US20200407107A1

US20200407107A1 - Single-piece locking lid display ready case

Info

Publication number: US20200407107A1
Application number: US16/913,482
Authority: US
Inventors: Jonathan Michael Genord; Westley Allen Simpson
Original assignee: Walmart Apollo LLC
Current assignee: Walmart Apollo LLC
Priority date: 2019-06-27
Filing date: 2020-06-26
Publication date: 2020-12-31

Abstract

A display ready case configured to be transformed from a transportation configuration to a display configuration. The display ready case including a top, bottom, left, right, front, and rear side, the top side including a tuck flap including two or more locking tabs configured to be inserted into two or more corresponding locking slots defined in the respective left and right sides, wherein an application of an external force to the tuck flap causes the two or more locking tabs to disengage from the two or more locking slots, thereby releasing the top side from the left and right sides, and where upon release of the top side from the left and right sides, the top side is removably coupled to the rear side via a perforation line, thereby enabling transformation of the display ready case to a display ready configuration.

Description

RELATED APPLICATION INFORMATION

This application claims the benefit of U.S. Provisional Application No. 62/867,379, filed Jun. 27, 2019, the contents of which are fully incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to shipping and display cartons, and more particularly to display ready cases having a cleaner appearance and requiring less labor in the transformation between a transportation configuration and a display ready configuration.

BACKGROUND

Each year millions of dollars are spent transporting products from their respective manufacturers to store shelves for display to potential customers. One cost-saving measure that has been implemented over the years has been to ship products in cartons that can be placed directly on store shelves. Generally this requires cutting or tearing perforations to remove portions of the cartons to afford a better view or display of the products within the cartons. This practice significantly reduces the labor otherwise required to remove products from the cartons for individual placement on the store shelves. This cost savings in labor can be passed on to the customer, thereby reducing the overall sales price of the products.
Although such display ready cartons have proven to be effective in reducing non-value added supply chain and shelf stocking costs, further improvements are desired. In particular, it has been noted that sales associates spend a significant amount of time cutting the cartons or tearing perforations to convert the carton into a display ready state. Further, irregular cuts and torn perforations on the front of the carton often leave the display carton with a messy appearance that tends to detract from an ideal product presentation. At the same time, it is recognized that the cartons must be robust enough to survive the supply chain. The present disclosure addresses these concerns.

SUMMARY OF THE DISCLOSURE

Embodiments of the present disclosure provide a robust shipping carton which can be easily transformed from a transportation configuration to a display ready configuration through the application of an external pulling or pushing force on a front facing portion of the carton to unlock one or more locking tab, followed by the application of a tearing force along a perforation line defined along a rear portion of the carton. Accordingly, embodiments of the present disclosure enable quicker and less labor-intensive transformation between the transportation configuration and the display ready configuration through the inclusion of a single perforation line located along a rear of the carton. Further, positioning of the perforation line along a rear of the carton promotes a clean appearance of the carton in the display ready configuration for an improved, cleaner presentation of the products contained therein.
One embodiment of the present disclosure provides a display ready carton or case including opposing top and bottom sides, opposing left and right sides and opposing front and rear sides. The top side can include a tuck flap configured to be folded substantially orthogonal to the top side to lie adjacent to and substantially parallel with the front side. The tuck flap can include two or more locking tabs configured to be inserted into two or more corresponding locking slots defined in the respective left and right sides, thereby selectively locking the top side to the left and right sides in a transportation configuration. An application of an external force to a center portion of the tuck flap can cause a deformation of the tuck flap, which in turn can cause the two or more locking tabs to disengage from the two or more locking slots, thereby releasing the top side from the left and right sides. The top side can be removably coupled to the rear side via a perforation line, thereby enabling transformation of the display ready case from the transformation configuration to the display ready configuration.
In one embodiment, each of the two or more locking slots is defined along the front portion of the respective left and right sides, adjacent the front side. In one embodiment, in the transformation configuration, the tuck flap is positioned adjacent to an interior of the front side. In one embodiment, each of the two or more locking tabs extend laterally outward from the tuck flap. In one embodiment, each of the two or more locking tabs include a taper configured to aid in an insertion of the two or more locking tabs into the two or more locking slots. In one embodiment, each of the two or more locking tabs included barbs configured to inhibit removal of the two or more locking tabs from the two or more locking slots when no external force is applied to a center portion of the tuck flap.
In one embodiment, the front side defines a cutout portion configured to enable a larger viewing window of contents within the display ready case in the display ready configuration. In one embodiment, each of the left side, right side, rear side, and front side include a bottom portion, which collectively form the bottom side. In one embodiment, at least one of the left and/or right side includes a connection tab configured to be fixedly coupled to at least one of the front and/or rear side. In one embodiment, the top side extends over the left and right sides in the transformation configuration, thereby inhibiting the top side from compressing contents within the display ready case when an external force is applied to the top side of the display ready case.
In another embodiment, the present disclosure provides a method of constructing a substantially cost neutral display ready case, in which the overall cost associated with fabricating the display ready case is similar to conventional shipping cartons, while the associated non-value added shelf stocking labor requirements associated with transforming the display ready case from the transformation configuration to the display ready configuration is reduced. In one embodiment, the method includes forming opposing top and bottom sides, opposing left and right sides and opposing front and rear sides of a display ready case. The top side can include a tuck flap configured to be folded substantially orthogonal to the top side to lie adjacent to and substantially parallel with the front side. The tuck flap can include two or more locking tabs configured to be inserted into two or more corresponding locking slots defined in the respective left and right sides, thereby selectively locking the top side to the left and right sides in a transportation configuration, wherein an application of an external pulling force to a center portion of the tuck flap causes a deformation of the tuck flap, which in turn causes the two or more locking tabs to disengage from the two or more locking slots, thereby releasing the top side from the left and right sides. The method further includes forming a perforation line between the top side and the rear side, thereby enabling transformation to a display ready configuration via separation of the top side.
The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which:

FIG. 1 is a net diagram depicting a display ready case, in accordance with an embodiment of the disclosure.

FIG. 2 is a perspective view depicting an assembled display ready case in the transportation configuration, in accordance with an embodiment of the disclosure.

FIG. 3A is a close-up, perspective view depicting a locking engagement between a locking tab and a locking slot of a display ready case, in accordance with an embodiment of the disclosure.

FIG. 3B is close-up, perspective view depicting the display case of FIG. 3A with the locking tab and locking slot disengaged.

FIG. 4A is a perspective view depicting a display ready case with the top side opened, in accordance with an embodiment of the disclosure.

FIG. 4B is a perspective view depicting the display case of FIG. 4A with the top side removed in the display ready configuration.

FIG. 5 is a schematic depicting how two display ready cases can be cut from stock material in a manner that minimizes waste, in accordance with an embodiment of the disclosure.

While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

Referring to FIG. 1, a net diagram depicting the surface area of a display ready case 100 is depicted in accordance with an embodiment of the disclosure. The display ready case 100 is configured to provide packaging for the transportation of merchandise in a supply chain, as well as to serve as shelf ready packaging that is optimized for efficient stocking and sale, thereby enabling the shipped merchandise to be placed directly onto store shelves and/or stocking locations without individually handling the product, unit packs or primary packages (i.e., contents) contained within the display ready case 100.
In some embodiments, the display ready case 100 can be constructed of a cardboard material, such as corrugated fiberboard, paperboard, mat board, or the like. In other embodiments, the display ready case 100 can be constructed of a rigid or semi-rigid plastic material. The use of other construction materials is also contemplated. In some embodiments, one or more of the sides 102, 104, 106, 108, 110 and/or 112, or portions thereof, can include more than a single layer of stock material to enhance the structural integrity of the display ready case 100.
With additional reference to FIG. 2, the display ready case 100 can include a top side 102 and an opposing bottom side 104, a left side 106 and an opposing right side 108, and a front side 110 and an opposing rear side 112, thereby forming a six sided rectangular prism in the transportation configuration (as depicted in FIG. 2). In one embodiment, each of the left side 106, front side 110, right side 108, and rear side 112 can include a bottom portion 104A-D, which can collectively form the bottom side 104. In other embodiments, formations of other than a six sided rectangular prism are contemplated, including a hexagonal prism and octagonal prism, among other three dimensional designs. In some embodiments, the display ready case 100 may not include a bottom side (e.g., a half slotted container).
It is noted that the top side 102 is generally, but not necessarily, disposed at the top of the display ready case 100 in the normal gravitational frame of reference. Thus, the downward direction as used herein refers to as the direction away from the top side 102; whereas the upward direction refers to the direction relative to the display ready case 100, away from the bottom side 104, regardless of whether the display ready case is aligned with the gravitational upward and downward directions. Similarly, the “top,” “bottom,” “front,” “rear,” “left,” and “right” sides or surfaces of elements may be described herein with reference to the frame of reference of the display ready case 100.
In one embodiment, the left side 106 can include a connection tab 114 configured to be fixedly coupled (e.g., glued, taped, stapled, etc.) to the rear side 112, thereby forming a continuous perimeter. In other embodiments, the connection tab 114 can be positioned on any of the right side 108, front side 110 or rear side 112. In some embodiments, the display ready case 100 can include multiple connection tabs 114.
In one embodiment, the front side 110 can include a cutout perimeter 116 defining a cutout portion in which a portion of the front side 110 is removed, thereby enabling a viewing window into the display ready case 100. For example, in one embodiment, the front side 110 can define a rectangular cutout portion 118 with filleted the corners. In other embodiments, any of the sides 102, 104, 106, 108, 110 and/or 112 can include a cutout portion.
In one embodiment, the top side 102 can include a tuck flap 118. In the transportation configuration, the tuck flap 118 can be folded substantially orthogonal to the top side 102 to lie adjacent to and substantially parallel with the front side 110. For example, in one embodiment, the tuck flap 118 can be positioned adjacent to an interior of the front side 110. In other embodiments, the tuck flap 118 can be operably coupled to any one of the bottom side 104, left side 106, right side 108, front side 110, and/or rear side 112, for positioning adjacent to any other adjacent side.
With additional reference to FIGS. 3A-B, in some embodiments, the tuck flap 118 can include one or more locking tabs 120 configured to be inserted into one or more corresponding locking slots 122 defined in the respective left side 106 and/or right side 108, thereby selectively locking the top side 102 to the left and right sides 106/108 in the transportation configuration (as depicted in FIG. 3A). For example, in one embodiment, the display ready case 100 can include a pair of locking tabs 120A/B configured to be inserted into a pair of locking slots 122A/B defined along a front portion of the left side 106 and right side 108 adjacent to the front side 110. In other embodiments, the display ready case 100 can include a single locking tab 120 configured to secure the tuck flap 118 to the front side 110 and/or left or right sides 106/108 in the transportation configuration. In yet another embodiment, the display ready case 100 can include one or more of locking tab 120 and a plurality of locking slots 122, such that the top side 102 can be locked in a partially opened configuration. In some embodiments, an interior of the top side 102 can include promotional or other product information configured to be viewed by potential consumers in the partially opened configuration.
In one embodiment, each of the locking tabs 120A/B can extend laterally outward from the tuck flap 118. In some embodiments, the locking tabs 120A/B can define a taper 124A/B (as depicted in FIG. 1) configured to ease insertion of the locking tabs 120A/B into the locking slots 122A/B, thereby locking the top side 102 to the left and right sides 106/108 in the transportation configuration. The top side 102 can be selectively released from the left and right sides 106/108 through the application of an external pulling or pushing force to a center portion 128 of the tuck flap 118. In particular, the application of an external force to the center portion 128 can cause a deformation of the tuck flap 118, which in turn can cause the locking tabs 120A/B to disengage from the locking slots 122A/B (as depicted in FIG. 3B). In some embodiments, the locking tabs 120A/B can include a barb 126A/B (as depicted in FIG. 1) configured to inhibit removal of the locking tabs 120A/B from the locking slots 124A/B when no external force is applied to the tuck flap 118. The locking tabs 120A/B can be selectively reinserted into the locking slots 122A/B as desired, thereby relocking the top side 102 to the left and right sides 106/108. In yet other embodiments, disengagement of the locking tabs 120 from the locking slots 122 can require tearing and/or permanent deformation of the material in proximity to the locking tabs 120 and/or locking slots 122, thereby creating a tamper evidence seal to the display ready case 100.
As further depicted in FIGS. 3A-B, in some embodiments, the top side 102 can include one or more over extensions 130 configured to extend over the respective left and right sides 106/108 in the transportation configuration, thereby inhibiting the top portion 102 from collapsing into an interior of the display ready case 100 and potentially compressing contents therewithin when an external force is applied to the top side 102 in the transportation configuration. Accordingly, in some embodiments, the overextensions 130A/B (as depicted in FIG. 1) serve to improve stackability of the display ready case 100.
With additional reference to FIGS. 4A-B, in one embodiment, a line of perforation 132 is defined between the top side 102 and the rear side 112, thereby enabling the top side 102 to be torn free from the display ready case 100 without the use of a cutting tool. Upon separation or removal of the top side 102 from the rear side 112, the display ready case 100 can be transformed to the display ready configuration (as depicted in FIG. 4B).
With additional reference to FIG. 5, the embodiments disclosed herein provide a method of constructing a substantially cost neutral display ready case 100, in which the overall cost associated with fabricating the display ready case 100 is similar to conventional shipping cartons, while the associated non-value added shelf stocking labor requirements associated with transforming the display ready case 100 from the transportation configuration to the display ready configuration is significantly reduced. For example as depicted in FIG. 5, the net diagrams for two or more display ready cases 100A/B on can be arranged on stock material 200, such that any unused material 202A-C is minimized. In some embodiments, the proportion of unused material 202A-C in the construction of the display ready cases 100A/B can be similar to conventional shipping cartons, such that overall production cost associated with embodiments of the display ready case are similar to conventional shipping cartons.
Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.
Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.
Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.
Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.
For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.

Claims

What is claimed is:

1. A display ready case, comprising:

opposing top and bottom sides, opposing left and right sides and opposing front and rear sides, the top side including a tuck flap configured to be folded substantially orthogonal to the top side to lie adjacent to and substantially parallel with the front side, the tuck flap including two or more locking tabs configured to be inserted into two or more corresponding locking slots defined in the respective left and right sides, thereby selectively locking the top side to the left and right sides in a transportation configuration,

wherein an application of an external force to a center portion of the tuck flap causes a deformation of the tuck flap, which in turn causes the two or more locking tabs to disengage from the two or more locking slots, thereby releasing the top side from the left and right sides, and whereupon release of the top side from the left and right sides, the top side is removably coupled to the rear side via a perforation line, thereby enabling transformation to a display ready configuration.

2. The display ready case of claim 1, wherein each of the two or more locking slots is defined in their respective left and right sides along a front portion of the left and right sides, adjacent to the front side.

3. The display ready case of claim 1, wherein in the transportation configuration, the tuck flap is positioned adjacent to an interior of the front side.

4. The display ready case of claim 1, wherein each of the two or more locking tabs extend laterally outward from the tuck flap.

5. The display ready case of claim 1, wherein each of the two or more locking tabs include a taper configured to aid in an insertion of the two or more locking tabs into the two or more locking slots.

6. The display ready case of claim 1, wherein each of the two or more locking tabs include a barb configured to inhibit removal of the two or more locking tabs from the two or more locking slots when no external force is applied to a center portion of the tuck flap.

7. The display ready case of claim 1, wherein the front side defines a cutout portion configured to enable a larger viewing window of contents within the display ready case in the display ready configuration.

8. The display ready case of claim 1, wherein each of the left side, right side, rear side, and front side include a bottom portion, which collectively form the bottom side.

9. The display ready case of claim 1, wherein one of the left and right side includes a connection tab configured to be fixedly coupled to one of the front and rear side.

10. The display ready case of claim 1, wherein the top side extends over the left and right sides in the transportation configuration, thereby inhibiting the top side from compressing contents within the display ready case when an external force is applied to a top of the display ready case in the transportation configuration.

11. A method of forming a display ready case, comprising:

forming opposing top and bottom sides, opposing left and right sides and opposing front and rear sides, the top side including a tuck flap configured to be folded substantially orthogonal to the top side to lie adjacent to and substantially parallel with the front side, the tuck flap including two or more locking tabs configured to be inserted into two or more corresponding locking slots defined in the respective left and right sides, thereby selectively locking the top side to the left and right sides in a transportation configuration, wherein an application of an external force to a center portion of the tuck flap causes a deformation of the tuck flap, which in turn causes the two or more locking tabs to disengage from the two or more locking slots, thereby releasing the top side from the left and right sides; and

forming a perforation line between the top side and the rear side, thereby enabling transformation to a display ready configuration via separation of the top side.

12. The method of claim 11, wherein each of the two or more locking slots is defined in their respective left and right sides along a front portion of the left and right sides, adjacent to the front side.

13. The method of claim 11, wherein in the transportation configuration, the tuck flap is positioned adjacent to an interior of the front side.

14. The method of claim 11, wherein each of the two or more locking tabs extend laterally outward from the tuck flap.

15. The method of claim 11 wherein each of the two or more locking tabs include a taper configured to aid in an insertion of the two or more locking tabs into the two or more locking slots.

16. The method of claim 11, wherein each of the two or more locking tabs include a barb configured to inhibit removal of the two or more locking tabs from the two or more locking slots when no external force is applied to a center portion of the tuck flap.

17. The method of claim 11, wherein the front side defines a cutout portion configured to enable a larger viewing window of contents within the display ready case in the display ready configuration.

18. The method of claim 11, wherein each of the left side, right side, rear side, and front side include a bottom portion, which collectively form the bottom side.

19. The method of claim 11, wherein one of the left and right side includes a connection tab configured to be fixedly coupled to one of the front and rear side.

20. The method of claim 11, wherein the top side extends over the left and right sides in the transportation configuration, thereby inhibiting the top side from compressing contents within the display ready case when an external force is applied to a top of the display ready case in the transportation configuration.