US20150136720A1

US20150136720A1 - Display hutch and methods of assembling the same

Info

Publication number: US20150136720A1
Application number: US14/543,279
Authority: US
Inventors: Scott M. Miller
Original assignee: Packaging Corp of America
Current assignee: Packaging Corp of America
Priority date: 2013-11-20
Filing date: 2014-11-17
Publication date: 2015-05-21

Abstract

A display hutch includes a hutch blank and a plurality of shelf blanks The hutch blank includes a back wall and at least two side walls. The back wall includes a plurality of back-wall slots. The at least two side walls include a plurality of side-wall slots. The plurality of shelf blanks includes a plurality of side tabs and one or more back tabs. Each of the side tabs is inserted into a respective side-wall slot and attached to the hutch blank. The plurality of shelf blanks and the hutch blank are configured to lay K.D. flat with the plurality of shelf blanks attached to the hutch blank. Each of the one or more back tabs is configured to be inserted into a respective one of the plurality of back-wall slots to form a plurality of shelves. The plurality of shelves is configured to support product for display.

Description

REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 61/906,719, filed Nov. 20, 2013, and entitled “Display Hutch,” which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to containers for displaying products. In particular, the present invention relates to a display hutch providing more efficient shipping and assembly.

BACKGROUND

Display hutches have been utilized to display products to customers at retail locations. Conventional display hutches, which employ a system of clips for attaching shelves, require excessive manual labor to assemble and necessitate additional components. This makes such display hutches inefficient to manufacture, assemble, and ship.

SUMMARY OF THE INVENTION

According to some aspects of the present disclosure, a display hutch includes a hutch blank and a plurality of shelf blanks The hutch blank includes a back wall and at least two side walls. The back wall includes a plurality of back-wall slots. The at least two side walls include a plurality of side-wall slots. The plurality of shelf blanks includes a plurality of side tabs and one or more back tabs. Each of the plurality of side tabs is inserted into a respective side-wall slot and attached to the hutch blank. The plurality of shelf blanks and the hutch blank are configured to lay K.D. flat with the plurality of shelf blanks attached to the hutch blank. Each of the one or more back tabs is configured to be inserted into a respective one of the plurality of back-wall slots to form a plurality of shelves. The plurality of shelves is configured to support product for display.
According to additional aspects of the present disclosure, a method of assembling a display hutch includes providing a hutch blank. The hutch blank has a back wall and at least two side walls extending from the back wall. The side walls include a plurality of side-wall slots. The method also includes providing a plurality of shelf blanks Each of the plurality of shelf blanks includes a plurality of side tabs. The method further includes inserting each of the plurality of side tabs into respective side-wall slots, folding each of the plurality of side tabs toward the side wall having the respective side-wall slot in which the side tab is inserted, attaching each of the plurality of side tabs to the respective side wall, and folding the hutch blank and the attached plurality of shelf blanks to be K.D. flat.
The above summary is not intended to represent each embodiment or every aspect of the present invention. Additional features and benefits of the present invention are apparent from the detailed description and figures set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 illustrates a hutch blank for forming a display hutch according to one embodiment of the present disclosure.

FIG. 2A illustrates a shelf blank that is used in forming the shelf blank of FIG. 2C.

FIG. 2B illustrates the shelf blank of FIG. 2A with adhesive.

FIG. 2C illustrates a shelf blank for forming a display hutch according to one embodiment of the present disclosure.

FIG. 2D illustrates a shelf blank for forming a display hutch according to another embodiment of the present disclosure.

FIG. 2E illustrates a shelf blank for forming a display hutch according to a further embodiment of the present disclosure.

FIG. 2F illustrates a shelf blank for forming a display hutch according to yet another embodiment of the present disclosure.

FIG. 3 illustrates a separable graphic panel blank for forming a display hutch according to one embodiment of the present disclosure.

FIG. 4 illustrates a flowchart for a method of assembling a display hutch according to one embodiment of the present disclosure.

FIG. 5 is an enlarged partial perspective view of a side tab of a shelf blank of FIG. 2C in the process of being inserted into a side-wall slot of the hutch blank of FIG. 1.

FIG. 6 is an enlarged partial perspective view of the side tab of FIG. 5 being attached to a side wall of the display hutch of FIG. 1 according to one embodiment of the present disclosure.

FIG. 7 is a partial perspective view of a graphic panel blank in the process of being attached onto an exterior surface of a side wall according to one embodiment of the present disclosure.

FIG. 8 is a hutch blank with attached shelf blanks in a knockdown (K.D.) flat configuration according to one embodiment of the present disclosure.

FIG. 9 is a side perspective view of a display hutch with a graphic panel blank being attached to the side wall in the process of being assembled according to one embodiment of the present disclosure.

FIG. 10 is an enlarged partial front view of a back tab of FIG. 2C after being inserted into a back-wall slot according to one embodiment.

FIG. 11 is a side perspective view of a display hutch in a final assembled state according to one embodiment of the present disclosure.

FIG. 12 is a front view of the display hutch of FIG. 11 and further includes product.

While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

FIG. 1 illustrates a hutch blank 10 according to on embodiment of the present disclosure. The hutch blank 10 of FIG. 1 includes a back wall 12, a first side wall 14 a, and a second side wall 14 b. The first side wall 14 a and the second side wall 14 b are hingedly attached to the back wall 12 along respective fold lines 15 a, 15 b. The back wall 12 includes a plurality of back-wall slots or openings 16 a-d. The back-wall slots 16 a-d are generally U-shaped. The first side wall 14 a and the second side wall 14 b include a plurality of side-wall slots or openings 18 a-f Both the plurality of the back-wall slots 16 a-d and the side-wall slots 18 a-f assist in supporting the shelving used in the hutch display. The first side wall 14 a and the second side wall 14 b also include a plurality of optional support-bar openings 20 a-f. The support bar openings 20 a-f assist in securing a plurality of optional support bars that assist in supporting the shelving.
The side-wall slots 18 a-f are paired. For example, the side-wall slot 18 a is paired with the side-wall slot 18 d to assist in securing one shelf. Similarly, the plurality of support-bar openings 20 a-d is also paired. For example, the support-bar opening 20 a is paired with support-bar opening 20 d to assist in securing a support bar. The first and second side walls 14 a,b are shown as having a contoured profile. It is contemplated that the first and second side walls may be more of a generally polygonal shape, such as a rectangle. It is contemplated that a hutch blank may include more than two side walls.
FIGS. 2A,B illustrate a sequence of interim blanks before forming a shelf blank of FIG. 2C according to one method. A shelf blank 60 of FIG. 2A is depicted with a plurality of panels 62-68 and a plurality of fold lines 69 a,b. Adhesive is placed at selected locations on the panels of the shelf blank 60. This is shown in FIG. 2B where adhesive is placed at location 68 a of panel 68 and at locations 62 a-c of panel 62. It is contemplated that the adhesive may be placed in different amounts or locations of the shelf blank 60. The panels 62 and 68 are folded inwardly such that panels 62 and 65 are attached together, and panels 67 and 68 are attached together. The resulting configuration is shown as shelf blank 70 of FIG. 2C.
As shown in FIG. 2C, the shelf blank 70 includes a plurality of side tabs 72 a,b, a back tab 74 and a plurality of side flaps 76 a,b. The side tabs 72 a,b are shaped and sized to correspond with the plurality of side-wall slots 18 as discussed below in FIGS. 5 and 6. The back tab 74 is adapted to be secured by back-wall slot 16 as discussed below in FIG. 10. The back tab 74 is shown as being continuous in FIG. 2C. It is contemplated that a plurality of back tabs may be formed in a shelf blank. The plurality of back tabs would be configured to be secured by a plurality of back-wall slots.
The length of the shelving L1 (see FIG. 2C) is generally from about 5 to about 30 inches, more specifically from about 8 to about 20 inches and even more specifically from about 12 to about 20 inches. This is the general length of the shelving when installed (i.e., from the back wall of the hutch blank to the front of the shelf).
It is contemplated that the shelving may be of different shapes and sizes than depicted in FIG. 2C. For example, FIGS. 2D-F illustrate a plurality of shelf blanks 170 a-caccording to further embodiments. As shown in FIGS. 2D-F, each of the shelf blanks 170 a-cincludes a plurality of side tabs 172 a-c and a respective back tab 174 a-c.
FIG. 3 illustrates an optional graphic panel blank 80 for use in a display hutch according to one embodiment of the present disclosure. The graphic panel blank 80, when separated along a score line 82, forms two graphic panel blanks 80 a,b. Each of the graphic panel blanks 80 a,b is attached to an exterior surface of a respective one of a first side wall or a second side wall of the hutch blank. The graphic panel blanks 80 a,b assist in covering an exterior surface of the first and second side walls of the hutch blank. It is desirable for the size and shape of the graphic panel blanks to be identical or substantially identical to the first and second side walls. The graphic panel blanks may also generally correspond with the first and second side walls. It is also contemplated that the graphic panel blanks may only cover a portion of the first and second side walls such as covering, for example, areas of attachment between the side tabs and the hutch blank. The graphic blank panels typically contain graphics or other information thereon identifying the product within the display hutch.
One non limiting example of a display hutch is shown in FIGS. 11 and 12. FIGS. 11 and 12 depict a display hutch 300 that includes a hutch blank 310, a plurality of shelves 370 a-d and the plurality of graphic panel blanks 80 a,b. The hutch blank 310 is similar to the hutch blank 10 except that the support bar openings are not present. The hutch blank 310 includes a back wall 312, a first side wall 314 a and a second side wall 314 b. The plurality of shelves 370 a-d is formed from the shelf blank 70 of FIG. 2C. The bottom-shelf blank 370 d is attached to the first and second side walls. To improve the strength of the display hutch, the bottom-shelf blank is typically attached to the first and second side walls by, for example, spanning and overlapping both the exterior surfaces of the first and second side walls. In such an embodiment, the bottom-shelf blank is not inserted into any of the plurality of side-wall slots and the side tabs of a bottom-shelf blank would be folded downwardly without attaching to the side walls.
The display hutch 300 in FIG. 12 displays products 404 on shelves 370 a,b. It is contemplated that a variety of products can be displayed on the display hutch and typically the products are displayed on each shelf. The products can be boxed, bagged, bottled, etc. on the shelves.
In one embodiment of a display hutch, each of the shelf blanks will be of the same size and shape. The number of shelves can vary, but are typically between 2 and 10 shelves and, more specifically from 3 to 5 shelves in each display hutch. It is contemplated that different sizes and shapes of the shelves may be used in forming a display hutch.
Referring now to FIG. 4, a flowchart is depicted for a method of assembling a display hutch according to one embodiment. As shown in block 110 of FIG. 4, a hutch blank (e.g., hutch blank 10) and a plurality of shelf blanks (e.g., plurality of shelf blanks 70) are provided. At block 112 of FIG. 4, one or more panels of the shelf blanks are folded and pre-glued. One non-limiting example of the shelf blank being pre-glued is shown with respect to FIGS. 2A-C.
A plurality of the shelf blanks is attached to the hutch blank via side tabs and side-wall slots at block 114 of FIG. 4. For example, as shown in FIGS. 5 and 6, a side tab 72 b of the shelf blank 70 is inserted into a respective one of the side-wall slot 18 e on the second side wall 14 b. Similarly, an opposing side tab 72 a of the shelf blank 70 would be inserted into a respective side-wall slot 18 b on the first side wall 14 a. Thus, the side tabs 72 a,b need to be of a size, shape and thickness that will enable insertion into the side-wall slots.
The side tabs 72 a,b are then folded towards and attached to a respective one of the first side wall 14 a and the second side wall 14 b of the hutch blank 10. In one non-limiting example, the side tabs 72 a,b are attached to the hutch blank 10 via fasteners such as a plurality of staples 75 a-c as shown in FIG. 6. It is contemplated that other means of attaching the side tabs 72 a,b to the side walls 14 a,b can be utilized such as, for example, stitching, glue or an adhesive.
Optional graphic panel blanks may be attached to an exterior surface of the side walls in block 116 of FIG. 4. This is shown in a non-limiting example in FIG. 7. FIG. 7 depicts the graphic panel blank 80 b in the process of being attached to an exterior surface of the second side wall 14 b via arrow A. The graphic panel blank may be attached to the second side wall 14 b using, for example, adhesives. It is contemplated that other attachment methods may be used to secure the graphic panel blank to the second side wall. Similarly, if a second graphic panel blank were used, it would be attached to the first side wall in a similar manner.
The display hutch is configured to lay knockdown (K.D.) flat with the plurality of shelf blanks being attached to the hutch blank for shipping at shown in blocks 118, 120 of FIG. 4. FIG. 8 displays a K.D. display hutch 200 a including a hutch blank 210 a, a plurality of shelf blanks 270 a-d and the graphic panel blanks 80 a,b. During the K.D. flat configuration, the side tabs are secured to the side-wall slots formed in the respective first and second side walls. By being in K.D. flat configuration, the shipping is made more efficient and cost-effective. It is contemplated that the display hutch may be made and used on site or shipped to other locations. It is contemplated that the display hutch may be shipped in other configurations besides the K.D. flat configuration.
After the display hutch is ready for use, it can be unfolded with the shelf blanks attached in block 122 of FIG. 4. FIG. 9 depicts a display hutch 200 b in an upright position including hutch blank 210 b and a plurality of shelves 270 a-d. As shown in FIG. 9, the shelf blanks 270 a-d are attached to the hutch blank 210 b such that the shelf blanks 270 a-d cascade in a direction from a top end 219 of the hutch blank 210 b to a bottom end 229 of the hutch blank 210 b. FIG. 9 also depicts a support bar 211, which supports the shelf 270 a when in its final position. The support bar 211 may be made of metal, polymeric material or corrugated paperboard. It is contemplated that a plurality of support bars may be used in the display hutch. The support bars, if used, are typically of a similar shape, size and strength. It is contemplated that the support bars may be of different shapes, sizes and/or strength. According to one non-limiting example, the lowermost one or lowermost two shelves can be supported by a support bar(s).
The shelf blanks are folded towards the back wall of the hutch display and the back tabs of the shelf blanks are inserted into the back-wall slots of the hutch blank to form a plurality of shelves as recited in blocks 126 and 128 of FIG. 4. FIG. 10 shows the back tab 54 b after being inserted into a back wall slot 16 d of the hutch blank 10. Product, as recited in block 130, can be placed on the plurality of shelves for display to customers, for example, at a retail location. It should be understood that it is within the scope and spirit of the present concepts to omit steps, include additional steps, and/or modify the order of steps presented above in FIG. 4.
The display hutch and method of assembling the same provide a number of significant advantages over conventional display hutches. In particular, conventional display hutches often employ a system of clips for attaching the shelves to the hutch blank. Such clips require an inefficient and extensive manual labor to embed each clip into the corrugated material of each shelf and the side walls. By contrast, the system of slots and tabs employed in the display hutch of the present disclosure can be assembled rapidly and efficiently. Moreover, the system of slots and tabs does not require extra components such as the clips of the conventional display hutches. Additionally, unlike conventional display hutches utilizing a system of clips, the display hutch of the present disclosure can be shipped in a K.D. flat configuration pre-assembled with the shelf blanks already attached to the hutch blank. Thus, after shipping, assembly of the display hutch of the present disclosure can be completed in a much more efficient manner. Indeed, a user need only unfold the side walls and back wall and form the shelves (e.g., fold the shelf blanks and insert the back tabs in the back slots). A user may also secure the optional support bars, if used.
Still further, while conventional display hutches that employ a system of clips can only attach the shelves at an inset position with respect to a front of the display hutch, it is contemplated that the display hutch of the present disclosure can attach the shelves at an inset position and/or at a position that is at the furthest point in the front of the display hutch.
The display hutches or containers of the embodiments described herein are typically manufactured using corrugated paperboard, preferably with the corrugations running in a vertical direction for increased strength. As non-limiting examples, the container is manufactured from C-flute, EB-flute, E-flute or B-flute corrugated paperboard. It is to be understood that the principles of this invention could be applied to containers comprising other materials, such as non-corrugated paperboard, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, polymeric materials, and other foldable materials.
While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims.

Claims

What is claimed is:

1. A display hutch comprising:

a hutch blank including a back wall and at least two side walls, the back wall including a plurality of back-wall slots, the at least two side walls including a plurality of side-wall slots; and

a plurality of shelf blanks including a plurality of side tabs and one or more back tabs, each of the plurality of side tabs being inserted into a respective side-wall slot and attached to the hutch blank, the plurality of shelf blanks and the hutch blank being configured to lay K.D. flat with the plurality of shelf blanks attached to the hutch blank, each of the one or more back tabs being configured to be inserted into a respective one of the plurality of back-wall slots to form a plurality of shelves, the plurality of shelves being configured to support product for display.

2. The display hutch of claim 1, further comprising one or more support bars for supporting one or more of the plurality of shelves.

3. The display hutch of claim 1, further comprising at least two graphics panel blanks each attached to an exterior surface of a respective one of the at least two side walls.

4. The display hutch of claim 3, wherein the at least two graphics panels cover areas of attachment between the side tabs and the hutch blank.

5. The display hutch of claim 1, further comprising a bottom-shelf blank that is attached to the hutch blank without being inserted into any of the plurality of side-wall slots.

6. The display hutch of claim 1, wherein the hutch blank and the plurality of shelf blanks are configured to be shipped with the plurality of side tabs attached to the hutch blank and in a K.D. flat configuration.

7. The display hutch of claim 1, wherein the at least two side walls have a contoured profile.

8. The display hutch of claim 1, wherein the display hutch comprises corrugated paperboard.

9. The display hutch of claim 1, wherein the display hutch comprises non-corrugated paperboard, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, or polymeric materials.

10. A method of assembling a display hutch for shipping, comprising:

providing a hutch blank, the hutch blank including a back wall and at least two side walls extending from the back wall, the at least two side walls including a plurality of side-wall slots;

providing a plurality of shelf blanks, each of the plurality of shelf blanks including a plurality of side tabs;

inserting each of the plurality of side tabs into respective side-wall slots;

folding each of the plurality of side tabs toward the side wall having the respective side-wall slot in which the side tab is inserted;

attaching each of the plurality of side tabs to the respective side wall; and

folding the hutch blank and the attached plurality of shelf blanks to be K.D. flat.

11. The method of claim 10, further comprising providing a bottom-shelf blank having a plurality of bottom-shelf tabs and attaching the plurality of bottom-shelf tabs of the bottom-shelf blank to the hutch blank without inserting the bottom-shelf tabs into any of the side-wall slots.

12. The method of claim 10, further comprising attaching at least one graphic panel to each of the at least two side walls.

13. The method of claim 10, wherein the attaching each side tab to the respective side wall includes fastening each side tab to the respective side wall.

14. The method of claim 10, wherein the attaching each side tab to the respective side wall includes gluing each side tab to the respective side wall.

15. The method of claim 10, wherein the back wall of the hutch blank includes a plurality of back-wall slots and the plurality of shelf blanks includes at least one back tab, and the method further comprises folding each shelf blank and inserting the at least one back tab on each of the shelf blanks into a respective one of the back-wall slots to form a plurality of shelves.

16. The method of claim 15, further comprising attaching at least one support bar configured to provide support to one or more of the plurality of shelves.

17. The method of claim 10 further comprising shipping the folded hutch blank and the attached plurality of shelf blanks while in a K.D. flat configuration.

18. The method of claim 10, wherein the display hutch comprises corrugated paperboard.

19. The method of claim 10, wherein the display hutch comprises non-corrugated paperboard, cardboard, corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, or polymeric materials.