Method of making a preassembled display with automatic stackable supports

Patent metadata

Field	Value
Publication number	US-9796498-B2
Application number	US-201615077982-A
Country	US
Kind code	B2
Filing date	Mar 23, 2016
Priority date	Jul 10, 2012
Publication date	Oct 24, 2017
Grant date	Oct 24, 2017

Abstract

A method of making a preassembled display with automatic stackable supports (PDASS) is described. A PDASS may include two or more blanks (for example pieces of corrugated paperboard) that are joined together, for example to initially form a knocked down flat (KDF). The PDASS may include an insert formed from a single blank, where the single insert blank, when the whole display is erected, automatically erects and provides asymmetric supports that form at opposing corners of the outer blank.

First claim

The invention claimed is:

1. A method of making a preassembled display, comprising:
providing an outer blank comprising:
one or more outside surfaces, one or more inside surfaces comprising one or more adhesion zones, one or more panels, one or more flaps, and one or more joints;

providing an insert blank comprising:
one or more outside surfaces, one or more inside surfaces, one or more panels,
one or more flaps, and one or more joints;

applying fast curing adhesive to one or more of the adhesion zones and applying slow curing adhesive to one or more of the adhesion zones;
adhering the insert blank to the outer blank at the one or more adhesion zones, wherein the insert blank is adapted to automatically erect when the outer blank is erected; and
creating a knock down flat by:
folding one or more of the panels of the outer blank at one or more of the joints of the outer blank; folding one or more of the panels of the insert blank at one or more of the joints of the insert blank; and

adhering one of the panels of the outer blank to another of the panels of the outer blank.

2. The method of claim 1 , further comprising: perforating the one or more joints of the outer blank and perforating the one or more joints of the insert blank.

3. The method of claim 1 , further comprising: scoring the one or more joints of the outer blank; and scoring the one or more joints of the insert blank.

4. The method of claim 1 , further comprising:
perforating one or more joints of the insert blank;
scoring one or more joints of the insert blank; and
perforating or scoring the one or more joints of the outer blank.

5. The method of claim 1 , further wherein: the fast curing adhesive is a hot melt adhesive, and the slow curing adhesive is a cold melt adhesive.

6. The method of claim 1 , further wherein the fast curing adhesive is adapted to substantially bond the insert blank to the outer blank before the blanks are folded to create the knock down flat, the slow curing adhesive allows the insert blank to move relative to the outer blank during the folding steps.

7. A method of making display from a preassembled display, comprising:
providing a knock down flat comprising: an outer blank comprising one or more outside surfaces, one or more inside surfaces comprising one or more adhesion zones, one or more panels, one or more flaps, and one or more perforated or scored joints; and
an insert blank comprising one or more outside surfaces, one or more inside surfaces, one or more panels, one or more flaps, and one or more perforated or scored joints,
wherein the one or more adhesion zones includes at least one fast curing adhesion zone and at least one slow curing adhesion zone,
wherein the insert blank is adhered to the outer blank at one or more adhesion zones that are located on one or more of the inside surfaces of the outer blank, and
wherein the insert blank is adapted to automatically erect when the outer blank is erected; and

partially erecting the knock down flat by:
holding one panel of the outer blank in place; and
moving another panel of the outer blank away from the panel being held such that the outer blank becomes partially erected,
wherein, as the panel being moved moves away from the panel being held, one or more panels of the outer blank pull and/or push one or more panels of the insert blank at the adhesion zones,

wherein as the outer blank becomes partially erected, the insert blank automatically erects.

8. The method of claim 7 , wherein, once the outer blank and the insert blank are partially erected, the insert blank nests or wraps inside the outer blank such that the insert blank substantially abuts one or more of the inside surfaces of the outer blank.

9. The method of claim 8 , wherein the insert blank nests or wraps along less than the entire inside of the outer blank.

10. The method of claim 7 , wherein the insert blank is formed from a single piece of corrugated paperboard.

11. The method of claim 7 , wherein as the insert blank automatically erects, the insert blank automatically forms a plurality of supports located at corners of the outer blank, wherein at least two of the supports are located at diagonally opposing corners of the outer blank, and wherein at least two diagonally opposing supports are asymmetrically shaped.

12. The method of claim 7 , wherein as the insert blank automatically erects, the insert blank automatically forms a first pair of supports located at a first pair of diagonally opposing corners of the outer blank and a second pair of supports located at a second pair of diagonally opposing corners of the outer blank, wherein the supports of the first pair are asymmetrically shaped and the supports of the second pair are asymmetrically shaped.

13. The method of claim 12 , wherein all four supports of the first pair and the second pair are asymmetrically shaped when compared to each other.

14. The method of claim 7 , further comprising: fully erecting the knock down flat by folding one or more flaps of the outer blank at one or more of the joints of the outer blank, wherein as the one or more flaps of the outer blank get folded, the one or more flaps of the insert blank automatically get folded, interlocking the one or more flaps of the outer blank.

Assignees

• Mars Inc

Inventors

• Wintermute William
• Shoettle David
• Clifford Stanley

Classifications

• B65D5/445

  Reinforcements formed separately from the container · CPC title

• B65D5/001 Primary

  stackable · CPC title

• Y10T156/1049

  Folding only · CPC title

• B31B50/81

  Forming or attaching accessories, e.g. opening devices, closures or tear strings · CPC title

• B31B50/26

  Folding sheets, blanks or webs · CPC title