of opposed projecting portions for each side panel extending parallel to the x-axis and beyond an adjacent respective second side. Each of the projecting portions includes (a) a second hinge line parallel with the y-axis attaching the projecting portion to the associated side panel, and (b) a third hinge line therein parallel to the y-axis to define a reinforcing panel and a leg panel. The reinforcing panel extends parallel to the x-axis for a distance slightly less than 1/2 of the distance that the side panel extends parallel to the x-axis so that when the reinforcing panels of each pair of projecting portions are bent back onto the associated side panel along the second hinge lines the associated leg panels are bent perpendicular to the reinforcing panels along the third hinge lines to come together and to form a leg which is inserted laterally into the side face of the array of packages.

Preferably, the blank or shroud includes a pair of squaring panels attached to respective second sides along a respective fourth hinge line parallel to the y-axis. These squaring panels are bent back along the fourth hinge lines and secured to the central panel so that the squaring panels strengthen the central panel. Also preferably provided is a securing means, such as lines of adhesive, for immovably securing the reinforcing panels to the side panels adjacent thereto. Although not usually necessary, it is also contemplated that similar securing means for immovably securing associated leg panels of a pair of reinforcing panels to one another may be employed.

In a preferred embodiment, the side panels are attached completely along a length of the associated the first side of the central panel. In addition, the side panels and the projecting portions are rectangularly shaped, and the third hinge lines are perforated score lines. A space is also preferably provided between associated adjacent opposed sides of the reinforcing panel and of the squaring panels.

Where a display case is provided, the display case includes a bottom tray on which a bottom of the array and the distal or bottom edge of the shroud rest. A securing means for securing the tray and the shroud together about the array of packages, such as a shrink wrap, is then used to form a unitary case suitable for shipping.

Also in accordance with the present invention, the one-piece formed shroud includes a central top panel which is rectangular shaped and which overlays the top of the array of packages with the top panel defining a pair of opposed first sides and a pair of opposed second sides. The formed shroud then further includes a pair of opposed T-shaped panels. Each T-shaped panel includes (a) a side panel forming a cross portion of the T-shaped panel with the side panel engaging an associated side face of the array, (b) a single leg forming a leg of the T-shaped panel with the leg being located between adjacent packages of the array as the associated side panel engages the side face of the array, and (c) a first hinge connection of the side panel to an associated first side of the central top panel.

It will be appreciated that the formed panel is preferably made of a corrugated cardboard material and that a pair of squaring panels are attached to respective second sides along a respective second hinge line with the squaring panels being bent back along the second hinge lines and secured to the central panel so that the squaring panels strengthen the central panel. Also, each side panel includes a respective pair of reinforcing panels for reinforcing the associated side panel with each reinforcing panel including a third hinge line which connects the reinforcing panel with the associated side panel whereby each reinforcing panel of a pair is bent back onto the side panel along the third hinge line and securing means immovably attaches the reinforcing panels to the side panels adjacent thereto. Further, each leg includes a pair of respective leg panels with each leg panel including a fourth hinge line which connects the leg panel with an associated reinforcing panel and with each leg panel of a pair being bent perpendicular to the associated reinforcing panel along the fourth hinge line.

It is an object of the present invention to provide a shroud or display case which provides a maximum amount of package access while still affording sufficient protection for the packages.

It is also an object of the present invention to provide a shroud or display case with a maximum package display.

It is a further object of the present invention to provide a shroud and display case whose construction and filling are automatable.

It is another object of the present invention to provide a shroud and display case which have high strength to protect the packages during distribution and warehousing.

It is also an object of this invention to provide a display case which has high resistance to compression at all four corners.

It is a further object of this invention to provide a display case with a high level of protection for the enclosed packages while minimizing the use of corrugated board.

It is yet another object of the present invention to provide a shroud and display case which are capable of supporting high quality graphics identifying the packages contained therein.

Other features and objects of the present invention are stated in or apparent from detailed descriptions of presently preferred embodiments of the invention found hereinbelow.

FIG. 1 is a bottom plan view of a one-piece blank from which a shroud is erected according of the present invention.

FIG. 2 is a bottom perspective view with portions broken away of the one-piece blank depicted in FIG. 1 partially folded into a shroud having a pair of opposed T-shaped panels according to the present invention.

FIG. 3 is a schematic top perspective view of the one-piece blank depicted in FIG. 1 completely folded into a shroud and being assembled into a display case according to the present invention.

With reference now to the drawings in which like numerals represent like elements throughout the views, a one-piece, die-cut blank 10 of corrugated board or the like is depicted in FIG. 1. It will be appreciated that die-cut blank 10 is foldable to form a shroud 12 as depicted partially formed in FIG. 2 and fully formed in FIG. 3 for covering a 4.times.2 array 14 of packages 16. Packages 16 are, for example, six-packs of KOOL-AID BURSTS.RTM.. Blank 10 includes a central top panel 18 which is designed to form a top of shroud 12. Central panel 18 is generally rectangular in shape and thus defines a pair of first sides 20a and 20b extending parallel to an x-axis and a pair of second sides 22a and 22b extending parallel to a y-axis. A z-axis is oriented to be perpendicular to an x-y plane forward by the x-axis and the y-axis. It will be appreciated that axes x, y and z are used as a convenient reference for describing the elements and locations thereof of the present invention and that these axes are not otherwise part of the blank 10 or of the invention.

Blank 10 also includes a pair of rectangular side panels 24a and 24b. As side panels 24a and 24b are otherwise identical, only side panel 24a will be described in detail, with the similar elements of side panel 24b being depicted with the same identifying numbers but with a "b" suffix rather than an "a" suffix. Side panel 24a includes a hinge or score line 26a parallel to the x-axis attaching side panel 24a foldably along hinge line 26a to first side 20a of central panel 18 along a length thereof.

Each side panel 24a and 24b also includes a respective pair of rectangular projecting portions 28a and 28b which are also identical to one another so that only one projecting portion 28a is described in detail. Projecting portion 28a extends parallel to the x-axis from side panel 24a and beyond the adjacent first side 20a or 20b. Each projecting portion 28a includes a second hinge or score line 30a parallel with the y-axis foldably attaching projecting portion 28a to side panel 24a. In addition, each projecting portion 28a also includes a perforated hinge or score line 32a parallel to the y-axis. Perforated hinge line 32a divides projecting portion 28a into a reinforcing panel 34a and a leg panel 36a, and the perforations of hinge line 32a make it possible to more easily fold leg panel 36a 90.degree. thereabout relative to reinforcing panel 34a. It will be appreciated that reinforcing panels 34a extend parallel to the x-axis for a distance which is slightly (typically by a little more than the thickness of leg panel 36a) less than 1/2 of the distance that side panel 24a extends along the x-axis. Thus, when reinforcing panels 34a of side panel 24a are bent back onto side panel 24a along hinge lines 30a as shown in FIGS. 2 and 3, leg panels 36a are bent perpendicular to reinforcing panels 34a along hinge lines 32a to come together and to form a leg 38a.

Blank 10 further includes squaring panels 40a and 40b attached to a respective second side 22a or 22b along a respective hinge or score line 42a or 42b which is parallel to the y-axis. When squaring panels 40a and 40b are bent along hinge lines 42a and 42b back onto central panel 18 as shown in FIG. 2, squaring panels 40a and 40b serve to strengthen central panel 18 and help central panel 18 maintain its rectangular shape, and help the formed shroud and assembled display case maintain its squareness. It will also be appreciated that a space 44a or 44b is provided between sides of reinforcing panels 34a, 34b adjacent to sides of squaring panels 40a, 40b to provide room for forming of shroud 12 as shown in FIG. 3.

Depicted in FIG. 2 is shroud 12 which has been partially formed from blank 10. As shown, reinforcing panel 34b on the left side of the figure (as well as the other reinforcing panels 34a and 34b) has been bent back along hinge line 30b onto side panel 24b and immovably secured to the overlying portion of side panel 24b by a securing means 46. Securing means 46 is suitably a series of hot melt adhesive or glue strips 48 where shroud 12 is made of a corrugated board material, though obviously other securing means known in the art could also be used. In a similar manner, it will be appreciated that squaring panels 40a and 40b are immovably secured to the overlying portion of central panel 18 by a securing means 50.

While shroud 12 is capable of serving as a protective top and side for array 14 of packages 16 if packages 16 have a suitable bottom, shroud 12 is preferably used as part of an overall display case 54 depicted in an unassembled configuration in FIG. 3. Display case 54 obviously includes shroud 12, which has been reconfigured from the configuration depicted in FIG. 2 by the bending opposed T-shaped panels (with side panels 24a and 24b, reinforcing panels 34a and 34b secured thereto and with legs 38a and 38b formed as discussed above) along hinge lines 26a and 26b, respectively, to form shroud 12 into its final shape. During this final bending along hinge lines 26a and 26b, it will be appreciated that spaces 44a and 44b provide clearance between the adjacent side edges of reinforcing panels 34a, 34b and of squaring panels 40a, 40b so that there is no interference between these side edges as the folding takes place.

Display case 54 also includes a bottom tray 56 which is also suitably formed of a corrugated board material in any manner well known in the art. It will be appreciated that bottom tray 56 is sized to receive array 14 therein with clearance between upstanding sides 58a and 58b of bottom tray 56 and the sides of array 14 so that side panels 24a and 24b can fit between upstanding sides 58a and 58b of bottom tray 56 and the sides of array 14. In addition, while array 14 is formed overall as a 4.times.2 array of eight packages 16, it will be seen that array 14 is divided into two 2.times.2 arrays to accommodate the insertion of legs 36a and 36b. Thus, a small space 60 is centrally created between the two 2.times.2 arrays in which legs 36a and 36b are trapped. Finally, display case 54 is completed by suitably securing array 14, shroud 12 and bottom tray 56 together with a suitable securing means 62 known in the art. A suitable securing means 62 is a shrink wrap sleeve 64 shown in the unshrunken condition, although other securing means such as full shrink wrap, straps or the like could also be used.

After shrink wrap 64 is shrunk around array 14, shroud 12 and bottom tray 56, it will be appreciated that display case 54 so formed is completed. Display case 56 then has two ends through which packages 16 are easily viewable, either directly or through a transparent, shrink-wrap film. In addition, packages 16 are also easily accessible by the user, either individually by breaking part of shrink wrap 64 or completely by removing shrink wrap 64 and then lifting shroud 12 from array 14. It will also be appreciated that central panel 18 as well as side panels 24a and 24b also provide a suitable surface for high quality graphics as desired.

Prior to removal of shrink wrap 64, display case 54 provides a sturdy container for packages 16 which are stackable. Legs 38a and 38b are double thickness and trapped between adjacent packages 16, providing obvious vertical support. Further, the double thickness of side panels 24a and 24b reinforced by reinforcing panels 34a and 34b also provide vertical support as well as side protection. The overall shape of shroud 12 is also maintained: as central panel is maintained in its rectangular configuration by squaring panels 40a and 40b, as side panels 24a and 24b are reinforced by reinforcing panels 34a and 34b, and as legs 38a and 38b are trapped in array 14 and engage bottom tray 56 and top panel 18. It will also be appreciated that all eight corners of array 14 are suitably protected against compressive forces or shocks, such as would be encountered were a case to be dropped, by a double thickness of material due to the configuration and location of shroud 12. Those skilled in the art will appreciate that the display case of this invention utilizes a relatively small amount corrugated board and that the cost to strength ratio of the case is thereby minimized.

While the present invention has been described with respect to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that variations and modifications can be effected within the scope and spirit of the invention.